Rockwell Automation Reliance SP500 User manual

Instruction Manual

SP500 AC Drive

Installation and Operation Manual

Version 3.1

D2-3356-5

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.

Contents

CONTENTS

Chapter 1 Introduction

1.1 Who Should Use This Manual.........................................................................1-1

1.2 Installation Overview .......................................................................................1-1

1.3 Requesting Assistance from Reliance Electric................................................1-1

Chapter 2 Learning About the SP500 Drive

2.1 Standard Features...........................................................................................2-1

2.2 Drive Description ............................................................................................. 2-2

2.3 Identifying the Drive by Model Number ...........................................................2-6

2.3.1 Power Ratings and NEMA Enclosure Ratings ......................................2-7

2.3.2 Enclosure Ratings and Sizes ................................................................2-8

2.4 Component Locations......................................................................................2-8

2.5 Option Kits.....................................................................................................2-13

Chapter 3 SP500 System Planning

3.1 Installation Site Requirements.........................................................................3-1

3.1.1 Determining the Total Area Required for Installation ............................3-2

3.1.2 Providing Proper Air Flow Clearances ..................................................3-4

3.1.3 Verifying the Drive’s 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 ......................................................................................3-9

3.5.1 Single-Motor Applications......................................................................3-9

3.5.2 Multiple-Motor Applications.................................................................3-10

Chapter 4 Installing the Drive

4.1 Mounting the Drive ..........................................................................................4-1

4.2 Routing Wires..................................................................................................4-1

4.3 Installing External Components.......................................................................4-6

4.3.1 Disconnects...........................................................................................4-6

4.3.2 Input AC Line Branch Protection...........................................................4-6

4.3.3 Transformers.........................................................................................4-6

4.3.4 Output Contactors.................................................................................4-7

4.3.5 Mechanical Motor Overload Protection.................................................4-7

4.4 Setting the Analog Input Jumper on the Regulator Board...............................4-7

4.5 Preparing the Motor.........................................................................................4-8

SP500 AC Drive Installation and Operation Manual Version 3.1

Chapter 5 Wiring the Drive

5.1 Input Power Wiring...........................................................................................5-1

5.2 Signal and Control Wiring ................................................................................5-3

5.2.1 Analog Speed Reference Wiring ...........................................................5-3

5.2.2 Analog Output Wiring.............................................................................5-4

5.2.3 Digital Input Wiring.................................................................................5-4

5.2.4 Snubber Resistor Wiring........................................................................5-8

5.2.5 Output Status Relay Wiring .................................................................5-10

5.3 Output Power Wiring......................................................................................5-10

5.4 Grounding ......................................................................................................5-11

Chapter 6 Completing the Installation

6.1 Checking the Installation With the Power Off...................................................6-1

6.2 Checking Drive Operation................................................................................6-2

Chapter 7 Keypad and Display Operation

7.1 Display Description ..........................................................................................7-1

7.2 Key Descriptions..............................................................................................7-2

7.3 LED Descriptions .............................................................................................7-3

7.4 Program Mode .................................................................................................7-4

7.5 Monitor Mode...................................................................................................7-5

7.5.1 Displaying the Percent 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 Drive Using Fault Codes .................................................9-3

9.3 Accessing and Clearing the Error Log .............................................................9-5

9.4 Checking the Drive’s Power Module Circuitry with the Power Off....................9-7

Appendix A Technical Specifications........................................................................................... A-1

Appendix B Record of User Settings........................................................................................... B-1

Appendix C Alphabetical Listing of Parameters...........................................................................C-1

Appendix D Compliance with Machinery Safety Standard EN-60204-1:1992.............................D-1

Appendix E Compliance with Electromagnetic Compatibility Standards..................................... E-1

Appendix F Replacement Parts................................................................................................... F-1

Glossary ..................................................................................................................... Glossary-1

Index ...........................................................................................................................Index-1

Contents

III

List of Figures

Figure 2.1 – SP500 System Diagram.......................................................................2-3

Figure 2.2 – SP500 System Diagram (Continued) ...................................................2-4

Figure 2.3 – Regulator Board Component Locations ...............................................2-5

Figure 2.4 – Identifying the Drive Model Number.....................................................2-6

Figure 2.5 – Enclosure A Component Locations......................................................2-9

Figure 2.6 – Enclosure B Component Locations....................................................2-10

Figure 2.7 – Enclosure C Component Locations....................................................2-11

Figure 2.8 – Enclosure D Component Locations....................................................2-12

Figure 3.1 – Enclosure A Dimensions ......................................................................3-2

