Warner Electric TCS-200 Installation & Operating Instructions Manual
P-2106-WE
819-0550
TCS-200 Tension Control
Installation & Operating Instructions
An Altra Industrial Motion Company
TCS-200
TABLE OF CONTENTS
Introduction ................................. 2
Theory of Operation ..........................3
Technical Specifications ....................... 4
Installation
Control ............................5
External Sensor ..................... 5
System Wiring ............................... 6
System Start-Up and Adjustment ................9
System Troubleshooting ...................... 11
Warranty Information .................. Back Cover
Follow the installation instructions in this manual
carefully to ensure safe, reliable operation. All
stated or implied warranties are voided if this
product is not installed in accordance with these
instructions.
INTRODUCTION
The Warner Electric Tension Control system is comprised
of the Electro Disc tension brake, a control module and
optional external sensor input.
This manual has been designed to cover installation,
start-up, adjustment and maintenance of your tension
control system and covers the control system only.
Further information on brake sizing and selection can be
found in catalog P-771.
Power Source
The TCS-200 Tension Control operates from a
power source of 24-30 VAC, 50/60 Hz input. Primary
voltage is determined by the customer’s input voltage
source. Specifications for the transformer are located
in the technical data section of this manual. It is the
responsibility of the user to supply the transformer.
Control
The TCS-200 is a current controlled power supply
designed to handle up to a 12 magnet Electro Disc
tension brake. This control can be operated as either
a manually adjusted tension control via the front panel
tension adjustment or via a remote tension adjustment.
The control also has the capability of being used for
simple roll follower applications.
COMPONENT PARTS LIST
TCS-200 Tension Control 6910-448-126
LIST OF ILLUSTRATIONS AND FIGURES
Figure 1 Dimensional Data, Mounting ............5
Figure 2 Power and Brake Connections ..........6
Figure 3 Remote Sensor and Switch
Connections ........................7
Chart 1 Roll Follower Input and Output
Data .............................11
External inputs are provided for remote “brake-on” and
“brake-off” switching circuits, as well as front panel
control of these functions.
Because the control provides constant current output,
brake torque is not substantially affected by changes
in brake operating temperatures. This provides for
repeatable brake torques for given input levels.
When the TCS-200 is operated in a remote torque or
roll follower adjust mode, a 1000 ohm potentiometer is
required. This should be a linear type potentiometer with
a rating of .5 watts, 10 percent tolerance, and .5 percent
linearity.
Brakes
Any of the Electro Disc tension brakes can be used with
the TCS-200 Tension Control. Brake can use from one
magnet to a maximum of twelve magnets. The brake
converts electrical current supplied by the control into
torque, which retards material flow, maintaining the
desired web tension.
2 Warner Electric • 800-825-9050 P-2106-WE • 819-0550
THEORY OF OPERATION
The Warner Electric Tension Control System is
comprised of a control transformer supplied by the
customer, a control module, Electro Disc tension brake,
and input sensor (optional). Depending on the type of
system desired, the input sensor may vary.
The customer supplied transformer converts the
incoming AC voltage to a 24 to 30 VAC level which
supplies power to the TCS-200. The primary voltage of
this transformer will be dependent on the AC line voltage
available at the machine.
The TCS-200 rectifies the 24 to 28 VAC to provide a
usable DC voltage level for powering the internal logic as
well as supplying current for brake operation.
The front panel tension adjust provides for setting the
brake output level when the control is operated in
the local torque adjusted mode. This potentiometer
provides a voltage which is fed to a comparator along
with a signal obtained from the current source amplifier
circuits. The sense amplifier monitors the current through
the sense magnet and provides for constant current
operating by increasing or decreasing the reference
signal to maintain a fairly constant current through the
brake for a given level of input signal.
The signal obtained from the current and tension adjust
comparator is then fed to another comparator that
provides a pulse-width-modulated signal. The pulse
width from this circuit is dependent on the current
required for the brake.
The pulse width output from this stage is then fed to the
output driver circuits that provide current to the brake
magnets. A short circuit detector is employed to shut
down the driver should a short circuit condition occur in
any of the magnets.
Logic circuits are used to provide “brake-on,” “brake-off”
and run modes of operation either through the internal
selector switch located on the TCS-200 front panel or via
an external customer supplied switch. In the run mode,
output operation is normal and is controlled by the
tension adjust potentiometer. “Brake-off” mode overrides
the tension adjustment and provides for resetting the
short circuit indicator. The “brake-on” input provides for
full output current to the brake.
A green power on indicator is provided as a visual aid to
indicate when AC power is applied to the control. A red
short circuit indicator is provided to indicate when the
short circuit indicator has triggered and the output driver
has been shut down.
When the TCS-200 is operated with a remote tension
adjust potentiometer or with a roll follower input, the front
panel tension adjust potentiometer becomes the span
adjust. The span adjust sets the maximum input from the
remote potentiometers.
