MCS-131 Series High Speed
Overexcitation Controls
P-262
819-0493
Installation & Operating Instructions
Contents
Basic Function . . . . . . . . . . . . . . . . . . . . . . . . . . . .1
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Installation
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
Initial Checkout . . . . . . . . . . . . . . . . . . . . . . . . . .3
Control Adjustments . . . . . . . . . . . . . . . . . . . . . .3
LED Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . .3
Interface Programming . . . . . . . . . . . . . . . . . . . .4
Board Setup And Programming . . . . . . . . . . . . .4
Dimensions and Adjustment Locations . . . . . . . .6-9
Warranty . . . . . . . . . . . . . . . . . . . . . . . . .Back Page
Warner Electric • 800-825-9050 P-262 • 819-0493
1
Failure to follow these
instructions may result in product damage,
equipment damage, and serious or fatal injury
to personnel.
Basic Function
The simplest clutch-brake control system comprises
an on-off switch and the clutch/brake. When
extreme accuracy or high duty cycle rates are not
required, this is the most desirable control to use.
However, for applications requiring greater accuracy
and speed, more sophisticated controls are
necessary. Overexcitation is a momentary voltage
many times greater than the control’s nominal value.
Overexcitation builds up a clutch and brake field
much faster than ordinary excitation, without
damage to the clutch or brake.
Specifications
Input Power: 120VAC ±10%,
50/60 Hz or 240VAC
±10%, 50/60 Hz,
Switch Selectable on
Board
Load: Clutch-Brake, 6 volt,
4.4 amps maximum
Output: Each Channel
Current Rise Time up to
Rated Max.: 2 Milliseconds
Current Fall Time: 2 Milliseconds
Overexcitation Time: Adjustable 2 to 14
milliseconds
Steady-State Output: Adjustable 0 to 6
volts
The MCS-131, when used with a 6 volt, size 500
clutch/brake, can reduce the response time for
rated current buildup or decay to 2 milliseconds.
The result is very quick and highly accurate
clutch/brake engagement and disengagement.
The steady-state output for each of the control’s
two channels can be independently adjusted from 0
to 6 volts. To prevent torque overlap when switching
from one channel to another, the switching interval
time delay can be adjusted from 0.1 to 7
milliseconds. In addition to steady-state level and
overlap adjustments, the over-excitation time is
adjustable from 2 to 14 milliseconds on each
channel.
With these adjustments, the control can be set to
precisely match the machine drive to its load. The
machine’s maximum cycle rate can also be
achieved while minimizing machine shock by
providing optimum cushioning to start-stop
functions.
The basic MCS-131 is identical to the earlier MCS130 with regard to outside dimensions and
mounting, but the terminal strip is slightly different.
However, the MCS-131 will directly replace the
earlier MCS-130.
Overlap Time Delay: Adjustable 1.5 to 8.5
milliseconds
Maximum Cycle Rate: 300 CPM on 5”
clutch-brake
Auxiliary Output: 12 volts DC @ 100
milliamps, 24 volts
DC @ 100 milliamps,
4.8 volts DC @ 1
amp (optional)
Inputs:
BASIC INPUTS: Open collector compatible, device
rating: 15 volts DC, 20 ma. minimum, maximum
saturation voltage ≤ 0.7 VDC.
In basic control mode, only inhibit and input
terminals are used for switching. See Figure 2.
EXPANDED INPUTS: Bag Logic Board, part number
6040-448-016 (optional). Open collector
compatible, device rating: 15 volts DC, 20 ma.
minimum, maximum saturation voltage ≤ 0.7 VDC.
Provides for start, stop, scanner and scanner inhibit.
See Figures 3, 4, and 5.
Warner Electric • 800-825-9050 P-262 • 819-0493
2
CH1 ON
CH1
LED
CH2
LED
1K Ω 1/4 w
1K Ω 1/4 w
+12
100 ma
CH2 ON
Stitch Logic Board, part number 6040-448-017
(optional). Open collector compatible, device rating:
15 volts DC, 20 ma. minimum, maximum saturation
voltage ≤ 0.7 VDC.
Provides for start, stop, and inhibit functions. See
Figures 6 and 7.
