Sprint Electric 400i User manual

HG105271EN00 Issue 1 (08/2021)
World Class Design | World Class Function | 30 Years Expertise in Industrial Motor Control
Product Manual
DC MOTOR DRIVE
400i

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
Isolated product
WARNING!
The drive and 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. This is achieved through basic insulation and protective earth grounding, or double-
insulation to provide SELV Control Circuits.
2. This protection allows a safe connection to other low voltage equipment.
3. Earth bonding is the responsibility of the installer.

Contents
1 Introduction 11 Introduction 1
2 Installation 22 Installation 2
2.1 Motor installation.......................................................................................................... 2
2.2 Drive Installation........................................................................................................... 2
2.3 Guide for systems used in the EU................................................................................ 4
2.4 Multiple drives............................................................................................................... 4
2.5 Requirements for EMC compliance ............................................................................. 5
2.6 Typical applications....................................................................................................... 6
2.7 Blockdiagramandterminalspecications................................................................. 8
3 Commissioning 113 Commissioning 11
3.1 Initial settings - without power...................................................................................11
3.2 Pre-operation motor check list...................................................................................12
3.3 Operating the drive ......................................................................................................12
4 Options 144 Options 14
5 Trouble shooting 155 Trouble shooting 15
6Specications 166Specications 16

1Introduction
11 IntroductionIntroduction
APPLICATION AREA: Industrial (non-consumer) "Motor speed control utilising DC Motors".
DRIVE MODEL AC SUPPLY
VOLTAGE
NOMINAL
OUTPUT
VOLTAGE
MAXIMUM
CURRENT
PRODUCT
DISSIPATION
at full current
ISOLATION
400i/LV60 30/60 24/48 4 A 12 W isolated
400i 110/240 90/180 4 A 12 W isolated
This isolated DC motor drive is designed for panel mounting, with connections made using
screw terminals
• All models are of open chassis construction for use in a suitable enclosure.
• The drives have isolated control electronics.
• 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 to automatically remove power after 30
seconds if the required speed cannot be achieved.
• Up to 150% of the preset maximum current for up to 30 seconds allowing for high, short-
term torques during acceleration etc.
• Independent control of either the current or speed loops by external inputs allow for
torque or speed control applications with overspeed or overcurrent protection.
• Demand signal can be derived from a potentiometer, 0-10 V signal or 4-20 mA loop.
• Speed feed back 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/stall relay -24 V unregulated output
Adjustable
parameters
Max speed Up ramp Max current
Min speed Down ramp IR comp
Stability
Switched
functions
Max feedback Torque control Tacho feedback
AV feedback
Jumper
functions
Dual supply voltage 4-20 mA input Phase angle limit
50% stall threshold
Performance
features
Dual loop control Precisiontachorectier Compact design
Relay driver outputs International compatibility Integral fusing

2Installation
22 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.
2.1 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.
2.2 Drive Installation
Requirements during installation and
operation:
• Optimisetheheatsinkairow.
• Avoid vibration.
• Protect the drive from pollutants.
• Ambient operating temperature must be
within -10ºC and +40ºC. To comply with
UL requirements, the temperature of the
surrounding air must not exceed 50ºC.
POWER CABLING: Use correctly rated
cable: minimum 600 Vac, 2 x armature
current
CONTROL SIGNALS: The 400i has isolated
control terminals and as such may be
connected to other systems. Avoid running
signal cables close to power cables.
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.
FUSING: The drive MUST BE FUSED
EXTERNALLY with semiconductor fuses that
MUST be rated at 1.75 x armature current,
and have an A2s rating lower than the I2t
value listed on page 14. Any Warranty
will be invalid if this fusing is incorrect.
400i Fuse Holder Clearing I2t
8 A CH0008A CP102071 35 A2s
SUPPRESSION: The drives have excellent
noise immunity. However, installations
involving electrical welding or RF induction
heatingmayrequirefurther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 5 for
EMC guidelines.
CAUTION!
EQUIPMENT DAMAGE HAZARD
Reversing systems: do not
transpose the armature
connections until the motor has
stopped, otherwise damage will
occur.
CAUTION!
EQUIPMENT DAMAGE HAZARD
For frequent stopping or jogging,
it is not good practice to rely on
switching the supply off and on
to stop and start with the run
contact permanently closed.
This may result in an
uncontrolled current pulse for
one half mains cycle under
certain conditions, e.g. main
contact bounce. This could 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 T20 and any other
RUN contacts.

