512C Series
Contents
1. 512C Series Converter Replacement of 512 with 512C 9 REPLACEMENT OF 512 WITH 512C 512C 512 Terminal Differences IEEE Tech Feedback Not comeses Speed Meter oupa TorauerCurent 5 19 Seipsint Rams OFF T10 Aux Speed Setpoint Aux Speed Setpoint Rescaled to be Normalised to Setpoint Ramp a 12 Total Setpoint 12V Undesirable to Provide access to PS Rails Total Setpoint Output is a useful alternative Stall Reset Stall Reset Signal Level Revised T16 10V Reference 12V Undesirable to provide access to PS Rails 10V Reference useful alternative 119 Health Output Health Relay Co Relay Removed Transistor O P rat Zero Speed Relay Relay removed T23 Zero Speed Output Zero Speed Relay Co Relay Removed Zero Setpoint Output Transistor O P Relays must be provided externally 512C Series Converter 9 2 Replacement of 512 with 512C Functional Differences 512C amp 512 Switch 4 now selects Zero Speed or Zero Ramped Setpoint Maximum Time Increased to 40 seconds Now 60 seconds at 150 Run Signal Level now active High to Eliminate Safety Hazard and Enable common switching Total Setpoint Sum at T2. If the motor runs under control but in the wrong direction correct as follows either Armature Control Reverse Field polarity Tachogenerator Control Reverse Field amp Tachogenerator Polarity e Increase speed demand to maximum and check armature voltage does not exceed motor rating adjust by P7 to give desired motor speed Set Minimum Speed by adjusting by to the required level note is only active if the speed setting potentiometer 15 wired to terminal Setthe Ramp Up time P1 and Ramp Down time P2 to the required rates With armature voltage feedback speed droop will occur as load is applied to the motor Set the IR Compensation P5 to remove this effect note excessive adjustment may cause instability 512C Series Converter Operating the Converter 4 6 e Adjust stability Potentiometer P3 to improve transient response note excessive adjustment may cause instability Note The compensation potentiometer P5 must be fully anticlockwise in Tachogenerator control adjustment will cause instability e Monitor the armature current as indicated on terminal 6 the current meter output verify that that at steady state the current does not exceed the controller rating i e the voltage on T6 is not greater than 5V with SW8 OFF 512C Series Converter 521 dtpindesicns LED INDICATIONS LED Indications LED1 STALL TRIP Illuminated when controller detects a Stall Condition This is deter
3. surowy xnv OZL OLL OVZ 0ZZ SLP O8E SMS Ing INIYYN O JYNLYWYY 1949 Ld AOVLIOA 3anivwav ONITVOS ou JOVLIOA Way Anean qarvasgrvo dWOO LMS ul OMS Sd SMS Be Id doo lino diL AIWTI NOLLO31O3d TIVLS NO i AlddNS YaMOd 001 AS 2 YILIW Mari OHOVL XW N d avis Id dool 99345 HONIND LH LG IMS VAS lMIOdlI3S AL 8d 135440 43995 ld Ez an 6 4 0 dW INIOdLAS C 9601 AOL wns 14104135 ILYN NANOG Lz Fa Leum 9001 LIWTI LNSYYND NOYOL 2 HLTV3H E 13104135 TYLOL 144 JIA ATL E O s 333 AOL 4 OHOVL T3 EI ON37 43445 Qa3344n8 LNIOdLAS NOWWOD AO d l dwya LNIO LAS d O 1410195 14109135 ANOIOL AHITV3H 14109135 WLOL day AOL 3GRAO TIS NOWWOD 594 AOL 9395 WNWINIW 512C Series Converter 512C Series Converter 1 1 1 technical Specifications TECHNICAL SPECIFICATIONS Environmen
4. Turn Anti clockwise when Tachogenerator Feedback used Minimum Speed Controls Minimum Motor Speed Setpoint when Speed Setpoint Potentiometer connected to Terminal 4 Rotate Clockwise to increase Minimum Speed Setpoint Approximately 30 adjustment when using 10K ohm Speed Setpoint Potentiometer P7 Maximum Speed Controls Maximum Motor Speed Rotate clockwise to Same increase maximum speed as 512 Zero Speed Offset Adjusts Zero or Minimum Speed for Zero Speed New Setpoint Feature Table 4 3 Customer Adjustments 3 3 512C Series Converter Operating the Converter 4 4 Basic Setting Up Procedure Caution BEFORE ATTEMPTING TO CONNECT POWER Controller Check e the Main power supply voltage is within the operating range of the controller e the Armature voltage and current ratings are compatible with controller supplied e the Field voltage and current ratings are suitable e All external wiring circuits are correct i e Power connections Control connections Motor connections Note Completely disconnect the controller before point to point checking with a buzzer or when checking insulation with a megger e For damage to equipment e For loose ends clippings drilling swarf etc lodged in the drive or ancillary equipment Motor e Inspect the motor in particular the commutator for any extraneous matter If an air supply is available it is recommended to blow over the commuta
5. CONFORMITY Date CE marked first applied 01 04 2000 EMC Directive Low Voltage Directive Issued for In accordance with the EEC Directive In accordance with the EEC Directive The drive is CE compliance with marked in the EMC 2004 108 EC 2006 95 EC accordance with the low voltage directive for electrical Directive when the unit is used as relevant We Parker Hannifin Manufacturing Limited We Parker Hannifin Manufacturing Limited address as below declare under our sole address as below declare under our sole responsibility that the above Electronic responsibility that the above Electronic Products when installed and operated with Products when installed and operated with equip ment and reference to the instructions in the Product reference to the instructions the Product liarices tthe Manual provided with each piece of Manual voltage range equipment is in accordance with the relevant provided with each piece of equipment is in When installed clauses from the following standard accordance with the relevant clauses from the correctly following standard BSEN61800 3 2004 EN50178 1998 MANUFACTURERS DECLARATIONS This is provided We Parker Hannifin Manufacturing Limited The above Electronic Products Since the potential to aid your address as below declare under our sole are components to be incorporated into hazards are mainly justification for responsibility that the above Electronic machinery and may no
