Camco VARI-PAK User manual

INSTALLATION AND OPERATING INSTRUCTIONS
VARI-PAK
CYCLING DC MOTOR CONTROL
– Designed for Indexing Applications –
© 2003 KB Electronics, Inc.
OLTOPON
JOG / TOP
RUN
DC MOTOR PEED CONTROL
VARI-PAK
NEMA-12
100
90
80
70
60
40
30
20
10
0
50
%
144 . Wolf Rd
Wheeling, IL 60090
[phone]
See Safety Warning on Page
The information contained in this manual is intended to be accurate. However, the manufacturer
retains the right to make changes in design which may not be included herein.
This manual covers the following CAMCO part numbers:
92A61633010000, 92A61633020000, 92A61633030000, 92A61633040000
Industrial Motion Control, LLC

TABLE OF CONTENTS
Section Page
i. implified Operating Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
ii. afety Warning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
I. Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
II. Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
III. etting 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
IX. Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
X. Trimpot Adjustments . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
XI. Function Indicator Lamps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
XII. Troubleshooting Guide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Tables
1. Electrical Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3
2. General Performance pecifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
3. electable Jumper Reference Chart . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4. Jumper J1 etting 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 pecifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
10. top Command . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
11. Jumper “JR” Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
12. olid tate witching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
13. Contact witching . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
14. Correct Keyway Position for CAM & Limit witch Assemblies . . . . . . . . . . . . . . . . . 13, 14
15. Cycle on Demand Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
16. equence of Cycle on Demand Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
17. Reversing Logic Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
18. Internal Wiring Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
ii

i. SIMPLIFIED OPERATING INSTRUCTIONS
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 con-
nections 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 volt-
age rating. Do not use control
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.
11⁄2– 2
Motor Horsepower Range
Jumper J1
90 VDC 180 VDC
3/4 – 1
1/6 1/3
1/4 – 1/3 1/2 – 3/4
1/2 1
3.3A
2A
10A
5A
1
IMPORTANT – 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 afety
Warning, on page 2, before proceeding.
MIN MAX CL IR
TB2
A1 A2 L1 L2
A1
M
AC LINE
INPUT
Do not connect
ground wire to any
other terminal
Earth
Ground
MOTOR
JUMPER J1 SETTING vs
MOTOR HORSEPOWER
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 posi-
tion in which the motor should receive its signal to start. Connect the normally closed side
of the cycling limit switch (L 1) to the control’s TB1 terminals TOP (4) and RTN (3). Note:
ee 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.
Note: Jumper “J1” is shown in the factory setting for
120 Volts AC controls (3.3 Amps).

I. INTRODUCTION
The VARI–PAK eries 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 pro-
vide the user with isolated logic functions: TOP, 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. tandard features include an LED indi-
cator array for “power on,” “stop” and “overload.” Part Numbers 92A61633020000 and
92A61633040000 also contain logic input for “Reverse Run” and “Reverse Jog.” The con-
trols contain trimpots that can be used to readjust Minimum and Maximum speed, Current
Limit and IR Compensation. The front panel contains a built-in 5K ohm speed potentiometer
and a Run, Jog/ top switch. ( ee table 3, on page 8, for selectable jumper information.)
2
ii. SAFETY WARNING! Please read carefully
This product should be installed and serviced by a qualified technician, electrician, or elec-
trical maintenance person familiar with its operation and the hazards involved. Proper instal-
lation, which includes wiring, mounting in proper enclosure, fusing or other over current pro-
tection, 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 ales Department. It is the responsibility of the equipment man-
ufacturer and individual installer to supply this afety Warning to the ultimate end user of this
product. ( W effective 9/2000).
This control contains tart/ top 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 shield-
ed motor cable and/or AC line cables may be required along with a signal isolator (Camco P/N
99A61455000000).
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! 1-800-645-5 07.

