Warner Electric MCS2000-DRV2 User Manual
MCS200 0-DRV2 Dual Voltage/
Dual Channel Driver
P-2010-6
819-0524
Service&Installation Instructions
For 24 VDC or
48 VDC Operation
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation
Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
System Wiring
Interfacing to MCS2000 Tension Controls . . . . 5
24 volt Brake Systems . . . . . . . . . . . . . . . . . . . 8
48 volt Brake Systems . . . . . . . . . . . . . . . . . . . 9
System Start-Up . . . . . . . . . . . . . . . . . . . . . . . . . 11
System Troubleshooting . . . . . . . . . . . . . . . . . . . 17
Listing of Figures and Illustrations . . . . . . . . . . . 19
Warranty Information . . . . . . . . . . . . . . . Back Page
The MCS2000-DRV2 has reduced input terminals on
the front of the unit that are pluggable which will
make installation and wiring much easier than the
previous versions. By using a pluggable terminal
block, if replacement is required then only the
controller has to be disconnected and removed and
a new controller installed without having to rewire the
entire system.
Footprint for the DRV2 is identical to that of the
MCS2000-DRV and MCS2000-DRVH drivers. The
MCS2000-DRV and MCS2000-DRVH can be
replaced with the MCS2000-DRV2 without having to
make any mechanical changes in the mounting
footprint.
Failure to follow these
instructions may result in product damage,
equipment damage, and serious fatal injury to
personnel.
Introduction
The MCS2000-DRV2 Dual Channel/Dual Voltage
drive is a replacement for the MCS2000-DRV and
MCS2000-DRVH Drivers in one unit. The unit is
designed so that it can operate from either 24 volts
DC input or 48 volts DC input and provide output
voltage and current for operation of any of the 24
volt DC tension brakes available from Warner
Electric.
The universal design replaces two separate drivers in
one package and provides for dual brake operation,
for either single brake when only one brake is
required or dual brake operation on splicer systems
where two brakes are required.
Additionally, LED indicators on the face of the control
make troubleshooting and monitoring operation
much simpler than previous versions. A combination
red and green LED for each channel determines
operation during normal run conditions as well as
during faults.
Each driver channel has its own individual
anti-residual adjustment to make brake adjustment
in the “off” state optimum. Anti-residual provides a
reverse current to the brakes in the off state to
minimize residual magnetism build-up. This allows
for reducing the drag torque in the brake during
initial start-up.
The driver can be controlled by any of the MCS2000
controllers offered as either a single channel system
or dual channel system. The MCS2000-ECA,
MCS2000-CTDA, or MCS2000-CTLC controllers can
provide the operating signals.
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Warner Electric • 800-825-9050 P-2010-6 • 819-0524
Specifications
Operating Temperature: + 104 ° F (40 ° C)
Model: MCS2000-DRV2 Dual Channel/Dual
Voltage Driver
Part Number: 6910-448-109
Input Voltage: 24 Volts DC or 48 Volts DC, + / - 10%
Output Voltage: 24 VDC or 48 VDC depending on
power supply input voltage.
In Overvoltage mode, output voltage is
limited to 48 volts DC for 30 seconds before
reducing back to 24 VDC.
Output Current: Maximum of 4.5 amps DC per
channel. Overload capacity to 6 amps maximum per
channel for 30 seconds, to be followed by maximum
3 amps for a period of minimum 120 seconds.
Anti-Residual Output: 10% of input power supply
voltage. Adjustable for each channel.
-2.4 volts DC with 24 VDC power supply input
-4.8 volts DC with 48 VDC power supply input
Storage Temperature: -13 ° F to + 131° F
(-25° C to + 55° C)
Enclosure: NEMA 1 (IP 20)
Certifications: CE
Analog Input Voltage: 0 to 10 Volts DC on Input A
or Input B. When operating with 48 volt DC power,
input of 0 to 5 volts corresponds to 24 Volt DC
output, and from 5 to 10 volts input overvoltage
mode from 24 to 48 volts DC with timed limitation.
