DE-STA-CO VARI-PAK DC CONTROL User Manual

INSTALLATION AND OPERATING INSTRUCTIONS
OLSTOPON
JOG / STOP
DC MOTOR SPEED CONTROL
VARI-PAK
NEMA-12
100
90
80
70
60
40
30
20
10
0
50
%
144 S. Wolf Rd
Wheeling, IL 60090
(847) 459-5200
VARI-PAK
CYCLING DC MOTOR CONTROL
– Designed for Indexing Applications –
This manual covers the following CAMCO part numbers:
92A61633010000, 92A61633020000, 92A61633030000, 92A61633040000
The information contained in this manual is intended to be accurate. However
retains the right to make changes in design which may not be included herein.
92A81359000000
See Safety Warning on Page 2
, the manufacturer
Industrial Motion Control, LLC
© 2003 KB Electronics, Inc.
TABLE OF CONTENTS
Section Page
i. Simplified Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ii. Safety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
I. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
I
I. Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
III. Setting Motor Current (Jumper J1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
IV. Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
V. Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
VI. Logic Function and Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
VII. Application Wiring Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
VIII. Application Wiring Diagrams (Reversible Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
IX.
X. Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
XI. Function Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
XII. Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Tables
1. Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
General Performance Specifications
2.
3. Selectable Jumper Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4. Jumper J1 Setting vs Motor Horsepower . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5. Terminal Block Wiring Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6. Jumper “JW” Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Figures
1. Typical Indexing Performance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
2A. Control Layout (Non-Reversing Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2B. Control Layout (Reversing Units) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
3. Mechanical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
4. AC Line & Armature Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
5. Remote Potentiometer Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
6. Analog Voltage Connection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
7. Run Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
8. Jog Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
9. Jog Command used as Stop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
10. Stop Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
11. Jumper “JR” Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
12. Solid State Switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
13. Contact Switching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Correct Keyway Position for CAM & Limit Switch
14.
15. Cycle on Demand Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Sequence of Cycle on Demand Operation
16.
17. Reversing Logic Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
18. Internal Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ii
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assemblies
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
. . . . . . . . . . . . . . . . . .
13, 14
4
15
i. SIMPLIFIED OPERATING INSTRUCTIONS
MIN MAX CL IR
TB2
A1 A2 L1 L2
A
M
AC LINE
INPUT
Do not connect ground wire to any o
ther terminal
E
arth
G
round
MOTOR
3.3A
2A
10A
5A
I
MPORTANT–You must read these simplified operating instructions before pro-
ceeding. 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
. 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. When power is applied, the power on (ON) LED on the front cover will illuminate.
Be sure input AC line voltage corresponds to control voltage rating. Be sure AC power is disconnected when making other con­nections to control. Do not bundle AC power and motor wires with wires connected to TB1 terminals.
B. Motor Leads – Connect the
motor leads to terminal block
TB2 terminals A1 and A2. Be sure motor nameplate voltage rating corresponds to control output volt­age rating. Do not use control
Note: Jumper “J1” is shown in the factory setting for 120 Volts AC controls (3.3 Amps).
JUMPER J1 SETTING vs
MOTOR HORSEPOWER
Jumper J1
Motor Horsepower Range
90 VDC 180 VDC
1/6 1/3
1/4 – 1/3 1/2 – 3/4
1/2 1
3/4 – 1 11⁄2 – 2
with shunt wound motors.
C. Motor Current Setting – Be sure Jumper J1 is set to the approximate rated motor
current (10A, 5A, 3.3A, 2A).
D. Trimpot Settings – Trimpots should be set to the approximate position as shown:
E. Main Speed Pot – Turn the main speed pot on the front cover of the control to a 15%
or greater setting.
Special Instruction for Cycle on Demand Applications
The camshaft of the Index Drive should be in the middle of its dwell position. This is the posi­tion in which the motor should receive its signal to start. Connect the normally closed side of the cycling limit switch (LS1) to the control’
See figure 14A-C, on pages 13 and 14, for information regarding the correct dwell position for your Index Drive model and cycling cam lobe positions.
TB1 terminals ST
s
OP (4) and RTN (3).
Note:
1
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. Proper instal­lation, which includes wiring, mounting in proper enclosure, fusing or other over current pro­tection, and grounding can reduce the chance of electrical shocks, fires, or explosion in this product or products used with this product, such as electric motors, switches, coils, solenoids, and/or relays. Eye protection must be worn and insulated adjustment tools must be used when working with control under power. This product is constructed of materials (plastics, metals, carbon, silicon, etc.) which may be a potential hazard. Proper shielding, grounding and filtering of this product can reduce the emission of radio frequency interference (RFI) which may adversely affect sensitive electronic equipment. If further information is required on this product, contact the Sales Department. It is the responsibility of the equipment man­ufacturer and individual installer to supply this Safety Warning to the ultimate end user of this product. (SW effective 9/2000).
This control contains Start/Stop and Inhibit circuits that can be used to start and stop the control. However, these circuits are never to be used as safety disconnects since they are not fail-safe. Use only the AC line for this purpose.
The potentiometer circuit (P1, P2, P3) of this control is not isolated from AC line. Be sure to follow all instructions carefully. Fire and/or electrocution can result due to improper use of this product.
This product complies with all CE directives pertinent at the time of manufacture.
Contact factory for detailed installation and Declaration of Conformity. Installation of a CE approved RFI filter (KBRF-200A [P/N 9945C] or equivalent) is required. Additional shield­ed motor cable and/or AC line cables may be required along with a signal isolator (Camco P/N 99A61455000000).
