Parker 512C Series User manual

Cont.1
512C Series Converter
Technical Manual
HA389196U001 Issue 9
©Copyright 2007 Parker SSD Drives, a division of Parker 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 SSD Drives company without written permission
from Parker SSD Drives, a division of Parker Hannifin 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 SSD Drives cannot accept responsibility for damage, injury, or expenses resulting therefrom.
WARRANTY
Parker SSD 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 Parker SSD Drives Standard Conditions of Sale
IA058393C.
Parker SSD Drives reserves the right to change the content and product specification without notice.
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Cont.2
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)
RComponent RRelevant Apparatus
Unit fitted: RWall-mounted REnclosure
Application Area
The equipment described is intended for industrial motor speed control utilising AC induction or
AC synchronous machines.
Personnel
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.
Product Warnings
Caution
Risk of electric
shock
Caution
Refer to
documentation
Earth/Ground
Protective
Conductor
Terminal
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Cont.3
Hazards
DANGER! - Ignoring the following may result in injury
1. This equipment can endanger life by exposure to
rotating machinery and high voltages.
2. The equipment must be permanently earthed due to
the high earth leakage current, and the drive motor
must be connected to an appropriate safety 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.
4. There may still be dangerous voltages present at
power terminals (motor output, supply input phases,
DC bus and the brake, where fitted) when the motor
is at standstill or is stopped.
5. For measurements use only a meter to IEC 61010 (CAT
III or higher). Always begin using the highest range.
CAT I and CAT II meters must not be used on this
product.
6. Allow at least 5 minutes for the drive's capacitors to
discharge to safe voltage levels (<50V). Use the
specified meter capable of measuring up to 1000V dc &
ac rms to confirm that less than 50V is present between
all power terminals and earth.
7. Unless otherwise stated, this product must NOT be
dismantled. In the event of a fault the drive must be
returned. Refer to "Routine Maintenance and Repair".
WARNING! - Ignoring the following may result in injury or 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 on the
wiring without first disconnecting the drive from the
circuit being tested.
•Whilst ensuring ventilation is sufficient, provide
guarding and /or additional safety systems to
prevent injury or damage to equipment.
•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.
•All control and signal terminals are SELV, i.e. protected
by double insulation. Ensure all external wiring is rated
for the highest system voltage.
•Thermal sensors contained within the motor must have
at least basic insulation.
•All exposed metalwork in the Inverter is protected by
basic insulation and bonded to a safety earth.
•RCDs are not recommended for use with this product
but, where their use is mandatory, only Type B RCDs
should be used.
EMC
•In a domestic environment this product may cause
radio interference in which case supplementary
mitigation measures may be required.
•This equipment contains electrostatic discharge
(ESD) sensitive parts. Observe static control
precautions when handling, installing and servicing
this product.
•This is a product of the restricted sales distribution class
according to IEC 61800-3. It is designated as
“professional equipment” as defined in EN61000-3-2.
Permission of the supply authority shall be obtained
before connection to the low voltage supply.
CAUTION!
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. 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:
•Stored energy might not discharge to safe levels
as quickly as suggested, and can still be present
even though the drive appears to be switched off
•The motor's direction of rotation might not be controlled
•The motor speed might not be controlled
•The motor might be energised
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:
•Stored energy •Supply disconnects •Sequencing logic •Unintended operation
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Contents
Contents Page
Cont.4
GETTING STARTED 1-1
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
AN OVERVIEW OF THE CONVERTER 2-1
Component Identification ............................................................................. 2-1
Control Features ........................................................................................... 2-2
Understanding the Product Code ................................................................. 2-3
INSTALLING THE CONVERTER 3-1
Mechanical Installation ................................................................................ 3-1
Mounting the Converter...........................................................................................3-2
•Filter Installation ...................................................................................3-2
Electrical Installation .................................................................................... 3-4
Recommendations...................................................................................................3-4
OPERATING THE CONVERTER 4-1
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 Source ..............................................................................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
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Contents
Contents Page
Cont.5
Preparation.............................................................................................................4-4
•Machine...............................................................................................4-4
•Controller.............................................................................................4-4
•Power-Up.............................................................................................4-5
LED INDICATIONS 5-1
LED Indications ............................................................................................. 5-1
TERMINAL DESCRIPTIONS 6-1
Control Terminals ...................................................................................................6-1
Power Terminals .....................................................................................................6-2
Field Terminals (Auxiliary Supply) .............................................................................6-2
FAULT FINDING 7-1
Troubleshooting............................................................................................ 7-1
ROUTINE MAINTENANCE AND REPAIR 8-1
Routine Maintenance.................................................................................... 8-1
Repair ........................................................................................................... 8-1
Returning the Unit to Parker SSD Drives....................................................................8-1
Disposal .................................................................................................................8-1
REPLACEMENT OF 512 WITH 512C 9-1
512C/512 Terminal Differences.................................................................... 9-1
Functional Differences 512C & 512 .............................................................. 9-2
BLOCK DIAGRAM 10-1
Block Diagram ............................................................................................ 10-1
TECHNICAL SPECIFICATIONS 11-1
Environmental Requirements ..................................................................... 11-1
Operating Conditions ................................................................................. 11-1
•Terminal Tightening Torques ...............................................................11-2
Electrical Ratings ...................................................................................................11-3
CERTIFICATION FOR THE CONVERTER 12-1
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
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Contents
Contents Page
Cont.6
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Getting Started 1-1
512C Series Converter
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 Part Number
UL Compression Lug Kits
See page 12.3 for more information.
