Altra Industrial Motion Warner Electric MCS-166

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Summary

Introduction to Pneumatic Tension Control System

Dancer Tension Control System Components

Lists the components of the Dancer Tension Control System.

Remote;Analog Control System Components

Lists the components of the Remote/Analog Control System.

System Components

Air Disc Tension Brake

Description of the Air Disc brake and its torque development.

Electro-Pneumatic Transducer Kit

Function and components of the transducer kit.

MCS-166 Power Supply Module

Details of the MCS-166 power supply module.

Control Modules (MCS-207;MCS-208)

Explanation of MCS-207 and MCS-208 control modules.

Specifications

MCS-166 Power Supply Module Specifications

Technical specifications for the MCS-166 power supply.

MCS-207 Dancer Control Module Specifications

Technical specifications for the MCS-207 control module.

MCS-208 Remote;Analog Control Module Specifications

Technical specifications for the MCS-208 control module.

Pivot Point Sensor Specifications

Specifications for MCS-605-1 and TCS-605-5 sensors.

Electro-Pneumatic Transducer Specifications

Specifications for the electro-pneumatic transducer.

Installation Procedures

Control Housing Mounting

Instructions for mounting control housings.

Wall Mounting Installation

Procedures for mounting control housings on a wall.

Shelf Mounting Installation

Procedures for mounting control housings on a shelf.

Panel Mounting Installation

Procedures for mounting control housings on a panel.

MCS-605-1 Sensing Potentiometer Installation

Step-by-step installation of the MCS-605-1 sensor.

System Wiring

System Wiring Precautions

Safety guidelines for wiring the system components.

MCS-166;MCS-207 Wiring Connections

Wiring connections for MCS-166 and MCS-207.

MCS-166;MCS-208 Wiring Connections

Wiring connections for MCS-166 and MCS-208.

MCS-208 Input Configurations

Various input signal configurations for MCS-208.

System Start-Up and Adjustment

MCS-166;MCS-207 Preliminary Set-Up

Initial setup steps for MCS-166/MCS-207 system.

MCS-166;MCS-207 Static Adjustment and Check Out

Performing static adjustments and checks for MCS-166/MCS-207.

MCS-166;MCS-207 P-I-D Gain Adjustments

Adjusting Proportional, Integral, and Derivative gains.

MCS-166;MCS-208 Preliminary Set-Up

Initial setup steps for MCS-166/MCS-208 system.

MCS-166;MCS-208 Static Adjustments and Check Out

Performing static adjustments and checks for MCS-166/MCS-208.

MCS-166;MCS-208 Input Calibration

Calibrating input signals for MCS-166/MCS-208 system.

MCS-166;MCS-208 Dynamic Adjustments

Performing dynamic adjustments for MCS-166/MCS-208 system.

System Troubleshooting

Dancer Control System Troubleshooting

Problems and solutions for the dancer control system.

Remote;Analog Control System Troubleshooting

Problems and solutions for the remote/analog control system.

The document describes the Pneumatic Tension Control System MCS-166/MCS-207/MCS-208, an electro-pneumatic system designed to maintain stable web tension in various industrial applications. This system is offered in two primary configurations: the Dancer Tension Control System and the Remote/Analog Control System.

Function Description

The core function of the system is to precisely control braking torque, which directly influences web tension. It achieves this by regulating air pressure to an Air Disc pneumatic tension brake. The system utilizes an electro-pneumatic transducer that converts an electrical signal from a control module into a proportional air pressure output. This air pressure is then supplied to the brake's air chambers, ensuring consistent tension.

The Dancer Tension Control System is a closed-loop control system. It consists of an Air Disc pneumatic tension brake, an electro-pneumatic transducer, an oil removal filter, an MCS-166 power supply, an MCS-207 control module, and a pivot point sensor. In this configuration, the MCS-207 Dancer Control Module receives a signal from the dancer pivot-point sensor. Based on this signal, it outputs an appropriate electrical signal to the transducer, which then adjusts the air pressure to the brake to maintain a stable dancer position. This closed-loop feedback mechanism ensures that the dancer arm remains within a desired operating range, compensating for changes in roll diameter or other process variations.

The Remote/Analog Control System is an open-loop control system. It comprises an Air Disc pneumatic tension brake, an electro-pneumatic transducer, an oil removal filter, an MCS-166 power supply, an MCS-208 Remote/Analog control module, and an input control device. The MCS-208 module accepts various input signals (e.g., from an external potentiometer, voltage input, or current loop input) and provides an output signal proportional to the input. This output signal is then converted into brake air pressure by the transducer. In this open-loop setup, any change in air pressure to the brake originates from the input signal provided to the control module. The MCS-208 can be operated either by a local torque knob on its faceplate or remotely via an external input.

