Peter electronic SGP 160-2,5 Training manual

electronic
Quality is our Drive.
Thyristor Controllers
SGP 160-2,5/4/8P/16P
Assembly- and Commissioning Instructions

SGP 160-2,5/4/8P/16P 1
as per 06/18 12300.10004
Table of Contents Page
1. Safety notes 3
2. Conformity 3
3. General description 4
4. Usage to the intended purpose 4
5. EC Declaration of Conformity 5
6. Block diagram 6
7. Functional description 6
8. Technical data 7
8.1 Ambient conditions 7
9. Installation 8
9.1 Connection 8
9.2 Power unit 8
9.3 Control unit 8
10. Parameter adjustments 9
10.1 Ramp-up and ramp-down times 9
10.2 Maximum speed 9
10.3 Minimum speed 9
10.4 I x R compensation with armature voltage control 9
10.5 Current limitation Imax 9
10.6 Adapting the resistor R21 for tachometer control 9
10.7 RC circuit of the speed controller 10
11. LED indicators 10
12. Remedying faults 10
13. Installation guidelines 11
13.1 Connection diagram SGP 160-2,5 (P) /4 (P) 11
13.2 Connection diagram SGP 160-8P/16P 12
13.3 Dimensional drawing 13
13.4 Radio interference suppression and shielding 14
13.5 Arrangement 14
13.6 Shielding 14
13.7 Cabling 15

2SGP160-2,5/4/8P/16P
Notes and symbols used in these instructions
Note: Notes explain the advantages of certain adjustments or settings and help
you to make use of the device in the best possible way.
Warning notices: Read them carefully and follow them strictly!
Warning notices are indicated in order to protect you against danger or to
help you to prevent the device from being damaged.
Caution: Danger to life through electric shock!
When you see this sign, always make sure that the device is de-energized
and secured against unintentional energizing.
These commissioning instructions were prepared with great care. Nevertheless, PETER
electronic GmbH & Co. KG does not assume liability for damage resulting from mistakes
possibly contained in this manual. Technical changes that serve to improve the product are
subject to change without notice.
Disposal Instructions
Equipment containing electrical components may not be disposed of
together with domestic waste. It must be collected separately as electrical
and electronic waste according to local and currently valid legislation.

SGP 160-2,5/4/8P/16P 3
1. Safety notes
The described devices are electrical equipment for use in industrial electrical power
installations. An impermissible removal of the covers during operation can cause
serious damage to your health, since these devices contain live parts with high
voltages.
Adjustment work may only be performed by trained staff observing the safety regulations.
Assembly and mounting work may only be carried out with the equipment deenergized.
Make sure that all drive components are properly earthed.
Please read these commissioning instructions carefully before putting the device into operation.
Besides, the user must ensure that the devices and associated components are fitted and
connected in accordance with the appliable local, legal and technical regulations. The VDE-
regulations VDE 0100, VDE 0110 (EN 60664), VDE 0160 (EN 50178) , VDE 0113 (EN 60204,
EN 61310),VDE 0660 (EN 50274) plus the appropriate regulations of the TÜV (Technical Control
Association) and the trade associations apply in Germany.
The user must ensure that the drive turns into a safe operating state following a device failure, in
the event of maloperation, or if the control unit has failed etc..
Caution: Even if the motor is at rest, it is not physically separated from the mains.
2. Conformity
In industrial linguistic usage the drive controllers of the type SGP 160-2.5/4/8P/16P are called
"devices", however, in the sense of the "device-safety-law", the "EMC-law" or the "EC-guideline
for machinery" they are not devices or machines ready for use or connection but they are compo-
nents. It is only possible to define their final function, when these components are integrated into
the design and construction of the user.
To be able to use the devices to their intended purpose, it requires power supply networks
according to DIN EN 50160 (IEC38).
The user takes the responsibility that the user’s design and construction comply with the appli-
cable legal provision.
The commissioning is strictly forbidden as long as the conformity of the final product with the
guidelines 2006/42/EC (Machinery directive) and 2006/95/EC (Low voltage directive) is not
proved.