LA389745U016
LA389745U032
EMC Installation Guidelines for Modules and Systems
A Parker SSD 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.
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1-2 Getting Started
512C Series 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.
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An Overview of the Converter 2-1
512C Series Converter
AN OVERVIEW OF THE CONVERTER
Component Identification
512C
HEALTH LEDS POTENTIOMETERS SWITCHES
CONTROL TE RMINAL BLOCK
TRA NSFORME R
TAPPING L INK
POWER TERMINALS
FIELD TERMINALS
& AUXILIARY SUPPLY
HEATS INK
LEGEND
PLATE
CONTROL
FIXING
POINTS
PCB
PROTECTIVE
GROUND
P1 P8
1 8
ON
1 2 3LED
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 MA I NS
380/415V 220/240V 110/120V
SELECTOR
OFF
T1T24
Figure 2-1 View of Component Parts
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2-2 An Overview of the Converter
512C Series Converter
Control Features
Speed
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 Control Action Closed Loop with Proportional Integral Control
Control Accuracy 2 %
Overspeed Inherent
Overload None 100% Continuous (consideration must be
given to motor when operating at low speed)
Inputs/
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
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An Overview of the Converter 2-3
512C Series 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 Parker SSD 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
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3-1 Installing the Converter
512C Series Converter
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
A B C D E F G
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
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Installing the Converter 3-2
512C Series Converter
Mounting the Converter
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 +40øC.
•Controller is used in a Pollution Degree 2 environment.
•Avoid vibration.
Filter Installation
L1 L2PEPE
LINE
LOAD
4 Holes M6 Insert
4 Holes M6 Clearance
230mm Leads
M5 Ring Lugs
A
B
C
D
L
W
E
H
PE L1 L2
Black
Red
Green
/Yellow
Product Filter Watt
Loss
Overall Dimensions Fixing
Centres
Product
Fixing
Terminal
L W H E A B C D
512C/04 CO389113 18W 264 165 45 240 253 120 210 148 4mm2
512C/08 CO389113 18W 264 165 45 240 253 120 210 148 4mm2
512C/16 CO389113 18W 264 165 45 240 253 120 210 148 4mm2
512C/32 CO389114 36W 264 165 70 240 253 120 210 148 6mm2
Table 3.2 Filter Installation Information
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3-3 Installing the Converter
512C Series Converter
MOTOR
•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.
512C/04 512C/08 512C/16 512C/32
Overall Width 160mm
Overall Height 240mm
Overall Depth 90mm 90mm 90mm 130mm
Weight 1.5Kg 1.5Kg 1.6Kg 2.9Kg
Airflow Clearance 75mm above and below
Mounting Centres 210mm vertical x 148mm horizontal
Control Terminals Screw Terminals will accept 2.5mm2 stranded wire.
Terminal Tightening Torque 0.6 Nm, 4.5 lbf-in
Field Terminals Screw terminals will accept 4mm2stranded wire.
Terminal Tightening Torque 0.6 Nm, 4.5 lbf-in
Power Terminals M5 Studs with Clamp.
Terminal Tightening Torque 2.7 Nm, 24 lbf-in
Earth Terminals
M5 Cheese Head Screw.
Terminal Tightening Torque 7.1 Nm, 63 lbf-in
Table 3.3 Motor Information
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Installing the Converter 3-4
512C Series Converter
Electrical Installation
Recommendations
•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.
IMPORTANT: The Converter fitted with an internal or external ac supply EMC filter is only suitable for
earth referenced supplies (TN).