6. can be achieved by either connecting two earthing conductors of the required value see table 11 1 or connecting one earthing conductor of at least 10mm IMPORTANT The Converter fitted with an internal or external ac supply EMC filter is only suitable for earth referenced supplies TN 512C Series Converter 4 1 Operating the Converter OPERATING THE CONVERTER Pre Installation Planning Basic Wiring Diagrams Basic Connection Mains Supply aaaeaii Signal Ground Branch Protection Fuses or Circuit Breaker Autotransformer SPEED SETPOINT EXTERNAL CURRENT LIMIT Optional 5 Health RUN Tachogenerator Relay Optional Speed pus Relay f When the mains voltage is non standard i e not selectable via the transformer tapping link 380 415V 220 240 or 110 120V connect low power Autotransformer to generate standard voltage Connect the output of the Autotransformer to the AUX terminal Move the Supply Selector from MAINS to AUX Select the appropriate voltage via the transformer tapping link The Autotransformer must be connected to the same phase as the incoming power to provide correct coding to the controller It is recommended that the 0V common be connected to protective earth ground for safety reasons In a system comprising of more than one controller the 0V common signals should be connected together and joined
7. season eee 3 4 R commendaliglssos 3 4 OPERATING THE CONVERTER 4 1 Pre Installation Planning e eee nenne entes etes seasons 4 1 Basic Wiring Diagrams 3 5 5 3 3 5 3 3 8 8 rr REIN 4 1 Setting Up amp CommMissioning ccccccccsscsssccssccssccesccscccssccssccesccssccescosscoess 4 2 Option Ip VERA 4 2 4 3 Basic Setting Up Procedure cccscccsccssccssccssccssccssccsscccscccsccsscccscccsccescoescees 4 4 Preparatlon 4 4 LED INDICATIONS 5 1 LED Indications 5 1 TERMINAL DESCRIPTIONS 6 1 Control A 6 1 Power Terminals iii Pe bea Pe Pes ee 6 2 Field Terminals Auxiliary Supply tette ete rre 6 2 FAULT FINDING 7 1 TFOUDIESNOOTING cescecsscescccsccescoasscesccesscescoascccsccsscacscoasceescesscaescosscacsccssceescosscees 7 1 ROUTINE MAINTENANCE amp REPAIR 8 1 Routine Maintenance esses sees 8 1 Cont 5 Contents Contents Page 2 20 8 1 Returning t
8. to protective earth ground at one point only Stall override link between terminals 14 and 15 required when using controller in current control 512C Series Converter Operating the Converter 4 2 Setting Up amp Commissioning Option Switches Speed Feedback Scaling FEEDBACK VOLTAGE 10 25V USE P7 TO TRIM 25 75V MAXIMUM SPEED 75 125V TO REQUIRED 125 325V VALUE Table 4 1 Full speed tachogenerator armature feedback voltage Example a Customer wishes to run motor at 1500rpm with a 60V 1000rpm tachogenerator Feedback voltage 90V From Table 4 1 set SW1 OFF SW2 OFF adjust P7 to give desired speed b Customer wishes to run motor at 2000rpm with 320V armature Feedback voltage 320V From Table 4 1 set SW1 ON SW2 OFF adjust P7 to give desired speed Note 75 necessary to set these switches for both tachogenerator and armature voltage feedback Speed Feedback Source SW3 OFF Tachogenerator Controller uses Tachogenerator Feedback for Speed Control SW3 ON Armature Voltage Controller uses Armature Voltage Feedback for Speed Control Zero Output Source SW4 OFF Zero Output Zero Setpoint Output SW4 ON Zero Output Zero Speed Output Current Scaling FULL LOAD CURRENT CONTROLLER OPTION Table 4 2 Current Calibration see note on next page Example Customer wishes to run 14 Amp Motor Option X Using 512 16 From table 4 2 set SW7 ON SW6 ON SW5 OFF Ia 14 Amp Option 2 Using 512 32 From t
9. 2 Cable Size Fuse Isolator Kit Fuse Rating Parker Part No e hsm T 1 E bee Table 11 1 Recommended Cable Sizes Note The cable sizes shown are based on a Form Factor of 1 5 and an overload allowance of 110 giving a multiplier of 1 65 they are selected for the notional rating of each controller Smaller cable may be used if the controller is calibrated at a lower current level Terminal Tightening Torques Control amp Field 0 6 Nm 0 4 4 5 lbf in Power 2 7 Nm 2 24 Ibf in Earth 7 1 Nm 5 25 63 Ibf in 512C Series Converter 11 3 Technical Specifications Electrical Ratings Pee Supply Voltage 110 120 220 240 Vac 10 380 415 460 480 Supply Frequency 50 60 Hz 5 Hz Nominal Armature 90 Vdc at 110 120 Vac Voltage 180 Vde at 220 240 Vac 320 Vdc at 380 415 Vac 4 10 8A dc 10 16A dc 10 32A dc 10 urrent Armature Current 0 5 to 1 to 2 to 16A 4 to 32A Calibration in 0 5A steps in 1A steps in 2A steps in 4 steps Nominal Motor Power at 1 125kW 225kW 9 kW 320 Vdc Armature 1 Hp 3 Hp 12 Hp Field Current 3 A dc Field Voltage DOM 0 9 X Supply Voltage Vs Maximum Armature Form Factor Typical Controller 15W 2 25w 2 Dissipation at la Earth Leakage Without Filter 5m
10. 512 Series Converter Technical Manual HA389196 Issue 10 Copyright 2013 Parker Hannifin Hannifin Ltd All rights strictly reserved No part of this document may be stored in a retrieval system or transmitted in any form or by any means to persons not employed by a Parker Hannifin Manufacturing Limited company without written permission from Parker Hannifin Manufacturing Ltd Although every effort has been taken to ensure the accuracy of this document it may be necessary without notice to make amendments or correct omissions Parker Hannifin Manufacturing Limited cannot accept responsibility for damage injury or expenses resulting therefrom WARRANTY Refer to Parker Hannifin Manufacturing Limited Terms and Conditions of Sale These documents are available on request at www parker com Parker Hannifin Manufacturing Limited reserves the right to change the content and product specification without notice FAILURE OR IMPROPER SELECTION IMPROPER USE OF THE PRODUCTS DESCRIBED HEREIN OR RELATED ITEMS CAN CAUSE DEATH PERSONAL INJURY AND PROPERTY DAMAGE This document and other information from Parker Hannifin Corporation its subsidiaries and authorized distributors provide product or system options for further investigation by users having technical expertise The user through its own analysis and testing is solely responsible for making the final selection of the system and components and assuring that all performance endu