3Installation
2.2.1 Mechanical dimensions
160 mm
100 mm
145 mm
45 mm
90 mm
400i E400i
screw terminals
4 off M4 x 20 mm
160 mm
35 mm
100 mm
The units are standard
single Eurocard format
and the connector type
is 41612/F.
Note: the b and z pins
are connected to both
rows for the armature
and supply to carry
current.
d
b
z
d unloaded
b loaded
z loaded
female
Figure 1 Mechanical dimensions

4Installation
2.3 Guide 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.
*
2.4 Multiple 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).
DRIVE 1
AC SUPPLY
FILTER
UNIT *
DRIVE 2
24V LOGIC CONTROL CLEAN EARTH
INSULATED FROM METAL WORK
ANALOGUE 0V (COM. TERMINAL18 ON DRIVES)
CLEAN EARTH INSULATED FROM METALWORK
BACKPLATE
METALWORK
DOORS
110V CONTROL
CUBICLE
METALWORK
EARTH
STAR
POINT
INCOMING SAFETY EARTH
MOTOR 2 MOTOR 1
WARNING
DO NOT EARTH
ANY CONTROL
TERMINALS OF
NON-ISOLATED
DRIVE UNITS
Figure 2 Star point connections for multiple drives

5Installation
• 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.
2.5 Requirements 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
ARMATURE
AND FIELD
OUTPUTS
CONTROL
SIGNAL
FILTERS
AC SUPPLY
FILTER
UNIT *
dc drive module
User’s metal enclosure
12
Figure 3 Connections for EMC compliance

