2Warner Electric • 800-825-9050 P-2003-2 • 819-0420
Contents
Introduction ............................2
Theory of Operation ......................3
Technical Specifications ..................3
Installation
Control Mounting .....................4
External Sensor Mounting...............5
System Wiring ..........................5
System Start-Up and Adjustment ..........11
Voltage Tables .........................19
System Troubleshooting .................20
Component Parts List
Coupling, MCS-605-1 284-8000-003
Roll Pin (Drive) for Sensor Coupling 679-8001-067
TCS-200-1 Tension Control 6910-448-086
TCS-200-1H Tension Control 6910-448-087
Ultrasonic Sensor 4-40in 7600-448-001
List of Illustrations and Figures
Figure 1 Dimensional Data, Mounting ....... 6
Figure 2 Power Connections .............. 7
Figure 3 Brake Connections .............. 8
Figure 4 Remote Torque and Roll
Follower Connections............. 9
Figure 5 Remote Switch, Analog Input and
Analog Input Isolation Connections . 10
Tables 1,2,3 Voltage/Current Tables .......... 19
Templates TCS-200-1H Template........... 21
TCS-200-1 Template ............ 21
Introduction
The Warner Electric Tension Control system is
comprised of a tension brake, control module, and
optional external sensor input.
This manual has been designed to cover installation,
start-up, adjustment, and maintenance of your
tension control system and covers the control system
only. Further information on brake sizing and selection
can be found in catalogs P-1234 or P-771.
Power Source
The TCS-200-1 series Tension Controls operates
from a power source of 115 or 230 VAC, 50/60 Hz
input. Primary voltage is determined by the
customer’s input voltage source. The control is
factory set to accept 115 VAC input. Refer to the
wiring section for 230 VAC input connections.
Control
The TCS-200-1 series controls are selectable
voltage or current controlled power supply designed
to power up to a 16 magnet Electro Disc tension
brake system, Electromagnetic Particle Brakes,
TB series brakes or Advanced Technology tension
brakes. This control can be operated manually from
the front panel or remotely via an analog voltage
input, a current input, a remote pot, or a roll follower.
External inputs are also provided for remote brake
“off”, “run”, and “stop” functions, as well as front
panel control of these functions.
The analog voltage and current inputs are
electrically isolated from the main power circuitry of
the control when 15-35 VDC supply is provided to
maintain full isolation. If isolation is not needed, an on
board 15 VDC supply is jumpered to act as a default.
Sensors
When the TCS-200-1 series controls are operated
in a remote torque adjust mode, a 1,000 ohm
potentiometer is required. This should be a linear type
potentiometer with a rating of .5 watts, 10 percent
tolerance, and a .5 percent linearity.
For roll follower input applications, a 1,000 ohm
potentiometer with a rating of .5 watts, 10 percent
tolerance, and .5 percent linearity is required for best
performance.
Brakes
All 24 VDC tension brakes that Warner Electric offers,
to a maximum of 4.25 amps, can be used with the
TCS-200-1 tension control. For all 24 VDC tension
brakes that require greater current capability from the
control (not to exceed 5.8 amps), use a TCS-200-
1H. The brake converts electrical current supplied by
the control into torque, which retards material flow,
maintaining the desired web tension.