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4-1 Operating the Converter
512C Series Converter
OPERATING THE CONVERTER
Pre-Installation Planning
Basic Wiring Diagrams
Basic Connection
L1 L2/N FL1 FL2 A+ A- F+ F- Aux
FS1 FS2
FS4
FS5
Tachogenerator
A u totr ansf or mer
Branch Protection (Fuses or Circuit Breaker)
1
1
Mains Supply
PE
GND
PE
GND
DC
Motor
Optional
13456789101112
141516
1923 13
10K
SPEED
RUN
10K
10K
100%
CURRENT
LIM IT
EXTERNAL
( Opti o nal)
SETPOINT
Speed
Relay
Health
Relay
3
2
Signal Ground
standard
voltage
cWhen the mains voltage is non-standard, i.e. not selectable via the transformer tapping link
(380/415V, 220/240V or 110/120V), connect a low power Autotransformer to generate a
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.
dIt 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.
eStall override link between terminals 14 and 15 required when using controller in current
control.
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Operating the Converter 4-2
512C Series Converter
Setting-Up & Commissioning
Option Switches
Speed Feedback Scaling
SW1 SW2 FEEDBACK VOLTAGE
OFF ON 10 - 25V USE P7 TO TRIM
ON ON 25 - 75V MAXIMUM SPEED
OFF OFF 75 - 125V TO REQUIRED
ON OFF 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: It is 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
SW5 SW6 SW7 04 08 16 32
OFF OFF OFF ½A 1A * 2A * 4A *
ON OFF OFF 1A 2A * 4A * 8A *
OFF ON OFF 1½A 3A * 6A * 12A *
ON ON OFF 2A 4A * 8A * 16A *
OFF OFF ON 2½A 5A 10A 20A
ON OFF ON 3A 6A 12A 24A
OFF ON ON 3½A 7A 14A 28A
ON ON ON 4A 8A 16A 32A
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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4-3 Operating the Converter
512C Series Converter
Note: * 8 Amp, 16 Amp and 32 Amp controllers can be scaled to currents of 4 Amp, 8 Amp or
16 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.
i.e. 4 Amp on 512C/04
8 Amp on 512C/08
16 Amp on 512C/16
32 Amp on 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
P1 Ramp Up Rate Rotate Clockwise for Faster Acceleration to Set
Speed.
Same
(Linear :- 1 to 40 seconds) as 512
P2 Ramp Down Rate Rotate Clockwise for Faster Deceleration to Set Speed. Same
(Linear :- 1 to 40 seconds) as 512
P3 Speed Loop Stability Optimises Speed Loop Stability. ( Excessive
adjustment may lead to instability)
Same
as 512
P4 I Limit Rotate Clockwise to increase Maximum Output
Current.
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.
Same
as 512
P5 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)
Turn Anti-clockwise when Tachogenerator Feedback
used.
Same
as 512
P6 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.)
Same
as 512
P7 Maximum Speed Controls Maximum Motor Speed. Rotate clockwise to
increase maximum speed.
Same
as 512
P8 Zero Speed Offset Adjusts Zero or Minimum Speed for Zero Speed
Setpoint.
New
Feature
Table 4.3 Customer Adjustments.
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Operating the Converter 4-4
512C Series Converter
Basic Setting-Up Procedure
Caution
BEFORE ATTEMPTING TO CONNECT POWER
Controller
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
Note: Completely disconnect the controller before point to point checking with a buzzer or when
checking insulation with a megger.
•For damage to equipment.
•For loose ends, clippings, drilling swarf etc., lodged in the drive or ancillary equipment.
Motor
•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.
Preparation
Machine
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.
Controller
•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.
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4-5 Operating the Converter
512C Series Converter
•Check switch selection
SW1 ) Speed Range (see table 4.1)
SW2 )
SW3 Tachogenerator / VA (see switch options on page 4.1)
SW4 Zero Speed / Zero Setpoint (see switch options on page 4.1)
SW5 )
SW6 ) Current Calibration (see table 4.2)
SW7 )
SW8 Controller / Calibrated Armature Current Meter Output
•Check all pots are set thus:-
Potentiometers P1, P2, P4, P5, P6, P7 fully Anticlockwise.
Potentiometers P3 & P8 mid 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.
† 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 10%) 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.
If the motor runs under control but in the wrong direction correct as follows either:-
Armature Control Reverse Field polarity
Tachogenerator Control Reverse Field & Tachogenerator Polarity
•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 P6 to the required level. (note P6 is only active if the
speed setting potentiometer is wired to terminal T4.)
•Set the 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.
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