Sprint Electric 400 Manual de usuario

HG105270EN00 Issue 1 (08/2021)

World Class Design | World Class Function | 30 Years Expertise in Industrial Motor Control

Product Manual

DC THYRISTOR DRIVE

400 / 800 / 1200

Please read this information before installing or using the product.

Install, use and maintain this product following the procedures provided.

The manual(s) cannot provide all details, variations and contingencies required for your

installation, operation and maintenance of this product or the apparatus with this product

installed. For further help or information, refer to your local Supplier sales oﬃ ce.

Application area

The equipment described is intended for industrial (non-consumer) motor speed control.

Intended users

To safely enable the user to obtain maximum beneﬁ t from the equipment:

• Ensure this information is available to all persons required to install, conﬁ gure or service

the described equipment or any other associated operation.

• Always store the manual in a conveniently accessible area for quick reference.

• Make it available for the next user/owner of the product.

Safety

Ensure all users and operators understand the included WARNINGS, CAUTIONS and

NOTES, which alert the user to safety issues. COMPLY WITH WARNINGS AND CAUTIONS

AT ALL TIMES. Each of these carries a special meaning and should be read carefully:

WARNING!

A WARNING is given when non-compliance with the warning may result in

personal injury and/or equipment damage.

CAUTION!

A CAUTION is given when non-compliance with the caution may result in

permanent equipment damage.

NOTE A note provides speciﬁ c information to make important instructions clear.

Symbols

Attention Electrostatic

Discharge (ESD)

Electric Shock

Hazard

See the instructions for use.

Speciﬁ c warnings not found

on the label.

This equipment contains

ESD sensitive parts. Observe

static control precautions

when handling, installing

and servicing this product.

Disconnect the mains

supply before working on

the unit.

Do not touch presets,

switches and jumpers!

Always use the correct

insulated adjustment tools.

This product is of the restricted sales distribution class according to IEC 61800-3

and has a "professional equipment" designation as deﬁ ned in EN 61000-3-2.

Installation

• Ensure mechanically secure ﬁ xings are in use as recommended.

• Ensure cooling airﬂ ow around the product is as recommended.

• Ensure cables/wire terminations are as recommended and are torqued correctly.

• Ensure the product rating is correct - do not exceed the rating.

Application risk

Electromechanical safety is the responsibility of the user. The integration of this product

into other apparatus or systems is not the manufacturer's or distributor of the product's

responsibility. It is the user's responsibility to ensure the compliance of the installation with

any regulations in force.

Health and safety at work

Electrical devices can constitute a safety hazard. Thorough personnel training is an aid

to SAFETY and productivity. SAFETY awareness not only reduces the risk of accidents and

injuries in your plant but also has a direct impact on improving product quality and costs.

If you have any doubts about the SAFETY of your system or process, consult an expert

immediately. Do not proceed without doing so. If in doubt, refer to the Supplier.

CAUTION!

EQUIPMENT DAMAGE HAZARD

• We thoroughly test our products. However, before installation and start-up,

inspect all equipment for transit damage, loose parts, packing materials, etc.

• Installation must observe the required environmental conditions for safe and

reliable operation.

• In a domestic environment, this product may cause radio interference, requiring

adequate measures to be taken. Obtain the permission of the supply authority

before connecting to the low voltage supply.

WARNING!

PERSONAL INJURY AND/OR ELECTRICAL SHOCK HAZARD

• Always isolate all power supplies from the equipment before starting any work.

• Never perform high voltage resistance checks on the wiring without ﬁ rst

disconnecting the product from the circuit under test.

• Use guarding and additional safety systems to prevent injury and electric shock.

• Metal parts may reach 90°C during operation.

Hazards

This equipment can endanger life through rotating machinery and high voltages.

WARNING!

Only qualiﬁ ed personnel must install, operate and maintain this equipment.

A qualiﬁ ed person is someone technically competent and familiar with all safety

information, established safety practices, installation, operation, maintenance

and the hazards involved with this equipment and any associated machinery.

General risks

Weight

Consideration should be given to the weight of our heavier products when handling.

Risk assessment

Under fault conditions or conditions not intended: the motor speed may be incorrect; the

motor speed may be excessive; the direction of rotation may be incorrect; the motor may be

energised.

In all situations, the user should provide suﬃ cient guarding and/or additional redundant

monitoring and safety systems to prevent risk of injury.