3
92A61633040000
Logic Provided
Type of
Operation
Maximum
Horsepower
HP, (kW)
Maximum DC
Load Current
(DC Amps)
Maximum AC
Load Current
(RMS Amps)
Motor Armature
Voltage (VDC)
Input Line Voltage
(VAC 50/60 Hz ± 10%)
Part Number
Run, Jog, top, Rtn
92A61633010000 92A61633020000 92A61633030000
120
120
240
240
0 – 90
0 – 90
0 – 180 0 – 180
15.0 15.0 15.0 15.0
10.2 10.2 10.2 10.2
1, (0.75) 1, (0.75)
2, (1.5) 2, (1.5)
Unidirectional
Reversing
Unidirectional
Reversing
Fwd Run, Fwd Jog, top, Rev Run, Rev Jog, Rtn
Run, Jog, top, Rtn
Fwd Run, Fwd Jog, top, Rev Run, Rev Jog, Rtn
IMPORTANT! Control part number and ratings must correspond to the AC line voltage, motor voltage and type of operation (Unidirectional or Reversing). ee table 1.
TABLE 1 – ELECTRICAL RATINGS

4
—
Specifications Specifications
Factory
Setting
Factory
Setting
Part Nos. Part Nos.
Parameter
(Units)
AC Line Input
(VAC ± 10%, 50/60 Hz)
9 A61633010000
9 A616330 0000
9 A61633030000
9 A61633040000
Horsepower Range HP, (kW)
Armature Voltage Range (VDC)
Current Ranges (ADC)
CL Trimpot Range
(% Range etting)
MIN peed Trimpot Range
(% Base peed)
MAX peed Trimpot Range
(% Base peed)
IR COMP Trimpot Range
(% Base peed)
peed Range (Ratio)
AC Line Voltage Regulation
(% Base peed)
Voltage Following Linearity
(% Base peed)
Load Regulation
(% Base peed)
Ambient Temperature Range (ºC)
Potentiometer, Front Cover
(ohms – watts)
Maximum Run/ top Operations
(ops/min)
Enclosure Type (NEMA) —
115
1/6 – 1, (0.12 – 0.75)
208/230 —
1/3 – 2, (0.25 – 1.5)1/3, (0.25)
—
1/4, (0.18)
0 – 100 85 0 – 200 170
2, 3.3, 5, 10 3.3 2, 3.3, 5, 10 2
0 – 170 150 0 – 170 150
0 – 30 0 0 – 30 0
60 – 120 100 60 – 120 100
0 – 15 4 0 – 30 8
50:1 — 50:1
± 0.5 — ± 0.5 —
± 0.5 — ± 0.5 —
±1 — ±1 —
0 – 45 — 0 – 45 —
5K – 1/3 — 5K – 1/3 —
30—30—
12—12
TABLE – GENERAL PERFORMANCE SPECIFICATIONS
100 250TIME (msec)
DECEL WITH
DYNAMIC BRAKE
MOTOR BASE RATED SPEED
FIXED
ACCEL
SPEED
(rpm)
1800
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

5
RB2 RB1 P1 P2 P3
CON1
120V
L2L1A2A1
TB2
J2B J2A
R
JW
CON2
240V
MIN MAX CL IR
P4
J3
90V 180V
J
NC NO
3.3A
J1
2A
KBPI 10A
5A
OF
JR
TB1
(3)
(2)
COM
(1)
+24V
(6)
JOG FWD
TOP
RTN
(4)
(5)
RUN FWD
A1B
A2A
A2B
A1A
FIGURE A – CONTROL LAYOUT (Non-Reversing Units)
(9 A61633010000 and 9 A61633030000)
(Illustrates Factory etting of Jumpers and Approximate Trimpot ettings)

6
RB2 RB1
(6)
(2)
(1)
COM
JR
OF
TB1
+24V
(3)
RTN
(4)
(5)
JOG FWD
TOP
P1
(7)
(8)
RUN REV
JOG REV
RUN FWD
P2 P3
CON1
120V
L2L1A2A1
TB2
J2B J2A
5A 2A 3.3A
10A
90V J3 180V
NC
J
NO
KBPI
R
JW
CON2
J1
240V
MIN MAX CL IR
120V
A2A
A1B
A2B
J1
240V
A1A
KBPI RELAY
P1
FIGURE B – CONTROL LAYOUT (Reversing Units)
(9 A616330 0000 and 9 A61633040000)
(Illustrates Factory etting of Jumpers and Approximate Trimpot ettings)