11. A 9 Current at 480Vac With Filter Note l 460 480 Vac Operation is available when used with an auxiliary supply input of a suitable standard value 2 See page 3 2 for filter watt loss information 3 Permanent earthing mandatory 512C Series Converter Certification for the Converter 2 1 CERTIFICATION FOR THE CONVERTER Caution The integration of this product into other apparatus or systems is not the responsibility of Parker Hannifin Manufacturing Limited with respect to applicability effectivity or safety of operation of the other apparatus or systems EMC and the Mark EMC Responsibility The following sections are the minimum necessary for installation and basic understanding Parker Hannifin Manufacturing Limited are adhering to the CEMEP recommendations on CE marking for EMC According to SI No 2372 implementing the EMC directive into UK law the requirement to CE mark for EMC applies only to relevant apparatus that has intrinsic function to the end user and which is placed on the market supplied The majority of drive modules systems sold by Parker Hannifin Manufacturing Limited will be incorporated into a higher system apparatus or machine which includes at least the motor cable and a driven load before providing intrinsic function to the end user As such the majority of Parker Hannifin Manufacturing Limited products are categorised as components CEMEP validity field 2 and it would be
12. able 4 2 set SW7 OFF SW6 ON SWS ON 16 Amp Turn down I Limit P4 to give 14 Amps 512C Series Converter 4 3 Operating the Converter Note 8 16 Amp and 32 Amp controllers can be scaled to currents of 4 Amp 8 Amp or 76 Amp or less but it is recommended that lower current controllers be used in these circumstances Current Motor Scaling SW8 OFF Current Meter Buffered Current Meter Output 5V Equivalent to 100 of Controller Current Rating 4 512 04 8 512 08 16 512 16 32 Amp 512C 32 SW8 ON Current Meter Buffered Current Meter Output 5V Equivalent to 100 of Calibrated Current Rating For Example 512C 16 SW5 ON SW6 ON SW7 OFF Calibrated Current 8 Amp therefore 5V 8amp Potentiometers Ramp Up Rate Rotate Clockwise for Faster Acceleration to Set Speed Same teamed fest Ramp Down Rate Rotate Clockwise for Faster Deceleration to Set Speed Same Linear 1 to 40 seconds as 512 adjustment may lead to instability as 512 Limit Rotate Clockwise to increase Maximum Output Same Current as 512 With no additional connection to Torque Current Limit Terminal T7 the Upper Limit is 110 To achieve the 150 maximum connect T7 to 7 5V IR Compensation Optimises speed regulation against load change when using Armature Voltage Feedback Rotate Clockwise to increase compensation and reduce regulation Excess adjustment may lead to instability
13. aligned e Ensure transit damage has not occurred to motor windings or connections Disconnect the controller before carrying out electrical measurement e g insulation resistance Overall Width Overall Height Airflow Clearance 75mm above and below Mounting Centres 210mm vertical x 148mm horizontal Screw Terminals will accept 2 5 stranded wire Control Terminals Terminal Tightening Torque 0 6 Nm 4 5 Ibf in Screw terminals will accept 4mm stranded wire Field Terminals Terminal Tightening Torque 0 6 Nm 4 5 Ibf in M5 Studs with Clamp Power Terminals Terminal Tightening Torque 2 7 Nm 24 Ibf in M5 Cheese Head Screw Earth Terminals 7 Terminal Tightening Torque 7 1 Nm 63 Ibf in Table 3 3 Motor Information 512C Series Converter Installing the Converter 3 4 Electrical Installation Recommendations e Although the controller is designed to provide double or reinforced insulation between the user and bare live parts it is recommended that the Ov Signal Ground is earthed Where number of controllers are used in a system the Ov Signal Ground terminals should be connected together and earthed at one point e The controller is designed for armature current form factor of 1 5 or less It is recommended that an armature choke be fitted where a form factor of less than 1 5 current cannot be guaranteed e Due to the earth leakage currents the controller and filter should be permanently earthed This
14. an 50V 15 present between all power terminals and earth 3 Ensure all incoming supplies are isolated before working on the equipment Be aware that there may be more than one supply connection to the drive 7 Unless otherwise stated this product must NOT be 4 There may still be dangerous voltages present at dismantled In the event of a fault the drive must be power terminals motor output supply input phases returned Refer to Routine Maintenance and Repair DC bus and the brake where fitted when the motor 15 at standstill or 15 stopped WARNING Ignoring the following may result in injury damage to equipment SAFETY Where there is conflict between EMC and Safety requirements personnel safety shall always take precedence Never perform high voltage resistance checks onthe All control and signal terminals are SELV i e protected wiring without first disconnecting the drive from the by double insulation Ensure all external wiring is rated circuit being tested for the highest system voltage e Whilst ensuring ventilation is sufficient provide e Thermal sensors contained within the motor must have at guarding and or additional safety systems to prevent least basic insulation injury or damage to equipment e All exposed metalwork in the Inverter is protected by e When replacing a drive in an application and before basic insulation and bonded to a safety earth returning to use it is essential that all user defi
