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