DE-STA-CO VARI-PAK DC CONTROL User Manual
INSTALLATION AND OPERATING INSTRUCTIONS
OLSTOPON
JOG / STOP
RUN
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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