6Installation
2.6 Typical applications
SPRINT ELECTRIC LTD. does not
accept any liability whatsoever for
theinstallation,tnessforpurposeor
application of its products. It is the users
responsibility to ensure that the unit is
correctly used and installed.
Health and Safety at Work
Devices constitute a safety hazard. It is
the responsibility of the user to ensure
compliance with any Acts or By-Laws
in force. ONLY skilled persons should
install this equipment.
-
+++
-+
32
COM
30
LIM
28
+10
26
MIN
24
I/P
22
O/P
20
RUN
18
COM
16
TAC
14
A+
12
A-
8
F-
6
F+
4
N
2
L
-
ERROR
AMPAND
FIRING CCTS
current
feedback
STALL
TIMER
SPEED ERROR AMP
feedback
max
speed
speed
demand
ramp reset
min
speed
COM
quench o/p
current
demand
stall
110
240
SUPPLY
SELECT
stab max
current
50/100%
S1 S2
5K 5K
torque
S4
tac/avf
IP
66
-IP
65
TI
64
-12
63
SS
62
+12
61
SO
56
RO
55
IO
54
ZS
53
ST
52
-24
51
+
S3
acw
cw 10K
RUN
CONTACT
SPEED
COM must be
earthed for
protective
class 1 code
COM must be
earthed for
protective
class 1 code
acw
cw 10K
Close
to run
Setpoint
(1 to 10K)
ARMATURE TIME
CONSTANT
T=L/R
armature
field
no field on
PM motors
tacho
(optional)
For half wave field output
connect field to F- and N.
Field volts = 0.45 x AC supply
DANGER
ELECTRIC SHOCK RISK
motor
For half wave field output
connect field to F2- and N.
Field volts = 0.45 x AC supply
32
COM
30
LIM
28
+10
26
MIN
24
I/P
22
O/P
20
RUN
18
COM
16
TAC
14
A+
12
A-
8
F-
6
F+
4
N
2
L
SEMICONDUCTOR
FUSE
AC
SUPPLY
acw
cw 10K RUN CONTACT If the speed exceeds the level
programmed by the speed setpoint,
then the current demand comes out of
limit and the speed loop takes control.
Note: Link together the two signal pads
64 to bring SP64 to terminal 22.
MOTOR
ARMATURE
MOTOR
FIELD
10K
acw
cw
DANGER
ELECTRIC SHOCK RISK
Note: A- and F- are
internally connected.
32
COM
30
LIM
28
+10
26
MIN
24
I/P
22
O/P
20
RUN
18
COM
16
TAC
14
A+
12
A-
8
F-
6
F+
4
N
2
L
TORQUE SPEED
TORQUE MODE SELECTED
BY SWITCHING S3 ON
MOTOR
ARMATURE
MOTOR
FIELD
SEMICONDUCTOR
FUSE
AC
SUPPLY
SEMICONDUCTOR
FUSE
AC
SUPPLY
DANGER
ELECTRIC SHOCK RISK
Figure 4 Basic connection
Figure 5 Basic connection with optional tacho
Figure 6 Torque control with overspeed limiting by separate setpoint
-
+++
-+
32
COM
30
LIM
28
+10
26
MIN
24
I/P
22
O/P
20
RUN
18
COM
16
TAC
14
A+
12
A-
8
F-
6
F+
4
N
2
L
-
ERROR
AMPAND
FIRING CCTS
current
feedback
STALL
TIMER
SPEED ERROR AMP
feedback
max
speed
speed
demand
ramp reset
min
speed
COM
quench o/p
current
demand
stall
110
240
SUPPLY
SELECT
stab max
current
50/100%
S1 S2
5K 5K
torque
S4
tac/avf
IP
66
-IP
65
TI
64
-12
63
SS
62
+12
61
SO
56
RO
55
IO
54
ZS
53
ST
52
-24
51
+
S3
acw
cw 10K
RUN
CONTACT
SPEED
COM must be
earthed for
protective
class 1 code
COM must be
earthed for
protective
class 1 code
acw
cw 10K
Close
to run
Setpoint
(1 to 10K)
ARMATURE TIME
CONSTANT
T=L/R
armature
field
no field on
PM motors
tacho
(optional)
For half wave field output
connect field to F- and N.
Field volts = 0.45 x AC supply
DANGER
ELECTRIC SHOCK RISK
motor
For half wave field output
connect field to F2- and N.
Field volts = 0.45 x AC supply
32
COM
30
LIM
28
+10
26
MIN
24
I/P
22
O/P
20
RUN
18
COM
16
TAC
14
A+
12
A-
8
F-
6
F+
4
N
2
L
SEMICONDUCTOR
FUSE
AC
SUPPLY
acw
cw 10K RUN CONTACT If the speed exceeds the level
programmed by the speed setpoint,
then the current demand comes out of
limit and the speed loop takes control.
Note: Link together the two signal pads
64 to bring SP64 to terminal 22.
MOTOR
ARMATURE
MOTOR
FIELD
10K
acw
cw
DANGER
ELECTRIC SHOCK RISK
Note: A- and F- are
internally connected.
32
COM
30
LIM
28
+10
26
MIN
24
I/P
22
O/P
20
RUN
18
COM
16
TAC
14
A+
12
A-
8
F-
6
F+
4
N
2
L
TORQUE SPEED
TORQUE MODE SELECTED
BY SWITCHING S3 ON
MOTOR
ARMATURE
MOTOR
FIELD
SEMICONDUCTOR
FUSE
AC
SUPPLY
SEMICONDUCTOR
FUSE
AC
SUPPLY
DANGER
ELECTRIC SHOCK RISK
-
+++
-+
32
COM
30
LIM
28
+10
26
MIN
24
I/P
22
O/P
20
RUN
18
COM
16
TAC
14
A+
12
A-
8
F-
6
F+
4
N
2
L
-
ERROR
AMPAND
FIRING CCTS
current
feedback
STALL
TIMER
SPEED ERROR AMP
feedback
max
speed
speed
demand
ramp reset
min
speed
COM
quench o/p
current
demand
stall
110
240
SUPPLY
SELECT
stab max
current
50/100%
S1 S2
5K 5K
torque
S4
tac/avf
IP
66
-IP
65
TI
64
-12
63
SS
62
+12
61
SO
56
RO
55
IO
54
ZS
53
ST
52
-24
51
+
S3
acw
cw 10K
RUN
CONTACT
SPEED
COM must be
earthed for
protective
class 1 code
COM must be
earthed for
protective
class 1 code
acw
cw 10K
Close
to run
Setpoint
(1 to 10K)
ARMATURE TIME
CONSTANT
T=L/R
armature
field
no field on
PM motors
tacho
(optional)
For half wave field output
connect field to F- and N.
Field volts = 0.45 x AC supply
DANGER
ELECTRIC SHOCK RISK
motor
For half wave field output
connect field to F2- and N.
Field volts = 0.45 x AC supply
32
COM
30
LIM
28
+10
26
MIN
24
I/P
22
O/P
20
RUN
18
COM
16
TAC
14
A+
12
A-
8
F-
6
F+
4
N
2
L
SEMICONDUCTOR
FUSE
AC
SUPPLY
acw
cw 10K RUN CONTACT If the speed exceeds the level
programmed by the speed setpoint,
then the current demand comes out of
limit and the speed loop takes control.
Note: Link together the two signal pads
64 to bring SP64 to terminal 22.
MOTOR
ARMATURE
MOTOR
FIELD
10K
acw
cw
DANGER
ELECTRIC SHOCK RISK
Note: A- and F- are
internally connected.
32
COM
30
LIM
28
+10
26
MIN
24
I/P
22
O/P
20
RUN
18
COM
16
TAC
14
A+
12
A-
8
F-
6
F+
4
N
2
L
TORQUE SPEED
TORQUE MODE SELECTED
BY SWITCHING S3 ON
MOTOR
ARMATURE
MOTOR
FIELD
SEMICONDUCTOR
FUSE
AC
SUPPLY
SEMICONDUCTOR
FUSE
AC
SUPPLY
DANGER
ELECTRIC SHOCK RISK