7
FIGURE 3 – MECHANICAL SPECIFICATIONS (Inches / [mm])
RECOMMENDED MOUNTING SCREW: 1/4" (M6)
[127.00]
5.000
[138.99]
5.472
[149.50]
5.886
[9.07] 0.357
[208.94]
8.226
[225.45]
8.876
[241.00]
9.488
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
[phone]

8
II. MOUNTING
Mount the control in a vertical position on a flat surface. Be sure to leave enough room below
the bottom of the control to allow for the AC line and motor connections and other wiring that
may be necessary. Care should be taken to avoid extreme hazardous locations where phys-
ical damage can occur. Note: Do not use this control in an explosion proof application.
If the control is mounted in a closed, unventilated cabinet, remember to allow for proper heat
dissipation. If full rating is required, a minimum enclosure size of 12” W x 24” H x 12” D
should be used.
Front Cover – The VARI–PAK case is designed with a hinge so that when the front cover is
open, all wiring stays intact. To open the cover, the four cover screws must be loosened, so they
no longer are engaged in the case bottom. After mounting and wiring, close the front cover,
making sure all wires are contained within the enclosure and the gasket is in place
around the cover lip. Tighten all four cover screws so that the gasket is slightly compressed.
Do not overtighten.
III. SETTING MOTOR CURRENT (Jumper J1)
Jumper J1 (on the Main Board) is used to
set the range of armature current which
can be further modified with the current
limit (CL) trimpot. The factory setting of J1
is 3.3 amps for 120 VAC controls and 2
amps for 240 VAC controls. The CL trim-
pot is factory set to provide 150% of the J1
setting. For example, when J1 is in the 10
amp position, the actual armature current
is 15 amps. When J1 is in the 5 amp posi-
tion, the control provides a maximum
armature current of 7.5 amps. The position of J1 should be set to the approximate DC motor
current rating. Table 4 is provided as a reference.
IV. WIRING
WARNING! Read afety Warning on page 2 before attempting to use this control.
Wire control in accordance with the National Electrical Code requirements and
other codes that apply. Be sure to fuse each conductor which is not at ground potential.
et to “R” position for
“cycle on demand”
Factory SettingDescriptionLocation*Jumper
J1
J2A, J2B
J3
JR
J
J1
JW
1
1
1
1
1
2
1
Establishes the range of maximum armature current ee section III, page 8
ets the AC input line voltage (120 or 240 Volts AC) for
the main PC Board
et according to model part
numbers. ee table 1, Page 3
ets the DC output voltage range to motor (90V/180V) et according to model part
numbers. ee table 1, Page 3
Used to activate the return (RTN) circuit. “F” position –
RTN is jumpered to common.
“O” position – RTN used as a logic disable.
ee section VI D, on page 11
et to “F” position
Used to set the TOP function operation. “NC” position –
Use a normally closed contact for open to stop operation.
“NO” position – Use a normally open contact for “close to
stop” operation.
et to “NC” position
ets the operating AC line voltage for the
Relay Board (120 or 240 VAC)
et according to model part
numbers. ee table 1, Page 3
Determines the priority of the Run and top logic com-
mands. ee table 6, on page 12.
TABLE 3 – SELECTABLE JUMPER REFERENCE CHART
*NOTE: Location 1Main peed Control Board – Location Relay Board (found on reversing models only).
11⁄2– 2
Motor Horsepower Range
Jumper J1
90 VDC 180 VDC
3/4 – 1
1/6 1/3
1/4 – 1/3 1/2 – 3/4
1/2 1
3.3A
2A
10A
5A
TABLE 4 – JUMPER J1 SETTING vs
MOTOR HORSEPOWER
!