Figure 3.2 – Enclosure B Dimensions ......................................................................3-2

Figure 3.3 – Enclosure C Dimensions......................................................................3-3

Figure 3.4 – Enclosure D Dimensions......................................................................3-3

Figure 3.5 – How to Measure Motor Lead Lengths ..................................................3-6

Figure 4.1 – Enclosure A Wire Routing Locations....................................................4-2

Figure 4.2 – Enclosure B Wire Routing Locations....................................................4-3

Figure 4.3 – Enclosure C Wire Routing Locations....................................................4-4

Figure 4.4 – Enclosure D Wire Routing Locations....................................................4-5

Figure 4.5 – Jumper J6 Settings for the Analog Input Speed Reference .................4-8

Figure 5.1 – Typical Electrical Connections..............................................................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........................5-7

Figure 5.9 – Snubber Resistor Wiring Connections for M/N 1SU2xxxx Drives ........5-9

Figure 5.10 – Snubber Resistor Wiring Connections for M/N 1SU4xxxx and

1SU5xxxx Drives................................................................................5-9

Figure 5.11 – Output Status Relay Wiring Connections.........................................5-10

Figure 7.1 – SP500 Keypad and Display..................................................................7-1

Figure 7.2 – SP500 Menu Structure.........................................................................7-4

Figure 7.3 – Example of a Program Mode Display..................................................7-5

Figure 7.4 – Example of a Monitor Mode Display.....................................................7-6

Figure 8.1 – Manual Torque Boost Adjustment Range.............................................8-7

Figure 8.2 – Volts/Hertz Curve .................................................................................8-8

Figure 9.1 – DC Bus Terminals on Model 1SU1xxxx and 1SU2xxxx Drives............9-2

Figure 9.2 – DC Bus Terminals on Model 1SU4xxxx and 1SU5xxxx Drives (except

1SU4x015, 1SU4x020).........................................................................9-2

Figure 9.3 – DC Bus Terminals on Model 1SU4x015 and 1SU4x020 Drives...........9-2

SP500 AC Drive Installation and Operation Manual Version 3.1

Contents

List of Tables

Table 2.1 – SP500 Model Number Notation.............................................................2-6

Table 2.2 – Power and NEMA Enclosure Ratings....................................................2-7

Table 2.3 – SP500 Option Kits ...............................................................................2-13

Table 3.1 – Air Flow Clearances...............................................................................3-4

Table 3.2 – Recommended Power Wire Sizes for M/N 1SU1xxxx and

1SU2xxxx Drives...................................................................................3-5

Table 3.3 – Recommended Power Wire Sizes for M/N 1SU4xxxx and

1SU5xxxx Drives...................................................................................3-5

Table 3.4 – Recommended Power Wire Sizes for M/N 1SU4x015 and

1SU4x020 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 Presets Digital Inputs.......................................................8-15

Table 8.2 – Auto-Restartable Faults.......................................................................8-16

Table 9.1 – Drive Faults and Corrective Actions ......................................................9-3

Table 9.2 – Resistance Checks for Input Diodes......................................................9-8

Table 9.3 – Resistance Checks for IGBTs................................................................9-8

SP500 AC Drive Installation and Operation Manual Version 3.1

Introduction

1-1

CHAPTER 1

Introduction

This chapter describes the manual’s intended audience and provides an overview of

the SP500 drive’s installation process.

1.1 Who Should Use This Manual

This manual is intended for qualified electrical personnel responsible for installing,

programming, starting up, and maintaining the SP500 drive.

1.2 Installation Overview

This manual describes how to install and troubleshoot the SP500 drive. Drive

installation consists of the following basic tasks:

•Plan your installation using the guidelines presented in chapter 3. If your installation

must be in compliance with Electromagnetic Compatibility Standards, read

Appendix E also.

•Mount the drive and install external components according to the guidelines

presented in chapter 4.

•Wire the drive’s input power, output power, 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

of the drive that can be replaced.

Before you begin the installation procedure, become familiar with the drive by reading

chapter 2, which provides an overview of the drive and its features, chapter 7, which

describes the operation of the keypad and the display, and Appendix A, which lists the

drive’s technical specifications.

1.3 Requesting Assistance from Reliance Electric

If you have any questions or problems with the products described in this instruction

manual, contact your local Reliance Electric sales office. For technical assistance, call

1-800-726-8112, Monday through Friday, 8:00 AM to 5:00 PM (EST).

1-2

SP500 AC Drive Installation and Operation Manual Version 3.1

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