Warner Electric MCS2000-PSDRV2 User Manual

MCS2000-PSDRV2 Power Supply/Dual

Voltage/Dual Channel Driver

819-0525
P-2010-7

Installation & Operating Instructions

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 . . . . . . . . . . . . .10

System Start-Up . . . . . . . . . . . . . . . . . . . . . . . 11

System Troubleshooting . . . . . . . . . . . . . . . . . 17

Listing of figures and illustrations . . . . . . . . . . .21

Warranty Information . . . . . . . . . . . . . . . . . . . BC

Introduction

The MCS2000-PSDRV2 Power Supply/Dual
Channel/Dual Voltage driver is a replacement for
the MCS2000-PSDRV and MCS2000-PSDRVH
Drivers in a single unit. The Power Supply section
will operate from 100 – 260 VAC and provide a 24
VDC output for operating either the driver section
of the unit or the MCS2000-ECA and other
sensors. The Dual Channel/Dual Voltage driver
section will 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 power
supply/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.

reduced input terminals on the front of the unit for
the driver section 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 PSDRV2 is identical to that of the
MCS2000-PSDRV and MCS2000-PSDRVH power
supply/drivers. The MCS2000-PSDRV and
MCS2000-PSDRVH can be replaced with the
MCS2000-PSDRV2 without having to make any
mechanical changes in the mounting footprint.

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. The MCS2000-PSDRV2 has

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Specifications

Model: MCS2000-PSDRV2 Dual Channel/Dual

Voltage Driver

Part Number: 6910-448-110

Power Supply Section:

Input: 100 – 260 VAC, 50/60 Hz., single phase

Ouput: 24 VDC, 3.1 Amps DC

Wiring: 3 Position pluggable terminal block for

AC Input
4 Position pluggable terminal block for DC Output
Power

Reset Mode: Requires power off and then power
on to reset driver

Driver Section:

Input Voltage: 24 Volts DC or 48 Volts DC,
+ / -10%

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.

Protection 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.

Wiring: Via 10 position pluggable terminal block

Operating Temperature: + 104 ° F (40 ° C)

Storage Temperature: -13 ° F to + 131° F

(-25° C to + 55° C)

Enclosure: NEMA 1 (IP 20)

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 minimum period of 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

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.

Certifications: CE

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Installation

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.

o 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.

o 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.

o 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.

o 4. Double check all mounting before

proceeding to the wiring section.

Driver Outline and Mounting Dimensions

Figure 1 Mounting Dimensions

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System Wiring

Controllers

The MCS2000-PSDRV2 will operate with any of
the MCS2000 series Controllers. It will provide
interface between the brakes and the MCS2000­ECA, MCS2000-CTDA or MCS2000-CTLC
Tension Controls. Additionally when the
MCS2000-ECA is used, the MCS2000-PSDRV2
can supply the 24 VDC power for operating the
controller as well.

Wiring between the various controls will vary
somewhat, but for all practical purposes are pretty
similar.

The MCS2000-PSDRV2 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.

CAUTION: It is recommended that shielded cable
or twisted wire pairs be used to minimize the
possibly of noise affecting either the controller or
driver circuitry. Additionally, lead lengths should
be kept as short as possible.

If only a single brake is to be used on the
MCS2000-PSDRV2, then skip to either the 24 volt
brake wiring section, page 8 or the 48 Volt brake
wiring section, page 10.

o 3. Connect a wire from terminal Out 2 (V) on

the MCS2000-ECA to terminal number 3
InB 0-10 V on the MCS2000-PSDRV2.
Insure that both terminals are tightened
securely.

o 4. Connect a wire from terminal Out 1 (0V) on

the MCS2000-ECA to terminal number 4
0V on the MCS2000-PSDRV2. Insure that
both terminals are tightened securely.

o 5. This completes the wiring between the

MCS2000-ECA and the MCS2000­PSDRV2. Double check all wiring before
proceeding to the next section.

o 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.

o 1. Connect a wire from terminal Out 1 (V) on

the MCS2000-ECA to terminal number 1
InA 0-10 V on the MCS2000-PSDRV2.
Insure that both terminals are tightened
securely.

o 2. Connect a wire from terminal Out 1 (0V) on

the MCS2000-ECA to terminal number 2
0V on the MCS2000-PSDRV2. Insure that
both terminals are tightened securely.

