Warner Electric MCS202-E1 User manual

WARNER ELECTRIC
MC403WEr-gb-1003 Page 1 of 3
MCS202-E1
MCS202-E154
MCS202-EC1
User Manual
WARNER ELECTRIC EUROPE
Rue Champfleur, B.P. 20095, F- 49182 St Barthélemy d’Anjou Cedex
Tél. [phone], Fax + 33 (0)2 41 21 24 00
www.warnerelectric-eu.com

MC403WEr-gb-1003 Page 2 of 3
WARNER ELECTRIC
MCS202-E1 / MCS202-E154 / MCS202-EC1
Every MCS202-E version has the same electrical characteristics and performances
❒MCS202-E1 Standard monoblock control unit (operator controls located on the front panel)
❒MCS202-E154 Same as above but constructed for IP54 protection - Non used receptables should be closed with a sealed
dummy connector
❒MCS202-EC1 Printed circuit board version (power switch, power input and brake switch to be provided and wired by the user.
Also used as replacement part for above models.
Power Switch “ON/OFF”
Power indicator
Brake Switch “ON/OFF”
Brake level indicator
Sensor error indicator
Loop Gain Potentiometer
(dancer arm stability)
Torque Offset Potentiometer
PCB Components
Power switch connector CON2
Fuse
Mains terminal strip
CON1
Voltage selector SW1
Dancer position pot VR3
Anti-residual pot VR5
Brake switch, CON3
Sensor polarity switch SW3
Rear view
Technical information
The electronic circuit utilises a single +15 VDC power source. The supply voltage for the sensor is +15 VDC, the sensor signal should
be minimum +3 VDC and maximum 10 VDC. When the Warner Electric sensor MCS605-E is used it should be operated within a
+/–30° band around the operating position. The input receptacle SK2 is compatible with the connector on the MCS605-E cable
included in the MCS-KIT.
In order to ensure correct starting and stopping of the machine, the DRIFT STOP function available on auxiliary receptacle SK3 has to
be wired to an external switch. When the unwinder is not running the DRIFT STOP function should be activated by closing the con-
tact.
In the event that the dancer arm movement provokes reversed results (full braking with minimum loop and no braking with maximum
loop) the sensor polarity has to be reversed. A sensor polarity switch is present at the rear of the MCS605-E sensor. When other types
of sensors are used, then SW3 on the printed circuit board should be reversed.
For applications where the diameter ratio (ratio between maximum and minimum diameter) exceeds 8:1, we recommend to use the
“change over gain” function by closing S3 from middle to small Ø.
All inputs in the auxiliary connector SK3 and brake power are optically isolated from the +15 VDC supply voltage.
Mains cable
Transformer
SK2, Sensor receptacle
SK3, Auxiliary receptacle
SK4, Brake receptacle
Front View

MC403WEr-gb-1003 Page 3 of 3
START-UP (based on employing a Warner Electric MCS605-E dancer arm sensor)
1. Mount sensor on dancer arm. Align both marks on the shaft and flange with the desired dancer arm operating position. Make sure
that the operating band for free dancer arm motion is at least +/– 30° around this operating position.
2. Connect the sensor to input receptacle SK2 utilising the cable supplied in the MCS KIT or follow the connector wiring instructions
given above.
3: Ensure that the brake is correctly mounted and can rotate freely. Connect the brake to receptacle SK4. Remember that the brake
is not polarised, so connections can be reversed without changing functioning.
4. Connect the control the the mains supply voltage. Check if the voltage switch is set for 240 VAC (equals nominal supply voltage
of 220 to 240 VAC) operation. For 115 VAC operation change the position of SW1 on the printed circuit board.
5. Apply mains supply voltage, the red Power LED should lit. Maintain the machine in the stop condition.
6. Activate BRAKE switch to the ON position, BRAKE LEVEL indicator may lit, SENSOR ERROR indicator may lit RED or GREEN
(dancer arm in maximum or minimum position). Close (or keep closed) the user supplied external ANTI-DRIFT switch S1. Adjust
the TORQUE OFFSET potentiometer to mid course. Turn LOOP GAIN potentiometer to maximum (fully CW) Move dancer arm
slowly from maximum loop to minimum loop (or inverse) and verify:
-The SENSOR ERROR indicator goes from red to green or inverse with a smooth colour transition around the operating posi-
tion. A non smooth transition means that the dancer arm potentiometer has been mounted incorrectly. In this case rotate the
potentiometer 180°
-The brake is engaged with the dancer arm in the maximum loop position and fully disengaged in the minimum loop position.
If the brake operation is inversed, then change the polartiy of the sensor by changing the polarity switch on the sensor (in case
other types of sensors are used, change the position of switch SW3 on the printed circuit board).
7. Deactivate the BRAKE switch to the OFF position, BRAKE LEVEL indicator should be off. Load the machine with a roll containing
maximum material. Ensure the dancer arm is in the maximum loop position. Adjust LOOP GAIN potentiometer to center position
(mid course).
8. Activate BRAKE switch to the ON position, BRAKE LEVEL indicator should be lit. Keep the external ANTI DRIFT switch S1 closed.
-Start the machine in low speed and adjust the TORQUE OFFSET potentiometer untill the dancer arm reaches the operating
position. Note that operation at this moment may not be stable.
-Open the external ANTI DRIFT switch S1 and adjust the LOOP GAIN potentiometer for good dancer arm stability.
-Slowly increase the machine speed and if necessary readjust the LOOP GAIN potentiometer for stable dancer arm operation.
Repeat this until maximum machine speed has been obtained.
9. In normal operation, the dancer arm should remain stable around the operating position. The ERROR SENSOR indicator should
be off. Slightly green or red is permitted.
In case of problems during commissionning or for special applications, contact your nearest Warner
Electric representative
WARNER ELECTRIC
Connector wiring
14
23
23
14
Earth (shield) Signal (green)
0 VDC (brown)
SK2
+15 VDC (white)
Female
Male
13
2
SK4
15
2
a
b
o
4
SK3
S2
S3
S1
3
S2a brake OFF
fully released
S2o under control
normal running
S2b brake ON
fully engaged
SK2 (Sensor)
Sensor MCS605–E
SK4 (Brake)
+24 VDC on pin1
Brake not polarised
OPEN CLOSED
S1: ANTIDRIFT While running While stopped
S3: CHANGE from medium diameter
GAIN to small diameter
SK3 (Auxiliary)
pin 1: +24 VDC, pin 2: 0 VDC