Motor Speed Control Safety Manual

The Parker Hannifin 506/507/508 series controllers are presented as compact, non-isolated motor speed controllers. Their primary function is to control DC shunt wound and permanent magnet motors. These controllers are designed to operate from a single-phase AC mains supply, accommodating voltage ranges of 110/120V AC or 220/240V AC at 50/60Hz. A key feature is the incorporation of a stall timer, automatically removing current from the motor after approximately 15 seconds if a stall is detected, for instance due to a faulty field circuit or excessive load. Further protection is provided by an instantaneous over-current trip mechanism to safeguard against severe armature current overloads. The document highlights that these controllers are intended for mounting on DIN rail within an enclosure. The mechanism for controlling the associated DC motor is a linear closed-loop feedback system that uses the motor's DC armature voltage, enabling consistent speed maintenance. Interestingly, these controllers can also operate in a linear motor torque mode using an adjustable setpoint; a standard over-speed limiting function is integrated into this mode.

The document details how the control of the associated DC motor is achieved through a linear closed-loop feedback signal based on the motor's own DC armature voltage. This closed-loop system ensures that a constant motor speed is maintained even under variable loads. To enhance speed measurement accuracy, the option of using a tacho-generator connected to the motor's shaft to supply the feedback signal is mentioned. A current loop within this speed feedback path is incorporated to maintain safe current levels to the motor's armature; the maximum current is adjustable via a potentiometer (Imax). This adjustment offers a linear response and can be switched to a lower range, representing half the controller's maximum current. The use of adjustable setpoints for both speed and current control, along with additional features like over-speed limiting and stall protection, are showcased. Furthermore, the manual briefly mentions that the feedback voltage switches should be set accordingly, especially when intending to utilize tachogenerator feedback and the importance of temporarily disconnecting the tachogenerator during initial armature control operation.

A significant portion of the document focuses on safety precautions and warnings. The document begins with a statement about the potential for death, personal injury, and property damage if the products are improperly selected or used. It stresses that the controllers are a non-isolated product, emphasizing the risk of connecting to earth or using earth-referenced components; this can cause permanent damage. Users are advised to use an independent, non-earth-referenced power supply. The necessity for qualified personnel is highlighted concerning installation, operation, and maintenance. Specific safety warnings include the presence of dangerous voltages at power terminals even when the motor is stopped, emphasizing the need to isolate all incoming supplies before working on the equipment. The document explicitly prohibits the use of CAT I and CAT II meters on this product. A safe voltage level of less than 50V should be ensured after at least 5 minutes of capacitor discharge. The potential for unforeseen operational issues under fault conditions, power loss, or unintended operating conditions is addressed, mentioning the risks of uncontrolled motor rotation or energization. The document also includes recommendations for additional safety measures such as incorporating UL-recognized semiconductor fuses upstream of the controllers, as well as the need for external motor overload protection devices in line with relevant electrical codes and standards.

The document emphasizes the critical importance of safety when working with the 506/507/508 controllers. It begins by explicitly stating that improper selection or use can lead to death, personal injury, or property damage. Several key safety measures are detailed: Always isolate incoming power supplies before commencing any work on the equipment, recognizing that multiple supply connections might exist. The presence of potentially dangerous voltages at various terminals (motor output, supply inputs, DC bus, and brake, if fitted) even when the motor is stopped is highlighted, underscoring the need for caution. The use of CAT I and CAT II meters is strictly prohibited. After powering down the device, allow at least five minutes for the drive's capacitors to discharge to a safe voltage level (<50V) before handling. The document explicitly prioritizes personnel safety over electromagnetic compatibility (EMC) requirements in case of any conflict. It also includes a risk assessment section that warns of potential malfunctions under fault conditions, power loss, or unintended operating conditions, including uncontrolled motor rotation or energization. Finally, the presence of electrostatic discharge (ESD) sensitive components is noted, prompting the observance of static control precautions during handling, installation, and servicing.

Installation, operation, and maintenance of the equipment should only be performed by qualified personnel possessing the necessary technical competence and familiarity with safety information, established safety practices, the installation process, operation, and maintenance of the equipment, and all associated hazards. This manual must be made available to all individuals involved in installation, configuration, or servicing. The document specifies that UL-recognized semiconductor fuses must be installed upstream of the controllers for short circuit protection. Specific details on the required semiconductor fuse manufacturer and type number would be found in a referenced table (not provided in this excerpt). Short circuit rating information is given: The 506 and 507 controllers are suitable for circuits delivering up to 1000 RMS symmetrical amperes at a maximum of 240V, while the 508 controller is rated for up to 5000 RMS symmetrical amperes at 240V maximum. External motor overload protection is mandatory; while a thermal sensor within the motor winding monitored by an external relay is suggested, the document clarifies that this specific combination cannot be evaluated by UL, leaving compliance determination to the installer and local inspector in accordance with the National Electrical Code or relevant local code requirements. The need for motor over-temperature sensing is emphasized, with PTC sensors or suitable relays required; detailed specifications are deferred to Chapter 4. The document also mentions the importance of proper grounding and provides guidance on EMC connections. Finally, the manual advises periodic inspection for dust buildup affecting ventilation, recommending removal with dry air.

