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Rockwell Automation Reliance SP500, Installation And Operation Manual

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Rockwell Automation Reliance SP500 Installation And Operation Manual Download Page 2

©1999 Rockwell International Corporation

The information in this manual is subject to change without notice.

Throughout this manual, the following notes are used to alert you to safety considerations:

Important: Identifies information that is critical for successful application and understanding of the product.

The thick black bar shown on the outside margin of this page will be used throughout this instruction manual to 
signify new or revised text or figures.

!

ATTENTION: Identifies information about practices or circumstances that can lead to personal 
injury or death, property damage, or economic loss.

Reliance, ReSource, and AutoMax are trademarks of Rockwell Automation.

!

ATTENTION: Only qualified electrical personnel familiar with the construction and operation of 
this equipment and the hazards involved should install, adjust, operate, and/or service this 
equipment. Read and understand this manual in its entirety before proceeding. 

Summary of Contents for Reliance SP500

Page 1: ...Instruction Manual SP500 AC Drive Installation and Operation Manual Version 3 1 D2 3356 5 ...

Page 2: ... page will be used throughout this instruction manual to signify new or revised text or figures ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Reliance ReSource and AutoMax are trademarks of Rockwell Automation ATTENTION Only qualified electrical personnel familiar with the construction and operation of t...

Page 3: ...Power Loss Rating 3 4 3 2 Wiring Requirements 3 4 3 2 1 Verifying Conduit Sizes 3 4 3 2 2 Recommended Power Wire Sizes 3 4 3 2 3 Recommended Control and Signal Wire Sizes 3 6 3 2 4 Recommended Motor Lead Lengths 3 6 3 3 Selecting Input AC Line Branch Circuit Fuses 3 8 3 4 Installing an Emergency Stop 3 9 3 4 1 Complying with Machinery Safety Standard EN 60204 1 1992 3 9 3 5 Motor Considerations 3 ...

Page 4: ...nt Selected Speed Reference 7 6 7 5 2 Scaling the RPM Display and Reference Using F 08 7 6 7 6 Drive Control 7 6 7 6 1 Changing the Reference Using the Keypad 7 7 Chapter 8 Programming Reference 8 1 Displaying or Changing Parameter Values 8 1 8 2 Ensuring Program Security 8 3 8 3 Parameter Descriptions 8 5 Chapter 9 Troubleshooting Reference 9 1 Verifying DC Bus Voltage 9 1 9 2 Troubleshooting the...

Page 5: ...5 2 Figure 5 2 Typical Control Terminal Strip Connections 5 3 Figure 5 3 Analog Speed Reference Wiring Connections 5 4 Figure 5 4 Analog Output Wiring Connections 5 4 Figure 5 5 Two Wire Start Stop Sample Control Wiring 5 5 Figure 5 6 Three Wire Start Stop Sample Control Wiring 5 5 Figure 5 7 Multi Speed Preset Sample Control Wiring 5 6 Figure 5 8 Terminal Usage During Multi Speed Preset Operation...

Page 6: ...IV SP500 AC Drive Installation and Operation Manual Version 3 1 ...

Page 7: ...x020 Drives 3 5 Table 3 5 Recommended Power Terminal Tightening Torque 3 5 Table 3 6 Recommended Control and Signal Wire Sizes and Tightening Torque 3 6 Table 3 7 Motor Lead Lengths 3 7 Table 3 8 Reactors 3 7 Table 3 9 AC Input Line Fuse Selection Values 3 8 Table 7 1 Key Descriptions 7 2 Table 7 2 Drive Status LED Descriptions 7 3 Table 7 3 Monitor Mode LED Descriptions 7 3 Table 8 1 Multi Speed ...

Page 8: ...VI SP500 AC Drive Installation and Operation Manual Version 3 1 ...

Page 9: ...er and control signal terminal strip using the instructions in chapter 5 Adjust parameter values if required The parameters are described in chapter 8 For quick reference the factory set values are listed in Appendix B Perform the power off and power on checks described in chapter 6 to complete the installation If problems occur during drive operation refer to chapter 9 Appendix F lists the parts ...

Page 10: ...1 2 SP500 AC Drive Installation and Operation Manual Version 3 1 ...

Page 11: ...oint adjustment Motor RPM load or output voltage display Drive diagnostics 500 millisecond power dip ride through 150 overload for one minute nominal 0 5 to 240 Hz three phase voltage output NEMA 1 and NEMA 4 12 enclosures A snubber resistor braking signal and a scaled voltage analog output 0 to 10 VDC which is proportional to Output frequency Output amps Output voltage Selected reference Quiet mo...

Page 12: ...e A high carrier frequency selection reduces acoustic noise but results in a derating of the drive s efficiency The volts per hertz V Hz regulator governs the open loop operation of the drive for adjustable speed performance of AC induction and synchronous motors The regulator maintains a ratio of voltage to output frequency that provides constant or variable torque across a wide speed range Drive...

Page 13: ...Learning About the SP500 Drive 2 3 Figure 2 1 SP500 System Diagram ...

Page 14: ...2 4 SP500 AC Drive Installation and Operation Manual Version 3 1 Figure 2 2 SP500 System Diagram Continued ...

Page 15: ...Learning About the SP500 Drive 2 5 Figure 2 3 Regulator Board Component Locations ...

Page 16: ...rating See section 2 3 1 for more information on the drive power ratings See section 2 3 2 for more information on the drive enclosure ratings All SP500 drives described in this instruction manual function in the same manner To identify the mechanical differences between certain models the manual uses the notation in table 2 1 Figure 2 4 Identifying the Drive Model Number Table 2 1 SP500 Model Num...