Failure to follow the afety Warning Instructions may result in electric shock, fire or explosion.
Do not fuse neutral or grounded conductors. Note: ee 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. ( ee 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. Twist logic wires (speed adjustment potentiometer or voltage signal input wires) to avoid
picking up electrical noise. If wires are longer than 18”, use shielded cable.
2. You may have to earth ground the shielded cable. If noise is coming from devices other
than the drive, ground the shield at the drive end (ground screw in enclosure). If noise is
generated by a device on the drive, ground the shield at the end away from the drive. Do
not ground both ends of the shield.
3. Do not bundle logic wires with power carrying lines or sources of electrical noise. Never
run speed adjustment potentiometer or voltage signal input wires in the same conduit as
motor or AC line voltage wires.
4. Connect earth ground to the earth ground screw provided in the enclosure. ( ee figure
4 for ground screw location.)
Two .875” (22.2 mm) knockout holes are provided for a standard 1/2” knockout connec-
tor (not supplied) for wiring. A plug is provided if only one knockout is required. Be sure
to use suitable connectors and wiring that is appropriate for the application.
A. AC Line – Connect AC Line to ter-
minals L1 and L2. (Be sure the
control model and rating match
the AC line input voltage. ee
table 1, on page 3.)
B. Motor Armature – Connect motor
armature to terminals A1 (+) and
A2 (-). ( ee table 1, on page 3).
WARNING! Do not wire switches
or relays in series with the arma-
ture. Armature switching can
cause catastrophic failure of
motor and/or control. Do not
bundle AC line and motor wires
with other wires (e.g. potentiometer, analog input, Run, Jog, Stop, etc.) since errat-
ic operation may occur. Do not use this control on shunt wound motors.
C. Ground – Be sure to ground (earth) the control by connecting a ground wire to the Green
Ground crew located to the right of the terminal block. Do not connect ground wire
to any other terminals on control.
D. Main Potentiometer – The control is supplied with the main potentiometer prewired.
However, the control can also be operated from a remote potentiometer, or from an iso-
lated analog voltage for voltage following. To operate from an external source remove
white, orange and violet potentiometer leads from terminals P1, P2 and P3. The leads
may be taped and left in the control. The potentiometer itself may be removed, if a seal
is used to cover the hole in the front cover. Note: Use shielded cable on all connec-
tions to P1, P , or P3 over 1 ” (30cm) in length. See section IV, items 1-4.
9
3.5
Terminal Block
Designation
Connection
Designation
Supply Wire Gauge* Maximum
Tightening Torque (in-lbs)
Minimum Maximum
TB2
TB1
A1, A2, L1, L2
Logic Connections
22
24
12
14
12
TABLE 5 – TERMINAL BLOCK WIRING INFORMATION
TB2
A1 A2 L1 L2
A1
M
AC LINE
INPUT
Do not connect
ground wire to any
other terminal
Earth
Ground
MOTOR
FIGURE 4 – AC LINE & ARMATURE CONNECTION
*Use Cu wire only (AWG)

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.
( ee 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).
( ee figure 6.) Adjust the MIN trimpot
clockwise to achieve a 0+ output voltage.
V. FUSING
AC Line Fusing – Most electrical codes require
that each ungrounded conductor contain fusing.
eparate branch circuit fusing or circuit breaker
may be required. Check all electrical codes that
may apply to the installation. This control does
not contain AC line fuses. A 20 amp rated fuse
or circuit breaker can be used.
VI. LOGIC FUNCTIONS AND WIRING
Warning! Do not use any of the logic functions (STOP, RTN) as an emergency
stop since they are not fail-safe. Use only an AC line (L1, L ) disconnect for that
purpose. To prevent erratic operation, do not bundle logic wiring with AC line and
motor wires. Use shielded cables on logic wiring over 1 ” (30 cm) in length. See sec-
tion IV, items 1-4, on page 9.
The control contains several logic functions which are described in detail below. All connec-
tions are made to terminal block TB1. ( ee figures 2A and 2B, on pages 5 and 6, for TB1
location.)
A. ”RUN” – Note:
This terminal is
sometimes
marked “START”
in older models.
Amomentary con-
tact closure
between terminals
“RUN” and “RTN”
latches the control
into a continuous
run mode. To stop
the control, the
stop circuit must be
activated by open-
ing the contact
between the
“ TOP” and “RTN” terminals. Note: All momentary closures must be present for
no less than 50 milliseconds and a normally closed (NC) contact must be main-
tained between the “Stop” and “RTN” terminals in order for the drive to run.
10
P1
P2
P3
5K
FIGURE 5 – REMOTE POTENTIOMETER
CONNECTION
-
+
VDC
0-10
VOLTAGE SOURCE
USE AN ISOLATED
P2
P1
FIGURE 6 – ANALOG VOLTAGE
CONNECTION
Warning! Do not ground (earth)
P1 or P2 connection
!
RUN JOG TP RTN +24V COM
OPEN
TO TOP
CLO E
TO TART
A NORMALLY CLO ED
CONTACT MU T BE
IN TALLED BETWEEN
"RTN" AND " TOP" IN
ORDER FOR CONTROL
TO TART, UNLE
JUMPER "JW" I IN THE
"R" PO ITION.
TB1
ee section IV,
items 1-4,
on page 9
FIGURE 7 – RUN COMMAND