7Installation
2.7 Block diagram and terminal specications
400i/E400i
32
30
28
26
24
22
20
18
16
14
10 / 12
8
6
4
2
COM
LIM
+10
MIN
I/P
O/P
RUN
COM
A1+
A2-
F2-
F1+
N
L
66
65
64
63
62
61
+I/P
-I/P
TI
-12
SS
+12
56
55
54
53
52
51
IO
ZS
ST
-24
SO
RO
--
++
+++ +
--
-+
TAC
-
RAMP OUTPUT RO 55
2.5V
4-20mA
50K
5K
MIN
5K
+12
390R
G = 2.5
DOWN UP IR COMP
STAB
STH
100K
50K
50%
100%
100K
MAX SPEED
FROM
T64 TORQUE TD
RAMP
RAMP RESET
RANGE
S1 S2 .5
P+I
AMP
STALL
TIMER
DRIVE
RUN
LOGIC
RECTIFIER
MAX
CURRENT
CURRENT FEEDBACK
SPEED
OUTPUT
S4 5%
SO 56
ZS 53
ZERO
STALL
OUTPUT
ST 52
CURRENT
OUTPUT
IO 54 ERROR
AMP
PHASE
SYNCH
FIRING
CIRCUITS
FIELD
BRIDGE
TAPPED
POWER
SUPPLY
TRF. PSU
+24
+12
+10
-12
-24
150%
100%
50%
0%
7.5V
5V
2.5V
0V
ON
+
-
TURNED ON BY STALL
+-
SUPPLY
SELECT
S3
470K
FUSE
Figure 7 Block diagram

8Installation
32 Common
30 Open collector output, 100 mA 30 V - turns ON if the drive goes into a stall condition
28 +10 V precision reference, 10 mA maximum. Short circuit proof
26 Minimum end of setpoint potentiometer or 4-20 mA current loop input
24 0 to +10 V input for 0-100% speed
22 Output - may be linked to any one of the signal pads (located on the top edge) by
connecting to an adjacent pad
20 Connect to COMMON to run 60 ms ON / 20 ms OFF
(WARNING:Runisanelectronicinhibitfunction.Theeldremainsenergisedand
all power terminals remain "live". RUN must not be relied upon during hazardous
operations)
18 Common - connect to earth for protective Class 1
16 Tacho input 12-200 V full scale, + or - polarity
14 (A+) armature output
12 (A-) armature output (and T10)
10 (A-) armature output (and T12)
8(F-)eldoutput
6(F+)eldoutput
4(N) AC supply input, according to supply select jumper
2(L) AC supply input
Forhalf-waveeldoutputvoltage,connecteldbetweenF-(T8)
andN(T4).Thisgivesaeldvoltageof0.45xACsupply.
Figure 8 Terminal specications
66 Auxiliary speed input, 0 to +10 V for 0-100% direct speed
65 Auxiliary inverting speed input, 0 to -10 V for 0-100% ramped speed
64 Torque input, 0 to +10 V for 0-100% current
63 -12 V output 10 mA maximum - do not short
62 Stop/start input:
close to -12 V to activate stall condition
close to +12 V to release stall condition
61 +12 V output, 10 mA maximum - do not short
56 Speed output - typically 7.5 V full scale adjustment of maximum speed preset will
alter the full scale reading from 4 V (anti-clockwise) to 9 V (clockwise) - 0 V to full scale
represents0-100%,impedance1kΩ
55 Setpointrampoutput,0-10V,impedance1kΩ
54 Currentoutput,0-5Vfor0-100%current,1kΩimpedance
53 Zero speed relay driver output, maximum 100 mA, switches to -24 V
52 Stall relay driver output, maximum 100 mA, switches to -24 V
51 -24 V relay supply, 25 mA - do not short
RL
internal
transistor
T52 or T53
external relay
coil 2K8
from T51
Signal pads on top edge of board - link to Terminal 22 (see above)
Main terminals
WARNING!
DANGEROUS POTENTIAL PRESENT
Control connections 16 to 32 and signal pads 51 to 66 are electrically
isolated from the power terminals 2 to 14. DO NOT TOUCH THE BOARD!