The MCS-166 Power Supply Module is a crucial component that powers both control modules. It accepts either 120 VAC or 220/240 VAC input power and provides a regulated 26-28 VDC output for the control modules.

The Electro-Pneumatic Transducer Kit is responsible for converting the electrical control signal into pneumatic pressure. It includes a recommended filter to ensure clean air supply.

The Pivot Point Sensors (MCS-605-1 and TCS-605-5) are specifically designed for the Dancer Tension Control System. They provide the dancer position signal to the MCS-207 module. The MCS-605-1 is used for dancer pivot rotation up to 60 degrees, while the TCS-605-5 handles rotations up to 300 degrees.

The system can also be configured to drive two Air Disc brakes in a dual brake application, potentially requiring an additional volume booster.

Usage Features

The system offers several features for flexible operation and adjustment:

Selectable Input Power: The MCS-166 power supply allows selection between 120 VAC and 220/240 VAC, making it adaptable to different power environments. An additional Low-High switch provides further flexibility for specific voltage conditions (e.g., 220 VAC or 240 VAC operation, or compensation for low line voltage).
Multiple Output Ranges: The MCS-207 and MCS-208 control modules offer various output ranges (e.g., 1-5 mA, 4-20 mA, 10-50 mA, 1-9 VDC) to accommodate different transducer input requirements. The standard transducer typically accepts a 4-20 mA output.
Dancer Position Adjustment (MCS-207): A front panel potentiometer allows users to set the desired dancer running position, enabling fine-tuning of tension control based on application needs.
Gain Adjustment (MCS-207): A front panel gain control allows adjustment of the overall system response based on changes in the dancer input signal. This is critical for achieving stable dancer operation and preventing hunting or oscillation. Internal P-I-D (Proportional-Integral-Derivative) gain adjustments (R32, R24, R16) are also available for advanced tuning when front panel adjustments are insufficient.
Torque Adjust/Span Adjustment (MCS-208): For the Remote/Analog Control System, a front panel "Torque Adjust/Span Adjust" potentiometer allows for manual torque adjustment in local mode and span adjustment in other operating modes. This enables users to set minimum and maximum output levels for precise tension control.
Multiple Control Input Modes (MCS-208): The MCS-208 supports various input control modes, including local torque adjust, remote torque adjust/roll follower potentiometer, voltage source input, and current source input, providing versatility for integration into different machine control architectures.
Brake-On/Brake-Off Functionality: Both control modules support Brake-On and Brake-Off switch inputs, allowing for full or minimum output to the transducer, respectively. This provides immediate control over braking action. An "Anti-Drift" input is also available on the MCS-207 for integrator reset functionality.
Dual Brake Application: The system can drive two Air Disc brakes, offering flexibility for applications requiring higher braking torque.

Maintenance Features

The manual emphasizes several aspects related to maintenance and safe operation:

Clear Installation Instructions: Detailed step-by-step instructions are provided for mounting control housings (wall/shelf and panel), installing sensors, transducers, and brakes, and wiring all components. This systematic approach helps ensure correct setup and minimizes potential issues.
Wiring Precautions: Specific guidelines are given for wiring, including using proper gauge wire, segregating AC and DC power lines, and using shielded cable for sensor and signal lines to prevent electrical noise. These precautions contribute to system reliability and longevity.
Troubleshooting Guides: Comprehensive troubleshooting charts are included for both Dancer and Remote/Analog Control Systems. These charts list probable causes for common symptoms (e.g., dancer not raising, dancer moving erratically, brake not engaging) and suggest solutions, aiding in quick diagnosis and repair.
Calibration Procedures: Detailed calibration procedures are outlined for the transducer and control modules (MCS-207 and MCS-208). These procedures involve setting zero and span potentiometers to ensure accurate output signals and pressure control.
Safety Warnings: Prominent AWARNING and NOTE sections highlight critical safety information, such as the risk of injury or death from electrical voltages, the importance of proper installation to avoid product damage and warranty voidance, and precautions for setting voltage selector switches.
Component Accessibility: The design allows for the removal of control logic assemblies from their housings by loosening captive screws, facilitating internal adjustments and maintenance.
Filter Inclusion: The electro-pneumatic transducer kit includes an oil removal filter, which is essential for supplying clean air to the transducer and brake, thereby extending their lifespan and maintaining performance.
Warranty Information: A clear warranty statement outlines the terms for repair or replacement of defective products, providing assurance to users.

Overall, the Pneumatic Tension Control System is designed for robust and precise web tension control, with user-friendly adjustments and comprehensive support for installation, operation, and troubleshooting.