Warner Electric MCS-208 - Manual (Page 23)

Warner Electric • 800-825-9050 P-276 • 819-9045 23
TRoUBLeSHooTING
Applies to the Dancer Control System
General: The chart below will be helpful when isolating exact problems which may occur in the control
system. The chart will also prove helpful when encountering problems with the initial start-up of the
system.
Symptom A. Dancer will not raise from bottom position.
Probably Cause Suggested Solution
Incorrect Dancer Position Setting • Adjust dancer position setting until dancer moves to normal
running position.
Dancer is not free to move because of • Remove obstruction, release any holding devices or safety locks.
obstruction.
No DC power to the control.
• Check for power LED illumination on MCS-207.
• Check for power LED illumination on MCS-166.
• Check fuses.
• Check proper DC input connections to control (refer to tension
control hookup instructions).
• Check AC power input to MCS-166 if used.
Brake is not engaging. • Check to be sure the lead wires to the transducer are connected
to terminal 1 and 2 of the control.
• Check to make sure sensor is connected.
• Check to see that the air supply is connected to the input of the
transducer.
• Also confirm that the air output on the transducer is connected to
the brake input.
• Using a voltmeter, check for output to the transducer. The dancer
should be in the bottom position. If the control is within the range
of the transducer, recalibrate the transducer per the calibration
procedure. If the transducer cannot be calibrated, replace the
transducer. If the output is not within the range of the transducer,
recalibrate the control. If the control cannot be calibrated, replace
the printed circuit board assembly.
• Check for proper pivot sensor alignment. Terminals 6 and 7 on
MCS-207 = 7.5 VDC±0.1 VDC with dancer centered: 6.1 VDC -
shortest web loop. 8.9 VDC - longest web loop.
• Check to see that the brake-off input is not activated.
Brake does not have the torque capacity • Verify that the correct brake was selected by repeating the
required for the application. selection procedure.
Symptom B: Dancer moves to and remains at upper limit during initial systems start-up.
Note: Refer to Symptom C if dancer moved to upper limit after it had been running normally at the proper position.
Probable Cause
Suggested Solution
Incorrect dancer position setting • Adjust dancer position setting until dancer moves to normal
running position.
Roll shaft not free to rotate with control off • Brake and shaft must be free to rotate with control off.
Sensor incorrectly connected to control • Verify sensor connections. Using a voltmeter, check the output
of the control as follows: Slowly raise the dancer and observe that
the control output decreases. Then slowly lower the dancer and
observe that the output increases. If the output indications are the
opposite, reverse the sensor leads at terminals 5 and 7 of the
control (see sensor wiring). If not output change occurs, check the
sensor cable connections (check pivot point coupling connection
if MCS-605-1 or TCS-605-5 sensor is used). If no output change
occurs, be sure that the transducer wires are not grounded to the
machine.