INSTALLATION AND OPERATING INSTRUCTIONS VARI-PAK CYCLING DC MOTOR CONTROL – Designed for Indexing Applications – ON STOP OL VARI-PAK DC MOTOR SPEED CONTROL 40 50 60 70 30 20 80 10 90 0 100 % 144 S. Wolf Rd Wheeling, IL 60090 (847) 459-5200 RUN JOG / STOP NEMA-12 This manual covers the following CAMCO part numbers: 92A61633010000, 92A61633020000, 92A61633030000, 92A61633040000 92A81359000000 See Safety Warning on Page 2 The information contained in this manual is intended to be accurate.
TABLE OF CONTENTS Section Page i. Simplified Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 ii. Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 I. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 II. Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . .
i. SIMPLIFIED OPERATING INSTRUCTIONS IMPORTANT – You must read these simplified operating instructions before proceeding. These instructions are to be used as a reference only and are not intended to replace the detailed instructions provided herein. You must read the Safety Warning, on page 2, before proceeding. A A. AC Power – Use 120 Volt AC rated controls on 120 Volts AC and 240 Volt AC rated controls on 240 Volts AC. Connect AC power to terminal block TB2 terminals L1 and L2.
ii. ! SAFETY WARNING! Please read carefully This product should be installed and serviced by a qualified technician, electrician, or electrical maintenance person familiar with its operation and the hazards involved.
3 Input Line Voltage (VAC 50/60 Hz ± 10%) 120 120 240 240 Part Number 92A61633010000 92A81359000000 92A61633020000 92A61633030000 92A61633040000 15.0 0 – 180 15.0 15.0 0 – 90 0 – 180 15.0 Maximum AC Load Current (RMS Amps) 0 – 90 Motor Armature Voltage (VDC) 10.2 10.2 10.2 10.2 Maximum DC Load Current (DC Amps) TABLE 1 – ELECTRICAL RATINGS 2, (1.5) 2, (1.5) 1, (0.75) 1, (0.
TABLE 2 – GENERAL PERFORMANCE SPECIFICATIONS Specifications Specifications Part Nos. Parameter (Units) Part Nos. Factory Setting 92A61633010000 92A61633020000 92A81359000000 AC Line Input (VAC ± 10%, 50/60 Hz) Horsepower Range HP, (kW) 92A61633030000 92A61633040000 Factory Setting 115 — 208/230 — 1/6 – 1, (0.12 – 0.75) 1/3, (0.25) 1/3 – 2, (0.25 – 1.5) 1/4, (0.18) Armature Voltage Range (VDC) 0 – 100 85 0 – 200 170 2, 3.3, 5, 10 3.3 2, 3.
FIGURE 2A – CONTROL LAYOUT (Non-Reversing Units) (92A61633010000, 92A61633030000 and 92A81359000000) (Illustrates Factory Setting of Jumpers and Approximate Trimpot Settings) MIN CL IR CON2 S R JW J1 KBPI NC NO JS 90V 180V J3 JR F TB1 RUN FWD (6) JOG FWD (5) STOP (4) RTN (3) +24V (2) COM (1) 2A 3.
FIGURE 2B – CONTROL LAYOUT (Reversing Units) (92A61633020000 and 92A61633040000) (Illustrates Factory Setting of Jumpers and Approximate Trimpot Settings) MIN CL IR CON2 P3 CON1 MAX S R J1 KBPI NC NO JS 90V 180V 240V P1 F J3 RB2 RB1 KBPI RELAY O JR TB1 RUN REV (8) JOG REV (7) RUN FWD (6) JOG FWD (5) STOP (4) RTN (3) +24V (2) COM (1) 2A 3.
8.226 [208.94] 8.876 [225.45] 9.488 [241.00] 0.357 [9.07] OL 100 NEMA-12 JOG / STOP RUN 144 S. Wolf Rd Wheeling, IL 60090 (847) 459-5200 % 10 0 80 90 20 60 70 50 30 40 DC MOTOR SPEED CONTROL VARI-PAK STOP 5.000 [127.00] 5.472 [138.99] ON RECOMMENDED MOUNTING SCREW: 1/4" (M6) 5.886 [149.
TABLE 3 – SELECTABLE JUMPER REFERENCE CHART Jumper Location* Description Factory Setting J1 1 Establishes the range of maximum armature current See section III, page 8 J2A, J2B 1 Sets the AC input line voltage (120 or 240 Volts AC) for the main PC Board Set according to model part numbers. See table 1, Page 3 J3 1 Sets the DC output voltage range to motor (90V/180V) Set according to model part numbers. See table 1, Page 3 JR 1 Used to activate the return (RTN) circuit.
Failure to follow the Safety Warning Instructions may result in electric shock, fire or explosion. Do not fuse neutral or grounded conductors. Note: See section V, Fusing, on page 10. A separate AC line switch, or contactor, must be wired as a disconnect switch, so that the contacts open each ungrounded conductor. (See figure 4, below for AC Line and Armature Connection.) Note: Do not bundle AC or motor leads with logic leads or erratic operation may occur.
1. Remote Potentiometer. Connect remote potentiometer wires to terminals P1, P2 and P3, so that the “high” side of the potentiometer connects to P3, the “wiper” to P2 and the “low” side to P1. (See figure 5.) 2. Analog Input. An isolated 0-10VDC analog voltage can also be used to drive the control. Note: If an isolated signal voltage is not available, an optional signal isolator (Camco P/N 99A61455000000) should be used. Connect the isolated input voltage to terminal P2 (positive) and P1 (negative).