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. ( ee figure 8.)
Application Note:
The “JOG” can also be used as a
normally open (NO) “STOP” com-
mand. When the control s started
w th the momentary “RUN” com-
mand, t can be stopped by
connect ng a momentary con-
tact between the “JOG” and the
“RTN” term nals. See f gure 9.
(Note: The control can also be
stopped by open ng the
“STOP” contact.)
C. ”STOP” — Use a normally
closed (NC) contact between ter-
minals “ TOP” and “RTN.” Ope-
ning the contact activates the
control’s Dynamic Brake produc-
ing a rapid stop. (Note: A nor-
mally open (NO) limit switch or
contact can also be used to acti-
vate the stop command. To
use a (NO) contact, move
jumper J to the “NO” posi-
tion). ( ee table 3, page 8.)
Application Note:
The sett ng of jumper “JW”
establ shes the pr or ty a
“STOP” command has over a
“RUN” command. If jumper
“JW” s placed n pos t on “S,”
the “STOP” command has
pr or ty over the “RUN”. If
the “STOP” s act vated
(contact open), the control
cannot be started w th the
“START” command. If jumper “JW” s n the “R” pos t on (factory sett ng), the “RUN”
command has pr or ty over the “STOP.” In th s mode of operat on the control can be
started w th the “RUN” command even though the “STOP” s act vated. Th s sett ng of
jumper JW n the “R” pos t on s used for cycle on demand appl cat ons. See table 6,
on page 12, for deta led nformat on of jumper “JW” operat on. Warn ng! Do not use as
safety stop. See Safety Warn ng on page 2.
D. ”RETURN” (RTN) – When Jumper “JR” is moved to position “O” from the factory setting
“F,” it disables all of the command functions (Run, Jog, top, etc.) and causes the control
to stop. To enable these functions, a contact must be placed between the “RTN” and
“COM” terminals.
Warning! Do not use as emergency or safety stop. See Safety Warning on page .
See figure 11, on page 1 , for jumper “JR” operation. Failure to follow the Safety
Warning Instructions may result in electric shock, fire or explosion.
11
RUN JOG TP RTN +24V COM
JOG
CLO E CONTACT
TO RUN, OPEN
TO TOP
ee section IV,
items 1-4,
on page 9
FIGURE 8 – JOG COMMAND
RUN JOG STP RTN +24V COM
STOP
NORMALLY OPEN
START
CONTACT, CLOSE
TO STOP
See section IV,
items 1-4,
on page 9
FIGURE 9 – JOG COMMAND USED AS STOP
RUN JOG STP RTN +24V COM
STOP
START
NORMALLY CLOSED
CONTACT, OPEN TO
STOP
See section IV,
items 1-4,
on page 9
FIGURE 10 – STOP COMMAND

12
E. + 4 VDC SUPPLY – The +24V terminal provides a nominal124 VDC @ 12 mA output for
use with an external load such as one solid-state 3-wire proximity switch.
F. Common “COM” — This terminal is referenced to all logic signals (RUN, JOG, TOP)
through the Return (“RTN”) terminal. The control is factory supplied with jumper “JR” in
the “F” position which connects the “RTN” and “COM” terminals together. Note: Control
will not operate unless jumper “JR” is in the “F” position.
VII. APPLICATION WIRING DIAGRAMS
Example 1: olid-state switching devices, such as NPN transistors or proximity switches,
may be used for logic commands if they meet the following criteria:
When start contact is
made, stop contact
must be closed for
control to run.
Jumper “JW” Setting Description Circuit Operation
“Run” has priority
over “ top.” Control
will run even if stop
contact is open. Use
this setting for “Cycle
on Demand” opera-
tion.
When start contact is
made, control will run
with stop open. If
stop is closed and
then reopened, con-
trol will stop.
“ top” has priority
over “Run.” Control
will run only when
stop contact is
closed.
JW
R
RUN JOG TP RTN
TOP
*
TART
RUN JOG TP RTN
TOP
TART
*
JW
R
TABLE 6 – JUMPER “JW” OPERATION
* ee section IV, items 1-4, on page 9.
COMRTN
RTN COM
OPEN TO
"F" "O"
"JR"
TOP
"JR"
*
"O""F"
FIGURE 11 – JUMPER “JR” OPERATION
Factory setting
Jumper “JR” in “F” position (factory setting)
connects “RTN” to “COM”
Jumper “JR” in “O” position opens the
“RTN” to “COM” circuit allowing the use of
an external disable contact. This will not
stop the indexer in run mode.
1Output voltage provided can vary between 20 and 24 Volts DC.