15. aration to be found at the end of this chapter Manufacturers suppliers installers of relevant apparatus CEMEP validity fields 3 amp 4 may use this compliance as a basis for their own justification of overall compliance with the EMC Directive It must be clearly understood by the customer before installation commences who is legally responsible for conformance with the EMC Directive Misappropriation of the CE mark is a criminal offence 512C Series Converter 1 2 22 Certification for the Converter Special Considerations for Installations Requiring Compliance with UL Standards Terminations UL Compression Lug Kits are available for the controllers which provide sets of lugs suitable for the following ratings These lugs must be applied with the correct tooling as described in the Installation Instructions provided with each kit The following terminal kits are available for the connection of Power Cabling Rating LA389745U016 16A AC 8 AWG 8 4mm DC 10 AWG 5 3mm GROUND 10 AWG 5 3mm LA389745U032 32A 4 AWG 21 2mm 6 AWG 13 GROUND 10 AWG 5 3mm The above wire sizes for AC and DC terminations are based on a form factor of 1 5 and an overload requirement of 150 as specified in UL Standard 508C Motor Overload Protection Motor over temperature sensing is required Motors used in conjunction with the drive controller shall be protected with PTC sensor s or relays suitable for use with the variable speed drive T
16. c mains supply in the range of 110Vac to 415Vac at 50 or 60Hz A simple transformer tap arrangement allows the converter to be programmed to suit the applied voltage The Speed of the DC Motor is controlled using a linear closed loop system with a feedback signal from either tachogenerator or armature voltage the feedback source being switch selectable A current loop within the speed loop always ensures that controlled levels of current are applied to the motor actual levels being scaleable via programmable switches Motor protection is provided by a Stall detection circuit which will remove current from the motor after approximately 60 seconds Converter protection is provided by a Instantaneous Overcurrent trip circuit overriding control in the event of a Short Circuit Optional Equipment UL Compression Lug Kits LA389745U016 See page 12 3 for more information LA389745U032 External AC Supply RFI Filter Refer to Chapter 3 For 512C units without internal filters on cable runs in excess of 25 for Part Numbers metres Fuse Isolator Kit See table 11 1 for part High speed semi conductor fuses are recommended numbers Table 1 1 Optional Equipment Equipment Inspection e Check for signs of transit damage e Check the product code on the rating label conforms to your requirement If the unit 15 not being installed immediately store the unit in a well ventilated place away from high temperatures humidity dust or metal part
17. d position Check transformer supply tap is compatible with the Mains supply voltage Check external run contacts are open Check external set points are all zero T If not use the Auxiliary Supply input at compatible voltage and apply Mains Power at required level up to 460Vac Power Up Once all the proceeding steps are completed the supply fuses may be replaced and power applied to the drive Although fairly general the following assumes the system to be a simple speed control drive and motor At switch on the Power ON LED should illuminate LED 2 see Page 5 1 Close RUN contact and give the drive a small speed demand approximately 1096 and increase the external auxiliary current limit if used to 50 Slowly increase the main current limit P4 until the motor starts to rotate If the motor increases speed to more than 10 of full speed immediately turn current limit P4 fully anticlockwise and or remove Run signal terminal 5 immediately If overspeeding occurred while using a tachogenerator for speed feedback correct the wiring as follows Problem Action Direction correct but overspeeding Reverse tacho polarity only Direction incorrect and overspeeding Reverse field polarity only When armature voltage feedback is used for speed feedback it is direction insensitive and overspeeding due to incorrect feedback cannot occur excess speed is probably due to incorrect feedback scaling check setting of switches SW1 and SW2
18. elevant Apparatus Unit fitted Wall mounted Enclosure Application Area The equipment described is intended for industrial motor speed control utilising DC Shunt Wound or DC Permanent Magnet Motors Personnel Installation operation and maintenance of the equipment should be carried out by qualified personnel A qualified person is someone who 15 technically competent and familiar with all safety information and established safety practices with the installation process operation and maintenance of this equipment and with all the hazards involved Product Warnings Caution Caution Earth Ground Risk of electric Refer to Protective shock documentation Conductor Terminal Cont 3 Safety Information Wa Hazards DANGER Ignoring the following may result in injury 1 This equipment can endanger life by exposure to 5 For measurements use only a meter to IEC 61010 CAT rotating machinery and high voltages or higher Always begin using the highest range CAT and CAT II meters must not be used on this 2 The equipment must be permanently earthed due to product the high earth leakage current and the drive motor 6 Allow at least 5 minutes for the drive s capacitors to must be connected to an appropriate safety earth discharge to safe voltage levels 50V Use the specified meter capable of measuring up to 1000V dc amp ac rms to confirm that less th
19. erminal 12 10v Reference for System applications Speed Trim Adjustment at Zero Setpoint Aux Speed Setpoint Normalised to Ramp Setpoint Removed to give spare terminals for Additional Functions Additional Auxiliary Supply terminal to allow use on other Mains Supply Voltages Complies with EMC Directive Relays must be provided externally WARNING THE 512 IS NOT A DIRECT REPLACEMENT FOR THE 512 IT IS FUNCTIONALLY EQUIVALENT WHEN A 512C IS USED TO REPLACE A 512 WITH THE HEALTH AND OR ZERO SPEED RELAYS UTILISED EXTERNAL RELAYS MUST BE PROVIDED CARE MUST ALSO BE TAKEN TO AVOID CONNECTING LIVE PARTS TO THE RELAY OUTPUT DRIVER TERMINALS 512C C 19 9 7 8 4 L1 T14 or T19 RUN Speed Relay Health Relay The 512C needs two external relays to become directly compatible with the 512 and the Run terminal must be rewired to provide a high level input to Run Existing wiring to the Health and Zero Speed relay contacts must be relocated to the external relays The Run signal is valid for Signal Levels from 10 to 24V DC and can be driven from either T14 10V or T19 Health The Zero Output terminal on the 512C must be selected to Zero Speed output by ensuring that SWA is On 512C Series Converter Block Diagram 1 1 xX Q O in Oo a x Q 9 BE