If a dual brake system is to be used, then proceed
to step 3.

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(green)

(red)

MSC2000-PSDRV2

“A” Antiresidual

Channel A

“B” Antiresidual

Channel B

1
2
3
4
5
6
7
8
9

10

InA 0-10V

0-V

InB 0-10V

0V

Brk A+
Brk A­Brk B+
Brk B-

-DC Pwr

+24-48V

+24V

+24V

0V

0V

MCS2000-ECA Controller

MCS2000-PSDRV2 Driver

Note: Wiring is shown for both channels. If only one channel is required, then follow wiring for channel “A”.

Figure 2 MCS2000-ECA to MCS2000-PSDRV2

Wiring to the MCS2000-CT’S 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.

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o 1. Connect the brown wire [Channel 1 Out

(V)] from the connector cable on the
MCS2000-CT controller to terminal 1 In A
0 – 10 V on the MCS2000-PSDRV2.
Insure that the terminal on the
MCS2000-PSDRV2 is tightened securely.

o 3. Connect the red wire [Channel 2 Out (V)]

from the connector cable on the
MCS2000-CT controller to terminal
3 In B 0-10 V on the MCS2000-PSDRV2.
Insure that the terminal on the
MCS2000-PSDRV2 is tightened securely.

o 2. Connect the green wire [Channel 1 Out

(0V)] from the connector cable on the
MCS2000-CT controller to terminal 2, 0 V
on the MCS2000-PSDRV2. Insure that the
terminal on the MCS2000-PSDRV2 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.

o 4. Connect the black wire [Channel 2 Out

(0V)] from the connector cable on the
MCS2000-CT controller to terminal 4 on
the MCS2000-PSDRV2. Insure that the
terminal on the MCS2000-PSDRV2 is
tightened securely.

o 5. This completes the wiring between the

MCS2000-CT and the MCS2000-PSDRV2.
Double check all wiring before proceeding
to the next section C.

o 6. Proceed to either the 24 volt brake wiring

section, page 8 of the manual 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-PSDRV2 Driver

Figure 3 MCS2000-CTDA or MCS2000-CTLC to MCS2000-PSDRV2

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Power and Brake Wiring

24 Volt Systems
Using The Internal 24V Power Supply

Brake Wiring (Optional AC Power Wiring)

o 1. Wire the positive (+) side of the 24 volt DC

power supply to terminal 10 of the

MCS2000-PSDRV2. Make sure that the

terminal is securely tightened on the

MCS2000-PSDRV2.

o 2. Wire the negative side (-) or DC common

of the 24 volt DC power supply to terminal

9 of the MCS2000-PSDRV2. Make sure

the terminal is securely tightened on the

MCS2000-PSDRV2.

Using External 24 VDC Power Source

o 1. Connect the positive side of the 24 VDC

power source to the positive (+) input,

terminal 10. Tighten terminal securely.

o 2. Connect the negative side of the 24 VDC

power source to the negative (-) input,

terminal 9. Tighten terminal securely.

o 1. Wire the brake for Channel “A” on

terminals 5 and 6 of the MCS2000­PSDRV2. Make sure the terminals
are securely tightened.

o 2. If a brake is to be used on Channel “B”

wire the brake to the Channel “B”
terminals 7 and 8 on the MCS2000­PSDRV2. Make sure the terminals are
securely tightened.

o 3. Wire AC power; hot neutral, and ground to

the power input terminals on the right side
of the MCS2000-PSDRV2. Make sure
terminals are securely tightened.

Note: Warner Electric Tension brakes are not

polarity sensitive, so wiring between
terminals on the MCS2000-DRV2 and
brake are not sensitive to the + and ­designations.

Note: Make sure the current capacity is sufficient

to handle the brake load and driver

circuitry. If any other external power

requirements are required, then the power

supply capacity must be sized to handle

these currents as well.

TB Series ATT Series MTB Series Magnetic Particle

TB-170
TB-260
TB-425
TB-500
TB-825

ATTB/ATTC-25
ATTB/ATTC-55

ATTB/ATTC-115

All MTB’s up to 12

*Up to 16 magnets if

outputs paralleled and

inputs paralleled
TB-1000
TB-1225
TB-1525

The following 24 volt tension brakes can be used
with the MCS2000-DRV2 Driver for 24 volt
operation.

