Reliance electric SP500 User manual

Installation and
Operation Manual
for the SP500
A-C VxS® Controller
Three-Phase Input and
Three-Phase Output
1/4-5 HP @ 200-230 VAC,
1/4-10 HP @ 380-460 VAC and
1/4 -10 HP @ 575 VAC
NEMA 1
NEMA 4X (Indoor Only)/12
woae
Instruction Manual D2-3267-1
PEN
ELECTRIC&L/

DANGER
ONLY QUALIFIED ELECTRICAL PERSONNEL FAMILIAR WITH THE
CONSTRUCTION AND OPERATION OF THIS EQUIPMENT AND THE HAZ-
ARDS INVOLVED SHOULD INSTALL, ADJUST, OPERATE, AND/OR SERVICE
THIS EQUIPMENT. READ AND UNDERSTAND THIS MANUAL IN ITS ENTIRETY
BEFORE PROCEEDING. FAILURE TO OBSERVE THIS PRECAUTION COULD
RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE.
VxS® and Reliance® are registered trademarks of Reliance Electric Industrial
Company or its subsidiaries.
® Copyright, Reliance Electric Industrial Company, 1993

Table of Contents
Receive and Accept Shipment ...........-00:e eee eeee eee eeeeeeee 1-1
About this Instruction Manual ........0...0 0.0000 c cece eee eee eee eee 1-1
Identify the Controller... 0.0... ee 1-2
Controller Description .......... 0c. c eee eee 1-3
Controller Nameplate ........... 0. cece eee teens 1-5
Receive and Accept the Shipment.................. 0c cece e eee eee eee 1-5
File a Return Request... 0.6... eee eee 1-6
Storage until Installation 2.0... 6. eee 1-6
SP500 Demo Packages — Model 1SU14001 Only ....................- 1-6
Specifications ....... 00... cee eee eee eee eee 2-1
Controller Specifications ........ 0.00... eee eee 2-1
Service Conditions .......... 0... c cece eens 2-5
Controller Input/output Specifications ............. 0... e eee eee 2-6
Controller InputS ........... 0. eee ee teens 2-6
Controller OutputS ........... cece teens 2-7
Controller Application Data ............. 0. e cece eee 2-8
Motor Applications ...... 0.0.0... . cece eee 2-8
Single-Motor Applications ........... 00... c eee eee eee eee 2-9
Multi-Motor Applications .......0.... 00... cece eee 2-9
Motor Lead Lengths ......... 0... cece eee eens 2-10
Controller Optional Kits 0.0.2... 0... cece eee 2-11
Controller
Power LOSS ........ 0.00 cece eee eee eee eee eee 2-12
Installation and Wiring ........ ccc cee eee e eee eee 3-1
Planning and Location ........ 0.0... ccc eee eens 3-1
Controller Mounting .......... 0.0 cece eee eee eee 3-2
Size A Controller Mounting (230VAC 182 HP) ..............0:e ee eee eee 3-2
Size B Controller Mounting (460 VAC 1-5 HP & 575 VAC 1-5 HP) ...... 3-4
Size C Controller Mounting
(230 VAC 2 (NEMA 4), 3 and 5 HP 460 VAC 7.5 and 10 HP, and
575
VAC 7.5 and 10 HP) ......... cece eens 3-5
Install an External Input Disconnect ............ 0... ee eee 3-6
Install A-C Branch Circuit Protection .............-.. 0c cece 3-7
Transformer Installation (If Needed) ....... 0.0... cee eee eee eee eee 3-9
Input Transformers ........ 0... cece eens 3-9
Output Transformers .......... 0.2 ec eect teens 3-9
Grounding ..... 0. eee eee 3-10
Motor Preparation .... 0... eee 3-10
Controller Wiring .... 0... eee tees 3-11
Power Wiring 2.0... eee eee 3-15
Control and Signal Wiring ........... 0... eee eee eee 3-18
Remote Analog Input Reference Jumper Setting ...................- 3-25
Optional Dynamic Braking Wiring ........... 0.00 c eee eee eee 3-26

