Eurotherm 512C/04 User manual

EUROTHERM
DRIVES
512C Series
Product Manual
HA389196 Issue 7
!Copyright Eurotherm Drives Limited 2001
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.

Cont.4
Hazards
WARNING!
This equipment can endanger life through rotating machinery and high voltages.
Failure to observe the following will constitute an ELECTRICAL SHOCK HAZARD.
"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.
IMPORTANT: Metal parts may reach a temperature of 90 degrees centigrade in operation.
Application Risk
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.
Risk Assessment
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
Guards
The user must provide guarding and /or additional safety systems to prevent risk of injury and
electric shock.
Protective Insulation
"All control and signal terminals are SELV, i.e. protected by double insulation. Ensure all
wiring is rated for the highest system voltage.
Note:
Thermal sensors contained within the motor must be double insulated.
"All exposed metalwork in the Inverter is protected by basic insulation and bonding to a
safety earth.
RCDs
These are not recommended for use with this product but ,where their use is mandatory, only
Type B RCDs should be used.
!
Safety Information

Contents
Contents Page
512C Converter
Chapter 1 GETTING STARTED
Introduction...................................................................................................1-1
Optional Equipment.................................................................................................. 1-1
Equipment Inspection....................................................................................1-1
About this Manual.........................................................................................1-2
Initial Steps ............................................................................................................... 1-2
How the Manual is Organised................................................................................... 1-2
Chapter 2 AN OVERVIEW OF THE CONVERTER
Component Identification..............................................................................2-1
Understanding the Product Code..................................................................2-2
Chapter 3 INSTALLING THE CONVERTER
Mechanical Installation.................................................................................3-1
Mounting the Converter............................................................................................. 3-2
"Filter Installation..................................................................................... 3-2
Electrical Installation.....................................................................................3-4
Recommendations..................................................................................................... 3-4
Chapter 4 OPERATING THE CONVERTER
Pre-Installation Planning..............................................................................4-1
Basic Wiring Diagrams.............................................................................................. 4-1
"Basic Connection ................................................................................... 4-1
Setting-Up & Commissioning........................................................................4-2
Option Switches........................................................................................................ 4-2
"Speed Feedback Scaling......................................................................... 4-2
"Speed Feedback Source ......................................................................... 4-2
"Zero Output Sourse................................................................................ 4-2
"Current Scaling ...................................................................................... 4-2
"Current Motor Scaling ............................................................................ 4-3
Potentiometers.......................................................................................................... 4-3
Basic Setting-Up Procedure ..........................................................................4-4
"Controller .............................................................................................. 4-4
"Motor .................................................................................................... 4-4
Preparation............................................................................................................... 4-4
"Machine................................................................................................. 4-4
"Controller .............................................................................................. 4-4
"Power-Up............................................................................................... 4-5

Contents
Contents Page
512C Converter
Chapter 5 LED INDICATIONS
LED Indications..............................................................................................5-1
Chapter 6 TERMINAL DESCRIPTIONS
Terminal Descriptions ...................................................................................6-1
Control Terminals ..................................................................................................... 6-1
Power Terminals ....................................................................................................... 6-2
Field Terminals (Auxiliary Supply)............................................................................... 6-2
Chapter 7 FAULT FINDING
Troubleshooting............................................................................................7-1
Chapter 8 ROUTINE MAINTENANCE AND REPAIR
Routine Maintenance ....................................................................................8-1
Repair............................................................................................................8-1
Returning the Unit to Eurotherm Drives....................................................................... 8-1
Disposal ................................................................................................................... 8-1
Chapter 9 REPLACEMENT OF 512 WITH 512C
512C/512 Terminal Differences ....................................................................9-1
Functional Differences 512C & 512...............................................................9-2
Chapter 10 BLOCK DIAGRAM
Block Diagram ............................................................................................10-1
Chapter 11 TECHNICAL SPECIFICATIONS
Environmental Requirements......................................................................11-1
Operating Conditions..................................................................................11-1
"Terminal Tightening Torques ................................................................ 11-2
Electrical Ratings ..................................................................................................... 11-3
Chapter 12 CERTIFICATION FOR THE CONVERTER
EMC and the 'CE' Mark.................................................................................12-1
'CE' EMC Responsibility............................................................................................ 12-1
Special Considerations for Installations Requiring Compliance with UL Standards...... 12-3
Certificates.............................................................................................................. 12-4

