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WARNER ELECTRIC
MCS2000-IS
INTERFACE FOR LOADCELL AND ULTRASONIC SENSORS
NOTICE
USER MANUAL
WARNER ELECTRIC EUROPE - Tél. +33 (0)2 41 21 24 24, Fax + 33 (0)2 41 21 24 00
www.warnerelectric-eu.com
MC521-gb-0330
SERVICE MANUAL MCS2000-IS
Page 1 /12
WARNER ELECTRIC
Table of content
MCS2000-IS ........................................................................................................................................................... 1
Interface for Loadcell and Ultrasonic Sensors........................................................................................................ 1
General description ............................................................................................................................................. 3
Amplifier with averaging function for two load cells......................................................................................... 3
Ultrasonic calibration stage with derivative compensation.............................................................................. 3
Typical MCS2000-IS application ......................................................................................................................... 4
In closed loop as load cell amplifier for unwinding system.............................................................................. 4
As tension indicator in open loop .................................................................................................................... 4
As reference for open loop control in the unwind system ............................................................................... 4
Typical applications and bloc schematic............................................................................................................. 5
Unwind system in open loop with ultrasonic sensor........................................................................................ 5
MCS2000-IS with 2 load cells and MCS2000-ECA......................................................................................... 5
Bloc schematic................................................................................................................................................. 6
The load cells ...................................................................................................................................................... 7
Rating selection ............................................................................................................................................... 7
Load cell setting............................................................................................................................................... 7
Load cell setting............................................................................................................................................... 8
MCS2000-IS Layout............................................................................................................................................ 9
Main components location............................................................................................................................... 9
Factory setting ............................................................................................................................................... 10
Inputs / Outputs – Setting specification ......................................................................................................... 11
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SERVICE MANUAL MCS2000-IS
MC521-gb-0330
WARNER ELECTRIC
General description
The interface sensor MCS2000-IS integrates two basic functions.
Amplifier with averaging function for two load cells
The unit can be connected either to one or two load cells. Two high gain and stability amplifiers
are able to amplify signal load cell as low as 10 mV with very high precision in order to get a
normalised 0-10V output. Each amplifier has a separated gain adjustment and individual offset
setting. Special care was brought in the IC selection to insure a long-term stability and to guarantee
precision in large temperature range. As the amplifier owns very sensitive input it is recommended
to mount it as close as possible from load cells. We recommend not going over 5 m. In case of use
of WARNER load cell an appropriated shielded cable is supplied. In other case it is of customer
responsibility to use a correct connection cable between the load cells and the unit MCS2000-IS.
The block schematic included in the present manual will provide all information about the installed
functions.
Ultrasonic calibration stage with derivative compensation
One ultrasonic sensor or any other voltage source can be connected to the unit. The calibration
stage is able to provide an output signal 0-10 V whatever the input voltage change provided this
input variation is at least 1 V regardless polarity slope but necessarily comprised into the range 010V. An output stage is installed where the calibrated signal can be added to other information
such a dV/dt compensation signal.
This function is mainly used when the MCS2000-IS is used in open loop with roll diameter
measurement. The line speed dV/dt can be added or subtracted to the main signal during
acceleration and deceleration
The block schematic will inform you about the complete functions of the unit.
As the MCS2000-IS unit must be installed as close as possible from load cells it has been
voluntary built in a rugged housing allowing its installation on the machine frame
MC521-gb-0330
SERVICE MANUAL MCS2000-IS
Page 3 /12
WARNER ELECTRIC
Typical MCS2000-IS application
In closed loop as load cell amplifier for unwinding system
Driver
Control
Tension in the WEB is
measured with 2 load cells.
The interface IS amplifies the
2 signals coming from the load
cells and delivers an averaged
value of the tension to the
closed loop controller. One
digital indicator shows in
continue the measured value
to the operator. One remote
indication is possible too.