NOTE: During a power loss event, the product will commence a sequenced shut-down

procedure. Therefore, the system designer must provide suitable protection for this case.

Maintenance

Only qualiﬁ ed personnel should maintain and effect repair using only the recommended

spares, alternatively return the equipment to the factory for repair. The use of unapproved

parts may create a hazard and risk of injury.

WARNING!

PERSONAL INJURY AND/OR EQUIPMENT DAMAGE HAZARD

When replacing a product, all user-deﬁ ned parameters that deﬁ ne the product's

operation must be installed correctly before returning to use. Failure to do so

may create a hazard and risk of injury.

The packaging is inﬂ ammable and incorrect disposal may lead to the generation

of lethal toxic fumes.

Repairs

Repair reports can only be given if the user makes suﬃ cient and accurate defect reporting.

Remember that the product without the required precautions can represent an electrical

hazard and risk of injury, and that rotating machinery is a mechanical hazard.

Protective insulation

Non-isolated product

WARNING!

The motor must be connected to an appropriate safety earth.

Failure to do so presents an electrical shock hazard. Exposed metal work in this

equipment is protected by basic insulation and bonding to a safety earth.

This product is classiﬁ ed as a component and must be used in a suitable enclosure.

1. There is no isolation between the Power and Control Circuits. ALL connections to

the Drive are HAZARDOUS. Mount the drive in an earthed enclosure.

2. The Installer MUST provide Protection for the End User by using Double or

Re-inforced Insulation. The drive's Control signal terminals operate at the output

voltage of the drive. Therefore, User controls MUST be made safe by the use of suitably

insulated components, i.e. Potentiometer, Run Switch.

3. DO NOT connect these Control signal terminals to low voltage equipment or any

non-isolated potential as this will cause signiﬁ cant damage to both the Drive and

attached equipment.

Contents

1 Introduction 11 Introduction 1

2 Mechanical dimensions 22 Mechanical dimensions 2

3 Guide for systems used in the EU 33 Guide for systems used in the EU 3

4 Multiple drives 34 Multiple drives 3

5 Requirements for EMC compliance 45 Requirements for EMC compliance 4

6 Installation 56 Installation 5

6.1 Motor installation 5

6.2 Drive Installation 5

7 Typical applications 67 Typical applications 6

8 Terminal descriptions 78 Terminal descriptions 7

9 Block diagram 89 Block diagram 8

10 Commissioning 910 Commissioning 9

10.1 Initial settings - without power 9

10.2 Pre-operation motor checklist 9

10.3 Operating the drive 11

10.4 DC Tachogenerator Feedback 12

11 Options 1211 Options 12

12 Trouble shooting 1312 Trouble shooting 13

13 Specications 1513 Specications 15

Disposal

This product contains materials that are consignable waste under the Hazardous Waste

Regulations 2005. Metal and plastic materials can be recycled, however, disposal of the

printed circuit board requires compliance with all valid environmental control laws.

Products that must be recycled in accordance with the WEEE Regulations are

marked with the symbol opposite. Contact us when recyling the product.

1Introduction

IntroductionIntroduction

APPLICATION AREA: Industrial (non-consumer) "Motor speed control utilising DC Motors".

DRIVE

MODEL

AC SUPPLY

VOLTAGE (V)

NOMINAL

OUTPUT

VOLTAGE (V)

MAXIMUM

CURRENT

(A)

NOMINAL

POWER

OUTPUT

DISSIPATION AT

RATED CURRENT

(W)

ISOLATION

400/LV60 60/30 48/24 4 200 W 12

non-isolated

400 240/110 180/190 4 0.55 kW 12

non-isolated

800/LV60 60/30 48/24 8 400 W 24

non-isolated

800 240/110 180/90 8 1.2 kW 24

non-isolated

1200/LV60 60/30 48/24 12 600 W 36

non-isolated

1200 240/110 180/90 12 2.0 kW 36

non-isolated

• All models are of open chassis construction. Enclosed versions are available as follows:

400E, 400ER, 800E, 800ER, 1200E, 1200ER. E = enclosed; R = reversing.

• Closed-loop control of both armature current and feedback voltage for precise control of

motor torque and speed.

• Motor and drive are protected by a stall timer that automatically removes power after 30

seconds if the required speed is not achievable.

• Provides for up to 150% of the preset maximum current for up to 30 seconds allowing for

high, short-term torques, for example, during acceleration.