20. gised A drive is a component within a drive system that may influence its operation or effects under a fault condition Consideration must be given to e Stored energy e Supply disconnects e Sequencing logic e Unintended operation Cont 4 Contents Contents Page iis ir 1 1 Optional Equiprrienit eie RR ER RR RR RR RR RERR RES 1 1 Equipment Inspection eee e ee eee e eee e eee eee tenete stesse 1 1 About this Manual ess 1 2 1 2 How the Manual is 1 2 AN OVERVIEW OF THE CONVERTER 2 1 Component Identification eee ecce e eee ee eee ee eee 2 1 Control T 2 2 Understanding the Product Code ccce ecce eee eee ee eee 2 3 INSTALLING THE CONVERTER 3 1 Mechanical Installation eee ee eee eee etes ass s tese 3 1 Mounting the Converter 3 2 Electrical Installation ne etes sanete
21. he Unit to Parker Hannifin Manufacturing Limited 8 1 Disposal iiie er er 8 1 REPLACEMENT OF 512 WITH 512C 9 1 512C 512 Terminal Differences 9 1 Functional Differences 512 amp 512 ccce ecce eee eee eee ee eere eene notte e een sette 9 2 BLOCK DIAGRAM 10 1 Block Diagram leider teet eoe oo cero e soa roa esos e Pose sua evo s epos ero pesos crean aes 10 1 TECHNICAL SPECIFICATIONS 11 1 Environmental Requirements 11 1 Operating Conditions ecce eee e eee 11 1 Electrical RATINGS 11 3 CERTIFICATION FOR THE CONVERTER 12 1 EMC and the Mark 12 1 RESPONSIO 12 1 Special Considerations for Installations Requiring Compliance with UL Standards 12 2 E TRUE 12 3 Cont 6 Getting Started 1 Introduction The 512C converter is intended for use in an Industrial Environment it should be mounted within an enclosure which provides protection to the converter and the user The converter should be permanently earthed at the terminals provided The 512C converter is suitable for the control of Permanent Magnet and Shunt Wound DC Motors The converters are designed to operate from a single phase a
22. his combination cannot be evaluated by UL hence it is the responsibility of the installer local inspector to determine whether the combination is in compliance with the National Electric Code or Local Code requirements Technical details can be found in Chapter 3 Installing the Drive Short Circuit Protection Requirements UL Listed JDDZ non renewable cartridge fuses rated 300V AC or 600V AC as appropriate depending on the rated input voltage of the drive must be installed upstream of the drive Function Rating Cable Size Fuse Rating Supply 6A 1 5mm 16AWG 10A fuse Motor 4A 1 5mm2 16AWG Ground 1 5mm2 16AWG Supply 12A 2 5mm2 14AWG 15A fuse Motor 8A 2 5mm2 14AWG Ground 2 5mm2 14AWG Supply 24A 6mm 10AWG 30A fuse Motor 16A 6mm2 10AWG Ground 6mm 2 10AWG Supply 48 6 2 6 60A fuse Motor 32A l mm 6AWG Ground l mm 6AWG Field 3A 1 5mm 2 16AWG 10A Short Circuit Rating Models Rated More than These controllers are suitable for use on a circuit capable of delivering not more than 5000 RMS symmetrical amperes 480 V Maximum Field Wiring Temperature Rating Use 60 C or 60 75 C Copper Conductors only Grounding The field grounding terminal is identified by the International Grounding Symbol D IEC Publication 417 Symbol 5019 512C Series Converter Certification for the Converter 1 2 3 Certificates EC DECLARATIONS OF
23. icles Refer to Chapter 2 Overview of the Converter to check the rating label product code Refer to Chapter 8 Routine Maintenance and Repair for information on returning damaged goods Refer to Chapter 11 Technical Specifications Environmental Details for the storage temperature 512C Series Converter 1 2 Getting Started About this Manual This manual is intended for use by the installer of the 512C converter It assumes a reasonable level of understanding in these disciplines Note Please read all Safety Information before proceeding with the installation and operation of this unit Enter the Model No from the rating label into the table at the front of this manual It is important that you pass this manual on to any new user of this unit This manual is for the following models from the 512C Converter Series 512C 04 4A DC Full Load Current 512C 08 8A DC Full Load Current 512C 16 16A DC Full Load Current 512C 32 32A DC Full Load Current Initial Steps Use the manual to help you plan the following Installation Know your requirements e certification requirements CE UL CUL conformance mount in an enclosure e conformance with local installation requirements e supply and cabling requirements How the Manual is Organised The manual is divided into chapters and paragraphs Page numbering restarts with every chapter i e 5 3 is Chapter 5 page 3 512C Series Converter An Overview
24. incorrect for Parker Hannifin Manufacturing Limited to apply the CE mark or produce an EC Declaration of Conformity in respect of EMC It is the manufacturer supplier installer of the relevant apparatus with the intrinsic function to the end user who must demonstrate conformance to the EMC directive However in a minority of cases single drives may have intrinsic function to the end user An example is that of add on intrinsic function where an existing fixed speed motor application such as a fan or a pump is converted to variable speed with an add on drive module CEMEP validity field 1 In this application Parker Hannifin Manufacturing Limited CE mark its drive module and issue an EC declaration of conformity Because the validity of the CE mark for EMC is not known when the product is manufactured the mark will be applied via the product manual and will not be on the product label From 1997 when the CE mark for the Low Voltage Directive becomes mandatory the CE mark will appear on the product label but its validity for EMC can only be identified from the product manual To assist manufacturers suppliers installers of relevant apparatus the Parker Hannifin Manufacturing Limited 512C modules are EMC compliant to EN50081 1 1992 ENS0082 1 1992 EN50081 2 1994 and prEN50082 2 1992 when fitted with the specified filter and installed according to these instructions as confirmed by the Manufacturers EMC decl