9Commissioning
33 CommissioningCommissioning
3.1 Initial settings - without power
The suggested Comissioning strategy is to start in the safest possible mode of operation and
progressively exercise each element of the system until full functionality has been achieved.
For this reason, all drive units are shipped to run using:
• the highest supply option
• a nominal speed
• ARMATURE VOLTAGE feedback mode - we recommend that initial commissioning
is carried out in Armature Voltage feedback mode
• the lowest current range
Supply selection
Drive model HIGH position LOW position
400i 240 V 110 V
400i/LV60 60 V 30 V
3. Use switches S1 and S2 to select a range suitable for the
armature voltage at full speed. For example, if the armature
voltage is 90 V, then set S1:OFF and S2:ON for 50 to 100 V
voltage feedback.
4. Switch S3 to off. (When on, this allows a Torque signal to be
entered via signal pad 64 (TI) on the top edge of the board.)
1. To avoid damage, ensure the drive's supply selection jumper matches the
incoming ac supply: 240 Vac or 110 Vac, (60 Vac or 30 Vac for LV60 models).
2. Ensure switch S4 is set to ON, selecting AVF.
Refer also to "Figure 9 User adjustments" on page 11 for the following switch selections:
5. For an intial start, adjust the following presets:
DOWN RAMP Fully anti-clockwise
UP RAMP Fully anti-clockwise
MIN SPEED Fully anti-clockwise
MAX SPEED Fully anti-clockwise
STABILITY Mid-way
IR COMP Fully anti-clockwise
MAX
CURRENT
Set MAX CURRENT from your motor rating plate. Rotating clockwise
gives 0-100% of the drive's 4 A current rating; 50% rotation will give a 2 A
current limit.
6. Ifatachogeneratoristted,disconnectthetachowirefromterminalT16andinsulate.

10 Commissioning
3.3 Operating the drive
1. Note the armature voltage rating given on the motor rating plate.
2. Apply mains power to the unit. The ON lamp will light. Apply mains power to the unit.
TheONlampwilllight.(Checktheeldenergisesifused,and+10Vprecisionreference
is available on Terminal 28).
3. Close the RUN contact.
4. Gradually increase the external setpoint to start the motor rotating. If the direction is
wrong, TURN OFF THE POWER, WAIT FOR THE MOTOR TO STOP TURNING and swap over
the cables connected to the A+ and A- terminals.
5. MAX SPEED: Increase the external setpoint further to ramp up to full speed. Fine adjust
using the MAX SPEED preset to achieve the armature voltage stated on the motor rating
plate. Do not exceed the armature voltage rating.
6. Reduce the external setpoint to ramp the drive to zero. The motor will stop rotating.
7. MIN SPEED: Adjust MIN SPEED to provide a speed preset.
8. RAMP UP/RAMP DOWN: Run the motor up and down while adjusting the RAMP UP and
RAMP DOWN potentiometers.
9. STABILITY: Adjust the STAB potentiometer to improve response. Clockwise rotation
gives a faster response. (Excessive rotation in either direction may lead to instability,
depending on load.)
10. IR COMP: Speed droop on heavy loads may occur where armature voltage feedback is
used. Compensate for this by clockwise adjustment of the IR comp preset. Excessive
rotation may lead to instability.
The drive is now commissioned for use in Armature Voltage feedback.
3.2 Pre-operation motor check list
With no power applied, complete the following check list:
• Check for the correct insulation between all motor windings and earth (disconnect all
drive cables before testing).
• Check inside the motor connection box for foreign objects, damaged terminals etc.
• Check that motor brushes are in good condition, correctly seated and free to move in
brush boxes.
• Check for the correct action of brush springs.
• Check that motor vents are free of any obstruction or protective covers.

