Eurotherm Drives 512C/08 User manual

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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 Eurotherm group company without written permission from Eurotherm
Drives 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. Eurotherm Drives cannot accept responsibility for damage, injury, or expenses
resulting therefrom.

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Eurotherm Drives warrants the goods against defects in design, materials and workmanship
for the period of 12 months from the date of delivery on the terms
detailed in Eurotherm Drives Standard Conditions of Sale IA058393C.
Eurotherm Drives reserves the right to change the content and product specification without notice.

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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, 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.
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Serial Number
(see product label)
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(refer to Certification
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The equipment described is intended for industrial motor speed control utilising DC Shunt
Wound or DC Permanent Magnet Motors.
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Installation, operation and maintenance of the equipment should be carried out by qualified
personnel. A qualified person is someone who is 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.
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• The equipment must be permanently earthed due to the high earth leakage current.
• The drive motor must be connected to an appropriate safety earth.
• Never perform high voltage resistance checks on the wiring without first disconnecting the
drive from the circuit being tested.
• When replacing a drive in an application and before returning to use, it is essential that all
user defined parameters for the product’s operation are correctly installed.
• This equipment contains electrostatic discharge (ESD) sensitive parts. Observe static
control precautions when handling, installing and servicing this product.
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The specifications, processes and circuitry described herein are for guidance only and may need
to be adapted to the user’s specific application.
Eurotherm Drives does not guarantee the suitability of the equipment described in this Manual
for individual applications.
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Under fault conditions, power loss or other operating conditions not intended, the equipment
may not operate as specified. In particular:
• The motor speed may not be controlled
• The direction of rotation of the motor may not be controlled
• The motor may be energised
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The user must provide guarding and /or additional safety systems to prevent risk of injury and
electric shock.
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• All control and signal terminals are SELV, i.e. protected by double insulation. Ensure all
wiring is rated for the highest system voltage.
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• All exposed metalwork in the Inverter is protected by basic insulation and bonding to a
safety earth.
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These are not recommended for use with this product but ,where their use is mandatory, only
Type B RCDs should be used.
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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 ac 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.
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Table 1-1 Optional Equipment
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• Check for signs of transit damage
• Check the product code on the rating label conforms to your requirement.
If the unit is not being installed immediately, store the unit in a well-ventilated place away from
high temperatures, humidity, dust, or metal particles.
Refer to Chapter 2: “An 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.

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This manual is intended for use by the installer of the 512C converter. It assumes a reasonable
level of understanding in these disciplines.
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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
,QLWLDO#6WHSV Use the manual to help you plan the following:
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Know your requirements:
• certification requirements, CE/UL/CUL conformance
• mount in an enclosure
• conformance with local installation requirements
• supply and cabling requirements
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The manual is divided into chapters and paragraphs. Page numbering restarts with every chapter,
i.e. 5-3 is Chapter 5, page 3.

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512C
HEALTH LEDS POTENTIOMETERS SWITCHES
CONTROL TERMINAL BLOCK
TRANSFORMER
TAPPING LINK
POWER TERMINALS
FIELD TERMINALS
& AUXILIARY SUPPLY
HEATSINK
LEGEND
PLATE
CONTROL
FIXING
POINTS
PCB
PROTECTIVE
GROUND
P1 P8
18
ON
123LED
LED1 - STALL TRIP
LED2 - POWER ON
LED3 - OVERCURRENT TRIP
P1 - RAMP UP
P2 - RAMP DOWN
P3 - SPEED STABILITY
P4 - CURRENT LIMIT
P5 - IR COMPENSATION
P6 - MINIMUM SPEED
P7 - MAXIMUM SPEED
P8 - ZERO SPEED OFFSET
MAINS OR
AUXILIARY
SUPPLY
AUX MAINS
380/415V 220/240V 110/120V
SELECTOR
Figure 2-1 View of Component Parts