MCS2000-IS
As tension indicator in open loop
Simple example where the tension in the
WEB is measured by a load cell and just
displayed. The MCS2000-IS is calibrated to
deliver a 0 – 10 V signal to an appropriate
display
MCS2000-IS
As reference for open loop control in the unwind system
T
Drive
MCS2000-IS
The diameter of the roll is measured by an
ultrasonic sensor. The MCS2000-IS is
calibrating this signal and translate it into a
true diameter information. The line speed
information delivered y the tacho-generator
is used to create a dV/dt compensation
during the acceleration and deceleration
phases. An external potentiometer P is used
to set the desired tension in the WEB.
P
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SERVICE MANUAL MCS2000-IS
MC521-gb-0330
WARNER ELECTRIC
Typical applications and bloc schematic
Unwind system in open loop with ultrasonic sensor
Master machine speed
MCS2000-DRV
Ground(0V) 14
19 VREF
15 Ground(0V)
US SENS 13
US SENS OUT 9
IN3 18
Air brake
alternative
External 24 VDC
or
MCS2000-PS
Ground(0V) 14
IN1 16
21 22
10k
Final tension
pot. setting
line speed info
+
-
MCS2000-IS with 2 load cells and MCS2000-ECA
External 24 VDC or,
MCS2000-PS
22 21
0V +24V
5 (-5 or -15 VDC)
6 (negative load cell signal input)
7 (positive load cell signal input)
Use shielded
8 (+5 or +15 VDC)
10
15
Sens. In
0V
1 (-5 or -15 VDC)
2 (negative load cell signal input)
3 (positive load cell signal input)
11
4 (+5 or 15 VDC)
Use
shielded
Use shielded
cable
with
cable with
max
lengthlenght
5m
max
5
MC521-gb-0330
14 (0V)
MCS2000-ECA
Available 0-10V
for remote
display or other
SERVICE MANUAL MCS2000-IS
Page 5 /12
WARNER ELECTRIC
Bloc schematic
12
+24 VDC in 21
Ground (0V) 22
+UE1 (+5V) out 8
+CELL 1 in 7
-CELL 1 in 6
-UE1 (-5V) out 5
+UE2 (+5V) out 4
+CELL 2 in 3
-CELL 2 in 2
UE2 (-5V) out 1
US SENS in 13
Ground(0V) 14
MAIN POWER
SUPPLY
+5V
-15V
O1
P1
AMP 1
A3
A6
P2
AMP 2
Bargraph
10 digits
P5
A7
P7
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11 CELL SUM out
SUM
switch
A4 Rotative
Rotative switch
O2
CALIB.
Green LED
P3
A1
A2
A5
SW1
POWER
SUPPLY
for setting and
fot setting and
selection
P4 selection
A1totoA10
A10
A1
P9
A9
10 SELECTED out
AMP 3
A8
9
18
P8
15
IN2 in 17
IN1 in 16
Load cell power
supply selection
± 5 V or ± 15 V
Factory setting ± 5V
+15V
dV/dt
P6
+/-
SUM
A10
19
SW2
SERVICE MANUAL MCS2000-IS
MC521-gb-0330
WARNER ELECTRIC
The load cells
Rating selection
You have to consider three important factors to size a load cell correctly:
- the own weight of the shaft
- the max tension in the web
- the web wrapping angle related to the defined resultant force on the load cell
It’s always better to place the force sensing direction ( indicated by manufacturer) in the web
resultant force direction
Weight of the shaft
The weight of the shaft (P) always create a vertical force. The
effect of this force has to be reported to force sensing
direction (P’)
P’ = P * cos B
B
P’
P
sensing
direction
A
Max tension in the web
The tension in the web is creating a resultant force (Ft) which
has to be reported to the force sensing direction
So far the force sensing direction is placed in same direction
as the web tension resultant the force applied to the measure
system is
Ft = 2 T * cos ( A/2 )
The max force applied on the system measurement then
is:
F = Ft + P’ = 2T * cos(A/2) + P * cos B
T
T
Ft
Security coefficient
Depending of the machine type the system measurement has
probably to support or to measure some force surges. We
generally introduce in the formula a security coefficient K.