OPTIONAL COMPONENTS: 4.8 volt power board,
part number 6040-448-014 (optional). Provides for
4.8 volt DC @ 1.0 amp output for operating MCS624 Register Mark Scanner.
Cover, part number 6040-448-015 (optional).
Provides for optional enclosure of basic MCS-131.
Applications
Typical applications for overexcitation include cutting
labels after printing, separating bags after
manufacture, filling, and other precision applications.
System capabilities are expanded by using the
optional logic boards with the basic control.
The basic control provides both 12 volts DC for use with
the 12 volt DC compact scanners, and 24 volts DC for
use with the MCS-638 color Mark Scanner. The MCS-624
Register Mark Scanner may be used also, when the 4.8
volt Power Board is used.
It should be noted that the maximum rated output for the
Clutch-Brake is limited to 4.4 amps. If applications require
use of Clutch-Brakes whose ratings exceed this maximum
limit, the factory should be consulted.
Installation
Mounting
Mount the Control with the terminal strip positioned
toward the top. This allows the transformer heat to rise
away from the other components.
Wiring
1. Connect clutch and brake to each pair of
respective Channel 1 and Channel 2 terminals
as required.
Control Adjustments
Set AC selector switch to the desired range
120 VAC or 240 VAC.
CH 1 Delay, CH 2 Delay:
2. Connect AC input to the AC input terminals.
Potentiometer adjustment which delays the actuation
of Channel 1 or Channel 2 to prevent Clutch-Brake
overlap. Range Adjustment: 0.1 to 7 milliseconds.
3. The earth ground terminal provides for connection of
the transformer core to earth ground.
4. Connect input switches per appropriate figure
for type switching desired.
CH 1 Torque, CH 2 Torque:
Potentiometer adjustment for steady-state output
voltage of Channel 1 and Channel 2. Range adjustment; 0 to 6 volts DC.
CH 1 Overexcitation, CH 2 Overexcitaiton:
Potentiometer adjustment for adjusting overexcitation
time period for Channel 1 and Channel 2. Range
adjustment: 2 to 14 milliseconds.
LED Indicators
a. For Basic Control Switching, use Figure 2.
b. For Bag Logic Module, use Figures 3 & 5,
or 4 & 5.
c. For Stitch Logic Module, use Figures 6 & 7.
5. For external LED indicator connection, connect as
follows:
Initial Checkout
Basic Control without interface options, per Figure 2.
1. Apply AC power to MCS-131 Control.
2. With inhibit terminal (2) grounded, control
CR 102, CR 302:
should power-up channel 2 on.
Indicates when Channel 1 or Channel 2 output is
actuated. CR 205, CR 405:
Indicates operation of overexcitation pulse for
Channel 1 or Channel 2 when switched.
CR 12: Input LED on “in” terminal. On when input
terminal is pulled low.
Warner Electric • 800-825-9050 P-262 • 819-0493
3
3. Ground input terminal (8), control should
switch to channel 1 on, and “in” LED should be on.
4. Remove ground from input terminal (8), control
should switch back to channel “on” and “in” LED
should be off.
Interface Programming
The two optional logic modules provide for expanded input switching of the basic control. Logic board
selection will be dependent primarily upon the input switching requirements. For most applications, the
bag logic module will be the more suitable.
Board Set Up and Programming
A. Bag Logic Board, 6040-448-016
Switch No. Function Affected Control Operation
SW 1 Stop Open: Pulse Control on terminal 7. Triggers on negative
transition of input pulse.
SW 2 Photo Input Closed: Dark Operation, switches
SW 3 Open: On negative transition
SW2 Photo Input Open: light Operation, switches
SW 3 Closed: On positive transition
SW4 Start Open: Pulse Control on terminal 1. Triggers on negative
transition of input pulse.
Closed: Level input on terminal 1. Active low, triggers on
negative transition of input.
Using the Bag Logic Module, 6040-448-016, control input terminal designations change somewhat as
shown in Figures 3 and 4.
Terminal No. Function Control Input Logic
1 Start Selectable on Card for Level or Pulse
2 Photo Inhibit Level only, Active Low
7 Stop Selectable on Card for Level or Pulse
8 Photo Input Level, Light/Dark Card Selectable
For waveform timing diagrams, see Figure 5.