The document mentions the importance of EMC considerations and that personnel safety always takes precedence where conflicts arise between EMC and safety requirements. The product is identified as meeting the immunity requirements of the relevant standard without the need for specified EMC filters. It is classified as "professional equipment" according to EN61000-3-2 and falls under a restricted sales distribution class according to IEC 61800-3, requiring permission from the supply authority before connection to the low voltage supply. The inclusion of a manufacturer's declaration is highlighted, ensuring compliance with relevant standards when used as a component within larger machinery. The document further states that because the potential hazards are primarily electrical rather than mechanical, the drive itself does not fall under the machinery directive; however, a manufacturer's declaration is supplied for its use as a component in machinery. The address and contact information for Parker Hannifin Manufacturing Limited, Automation Group, SSD Drives Europe, are provided.

The document describes several adjustable parameters for optimizing controller performance. Maximum speed can be calibrated using potentiometer P7. Ramp-up (P1) and ramp-down (P2) rates are adjustable to control acceleration and deceleration. In armature voltage feedback mode, speed droop under load can be compensated for using potentiometer P5 (IR compensation). However, excessive adjustment in this area may lead to instability. The maximum current limit can also be adjusted using potentiometer P4 (Ilimit). An optional speed setpoint potentiometer allows overspeed limiting; if not required, the setpoint can be connected directly to +10V. The document also notes that even when using tachogenerator feedback, it may be advisable to initially operate under armature control, temporarily disconnecting the tachogenerator to avoid affecting controller operation. If the motor is in control but rotates in the wrong direction, this necessitates reversing either the armature field polarity (armature control) or both the field and tachometer polarity (tacho control). Adjusting potentiometers P1, P2, and P5 allows for fine-tuning of the motor's response characteristics to meet specific application requirements. The document provides a troubleshooting guide to address scenarios where the motor may not run, indicating potential issues with insufficient current (requiring Ilimit adjustment) or a stalled condition indicated by LED2.

The manual provides guidance for troubleshooting common issues. If the motor runs in the wrong direction, it instructs the user to power off and reverse both the armature and tacho connections. If the motor fails to start, it suggests increasing the current limit (Ilimit) potentiometer (P4) as insufficient current might be the cause, or to check the setting on the mains switch. A stall condition, indicated by the Health light (LED2) illuminating after 15 seconds, suggests reapplying power after removing it to reset the condition. Blown line fuses (if fitted) also indicate a potential issue requiring attention. The manual also provides recommendations for dealing with situations where a motor is in control but rotates in the wrong direction. It clearly outlines the steps for addressing these scenarios, detailing whether to reverse armature field polarity, tacho polarity, or both, depending on the control method (armature or tacho control). In cases of persistent problems or controller failure, clear instructions are given on the information required to contact Parker SSD Drives Service Centre for support, specifically requesting the model and serial number from the unit's rating label, along with detailed fault information. The section concludes by recommending a periodic inspection to identify any dust or obstructions that might hinder the unit's ventilation; dry air cleaning is suggested for this purpose.

The document asserts that the Parker Hannifin 506/507/508 controllers comply with relevant safety and EMC standards. Specifically, it mentions compliance with IEC 61800-3, classifying the product within a restricted sales distribution class, and designates it as "professional equipment" as defined in EN61000-3-2. This classification necessitates obtaining permission from the supply authority before connecting to the low voltage supply. The document further notes that the product meets the immunity requirements of the relevant standard without the need for additional EMC filters. The manufacturer's declaration of conformity is mentioned, indicating that the product, when installed and operated according to the instructions in the provided manual, adheres to the relevant standards. The company, Parker Hannifin Manufacturing Limited, assumes sole responsibility for this declaration. The document emphasizes that the controllers are intended for incorporation into machinery and are not for standalone operation; the complete machinery or installation must meet safety considerations before use.

Parker Hannifin Manufacturing Limited, with its address stated as New Courtwick Lane, LITTLEHAMPTON, WEST SUSSEX BN17 7RZ, UK, and contact details of Telephone: +44(0)1903 737000 and Fax: +44(0)1903 737100, explicitly declares its sole responsibility for the compliance of the electronic products (506/507/508 controllers) when installed and operated as detailed in the product manual. This declaration is in accordance with the relevant standards and regulations. It's important to note that the potential hazards are primarily electrical; therefore, the drive itself is not subject to the machinery directive. However, as the potential hazards are mainly electrical rather than mechanical, the drive does not fall under the machinery directive. Nevertheless, a manufacturer's declaration is provided for when the drive is utilized (as a component) in machinery, ensuring that all necessary safety considerations are met before the complete machinery or installation is put into service. Dr. Martin Payn is identified as the Conformance Officer for Parker Hannifin in this regard.