Sprint Electric 4Q 3600XRi, Product Manual

Page 1: ...HG105273EN00 Issue 1 03 2021 World Class Design World Class Function 30 Years Expertise in Industrial Motor Control Product Manual DC MOTOR DRIVE 3600XRi 4Q ...

Page 2: ...rs 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 cau...

Page 3: ...UIPMENT 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 t...

Page 4: ...ed parameters that define 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 inflammable and incorrect disposal may lead to the generation of lethal toxic fumes Repairs Repair reports can only be given if the user makes sufficient and accurate defect reporting Remember that the product without the require...

Page 5: ...ioning 7 7 Commissioning 7 7 1 Initial settings without power 7 7 2 Block diagram 8 7 3 Terminal descriptions 11 7 4 Preset switches and links 14 7 5 Pre operation motor check list 18 7 6 Field and setpoint check 18 7 7 Operating the drive 18 7 8 Bi directional operation 19 8 Options 20 8 Options 20 8 1 Torque Control Mode 20 8 2 Maximum Current Mode 21 8 3 Quench Mode 21 8 4 Stall Mode 23 8 5 Opt...

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Page 7: ... and feedback voltage for precise control of motor torque and speed A stall timer protects the motor and drive and automatically removes power after 30 seconds if the required speed is not achievable Durng this period the unit can provide up to 150 of the preset maximum current for up to 30 seconds allowing for high short term torques during acceleration etc Electrically isolated control circuits ...

Page 8: ...rth connection Connect the earth cross sectional area at least 6 mm2 to the heatsink earth screw provided Use a star washer to obtain optimum earth continuity 175 mm 165 mm 70 mm 200 mm fin 100 mm side view plan view 3600XRi airflow heatsink earth screw 90 mm 36 A terminals terminals terminals 70 61 60 51 1 16 cover A1 A2 L2 N L F2 F1 Figure 1 Mechanical dimensions 3600XRi Suitable fixing bolts 4 ...

Page 9: ... ensure that the noise emissions and immunity are optimised EN618003 specifies two alternative operating environments These are the Domestic 1st environment and Industrial 2nd environment There are no limits specified for conducted or radiated emissions in the industrial environment hence it is usual for the AC supply filter to be omitted in Industrial systems Definition of an industrial environme...

Page 10: ...en 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 m...

Page 11: ... squared seconds rating according to the Rating table page 28 The fuse current rating must be at least 1 75 times the armature current The voltage rating must be suitable for the AC supply Failure to use the correct semiconductor fuse ratings will invalidate any warranty Special consideration must be given to installations in member states of the EU Refer to 5 Requirements for EMC compliance on pa...

Page 12: ...SHOCK RISK MOTOR We recommend two fuses for line to line operation only one fuse is necessary on the live L for line to neutral operation incoming FUSES We recommend an initial start using the Basic Connection WARNING PERSONAL INJURY AND OR EQUIPMENT DAMAGE HAZARD To ensure safe operation of the unit always apply the ac supply before closing the run contact to prevent spurious firing due to errati...

Page 13: ...SPEED Fully anti clockwise MIN SPEED Fully anti clockwise FORWARD UP RAMP Fully anti clockwise FORWARD DOWN RAMP Fully anti clockwise REVERSE UP RAMP Fully anti clockwise REVERSE DOWN RAMP Fully anti clockwise STABILITY Mid way IR COMP Fully anti clockwise MAX CURRENT Set the MAX CURRENT from your motor rating plate clockwise rotation of the potentiometer gives 0 100 current limit For example 50 r...

Page 14: ... P8 P11 REVERSE Lower P2 5K 1 50K 24 V FS 1S ZS 1 s delay zero setpoint detect direction detect zero speed detect P1 MAX SPEED P5 IR COMP switched inverter I a 110 Speed PI Current Limit STABILITY P7 IMAX P6 IMAX P10 Current PI Synch Firing Bridge select zero current detection 1 2Q x 0 5 4Q Lower control terminal Upper control terminal Power terminal Switch Link Preset KEY NOTE Fit only one link t...

Page 15: ... L2 N L1 L F F 1S ZS 1 s delay switched inverter I a 110 50 STALL FWD REV V a 50 S4 x4 S3 x2 x1 S8 current scale S1 S2 F2 F1 110 V 240 V 24 V 12 V 10 V STALLED S6 S5 S7 ZERO STALL REVERSE TACH AVF 24 V STALL TIMER RUNNING x1 Motor Armature Mains Supply Power Supply Motor Field Figure 5 Block diagram ...