Warner Electric • 800-825-9050 P-262 • 819-0493
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B. Switch Logic Module, 6040-448-017
This module expands the input capabilities of the basic MCS-131 Control. For most application, however, the
Bag Logic Module, 6040-448-016, will be used.
Switch No. Function Affected Control Operation
1 Always Closed ----------
2 Input Signals Open: Pulse Control
Closed: Level Control
3 Not Used
4 Always Closed ----------
Using the Stitch Logic Board, 6040-448-017, switching inputs change somewhat from the basic MCS-131
Control. Input switching configurations are shown in Figure 6.
Terminal No. Function Control Input Logic
1 Start Pulse or Level
2 Inhibit Level only, Active Low
7 Stop Pulse or Level
For waveform timing diagram, see Figure 7.
Cautions
Fusing: For 120 VAC operation a 1.6A slo-blo fuse should be used.
for 240 VAC operation a 1.0A slo-blo fuse should be used.
Note: When replacing a fuse, the same type and size as specified should be used to prevent
control damage.
AC: AC line voltages are present at the terminal strip.
Warner Electric • 800-825-9050 P-262 • 819-0493
5
50
6
0
50
6
0
0 to 6
CH1
(Clutch)
CH2
(Brake)
Adjustable Over Excitation
Time 2 to 14 MSEC.
Adjustable For
Steady State Output
0.1 10 17 MSEC.
Adjustable Delay
To Prevent Overlap
Current
Voltage
DC
+24V COM
+4.8V
18
17
16
Switching
S1-
Input Switch
Open - Channel 2 ON
Closed - Channel 1 ON
Inhibit Switch
Open - System Inhibited, Channel 1 ON
Clesed - Normal Operation
S2-
120 V
or
240V
AC
AC
Input
Earth
GND
DC
COM
+12 V
CH2
CH1 IN N/C
--
+
+
CH2
CH1
INH
N/C
S1
S2
MCS-131
TERMINAL DESIGNATIONS
1 NO. Connection
2 Inhibit
3
4
5
6
7 NO. Connection
8 Input
9 LED Channe1 1
10 LED Channel 2
11 +12 VDC Output
12 DC Common
13 Earth Ground
14
15
16 +4.8 VDC Output (Optional Board)
17 DC Common
18 +24 VDC Output
Channel 1 Output
Channel 2 Output
AC Input
15
14
13
12
11
10
98
7
6
5
4321
LED
Figure 1 - Voltage and Current Waveforms
Warner Electric • 800-825-9050 P-262 • 819-0493
Figure 2 - Basic Control with Switch Inputs
6
DC
COM
+24V
+4.8V
AC
INPUT
EARTH
GNDDCCOM
+12V
CH2
LED
CH1
P.E.
STOP
CH 2 CH 1
INH
START
OPTIONAL LOGIC BOARD 6090-448-016
MCS-131
120 V
OR
240V
AC
120 V
OR
240V
AC
MCS-638
S3
S3
S2
S2
S1
S1
SWITCHING
S1 - START INPUT SWITCH
S2 - PHOTOELECTRIC INHIBIT SWITCH
S3 - STOP INPUT SWITCH
NOTE: INPUT SWITCHING DEPENDENT ON
SWITCH SETTINGS ON LOGIC BOARD, PART NUMBER 6040-448-016
SWITCHING
S1 - START INPUT SWITCH
S2 - PHOTOELECTRIC INHIBIT SWITCH
S3 - STOP INPUT SWITCH
NOTE: INPUT SWITCHING DEPENDENT ON
SWITCH SETTINGS ON LOGIC BOARD, PART NUMBER 6040-448-016
TERMINAL DESIGNATIONS+
+
_
_
1. START INPUT
2 PHOTOELECTRIC INHIBIT
3
4
5
6
7 STOP INPUT
8 PHOTOELECTRIC INPUT
9 LED CHANNEL 1
10 LED CHANNEL 2
11 +12 VDC OUTPUT
12 DC COMMON
13 EARTH GROUND
14
15
16 +4.8 VDC OUTPUT (Optional Board)
17 DC COMMON
18 +24 VDC OUTPUT
1. START INPUT
2 PHOTOELECTRIC INHIBIT
3
4
5
6
7 STOP INPUT
8 PHOTOELECTRIC INPUT
9 LED CHANNEL 1
10 LED CHANNEL 2
11 +12 VDC OUTPUT
12 DC COMMON
13 EARTH GROUND
14
15
16 +4.8 VDC OUTPUT (Optional Board)
17 DC COMMON
18 +24 VDC OUTPUT
CHANNEL 1 OUTPUT
CHANNEL 1 OUTPUT
CHANNEL 2 OUTPUT
CHANNEL 2 OUTPUT
AC INPUT
AC INPUT
+
+
+
+
_
_
_
_
12
3
4
5
6
7
89
10
11
12
13
14
1516
17
18
TERMINAL DESIGNATIONS
+24V
DC
COM
+4.8V
POWER SUPPLY
6040-448-016
AC
INPUT
EARTH
GND
DC
COM
+12V
LED
CH2 CH1
P.E.