MPB/MPC2

magnets

MPB/MPC15
MPB/MPC70

MPB/MPC120

MPB240

POB/POC-0.3 to 20’s

PRB-H’s 1.2 to 20’s

PTB’s 2.5 to 20’s

PMC-A’s 10 to 40’s

PHC-R 0.6 to 40’s

*POB/POC-40 & 80 if output

and inputs paralleled

* When 16 magnet MTB Brakes and POB/POC-40 and 80 Magnetic Particle Brakes are used,
inputs and outputs must be wired parallel to obtain sufficient output current for proper brake.

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Brake

Brake

“A”

“B”

24 Volt
Power

Supply

- DC

+DC

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

Wiring with 24 volt DC External Power Supply

Figure 4 24 Volt System Power Supply and Brake Wiring

Wiring using internal 24 volt DC Power

MCS2000-PSDRV2 Power Supply /Driver

Note: If the internal power supply is used, the
maximum current available is 3.1 amps. If higher
current is required, then either a second
MCS2000-PS power supply is required or an
external 24 VDC source is needed in place of the
internal supply.

48 Volt Systems

Note: Make sure the current capacity is

sufficient to handle the brake load and
driver circuitry. If any other external power
requirements are required, then the power
supply capacity must be sized to handle
these currents as well.

o 3. Wire the brake for Channel “A” on

terminals 5 and 6 of the MCS2000-

o 1. Wire the positive (+) side of the 48 volt DC

power supply to terminal 10 of the
MCS2000-PSDRV2. Make sure that the
terminal is securely tightened on the
MCS2000-PSDRV2.

o 2. Wire the negative side (-) or DC common

of the 48 volt DC power supply to terminal
9 of the MCS2000-PSDRV2. Make sure the
terminal is securely tightened on the

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MCS2000-PSDRV2.

o 4. If a brake is to be used on Channel “B”

PSDRV2. Make sure the terminals are
securely tightened.

wire the brake to Channel “B” terminals 7
and 8 on the MCS2000-PSDRV2. Make
sure the terminals are securely tightened.

9

Note: Warner Electric Tension brakes are not

polarity sensitive, so wiring between
terminals on the MCS2000-DRV2 and
brake are not sensitive to the + and

ATT Series MTB Series Magnetic Particle

- designations.

The following 24 volt tension brakes can be
used with the MCS2000-DRV2 Driver for 48 volt
operation with overcurrent feature.

ATTB/ATTC-25
ATTB/ATTC-55

ATTB/ATTC-115

All MTB’s up to 12

magnets

* Up to 16 magnets if

outputs paralleled

MPB/MPC2
MPB/MPC15
MPB/MPC70

MPB/MPC120

MPB240

POB/POC-0.3 to 20’s

PRB-H’s 1.2 to 20’s

PTB’s 2.5 to 20’s

PMC-A’s 10 to 40’s

PHC-R 0.6 to 40’s

*POB/POC-40 & 80 if output

and inputs paralleled

* When 16 magnet MTB Brakes and POB/POC-40 and 80 Magnetic
Particle Brakes are used, inputs and outputs must be wired parallel to
obtain sufficient output current for proper brake operation.

48 Volt DC Power Supply

MCS2000-PSDRV2 Driver

Figure 5 48 Volt System Power Supply and Brake Wiring

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System Start-Up

AR “A”

Channel “A”

The Channel “A” is operating in the anti-residual
mode with the following indication.

Flashing “ON” 1.5 sec, “OFF” 0.5 sec

RED LED is “OFF”

- (Green)

- (Green LED)

- (Red LED)

24 Volt System

o 1. Prior to applying power, double check all

wiring between Tension Control and Driver,
Driver and Brake or Brakes, and 24 Volt
Power Source and Driver.

o 2. Once connections are checked and

confirmed that all wiring is correct, turn
power on to the Power Supply and
Controller and observe “RED” and
“GREEN” LED Indicators on the Driver.

o 3. If everything is normal, then the “GREEN”

LED will be on and “RED” LED’s will
be off. Any other indication of the
“RED” and “GREEN” LED’s refer to the
troubleshooting section, page 17 of the
manual for troubleshooting and
diagnostics.