Page 17: ...9 4 0 7 5 120 1SU21003 Three Phase 3 HP 1 C 200 230 12 5 5 0 10 6 210 1SU24003 Three Phase 3 HP 4X 12 C 200 230 12 5 5 0 10 6 210 1SU21005 Three Phase 5 HP 1 C 200 230 17 2 6 9 14 2 250 1SU24005 Three Phase 5 HP 4X 12 C 200 230 17 2 6 9 14 2 250 1SU41001 Three Phase 1 HP 1 B 380 460 2 5 2 0 2 1 60 1SU44001 Three Phase 1 HP 4X 12 B 380 460 2 5 2 0 2 1 60 1SU41002 Three Phase 2 HP 1 B 380 460 4 2 3 ...

Page 18: ... 8 show the main components of the SP500 drives enclosures A through D Appendix F lists replacement parts Model Number Input Power and Horsepower Rating NEMA Rating Enclosure Size AC Input Volts Input Amps Input KVA Output Amps Power Loss Watts 1SU51002 Three Phase 2 HP 1 B 575 3 4 3 3 2 7 90 1SU54002 Three Phase 2 HP 4X 12 B 575 3 4 3 3 2 7 90 1SU51003 Three Phase 3 HP 1 B 575 5 2 5 1 4 3 120 1SU...

Page 19: ...g About the SP500 Drive 2 9 Figure 2 5 Enclosure A Component Locations CONTROL STRIP REGULATOR PCB MEMBRANE SWITCH BRACKET ASSEMBLY INTERNAL FAN ASSEMBLY POWER TERMINAL STRIP POWER PCB GND CONNECTION TERMINAL ...

Page 20: ...d Operation Manual Version 3 1 Figure 2 6 Enclosure B Component Locations CONTROL TERMINAL STRIP REGULATOR PCB MEMBRANE SWITCH BRACKET ASSEMBLY INTERNAL FAN ASSEMBLY CAPACITOR PCB 3 5 HP ONLY POWER TERMINAL STRIP POWER PCB GND CONNECTION ...

Page 21: ...INAL STRIP REGULATOR PCB MEMBRANE SWITCH BRACKET ASSEMBLY INTERNAL FAN ASSEMBLY CAPACITOR PCB GND CONNECTIONS POWER PCB POWER TERMINAL STRIP REGULATOR PCB MEMBRANE SWITCH BRACKET ASSEMBLY INTERNAL FAN ASSEMBLY CONTROL TERMINAL STRIP CAPACITOR PCB POWER TERMINAL POWER PCB GND CONNECTIONS STRIP ...

Page 22: ...2 12 SP500 AC Drive Installation and Operation Manual Version 3 1 Figure 2 8 Enclosure D Component Locations ...

Page 23: ... 5 2 4 for more information Table 2 3 SP500 Option Kits Option Kit Description Option Kit Model Number Instruction Manual Low Energy Snubber Resistor Braking Kit for M N 1SU2xxxx Drives 2DB2005 D2 3178 Low Energy Snubber Resistor Braking Kit for M N 1SU4xxxx Drives 2DB4010 D2 3179 Low Energy Snubber Resistor Braking Kit for M N 1SU4x015 and 1SU4x020 Drives 2SR40700 2SR41800 D2 3291 Low Energy Snub...

Page 24: ...2 14 SP500 AC Drive Installation and Operation Manual Version 3 1 ...

Page 25: ...ers 3300 feet derate the output current by 1 Verify that the drive location will meet the following environmental conditions Operating temperature ambient 0 to 40 C 32 to 104 F Storage temperature ambient 40 to 65 C 40 to 149 F Humidity 5 to 95 non condensing Verify that NEMA 1 drives can be kept clean cool and dry Be sure NEMA 1 drives are located away from oil coolants or other airborne contamin...

Page 26: ...n Figures 3 1 to 3 4 provide drive dimensions for enclosures A through D as an aid in calculating the total area required by the SP500 drives Appendix A lists drive weights Figure 3 1 Enclosure A Dimensions Figure 3 2 Enclosure B Dimensions 263 5 mm 10 37 304 8 mm 12 00 73 0 mm 2 88 20 7 mm 0 81 121 9 mm 4 8 146 0 mm 5 57 ...

Page 27: ...SP500 System Planning 3 3 Figure 3 3 Enclosure C Dimensions Figure 3 4 Enclosure D Dimensions ...

Page 28: ...s It is important to determine the size of the conduit openings accurately so that the wire planned for a specific entry point will fit through the opening Figures 4 1 through 4 4 show conduit opening sizes 3 2 2 Recommended Power Wire Sizes Size input power wiring according to applicable codes to handle the drive s continuous rated input current Size output wiring according to applicable codes to...

Page 29: ...es for M N 1SU4xxxx and 1SU5xxxx Drives Type of Wiring Terminals Size of Wire maximum AC Input Power R L1 S L2 T L3 14 AWG 2 mm2 Output Power U T1 V T2 W T3 14 AWG 2 mm2 DC Bus 14 AWG 2 mm2 Snubber Resistor 10 VDC 10 COM 14 AWG 2 mm2 Ground GND 14 AWG 2 mm2 Table 3 4 Recommended Power Wire Sizes for M N 1SU4x015 and 1SU4x020 Drives Type of Wiring Terminals Size of Wire maximum AC Input Power R L1 ...