• Independent control of either the current or speed loops by external inputs allows for

torque or speed control applications with overspeed or overcurrent protection.

• Derive the demand signal from a potentiometer, 0-10 V signal or 4-20 mA loop.

• Speed feedback signal selection: ARMATURE VOLTAGE, or shaft-mounted TACHOMETER.

Input and

outputs

+aux input speed output rail outputs

-aux input current output +12 V regulated output

current input ramp output +10 V precision reference

4-20 mA input stall relay driver -12 V regulated output

0 to 10 V input zero speed driver -24 V unregulated output

Adjustable

parameters

Max speed Up ramp Max current

Min speed Down ramp IR comp

Stability

Switched

functions

Max feedback Tacho feedback

Torque control AV feedback

Jumper

functions

Dual supply voltage Phase angle limit

4-20 mA input 50% stall threshold

Performance

features

Dual loop control Precision tacho rectier Compact design

Relay driver outputs International compatibility Integral fusing

2Mechanical dimensions

Mechanical dimensionsMechanical dimensions

WARNING!

PERSONAL INJURY AND/OR

EQUIPMENT DAMAGE HAZARD

The drives are NON-ISOLATED.

Do not allow contact of the enclosure with the drive card electronics.

Figure 1 Mechanical dimensions

100 mm

89 mm

130 mm

117 mm

50 mm

120 mm

Fixings

Model 400:

has four corner

fixings suitable for

M4 x 20 mm bolts

Models 800 & 1200:

has two centre

fixings suitable for

M5 x 35 mm bolts

Model 400 Model 800/1200

fin

air

flow

40 mm 70 mm

IMPORTANT: The heatsink

MUST be earthed using the

screw provided.

3Guide for systems used in the EU

Guide for systems used in the EUGuide for systems used in the EU

Special consideration must be given to installations in member states of the European Union

regarding noise suppression and immunity. According to IEC 1800-3 (EN61800-3) the drive

units are classied as complex components only for professional assemblers, with no CE

marking for EMC.

The drive manufacturer is responsible for the provision of installation guidelines.

The resulting EMC behaviour is the responsibility of the manufacturer of the system

or installation. The units are subject to the LOW VOLTAGE DIRECTIVE 73/23/EEC and

are CE marked accordingly.

Following the procedures outlined below will normally be required for the drive system

to comply with the European regulations, some systems may require different measures.

Installers must have a level of technical competence to correctly install. Although the drive

unit itself is not subject to the EMC directive, considerable development work has been

undertaken to ensure that the noise emissions and immunity are optimised.

EN618003 species two alternative operating environments. These are the Domestic

(1st environment) and Industrial (2nd environment). There are no limits specied for

conducted or radiated emissions in the industrial environment, hence it is usual for

the AC supply lter to be omitted in Industrial systems.

Denition of an industrial environment: all establishments, other than those directly

connected to a low-voltage power supply network that supplies buildings used for

domestic purposes.

Multiple drivesMultiple drives

The arrangement shown below is for multiple drives with one lter, showing the star point

earthing method.

The lter should be rated for the worst case total armature current load. The drive units

are designed to function normally on unltered AC supplies shared with other thyristor DC

drives. (Not AC drives).

AC SUPPLY

FILTER

UNIT *

24V RELAY CONTROLCLEAN EARTH

INSULATED FROM METALWORK

ANALOGUE SCREEN CLEAN EARTH

INSULATED FROM METALWORK

BACKPLATE

METALWORK

DOORS

110V CONTROL

CUBICLE

METALWORK

EARTH

STAR

POINT

INCOMING SAFETY EARTH

DRIVE 1

Note:

Earth connection

not made to 400

DRIVE 2

Note:

Earth connection

not made to 400

WARNING

Do not earth any

control terminals of

the drive units.

Failure to heed this

warning will result in

permanent damage.

MOTOR 2 MOTOR 1

Figure 2 Star point connections for multiple drives

4Requirements for EMC compliance

• Keep parallel runs of power and control cables at least

0.3 metres apart. Cross-overs must be at right angles.

• Keep sensitive components at least 0.3 metres from

the drive and power supply cables.

• The AC connections from the lter to the drive must be

less than 0.3 metres or, if longer, correctly screened.

• Do not run ltered and unltered AC supply cables

together.

• Control signals must be ltered or suppressed, e.g.

control relay coils and current carrying contacts. The

drive module has built-in lters on signal outputs.