o 4. If drive is functional and no problems are

noted, then the Anti-residual output to the
brake or brakes needs to be adjusted
accordingly. Adjust the anti-residual output
for Channel “A” as follows:

o 4a. Using a digital DC Voltmeter,

connect the positive lead to
terminal 1 and the negative lead to
terminal 2 of the MCS2000­PSDRV2 for Channel “A” input.

o 4b. Adjust the Tension controller being

used to give a 0 VDC reading on
the Channel “A” input.

o 4c. Using a small screwdriver, rotate

the anti-residual potentiometer “A”
fully counter-clockwise so the
output voltage to the brake is zero
level. Voltage can be measured to
the Channel “A” brake on terminals
5 and 6 of the MCS2000-PSDRV2.
Terminal 5 is positive, and terminal
6 is negative. Note that the
“GREEN” LED for Channel “A” is
flashing at this time.

o 4d. Now slowly adjust the anti-residual

potentiometer “A” clockwise while
feeling the reaction on the brake.
When the optimum anti-residual
output is obtained, the brake will be
very free to rotate or the armatures,
in the case of the TB’s, will feel like
they are floating away from the
magnet assembly.

Note: Using a meter across the brake “A”

terminals 5 and 6 as noted in 4c above,
the voltage observed should be negative at
this time.

o 4e. Once this point is found, do not

adjust this potentiometer further or
the brake can re-engage.

o 4f. If a second brake is used on

Channel “B”, then proceed to step
5 otherwise this completes the
anti-residual adjustment for the “A”
Channel. Continue to step 6.

The following LED indications will be present

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when anti-residual current is applied to the brake.

AR “B”

Channel “B”

The Channel “B” is operating in the
anti-residual mode with the following indication.

Flashing “ON” 1.5 sec, “OFF” 0.5 sec

RED LED is “OFF”

- (Green)

- (Green)

- (Red)

flashing at this time.

o 5. Adjust the anti-residual output for Channel

“B” as follows if a brake is used on this
output. If no brake is used, then disregard
this portion of the start-up. Proceed to
step 6.

o 5a. Using a digital DC Voltmeter,

connect the positive lead to
terminal 3 and the negative lead to
terminal 4 of the MCS2000­PSDRV2 for Channel “B” input.

o 5b. Adjust the Tension controller being

used to give a 0 VDC reading on
the Channel “B” input.

o 5c. Using a small screwdriver, rotate

the anti-residual potentiometer “B”
fully counter-clockwise so the
output voltage to the brake is zero
level. Voltage can be measured to
the Channel “B” brake on terminals
7 and 8 of the MCS2000-PSDRV2.
Terminal 7 is positive, and terminal
8 is negative. Note that the
“GREEN” LED for Channel “B” is

o 5d. Now slowly adjust the anti-residual

potentiometer “B” clockwise while

feeling the reaction on the brake.

When the optimum anti-residual

output is obtained, the brake will be

very free to rotate or the armatures,

in the case of the TB’s, will feel like

they are floating away from the

magnet assembly.

Note: Using a meter across the brake “B”

terminals 7 and 8 as noted in 5c above,
the voltage observed should be negative
at this time.

o 5e. Once this point is found, do not

adjust this potentiometer further or

the brake can re-engage.

o 5f. This completes the adjustment for

the Channel “B” anti-residual.

Proceed to step 6.

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The following LED indications will be present
when anti-residual current is applied to the brake.

o 6. Adjust the input voltage from the tension

controller to the Channel “A” input
observing the “RED” and “GREEN” LED’s.
If a 24 volt system is being commissioned,
then only the “GREEN” LED should be
functional unless there is a problem with
the controller, brake, or wiring.

proceed to the troubleshooting section on
page 17 to determine cause and
appropriate action to take.

