Rockwell Automation Reliance SP500 Installation And Operation Manual
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Rockwell Automation Reliance SP500 Installation And Operation Manual

Rockwell Automation Reliance SP500 Installation And Operation Manual

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SP500 AC Drive
Installation and Operation Manual
Version 3.1
Instruction Manual
D2-3356-5

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Summary of Contents for Rockwell Automation Reliance SP500

  • Page 1 SP500 AC Drive Installation and Operation Manual Version 3.1 Instruction Manual D2-3356-5...
  • Page 2 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. Reliance, ReSource, and AutoMax are trademarks of Rockwell Automation. ©1999 Rockwell International Corporation...

  • Page 3: Table Of Contents

    ONTENTS Chapter 1 Introduction Who Should Use This Manual ................. 1-1 Installation Overview ..................1-1 Requesting Assistance from Reliance Electric ..........1-1 Chapter 2 Learning About the SP500 Drive Standard Features ................... 2-1 Drive Description ..................... 2-2 Identifying the Drive by Model Number ............2-6 2.3.1 Power Ratings and NEMA Enclosure Ratings ........
  • Page 4 Chapter 5 Wiring the Drive Input Power Wiring...................5-1 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 Output Power Wiring ..................5-10 Grounding ......................5-11 Chapter 6 Completing the Installation...
  • Page 5 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 –...
  • Page 6 SP500 AC Drive Installation and Operation Manual Version 3.1...
  • Page 7 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...................
  • Page 8 SP500 AC Drive Installation and Operation Manual Version 3.1...

  • Page 9: Chapter 1 Introduction

    HAPTER 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.
  • Page 10 SP500 AC Drive Installation and Operation Manual Version 3.1...

  • Page 11: Chapter 2 Learning About The Sp500 Drive

    HAPTER Learning About the SP500 Drive This chapter describes the SP500 drive and how to identify it based on its model number. This chapter also provides power and enclosure rating information. 2.1 Standard Features The SP500 drive has the following features: •...

  • Page 12: Drive Description

    • User-selectable relay contact for indications of drive running, drive faulted, or drive at selected speed • User-selectable power-up start, auto-restart, and coast-to-rest or ramp-to-rest stop functions • User-selectable local or remote operation • 29 user-adjustable software parameters 2.2 Drive Description The SP500 drive is an AC PWM (pulse-width-modulated) inverter that operates on single- or three-phase power.

  • Page 13: Figure 2.1 - Sp500 System Diagram

    Figure 2.1 – SP500 System Diagram Learning About the SP500 Drive...

  • Page 14: Figure 2.2 - Sp500 System Diagram (Continued)

    Figure 2.2 – SP500 System Diagram (Continued) SP500 AC Drive Installation and Operation Manual Version 3.1...

  • Page 15: Figure 2.3 - Regulator Board Component Locations

    Figure 2.3 – Regulator Board Component Locations Learning About the SP500 Drive...

  • Page 16: Identifying The Drive By Model Number

    2.3 Identifying the Drive by Model Number A model number identifies each SP500 AC drive. See figure 2.4. This number appears on the shipping label and on the drive’s nameplate located on the right side of the drive housing. The drive’s model number contains codes that indicate: input voltage range, enclosure rating, and horsepower rating.

  • Page 17: Power Ratings And Nema Enclosure Ratings

    2.3.1 Power Ratings and NEMA Enclosure Ratings Table 2.2 provides SP500 drive power and NEMA enclosure ratings. Table 2.2 – Power and NEMA Enclosure Ratings Input Power Power Model and Horsepower NEMA Enclosure AC Input Input Input Output Loss Number Rating* Rating Size**...

  • Page 18: Enclosure Ratings And Sizes

    Table 2.2 - Power and NEMA Enclosure Ratings (Continued) Input Power Power Model and Horsepower NEMA Enclosure AC Input Input Input Output Loss Number Rating* Rating Size** Volts Amps Amps* Watts*** 1SU51002 Three-Phase - 2 HP 1SU54002 Three-Phase - 2 HP 4X/12 1SU51003 Three-Phase - 3 HP...

  • Page 19: Figure 2.5 - Enclosure A Component Locations

    CONTROL STRIP TERMINAL REGULATOR PCB MEMBRANE SWITCH/ BRACKET ASSEMBLY INTERNAL FAN ASSEMBLY POWER TERMINAL STRIP POWER PCB GND CONNECTION Figure 2.5 – Enclosure A Component Locations Learning About the SP500 Drive...