Page 30: ... Note that these capacitively coupled currents should be taken into consideration when working in areas where drives are running If the motor lead length must exceed these limits the addition of output line reactors or other steps must be taken to correct the problem See tables 3 7 and 3 8 Note that the motor lead lengths shown in table 3 7 are maximum distances Your application may be restricted ...

Page 31: ...kHz 8 kHz 4 kHz 6 kHz 8 kHz 1 None 500 500 500 250 250 250 150 150 150 2 500 500 500 350 350 350 250 200 200 3 1000 1000 1000 400 400 400 250 200 200 5 1000 1000 1000 500 500 500 250 200 200 7 5 to 10 N A N A N A 500 500 500 250 250 250 15 to 20 N A N A N A 500 500 500 N A N A N A 1 A 5 MTE reactor filter at the drive A reactor filter is not required Above lead lengths are maximum distances 500 50...

Page 32: ...nch circuit protection be provided to protect input power wiring Install the fuses recommended in table 3 9 Do not exceed the fuse ratings Table 3 9 AC Input Line Fuse Selection Values Model Number Fuse Rating Model Number Fuse Rating Model Number Fuse Rating 1SU11001 20A 1SU41001 6A 1SU51001 4A 1SU14001 12A 1SU44001 6A 1SU54001 4A 1SU41002 8A 1SU51002 7A 1SU21001 10A 1SU44002 8A 1SU54002 7A 1SU24...

Page 33: ...of the associated machinery In order to fully comply with machinery safety standard EN 60204 1 1992 part 9 2 5 4 at least one of the two stop methods must be a category 0 stop Refer to Appendix D for more information 3 5 Motor Considerations To obtain motor nameplate horsepower the drive s output current rating at the selected carrier frequency should be equal to or greater than motor nameplate cu...

Page 34: ... or less than the maximum sine wave output current at the selected carrier frequency for the drive When one or more of the motors connected to the output of the drive are to start independently using a secondary switching device to add or remove the motor from the circuit Any motor that starts or stops while the drive is running must have a current rating less than 10 of the maximum sine wave curr...

Page 35: ...d international codes e g NEC CEC Signal wiring control wiring and power wiring must be routed in separate conduits to prevent interference with drive operation Do not route wires behind the drive Use grommets when hubs are not provided to guard against wire chafing Figures 4 1 through 4 4 show the wire routing grounding terminal and power terminal strips of the SP500 drives Do not route more than...

Page 36: ...4 2 SP500 AC Drive Installation and Operation Manual Version 3 1 Figure 4 1 Enclosure A Wire Routing Locations ...

Page 37: ...Installing the Drive 4 3 Figure 4 2 Enclosure B Wire Routing Locations ...

Page 38: ...4 4 SP500 AC Drive Installation and Operation Manual Version 3 1 Figure 4 3 Enclosure C Wire Routing Locations ...

Page 39: ...Installing the Drive 4 5 Figure 4 4 Enclosure D Wire Routing Locations ...

Page 40: ...ne before the drive s AC input terminals Table 3 9 provides fuse values 4 3 3 Transformers Input isolation transformers may be needed to help eliminate the following Damaging line voltage transients Line noise from the drive back to the incoming power source Damaging currents that could develop if a point inside the drive becomes grounded Observe the following guidelines when installing an isolati...

Page 41: ... the electronic thermal motor overload relays in single motor applications Note however that temperature sensing devices integral to the motor are the best way of thermally protecting AC motors under all conditions Parameter F 14 must be enabled to provide overload protection Refer to section 8 3 for the parameter description In multiple motor applications each motor must have its own user supplie...

Page 42: ...cally detect it Verify that parameters F 11 gain and F 12 offset are set correctly before starting the drive 4 5 Preparing the Motor Follow these guidelines when preparing to install the motor Verify that the motor is the appropriate size to use with the drive Verify that the total motor lead length does not exceed the values given in section 3 2 4 Follow the instructions in the motor instruction ...

Page 43: ...hat the motor is properly aligned with the application s machine to minimize unnecessary motor loading due to shaft misalignment If the motor is accessible when it is running install a protective guard around all exposed rotating parts ...

Page 44: ...4 10 SP500 AC Drive Installation and Operation Manual Version 3 1 ...

Page 45: ...ge and frequency Step 2 Wire the AC input power leads by routing them according to the type of enclosure See figures 4 1 through 4 4 See tables 3 2 through 3 4 for recommended wire sizes Step 3 Connect the AC input power leads to terminals R S T on the power terminal strip See figure 5 1 Step 4 Tighten terminals R and S single phase input or terminals R S T three phase input to the proper torque a...

Page 46: ...l Version 3 1 Figure 5 1 Typical Electrical Connections User Supplied GND U U U U U U User Supplied M U T1 V T2 W T3 R L1 S L2 T L3 SP500 AC Input Voltage GND GND Motor Overload Relay Optional if Electronic Overload is Used Manual Disconnect Fuse Drive ...

Page 47: ...Regulator board s terminal strip See figure 5 3 This reference signal is jumper selectable for either a 0 to 10 VDC or 0 to 20 mA input The setting of jumper J6 on the Regulator board determines whether the input reference is a voltage or current signal This reference signal can be provided by either a user supplied 5K ohm potentiometer or an external 0 10 VDC 0 20 mA supply See section 4 4 for mo...

Page 48: ...t Wiring Digital input wiring connects to terminals 6 through 11 on the Regulator board s terminal strip The drive has a 24 VDC power supply that provides the required voltage for control signals Enabling or disabling a control signal requires that a contact switch be opened or closed Important The 24 VDC power supply is unregulated and will nominally supply 24 VDC It is not to be used with any ex...

