MCS-805 Series Clutch/Brake Controls
P-239-31
Installation Instructions
Contents
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
Warranty. . . . . . . . . . . . . . . . . . . . . . . . . . . back cover
Introduction
Failure to follow these
instructions may result in product damage,
equipment damage, and serious or fatal
injury to personnel.
Warner Electric’s MCS-805-1 and MCS-805-2
series clutch/brake controls are designed for
operation with Warner Electric electrically
released brakes. The correct brake release voltage is a specific point between 35-75VDC. This
point is set by adjusting the control at the time
of brake installation. These controls are factory
set for 60 volts output.
The MCS-805-1 and MCS-805-2 controls operate from 120/230VAC single phase input power.
Switching may be provided on either the AC or
DC side of the control.
The MCS-805-1 and the MCS-805-2 have an
internal adjustment potentiometer that is use for
the release band adjustment. The MCS 805-2 is
similar to the MCS-805-1 except that it has
torque adjustment capability for soft stop applications. The MCS 805-2 requires two switching
circuits when used for those applications requiring soft engagement.
Warner Electric • 800-234-3369 P-239-31
2
Specifications:
Reorder Information
Input power:
• MCS-805-1 120/230VAC ± 10%,
50/60Hz, single phase.
• MCS-805-2 120/230VAC ± 10%,
50/60Hz, single phase
Output:
MCS-805-1 35-75VDC, 0.40 amps
MCS-805-2 35-75VDC, 0.40 amps
Switching inputs:
(external to control, supplied by customer)
• DC switching: single pole, single throw.
Minimum contact rating 1 amp, 120 VDC.
• AC switching: single pole, single throw.
Minimum contact rating 1 amp, 120 VAC.
Ambient temperatures:
-20° to 150°F (-29° to 65°C)
Circuit protection: (fusing)
3/4 Amps, 250V Slow Blow, 3AG
Adjustments:
Release band adjustment (via internal potentiometer)
MCS-805-2 only: Torque adjust (via external
potentiometer)
Model Part No.
MCS-805-1 6090-448-006
MCS-805-2 6090-448-007
Mounting
Any vertical, horizontal, or angled surface is suitable for mounting the MCS-805-1 or MCS-805-
2. Follow these procedures to mount your control:
a. Remove the front cover by removing the top
retaining screws.
b. Set the control on the mounting surface and
mark for the four mounting holes in accordance with dimensions.
c. Install and tighten the four screws.
The control is now ready to be wired.
To avoid injury (or even death),
always make certain all power is off before
attempting to install this control or any electrical equipment. Do not touch the board if
power is applied.
Wiring Entrance:
Two 7/8" diameter conduit entrance holes
located on the bottom and on the top of the
control chassis.
Warner Electric • 800-234-3369 P-239-31
3
Installation
Brake Release Adjustment
a. For 115VAC: Connect power supply to termi-
nals 1 and 4. Install a jumper between terminal 1 and terminal 2. Also, install a second
jumper between terminal 3 and terminal 4.
For 230VAC: Connect power supply to terminals 1 and 4. Install a jumper between terminal 2 and terminal 3.
b. A chassis ground should be provided as a
non-current conducting ground wire (color
coded green). Connect this ground to terminal 9.
c. Switching.
• For switching DC side: switch must be
connected to terminals 7 and 8. Switch
open will allow brake to be engaged.
Switch closed will release the brake. For
MCS-805-2 Only: Switch open will allow
brake to be partially engaged and AC
power off will allow brake to be fully
engaged.
• For switching AC side: Line power off will
allow brake to be engaged. Line power on
will release brake. Install a jumper
between terminals 7 and 8.
d. Connect the positive terminal of the brake to
terminal 6 on the control and the negative
terminal of the brake to the terminal 5 on the
control.
When setting the MCS-805 control, the objective is to achieve armature release by adjusting
the coil voltage so it counteracts the permanent
magnet to the maximum extent possible.
Proceed as follows:
a. Turn on the control. Loosen locking nut on
the adjustment potentiometer. Turn the
potentiometer adjusting screw to the maximum counterclockwise position. Slowly turn
the adjustment screw clockwise until the
brake armature disengages from the magnet.
If the usual autogap spring is used, this will
normally cause the armature to separate
approximately 1/32" from the magnet. If the
autogap is not used, an external release force
of approximately 5-10 pounds should be
applied by hand, to detect the point of armature release. Using a voltmeter, note and
record the voltage at this point.
b. Turn the adjusting screw to the maximum
clockwise position that will normally cause
the armature to be reengaged. If the armature
does not make contact, it should be physically moved into contact, with caution exercised to prevent fingers from being injured.
c. Turn the adjusting screw slowly counterclock-
wise until the armature releases through the
same technique as used under (a). Note and
record the voltage, which will be somewhat
higher than the value noted under (a). Adjust
the final voltage setting to the mid-point
between the two readings and tighten the
locking nut on the adjustment screw. The
brake is then ready for normal operation.
For MCS-805-2 Only: Set partial engagement
torque the external potentiometer. Switch connected to terminals 7 and 8 must be open to
make this adjustment. A setting of 10 gives
maximum torque.
Warner Electric • 800-234-3369 P-239-31
4
Dimensions
Top and Bottom
3-
7/16"
1-
1/8"
2-
5/8"
7/8" Diameter Knockouts for
1/2" Conduit Both Ends
Typical
Back
3-
3/4"
6"
4-
13/16"
5"
9/16"
9/32" Diameter
4 Mounting Holes
Clearance for 1/4" Screw
Side
3-
7/16"
Front
5"
7-
1/8"
1 2 3 4 5 6 7 8 9
AC INPUT
120/230 VAC
50/60 Hz
Brake
-+
S
1
GND
DC Switching
(Jumper if not used)
1 2 3 4
120 VAC
1 2 3 4
230 VAC
1 2 3 4 5 6 7 8 9
AC INPUT
120/230 VAC
50/60 Hz
Brake
-+
S
1
GND
DC Switching
Closed - brake released
Open - brake in tq. adj. mode
1 2 3 4 1 2 3 4
120 VAC 230 VAC
S
1
S
1
S1Open - brake engaged
S2Closed - brake released
or tq. adj. mode per S
1
Connection
Warner Electric • 800-234-3369 P-239-31
5
Warranty
Warner Electric, Inc. 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, Inc.’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, Inc. factory. Additional warranty information may
be obtained by writing the Customer Satisfaction Department, Warner Electric, Inc., 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, Inc.’s obligation under this warranty is limited to the repair or replacement of the
defective product and in no event shall Warner Electric, Inc. 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, Inc. 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 EXPRESS 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, Inc.
449 Gardner Street
815-389-3771
www.warnerelectric.com
P-239-31 10/02 Printed in USA
¥ South Beloit, IL 61080
¥ Fax: 815-389-2582
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