4SGP160-2,5/4/8P/16P
3. General description
The electronic speed controllers SGP 160-2.5/4/8P/16P are used for the speed control of d.c.
shunt-wound motors with external and permanent excitation. A remarkable feature of these
controllers is the high speed stability, irrespective of fluctuations in temperature, voltage and load.
By means of the controllers SGP 160-2.5/4/8P/16P it is possible to make a variety of adjust
-
ments, such as minimum and maximum speed, ramp-up and ramp-down time, current limitation,
as well as I x R compensation. Since the controller is equipped with mains-potentialfree control
inputs, an external control is easily possible.Since the controller can be equipped with mains-
potential-free control inputs, an external control is easily possible.
4. Usage to the intended purpose
The devices of the SGP 160-2.5/4/8P/16P-series are electrical equipment that is used in indus-
trial electrical power installations. They are designed for the application in machines, in order to
control speed-variable drives with d.c. motors.
Typical Applications
• conveying systems
• printing machines
• pumps
• rotary table drives
• welding wire feed mechanisms
• packaging machinery

SGP 160-2,5/4/8P/16P 5
5. EC Declaration of Conformity
EC Declaration of Conformity
The manufacturer / company placing the product on the market
(authorized representatives of the manufacturer / companies placing the product on the market
that are established within the Community)
Name / Address: PETER electronic GmbH & Co. KG
Bruckäcker 9
92348 Berg
hereby declares that the following product (device, component, unit) in the version as supplied
Product designation: DC Thyristor Controller
Series / type designation: SGP 160-2,5/4/8P/16P
Article number: 223...
Year of manufacture: 1999
complies with the provisions of the following EU-directives:
2014/30/EU
2014/35/EU
2011/65/EU
This EC Declaration of Conformity is no longer valid, if the product is modified or changed
without our agreement.
This declaration is issued under the sole responsibility of the signatory.
Berg, 15.04.2016 Dr. Thomas Stiller, Managing director
(place, date) (signatory and function of the signatory) (signature)
Electromagnetic compatibility
Electrical equipment designed for use within certain voltage limits
The restriction of the use of certain hazardous substances in
electrical and electronic equipment
The following harmonized standards have been applied:
EN 60947-1:2007+A1:2012
EN 60947-4-2:2012
Low-voltage switchgear and controlgear General rules
Low-voltage switchgear and controlgear
Contactors and motor-starters - AC semiconductor motor
controllers and starters

6SGP160-2,5/4/8P/16P
6. Block diagram
7. Functional description
Speed setpoint
The setpoint voltage is 0 ... 10VDC. The setpoint value can be generated either by means of the
potentiometer or externally. By connecting a 500 Ohm resistor in parallel to the setpoint input
terminals it is possible to feed in a setpoint current of 0...20mA. With the setpoint integrator it is
possible to realize an acceleration and deceleration time that is linear in time.
Speed controller
The speed controller is designed alternatively for tachometer control or armature voltage control
with adjustable I x R compensation.
Current controller
The current controller generates the control voltage for the pulse stage. If the current actual value
exceeds the adjusted current setpoint, the motor voltage will be reduced. Thus the motor and the
drive are not overloaded.
Pulse stage
The pulse stage generates the control pulses for the thyristors. Their length from the trigger point
to the next zero crossing of the voltage wave enables a safe operation of the device even under
highly inductive load.
Power unit
The power unit consists of a single-phase, half-controllable bridge circuit and an exciting-voltage
source. The circuit additionally includes measures to protect the power semiconductors against
overvoltage.
n max
n min
Setpoint
integrator
n
I max
Speed
controller
Vp
IxR TM
Pulse
stage
I
Current
controller Power unit
Mains
Isolating module
as option