  • Page 20: Figure 2.6 - Enclosure B Component Locations

    CONTROL TERMINAL STRIP REGULATOR PCB MEMBRANE SWITCH/ BRACKET ASSEMBLY INTERNAL FAN ASSEMBLY CAPACITOR PCB POWER PCB (3 & 5 HP ONLY) GND CONNECTION POWER TERMINAL STRIP Figure 2.6 – Enclosure B Component Locations 2-10 SP500 AC Drive Installation and Operation Manual Version 3.1...

  • Page 21: Figure 2.7 - Enclosure C Component Locations

    CONTROL TERMINAL CONTROL TERMINAL STRIP STRIP REGULATOR PCB REGULATOR PCB MEMBRANE SWITCH/ MEMBRANE SWITCH/ BRACKET ASSEMBLY BRACKET ASSEMBLY INTERNAL FAN INTERNAL FAN ASSEMBLY ASSEMBLY POWER TERMINAL CAPACITOR PCB POWER TERMINAL CAPACITOR PCB STRIP STRIP GND CONNECTIONS GND CONNECTIONS POWER PCB POWER PCB Figure 2.7 –...

  • Page 22: Figure 2.8 - Enclosure D Component Locations

    Figure 2.8 – Enclosure D Component Locations 2-12 SP500 AC Drive Installation and Operation Manual Version 3.1...

  • Page 23: Option Kits

    2.5 Option Kits Table 2.3 provides a listing of the available SP500 option kits. Table 2.3 – SP500 Option Kits Option Kit Instruction Option Kit Description Model Number Manual Low Energy Snubber Resistor Braking Kit for 2DB2005 D2-3178 M/N 1SU2xxxx Drives Low Energy Snubber Resistor Braking Kit for 2DB4010 D2-3179...
  • Page 24 2-14 SP500 AC Drive Installation and Operation Manual Version 3.1...

  • Page 25: Chapter 3 Sp500 System Planning

    HAPTER SP500 System Planning This chapter provides information that you must consider when planning an SP500 drive installation. Installation site, wiring, and motor application requirements are included. ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment.

  • Page 26: Determining The Total Area Required For Installation

    3.1.1 Determining the Total Area Required for Installation 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 146.0 mm (5.57”) 121.9 mm (4.8”) 73.0 mm (2.88”) Figure 3.1 –...

  • Page 27: Figure 3.3 - Enclosure C Dimensions

    Figure 3.3 – Enclosure C Dimensions Figure 3.4 – Enclosure D Dimensions SP500 System Planning...

  • Page 28: Providing Proper Air Flow Clearances

    3.1.2 Providing Proper Air Flow Clearances Be sure there is adequate clearance for air ventilation around the drive. For best air movement, do not mount SP500 drives directly above each other. Note that no devices are to be mounted behind the drive. This area must be kept clear of all control and power wiring.

  • Page 29: Table 3.2 - Recommended Power Wire Sizes For M/N 1Su1Xxxx And

    Table 3.2 – Recommended Power Wire Sizes for M/N 1SU1xxxx and 1SU2xxxx Drives Size of Wire Type of Wiring Terminals (maximum)* AC Input Power R, S, T 14 AWG, 2 (mm Output Power U, V, W 14 AWG, 2 (mm DC Bus –...

  • Page 30: Recommended Control And Signal Wire Sizes

    3.2.3 Recommended Control and Signal Wire Sizes Table 3.6 shows the recommended wire sizes to connect I/O signals to the terminal strip on the Regulator board. The minimum wire insulation rating is 600V. Operator controls can be up to 303 meters (1000 feet) from the SP500 drive. All signal wires should be twisted-pair.

  • Page 31: Table 3.7 - Motor Lead Lengths

    Table 3.7 – Motor Lead Lengths Maximum Lead Maximum Lead Maximum Lead SP500 HP Filter Type Length in Feet with Length in Feet with Length in Feet with Rating 230 VAC Motor 460 VAC Motor 575 VAC Motor Carrier Frequency Carrier Frequency Carrier Frequency 4 kHz 6 kHz 8 kHz 4 kHz 6 kHz 8 kHz 4 kHz 6 kHz 8 kHz...

  • Page 32: Selecting Input Ac Line Branch Circuit Fuses

    3.3 Selecting Input AC Line Branch Circuit Fuses ATTENTION: Most codes require that upstream branch circuit protection be provided to protect input power wiring. Install the fuses recommended in table 3.9. Do not exceed the fuse ratings. Input line branch circuit protection fuses must be used to protect the input power lines. See figure 5.1.