Page 16: ... S5 when ON the relay remains energised until a stall condition occurs S6 when ON the relay remains eneergised until the speed falls below 1 S7 when ON the relay is energised for speeds above 5 of full scale in the forward direction and de energises at zero or reverse speed S8 TAC AVF Select the speed feedback source When ON ARMATURE VOLTAGE is selected default When OFF TACHO is selected 4Q TORQUE...

Page 17: ... 7 4 3 5 Quench Mode on page 17 It is good practice to connect a normally open auxiliary contact of the drive s supply contactor in series with this input WARNING Run is an electronic inhibit function The field remains energised and all power terminals remain live RUN must not be relied upon during hazardous operations 8 COM Common internally connected to T5 T58 and T68 9 TACH Tacho input 25 400 V...

Page 18: ... zero speed if connected as in Figure 7 Relay circuits on page 13 60 TIM Relay driver Maximum 25 mA External relay is de energised when the stall timer is operating current demand 105 if connected as in Figure 7 Relay circuits on page 13 61 12 12 V output 10 mA maximum 62 SS Stop Start input Close to 12 V to force a stall condition Close to 12 V to release stall condition 63 12 12 V output 10 mA m...

Page 19: ...itive A2 Motor armature connection negative L2 N Line ac return either neutral or L2 L Line ac supply input F2 Motor field connection negative F1 Motor field connection positive Terminals 52 53 59 60 Minimum coil resistance 2k8 Ω RL Terminal 51 24 V Figure 7 Relay circuits ...

Page 20: ...N SPEED preset is used to adjust the burden resistance FORWARD UP RAMP Forward acceleration FORWARD DOWN RAMP Forward acceleration REVERSE UP RAMP Reverse acceleration REVERSE DOWN RAMP Reverse acceleration STAB Stability IRCOMP IR compensation MAX CURRENT 2x current limit presets Refer to 8 2 Maximum Current Mode on page 21 7 4 2 Switches 7 4 2 1 S1 S2 These two switches set the maximum current a...

Page 21: ...eed is less than 1 the relay is de energised and the opposite is true terminals 10 and 12 are short and terminals 11 and 12 are open If more than one of S5 S7 is ON then the relay operation is the ANDing of the switch states For example if switches S5 and S6 are ON the relay is only de energised if the motor is stalled AND the speed is less than 1 In effect this indicates a failure for the motor t...

Page 22: ...6 sets the maximum positive and negative currents 5V 100 of calibrated current 2Q TORQUE With the link in this position the voltage on T6 sets the maximum positive current 10V 100 of calibrated current The maximum negative current is only limited by the setting of the negative current preset SPEED With the link in this position the voltage on terminal 6 is an auxiliary input to the speed loop dema...

Page 23: ...re both less than 1 CAUTION We recommend that the FS or the 1S link is fitted at all times If no links are fitted a stall condition or the removal of RUN from T7 will reset the speed ramp but the drive will not be quenched Also if only the ZS link is fitted and the motor cannot reach zero speed neither a stall condition nor removal of RUN will quench the drive 7 4 3 6 Stall Mode Refer to 8 4 Stall...

Page 24: ... turning fully counter clockwise 5 Remove the power supply and reconnect the Armature Leads 7 7 Operating the drive WARNING PERSONAL INJURY AND OR EQUIPMENT DAMAGE HAZARD Do not exceed the drive and motor armature voltage and current ratings 1 Note the armature voltage rating given on the motor rating plate 2 If the optional DC Tachogenerator is connected ensure that the wire from it is disconnect...

Page 25: ...y the wire to T9 must be negative when the speed demand into T3 is positive 1 Having measured the Tach voltage at maximum speed TURN OFF THE POWER 2 Set switch S8 to OFF to select TACHO operation 3 Set switches S3 S4 to select a speed range that encompasses the tacho voltage measured under AVF operation For example if the tachogenerator is 60 V 1000 rpm and the motor speed is 1500 rpm then the tac...

Page 26: ...n all 4 quadrants on positive and negative currents The 4Q TORQUE mode can be used for load sharing by inputting the modulus current signal from SP69 on a master drive C D A B 6 AUX speed feedback speed demand 0 5 error amp inverter curre current demand swings 7 5 V A B C D electronic switches ve clamp ve clamp speed input 4Q TORQUE 2Q TORQUE SPEED POS I MOTOR FWD NEG I BRAKE REV 1 2 3 left hand P...