SGP 160-2,5/4/8P/16P 7
8. Technical data
8.1 Ambient conditions
SGP 160-2,5 SGP 160-4 SGP 160-8P SGP 160-16P
Operating voltage acc.
to DIN EN 50160 (IEC38)
230V ±15% 50/60Hz
max. Motor shaft power 0,25kW 0,37kW 0,9kW 1,8kW
Armature voltage 0 ... 180VDC
eff. Armature current 2,5A 4A 8A 16A
Excitation voltage /
current
200V / 0,5A 200V / 1A
Control characteristics
with I x R compensation
with tachometer control
1:30 / ±3%
1:100 / ±1%
Setpoint input 0 - 10VDC / mains potential-free with option „P“
5 - 10k Ohm potentiometer
Actual value input 12 - 300VDC depending on adaptation
factory-adapted to 160V armature voltage
Device fuse (internal) 4A 6,3A 160mA / 2x 20A
Connection 16-pole terminal strip control unit: 6-pole terminal strip
power unit: 6-pole terminal strip
Connection option „ST“ 31-pole Plug-connector
DIN 41617
-
Operating temperature 0 ... 45°C not subj. to moisture condensation
Storage temperature -25 ... 75°C
Cooling Convection
Temperature-dependent
power reduction
2%/°C above 45°C
max. 55°C
Protection class IP 00
Environment Overvoltage category III, pollution degree 2

8SGP160-2,5/4/8P/16P
9. Installation
To realize the power rating, the device is to be fastened on a vertical mounting surface, with the
terminal strip facing either to the left or to the right. Make sure that no additional heat sources,
such as heaters, radiators or power resistors are placed underneath the device. For dimensions
and fixing holes refer to the dimensional drawing.
9.1 Connection
Only connect according to the attached terminal diagram.
9.2 Power unit
(Terminal strip version acc. to DIN 41617 indicated in brackets only for SGP 160-2,5/4)
9.3 Control unit
9.3.1 Option „P“
n the case of option „P“ the control terminals for the controller inhibit and the setpoint are
potential-free and may be connected to earthed systems.
Attention!
A protective/safety separation, however, is not achieved.
SGP 160-2,5/4 SGP 160-8/16P
Terminal 16 (1, 2) 220V 50/60Hz Mains Phsae L
Terminal 8 (17, 18) 220V 50/60Hz Mains neutral conductor N
Terminal 10 (13, 14) +A Armature A+
Terminal 12 (9, 10) +C Field winding F+
Terminal 13 (7, 8) -D Field winding F-
Terminal 14 (5, 6) -B Armature -B
Terminal 1 (31) Controller inhibit 24V When the contact is open,
Terminal 2 (29, 30) Controller inhibit Input the controller is inhibited
Terminal 3 (27, 28) Setpoint potentiometer 10VDC
Terminal 4 (25, 26) Setpoint input 0 ... 10VDC
Terminal 5 (23,24) Setpoint potentiometer
Base point
Terminal 6 (21,22) Actual value input

SGP 160-2,5/4/8P/16P 9
10. Parameter adjustments
10.1 Ramp-up and ramp-down times
With the trimmer tint (P2) the ramp-up and the ramp-down can be adjusted between 0 ... approx.
5sec. When the controller inhibit is actuated, the ramp-up integrator is reset.
10.2 Maximum speed
With the trimmer nmax (P3) max. armature voltage can be limited between 90 ... 180V.
10.3 Minimum speed
With the trimmer n
min (P4) the minimum speed can be limited to 0 ... 50% of the adjusted
maximum speed.
10.4 I x R compensation with armature voltage control
The compensation voltage is adjusted with the trimmer I x R (P1). The compensation increases if
the trimmer is turned clockwise. The adjustment is to be made when the motor has its normal
operating temperature. The drive is to be adjusted to approx. 50% of the nominal speed,
unloaded as far as possible, and the speed is to be measured.
Then load the drive and compensate the resulting speed drop with the trimmer P1. Afterwards
check the effects of the compensation at minimum and maximum speed and re-adjust if
necessary. Make sure that an over-compensation, i.e., a speed rise under load, is avoided at any
rate, as otherwise the drive becomes unstable. In the case of tachometer control the potentio-
meter P1 is set to left stop.
10.5 Current limitation Imax
As a rule, the current limitation is to be adjusted with the potentiometer Imax (P5) so that the
maximum current required for the start-up and acceleration is provided. In the case of gearmotors
make sure that the limit torque of the gearing is not exceeded by adjusting the limit current too
high.
10.6 Adapting the resistor R21 for tachometer control
When the controller is operated with a d.c. tachometer, it may be necessary to adapt the resistor
R21 accordingly (depending on the amount of the tachometer voltage at nominal speed).
Basically, only resistors with a loading capacity of 1 watt are to be used. The trimmer I x R is set to
left stop. The resistance value can be determined with the following formula.
UTacho = voltage value of the d.c. tachometer in volts per 1000 revolutions
nMotor = nominal speed of the motor at UArmature max.
The calculated resistance is to be inserted in k Ohm.
)(2110
1500


