The Warner Electric MCS202-E is a control unit designed for tension control applications, primarily in unwinding systems utilizing a dancer arm. It comes in three main versions: MCS202-E1, MCS202-E154, and MCS202-EC1, all sharing the same electrical characteristics and performance.
Function Description:
The MCS202-E acts as a tension controller, regulating the braking force applied to an unwinding roll based on the position of a dancer arm. The dancer arm's position, sensed by a compatible sensor (such as the Warner Electric MCS605-E), provides feedback to the control unit. The unit then adjusts the brake's torque to maintain a desired web tension, keeping the dancer arm within its optimal operating range.
Key control elements include:
- Loop Gain Potentiometer: This adjusts the sensitivity of the control loop, influencing the dancer arm's stability. A higher gain might lead to quicker responses but could also introduce instability, while a lower gain might result in slower responses but greater stability.
- Torque Offset Potentiometer: This sets the baseline braking torque, allowing for initial adjustment to bring the dancer arm to its operating position before the loop gain takes over for fine-tuning.
- Drift Stop Function: This feature, activated by an external switch connected to auxiliary receptacle SK3, is crucial for ensuring correct starting and stopping of the machine. When the unwinder is not running, activating this function by closing the contact prevents unwanted drift.
- Sensor Polarity Reversal: In cases where the dancer arm movement produces reversed results (e.g., full braking with minimum loop), the sensor polarity can be reversed. This can be done via a switch on the MCS605-E sensor itself or, for other sensor types, via switch SW3 on the printed circuit board.
- Change Over Gain Function: For applications with a high diameter ratio (exceeding 8:1 between maximum and minimum diameter), this function can be activated by closing S3 from middle to small Ø. This likely adjusts the gain profile to better manage tension as the roll diameter changes significantly.
The unit provides visual indicators for its status:
- Power Indicator: Lights up when mains supply voltage is applied.
- Brake Level Indicator: Illuminates when the brake switch is ON, indicating that the brake is engaged.
- Sensor Error Indicator: Can display RED or GREEN, indicating the dancer arm's position (maximum or minimum loop) or potential issues. A smooth color transition around the operating position indicates correct sensor mounting.
Important Technical Specifications:
- Power Source: The electronic circuit operates on a single +15 VDC power source.
- Sensor Supply Voltage: +15 VDC is supplied to the sensor.
- Sensor Signal Range: The sensor signal should be a minimum of +3 VDC and a maximum of 10 VDC.
- Optimal Dancer Arm Operating Band: When using the MCS605-E sensor, it should be operated within a +/-30° band around the operating position.
- Input Receptacle SK2: Compatible with the connector on the MCS605-E cable included in the MCS-KIT.
- Brake Power: +24 VDC on pin 1 of SK4. The brake is not polarized, allowing for reversed connections without affecting functionality.
- Mains Supply Voltage: The unit can be configured for 240 VAC (nominal 220-240 VAC) or 115 VAC operation, adjustable via SW1 on the printed circuit board.
- Isolation: All inputs in the auxiliary connector SK3 and brake power are optically isolated from the +15 VDC supply voltage, enhancing safety and preventing interference.
Usage Features:
- MCS202-E1: Standard monoblock control unit with operator controls conveniently located on the front panel.
- MCS202-E154: Similar to the E1 but constructed for IP54 protection, making it suitable for environments requiring dust and splash resistance. Unused receptacles should be sealed with dummy connectors.
- MCS202-EC1: A printed circuit board version, intended for integration into existing systems. The user must provide and wire the power switch, power input, and brake switch externally. It also serves as a replacement part for the other models.
- Front Panel Controls: Easy access to Power Switch, Brake Switch, Loop Gain Potentiometer, and Torque Offset Potentiometer for quick adjustments.
- Rear Panel Connections: Clearly labeled connectors for power, sensor, brake, and auxiliary functions.
- User-Adjustable Settings: Potentiometers for Loop Gain and Torque Offset allow for fine-tuning of tension control. Switches for sensor polarity and change over gain provide flexibility for different application requirements.
Maintenance Features:
- Fuse: A fuse is present on the PCB for circuit protection, which can be replaced if necessary.
- Modular Design (EC1): The MCS202-EC1, being a PCB version, can serve as a direct replacement for the internal electronics of the E1 and E154 models, simplifying repairs.
- Troubleshooting Indicators: The Power LED, Brake Level indicator, and Sensor Error indicator provide visual cues for diagnosing operational status and potential issues.
- Commissioning Guide: The manual provides a detailed start-up procedure, including steps for mounting the sensor, connecting components, checking voltage, and adjusting potentiometers for optimal performance. This guide helps in identifying and resolving common setup problems, such as incorrect sensor mounting or reversed brake operation.
- Technical Support: In case of complex problems or special applications, users are advised to contact their nearest Warner Electric representative for assistance.
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