I. INTRODUCTION
The VARI–PAK Series is housed in a rugged die cast aluminum NEMA 12 enclosure. The controls are designed specifically for cycling and indexing applications. A variety of models provide different features and input voltage ratings (see table 1, on page 3). The controls pro­vide the user with isolated logic functions: STOP, JOG and RUN. Other functions, such as cycle on demand, can easily be obtained. An important feature of the control is jumper J1 which is used for DC current selection. It automatically presets the IR Compensation and Current Limit for safe operation on various motors. Standard features include an LED indi­cator array for “power on,” “stop” and “overload.” Part Numbers 92A61633020000 and 92A61633040000 also contain logic input for “Reverse Run” and “Reverse Jog.” The con­trols contain trimpots that can be used to readjust Minimum and Maximum speed, Current Limit and IR Compensation. and a Run, Jog/Stop switch. (See table 3, on page 8, for selectable jumper information.)
2
A label like the one shown, appears on the top side of your VARI-PAK unit. If this label is not on your control, notify CAMCO immediately! 1-800-645-5207.
The front panel contains a built-in 5K ohm speed potentiometer
Logic Provided
Type of
Operation
Jog, Rtn
Stop, Rev Run, Rev
Fwd Run, Fwd Jog,
Jog, Rtn
Stop, Rev Run, Rev
Fwd Run, Fwd Jog,
HP, (kW)
Maximum
Horsepower
(DC Amps)
Load Current
Maximum DC
15.0 10.2 1, (0.75) Unidirectional Run, Jog, Stop, Rtn
15.0 10.2 1, (0.75) Reversing
(RMS Amps)
Load Current
Maximum AC
2, (1.5) Reversing
10.2
15.0 10.2 2, (1.5) Unidirectional Run, Jog, Stop, Rtn
TABLE 1 – ELECTRICAL RATINGS
0 – 90
0 – 90
0 – 180
Voltage (VDC)
Motor Armature
120
10%)
(VAC 50/60 Hz ±
Input Line Voltage
Part Number
IMPORTANT! Control part number and ratings must correspond to the AC line voltage, motor voltage and type of operation (Unidirectional or Reversing). See table 1.
92A81359000000
92A61633010000
92A61633020000 120
92A61633030000 240
92A61633040000 240 0 – 180 15.0
3
TABLE 2 – GENERAL PERFORMANCE SPECIFICATIONS
100 250TIME (msec)
DECEL WITH DYNAMIC BRAKE
MOTOR BASE RATED SPEED
FIXED ACCEL
SPEED
(rpm)
1800
Specifications Specifications
P
Parameter
(Units)
AC Line Input
(VAC ±10%, 50/60 Hz)
H
orsepower Range HP, (kW)
A
rmature Voltage Range (VDC)
C
urrent Ranges (ADC)
CL Trimpot Range
(
% Range Setting)
MIN Speed Trimpot Range
(% Base Speed)
MAX Speed Trimpot Range
(% Base Speed)
IR COMP Trimpot Range
(% Base Speed)
art Nos.
9
2A61633010000
9
2A61633020000
92A81359000000
Factory
S
etting
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)
0
– 100
2
, 3.3, 5, 10
8
5
3
.3
0 – 170 150 0 – 170 150
0 –30 0 0 – 30 0
60 – 120 100 60 – 120 100
0 – 15 4 0 – 30 8
Speed Range (Ratio) 50:1 50:1
oltage Regulation
AC Line V
(% Base Speed)
Voltage Following Linearity
(% Base Speed)
Load Regulation
(% Base Speed)
± 0.5 ± 0.5
± 0.5 ± 0.5
± 1 ± 1
Ambient Temperature Range (ºC) 0 – 45 0 – 45 — Potentiometer, Front Cover
(ohms – watts)
Maximum Run/Stop Operations
(ops/min)
Enclosure
Type (NEMA)
5K – 1/3 5K – 1/3
30 30
12 12
P
art Nos.
9
2A61633030000
92A61633040000
0
– 200
2
, 3.3, 5, 10
Factory
S
etting
1
70 2
4
FIGURE 1 – TYPICAL INDEXING PERFORMANCE
Maximum Cycle Rate: 30 cycles per minute with typical 1 HP motor. Total reflected inertia not to exceed 20% of armature inertia. Acceleration time (fixed at 0.1 sec.) may be extended when operating in Current LImit
RB2 RB1
P1 P2 P3
CON1
120V
L2L1A2A1
TB2
J2B J2A
R
S
JW
CON2
240V
MIN MAX CL IR
P4
J3
90V 180V
JS
NC NO
3.3AJ12A
KBPI
10A
5A
O
F
JR
TB1
(3) (2)
COM (1)
+24V
(6) JOG FWD
STOP RTN
(4)
(5)
RUN FWD
A1B
A2A
A2B
A1A
FIGURE 2A – CONTROL LAYOUT (Non-Reversing Units)
(92A61633010000, 92A61633030000 and 92A81359000000)
(Illustrates Factory Setting of Jumpers and Approximate Trimpot Settings)
5
RB2 RB1
(6)
(2) (1)
COM
JR
O
F
TB1
+24V
(3)
RTN
(4)
(5)
JOG FWD STOP
P1
(7)
(8)
RUN REV JOG REV RUN FWD
P2 P3
CON1
120V
L2L1A2A1
TB2
J2B J2A
5A2A3.3A
10A
90VJ3180V
NC
JS
NO
KBPI
R
S
JW
CON2
J1
240V
MIN MAX CL IR
120V
A2A
A1B
A2B
J1
240V
A1A
KBPI RELAY
P1
FIGURE 2B – CONTROL LAYOUT (Reversing Units)
(92A61633020000 and 92A61633040000)
(Illustrates Factory Setting of Jumpers and Approximate Trimpot Settings)
6
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