sensing
The final formula : Fc = 2 K T * cos (A/2) + P * cos B
direction
The above formula is valid for the system measurement. Depending of the mechanical montage
the result Fc has to be divided by 2. See current case here below :
P
Ft
P
Ft
MC521-gb-0330
T = Max tension in the web
P = Weight of the sensing shaft
B = Vertical - sensing direction angle
A = Web wrapping angle
Ft= Max force applied to the sensing system
Fc = Max force applied to the sensing system with security coeff.
K = Security coeff taking account force surges and unbalanced
force distribution when using 2 load cells.
Usually comprised between 1,2 and 1,5
SERVICE MANUAL MCS2000-IS
Page 7 /12
WARNER ELECTRIC
Load cell setting
One load cell
In description here below:
Load max = weight of the shaft + load created by the tension
Load min = weight of the shaft
P
Ft
1. Select one channel and put a jumper on the input of the nonactive channel (Eg. Channel 1 active)
2. Turn the switch to A2
• Apply the max load to the shaft
• Adjust P1 to get the bargraph fully lit up (10V)
3. Turn the switch to A3
• Apply the min load (just the own weight of the shaft)
• Adjust P3 to get the bargraph just turned off
4. Turn the switch to A7
• Apply the max load to the shaft
• Adjust P1 to get the bargraph fully lit up
Two load cells
P
In description here below:
Load max = weight of the shaft + load created by the tension
Load min = weight of the shaft
Ft
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1. Select the first channel to set (Select channel 1 first)
2. Turn the switch to A2 (first channel)
• Apply the max load to the shaft
• Adjust P1 to lit up the first 5 digits of the bargraph
3. Turn the switch to A3
• Apply the min load (just the own weight of the shaft)
• Adjust P3 to get the bargraph just turned off
4. Turn the switch to A5 (second channel)
• Apply the max load to the shaft
• Adjust P2 to lit up the first 5 digits of the bargraph
5. Turn the switch to A6
• Apply the min load (just the own weight of the shaft)
• Adjust P4 to get the bargraph just turned off
6. Turn the switch to A7
• Apply the max load to the shaft
• Adjust P5 to get the bargraph fully lit up
SERVICE MANUAL MCS2000-IS
MC521-gb-0330
WARNER ELECTRIC
MCS2000-IS Layout
Main components location
Green led power
indicator - “ON”
when 24V applied
POT 6
POT 7
POT 8
POT 5
POT 4
POT 3
POT 2
Main power supply
superposed board
POT 1
US ENS input slope
selection, SW1
IN1 input - dV/dt
polarity selection,
SW2
Terminal block
2 rows :
1 to 11 and
12 to 22
Selection
A1 to A10
Load cells power supply Selection ,SW6,SW7
+/- 5V or +/- 15V
POT 9
12 positions rotative switch. SW3
Gain range selection . SW4,SW5
MC521-gb-0330
SERVICE MANUAL MCS2000-IS
Page 9 /12
WARNER ELECTRIC
Factory setting
SW1
SW2
SW4
SW5
SW6
SW7
ROTATIVE
SWITCH SW3
Pos A1 to A10
Factory setting=A10
SW1
SW6
SW7
SW6
SW7
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Input slope selection for US SENS
To get output decreasing on terminal
9 with input increasing on terminal 13
(Factory setting)