  • Page 33: Installing An Emergency Stop

    3.4 Installing an Emergency Stop ATTENTION: The user must provide an external, hardwired emergency stop circuit outside of the drive circuitry. This circuit must disable the system in case of improper operation. Uncontrolled machine operation may result if this procedure is not followed. Depending upon the requirements of the application, the SP500 drive can be programmed to provide either a coast-to-rest (default) or a ramp-to-rest (user-option) operational stop without physical separation of the power source from the motor.

  • Page 34: Multiple-Motor Applications

    If the motor will be operated below one-half of its rated speed, the motor overload relay may not protect the motor because of reduced cooling action due to the reduced speed. A motor thermostat, internal to the motor, should be installed to monitor the actual temperature of the windings.

  • Page 35: Chapter 4 Installing The Drive

    HAPTER Installing the Drive This chapter shows how to mount the SP500 drive and its external components. Also shown are the entry areas for routing wiring in and out of the drive. 4.1 Mounting the Drive Attach the drive to the selected flat, vertical surface using the mounting holes provided.

  • Page 36: Figure 4.1 - Enclosure A Wire Routing Locations

    Figure 4.1 – Enclosure A Wire Routing Locations SP500 AC Drive Installation and Operation Manual Version 3.1...

  • Page 37: Figure 4.2 - Enclosure B Wire Routing Locations

    Figure 4.2 – Enclosure B Wire Routing Locations Installing the Drive...

  • Page 38: Figure 4.3 - Enclosure C Wire Routing Locations

    Figure 4.3 – Enclosure C Wire Routing Locations SP500 AC Drive Installation and Operation Manual Version 3.1...

  • Page 39: Figure 4.4 - Enclosure D Wire Routing Locations

    Figure 4.4 – Enclosure D Wire Routing Locations Installing the Drive...

  • Page 40: Installing External Components

    4.3 Installing External Components Install the input power and output power components that are located outside of the SP500 enclosure. See figure 5.1. The following sections describe disconnect, transformer, and AC line branch protection installation. 4.3.1 Disconnects An input disconnect (for example, a switch or circuit breaker) must be installed in the line before the drive input terminals in accordance with local, national, and international codes (e.g., NEC/CEC).

  • Page 41: Output Contactors

    • Do NOT use an input isolation transformer rated more than 100 KVA for 230 VAC (or 1000 KVA for 460 VAC) with less than 5% impedance directly ahead of the drive without additional impedance between the drive and the transformer. If your SP500 application requires the use of an output transformer, contact Reliance Electric for assistance.

  • Page 42: Preparing The Motor

    9 10 11 12 13 14 0-20 mA 0-10 VDC Figure 4.5 – Jumper J6 Settings for the Analog Input Speed Reference Use the following procedure to set jumper J6: ATTENTION: DC bus capacitors retain hazardous voltages after input power has been disconnected. After disconnecting input power, wait five (5) minutes for the DC bus capacitors to discharge and then check the voltage with a voltmeter to ensure the DC bus capacitors are discharged before touching any internal components.
  • Page 43 • Verify that 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. Installing the Drive...
  • Page 44 4-10 SP500 AC Drive Installation and Operation Manual Version 3.1...

  • Page 45: Chapter 5 Wiring The Drive

    HAPTER Wiring the Drive This chapter describes how to wire the SP500 drive including: input wiring, control and signal wiring, output wiring, and grounding. 5.1 Input Power Wiring Use the following steps to connect AC input power to the drive: Step 1.

  • Page 46: Figure 5.1 - Typical Electrical Connections

    AC Input Voltage Manual Disconnect Fuse User- Supplied R/L1 S/L2 T/L3 SP500 Drive U/T1 V/T2 W/T3 User- Motor Overload Relay Supplied (Optional if Electronic Overload is Used) Figure 5.1 – Typical Electrical Connections SP500 AC Drive Installation and Operation Manual Version 3.1...

  • Page 47: Signal And Control Wiring

    5.2 Signal and Control Wiring The terminal strip on the Regulator board provides terminals for connecting signal (for example, external speed reference and analog output) and control (for example, stop, start, and function loss) wiring. See figure 5.2. Terminals for the following wire connections are provided: •...

  • Page 48: Analog Output Wiring

    User-Supplied User-Supplied Speed Reference Speed Reference Input Signal Potentiometer 0-10 VDC 0-20 mA +10 VDC 5kΩ Figure 5.3 – Analog Speed Reference Wiring Connections 5.2.2 Analog Output Wiring Analog output wiring connects to terminals 4 and 5 on the Regulator board’s terminal strip.

  • Page 49: Figure 5.5 - Two-Wire Start/Stop Sample Control Wiring

    Start and Stop Control Wiring Start and stop control wiring connects to terminals 6, 7, and 11. See figures 5.5 and 5.6. Note that these start/stop wiring connections are not to be used in multi-speed preset applications which are discussed in the following section. Start/ Stop Reset...