512C Product Manual 1-1
512C Converter
2
GETTING STARTED
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 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.
Optional Equipment
Item
ItemItem
Item Part Number
Part NumberPart Number
Part Number
UL Compression Lug Kits
See page 12.3 for more information.
LA389745U016
LA389745U032
EMC Installation Guidelines for Modules and Systems
A Eurotherm Drives application manual detailing EMC requirements
HA388879
External AC Supply (RFI) Filter
For 512C units without internal filters, on cable runs in excess of 25
metres
Refer to Chapter 3
for Part Numbers
Fuse Isolator Kit
High speed semi-conductor fuses are recommended.
See table 11.1 for part
numbers.
Table 1-1 Optional Equipment
Equipment Inspection
"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.

1-2 512C Product Manual
512C Converter
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:
"certification requirements, CE/UL/CUL conformance
"mount in an enclosure
"conformance with local installation requirements
"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.

An Overview of the Converter 2-1
512C Converter
3
AN OVERVIEW OF THE CONVERTER
Component Identification
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

2-2 An Overview of the Converter
512C Converter
Control Features
Speed
SpeedSpeed
Speed
Control
ControlControl
Control Control Action Closed Loop with Proportional Integral Control and Adjustable Stability
Speed Feedback Armature Voltage Tachogenerator
100% Load Regulation 2 % Typical 0.1 % Typical
Maximum Torque/Speed
Range 20:1 100:1
Overload 150% for 60 seconds.
Torque
TorqueTorque
Torque Control Action Closed Loop with Proportional Integral Control
Control
ControlControl
Control Accuracy 2 %
Overspeed Inherent
Overload None 100% Continuous (consideration must be
given to motor when operating at low speed)
Inputs/
Inputs/Inputs/
Inputs/
Outputs
OutputsOutputs
Outputs Analogue Inputs Setpoint Ramp 0 to +10V 100Kohm
Auxiliary Speed
Setpoint 0 to +10V 100Kohm
Current Limit 0 to +7.5V 50Kohm
Tachogenerator
Input 0 to +350Vdc 110Kohm
Analogue Outputs Speed 0 to +10V 5mA
Current
(SW8 Off) 0 to +5V (0 to Idc) 5mA
Current
(SW8 On) 0 to +5V (0 to Ical) 5mA
Setpoint Ramp 0 to +10V 5mA
Total Setpoint 0 to +10V 5mA
+10V Reference +10V 5mA
-10V Reference - 10V 5mA
Digital Inputs Run +10 to
+24V 100Kohm
Stall Override +10 100Kohm
Digital Outputs Health +24V 50mA
Source
Zero Speed or
Setpoint +24V 50mA Source

An Overview of the Converter 2-3
512C Converter
Understanding the Product Code
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
No. Variable Description
1 512C Generic product
2 XX Two numbers specifying the current output, for example:
04 = 4Amp
08 = 8Amp
16 = 16Amp
32 = 32Amp
3 XX 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
00 Standard Eurotherm Drives livery
01-99 Defined customer liveries
4 XX Two numbers specifying the cover:
IP00 Open Frame
5 XX Two numbers specifying the special options:
00 = Standard
01 - 99 = Documented Special Options

3-1 Installing the Converter
512C Converter
4
INSTALLING THE CONVERTER
IMPORTANT: Read Chapter 12: "Certification for the Converter" before installing this unit.
Mechanical Installation
512C
EUROTHERM
DRIVES
A
C
C
B
D
E
F
G
PRODUCT OVERALL
DIMENSIONS FIXING CENTRES SIZE SLOT DETAIL
ABCDE FG
512C/04 240mm 160mm 90mm 210mm 148mm M6 15mm 7mm
512C/08 240mm 160mm 90mm 210mm 148mm M6 15mm 7mm
512C/16 240mm 160mm 90mm 210mm 148mm M6 15mm 7mm
512C/32 240mm 160mm 130mm 210mm 148mm M6 15mm 7mm
Table 3.1 Product Dimensions