• The AC supply lter must have a good earth connection

to the enclosure back plane. Take care with painted

metal to ensure good conductivity.

• The AC input lter has earth leakage currents. Earth

RCD devices may need to be set at 5% of rated current.

• The metal enclosure will be RF ground. The AC lter,

drive earth and motor cable screen should connect

directly to the metal cabinet for best performance.

• Linear control signal cables must be screened, with

the screen earthed at the drive end only. Minimise the

length of screen stripped back and connect it to an

analogue earth point.

• (1) The motor cable must be screened or armoured

with 360 degree screen terminations to earth at each

end. The cable must have an internal earth cable and

the screen must extend into the enclosure and motor

terminal box to form a Faraday cage without gaps.

• (2) The internal earth cable must be earthed at each

end. The incoming earth must be effective at RF.

WARNING! The earth safety must always take

precedence.

Requirements for EMC complianceRequirements for EMC compliance

WARNING!

ELECTRIC SHOCK HAZARD

AC supply lters

must not be used

on supplies that

are unbalanced or

oat with respect to

earth.

The drive and AC

lter must only

be used with a

permanent earth

connection. No

plugs/sockets are

allowed in the AC

supply.

The AC supply

lter contains high

voltage capacitors

and should not

be touched for a

period of at least 20

seconds after the

removal of the AC

supply.

DRIVE

CONTROL

TERMINALS

DRIVE

AC SUPPLY

INPUTS

DRIVE EARTH

TERMINAL

(not on 400)

ARMATURE

AND FIELD

OUTPUTS

CONTROL

SIGNAL

FILTERS

AC SUPPLY

FILTER

UNIT *

dc drive module

User’s metal enclosure

Figure 3 Connections for EMC compliance

5Installation

InstallationInstallation

WARNING!

ELECTRIC SHOCK HAZARD

Disconnect the mains supply

before working on the unit. DO

NOT TOUCH PRESETS, SWITCHES

AND JUMPERS! Always use the

correct insulated adjustment

tools.

6.1

Motor installation

• Foot-mounted motors must be level and

secure.

• Ensure accurate alignment of the motor

shaft and couplings.

• Do not hammer pulleys or couplings

onto the motor shaft.

• Protect the motor from ingress of

foreign matter during installation.

Earthing: Connect the motor to the system

enclosure earth.

6.2

Drive Installation

Requirements during installation and

operation:

HEATSINK AIRFLOW: Optimise the heatsink

airow.

• Avoid vibration.

• Protect the drive from pollutants.

• The ambient operating temperature

must be within -10ºC and +40ºC.

POWER CABLING: Use correctly rated

cable: minimum 600 Vac, 2 x armature

current

FUSING: The drives have built-in line fuses

for wiring protection:

400 6.3 A HRC

800 15 A HRC

1200 15 A HRC

Protect the drive thyristor bridge by tting

external semiconductor fuses. Refer to "7

Typical applications" on page 6.

CONTROL SIGNALS: All control inputs to

these drives are NON-ISOLATED. Do not

connect any of the terminals to earth or

other low voltage. A common HAZARD is

accidental earthing of the external pot and

contact wiring. Avoid running signal cables

close to power cables.

SUPPRESSION: The drives have excellent

noise immunity. However, installations

involving electrical welding or RF induction

heating may require additional lters on the

line and armature terminals. Contactor coils

and sparking contacts may also require

suppression. A 100 Ω resistor in series with

a 0.1 µF capacitor is usually adequate in

these situations. Refer to page 4 for

EMC guidelines.

CAUTION!

EQUIPMENT DAMAGE HAZARD

Reversing systems: do not

transpose the armature

connections until the motor has

stopped, otherwise damage will

occur.

SUPPLY: Please ensure that the supply

selection jumper on the drive matches the

incoming supply. Failure to do this may

result in permanent damage to the drive

unit and will invalidate any warranty.

CAUTION!

EQUIPMENT DAMAGE HAZARD

For frequent stopping, it is

not good practice to rely on

switching the supply off and

on again to stop and start the

drive with the run contact

permanently closed.

This practice may result in an

uncontrolled current pulse for

one half mains cycle under

certain conditions, e.g. main

contact bounce, and might lead

to undesired motor movement

or device damage.

In rapid start-stop systems, use

a spare normally-open contact

on the main supply contactor

in series with T5 and any other

RUN contacts.

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