Page 49: ...set applications which are discussed in the following section Figure 5 5 Two Wire Start Stop Sample Control Wiring Figure 5 6 Three Wire Start Stop Sample Control Wiring Start Stop IET Reset Fwd Rev Function Loss Customer Interlock Stop Start IET Reset Forward Reverse Function Loss 24 VDC Common Stop IET Reset Fwd Rev Function Loss Customer Interlock Start Stop Start IET Reset Forward Reverse Func...

Page 50: ...tart stop wiring See figure 5 8 When you enable multi speed preset operation the state of terminals 7 and 8 determine the source of the speed reference Terminal 7 Terminal 8 Speed Reference Source 0 0 Terminal Strip Analog Input 0 1 Multi Speed Preset 1 Parameter F 23 1 0 Multi Speed Preset 2 Parameter F 24 1 1 Multi Speed Preset 3 Parameter F 25 Figure 5 7 Multi Speed Preset Sample Control Wiring...

Page 51: ...factory installed jumper connects terminals 10 and 11 which provides that signal Remove this jumper if a function loss input a coast stop pushbutton or another external interlock for example a motor thermostat is used Removing the jumper allows the drive to stop when the contact is open Figure 5 8 Terminal Usage During Multi Speed Preset Operation ATTENTION The user must provide an external hardwi...

Page 52: ...the Regulator board s terminal strip See figures 5 9 and 5 10 Drive Model Number Snubber Resistor Terminals Control Terminal Strip Connections Power Terminal Strip Connections 1SU2xxxx 1 2 147 45 12 13 N A N A DC Bus DC Bus 1SU4xxxx 1SU5xxxx 1 2 147 45 13 14 12 13 N A N A N A DC Bus DC Bus 10V 10 COM 1SU4x015 1SU4x020 Refer to instruction manual D2 3291 ...

Page 53: ...olts 1 2 147 45 SP500 Drive 12 13 DC Bus Volts Regulator Board Control Terminal Strip Power Terminal Strip 24 VDC Common Braking Signal Snubber Resistor Snubber Resistor Snubber Resistor Braking Signal 1 DC Bus Volts 1 2 147 45 10V 10V Com 10V Supply 1 13 14 SP500 Drive 1 These connections are not used with M N 2SRxxxx Snubber Resistor kits Note The 10V and 10V Com terminals on the power terminal ...

Page 54: ...uce the effectiveness of noise reduction methods If more than three drive motor connections per conduit are required you must use shielded cable If possible each conduit should contain only one set of motor leads Step 2 Connect the AC output power motor leads to terminals U V and W on the power terminal strip See figure 5 1 Step 3 Tighten terminals U V and W to the proper torque as shown in table ...

Page 55: ...d then to earth ground See figures 4 1 through 4 4 and 5 1 Step 3 Connect a suitable grounding connector to the motor frame and transformer if used Run each conductor unbroken to earth ground When adding more than one grounding conductor wire to a single chassis ground twist the conductors together Step 4 Reattach the drive s cover ATTENTION The user is responsible for conforming with all applicab...

Page 56: ...5 12 SP500 AC Drive Installation and Operation Manual Version 3 1 ...

Page 57: ...und the drive Step 7 Check that there is adequate clearance around the drive Step 8 Verify that the wiring to the control terminal strip and power terminals is correct Refer to chapter 5 ATTENTION Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install adjust operate and or service this equipment Read and understand...

Page 58: ...tion Use the following procedure to check the operation of the drive Step 1 Turn off lock out and tag power to the drive Wait five minutes Step 2 Remove the cover and check the DC bus potential with a voltmeter as described in section 9 1 Verify that the DC bus capacitors are discharged Replace the cover Step 3 Uncouple the driven equipment from the motor if possible Step 4 Apply power to the driv...

Page 59: ...actorily check the parameter settings Refer to chapter 8 Step 9 Press the STOP RESET key to stop the drive Step 10 Turn off lock out and tag power to the drive Wait five minutes Remove the cover and check the DC bus potential with a voltmeter as described in section 9 1 Verify that the DC bus capacitors are discharged Replace the cover Step 11 Couple the driven equipment to the motor Step 12 Turn ...

Page 60: ...6 4 SP500 AC Drive Installation and Operation Manual Version 3 1 ...

Page 61: ...rive select motor direction and adjust speed Regardless of the control source selected you can use the keypad to stop the drive and reset drive faults The following sections describe the keypad the display and the LEDs Monitor mode and program mode are described in more detail later in this chapter 7 1 Display Description The display is a four character seven segment LED At drive power up SELF is ...

Page 62: ...eter value in program mode Save a parameter value in program mode The MODE ENTER key provides these functions regardless of the control source selected local or remote Use the FORWARD REVERSE key to select the direction of motor shaft rotation when the control source is local F 00 0 Use the START key to apply power to the motor when the control source is local F 00 0 When this key is pressed and t...

Page 63: ...re in program mode The keypad and display are in monitor mode On Off The requested motor rotation direction is forward The requested motor rotation direction is not forward On Off The requested motor rotation direction is reverse The requested motor rotation direction is not reverse On Off The drive is being controlled from the terminal strip The drive is being controlled from the keypad Table 7 3...

Page 64: ...OP RESET key Step 2 Press the MODE ENTER key until the PROGRAM LED turns on Parameter F 00 will be displayed Use the key or key to scroll through the parameter list The error log follows parameter F 49 and precedes parameter F 00 as shown in figure 7 2 To exit program mode Step 1 Press the MODE ENTER key until a parameter number or ERR is displayed Step 2 Press the STOP RESET key until the PROGRAM...