  • Page 50: Figure 5.7 - Multi-Speed Preset Sample Control Wiring

    Multi-Speed Preset Wiring Multi-speed preset wiring connects to terminals 6 through 8, and 11. See figure 5.7. When control type 3 is selected through parameter F-00, remote terminal strip control is enabled with multi-speed presets. This mode of operation changes the functionality of terminals 6 through 8 and may be used in place of 2- and 3-wire start/stop wiring.

  • Page 51: Figure 5.8 - Terminal Usage During Multi-Speed Preset Operation

    F-00 = 0, 1, 2 F-00 = 3 (Multi-Speed Presets) Figure 5.8 – Terminal Usage During Multi-Speed Preset Operation IET Reset Control Wiring IET reset control wiring connects to terminals 8 and 11. See figures 5.5 and 5.6. Note that these reset wiring connections are not to be used in multi-speed preset applications.

  • Page 52: Snubber Resistor Wiring

    5.2.4 Snubber Resistor Wiring Snubber resistor wiring connects to terminals 12 and 13 on the Regulator board’s terminal strip. See figures 5.9 and 5.10. Snubber Resistor Control Terminal Power Terminal Drive Model Number Terminals Strip Connections Strip Connections 1SU2xxxx 1 (+) 2 (–) 147 (+) (+) DC Bus...

  • Page 53: Figure 5.9 - Snubber Resistor Wiring Connections For M/N 1Su2Xxxx Drives

    Regulator Board Snubber Resistor Braking Signal Control Terminal +147 DC Bus Volts 12 13 Strip Snubber Resistor Power Terminal Strip DC Bus Volts SP500 Drive Figure 5.9 – Snubber Resistor Wiring Connections for M/N 1SU2xxxx Drives Regulator Board Snubber Resistor Braking Signal Control Terminal...

  • Page 54: Output Status Relay Wiring

    5.2.5 Output Status Relay Wiring Output status wiring connects to terminals 14 through 16 on the Regulator board’s terminal strip. See figure 5.11. Parameter F-09 specifies the type of status indication provided by the output relay. See the F-09 parameter description in section 8.3 for more information.

  • Page 55: Grounding

    5.4 Grounding ATTENTION: The user is responsible for conforming with all applicable local, national, and international codes. Use the following steps to ground the drive: Step 1. Remove the drive’s cover. Step 2. Run a suitable equipment grounding conductor unbroken from the drive’s ground terminal to the motor’s ground terminal and then to earth ground.
  • Page 56 5-12 SP500 AC Drive Installation and Operation Manual Version 3.1...

  • Page 57: Chapter 6 Completing The Installation

    HAPTER Completing the Installation This chapter provides procedures to check the installation. 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.

  • Page 58: Checking Drive Operation

    Step 9. Check that the wire sizes are within terminal specifications and that the terminals are tightened to the appropriate torque specifications. Refer to tables 3.2 through 3.6. Step 10. Check that the user-supplied branch circuit protection is installed and correctly rated.
  • Page 59 Step 7. Verify the direction of the motor shaft rotation. If it is incorrect for your application, use the following procedure to change the direction of rotation. If it is correct, go to step 8. a. Press the STOP/RESET key to stop the drive. b.
  • Page 60 SP500 AC Drive Installation and Operation Manual Version 3.1...

  • Page 61: Chapter 7 Keypad And Display Operation

    HAPTER Keypad and Display Operation The front-panel keypad and display, shown in figure 7.1, are used to program, monitor, and control the drive. They operate in two modes: monitor mode and program mode. In monitor mode (the default mode), you can monitor specific drive outputs and the drive’s speed reference.

  • Page 62: Key Descriptions

    7.2 Key Descriptions The keypad’s six membrane keys are used to monitor, program, and control the drive. Table 7.1 describes the keys. Table 7.1 – Key Descriptions Use the UP and DOWN arrow keys to: • Step through the drive parameters and error log when the drive is in program mode. •...

  • Page 63: Led Descriptions

    7.3 LED Descriptions The keypad area contains eight LEDs that indicate either drive status or which drive output value is displayed in monitor mode. Tables 7.2 and 7.3 describe the drive status LEDs and monitor mode LEDs, respectively. Table 7.2 – Drive Status LED Descriptions State Description The drive is generating an output voltage and...

  • Page 64: Program Mode

    7.4 Program Mode Program mode allows you to display and modify drive parameter values when the drive is stopped. The following can be displayed in program mode: • Parameter numbers • Parameter values • Error log information To enter program mode: Step 1.