25. mined by the state of the Speed Loop if Speed control is lost a Stall condition is determined a Trip will occur after 60 seconds The motor may not be stationary LED2 POWER ON Illuminated when power supplied to Auxiliary Supply either directly or via the Auxiliary terminal LED3 OVERCURRENT Illuminated when Armature Current exceeds 31 times Calibrated Current QE HVKIVIIGQIG ISIS PILT im STALL OVERCURRENT POWER ON 512C Series Converter Terminal Descriptions 6 1 TERMINAL DESCRIPTIONS Control Terminals TI Tacho Feedback Motor Mounted Tachogenerator Input 350 Vdc Max Approx Proportional to Motor Speed 110 kohm T T3 Speed Meter Output Analogue Output O to 10V for O to 100 output speed S C protected T4 Minimum Speed Setpoint Potentiometer return minimum speed Must be used in adjustable O to 30 with 10K setpoint conjunction with a potentiometer setpoint potentiometer Run Digital Input to Run Controller 10V to 24V to Run OV to Stop 5 Current Meter Output Analogue Output O to 10V 5mA output Scaling S C protected SW8 On 5V 100 Calibrated Current SW8 Off 5V 100 Controller Current Torque Current Limit Analogue Input 7 5V 0 to 150 of Calibrated Current Setpoint Ramp O P Analogue Output 5mA output O to 10V 0 to 100 Ramped Setpoint S C protected T T T T Aux Speed Setpoint Analogue I
26. ned e RCDs are not recommended for use with this product parameters for the product s operation are correctly but where their use is mandatory only Type B RCDs installed should be used EMC Ina domestic environment this product may cause e This is a product of the restricted sales distribution class radio interference in which case supplementary according to IEC 61800 3 It is designated as mitigation measures may be required professional equipment as defined in EN61000 3 2 This equipment contains electrostatic discharge Permission of the supply authority shall be obtained ESD sensitive parts Observe static control before connection to the low voltage supply precautions when handling installing and servicing this product PCAUTION SSCs APPLICATION RISK e The specifications processes and circuitry described herein are for guidance only and may need to be adapted to the user s specific application We can not guarantee the suitability of the equipment described in this Manual for individual applications RISK ASSESSMENT Under fault conditions power loss or unintended operating conditions the drive may not operate as intended In particular e Stored energy might not discharge to safe levels e The motor s direction of rotation might not be controlled as quickly as suggested and can still be present e The motor speed might not be controlled even though the drive appears to be switched off The motor might be ener
27. nput approx O to 4 10V 0 to 10096 Speed 100 kohm T12 Total Setpoint O P Analogue Output output O to 10V 0 to 100 Speed S C protected Setpoint Ramp Analogue Input approx O to 10V 0 to 100 Speed 100 kohm 10V Reference Analogue Output 5mA output 10V Reference for Speed Current Setpoints S C protected Stall Override Digital Input to Override Stall Detection approx 10V Override 100 kohm 10V Reference Analogue Output 5mA output 10V Reference for Speed Current Setpoints S C protected 119 Health Output Digital Output 50mA Source 24V Healthy Unprotected Zero Speed Output _ Digital Output 50mA Source Zero Setpoint Output 24V Running Unprotected OV Stopped LC 8866666665 512C Series Converter 7 8 9 10 11 13 14 15 16 0 2 3 4 2 2 2 T 6 2 Terminal Descriptions Power Terminals vem L1 AC Input Line 1 Mains Supply Linel Input o L2 N AC Input Line2 Mains Supply Line2 Input or Neutral Must also be used as Auxiliary Neutral Supply Return when Auxiliary Supply Input used Armature Positive Motor Armature Positive Output Armature Negative Motor Armature Negative Output Field Terminals Auxiliary Supply Field Positive Motor Field positive DC Output Field Negative Motor Field negative DC Output Po aT Field Rectifier Supply Mains Supply Input Field Rec
28. of the Converter 2 1 AN OVERVIEW OF THE CONVERTER Component Identification CONTROL TERMINAL BLOCK 24 T1 000000000000000000000000 1 C eee z 2 je e e e eo CONTROL LED 1 2 3 P1 A 9 HEALTH LEDS POTENTIOME TERS SWITCHES LED1 STALL TRIP P1 RAMP UP LED2 POWER ON P2 RAMP DOWN LED3 OVERCURRENT TRIP SPEED STABILITY 4 CURRENT LIMIT P5 IRCOMPENSATION 51 2 MINIMUM SPEED P7 MAXIMUM SPEED P8 ZERO SPEED OFFSET 380 415V 220 240V 110 120V LEGEND TRANSFORMER PLATE TAPPING LINK AUX MAINS o MAINS OR AUXILIARY SUPPLY SELECTOR lt HEATSINK O FIELD TERMINALS POWER TERMINALS amp AUXILIARY SUPPLY PROTECTIVE GROUND Figure 2 1 View of Component Parts 512C Series Converter 2 An Overview of Converter Control Features Speed Control Torque Control Inputs Outputs Control Action Speed Feedback 100 Load Regulation Maximum Torque Speed Range Overload Control Action Accuracy Overspeed Overload Analogue Inputs Analogue Outputs Digital Inputs Digital Outputs Closed Loop with Proportional Integral Control and Adjustable Stability Armature Voltage Tachogenerator 2 Typical 0 1 Typical 20 1 100 1 150 for 60 seconds Closed Loop with Proportional Integral Control 2 Inherent None 100 Continuous con