STOP
CH2
CH1
INH
STAR T
+
+
_
_
OPTIONAL LOGIC BOARD 6040-448-016
MCS-131
MCS-624
18
17
16
15
14 13 12
11
10
87
9
6
5
432
1
Figure 3 - Expanded Input Switching with Logic Board, 6090-448-016 and MCS-638
Color Mark Scanner
Figure 4 - Expanded Input Switching with Logic Board 6040-448-016 and MCS-624 Mark Reader
Warner Electric • 800-825-9050 P-262 • 819-0493
7
CH 2
CH 1
ON
ON
ON
ON
OUTPUTS
SWITCHING SIGNALS
STAR T
SCANNER
SCANNER
INHIBIT
STOP
6040-448-016 SWITCH PROGRAMMING
Open: The output f.f. goes low, ligic “0” at the negative transition
of the “stop” inut. It may be immediately retriggered.
Closed: The output f.f. goes low, ligic “0” at the negative transiotion
of the “stop” input and remains low as long as this
input is low.
Open: The scanner input must be low, logic “0”, and go hight,
Closed: logic “1” when a mark is detected.
Closed: the scanner input must be high, logic “1”, and go low,
Open: logic “0” when a mark is detected.
Open: The output f.f. trips high, logic “1” at the negative
transition of the “start” input.
Closed: The information in the output f.f. remains latched after the
negative going transition of the “start” input.
SW 1
SW 2*
SW 3*
SW 2*
SW 3*
SW 4
* Only one of the two switches may be closed.
OPTIONAL LOGIC BOARD 6040-448-017
MCS-131
STAR T
INH
CH 1
CH 2
STOP
N.C.CH1CH2
LED
+12V
DC
COM
EARTH
GND
AC
INPUT
+
+
-
-
DC
COM
+24V
+4.8V
18 17 16
120 VAC
OR
240 VAC
15 14 13 12 11 10 9 8 7 6 5 4 3
2
1
S2
S3
S1
SWITCHING
S1 - START INPUT SWITCH
S2 - STOP INPUT SWITCH
S3 - INHIBIT INPUT SWITCH
NOTE: SWITCHING LOGIC DEPENDENT ON SWITCH
SETTINGS ON LOGIC BOARD 6040-448-017
TERMINAL DESIGNATIO NS
1. START INPUT
2 INHIBIT
3 +
4 5 -
6 +
7 STOP INPUT
8 NO. CONNECTION
9 LED CHANNEL 1
10 LED CHANNEL 2
11 +12 VDC @ 100 MA.
12 DC COMMON
13 EARTH GROUND
14 -
15 16 +4.8 VDC OUTPUT (Optional Board)
17 DC COMMON
18 +24 VDC OUTPUT
CHANNEL 1 OUTPUT
CHANNEL 2 OUTPUT
AC INPUT
Figure 5 - Input - Output Switching Relationships with Logic Board 6040-448-018
Warner Electric • 800-825-9050 P-262 • 819-0493
Figure 6 - Extended Input Switching With Logic Board 6040-448-017
8
6040-448-017 Switch Programming
SW 1 Always Closed
SW 2 Open: Pulse Control
Closed: Level Control for Start/Stop at Terminal 1
SW 3 Not Used
SW 4 Always Closed
ON
ON
ON
ON
ON
CH 1
CH 2
STAR T
INH
STOP
OUTPUTS
SWITCHING SIGNALS
COMPONENT AREA
5.000
(124)
MAX.