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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:
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65 65$PS
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PHFKDQLFDO#SDFNDJH#VW\OH/#DQG#DQ\#RSWLRQ#LQVWDOOHG#RYHU#DQG#DERYH#WKH
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845&23; 573PP 493PP <3PP 543PP 47;PP 0948PP :PP
845&249 573PP 493PP <3PP 543PP 47;PP 0948PP :PP
845&265 573PP 493PP 463PP 543PP 47;PP 0948PP :PP
Table 3.1 Product Dimensions

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Before connecting AC supplies to this equipment:
• 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.
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Table 3.2 Filter Installation Information

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02725 • Ensure motor is mechanically secure and mounted according to manufacturers specifications
and practice.
• Inspect brush gear, ensure commutator is in good condition and brushes are free to move in
brush box and in good condition.
• Check obstructions in motor vents to maintain cooling air path.
• Ensure motor choke (if specified) is correctly wired.
• Ensure motor is free to rotate and that pulleys and couplings are correctly aligned.
• Ensure transit damage has not occurred to motor windings or connections. Disconnect the
controller before carrying out electrical measurement e.g. insulation resistance.
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Table 3.3 Motor Information

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• Although the controller is designed to provide double or reinforced insulation between the
user and bare live parts, it is recommended that the “0v/Signal Ground” is earthed. Where a
number of controllers are used in a system the “0v/Signal Ground” terminals should be
connected together and earthed at one point.
• The controller is designed for armature current form factor of 1.5 or less. It is recommended
that a armature choke be fitted where a form factor of less than 1.5 current cannot be
guaranteed.
• Due to the earth leakage currents the controller and filter should be permanently earthed.
This 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 10mm2.
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10K
SPEED
FS1 FS2
FS4
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RUN Tachogenerator
Autotransformer
Branch Protection (Fuses or Circuit Breaker)
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10K
100%
CURRENT
LIMIT
EXTERNAL
(Optional)
SETPOINT
Speed Relay
Health Relay
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1
1
2
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Mains Supply
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GRD
PE
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Motor
Optional
4Optional Autotransformer for non standard mains voltages.
5It 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 to protective earth/ground at one point only.
6Stall override link between terminals 14 and 15 required when using controller in current
control.

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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.
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Table 4.2 Current Calibration ( * see note on next page )
Example: Customer wishes to run 14 Amp Motor.
Option 1 Using 512/16 - From table 4.2 set SW7 ON, SW6 ON, SW5 OFF Ia = 14 Amp
Option 2 Using 512/32 From table 4.2 set SW7 OFF, SW6 ON, SW5 ON - Ical = 16 Amp
Turn down I Limit (P4) to give 14 Amps

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Table 4.3 Customer Adjustments.

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Check:-
• the Main power supply voltage is within the operating range of the controller.
• the Armature voltage and current ratings are compatible with controller supplied.
• the Field voltage and current ratings are suitable.
• All external wiring circuits are correct, i.e:-
Power connections
Control connections
Motor connections
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• For damage to equipment.
• For loose ends, clippings, drilling swarf etc., lodged in the drive or ancillary equipment.
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• Inspect the motor, in particular the commutator for any extraneous matter. If an air supply is
available, it is recommended to blow over the commutator.
• Check the brushes are properly seated and that the brush spring tension is adequate.
• If possible check that the motor (and vent fan if fitted) can be turned freely by hand.
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Check:-
• That rotation of the motor in either direction will not cause damage.
• That nobody else is working on another part of the equipment that will be affected by
powering up.
• That other equipment will not be adversely affected by powering up.
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• Prevent application of the main power supply by removal of the supply fuses.
• Disconnect the load from the motor shaft if possible.
• If there 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.
• If it is possible to rotate the motor, and tachogenerator feedback is in use, check that forward
rotation results in positive tacho feedback, i.e. terminal 1 is positive with respect to terminal 8
or 11.