  • Page 65: Monitor Mode

    A sample program mode display is shown in figure 7.3. Mode Forward Enter Reverse %Load Program STOP Volts Forward START RESET Remote Reverse Figure 7.3 – Example of a Program Mode Display For information about: Refer to section: Displaying or changing parameter values Ensuring program security Individual parameters Accessing the error log...

  • Page 66: Displaying The Percent Selected Speed Reference

    A sample monitor mode display is shown in figure 7.4. Mode Forward Enter Reverse %Load Program STOP Volts Forward START RESET Remote Reverse Figure 7.4 – Example of a Monitor Mode Display 7.5.1 Displaying the Percent Selected Speed Reference To display the percent selected speed reference, parameter F-13 must be set to ON. Use the following procedure to display the percent selected speed reference: Step 1.

  • Page 67: Changing The Reference Using The Keypad

    The functions of the keypad keys are described in section 7.2. Refer to the F-00 Control Source Select parameter description in chapter 8 for more information on selecting a drive control source. 7.6.1 Changing the Reference Using the Keypad The speed reference can be increased or decreased using the key when F-00 = 0 or 2.
  • Page 68 SP500 AC Drive Installation and Operation Manual Version 3.1...

  • Page 69: Chapter 8 Programming Reference

    HAPTER Programming Reference To program the SP500 drive for a specific application, you display the appropriate parameter and adjust it as required. The parameters specify characteristics of the drive. This chapter describes how to access, display, and modify parameters. Section 8.3 describes each parameter in detail.
  • Page 70 Step 4. Press the MODE/ENTER key to display the parameter value. Mode Forward Enter Reverse %Load Program Volts Forward STOP START RESET Reverse Remote Step 5. Press the key to change the value. Note that if programming has been disabled in parameter F-20 (Password Lockout Enable), the value will not change.

  • Page 71: Ensuring Program Security

    8.2 Ensuring Program Security ATTENTION: It is the user’s responsibility to determine how to distribute the password. Reliance Electric is not responsible for unauthorized access violations within the user’s organization. Parameter values can be password-protected using parameter F-20 (Password Lockout Enable). When F-20 is set to ON, parameter values can be displayed but cannot be modified from the keypad unless the correct password is entered in F-20.
  • Page 72 Step 3. Press the key until the password number, 257, is displayed. (Holding down the key increases the scroll speed.) Mode Forward Enter Reverse %Load Program Volts Forward STOP START RESET Reverse Remote Step 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.

  • Page 73: Parameter Descriptions

    8.3 Parameter Descriptions F-00 Control Source Select This parameter selects Parameter Range: 0 = Local control; control signals and speed reference from the drive control the keypad source and speed 1 = Remote control; control signals from the terminal strip; reference source.
  • Page 74 F-02 Deceleration Time (continued) If the frequency requested from the keypad (using the keys) is less than the maximum speed setting, the time to ramp to that frequency will be proportionally less than the actual rate setting. For example, if F-04 = 60Hz and F-02 = 4 seconds, it will take 2 seconds to ramp to a frequency reference of 0Hz from 30 Hz.

  • Page 75: Figure 8.1 - Manual Torque Boost Adjustment Range

    F-05 Current Limit This parameter limits Parameter Range: 10% to 150% of rated drive current motor output torque Default Setting: 150% while it is running or accelerating. Step Size: 1.0% When output current attempts to exceed the preset current limit, motor current will be maintained or reduced, or the acceleration / deceleration time will be extended.

  • Page 76: Figure 8.2 - Volts/Hertz Curve

    F-07 V/Hz (Base Speed) (continued) The V/Hz curve allows the drive to maintain a constant V/Hz ratio, providing constant torque at any frequency. See figure 8.2. Base Frequency FREQUENCY (Hz) Figure 8.2 – Volts/Hertz Curve F-08 RPM at Base Speed This parameter scales Parameter Range: 10 to 9999...

  • Page 77: Remote Reference Gain

    F-09 Configurable Output Relay Select This parameter Parameter Range: 0 = Output relay is energized to show state of drive specifies the type of running. status indication the 1 = Output relay is energized to show state of active fault output relay contacts (IET).