Page 65: ...d Volts Percent Selected Speed Reference if F 13 ON To select a value to monitor press the MODE ENTER key until the LED turns on next to the desired display item Pressing the MODE ENTER key will advance you through each of the displays Note that all the LEDs will turn on to indicate the percent selected speed reference display if parameter F 13 is set to ON Refer to section 7 5 2 Figure 7 3 Exampl...

Page 66: ...y to save the value F 13 will be displayed Step 7 Press the STOP REST key to exit program mode Step 8 Start the drive by pressing the START key Step 9 Press the MODE ENTER key until all three monitor mode LEDs are on The display will show the active speed reference as 1 to 100 of maximum speed F 04 7 5 2 Scaling the RPM Display and Reference Using F 08 The RPM display and reference can be scaled t...

Page 67: ...erence Using the Keypad The speed reference can be increased or decreased using the or key when F 00 0 or 2 The display will show the internal speed reference in hertz Hz while the keys are pressed There will be a slight delay before the display returns to the active monitor mode Note that changing the drive s internal speed reference using the or key when the drive is under remote control will ha...

Page 68: ...7 8 SP500 AC Drive Installation and Operation Manual Version 3 1 ...

Page 69: ...ameter Values Use the following procedure to display or change parameter values Step 1 Stop the drive if it is running by pressing the STOP RESET key Step 2 Enter program mode by pressing the MODE ENTER key until the PROGRAM LED turns on The first parameter number F 00 will be displayed Step 3 Press the or key until the desired parameter number is displayed Each parameter number will be displayed ...

Page 70: ...rameter value Step 5 Press the or key to change the value Note that if programming has been disabled in parameter F 20 Password Lockout Enable the value will not change Refer to section 8 2 Ensuring Program Security for more information Step 6 Press the MODE ENTER key to save the changed value The parameter number is displayed again Mode Enter START Forward Reverse STOP RESET RPM Load Volts Remote...

Page 71: ... determine how to distribute the password Reliance Electric is not responsible for unauthorized access violations within the user s organization Step 1 In program mode press the or key until F 20 is displayed Step 2 Press the MODE ENTER key to access the parameter ON or OFF is displayed to indicate whether the password lockout feature is currently enabled or disabled Program Enabled Program Disabl...

Page 72: ...ep 4 Press the MODE ENTER key to save the password number ON or OFF is displayed to indicate the current state of the password lockout Step 5 Press the MODE ENTER key to exit the parameter The parameter number is displayed again Mode Enter START Forward Reverse STOP RESET RPM Load Volts Remote RUN Program Forward Reverse Mode Enter START Forward Reverse STOP RESET RPM Load Volts Remote RUN Program...

Page 73: ...ast an overcurrent fault may occur OC will be displayed F 00 Control Source Select This parameter selects the drive control source and speed reference source Parameter Range Default Setting Step Size 0 Local control control signals and speed reference from the keypad 1 Remote control control signals from the terminal strip speed reference from the analog input 2 Remote control control signals from...

Page 74: ...The SP500 drive is intended to operate the motor at a predetermined minimum speed unless disconnected from the power source The user is responsible for assuring safe conditions for operating personnel by providing suitable guards audible or visual alarms or other devices to indicate that the driveis operating at minimum speed possibly zero speed or the user must verify that the motor output shaft ...

Page 75: ...lly increase the value until motor operation is satisfactory If torque boost is set too high relative to the load and acceleration rate an overcurrent fault may occur OC will be displayed F 05 Current Limit This parameter limits motor output torque while it is running or accelerating Parameter Range Default Setting Step Size 10 to 150 of rated drive current 150 1 0 F 06 Manual Torque Boost This pa...

Page 76: ...x im u m V Hz V H z F 08 RPM at Base Speed This parameter scales the RPM display and the setpoint to a user specified engineering unit Parameter Range Default Setting Step Size 10 to 9999 1750 1 0 unit Display Scaling Examples Example 1 Assume that an application requires the display show 1750 RPM when the drive is running at a base speed of 60 Hz The RPM display is scaled according to the followi...

Page 77: ...gs at the various carrier frequencies Normally the maximum speed reference the amount of reference at maximum speed F 04 is either 10 VDC or 20 mA The reference gain is used to scale the speed reference to another value for example 9 5 VDC or 19 mA Enter the parameter value in percent of full scale reference F 09 Configurable Output Relay Select This parameter specifies the type of status indicati...

Page 78: ... reference required is 9 5 VDC scale as follows Desired Maximum Reference mA Reference Range 20 x 100 gain mA reference 19 2 20 x 100 96 gain Desired Maximum Reference VDC Reference Range 10 x 100 gain VDC reference 9 5 10 x 100 95 gain F 12 Remote Reference Offset This parameter scales the remote speed reference 0 to 10VDC or 0 to 20 mA to a minimum value Parameter Range Default Setting Step Size...

Page 79: ...cent Selected Speed Reference Display Enable This parameter enables or disables the fourth monitor mode display Parameter Range Default Setting Step Size ON Fourth monitor mode display is enabled OFF Fourth monitor mode display is disabled OFF N A F 14 Electronic Thermal Overload This parameter sets the trip level for the electronic thermal overload fault OL when F 15 ON Parameter Range Default Se...