Page 27: ...r details of the link settings reset setpoint ramp speed feedback amplifier zero setpoint detector logic 1 at zero 1 threhold zero speed detector logic 1 at zero 1 threshold OR AND OR OR one second timer quench standstill zero speed and zero feedback speed setpoint speed feedback stall latch run input QUENCH ZS 1S FS Figure 8 Drive quench circuit NOTE The AND gate marked in Figure 8 Drive quench c...

Page 28: ... ZS 70 69 COM 24 IP IO DC TACHO optional COM must be earthed for protective class 1 AC I P DANGER ELECTRIC SHOCK RISK MOTOR RUN 10K BASIC CONNECTION FORWARD AND REVERSE SPEED CONTROL BY POTENTIOMETER ccw cw OPTIONAL START ramp to stop 1 10 2 MIN 3 I P 4 MAX 5 COM 6 AUX 7 RUN 8 COM 9 TAC 10 11 12 STA JOG FWD REV A1 A2 L2 N L 13 14 15 16 RAMP quench RL2 RL2 shown energised SP64 XIP RL2 COIL RL2 SET ...

Page 29: ...el For a 150 overload the time for the stall detection circuit to operate is approximately 30 seconds for a 125 overload it is around 60 seconds etc If the overload falls below 105 before the stall timer has tripped the timer will ramp down This characteristic of the stall circuit has the effect of limiting the average current to the motor In some applications it may be required to provide protect...

Page 30: ...o zero setpoint ramp T13 T14 STOP START 0 V T3 speed setpoint XIP T64 24 V RL2 RL2 START RELAY OPTIONAL START ramp to zero 8 6 FORWARD REVERSE truth table Refer to Figure 4 Basic connection on page 6 FORWARD T15 REVERSE T16 MAXIMUM OUTPUT No connection No connection 10 V CLOSED CLOSED 10 V OPEN CLOSED 10 V CLOSED OPEN 10 V Opening the FORWARD push button momentarily selects the 10 V output which i...

Page 31: ...EDs on page 17 for STALL and TIMER lamp operation Insufficient torque Check current settings S1 S2 MAX CURRENT Timer lamp shows that stall timer is integrating Check the motor is correctly rated for the application No field motor jammed Check the circuits and motor No armature current Check the armature circuit Demagnetised PM motor Replace the motor Motor jammed Free the motor Motor will not turn...

Page 32: ...nt output zero speed ramp output shaft reverse demand output Supply ranges 45 Hz to 65 Hz auto ranging 24 30 48 60 110 240 415 Max V 28 36 58 72 130 264 440 Min V 22 27 44 54 100 200 360 Over full temperature range with outputs loaded Power rails 24 V 25 unregulated 25 mA 12 V 5 unregulated 10 mA maximum 10 V 5 regulated 10 mA maximum AC power up reset minimum off time before re supply 500 ms Fiel...

Page 33: ...ar ramp independent up and down ramps Stability Varies speed loop gain IRCOMP 0 to 30 of armature voltage for 0 to 100 armature current Max current 0 to 25 50 75 or 100 separate max current presets for positive and negative switch select 3 operation modes Switched functions S1 S2 Current range S3 S4 Speed feedback range 4 ranges of feedback voltage S5 S6 S7 Relay function stall zero reverse S8 Spe...

Page 34: ...d 510 A2 seconds 8 LN 240 110 180 90 8 A isolated 510 A2 seconds 16 LN 240 110 180 90 16 A isolated 510 A2 seconds 16 LL 415 240 320 180 16 A isolated 510 A2 seconds 32 LL 415 240 320 180 32 A isolated 5000 A2 seconds 36 LL 415 240 320 180 36 A isolated 5000 A2 seconds 1 Low volt versions are available operating on 60 30 Vac supplies giving 48 24 Vdc output and 48 24 Vac supplies giving 38 18 Vdc ...

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Page 36: ...ire obligation of Sprint Electric The warranty contained in the contract between the parties is the sole warranty of Sprint Electric Any statements contained herein do not create new warranties or modify the existing warranty We will be under no liability for any defect arising from fair wear and tear negligence wilful damage misuse abnormal working conditions failure to follow the manufacturer s ...