11 Commissioning
Figure 9 User adjustments
WARNING!
When power is applied to the drive,
ALWAYS use an insulated tool when adjusting the presets.
RAMP DOWN: Rotate clockwise to
increase drive deceleration from 1 to 30
seconds - note that natural coast down is
a liimit.
RAMP UP: Rotate clockwise to increase
drive acceleration from 1 to 30 seconds.
MIN SPEED: Rotate clockwise to increase
minimum speed. Use to adjust 4-20 mA
loop burden resistor between 0 and 390 Ω
if 4-20 mA mode is selected.
MAX SPEED: Rotate clockwise to
increase speed. Change the range with S1
and S2.
STAB: Rotate clockwise to increase
response. Excessive rotation may cause
instability. If rated motor motor voltage is
much lower than AC supply then
anticlockwise is prefered.
IR COMP: Rotate clockwise to increase
level of armature voltage droop
compensation. Excessive rotation may
cause instability. Always set fully
anti-clockwise in Tacho mode.
I MAX: Rotate clockwise to increase level
of armature voltage
droop compensation. Excessive rotation
may cause instability. Always set fully
anti-clockwise in Tacho mode.
AC power is
applied when lit.
To implement the
50% THRESHOLD,
link the two points
marked STH. Drive
quenches when lit if
stall timer trips - the
time depends upon
the current demand:
STANDARD
150% 30 secs
125% 60 secs
115% 120 secs
100% no trip
WITH 50%
THRESHOLD
150% 15 secs
100% 30 secs
75% 60 secs
50% no trip
MAX
SPEED
MIN
SPEED
RAMP
UP
RAMP
DOWN STAB IR
COMP
I MAX
ONSTALL
ANTI-CLOCKWISE
MID-WAY
CLOCKWISE
32
+10
30
MIN
I/P
COM TAC
O/P
RUN
COM
12
A-
A-
F- F+ N
L
28 26 24 22 20 18 16 14
10 8 6 4 2
A+
LIM
DANGER!
ELECTRIC SHOCK HAZARD
SUPPLY
SELECT
HIGH
LOW
S1
S2 These two switches select between four maximum feedback voltage
ranges. Use the MAX SPEED
PRESET to adjust within the range.
The drive will control from 0 V to the
selected maximum 0-10 V input.
S3 When ON, the drive operates as a
torque controller. Drive current is
controlled between 0% and the level
set on the MAX CURRENT preset by
a 0-10 V signal on T64. Note the stall
timer is automatically inhibited in this
mode.
S4 Select the speed feedback source:
When ON, ARMATURE VOLTAGE
is selected (default). When OFF,
TACHO is selected. HRC FUSE
6.3 A
5 x 20 mm
This jumper selects
the appropriate
supply tap on the
control transformer.
Refer to the
specification for
supply ranges.
CHECK model type:
240/110 Vac for
standard units;
60/30 Vac for
models with LV
suffix.
SUPPLY
SELECT *
1 2 3 4
MAXIMUM
FEEDBACK
TORQUE
TAC/AVF
12 - 25
25 - 50
50 - 100
100 - 200
OFF ON
VOLTS
OFF OFF
ON OFF
OFF ON
ON ON
S1 S2
RANGE
MAX SPEED
*
4-20 mA Terminal 26 becomes
loop input and
Terminal 32 the return.
MIN SPEED preset
trims burden to 250 Ω.
0-20 mA
this pair only
4-20 mA
both pairs
to T22 any one
pair may
be linked
T22
Signal pads 51 to 66 - any one signal pad may be connected to
T22 by linking the appropriate pads together
64 TI
66 51
STH