Page 80: ... to rest stop If F 17 OFF the forward reverse input allows forward or reverse rotation of the motor If F 17 ON reverse rotation of the motor is prohibited When F 17 ON pressing the FORWARD REVERSE key on the keypad in local control or wiring to terminal 9 on the terminal strip in remote control does not affect drive operation F 16 Coast Stop Enable This parameter selects how the motor will stop wh...

Page 81: ...in hertz ON Setpoint is displayed in the units specified in F 08 ON N A Example Assume a drive is currently running at 60 Hz 1750 RPM F 08 1750 and F 10 ON When the key is pressed 1750 is displayed When the key is pressed three more times the display will change from 1750 to 1749 to 1748 to 1747 The reference is then rescaled based on this input Input Reference Reference 1747 F 08 1750 x F 04 60 H...

Page 82: ... at any of the avoidance band frequencies Setting F 22 to 0 disables the avoidance frequency F 20 Password Lockout Enable This parameter enables or disables parameter password protection Parameter Range Default Setting Step Size OFF Password lockout disabled parameters can be modified ON Password lockout enabled parameters cannot be modified OFF N A ATTENTION It is the user s responsibility to det...

Page 83: ...4 Hz Avoidance Band 30 2 to 34 2 Hz Requested Output Frequency Output Frequency After Avoidance Band Correction 25 0 Hz 25 0 Hz 30 0 Hz 30 0 Hz 31 0 Hz 30 2 Hz 32 0 Hz 30 2 Hz 34 0 Hz 30 2 Hz 34 2 Hz 30 2 Hz 34 3 Hz 34 3 Hz 35 0 Hz 35 0 Hz F 23 F 24 and F 25 Multi Speed Presets 1 2 and 3 These parameters allow the setting of up to three different preset speeds Parameter Range Default Setting Step ...

Page 84: ...ut is asserted during the countdown the auto restart procedure is cancelled and the fault is latched If a fault occurs that is auto restartable and other faults are active that are not auto restartable the auto restart function will be disabled until all faults are cleared When F 26 0 the drive logs the first occurrence of a fault in the fault log Any subsequent occurrence of that fault while atte...

Page 85: ... Selection This parameter displays the drive s voltage rating Parameter Range Default Setting Step Size N A N A N A ATTENTION This parameter is set at the factory and must not be changed by the user F 29 Analog Output Select This parameter selects which monitor mode value is directed to the analog output regardless of which monitor mode value is displayed Parameter Range Default Setting Step Size ...

Page 86: ...8 18 SP500 AC Drive Installation and Operation Manual Version 3 1 ...

Page 87: ...SP500 drive s DC bus capacitors retain hazardous voltages after input power has been disconnected Perform the following steps before touching any internal components Step 1 Turn off lock out and tag input power to the drive Wait five minutes Step 2 Remove the drive s cover Step 3 Verify that there is no voltage at the drive s input power terminals Step 4 Measure the DC bus voltage at the DC bus po...

Page 88: ...SU4x015 1SU4x020 Figure 9 3 DC Bus Terminals on Model 1SU4x015 and 1SU4x020 Drives AC POWER INPUT LEADS DC BUS VOLTS SNUBBER RESISTOR BRAKING MOTOR LEADS T1 T2 T3 For single phase units connect AC input power to terminals R and S AC POWER INPUT LEADS DC BUS VOLTS SNUBBER RESISTOR BRAKING SNUBBER RESISTOR BRAKING 10V SUPPLY MOTOR LEADS MOTOR LEADS DC BUS VOLTS SNUBBER RESISTOR BRAKING AC POWER INPU...

Page 89: ...een asserted terminals 10 and 11 Possible Cause Corrective Action The external equipment connection to the function loss terminals has failed or is giving repeated stop requests Check the external equipment wired to the remote function loss terminals 10 and 11 Refer to chapter5 Check the function loss input connections The DC bus is charged above the electronic trip threshold Note that the fault w...

Page 90: ...t wiring are properly connected Refer to chapter 5 Verify that the output wiring to the motor is not connected to ground or any other voltage source Refer to chapter 5 Instantaneous overcurrent resulting in 200 rated drive current Increase the acceleration time in F 01 or the deceleration time in F 02 Refer to chapter 8 for parameter descriptions Adjust the current limit level in F 05 if it is too...

Page 91: ...eating due to excessive current within a specified period Note that the fault will not clear until the input line voltage is within the proper range This may take a few seconds Possible Cause Corrective Action The current limit setting in F 05 is incorrect If the current limit level is too low relative to the load increase the current level in F 05 Refer to chapter 8 for the parameter description ...

Page 92: ...ay Step 3 Press the MODE ENTER key to access the error log Sample Display Step 4 Press the key to move through the error codes Sample Display Mode Enter START Forward Reverse STOP RESET RPM Load Volts Remote RUN Program Forward Reverse Mode Enter START Forward Reverse STOP RESET RPM Load Volts Remote RUN Program Forward Reverse Mode Enter START Forward Reverse STOP RESET RPM Load Volts Remote RUN ...

Page 93: ...tep 6 Check all AC line and DC bus fuses Step 7 If a fuse is open use a multimeter to check the input diodes and output IGBTs See tables 9 2 and 9 3 Step 8 Reconnect the motor to the drive Step 9 Reattach the drive s cover Step 10 Reapply input power Step 5 Press the STOP RESET key to clear the log The display will return to the active monitor display Mode Enter START Forward Reverse STOP RESET RP...