kR
MotorTacho
nU

10 SGP 160-2,5/4/8P/16P
10.7 RC circuit of the speed controller
The circuit of the speed controller is so designed that the controller can be used for a variety of
drive cases without changing the circuit. However, in some extreme cases, e.g., heavy gyrating
masses of the machines, it may become necessary to change the factory-installed circuit.
11. LED indicators
2 LEDs visually indicating the operational status are located on the control board.
green LED: The controller is ready for operation; supply voltage is available.
red LED: The controller inhibit is activated and the motor has been stopped.
12. Remedying faults
The devices are designed for a problem-free and safe operation. Nevertheless, should trouble
arise, the following list is meant to help you to remedy the fault.
Designation factory-installed Function
R27 560k Ohm Adjustment of the P-gain
By increasing the resistance the P-gain is increased
too.
C17 2,2μFAdjustment of the I-gain
By increasing the capacitance of the capacitor the
integral-action time is prolonged
Fault Reason
Motor will not run - no mains voltage
- defective fuse
- no setpoint
- terminals 1 and 2 for controller inhibit not closed
- potentiometer Imax on left stop
In the case of a small setpoint the
motor runs up and cannot be
controlled
- no actual value of speed
- connection between terminals 6 and 14 is missing
(SGP 160-8/16P Klemmen B- and 6)
- tachometer not connected or reversed polarity
- R21 too high resistance
- externally excited motors: exciter field is not
connec ted
Motor does not run up to speed - R21 incorrectly adapted (too low resistance)
- motor too large or Imax adjusted to a too small value
- setpoint too small or setpoint potentiometer wrongly
connected
Motor swings - I x R compensation adjusted too high
- heavy gyrating masses of the drive
The controller RC circuit has to be changed

SGP 160-2,5/4/8P/16P 11
13. Installation guidelines
13.1 Connection diagram SGP 160-2,5 (P) /4 (P)
Setpoint 0-10VDC
Tachometer
Connection in the case of
armature voltage control
(17/18)
Plug-connector version indicated in brackets
(29/30)
Connection for external setpoint
controller inhibit
When the contact is
open the controller
is inhibited
12
(31) (23/24)
345
+
(27/28) (25/26)
-
(29/30)
Controller inhibit
When the contact
is open the controller
is inhibited
12
(31)
5-10kOhms
Setpoint poti
T
(23/24) (27/28) (25/26)
345
(21/22)
876
M
(5/6)
+-
Field
(13/14)
910 11
(9/10)
12 13 14
Mains
filter
L
+
Smoothing
reactor
-
PEN
15 16
(1/2)
-+
I
0..20mA
500 Ohm
(7/8)

12 SGP 160-2,5/4/8P/16P
13.2 Connection diagram SGP 160-8P/16P
Setpoint
0-10VDC
Tachometer
Connection for external setpoint
+-
Controller inhibit
When the contact
is open the controller
is inhibited
12
5-10kOhms
Setpoint poti
T
345 6
M
+-
Field
Mains
filter
L
+
Smoothing
reactor
PE N
Connection Control unit
(6-pole terminal strip)
-
Connection Power unit
(6-pole terminal strip)
Connection in the case of armature voltage control
connection in the
case of Tacho
control +A +C -D -B
220V
50/60Hz
500 Ohm
I
0..20mA