48 Volt System

o 1. Prior to applying power double check all

wiring between Tension Control and Driver,
Driver and Brake or Brakes, and 48 Volt
Power Source and Driver.

o 7. If no other indications are present on the

LED’s then the system is functioning
properly. The intensity of the “GREEN”
LED does not change with the amount of
output current being supplied to the brake.

o 8. If other LED indications are present,

proceed to the troubleshooting section on
page 17 to determine cause and
appropriate action to take.

o 9 Adjust the input voltage from the tension

controller to the Channel “B” input if a
brake is connected to the Channel “B”
output observing the “RED” and “GREEN”
LED’s. If a 24 volt system is being
commissioned, then only the “GREEN”
LED should be functional unless there is a
problem with the controller, brake, or
wiring.

o 10. If no other indications are present on the

LED’s then the system is functioning
properly. The intensity of the “GREEN”
LED will not change with the amount of
output current being supplied to the brake.

o 11. If other LED indications are present,

o 2. Once connections are checked and

confirmed that all wiring is correct, turn
power on to the Power Supply and
Controller and observe “RED” and
“GREEN” LED Indicators on the Driver.

o 3. If everything is normal, then the

“GREEN” LED will be on and “RED”
LED’s will be off. Any other indication of
the “RED” and “GREEN” LED’s, refer to
the troubleshooting section, page 17 of
the manual for troubleshooting and
diagnostics

o 4. If drive is functional and no problems are

noted, then the anti-residual output to the
brake or brakes needs to be adjusted
according. Adjust the anti-residual output
for Channel “A” as follows.

o 4a. Using a digital DC Voltmeter,

connect the positive lead to
terminal 1 and the negative lead to
terminal 2 of the MCS2000­PSDRV2 for Channel “A” input.

o 4b. Adjust the Tension controller being

used to give a 0 VDC reading on
the Channel “A” input.

o 4c. Using a small screwdriver, rotate

the anti-residual potentiometer “A”
fully counter-clockwise so the
output voltage to the brake is zero
level. Voltage can be measured to
the Channel “A” brake on terminals
5 and 6 of the MCS2000-PSDRV2.

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o 4d. Now slowly adjust the anti-residual

AR “B”

Channel “B”

- (Green)

- (Red)

The Channel “B” is operating in the
anti-residual mode with the following indication.

Flashing “ON” 1.5 sec, “OFF” 0.5 sec

RED LED is “OFF”

- (Green)

potentiometer “A” clockwise while
feeling the reaction on the brake.
When the optimum anti-residual
output is obtained, the brake will be
very free to rotate without much
resistance. This is best if done at
core diameter.

Note: Using a meter across the brake “A”

terminals 5 and 6 as noted in 4c above,
the voltage observed should be negative
at this time.

o 4e. Once this point is found, do not

adjust this potentiometer further or
the brake can re-engage.

o 4f. If a second brake is used on

Channel “B”, then proceed to
step 5 otherwise this completes
the anti-residual adjustment for the
“A” Channel. Continue to step 6.

The following LED indications will be present when anti-residual current is applied to the brake.

This is anti-residual mode only.

o 5. Adjust the anti-residual output for Channel

“B” as follows if a brake is used on this
output. If no brake is used, then disregard
this portion of the start-up. Proceed to
step 6.

o 5c. Using a small screwdriver, rotate the

anti-residual potentiometer “B” fully
counter-clockwise so the output
voltage to the brake is zero level.
Voltage can be measured to the
Channel “B” brake on terminals 7

o 5a. Using a digital DC Voltmeter,

connect the positive lead to terminal
3 and the negative lead to terminal
4 of the MCS2000-PSDRV2 for
Channel “B” input.

o 5b. Adjust the Tension controller being

o 5d. Now slowly adjust the anti-residual

used to give a 0 VDC reading on the

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Channel “B” input.

and 8 of the MCS2000-PSDRV2.
Terminal 7 is positive, and terminal 8
is negative. Note that the “GREEN”
LED for channel “B” is flashing at
this time.

potentiometer “B” clockwise while
feeling the reaction on the brake.
When the optimum anti-residual

output is obtained, the brake will be

AR “B”

Channel “B”

- (Green)

- (Red)

The Channel “B” is operating in the
anti-residual mode with the following indication.

Flashing “ON” 1.5 sec, “OFF” 0.5 sec

RED LED is “OFF”

- (Green)

very free to rotate without much
resistance. This is best if done at
core diameter.

Note: Using a meter across the brake “B”

terminals 7 and 8 as noted in 5c above, the
voltage observed should be negative at this
time.

o 5e. Once this point is found, do not

adjust this potentiometer further or
the brake can re-engage.

o 5f. This completes the adjustment for

the Channel “B” anti-residual.
Proceed to step 6.