13
Capable of switching 30 VDC, at 24 mA,
with an off-state leakage current of less
than 1 mA. ( ee 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. ( ee
figure 12.)
Example 2: For optimum operation,
contacts used on logic inputs should be
rated for low-level logic switching (i.e.
gold contacts). ( ee figure13.)
Example 3: “Cycle on Demand” –
Important Information
In a “Cycle on Demand” application, the
CAMCO Index Drive will make one com-
plete cycle of movement of table or con-
veyor and then dwell until it receives an
external signal from the machine’s con-
troller or operator to start again. If motor
receives a signal to start while the CAMCO
Index Drive is in its dwell position, the
motor will accelerate from a paused posi-
tion to full speed during one half of the
dwell of the main index cam. When the
motor has reached its maximum speed
and is no longer accelerating, the motion of
the CAMCO Index Drive can start. As the
Indexer re-enters its dwell portion of the
main cam, the signal cam located on the
camshaft of the CAMCO Index Drive will
actuate the limit switch to signal a stop.
(Note: Due to time delays, the signal cam
may have to signal a stop some degrees
before the index drive actually enters the dwell.) It is important that the motor is made to stop
while in the dwell of the main cam. topping in any other position could damage the control or
the Index Drive! Read all the instructions carefully in order to familiarize yourself with your new
CAMCO Index Drive. ( ee figures 14A, 14B and 14C.)
RUN JOG TP RTN +24V COM
NOTE: JUMPER
"JR" MU T
TOP
JOG
TART
BE IN THE
"F" PO ITION
+V
ee section IV,
items 1-4,
on page 9
FIGURE 1 – SOLID STATE SWITCHING
RUN JOG STP RTN +24V COM
NOTE: JUMPER
"JR" MUST
BE IN THE
"O" POSITION
RTNSTOP
JOG
START
+V
See section IV,
items 1-4,
on page 9
FIGURE 13 – CONTACT SWITCHING
Type II Extra
CAM LOBE
Keyway
A standard Roller Gear unit
with the CAM & Limit witch
mounted on the correct key-
way position directly opposite
of the output shaft, 90º (clock-
wise) from the CAM Lobe.
The CAM & Limit witch may
also be mounted on the
reducer. If the unit has a
“Type II” motion, a special
Limit witch CAM is needed
with one extra Lobe, 180º
from the first Lobe (as shown).
Note: On some RDM units
(such as the 601 RDM), the
CAM & Limit Switch is
mounted at an angle.
FIGURE 14 – CORRECT KEYWAY POSITION FOR CAM & LIMIT SWITCH ASSEMBLIES
FIGURE 14A – ROLLER GEAR UNIT