  • Page 78: Remote Reference Offset

    F-11 Remote Reference Gain (continued) To calculate the scaled reference if you are using a 0 to 20 mA remote reference, use the following equation: Desired Maximum Reference (mA) x 100 = % gain (mA reference) Reference Range (20) Example If the remote speed reference is 0 to 20 mA and the maximum reference required is 19.2 mA, scale as follows: 19.2...
  • Page 79 F-13 Percent Selected Speed Reference Display Enable This parameter Parameter Range: ON = Fourth monitor mode display is enabled. enables or disables OFF = Fourth monitor mode display is disabled. the fourth monitor mode display. Default Setting: Step Size: If F-13 = ON, the current value of the active speed reference can be displayed by pressing the MODE/ENTER key (while the drive is running) until all three monitor mode LEDs are on.

  • Page 80: Reverse Disable

    F-15 Electronic Thermal Overload Enable (continued) When F-15 = ON, the drive faults if it exceeds the thermal overload time (60 seconds at 150% of F-14). When an external thermal switch or other overtemperature monitoring device is connected to the function loss circuit (terminals 10 and 11), this parameter may be set ON or OFF.

  • Page 81: Rpm Setpoint Enable

    F-18 RPM Setpoint Enable The parameter Parameter Range: OFF = Setpoint is displayed in hertz. enables the setpoint to ON = Setpoint is displayed in the units specified in F-08. be displayed in F-08 units. Default Setting: Step Size: If F-18 = ON, pressing the keys will change the setpoint in units of 1 between minimum speed in F-08 units and maximum speed in F-08 units.
  • Page 82 F-20 Password Lockout Enable This parameter Parameter Range: OFF = Password lockout disabled (parameters can be enables or disables modified) parameter password ON = Password lockout enabled (parameters cannot be protection. modified) Default Setting: Step Size: ATTENTION: It is the user’s responsibility to determine how to distribute the password.

  • Page 83: Table 8.1 - Multi-Speed Presets Digital Inputs

    F-22 Avoidance Bandwidth (continued) Example Assume: Minimum Speed (F-03) = 3 Hz Maximum Speed (F-04) = 60.0 Hz Avoidance Frequency (F-21) = 32.2 Hz Avoidance Bandwidth (F-22) = 4 Hz Avoidance Band = 30.2 to 34.2 Hz Requested Output Output Frequency After Frequency Avoidance Band Correction 25.0 Hz...
  • Page 84 F-26 Auto-Restart Number of Attempts This parameter selects Parameter Range: 0 to 10 the number of times Default Setting: the drive will attempt to restart after certain Step Size: faults have shut down the drive. ATTENTION: If parameter F-26 ≠ 0, the drive will attempt to restart automatically after auto-restartable drive faults (see table 8.2) have shut down the drive.

  • Page 85: Version Information

    F-27 Auto-Restart Retry Wait Time This parameter Parameter Range: 1 to 30 seconds specifies the amount Default Setting: of time the drive will wait between auto- Step Size: 1.0 second restart attempts. This parameter is used with parameter F-26 (Auto-Restart Number of Attempts). Refer to the F-26 parameter description for information regarding this feature.
  • Page 86 8-18 SP500 AC Drive Installation and Operation Manual Version 3.1...

  • Page 87: Chapter 9 Troubleshooting Reference

    HAPTER Troubleshooting Reference 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. The SP500 drive is monitored by internal diagnostics. If a fault occurs, the drive displays a two-digit fault code to identify the problem.

  • Page 88: Figure 9.1 - Dc Bus Terminals On Model 1Su1Xxxx And 1Su2Xxxx Drives

    (T1) (T2) (T3) AC POWER MOTOR LEADS DC BUS INPUT LEADS* VOLTS (SNUBBER RESISTOR BRAKING) *For single-phase units, connect AC input power to terminals R and S. Figure 9.1 – DC Bus Terminals on Model 1SU1xxxx and 1SU2xxxx Drives AC POWER MOTOR LEADS DC BUS (SNUBBER...

  • Page 89: Troubleshooting The Drive Using Fault Codes

    9.2 Troubleshooting the Drive Using Fault Codes Table 9.1 defines the fault codes for user-correctable faults, lists possible causes, and suggests actions to take to correct the problem. All other faults require replacement of the drive. If a fault occurs, do the following: Step 1.
  • Page 90 = LOW BUS VOLTAGE The DC bus voltage has fallen below the electronic trip low threshold level. Note that the fault will not clear until the linput line voltage is within the proper range. This may take a few seconds. Important: If a line dip or momentary power loss occurs and the DC bus is able to rise back to the proper level within 500 ms, the drive will automatically restart (if the drive was running when the fault occurred).

  • Page 91: Accessing And Clearing The Error Log

    = ELECTRONIC THERMAL OVERLOAD The electronic thermal overload trip level has been exceeded. This fault protects the drive motor from overheating 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.
  • Page 92 Use the following procedure to access the error log: Step 1. Enter program mode by pressing the MODE/ENTER key until the PROGRAM LED turns on. Mode Forward Enter Reverse %Load Program Volts STOP Forward START RESET Remote Reverse Step 2. Press the key until ERR is displayed.