Keypad and Display Operation ...........200ceeeeee eee e ee eeeee 4-1
Keypad and Display Description ............ 0... cece eee 4-1
Indicator LightS ........ 0... ccc ccc eee tenets 4-1
Display Mode LEDS ........ 0... cc cece cette eens 4-2
Operation Mode LEDS ......... 2... cece eee eee eee eens 4-3
Key Descriptions .... 0... eee eens 4-4
Power Up .... 0. eee eee een eee ee 4-7
Modes of Controller Operation ........... 0000 eee eee eens 4-7
Display MOdeéS ....... 0... eee 4-7
Program Mode... 1... cece eee eee eee 4-9
Lg co) a © 4-10
Adjusting the Drive Functions ............... cece scene eee eee e eens 5-1
FUNCTIONS ......... 0. cece eee tee eee tenes 5-2
F-00 — REMOTE ENABLE ............ 2.0 e cece eee ener eens 5-3
F-01 — ACCELERATION ............ 2 cece cece eee eee 5-4
F-02 — DECELERATION ............ 2. cece eee eee eee 5-5
F-03 — MINIMUM SPEED ............. 0... c cette eee eee 5-6
F-04 — MAXIMUM SPEED ............ 0.000 cece 5-7
F-O5 — CURRENT LIMIT .............. 0c eee eee ee eee 5-8
F-06 — MANUAL TORQUE BOOST .............. cece eee eee 5-9
F-07 — V/HZ (Base Speed) ........... eee eee tees 5-10
F-08 — RPMAT BASE SPEED .............00 00 eee eens 5-11
F-09 — IET (INSTANTANEOUS ELECTRONIC TRIP)
OUTPUT ENABLE ..........00. eee cece eee 5-12
F-10
— CARRIER FREQUENCY .......... 0.0000 e eee eee 5-13
F-11 — REMOTE REFERENCE GAIN ............... 00 c eee eee eee 5-14
F-12 — REMOTE REFERENCE OFFSET ..............000e eee eeeeee 5-15
F-13 — REMOTE REFERENCE DISPLAY ENABLE
(4TH DISPLAY MODE) ...........00. 0. cece eee ee eee eee 5-16
F-14 — ELECTRONIC THERMAL OVERLOAD .............--++22 eee 5-17
F-15 — ELECTRONIC THERMAL OVERLOAD ENABLE .............- 5-18
F-16 — COAST STOP ENABLE .......... 0.0000 e eee eee 5-19
F-17 — REVERSE DISABLE ............ 0.000 c eee eee eee eee 5-20
F-18 — VERSION INFORMATION ...........-.0: cece eee eee 5-21
ERR — ERRORLOG .......... 0c cee eee eee eens 5-22
Start the Controller ............ ccc eee eee eee eee eee eens 6-1
Check the Installation .......... 0.00. cee eee 6-1
Start the Controller .......... 0... cece eee 6-3
Cover Installation, NEMA 4X (Indoor Only)/12 ..............0:: eee eee 6-5
Troubleshooting, Fault Codes, and Replacement Parts .............. 7-1
System Operation .......... 0... cece eee eee eee 7-1
Fault Codes ....... 0... eee eect eee ttt neeee 7-4
How to Access and Read the Error Log ......... cece cece 7-4
Verify D-CBus Voltage... 66. 7-5
Glossary of Common Terms .............0c0se eee e cece eee eee eee 8-1
La: =>, Qe 9-1

Figure 1-1.
Figure 1-2.
Figure 2-1.
Figure 3-1.
Figure 3-2.
Figure 3-3.
Figure 3-4.
Figure 3-5.
Figure 3-6.
Figure 3-7.
Figure 3-8.
Figure 3-9.
Figure 3-10.
Figure 3-11.
Figure 3-12.
Figure 3-13.
Figure 3-14.
Figure 3-15.
Figure 3-16.
Figure 3-17.
Figure 3-18.
Figure 3-19.
Figure 4-1.
Figure 5-1.
Figure 5-2
Figure 5-3.
Figure 7-1.
Figure 7-2.
Figure 7-3.
Figure 7-4.
List of Figures
Controller Functional Block Diagram ............-.2220000 ee 1-4
Nameplate Information. ............ 00.0cece eee eee eee eee 1-5
Motor Lead Length Connections .................. eee eae 2-10
Size A Physical Dimensions. .................0+0e eee ee eee 3-3
Size B Physical Dimensions. ...............0.:00ee eee eee 3-4
Size C Physical Dimensions. ......... 0.0.0.0. cece eee eee 3-5
Size A Wiring Locations. ......... 0... c cece eee eee 3-12
Size B Wiring Locations. ............. 0... c cece eee eee 3-13
Size C Wiring Locations. ............. 0... cece eee eee eee 3-14
Power Terminal Strip For Model 1SU2xxx Controllers. ........ 3-15
Power Terminal Strip For Model 1SU4xxx and
1SU5xxx Controllers. 2.2... eee 3-15
Control Terminal Strip. ......... 00... eee eee 3-18
Speed Reference Input Wiring ...............-.e eee e eee 3-21
Analog Meter Output Wiring. ........... 00.0... c eee eee 3-21
IET/Controller Running Wiring ............ 0... e eee eee 3-22
Start-Stop Control Wiring. ............. eee eee eee eee 3-23
IET Reset Control Wiring. .......... 0.0c cece eee eee ee 3-23
Forward/Reverse Control Wiring. ............. 0c cece ee 3-24
Coast-Stop Pushbutton Control Wiring. .................008 3-24
J6 Jumper Settings. .......... eee eee eee 3-25
Dynamic Braking Output Wiring for
Model 1SU2xxx Controllers. ...... 0... c cece 3-27
Dynamic Braking Output WiringFor
Models 1SU4xxx and1SU5xxx Controllers. ..............0083-28
SP500 Controller Keypad and Display. ...................-- 4-1
Factory Default Settings ............ 2.0 c cece eee eee eee 5-1
Manual Torque Boost Adjustable Range. ................66% 5-10
Volts/Hertz Curve. ..... 2.00. cece eee 5-11
System Block Diagram. .............. 0 cece eee eee eee eee 7-2
System Block Diagram (cont’d.) ............00: eee eee eee 7-3
D-C Bus Terminals on Model 1SU2xxx Controllers. .......... 7-5
D-C Bus Terminals on Model 1SU4:0x and
1SU5.0«x Controllers. 2... eee 7-5