12 Options
44 OptionsOptions
Consider the following changes to tune/improve the performance of the drive/system.
• SPEED FEEDBACK SELECTION If the system is to use Tacho feedback you can now adjust
for the tachogenerator's output voltage, and hence the speed of the motor.
NOTE: IR COMP must NOT be used with Tacho feedback - set the potentiometer
fully anti-clockwise.
a. With the power off, connect the tachogenerator's output voltage to Terminal 16.
Set the Tach/Avf switch S4 to OFF (left).
Calculate the output voltage from the tachogenerator:
For example, if quoted as "100 V per 1000 revs/min" then
feedback voltage = (motor speed/1000) x 100 V
Alternatively, it can be estimated as follows:
1. Whilst still in Avf mode and running at 100% speed, measure the tacho
volts on the wire intended for connection to Terminal 16 - WARNING:
possible high voltage. Note this voltage, stop the motor and turn off
the supply.
2. Set the Tach/Avf switch S4 to OFF (left) to disconnect Avf and then
reconnect the tacho wire to Terminal 16.
b. Reset switches S1 and S2 to a suitable range for the measured/calculated Tacho
voltage.
c. Run the drive using a low to middle speed setpoint.
d. Adjust the Max spd preset to achieve the required shaft speed at maximum speed
setpoint.
Run the drive in Armature Voltage feedback mode and check the polarity of the
tacho using a voltmeter. The tacho feedback polarity must be negative with respect to
COMMON, Terminal 24 for a Positive Speed Demand on Terminal 8.
WARNING!
PERSONAL INJURY HAZARD
Terminals A+, A-, F+, F-, N & L are at high potential.
Do not touch the terminals or any connected conductor.
• TORQUE CONTROL MODE: Switch S3 allows a Torque signal to be entered when ON via
signal pad 64 (TI) which is on the top edge of the board.

13 Trouble shooting
+-
Setpoint ramp
output on 55.
0 - 10 V.
speed demand
SPEED ERROR
AMPLIFIER
output current
demand +
CURRENT
ERROR AMP.
output phase
angle demand
FIRING AND
BRIDGE
CIRCUITS
CURRENTAMP.
output on 54.
0 to +5 V for zero
to full range
STALL TIMER
timing active while
demand >100%
30 seconds
Speed feedback
output on 56
0 to 7.5 V typical
S1 S2 range
0 to +10 V
MOTOR
TACH
-
The outer speed (Volts)
loop controls the inner
torque (current) loop.
1STALL problems, indicated by the
STALL lamp coming on after running,
are caused by the drive unit not able
to give set speed.
2Typical STALL reasons:
a. MAX CURRENT preset not
correctlyset,henceinsucient
torque.
b. Motor not powerful enough for
application. Speed calibration set
beyond capability of supply.
c. Any factor which prevents motor
from rotating at set speed, e.g.
jammed load; low supply voltage.
3Pot wired with T26 and T28
transposed. motor slows down
instead of speeding up.
4Pot wired with T26 and T24
transposed. Motor slows down
for clockwise rotation. T28 may be
shorted to T26.
5Pot wired with T28 and T24
transposed. Motor slows down for
anti-clockwise rotation. T28 becomes
shorted to T26.
6Loose or intermittent tacho coupling
causes instability or overspeeding.
Make sure coupling is secure and
non-elastic.
7Open circuit T26. Motor runs at full
speed.
8Incorrect feedback scaling causes
overspeeding. Calculate the desired
maximum tacho Volts - adjust S1, S2.
9Tacho failure. Until a replacement
is obtained, change to ARMATURE
VOLTAGE feedback, S4. Rescale with
S1, S2.
10 Armature resistance should normally
be a few Ohms. The armature time
must be isolated from earth and the
eldcoil.
11 Shorted turn on motor armature can
cause power device failure. Check
resistance through 360º rotation.
12 Brushes should be in good condition,
correctly seated, and free to move in
brush boxes.
13 Field resistance should normally be a
fewhundredOhms.Theeldmustbe
isolated from earth and the armature.
14 Donotopencircuiteld.Donot
open circuit armature unless RUN is
openedrst.
15 The AC supply must lie within the
limitsspeciedonpage14.Ensure
the selection jumper is correct.
55 Trouble shootingTrouble shooting
The drive consists of two highly accurate feedback control loops.
NOTE:TheunithasaninternaleldHRC(HighRupturingCapacity)fusethatprotects
theeldoutputandPSUtransformer.Failureofthisfusewilldisablethedrive.
Part number CH0036A3.
• Terminals T2 to T14 are non-isolated.
• Control terminals T16 to T32 are isolated
• T22 can link to any one signal pad.
• The signal pads are isolated.