Page 94: ...nent is OK if resistance R is Component is defective if 1 R L1 50 R 10 Megohm Continuity short circuit or open when the meter is connected with reversed polarity 2 S L2 3 T L3 4 R L1 5 S L2 6 T L3 Table 9 3 Resistance Checks for IGBTs IGBT No Meter Connection Component is OK if resistance R is Component is defective if 1 W T3 50 R 10 Megohm Continuity short circuit or open when the meter is connec...

Page 95: ...ximum Load 150 for 1 minute nominal based on drive nameplate rating Motor Lead Lengths 76 meters 250feet total See table 3 7 for more information Overcurrent Trip IET 200 rated drive current Table A 2 Dimensions Enclosure Height Depth Width Weight A 304 8mm 12 00 121 9mm 4 80 146 0mm 5 75 2 7kg 6 lb B 301 7mm 11 88 160 1mm 6 30 222 3mm 8 75 5 4kg 12 lb C 357 8mm 14 10 158 2 mm 6 20 278 1mm 10 9 8 ...

Page 96: ...hen the drive is running When the contact is open the drive turns off The drive will remain off as long as the contact is open Table A 5 Drive Outputs Analog Output 0 10 VDC scaled signal The scaled signal is selected through parameter F 29 and can be one of the following Output Voltage 0 to 115 VAC M N 1SU1xxxx drives 0 to 253 VAC M N 1SU2xxxx drives 0 to 506 VAC M N 1SU4xxxx drives 0 to 632 VAC ...

Page 97: ... Carrier Frequency kHz 4 6 8 N A 4 F 11 Remote Reference Gain 60 100 0 10 100 F 12 Remote Reference Offset 0 40 0 10 0 F 13 Percent Selected Speed Reference Display Enable ON OFF N A OFF F 14 Electronic Thermal Overload 20 100 1 0 100 F 15 Electronic Thermal Overload Enable ON OFF N A ON F 16 Coast Stop Enable ON OFF N A ON F 17 Reverse Disable ON OFF N A OFF F 18 RPM Setpoint Enable ON OFF N A OF...

Page 98: ...Setting Setting Date F 26 Auto Restart Number of Attempts 0 10 0 disabled N A 0 F 27 Auto Restart Retry Wait Time seconds 1 30 1 0 1 F 28 Drive Voltage Selection This parameter is set at the factory Do not change the setting F 29 Analog Output Select SPd LOAd UOL rEF N A SPd F 49 Version Information x xx N A Read Only ...

Page 99: ...oast Stop Enable F 16 Configurable Output Relay Select F 09 Control Source Select F 00 Current Limit F 05 Deceleration Rate F 02 Drive Voltage Selection F 28 Electronic Thermal Overload F 14 Electronic Thermal Overload Enable F 15 Manual Torque Boost F 06 Maximum Speed F 04 Minimum Speed F 03 Multi Speed Preset 1 F 23 Multi Speed Preset 2 F 24 Multi Speed Preset 3 F 25 Password Lockout Enable F 20...

Page 100: ...e Installation and Operation Manual Version 3 1 Remote Reference Gain F 11 Remote Reference Offset F 12 Reverse Disable F 17 RPM at Base Speed F 08 RPM Setpoint Enable F 18 V Hz Base Speed F 07 Version Information F 49 ...

Page 101: ...rcuits 7 2 6 Transformers 7 5 Protection against supply interruption or voltage reduction and subsequent restoration 8 Equipotential bonding 8 2 1 General the PE terminal 8 2 2 Protective conductors connection points 8 2 3 Continuity of the protective bonding circuit 8 2 7 Protective conductor connecting points 8 3 Bonding of the protective bonding circuit for operational purposes 8 4 Insulation f...

Page 102: ...1 Separation between control and electric drives 11 5 Communications 12 Electronic equipment 12 2 2 Electronic control equipment 12 2 3 Equipotential bonding 12 3 Programmable equipment 12 3 1 Programmable controllers 12 3 2 Memory retention and protection 12 3 3 Programming equipment 12 3 4 Software verification 12 3 5 Use in safety related functions 13 Controlgear Location mounting and enclosure...

Page 103: ...ential commercial and light industrial EN50081 2 1992 Electromagnetic compatibility Generic emission standard Part 2 Industrial EN50082 1 1992 Electromagnetic compatibility Generic immunity standard Part 1 Residential commercial and light industrial EN50082 2 1995 Electromagnetic compatibility Generic immunity standard Part 2 Industrial Note that the conformity of the SP500 drive to the above stan...

Page 104: ...ains Filters Verify that you have the correct AC Mains Filter for your application Use the following guidelines to mount the SP500 drive to the AC Mains Filter and then mount the drive filter assembly to a panel Attach the SP500 drive to the AC Mains Filter See figure E 1 No other type of mounting is permitted The required mounting hardware is supplied with the filter Attach the SP500 drive AC Mai...

Page 105: ...ns SP500 Drive Mounts on T op of Mains Filter Screws Provided Flexible Conduit Provided G A D E F C B D E F T op View L1 L2 L3 E GND ACMains Filter AC Filter Mains Front View Filter Only Side View Filter and Drive See table E 2 for dimensions H G J K Conduit Entry M5Nuts Filter Only Cover Removed ...

Page 106: ...l Note that the filter s output leads are red yellow and blue This color coding is stenciled on the printed circuit board at the filter s input power terminals to help identify the filter s output wiring relative to the filter s input wiring When the drive is connected to single phase AC input power follow the color coding shown in figure E 2 and connect all three filter output leads to the drive ...