Table 1-1.
Table 2-1.
Table 2-2.
Table 2-3.
Table 2-4.
Table 2-5.
Table 2-6.
Table 2-7.
Table 3-1.
Table 3-2.
Table 3-3.
Table 3-4.
Table 3-5.
Table 3-6.
Table 3-7.
Table 3-8.
Table 3-9.
Table 6-1.
Table 7-1.
Table 7-2.
Table 7-3.
Table 7-4.
List of Tables
Controller Model Notation ...............0 ccc cece eee eeee 1-2
Model 1SU14001 Controller Ratings with Single-Phase Power 2-1
Model 1SU2xxx Controller Ratings with Single-Phase Power .. 2-1
Model 1SU2xxx Controller Ratings with Three-Phase Power .. 2-2
Model 1SU4xxx Controller Ratings with Three-Phase Power .. 2-3
Model 1SU5xxx Controller Ratings with Three-Phase Power .. 2-4
Controller Optional Kits ............. 00. cee eee eee 2-11
Controller Power Loss ...........0. 00 cee cece eee eee eee 2-12
Controller Model Dimensional Size ................2..000- 3-2
Single-Phase A-C Input Line Branch Circuit Protection. ....... 3-7
Three-Phase A-C Input Line Branch Circuit Protection for
Model 1SU2xxx Controllers. ............. 000: cece 3-7
Three-Phase A-C Input Line Branch Circuit Protection for
Model 1SU4xxx Controllers. ........ 2.000 cece eee eee 3-8
Three-Phase A-C Input Line Branch Circuit Protection for
Model 1SU5xxx Controllers. «0.0... 0... cece eee eee 3-8
Recommended Power Wire Size ..........-... ec e eee ee eee 3-16
Power Terminal Tightening Torques ............ 00. c eee eee 3-16
Recommended Control and Signal Wire Sizes .............. 3-19
Control Terminal Strip Tightening Torques .................- 3-19
D-C Bus Voltage Value. ........... eee eee eee 6-3
Fault Code Action List. ........... 0.0 e ee eee eee 7-6
Replacement Parts List For Model 1SU2xxx Controllers ...... 7-8
Replacement Parts List For Model 1SU4x.«x« Controllers ...... 7-8
Replacement Parts List For Model 1SU5xxx Controllers ...... 7-9

1: Receive and
Accept Shipment
DANGER
ONLY QUALIFIED ELECTRICAL PERSONNEL FAMILIAR WITH THE CONSTRUC-
TION 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 PROCEED-
ING. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE
BODILYINJURY OR LOSS OF LIFE.
About this Instruction Manual
The SP500 A-C V&S® Controller products described in the instruction
manual are manufactured by Reliance Electric Industrial Company.
This instruction manual provides the information necessary to install,
start up, operate and troubleshoot the SP500 controller.
Section 2 provides the specifications required to ensure proper
operation of the controllers.
Section 3 instructs on how to install the controller along with,
necessary wiring, and precautions.
Keypad operation is described in Section 4. A thorough understanding
of the keypad, display and indicators is necessary to adjust, start-up,
operate or troubleshoot the SP500 controller.
Section 5 instructs on how to adjust the drive functions and the
defaults as shipped from the factory.
Section 6 gives Controller Startup procedures.
Section 7 provides troubleshooting information and fault code
conditions, replacement parts, and illustrates the drive functionality
through a system functional block diagram.
Section 8 contains a Glossary of common terms used throughout this
instruction manual.
Section 9 is an alphabetical index arranged by subject to be used to
locate specific information quickly.
1-1