  • Page 93: Checking The Drive's Power Module Circuitry With The Power Off

    Step 5. Press the STOP/RESET key to clear the log. The display will return to the active monitor display. Mode Forward Enter Reverse %Load Program Volts Forward STOP START RESET Remote Reverse 9.4 Checking the Drive’s Power Module Circuitry with the Power Off ATTENTION: DC bus capacitors retain hazardous voltages after input power has been disconnected.

  • Page 94: Table 9.2 - Resistance Checks For Input Diodes

    Table 9.2 – Resistance Checks for Input Diodes Meter Input Connection Diode Component is OK if Component is resistance (R) is: defective if: R/L1 50 < R < 10 Megohm Continuity (short circuit) or open when the meter is S/L2 connected with reversed polarity.

  • Page 95: Appendix A Technical Specifications

    PPENDIX Technical Specifications Table A.1 – Service Conditions AC Line Distribution Capacity 100KVA, single-phase 115VAC and three-phase 230VAC, with 5,000 amps (Maximum) symmetrical fault current capacity for M/N 1SU1xxxx and1SU2xxxx drives 1000KVA, three-phase 460 and 575VAC, with 30,000amps symmetrical fault current capacity for M/N 1SU4xxxx and 1SU5xxxx drives Control Method All-digital, pulse-width-modulated (PWM)
  • Page 96 Table A.4 – Drive Inputs Analog Speed Reference 0 to 10 VDC or 0 to 20 mA Start Edge-sensitive signal that must see an open-to-closed contact transition. This transition may be a momentary or fixed closure. Stop An open contact that must be closed when the drive is running. The drive will remain off as long as the contact is open.

  • Page 97: Appendix B Record Of User Settings

    PPENDIX Record of User Settings Parameter Default Parameter Name Range Step Size Setting Setting Date F-00 Control Source Select 0, 1, 2, 3 F-01 Accel Time (seconds) 0.5 - 90.0 0.10 F-02 Decel Time (seconds) 0.5 - 90.0 0.10 F-03 Minimum Speed (Hz) 0.5 - 30.0 0.10/0.25...
  • Page 98 Parameter Default Parameter Name Range Step Size Setting Setting Date F-26 Auto-Restart Number of Attempts 0 - 10 0 = disabled F-27 Auto-Restart Retry Wait Time 1 - 30 (seconds) F-28 Drive Voltage Selection This parameter is set at the factory. Do not change the setting.
  • Page 99 PPENDIX Alphabetical Listing of Parameters Acceleration Time ....................F-01 Analog Output Select.....................F-29 Auto-Restart Number of Attempts................F-26 Auto-Restart Retry Wait Time................F-27 Avoidance Bandwidth ....................F-22 Avoidance Frequency ....................F-21 Carrier Frequency....................F-10 Coast 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...
  • Page 100 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 SP500 AC Drive Installation and Operation Manual Version 3.1...

  • Page 101: Appendix D Compliance With Machinery Safety Standard En-60204-1:1992

    PPENDIX Compliance with Machinery Safety Standard EN-60204-1:1992 The SP500 AC Speed Controller for Electric Motors complies with the following sections of Machinery Safety Standard EN-60204-1:1992. EN-60204-1 Section Title Protection against electrical shock 6.2.1 Protection by enclosure 6.2.3 Protection against residual voltages 6.3.1 Protection by automatic disconnect of supply Protection by the use of PELV (Protective Extra Low Voltage)
  • Page 102 EN-60204-1 Section Title Protective interlocks 9.3.5 Reverse current braking Control functions in case of failure 9.4.2.1 Use of proven circuit techniques and components 9.4.3 Provisions for redundancy 9.4.3.1 Earth faults 9.4.3.2 Voltage interruption Operator interface and machine mounted control devices 10.8 Display Control interfaces...