14
The “Cycle on Demand” function is
required for most indexing table applica-
tions. The control can be easily set for
this operation as follows:
1. Jumper “JW” must be in the “R” posi-
tion (factory setting) see table 6, on
page 12.
2. Jumper “JR” must be in the “F” posi-
tion (factory setting) see section VI D,
on page 11.
3. Wire limit switch L 1 (normally closed)
and start switch (normally open) as
shown.
The “Cycle on Demand Operation”
begins with limit switch L 1 riding on the
CAM lobe. ( ince L 1 is a normally
closed switch, it will be open when riding
on the lobe.) The cycle is initiated by
momentarily closing the start switch. The
drive will start even though L 1 is open.
(Jumper JW is in the “R” position giving priority to the start switch which overrides the
stop.) As the camshaft rotates, it moves off L 1 which closes. When the lobe rotates
around back to L 1, L 1 now opens and the drive stops. The drive is now ready to repeat
the cycle by initiating another start command. ee figure 16, on page 15.
Note: A normally open (NO) TOP contact can also be used. To convert to a normal-
ly open TOP, move jumper J from the factory position “NC” to position “NO.”
Keyway
Keyway
FIGURE 14B – RIGHT ANGLE UNIT
A standard right angle unit with the CAM &
Limit witch mounted on the housing has a
correct keyway position directly opposite of
the CAM Lobe. CAM & Limit witch may also
be mounted on the reducer.
FIGURE 14C – PARALLEL UNIT
A standard parallel unit with the CAM & Limit
witch mounted on the housing has a correct
keyway position directly opposite of the output
shaft, 90º (clockwise) from the CAM Lobe. CAM
& Limit witch may also be mounted on the
reducer.
MOMENTARY
TART
1
2
3
4
5
6 RUN
JOG
TOP
RTN
+24V
COM
L 1 (N/C)
WITCH
(N/O)
ee section IV,
items 1-4,
on page 9
FIGURE 15 – CYCLE ON DEMAND WIRING

15
VIII. APPLICATION WIRING DIAGRAMS (Reversible Models)
P/N 92A61633020000 (120 VAC) – P/N 92A61633040000 (240 VAC).
Reversing models carry out the same functions as the unidirectional models except they can
be made to index in both the forward and reverse direction. A special circuit APRM® pro-
vides a lockout feature that prevents catastrophic damage to the drive if a “Reverse” com-
mand is given during “Forward” operation (and vice versa). The reversing drives contain two
additional positions on the terminal block: “Run Rev” and “Jog Rev.” The stop logic com-
mand is made with a normally closed (NC) contact.
Note: The sense of the stop logic can be changed from normally closed (NC) to nor-
mally open (NO) by placing jumper J in the “NO” position.
The wiring diagrams on page 16 illustrate typical logic circuits. Many other configurations are
possible. Consult factory if help is needed.
IX. OPERATION
WARNING! Read Safety Warning on page before attempting to operate the
control or severe injury or death can result. Failure to follow the Safety
Warning Instructions may result in electric shock, fire or explosion.
ROTATION
OF CAM
CONTACT IS OPENING
LS1 LS1
CONTACT CLOSES
1) CLO E TART BUTTON TO INITIATE
CYCLE (MOMENTARY CLO URE) 2) CAM ROTATE , L 1 CONTACT CLO E
CLO ED
CONTACT REMAIN
L 1 L 1
CONTACT OPEN
1) CAM CONTINUE TO ROTATE THROUGH
CYCLE, L 1 REMAIN CLO ED
4) CAM ROTATE UNTIL LOBE UNTIL L 1 CONTACT,
DRIVE BRAKE TO A TOP. CLO E MOMENTARY
TART BUTTON TO INITIATE NEW CYCLE.
FIGURE 16 – SEQUENCE OF CYCLE ON DEMAND OPERATION
!