B. ”JOG” (Stop) – A maintained contact closure between terminals “JOG” and “RTN” will cause the control to run continuously. This is not a latching function. The drive will run only as long as the contact is closed and stop when it is opened. (See figure 8.) Application Note: The “JOG” can also be used as a normally open (NO) “STOP” command. When the control is started with the momentary “RUN” command, it can be stopped by connecting a momentary contact between the “JOG” and the “RTN” terminals.
TABLE 6 – JUMPER “JW” OPERATION Jumper “JW” Setting Description Circuit RUN S R JW Factory setting JOG “Run” has priority over “Stop.” Control will run even if stop contact is open. Use this setting for “Cycle on Demand” operation. STP Operation RTN * STOP When start contact is made, control will run with stop open. If stop is closed and then reopened, control will stop. START RUN S R JW JOG “Stop” has priority over “Run.” Control will run only when stop contact is closed.
Capable of switching 30 VDC, at 24 mA, with an off-state leakage current of less than 1 mA. (See figure 12.) Warning! Do not ground or short +24V to COM or return on TB1. Do not use +24V for other than open collector sensors. (See figure 12.) Example 2: For optimum operation, contacts used on logic inputs should be rated for low-level logic switching (i.e. gold contacts). (See figure13.
FIGURE 14B – RIGHT ANGLE UNIT FIGURE 14C – PARALLEL UNIT Keyway Keyway A standard right angle unit with the CAM & Limit Switch mounted on the housing has a correct keyway position directly opposite of the CAM Lobe. CAM & Limit Switch may also be mounted on the reducer. The “Cycle on Demand” function is required for most indexing table applications. The control can be easily set for this operation as follows: 1. Jumper “JW” must be in the “R” position (factory setting) see table 6, on page 12. 2.
FIGURE 16 – SEQUENCE OF CYCLE ON DEMAND OPERATION LS1 CONTACT IS OPENING LS1 CONTACT CLOSES ROTATION OF CAM 1) CLOSE START BUTTON TO INITIATE CYCLE (MOMENTARY CLOSURE) 2) CAM ROTATES, LS1 CONTACT CLOSES LS1 LS1 CONTACT REMAINS CLOSED 1) CAM CONTINUES TO ROTATE THROUGH CYCLE, LS1 REMAINS CLOSED CONTACT OPENS 4) CAM ROTATES UNTIL LOBE UNTIL LS1 CONTACT, DRIVE BRAKES TO A STOP. CLOSE MOMENTARY START BUTTON TO INITIATE NEW CYCLE. VIII.
FIGURE 17 – REVERSING LOGIC WIRING DIAGRAMS FIGURE 17A – GENERAL CONNECTION DIAGRAM FIGURE 17B – REVERSING USING EXTERNAL CONTACTS * 8 RUN REV 7 JOG REV 6 RUN FWD 5 JOG FWD STOP 4 STOP 3 RTN 3 RTN 2 +24V 1 COM 8 RUN REV 7 JOG REV 6 RUN FWD 5 JOG FWD 4 * JOG FWD LS1 FIGURE 17C – CYCLE ON DEMAND WITH REVERSE LS2 (N/O) REVERSE START CYCLE USE NORMALLY OPEN MAINTAINED CONTACTS FIGURE 17D – FORWARD AND REVERSE CYCLE ON DEMAND * 8 RUN REV 7 JOG REV 6 RUN FWD 5 JOG FW
WARNING! Do not adjust trimpots with main power on if possible. If adjustments are made with power on, insulated adjustment tools must be used and safety glasses must be worn. High voltage exists in this control. Electrocution and/or fire can result if caution is not exercised. Safety Warning on page 2 must be read and understood before proceeding. Failure to follow the Safety Warning Instructions may result in electric shock, fire or explosion. ! A.
C. Overload Indicator (OL) – When the motor is loaded to the current limit setpoint (CL setpoint is established by the setting of jumper J1 and the CL trimpot) this lamp will glow RED. If the OL indicator remains lighted during control operation, a fault condition may exist. Possible causes for this condition are as follows: 1. Motor is overloaded - check motor amps with DC ammeter in series with armature. 2. Motor may be defective - check motor for shorts or grounds. 3.
XII – TROUBLESHOOTING GUIDE MOTOR WILL NOT RUN: 1. Check control operation by placing RUN - JOG/STOP in RUN position. 2. Make sure disconnect fuses or circuit breaker in AC line are okay. 3. Check fuse on PC board, and if open, replace. 4. Check logic. See Start-up Procedures and Application Section. 5. Be sure speed pot is not set at zero. 6. Unit is in current limit – See if “OL” indicator is lighted. Check position of jumper J1. (See table 4, p. 8) and CL trimpot setting. 7.
F O JW S 90V 180V NC NO P3 P2 RUN REV (8) JOG REV (7) RUN FWD (6) JOG FWD (5) STOP (4) RTN (3) +24V (2) COM (1) R JS A2A CON2 TB2 A1B P1 RB1 RB2 J3 A1 J1 CL A2B A2 A1A P1 CON1 MAX L1 120V 2A 3.
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INDUSTRIAL MOTION CONTROL, LLC 1444 SOUTH WOLF ROAD WHEELING, IL 60090 USA Tel: 847-459-5200 Toll-Free: 800, 645-5207