To get output increasing on terminal 9
with input decreasing on terminal 13
Load cell power supply
+5V Factory setting
- 5V Factory setting
+15V
SW2
DV/dt polarity compensation
To get output decreasing on terminal
19 with input increasing on terminal 16
To get output increasing on terminal 19
with input decreasing on terminal 16
(Factory setting)
Load cell amplifier gain range
UCELL1
SW4
High gain
UCELL2
SW5
High gain
UCELL1
SW4
Low gain
UCELL2
SW5
Low gain
SERVICE MANUAL MCS2000-IS
MC521-gb-0330
WARNER ELECTRIC
Inputs / Outputs – Setting specification
Block schematic
reference
Î
Í
Information
Specification
-5 (-15) VDC / max. curent 100 mA,
short circuit protected
Negative, input impedance 5kΩ, max. gain 1000
Positive, input impedance 5kΩ, max. gain 1000
+5 (+15) VDC / max. curent 100 mA,
short circuit protected
-5 (-15) VDC / max. curent 100 mA,
short circuit protected
Negative, input impedance 5kΩ, max. gain 1000
Positive, input impedance 5kΩ, max. gain 1000
+5 (+15) VDC / max. curent 100 mA,
short circuit protected
0-10 VDC, 10 mA, short circuit protected
0-10 VDC, 10 mA, short circuit protected
0-10 VDC, 10 mA, short circuit protected
- UE2
1
OUT
Power load cell 2
- CELL 2
+ CELL 2
+ UE2
2
3
4
IN
IN
OUT
Signal load cell 2
Signal load cell 2
Power load cell 2
- UE1
5
OUT
Power load cell 1
- CELL 1
+ CELL 1
+ UE1
6
7
8
IN
IN
OUT
Signal load cell 1
Signal load cell 1
Power load cell 1
US SENS OUT
SELECTED OUT
CELL SUM
9
10
11
OUT
OUT
OUT
Calibrated signal
Selection 9 or 11
Calibrated
load cell
+24VDC-SENS
US SENS
12
13
OUT
IN
GROUND
GROUND
IN 1
14
15
16
--IN
IN 2
IN 3
VREF
-+24 VDC
17
18
19
20
21
IN
IN
OUT
-IN
GROUND
22
--
SWITCHES
SW1 to SW7
See explanation pages 9 and 10
POT G1
POT G2
POT O1
POT 02
POT G TOT
POT
POT 0
POT G
POT
P1
P2
P3
P4
P5
P6
P7
P8
P9
Gain load cell 1 / max. 1000 – min. 450
Gain load cell 2 / max. 1000 – min. 450
Offset load cell 1 / ± 5 V
Offset load cell 2 / ± 5 V
Gain load cell 1 + 2 / max. gain 2 – min gain 1
Gain on dV/dt correction – 0 to 10 V
Offset for US SENS input 13, max. 2.5 V
Gain for US SENS input 13, max. 5, min. 1
Gain for SELECTED OUT, output 10
max. 1.1 / min 0.2
AMP 1
AMP 2
MC521-gb-0330
Ultrasonic
or other
For dV/dt
compensation
External access
External access
Sum IN1, 2 and 3
Main supply
+24 VDC / max. current capacity – 300 mA
Input impedance 10 kΩ, Delta max. 9 VDC,
min. 1 VDC, 0 VDC connect to Ground
General ground of the circuitry
General ground of the circuitry
Input impedance 10 kΩ, max. 10 VDC
Input impedance 10 kΩ, max. 10 VDC
Input impedance 10 kΩ, max. 10 VDC
Max. 10 VDC, 10 mA, short circuit protected
Free
Power supply board +24 VDC ± 2 V
Capacity 300 mA + output 12
0 V for power supply input
Amplifier channel 1
Amplifier channel 2
SERVICE MANUAL MCS2000-IS
Page 11 /12
WARNER ELECTRIC
Your distributor
Ihr Vertriebshändler
Votre distributeur
WARNER ELECTRIC EUROPE
BP 20095, F-49182
St Barthélemy d'Anjou Cedex
Tel.
Fax
+33 (0)2 41 21 24 24
+33 (0)2 41 21 24 00
www.warnerelectric-eu.com
Page 12 / 12
SERVICE MANUAL MCS2000-IS
MC521-gb-0330