8.000
(203.2)
7.200
(182.9)
.400
(10.2)
.300
(7.6)
LED IN
CH 1
DELAY
DELAY
CH 2
CH 1 OEX
CH 2 OEX
CH 1 S. S.
CH 2 S. S.
TERMINAL STRIP
LOGIC BOARD
(OPTIONAL)
LEDʼS
CH 1 OEX
CH 2 OEX
CH 1
CH 2
(OPTIONAL)
UP
UNIT TO BE
MOUNTED IN THIS
DIRECTION ONLY
FUSE
120/140 VAC
SWITCH
.220
(5.6) 4 PLACES
11. 500
(292.1)
10.900
(276.9)
DIMENSIONS IN (000) ARE IN MM.
REGULATO R
BOARD
Figure 7 - Input - Output Switching Relationships With Logic Board 6040-448-017
Figure 8 - Dimensional Outline and Adjustment Location
Warner Electric • 800-825-9050 P-262 • 819-0493
9
Warranty
Warner Electric LLC warrants that it will repair or replace (whichever it deems advisable) any
product manufactured and sold by it which proves to be defective in material or workmanship
within a period of one (1) year from the date of original purchase for consumer, commercial or
industrial use.
This warranty extends only to the original purchaser and is not transferable or assignable without
Warner Electric LLC’s prior consent.
Warranty service can be obtained in the U.S.A. by returning any defective product, transportation
charges prepaid, to the appropriate Warner Electric LLC factory. Additional warranty information
may be obtained by writing the Customer Satisfaction Department, Warner Electric LLC, 449
Gardner Street, South Beloit, Illinois 61080, or by calling 815-389-3771.
A purchase receipt or other proof of original purchase will be required before warranty service is
rendered. If found defective under the terms of this warranty, repair or replacement will be made,
without charge, together with a refund for transportation costs. If found not to be defective, you
will be notified and, with your consent, the item will be repaired or replaced and returned to you at
your expense.
This warranty covers normal use and does not cover damage or defect which results from
alteration, accident, neglect, or improper installation, operation, or maintenance.
Some states do not allow limitation on how long an implied warranty lasts, so the above limitation
may not apply to you.
Warner Electric LLC’s obligation under this warranty is limited to the repair or replacement of the
defective product and in no event shall Warner Electric LLC be liable for consequential, indirect,
or incidental damages of any kind incurred by reason of the manufacture, sale or use of any defective product. Warner Electric LLC neither assumes nor authorizes any other person to give any
other warranty or to assume any other obligation or liability on its behalf.
WITH RESPECT TO CONSUMER USE OF THE PRODUCT, ANY IMPLIED WARRANTIES WHICH
THE CONSUMER MAY HAVE ARE LIMITED IN DURATION TO ONE YEAR FROM THE DATE OF
ORIGINAL CONSUMER PURCHASE. WITH RESPECT TO COMMERCIAL AND INDUSTRIAL
USES OF THE PRODUCT, THE FOREGOING WARRANTY IS IN LIEU OF AND EXCLUDES ALL
OTHER WARRANTIES, WHETHER EXPRESSED OR IMPLIED BY OPERATION OF LAW OR
OTHERWISE, INCLUDING, BUT NOT LIMITED TO, ANY IMPLIED WARRANTIES OF
MERCHANTABILITY OR FITNESS.
Some states do not allow the exclusion or limitation of incidental or consequential damages, so the
above limitation or exclusion may not apply to you. This warranty gives you specific legal rights and
you may also have other rights which vary from state to state.
Changes in Dimensions and Specifications
All dimensions and specifications shown in Warner Electric catalogs are subject to change without
notice. Weights do not include weight of boxing for shipment. Certified prints will be furnished
without charge on request to Warner Electric.
Warner Electric LL C
31 Industrial Park Road • New Hartford, CT 06057
815-389-3771
www.warnerelectric.com
An Altra Industrial Motion Company
• Fax: 815-389-2582
P-262 819-0493 06/11
11
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