Because this is a very simple tension control, no
antiresidual circuits, zero adjust circuits, or other complex
control circuits found in other Warner Electric tension
control systems are included in the TCS-200.
Warner Electric • 800-825-9050 P-2106-WE • 819-0550 3
TECHNICAL SPECIFICATIONS
Input Power 24 to 30VAC, ± 10 %, 50/60 Hz, 1 Phase, 5 amps (150 VA)
Output Pulse-width-modulated, full-wave rectified
0 to 270 mA continuous per magnet
Up to 12Electro Disc magnets
Ambient Temperature -20°F to +115°F (-29 °C to +46°C)
Fusing Internal
6 amp, fast-blow, 32V — 5 mm x 20 mm
Protection Internal short-circuit protection on driver output stage
Sensor Inputs Remote torque adjustment
Roll follower
Auxiliary Inputs Brake-On
- Applies full 270 mA-per magnet to the brake.Will operate and provide “brake-on” in the
event that both “brake-on” and “brake-off” are activated. Active low.
- Minimum contact rating: 20 VDC at .01amp
- Maximum off state leakage current: < 100 microamps ·
Brake-Off
- Removes output current to the brake. Puts brake at zero current level.
- Active low.
- Minimum contact rating: 20 VDC at .01 amp
- Maximum off state leakage current: < 100 microamps
Controls (Front Panel) Tension Adjust
Provides current adjust to the brake from 0 to 100% In the remote mode, provides for
maximum output level set to the brake.
Brake Mode Switch
Provides for brake-off, brake-run (normal operation) and brake-on modes of operation to
the brake.
General The control chassis must be considered NEMA 1 and should be kept clear of areas
where foreign materials, dust, grease, or oil might affect control operation. Control chassis
should be electrically grounded.
Neither the sensor (if used) or brake wires are at ground potential and should be
considered "floating" unless both sides of the AC input power are disconnected.
Customer Supplied
Components
Transformer
Primary - Determined by available AC line voltage
Secondary - 24 to 30VAC, ± 10%, 50/ 60Hz, 1 Phase, 5 amps (150 VA)
Suggested Transformers:
Manufacturer Part No. Primary Secondary
Abbott 6812- 160 115VAC 24V@6amps
Quality 6-K- 119VBR 115/230VAC 24V@8 amps
Signal 24- 6 115VAC 24V@6amps
Signal DL-24- 6 115/230VAC 24V@6amps
Triad F-260-U 115VAC 24V@6amps
Potentiometers Remote Torque Adjust
1000ohms, 10% tolerance, .5% linearity, .5watts, linear taper
Roll Follower
1000ohms, 10% tolerance, .5% linearity, .5watts, linear taper
4 Warner Electric • 800-825-9050 P-2106-WE • 819-0550
INSTALLATION
This Installation and Operation Manual was arranged for
the systematic installation and start-up of your tension
control system. For this reason, and to achieve the best
possible results, we recommend that you check off each
completed step in the space provided before proceeding
to the next step.
Sample:
Check box after completing each step.
Control Mounting
1. Determine a suitable location for the control to be
q
2. Remove the two cover screws, and remove the
q
3. Using the dimensional data supplied in Figure
q
x
Remove two cover retaining screws and
q
remove cover from the control chassis.
mounted. Consideration should be given as to
whether the front panel adjustments will require
access by the operator.
cover from the control chassis.
1, drill three mounting holes using a #16 drill if
#8 through-bolts are used, or a #29 drill and tap
holes for #8 screws.
4. Attach the TCS-200 control chassis to the
q
mounting surface and secure with mounting
hardware (not provided, customer supplied).
Note: The control chassis has been designed to
accomodate two half-inch conduits for wiring when
the control is mounted to the machine frame. If conduit
is used,·proceed to step 5, otherwise proceed to the
control wiring section of this manual.
5. Attach conduit or seal tight connectors to the
q
TCS-200 with the retaining nut on the inside of
the control.
The control is now ready to be wired. Refer to the wiring
section of this manual for proper system wiring.
Brake Installation
Refer to proper manual for brake installation and set-up
procedures.
External Sensor Mounting (Optional)
Options for two types of external sensor inputs are
available. These consist of either external torque adjust,
or roll follower input which provides a signal directly
proportional to the diameter of the roll to be processed.
6.500
MAX
.750±.015
4.460 MAX
.875 (2)
CONDUIT
CONNECTION
Determine which type of external sensor will be used and
proceed to that section of this manual.
2.500
MAX
1.812
MAX
2.062
MAX
.180 (2)
MOUNTING
SLOT
.375 (2)
MOUNTING
2.250±.015
.180
.658
NOM
5.185±.015
1.345
±.020
Warner Electric • 800-825-9050 P-2106-WE • 819-0550 5
1.750
±.015
Figure 1
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