Status and Diagnostic Indicators: 2 LED’s on each
channel indicate normal operation and fault
conditions during operation. One Green and one
Red LED.
Protection:
Input: Polarity protected to prevent damage in the
event of inversion of DC power supply voltages.
Output: Short circuit protected during operation
and power up. Output is also protected from
overload conditions. Once short circuit is detected,
drive locks out for 10 msec and resets. After 4
cycles, drive trips out and requires reset.
Reset Mode: Requires power off and then power on
to reset driver.
Wiring: Via 10 position pluggable terminal block.
Warner Electric • 800-825-9050 P-2010-6 • 819-0524
3
Installation
5.83
(148)
7.28
(185)
.19
(4.8)
6.46
(164)
2.36
(60)
2.95
(75)
6.86
(174)
MSC2000-DRV2
“A” Antiresidual
Channel A
“B” Antiresidual
Channel B
1. In A 0-10V
2. 0V
3. In B 0-10V
4. 0V
5. Brk A+
6. Brk A-
7. Brk B+
8. Brk B-
9. -DC Power
10. + 24 - 48 VDC
Mounting
Select a location that will allow for sufficient air
movement around the control.
Overall Dimensions: 6.85 x 2.95 x 7.28 inches
(174 x 75 x 185 mm)
Note: Unit must be mounted vertically to have
best possible cooling effect.
1. Using the dimensional data from Figure 1, drill
and tap 4 mounting holes for either 4.5 mm
screws or #10 screws on the panel or
mounting surface the drive will be mounted to.
2. Using either 4.5 mm or #10 screws, mount the
unit to the panel or mounting surface. Tighten
screws sufficiently so that unit will not come
loose during normal machine operation or
vibration.
Note: 0 Volt terminals in control are tied to control
housing. A good ground is required between the
control and the panel or mounting surface.
3. After unit is mounted and secured, make sure
that spacing is sufficient around the housing
and that at least a clearance of at least 2.00
inches (50.8 mm) for the front panel wiring
plug to facilitate wiring unit and plugging
connector to control.
4. Double check all mounting before proceeding
to the wiring section.
Driver Outline and Mounting Dimensions
Warner Electric • 800-825-9050 P-2010-6 • 819-0524
4
Mounting Dimensions
Figure 1
System Wiring
Controllers
If only a single brake is to be used on the
MCS2000-DRV2, then skip to either the 24 volt
brake wiring section, page 8 or the 48 volt brake
wiring section, page 10.
The MCS2000-DRV2 will operate with any of the
MCS2000 series Controllers. It will provide interface
between the brakes and the MCS2000-ECA,
MCS2000-CTDA or MCS2000-CTLC Tension
Controls.
Wiring between the various controls will vary
somewhat, but for all practical purposes are
pretty similar.
The MCS2000-DRV2 will operate with any of the 24
volt Warner Electric Tension Brakes or Clutches as
long as the maximum current rating per channel is
not exceeded.
Wiring to the MCS2000-ECA Control
Refer to Figure 2 for wiring hook-ups.
It is recommended that shielded
cable or twisted wire pairs be used to minimize
the possibility of noise affecting either the
controller or driver circuitry. Additionally, lead
lengths should be kept as short as possible.
3. Connect a wire from terminal Out 2 (V) on the
MCS2000-ECA to terminal number 3 InB
0-10 V on the MCS2000-DRV2. Insure that
both terminals are tightened securely.
4. Connect a wire from terminal Out 1 (OV) on
the MCS2000-ECA to terminal number 4 OV
on the MCS2000-DRV2. Insure that both
terminals are tightened securely.
5. This completes the wiring between the
MCS2000-ECA and the MCS2000-DRV2.
Double check all wiring before proceeding to
the next section.
6. Proceed to either the 24 volt brake wiring
section, page 8 or the 48 volt brake wiring
section, page 10 of the manual.
Note: Also refer to MCS2000-ECA Manual for
exact terminal strip locations and designations.