The following LED indications will be present when anti-residual current is applied to the brake.

This is anti-residual mode only.

o 6. Adjust the input voltage from the tension

controller to the Channel “A” input
observing the “RED” and “GREEN” LED’s.
If a 48 volt system is being commissioned,
then only the “GREEN” LED should be
functional with the input voltage between
the 0 to 5 volt level, unless there is a
problem with the controller, brake, or wiring.

o 6b. Allow the control to operate in this

mode for 60 seconds or more and
observe the LED’s. After the
Overexcitation circuit times out,
the “RED” LED will be flashing at a
frequency of approximately 30
hertz with the LED being “ON”
approximately 1 second and “OFF”
approximately 1 second. Measuring

o 6a. Adjust the input voltage from the

tension controller to the Channel “A”
input above 5 volts while observing

the output to the brake on Terminals
5 and 6 should indicate the brake is

at 24 volts DC.
the “GREEN” and “RED” LED’s. The
“GREEN” LED should be on steady
and the “RED” LED should be
flashing at a rate of approximately
30 hertz frequency with the LED on
for typically 0.5 second and off for

Warner Electric • 800-825-9050 P-2010-7 • 819-0525

1.5 seconds. This indicates the
brake is operating in the overcurrent
mode and will be limited to 60
seconds.

o 6c. Reduce the input on Terminals 1 and

2 to less than 5 volts DC and

observe the LED’s at this time. The

“GREEN” LED will be “ON”, and the

“RED” LED will be flashing at a

frequency of approximately 20 hertz,

with the “ON” time of approximately

0.5 second and the “OFF” time of

approximately 2.5 seconds. The

15

operate in the 0 to 24 volt range, but
the overexcitation level from 24 volts
to 48 volts is not available as the
circuit has not reset as yet.

o 6d. Once the overexcitation has reset,

the “GREEN” LED will be “ON” and
the “RED” LED will be flashing as in
step 6a above when the input
voltage goes above 5 volts again at
Terminals 1 and 2 of the
MCS2000-PSDRV2.

o 7. If no other indications are present on the

LED’s then the system is functioning
properly. The intensity of the “GREEN” LED
does not change with the amount of output
current being supplied to the brake. This
completes the checkout of the “A” Channel.
Proceed to step 9.

o 8. If LED indications are present other than

those described above, proceed to the
troubleshooting section on page 17 to
determine cause and appropriate action to
take.

o 9. Adjust the input voltage from the tension

controller to the Channel “B” input
observing the “RED” and “GREEN” LED’s. If
a 48 volt system is being commissioned,
then only the “GREEN” LED should be
functional with the input voltage between
the 0 to 5 volt level, unless there is a
problem with the controller, brake, or wiring.

o 9a. Adjust the input voltage from the

tension controller to the Channel “B”
input above 5 volts while observing
the “GREEN” and “RED” LED’s. The
“GREEN” LED should be on steady
and the “RED” LED should be
flashng at a rate of approximately 30
hertz frequency with the LED on for
typically 0.5 second and off for 1.5
seconds. This indicates the brake is
operating in the overcurrent mode
and will be limited to 60 seconds.

overexcitation circuit times out, the
“RED” LED will be flashing at a
frequency of approximately 30
hertz with the LED being “ON”
approximately 1 second and “OFF”
approximately 1 second. Measuring
the output to the brake on Terminals
5 and 6 should indicate the brake is
at 24 volts DC.

o 9c. Reduce the input on Terminals 3

and 4 to less than 5 volts DC and
observe the LED’s at this time.
The “GREEN” LED will be “ON”,
and the “RED” LED will be flashing
at a frequency of approximately 20
hertz, with the “ON” time of
approximately 0.5 second and the
“OFF” time of approximately 2.5
seconds. The control output to the
brake can operate in the 0 to 24 volt
range, but the overexcitation level
from 24 volts is not available as the
circuit has not reset as yet.

o 9d. Once the overexcitation has reset,

the “GREEN” LED will be “ON” and
the “RED” LED will be flashing as
in step 6a above when the input
voltage goes above 5 volts again
at Terminals 3 and 4 of the
MCS2000-PSDRV2.