Page 107: ...t the filter ground wire green yellow to the drive ground Figure E 2 Typical SP500 Single Phase Connections Figure E 3 Typical SP500 Three Phase Connections R S T GND U V W GND SP500 L L L E GND REDYELLOW BLUE YELLOW AC MAINS FILTER GREEN A B 1 2 3 MOTOR FILTER S AC INPUT POWER DRIVE S AC INPUT POWER R S T GND U V W GND SP500 L L L E GND REDYELLOW BLUE YELLOW AC MAINS FILTER GREEN A B 1 2 3 MOTOR ...

Page 108: ...Connect AC input power to the filter by first removing the filter s cover and then connecting the AC input power leads to the terminals at the top of the filter See figure E 1 The AC input power leads should have lugs attached The filter has a conduit opening to secure the AC input power conduit E 3 4 Grounding the Drive Filter Assembly Connect the drive filter assembly to earth ground at the term...

Page 109: ... or equivalent Note that the use of flexible metal conduit open wire or wire in trays is not acceptable Many flexible metal conduit products have not been designed for RF containment and are not adequate to maintain compliance Proper glands must be used to terminate the operator s control station conduit cable at the station and the drive The gland must secure the cable screen to the conductive su...

Page 110: ...E 8 SP500 AC Drive Installation and Operation Manual Version 3 1 ...

Page 111: ...31 050 1 1 Fan Assembly Internal 615159 1R 1 1 Table F 2 Replacement Parts List for Model 1SU4xxxx Drives Part Number Quantity per Horsepower Description 1 HP 2 HP 3 HP 5 HP 7 5 HP 10 HP 15 HP 20 HP Fan Assembly 615161 S 1 1 2 2 2 2 NEMA 4X Cover Gasket 805512 1R 805522 1R 1 1 1 1 1 1 NEMA 1 Cover 805504 7R 805508 9R 805522 20R 1 1 1 1 1 1 1 1 NEMA 12 Cover 805512 20R 1 1 Membrane Switch Keypad Br...

Page 112: ...Description 1 HP 2 HP 3 HP 5 HP 7 5 HP 10 HP Fan Assembly 615161 S 1 1 2 2 NEMA 4X Cover Gasket 805512 1R 805522 1R 1 1 1 1 1 1 NEMA 1 Cover 805504 7R 805508 9R 1 1 1 1 1 1 Membrane Switch Keypad Bracket 709507 1R 709511 1R 1 1 1 1 1 1 Regulator PCB 56953 3xx 56954 3xx 1 1 1 1 1 1 Capacitor PCB 56922 055 56939 105 1 1 1 1 Fan Assembly Internal 615159 1R 1 1 1 ...

Page 113: ...requency range of the drive s output voltage This sets the speed of the motor Hz the abbreviation for hertz The number of cycles per second IET the abbreviation for instantaneous electronic trip A fault condition that occurs while the drive is running resulting in a motor coast to rest stop The drive senses a condition that could result in equipment damage and turns itself off input power factor t...

Page 114: ...e s total maximum output voltage while delivering rated current under full load conditions rated output frequency the fundamental output wave frequency rectifier a static power converter that changes AC power to DC power speed range the speed minimum and maximum at which a motor must operate under constant or variable torque load conditions stall a motor state in which the motor remains motionless...

Page 115: ... 8 12 Conduit size 4 2 to 4 5 Configurable Output Relay Select F 09 8 9 Control Source Select F 00 8 5 Control terminal strip 2 9 to 2 12 5 3 Control wiring 5 3 to 5 9 Current Limit F 05 8 7 D DC bus terminals 9 2 verifying capacitor voltage 9 1 to 9 2 Deceleration Time F 02 8 5 to 8 6 Digital input wiring Forward reverse 5 7 A 2 Function loss 5 7 A 2 IET reset 5 7 A 2 Multi speed Preset 5 6 to 5 ...

Page 116: ...2 F 1 to F 2 Minimum Speed F 03 8 6 Model numbers 2 6 to 2 8 Monitor mode 7 5 to 7 6 Motor motor lead lengths 3 6 to 3 7 A 1 multiple motor applications 3 10 overload protection mechanical 4 7 single motor applications 3 9 Mounting dimensions 3 2 to 3 3 A 1 Multi Speed Presets 1 2 3 F 23 F 24 F 25 8 15 Multi Speed presets digital inputs 5 6 to 5 7 N NEMA enclosures 2 8 O Option kits see Kits Outpu...

Page 117: ...splay and reference 7 6 Signal wiring 5 3 to 5 10 Site requirements 3 1 Snubber resistor braking 2 13 4 2 to 4 5 5 8 to 5 9 A 2 Specifications conduit opening sizes 4 2 to 4 5 environmental 3 1 A 1 dimensions 3 2 to 3 3 A 1 drive inputs A 2 drive outputs A 2 service conditions A 1 terminal torque ratings 3 5 wire sizes 3 4 to 3 5 Start digital input 5 5 to 5 7 Stop digital input 5 5 to 5 7 Stoppin...

Page 118: ...Index 4 SP500 AC Drive Installation and Operation Manual Version 3 1 ...

Page 119: ...r you have completed this form please return it to Reliance Electric Technical Documentation 24800 Tungsten Road Cleveland Ohio 44117 Fax 216 266 7785 Thank you for your comments Publication Name SP500 AC Drive Installation and Operation Manual V3 1 Publication Number D2 3356 5 Publication Date July 1999 Comments Your Name Date Company Name Phone Address Technical Writing Internal Use Date DIF Num...

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Page 122: ...Publication D2 3356 5 July 1999 1999 Rockwell International Corporation All rights reserved Printed in USA ...

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