1. Connect a wire from terminal Out 1 (V) on the
MCS2000-ECA to terminal number 1 InA 0-10
V on the MCS2000-DRV2. Insure that both
terminals are tightened securely.
2. Connect a wire from terminal Out 1 (0V) on
the MCS2000-ECA to terminal number 2 0V
on the MCS2000-DRV2. Insure that both
terminals are tightened securely.
If a dual brake system is to be used, then proceed to
step 3.
Warner Electric • 800-825-9050 P-2010-6 • 819-0524
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AR “A”
AR “B”
1. In A 0-10V
2. 0V
3. In B 0-10V
4. 0V
5. Brk A+
6. Brk A-
7. Brk B+
8. Brk B-
9. -DC Power
10. + 24 - 48 VDC
(green)
(red)
(red)
(red)
(green)
(green)
MCS2000-ECA Controller MCS2000-DRV2 Driver
Note: Wiring is shown for both channels. If only one channel is required, then follow wiring
shown for channel “A” only.
Figure 2
MSCS2000-ECA to MCS2000-DRV2
Wiring to the MCS2000-CTDA or
MCS2000-CTLC Controllers
Note: Since the MCS2000-CTDA and
MCS2000-CTLC controllers have 25 pin DB
connectors with cables, wiring is made via
the cable.
Care must be taken to insure
the correct wires are connected and none
of the other wires contact or short out. It is
recommended that unused wires be cut
off and taped so that shorting and grounding
out does not occur.
Note: Refer to the MCS2000-CTDA or
MCS2000-CTLC Manual for exact wire
functions and designations.
Refer to Figure 3 for wiring hook-ups.
Warner Electric • 800-825-9050 P-2010-6 • 819-0524
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1. Connect the brown wire [Channel 1 Out (V)]
MCS2000-CT
Cable Assembly
MSC2000-DRV2
“A” Antiresidual
Channel A
“B” Antiresidual
Channel B
1. In A 0-10V
2. 0V
3. In B 0-10V
4. 0V
5. Brk A+
6. Brk A-
7. Brk B+
8. Brk B-
9. -DC Power
10. + 24 - 48 VDC
(Brown)
(Green)
(Red)
(Black)
from the connector cable on the
MCS2000-CT controller to terminal number 1
In A 0 – 10 V on the MCS2000-DRV2. Insure
that the terminal on the MCS2000-DRV2 is
tightened securely.
2. Connect the green wire [Channel 1 Out (0V)]
from the connector cable on the
MCS2000-CT controller to terminal number 2,
0 V on the MCS2000-DRV2. Insure that the
terminal on the MCS2000-DRV2 is tightened
securely.
If a dual brake system is to be used, then proceed to
step 3.
If only a single brake is to be used on the
MCS2000-DRV2, then skip to either the 24 volt brake
wiring section, page 8 or the 48 volt brake wiring
section, page 10.
3. Connect the red wire [Channel 2 Out (V)] from
the connector cable on the MCS2000-CT
controller to terminal number 3 In V 0-10 V on
the MCS2000-DRV2. Insure that the terminal
on the MCS2000-DRV2 is tightened securely.
4. Connect the black wire [Channel 2 Out (0V)]
from the connector cable on the
MCS2000-CT Connector controller to
terminal number 4 on the MCS2000-DRV2.
Insure that the terminal on the
MCS2000-DRV2 is tightened securely.
5. This completes the wiring between the
MCS2000-ECA and the MCS2000-DRV2.
Double check all wiring before proceeding to
the next section.
6. Proceed to either the 24 volt brake wiring
section, page 8 or the 48 volt brake wiring
section, page 10 of the manual.
Note: Wiring is shown for both channels. If only
one channel is required, then follow wiring
using only the brown and green wires as shown.
MCS2000-CT Cable and Connector MCS2000-DRV2 Driver
MCS2000-CTDA or MSC2000-CTLC to MCS2000-DRV2
Warner Electric • 800-825-9050 P-2010-6 • 819-0524
Figure 3
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