o 10. If no other indications are present on

the LED’s then the system is functioning
properly. The intensity of the “GREEN” LED
does not change with the amount of output
current being supplied to the brake. This
completes the checkout of the “B” Channel.
The system is now ready for set-up of the
controller. Proceed to the controller manual
to set up the controller properly.

o 11. If LED indications are present other than

those described above, proceed to the
troubleshooting section on page 17 to
determine cause and appropriate action to
take.

o 9b. Allow the control to operate in this

mode for 60 seconds or more and

o 12. This completes the set up of the

MCS2000-DRV2 Driver.

observe the LED’s. After the

Warner Electric • 800-825-9050 P-2010-7 • 819-0525

16

LED’s

Green Green Red Red

ON

ON

ON

ON

OFF

OFF

OFF

OFF

LED Operation Functional Description

MCS2000-PSDRV2 is Powered Off

MCS2000-PSDRV2 is “ON” and ready

MCS2000-PSDRV2 is in anti-residual mode

MCS2000-PSDRV2 Overcurrent enabled
Limited to 60 sec maximum at full output.

MCS2000-PSDRV2 Overcurrent limit
has gone past 60 sec. Output has reduced
back to 24 volts.

MCS2000-PSDRV2 Normal operation but
overcurrent is not available as it is still in
limit mode and will reset on time out.

0.5 Sec ON/2.5 sec OFF

1 Sec ON/1 Sec OFF

0.5 Sec ON/1.5 Sec OFF

1.5 Sec ON/0.5 Sec OFF

System Troubleshooting

Troubleshooting the MCS2000-PSDRV2 Dual
Channel/Dual Voltage Driver is fairly straight
forward. There are certain basic checks that can
be made using a digital meter. All readings taken
on the MCS2000-PSDRV2 will be either DC
voltages or DC currents, or AC line voltage. A
meter sufficient to measure up to 100 VDC and
10 Amps DC and 300 VAC will be suitable for
taking any of the measurements deemed
necessary.

Additionally, the MCS2000-PSDRV2 offers a
certain amount of diagnostics built into the
unit via the “GREEN” and “RED” LED’s for
troubleshooting purposes.

As with any electronic device, care should be
taken when installing, wiring and commissioning
the unit. Failure to do so may damage or destroy
the driver and void the warranty.

The following diagnostic indications are possible
with the two indicator LED’s on the face of the
controller.

Figure 6 LED Indicator Operations and Descriptions – Normal Operation

Note: Each Channel “A” and “B” can be operated independently, so one channel can have one
set of indications while the second channel can have a completely different set of indications.
This will be dependent on how controller is set to operate the MCS2000- PSDRV2 Driver.

Warner Electric • 800-825-9050 P-2010-7 • 819-0525

17

The following chart shows a comparison of the MCS2000-PSDRV, MSC2000-PSDRVH and the

LED’s

Green

Green

Red

Red

LED Operation

OFF

OFF

ON

ON ON

Functional Description

Internal installation error at power up.
Fault Error. Output locked “OFF”,
Driver has tripped.

Return MCS2000-PSDRV2 for Repair.

0.5 Sec ON/0.5 Sec OFF

1.5 Sec ON/0.5 Sec OFF

Short Circuit or Overload on Output at
Power Up. Output Locked “OFF”, Driver
has tripped.

Reset by Power Off and then Power On.

Short Circuit or Overload during normal
operation. Output Locked “OFF”. Driver
has tripped.

Reset by Power Off and then Power On.

Internal auxiliary power supply out of
tolerance. Output Locked “OFF”.

Auto Reset when condition clears.

Internal auxiliary power supply failure or
drive power supply greater than 48 VDC,
+10%. Output Locked “OFF”.

Auto Reset when condition clears.

OR

MCS2000-PSDRV2 terminal connections.

Figure 7 LED Indicator Operations and Descriptions – Fault Conditions

Warner Electric • 800-825-9050 P-2010-7 • 819-0525

18

Other Potential Faults

Symptom Possible Solution

Check LED’s for various conditions.

Check incoming DC power to MCS2000-PSDRV2 either 24 VDC or 48 VDC. Check that power is applied.

No Output to Brake

Brake does not produce sufficient torque

Brake seems to drag when off

If unit has power, check that input signals to Input “A” and Input “B” vary between 0 and 10 VDC.

Check that brake coil is not open by doing a resistance check on the magnet coil. Refer to the Tension

Catalog for proper resistance.