Identify the Controller
Each Reliance Electric SP500 controller can be identified by its model
number(for standard controllers) or by the sales order number (for
customer-specified controllers). This number appears on the shipping
label and is stamped on the controller nameplate. (Refer to controller
nameplate for more information.) Verify that the model number shown
on the nameplate matches the shipping label. Refer to this model
number whenever discussing the equipment with Reliance Electric
personnel.
The standard model number describes the controller as follows:
STANDARD MODEL NUMBER
1s U2 1 001
BASIC
CATALOG |
NUMBER
LABEL
U= UL, CSA, IEC LISTED
VOLTAGE
1 - 115 VAC
2- 200 — 2350 VAC
4- 380 — 460 VAC
5 - 575 VAC
ENCLOSURE
1- NEMA 1 OR CHASSIS
4
-NEMA 4X (INDOOR ONLY)
- NEMA 12
HORSEPOWER RATING
001
002
003
005
007
010
HP
HP
HP
HP
HP
HP
1/4 -
Pritt
ONAN OuN0000
1-2
Note: All SP500 controllers described in this manual function the
same. However, when necessary, differences between the specific
controller models will be pointed out by using the notation in Table 1-1.
Table 1-1. Controller Model Notation
Model Notation Input Voltage (VAC) Horsepower (Hp)
18SU2%x 208-230 1, 2,3,5, 7.5, 10
18U4x0x 380-460 1, 2, 3, 5 (4kw) 7.5, 10
1SU5xxx 575 1, 2,3,5, 7.5, 10

Controller Description
SP500 controllers operate on a three-phase (single-phase) A-C power
source at the appropriate ratedinput voltage. As shown in Figure 1-1,
the A-C power source is supplied to the controller’s input terminals
and passes through three suppressors (MOV). The suppressors are
used to limit voltage transients within the maximum voltage rating of
the diode module.
The diode module rectifies the incoming A-C source to a constant D-C
voltage. This D-C voltage is then applied to an internal power supply
and to a large D-C bus capacitor. The internal power supply is a D-C
to D-C type to provide the necessary voltage and current source
required within the controller. The large D-C bus capacitor filters the
D-C voltage which then enters an IGBT (insulated-gate bipolar
transistor) inverter bridge. Under software control from an internal
microcontroller, the IGBT transforms the constant D-C voltage into a
PWM (Pulse-width Modulated) voltage signal corresponding to the
variable voltage and variable frequency source selected for the motor.
The IGBT inverter bridge is switched by the microcontroller using a 4,
6,
or 8 kHz carrier frequency. A low carrier frequency will maximize the
power rating of the controller butalso increaseacoustic noise. A
higher carrier frequency selection reduces acoustic noise but results
in a derating of the controller output (Refer to Specifications,
Section 2). The microcontroller also provides for operational input
data from the local operator interface and operates the controller.
The microcontroller directs the overall operation of the SP500
controller for adjustable-speed performance of A-C induction and
synchronous motors. User programmable functions, configurethe
controller's performance to fit motor characteristics and the users end
application. (Refer to Motor Applictions in Section 2, and Adjusting
Drive Functions, Section 5 for more information.) External control of
the controller is provided by the local operator interface or user
installed wiring.
The local operator interface contains a display, indicators, and control
and programming keys. (Refer to Section 4, Keypad and Display
Operation, for more information.) In addition to using the local
operator interface, user wiring can be installed for operational control,
motor speed adjustment, analog metering, dynamic braking (optional)
and an emergency stop (customer supplied). (Refer to Installation and
Wiring, Section 3).
The controller is intended to operate under trip free (fault)
characteristics. The controller uses selected signals to extend the
acceleration (starting) and deceleration (stopping) ratesof the motor.
When a fault does occur, however, the controller’s microcontroller
generates an instantaneous electronic trip (IET) signal to turn the
controller off (coast-to-stop). An indicationof theIET fault, which
occured, is stored in the controller and can be displayed on the local
operator interface. After a fault, the STOP/RESET key or a wired IET
RESET pushbutton switch must be pressed (resetting theIET signal)
to clear the fault from the controller (Refer to Section 7,
Troubleshooting, Fault Codes, and Replacement Parts).

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wes6eig
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1-1,
eunBi4
INPUT
SP500 A-C V*S CONTROLLER
LINE mse SUPPRESSORS
INPUT i won
INPUTS
EXTERNAL SPEEDREFERENCE
START
DIODE
MODULE
D-c BUS
CAPACITOR
IGBT MODULE
-
POWER SUPPLY
(D-C TO D-C)
INTERFACE
(KEYBOARD/DISPLAY)
DATA
| LOCAL OPERATOR
T
STOP
IET RESET
FORWARD/REVERSE
FUNCTION LOSS
FEEDBACK SIGNALS
CONTROL
SIGNALS
MICROCONTROLLER
Po
AC INDUCTION
MOTOR
OUTPUTS
pte §=—ANALOG OUTPUT, METERING
DYNAMICBRAKING
|_______tIET/RUN