29. pter 12 Certification for the Converter before installing this unit Mechanical Installation eee 512C D A l a O 1 4 m PRODUCT OVERALL DIMENSIONS FRING CENTRES SIZE SLOT DETAIL Table 3 1 Product Dimensions 512C Series Converter Installing the Converter 3 2 Mounting the Converter Before connecting AC supplies to this equipment e Ensure good airflow over the heatsink Maintain clearance of 75mm above and below controller For safety maintain a clearance of 20mm at the sides of the controller Operating temperature range does not exceed 0 to 40 C Controller is used in a Pollution Degree 2 environment Avoid vibration Filter Installation pesas Dimensions Fixing a Centres Fixing lee Se EE De s Table 3 2 Filter Installation Information 512C Series Converter 3 3 Installing the Converter MOTOR e Ensure motor is mechanically secure and mounted according to manufacturers specifications and practice e Inspect brush gear ensure commutator is in good condition and brushes are free to move in brush box and in good condition e Check obstructions in motor vents to maintain cooling air path e Ensure motor choke if specified is correctly wired e Ensure motor is free to rotate and that pulleys and couplings are correctly
30. rance maintenance safety and warning requirements of the application are met The user must analyze all aspects of the application follow applicable industry standards and follow the information concerning the product in the current product catalog and in any other materials provided from Parker or its subsidiaries or authorized distributors To the extent that Parker or its subsidiaries or authorized distributors provide component or system options based upon data or specifications provided by the user the user is responsible for determining that such data and specifications are suitable and sufficient for all applications and reasonably foreseeable uses of the components or systems Cont 2 Safety Information Wa Requirements IMPORTANT Please read this information BEFORE installing the equipment Intended Users This manual is to be made available to all persons who are required to install configure or service equipment described herein or any other associated operation The information given is intended to highlight safety issues EMC considerations and to enable the user to obtain maximum benefit from the equipment Complete the following table for future reference detailing how the unit is to be installed and used INSTALLATION DETAILS Serial Number see product label Where installed for your own information Unit used as a refer to Certification for the Converter Component R
31. rial number see the unit s rating label e Details of the fault Contact your nearest Parker Hannifin Manufacturing Limited Service Centre to arrange return of the item You will be given a Returned Material Authorisation Use this as a reference on all paperwork you return with the faulty item Pack and despatch the item in the original packing materials or at least an antistatic enclosure Do not allow packaging chips to enter the unit Disposal This product contains materials which are consignable waste under the Special Waste Regulations 1996 which complies with the EC Hazardous Waste Directive Directive 91 689 EEC We recommend you dispose of the appropriate materials in accordance with the valid environmental control laws The following table shows which materials can be recycled and which have to be disposed of in a special way plastics material yes no The printed circuit board should be disposed of in one of two ways 1 High temperature incineration minimum temperature 1200 C by an incinerator authorised under parts A or B of the Environmental Protection Act 2 Disposal in an engineered land fill site that is licensed to take aluminium electrolytic capacitors Do not dispose of in a land fill site set aside for domestic waste Packaging During transport our products are protected by suitable packaging This is entirely environmentally compatible and should be taken for central disposal as secondary raw material
32. sideration must be given to motor when operating at low speed Setpoint Ramp Oto 10V 100Kohm Auxiliary Speed Oto 10 100Kohm Setpoint Current Limit Oto 7 5V 50Kohm Tachogenerator Oto 110Kohm Input 350Vdc Speed Oto 10V 5mA Current 5V 5 SW8 Off 0 to Idc Current 5V 5 SW8 On 0 to Ical Setpoint Ramp Oto 10V 5mA Total Setpoint Oto 10V 5mA 10V Reference 10V 5mA 10V Reference 10V 5mA Run 10 to 100Kohm 24V Stall Override 10 100Kohm Health 24V 50mA Source Zero Speed or 24V 50mA Setpoint Source 512C Series Converter An Overview of the Converter 2 3 Understanding the Product Code 512C Series Converter The unit is fully identified using a five block alphanumeric code which records how the Converter was calibrated and its various settings when despatched from the factory The Product Code appears as the Model No Each block of the Product Code is identified as below Block Variable Description No Two numbers specifying the current output for example 4Amp 8Amp l Amp 32Amp Two numbers specifying mechanical package including livery and mechanical package style and any option installed over and above the standard features of the product Two numbers Livery Standard Parker Hannifin Manufacturing Limited livery Defined customer liveries 3 1 Installing the Converter INSTALLING THE CONVERTER IMPORTANT Read Cha
33. t be operated alone electrical rather EMC Products when installed and operated with The complete machinery or installation using than mechanical compliance n reference to the instructions in the Product this equipment may only be put into service the drive does not when the unit is Manual provided with each piece of when the safety considerations of the Directive ff under the usedasa equipment is in accordance with the relevant 2006 42 EC are fully adhered to machinery component clauses from the following standard Particular reference should be made to directive However EN60204 1 Safety of Machinery Electrical We do supply Equipment of Machines manufacturer s instructions warnings and safety declaration for information of the Product Manual must be When the drive is adhered to used as a component in machinery BSEN61800 3 2004 Dr Martin Payn Conformance Officer Compliant with the immunity requirements of the Standard without specified EMC filters Parker Hannifin Manufacturing Limited Automation Group SSD Drives Europe NEW COURTWICK LANE LITTLEHAMPTON WEST SUSSEX BN17 7RZ TELEPHONE 44 0 1903 737000 FAX 44 0 1903 737100 Registered Number 4806503 England Registered Office 55 Maylands Avenue Hemel Hempstead Herts HP2 4SJ 512C Series Converter