SGP 160-2,5/4/8P/16P 13
13.3 Dimensional drawing
112
100
5
90
510
SGP 160-2,5/4
Depth:
160 5
90 11
Depth: 115mm
SGP 160-8P/16P
200
185 7,5
P2 P3 P4 P1 P5
t int I max
IxR
N min
N max
+
R 27
C 17
R 21
fuse
SGP 160-2,5 = 35mm
SGP 160-4 = 45mm

14 SGP 160-2,5/4/8P/16P
13.4 Radio interference suppression and shielding
Even when installing thyristor controllers, interference from the realm of radio interference
suppression and immunity must be reduced to a tolerable level (EC-EMC-guidelines). An inter-
ference suppression that has to be subsequently implemented in an already installed system
often causes high costs.
The use of interference suppression filters in the mains supply line or on the output alone does
not resolve these interference problems. These problems can only be solved by an appropriate
arrangement of the filter elements, and a proper implementation of the cabling and shielding.
However, whether the radio interference limit values are complied with can only be checked by
measurements.
13.5 Arrangement
The controller and the filter have to be mounted as close as
possible next to each other and must be earthed with a
large-surface contact. This is best done by means of a
mounting plate (figure 1). The varnish on the contact areas
of this mounting plate must be removed in advance. The
varnish on the contact areas of the controller or the filter
has to be removed too.
Some switchgear cabinet suppliers offer mounting plates
with conductive coating.
13.6 Shielding
To prevent the controller from radiating interfering energy to the environment, the controller
should be installed in a metal-enclosed housing (switchgear cubicle or switchbox); the following
cables must be shielded:
- Cable between mains filter and controller, if it is longer than 30cm.
- Control cables, if they are longer than 2m.
Cables for digital signal transmission must be connected on both ends to the earth potential.
Cables for highly impedant analog control signals (setpoint value) must only be earthed on one
side in order to avoid a 50Hz-hum.
The shield bondings must always be implemented with large-surface contact. (Figure 2a,2b).
Therefore bondings with sheath wire, via connector pins or wire connectors are not allowed
(Figure 2c).
SGP
unshielded
max. 30cm
filter
metal
mounting plate
shielded
motor cable
Figure 1
shield bonding for cable glands
housing conductive
(vamish removed)
e. g.,cable gland made of metal
with shield bonding option
housing conductive
(vamish removed)
e. g., shielding clamp for
cables from ø 3 - 8mm
conductive (vamish removed)
shield bonding an mounting plate
sheath wire
incorrect shield bonding
Figure 2a 2b 2c

SGP 160-2,5/4/8P/16P 15
13.7 Cabling
To avoid mutual interference/cross couplings when laying the cables, it must be ensured that a
minimum distance of 20 cm is maintained between control cables and power cables. If control
cables have to cross power cables they have to be laid at an angle of 90° (Figure 3).
When connecting shielded cables make sure that the unshielded cable ends are as short as
possible. The large-surface shield bonding must not necessarily be located on the end of the
shielding but may also be established in a suitable place - at a distance of some centimetres. The
shield must always be connected on both ends to ground (Figure 4).
ATTENTION!
When using mains filters the leakage currents are increased.
For the respective leakage currents please refer to the corresponding data sheets.
Leakage currents up to 3.5mA and permanent connection require no special additional earthing
measures.
According to VDE 0160 (EN 50178) the following applies to the most common applications:
If in the case of permanently connected devices an operational leakage current of 3.5mA is
exceeded, one of the following conditions must be complied with.
1. Protective conductor cross section of at least 10mm²
2. Monitoring of the protective conductor by means of a device/system which in case of a fault
causes an automatic switch-off.
3. Installation of a second conductor, electrically in parallel to the protective conductor via
separate terminals. This conductor by itself must meet the requirements according to VDE
0100, part 540.
Recommended filters:
mains filter NF 250/6 Article-No.27000.25006
NF 250/10 Article-No.27000.25010
NF 250/20 Article-No.27000.25020
at least
20cm
control cable
power cable
90°
mounting plate
large-surface
shield-bonding
vamish removed
SGP
unshielded ends
as short as possible
terminals
Figure 3 Figure 4

16 SGP 160-2,5/4/8P/16P

SGP 160-2,5/4/8P/16P 21