16
After the control has been set up properly (the jumpers set to the desired positions and the
wiring completed), the start-up procedure can begin. If AC power has been properly brought
to the control, the “ON” and the “ TOP” indicators will be lighted. Before initially starting, be
sure the main potentiometer is set to approximately 15% rotation. To start the control, move
the Run-Jog/ top witch to the “Run” position and release. The “ top” indicator should extin-
guish and the motor should rotate as the potentiometer knob is rotated clockwise.
Note: If the motor rotates in the wrong direction, it will be necessary to disconnect the
main AC power and reverse the armature wires. To stop the motor, move the Run-
Jog/ top witch to the top position. If power is lost the control will not restart,
unless the Run- Jog/ top witch is moved to the “Run” position.
X. TRIMPOT ADJUSTMENTS
The control contains trimpots which have been factory adjusted for most applications.
Figures 2A and 2B, on pages 4 and 5, illustrate the location of the trimpots and their approx-
imate adjustment positions. ome applications may require readjustment of the trimpots in
order to tailor the control to exact requirements. ( ee table 2, on page 4, for range and fac-
tory setting of trimpots.) Readjust trimpots as follows:
1
2
3
4
5
6 RUN FWD
JOG FWD
TOP
RTN
+24V
COM
L 1
JOG REV7
8 RUN REV
*
3
4
5
6 RUN FWD
JOG FWD
TOP
RTN
JOG REV7
8 RUN REV
FWD
JOG
U E NORMALLY OPEN
MAINTAINED CONTACT
*
3
4
5
6 RUN FWD
JOG FWD
TOP
RTN
L 1 (N/C)
JOG REV7
8 RUN REV
L 2 (N/O)
REVER E
TART
END OF
CYCLE
CYCLE
*
3
4
5
6 RUN FWD
JOG FWD
TOP
RTN
L 1
JOG REV7
8 RUN REV
RUN REV
RUN FWD
TOP REV
L 2
TOP FWD
*
FIGURE 17A – GENERAL
CONNECTION DIAGRAM
FIGURE 17 – REVERSING LOGIC WIRING DIAGRAMS
FIGURE 17B – REVERSING
USING EXTERNAL CONTACTS
FIGURE 17C – CYCLE ON DEMAND
WITH REVERSE
FIGURE 17D – FORWARD AND REVERSE
CYCLE ON DEMAND
* ee section IV, items 1-4, on page 9.

WARNING! Do not adjust trimpots with main power on if possible. If adjust-
ments 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 must be read and
understood before proceeding. Failure to follow the Safety Warning Instructions may
result in electric shock, fire or explosion.
A. Minimum Speed (MIN) – The MIN trimpot is used to set the minimum voltage of the
drive. This sets the minimum speed of the motor. Adjust the MIN trimpot as follows:
1. Rotate Main Potentiometer to minimum speed position (full counterclockwise).
2. Increase setting of MIN trimpot so that motor runs at desired minimum speed.
B. Maximum Speed (MAX) – The MAX trimpot is used to set the maximum voltage of the
drive. Adjust the MAX trimpot as follows:
1. Rotate Main Potentiometer to maximum speed position (full clockwise).
2. Adjust MAX trimpot setting to desired setting of motor speed.
C. Current Limit (CL) – This trimpot is used to set the maximum amount of DC current that
the motor can draw. The amount of DC current determines the amount of motor torque.
The CL trimpot is factory set at 150% of the current established by the jumper J1 selec-
tion. Readjust the CL trimpot as follows:
1. Turn CL trimpot to minimum (CCW) position. Be sure jumper J1 is in proper position
approximately equal to the motor DC ampere rating. ( ee section III, on page 8.)
2. et the main potentiometer at approximately 30 – 50% rotation.
3. Wire in a DC ammeter in series with armature lead. Lock shaft of motor.
4. Apply power. Rotate CL trimpot CW until desired CL setting is reached (factory set-
ting is 1.5 times rated motor current).
CAUTION:
1. Adjusting the CL above 150% of motor rating can cause overheating and
demagnetization of some PM motors. Consult motor manufacturer.
. Do not leave the motor in a locked condition for more than a few seconds since
armature damage may occur.
D. IR Compensation (IR) – The IR Comp circuit is used to stabilize motor speed under vary-
ing loads. Readjust the IR trimpot as follows:
1. Run the motor at approximately 30-50% of rated speed under no load and measure
actual speed.
2. Load the motor to rated current. Rotate IR trimpot so that the loaded speed is the
same as the unloaded speed measured in 1.
Control is now compensated so that minimal speed change will occur over a wide
range of motor load. (Note: Too much IR Comp will cause unstable [oscillatory]
operation.)
XI. FUNCTION INDICATOR LAMPS
The control contains three LED Indicator Lamps on the front cover that reflect its operational
status.
A. Power On Indicator (ON) – This lamp will glow GREEN when the AC line is connected
to the control.
B. Stop Indicator (STOP) – This lamp will glow YELLOW when the control is placed in the
TOP mode with the Run-Jog/ top witch or logic contact.
17
!

C. Overload Indicator (OL) – When the motor is loaded to the current limit setpoint (CL set-
point 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. The CL may be set too low - check position of jumper J1 and CL trimpot.
Note: In some applications, especially those requiring the motor to cycle on
and off or from one speed to another, the OL indicator may blink indicating a
transient overload. This is a normal condition for the application.
18