34. tal Requirements Enclosure Chassis Mounting Operating Temperature to 40 C Derate 1 5 Degree above 40 C Humidity 85 R H at 40 C non condensing Altitude Above 1000m derate 1 100m to a maximum of 2000m Storage Temperature 259C to 55 C Transport Temperature 259C to 70 C Climatic Conditions Class 3k3 as defined by EN50178 1998 Operating Conditions Installation Category Overvoltage Category 111 Pollution Pollution Degree 2 Maximum Supply Voltages 480 L L Non earth referenced IT Derived from a 3 phase or earth referenced TN supply 480Vac L N Earth referenced TN Wiring Control Cabling 0 75sq mm minimum Power cable to be minimum 600V AC rated at 1 5 x armature current High speed semi conductor fuses of the correct rating are recommended controller semi conductor protection as the 512C is not internally fused The suitability of the semi conductor fuse branch protection should be decided by the installer Ensure a protective earth connection is made compatible with the rating Isolated control wiring should not be run close to the power cabling If screened cables are used recommended on setpoints and tachogenerators connect screens to earth only at controller end Parker Hannifin Manufacturing Limited can supply fuse assemblies which can be bulkhead mounted and also act as convenient supply isolators 512C Series Converter Technical Specifications 11
35. tifier ee R2 Field Rectifier Supply Mains Supply Input Field Rectifier o Aux L1 Auxiliary Supply Auxiliary Supply Input to Control Auxiliary Supply Return via Transformer L2 N The signal applied to Aux 11 must be in phase with L1 in order to provide the correct coding for the controller 512C Series Converter Fault Finding Troubleshooting PROBLEM POSSIBLE CAUSE REMEDY No Power On LED 2 No Supply Available Check Supply Availability and Supply Fuse fitted or Illuminated Circuit Breaker closed Incorrect Supply Voltage Check Supply Voltage and Transformer Tapping Applied to Controller position are compatible Motor will not run at Start Run Signal not present Check Control Circuit Wiring Switch On No Speed Setpoint Check Total Setpoint terminal 12 Check Setpoint Potentiometer amp Wiring No Armature Current Check P4 adjustment amp External Current Limit Potentiometer setting amp wiring if used No Field Check Field AC Supply and Field connections Motor Runs and Stops Incorrect Current Limit Setting Check PA setting after short period with Stall LED1 Illuminated Check external current limit setting Incorrect Current Calibration Check Programming Switches SW5 6 7 Motor Jammed Free Obstruction Incorrect Feedback Voltage Check Feedback Voltage Calibration Switches SW1 2 Calibration Note These Switches must be set for both Tachogenerator amp Armature Voltage Feedback Ma
36. tor e Check the brushes are properly seated and that the brush spring tension is adequate e If possible check that the motor and vent fan if fitted can be turned freely by hand Preparation Machine Check e That rotation of the motor in either direction will not cause damage e That nobody else is working on another part of the equipment that will be affected by powering up e That other equipment will not be adversely affected by powering up Controller e Prevent application of the main power supply by removal of the supply fuses e Disconnect the load from the motor shaft if possible Ifthere is any doubt as to the integrity of a particular installation insert a high wattage resistor i e fire bar elements in series with the motor armature fitis possible to rotate the motor and tachogenerator feedback is in use check that forward rotation results in positive tacho feedback terminal 1 is positive with respect to terminal 8 or 11 512C Series Converter 4 5 Operating the Converter e Check switch selection 5 Speed Range see table 4 1 52 SW3 Tachogenerator VA see switch options on page 4 1 SW4 Zero Speed Zero Setpoint see switch options on page 4 1 SWS SW6 Current Calibration see table 4 2 SW SW8 Controller Calibrated Armature Current Meter Output Check all pots are set thus Potentiometers P1 P2 P4 P5 P6 P7 fully Anticlockwise Potentiometers P3 amp P8 mi
37. ximum Controller Output Check compatibility of Motor Voltage to Controller Exceeded Output Voltage Faulty Tachogenerator and or Check Tachogenerator use Armature Voltage Coupling Feedback Temporarily Motor runs at Full Speed Incorrect Tachogenerator Check Tachogenerator viability and connectivity only Polarity or Open Circuit Tachogenerator Open Circuit Speed Setpoint Check Terminal 13 or 10 as appropriate Potentiometer Minimum Speed Setting Check Minimum Speed Potentiometer Zero Speed Offset Adjustment Adjust P8 to give Zero Speed Setpoint Motor Speed Stability P3 0 P3 RedueP3 Oscillating IR a P5 No IR compensation Ll NR Tachogenerator Feedback Reduce P5 for Armature Voltage Feedback 512C Series Converter 8 1 Routine Maintenance and Repair ROUTINE MAINTENANCE amp REPAIR Caution Maintenance and repair should only be performed by competent persons using only the recommended spares Use of incorrect parts may create a hazard and risk of injury Routine Maintenance Periodically inspect the Converter for build up of dust or obstructions that may affect ventilation of the unit Remove this using dry air Repair There are no user serviceable components IMPORTANT MAKE NO ATTEMPT TO REPAIR THE UNIT RETURN IT TO PARKER HANNIFIN MANUFACTURING LIMITED Returning the Unit to Parker Hannifin Manufacturing Limited Please have the following information available The model and se
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