14 Specications
Function Specication Comments
CONTROL ACTION DUAL LOOP PROPORTIONAL + INTEGRAL
FEEDBACK METHOD ARMATURE VOLTS TACHOMETER SWITCH SELECTABLE
0-100% REGULATION 2% TYPICAL 0.1% TYPICAL
BEWARE MOTOR HEAT
AT LOW SPEED
MAX TORQUE SPEED RANGE 20 : 1 100 : 1
OVERLOAD 150% CONTINUOUS CURRENT FOR 30 SECONDS
Customer Presets
MAX SPEED 12 - 200 V FULL SCALE FEEDBACK SWITCH SELECTABLE
MIN SPEED 0-30% OF MAX SPEED NON-INTERACTIVE
UP/DOWN RAMPS INDEPENDENTLY ADJUSTABLE 1-30 SECONDS LINEAR RAMPS
STABILITY VARIES SPEED LOOP GAIN
IR COMPENSATION 0-30% OF ARMATURE VOLTAGE DO NOT USE WITH TACHO
MAX CURRENT LINEAR SETTING FROM 0-100% 150% OVERLOAD
Switch Selectable
SPEED RANGE FOUR RANGES OF FEEDBACK VOLTAGE S1, S2
TORQUE MODE 0-10 V INPUT FOR 0-100% CURRENT, WITH AUTOMATIC
OVERSPEED PROTECTION S3
TACHO/AVF SELECT TACHO OR ARMATURE VOLTAGE FEEDBACK S4
Jumper Functions
SUPPLY SELECT DUAL SUPPLY VOLTAGE SELECTOR JUMPER SELECTABLE
Link Functions
4-20 mA ALLOWS 4-20 mA LOOP SIGNAL INPUT 5 V COMPLIANCE
50% STALL LEVEL (STH link) ALLOWS LARGE PEAK CURRENTS 150% PEAK
SUPPLY RANGES LV30 LV60 110 240
OVER FULL TEMP RANGE WITH
OUTPUTS LOADED
45 Hz to 65 Hz MAX 36 V 72 V 130 V 264 V
AUTO RANGING MIN 27 V 54 V 100 V 200 V
SIGNAL OUTPUTS SPEED, CURRENT, RAMP ALL BUFFERED
RELAY OUTPUTS STALL, ZERO SPEED RELAY DRIVERS FOR 24 Vdc
RAIL OUTPUTS -24 V UNREGULATED 25 mA +/- 20%
+12 V, +10 V, -12 V REGULATED 10 mA 0.01%/DEG C 5%
FIELD OUTPUT 0.9 (0.45) x AC SUPPLY. 0.5 A MAXIMUM. FULL (0.9) OR HALF WAVE
(0.45)
IP RATING IP00
ALTITUDE 3000 METRES MAXIMUM FOR FULL RATING DE-RATE 1%/100 m
HUMIDITY 85% R.H AT 40ºC, NON-CONDENSING
FORM FACTOR TYPICAL 1.5 AT MAXIMUM OUTPUT
TEMPERATURE STORAGE AND OPERATING -10 TO + 50ºC AMBIENT
MAX I2t FOR EXTERNAL
FUSING (Amps2Seconds) 50 I2tREFER TO SUPPLIER FOR SEMI-
CONDUCTOR FUSES
66 SpecicationsSpecications

©2021, Sprint Electric. All rights reserved.
We accept no liability whatsoever for the installation,
fi tness for purpose or application of this product.
It is the user’s responsibility to ensure the unit is
correctly used and installed.
This leafl et is protected by copyright. No part of it may
be stored or reproduced in any form without written
permission from Sprint Electric.
The information in this publication was correct at the
time of going to print.
We reserve the right to modify or improve the product
without notifi cation.
The contents of this manual shall not become part of
or modify any prior existing agreement, commitment,
or relationship. The sales contract contains the entire
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 instructions, unauthorised alteration or
repair of hardware, unauthorised or accidental alteration
of software or confi guration, lost profi ts, commercial
loss, economic loss, or loss arising from personal injury.
We may, at our discretion, raise a charge for any faults
repaired that fall outside the warranty cover.
Sprint Electric Limited, Peregrine House, Ford Lane, Ford, Arundel BN18 0DF, U.K.
Tel: [phone] Fax:[phone] Email: [email protected]
www.sprint-electric.com
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.