Check that brake is wired to the MCS2000-PSDRV2.

Verify that the brake is the proper size for the application. Contact Warner Electric for assistance.

Check that maximum voltage is being applied to the brake. Also, check that brake coil is drawing
rated current at maximum voltage by placing a digital current meter in series with one of the
brake leads.

Check the Driver LED’s to insure that the control has not gone into a fault condition.

Check mechanically that the brake armature or magnets are free and not binding and can engage
properly.

Check that the input signal to the Channel “A” and Channel “B” inputs goes to full 10 volts on the
control inputs. If inputs do not go to 10 volts maximum, check the controller for proper operation
and set up. Refer to the particular control manual for proper adjustments.

Check that the anti-residual output is set properly. Too little output and the brake will drag due to
possibly high residual.

Check that the anti-residual output is not adjusted too high. Adjusting the anti-residual too high
can result in the brake re-engaging.

Refer to the Anti-Residual Adjustment section of this manual for proper adjustment and readjust
as necessary.

The MCS2000-PSDRV2 is a universal driver designed as a replacement for the previous
MCS2000-PSDRV and MCS2000-PSDRVH in one version.

The MCS2000-DRV2 is different from

Terminal block connections are slightly different on the MCS2000-PSDRV2 since the previous
drivers had additional inputs that typically were not used.

my old driver

If the application used some of the previous terminals, then consult the factory for assistance in
making the MCS2000-PSDRV2 compatible for the application.

Warner Electric • 800-825-9050 P-2010-7 • 819-0525

19

The following chart shows a comparison of the MCS2000-PSDRV, MSC2000-PSDRVH and the
MCS2000-PSDRV2 terminal connections.

These only apply to the Driver portion of the pluggable terminal block. The Power Supply section
between the three versions are the same and did not change.

MCS2000-DRV MCS2000-PSDRV2 MCS2000-DRVH MCS2000-PSDRV2

REF 10 V

0 V

In BxV

In B 0 – 10 V

0 V

In AxV

In A 0 – 10 V

0 V

BRK COM

BRK B +

BRK COM

BRK A +

+ 24 V

0 V

Not Available
Not Available
Not Available

Terminal #3
Terminal #4

Not Available

Terminal #1
Terminal #2
Terminal #8
Terminal #7
Terminal #6
Terminal #5

Terminal #10

Terminal #9

Ref 10 V

0 V

In BxV

In B 0 – 10 V

In B 0 – 20 ma

Out BxV

0 V

In AxV

In A 0 – 10 V

In A 0 – 20 ma

Out AxV

0 V

BRK B +

BRK COM

BRK A +

BRK COM

+ 48 V

0 V

Not Available
Not Available
Not Available

Terminal #3
Not Available
Not Available

Terminal #4
Not Available

Terminal #1
Not Available
Not Available

Terminal #2

Terminal #7

Terminal #8

Terminal #5

Terminal #6

Terminal #10

Terminal #9

If problems arise that are not covered in the above troubleshooting section, then either the local
Warner Electric Representative or Warner Electric Distributor should be contacted for additional
assistance.

This completes the installation of the MCS2000-PSDRV2 Driver. This manual covers only the
Driver and does not cover the controller part of the system. Refer to the appropriate manual for
set-up and operation of the controller. Failure to do so could result in damage to the controller
and/or driver and possibly void the warranty.

Warner Electric • 800-825-9050 P-2010-7 • 819-0525

20

Figure Description

Page
Number

Figure 1 Outline and Mounting Dimensions 4

Figure 2

Figure 3

MCS2000-ECA to MCS2000-DRV2
Wiring 6

MCS2000-CTxx to MCS2000-DRV2
Wiring 7

Figure 4 24 Volt Power and Brake Wiring 9

Figure 5 48 Volt Power and Brake Wiring 10

Figure 6

Figure 7

LED Indicator Operations and
Descriptions – Normal 17
LED Indicator Operations and
Descriptions – Faults 18

Warner Electric • 800-825-9050 P-2010-7 • 819-0525

21

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 LLC

31 Industrial Park Road • New Hartford, CT 06057
815-389-3771 • Fax: [phone]
www.warnerelectric.com

P-2010-7 • 819-0525 6/12 Printed in USA