  • Page 103: Appendix E Compliance With Electromagnetic Compatibility Standards

    PPENDIX Compliance with Electromagnetic Compatibility Standards E.0 Introduction This appendix provides information on the SP500 drive’s compliance with European community electromagnetic compatibility standards and covers the following: • Requirements for standards compliance • Guidelines on installing the AC Mains Filter •...
  • Page 104 • be installed according to the instructions in this appendix. Note that when using 15 – 20 HP SP500 drives, a special cover is required. The model number of the SP500 cover kit is M/N 2CK4120. Follow the instructions provided with the kit when replacing the cover. The instructions in this appendix assume that the drive has the correct cover on it.
  • Page 105 T op View (Filter Only , Cover Removed) M5 Nuts K, Conduit Entry L3 E(GND) SP500 Drive AC Mains Mounts on T op Filter Mains of Mains Filter Filter (Screws Provided) Flexible Conduit (Provided) Side View Front View (Filter and Drive) (Filter Only) See table E.2 for dimensions.
  • Page 106 Table E.2 - AC Mains Filter Mounting Dimensions and Weights AC Mains Filter AC Mains Filter AC Mains Filter AC Mains Filter Dimension M/N 2DF2282 M/N 2DF4283 M/N 2DF4284 M/N 2DF4285 146 mm 217 mm 272 mm 272 mm 5.7" 8.5"...
  • Page 107 • When the drive is connected to three-phase AC input power, the three output leads from the filter should be connected to the drive’s AC input power terminals as shown in figure E.3. • Connect the filter ground wire (green/yellow) to the drive ground. FILTER’S AC INPUT POWER E(GND) AC MAINS FILTER...
  • Page 108 E.3.2 Motor Leads The motor leads must be run in continuous, rigid, conductive conduit, continuously-screened armored cable, 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.
  • Page 109 EN-60204-1, Part 15.2.2: Identification of the Protective Conductor For insulated conductors, the two-color combination of green and yellow should meet the following criteria for any given 15 mm length: one of the colors should cover at least 30% and no more than 70% of the surface, with the other color covering the remainder of the surface.
  • Page 110 SP500 AC Drive Installation and Operation Manual Version 3.1...

  • Page 111: Appendix F Replacement Parts

    PPENDIX Replacement Parts The following tables list the replacement parts available from Reliance Electric. Replacement parts are not available for 1 and 2 HP drives (M/N 1SU1xxxx and 1SU2xxxx). For M/N 1SU24002, use the replacement parts listed for the 3 HP drive. Table F.1 –...
  • Page 112 Table F.3 – Replacement Parts List for Model 1SU5xxxx Drives Quantity per Horsepower Description Part Number 1 HP 2 HP 3 HP 5 HP 7.5 HP 10 HP Fan Assembly 615161-S – – NEMA 4X Cover/Gasket 805512-1R – – 805522-1R –...

  • Page 113: Glossary

    LOSSARY accelerating torque - an increase in torque (force) generated by a motor in order to achieve running speed. base speed - the manufacturer’s nameplate rating at which point the motor will develop rated horsepower at rated load and voltage. base frequency - the motor nameplate frequency rating.
  • Page 114 overcurrent - a current greater than a specified maximum current value. overload capacity - the ability of the drive to withstand currents beyond the system’s continuous rating. It is normally specified as a percentage of full load current for a specified time period.

  • Page 115: Index

    NDEX Acceleration Time (F-01), 8-5 DC bus AC input terminals, 9-2 diodes, checking, 9-7 to 9-8 verifying capacitor voltage, 9-1 to 9-2 line branch circuit fuses, 3-8, 4-6, 5-2 Deceleration Time (F-02), 8-5 to 8-6 ratings, 2-7 to 2-8 Digital input wiring wire sizes, 3-4 to 3-5 Forward/reverse, 5-7, A-2 wiring, 3-4 to 3-5, 3-8, 4-1 to 4-6, 5-1 to 5-2...
  • Page 116 Membrane switch/bracket assembly, 2-9 to 2-12, F-1 to F-2 Minimum Speed (F-03), 8-6 Grounding, 2-9 to 2-12, 5-11 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 Humidity, 3-1, 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...
  • Page 117 Power-Up Start Enable (F-19), 8-13 Program mode, 7-4 to 7-5 Terminal strip torque specifications, 3-5 wire sizes, 3-4 to 3-5 wiring, 5-3 to 5-10 Ratings Testing, IGBT, 9-7 to 9-10 AC input, 2-7 to 2-8 Torque specifications, 3-5 NEMA, 2-7 to 2-8 Transformer, isolation, 4-6 to 4-7 power, 2-7 to 2-8 power loss, 2-7 to 2-8...
  • Page 118 Index-4 SP500 AC Drive Installation and Operation Manual Version 3.1...
  • Page 119 Documentation Improvement Form Use this form to give us your comments concerning this publication or to report an error that you have found. For convenience, you may attach copies of the pages with your comments. After you have completed this form, please return it to: Reliance Electric Technical Documentation 24800 Tungsten Road...
  • Page 122 © 1999 Rockwell International Corporation. All rights reserved. Printed in USA. Publication D2-3356-5 - July 1999...

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