Rockwell Automation Reliance SP500 User manual

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

©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.

Contents I
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

II 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

IV SP500 AC Drive Installation and Operation Manual Version 3.1

Contents V
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

VI 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

Learning About the SP500 Drive 2-1
CHAPTER 2
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:
•On-board keypad and display providing:
Start/Stop/Reset control
Forward/Reverse (reverse-disable selectable)
Setpoint 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 motor operation with high carrier frequency selection
•Drive protection
Overcurrent
Short circuit
Ground fault
Overvoltage
Undervoltage
Overtemperature
•UL/CSA electronic overload that meets NEC/CEC requirements

2-2 SP500 AC Drive Installation and Operation Manual Version 3.1
•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. See figures 2.1 and 2.2. AC input power is applied to the
drive’s input terminals. Voltage transients are suppressed by three
metal-oxide-varistor (MOV) suppressors. These suppressors keep any input voltage
transients within the maximum voltage rating of the input diode module.
The input diode module rectifies the incoming AC voltage into a constant DC bus
voltage which is filtered by the DC bus capacitor bank. An internal DC-to-DC power
supply uses power from the DC bus and provides the necessary voltages required by
the drive. Under regulator software control, the IGBT (insulated-gate
bipolar-transistor) inverter bridge converts the constant DC voltage into an AC PWM
waveform. The regulator switches the IGBT inverter bridge using a 4, 6, or 8 kHz
carrier frequency (user-selectable). A low carrier frequency maximizes the power
rating of the drive but also increases acoustic noise. 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 operation can be adjusted by the
parameters entered through the keypad. A microprocessor on the Regulator board
controls drive regulation. See figure 2.3. The Regulator board accepts internal power
feedback signals and an external speed reference signal. The Regulator board
provides display data for a four-character display, which is used to indicate drive
parameters, parameter values, and fault codes.
The drive can be controlled either locally through the keyboard and display (see
section 7) or remotely through the terminal strip (see section 5).
The drive is intended to operate trip-free under any condition. The drive uses selected
signals to extend the acceleration (starting) and deceleration (stopping) rates of the
motor when an overcurrent condition occurs. When a fault does occur, however, the
regulator generates an instantaneous electronic trip (IET) signal to turn the drive off
(coast-to-rest). The drive stores an indication or record of the IET fault, which can be
viewed on the four-character display. After a fault, the STOP/RESET key or a
user-supplied IET RESET pushbutton must be pressed to reset the IET signal and
clear the fault from the drive.

Learning About the SP500 Drive 2-3
.
Figure 2.1 – SP500 System Diagram

2-4 SP500 AC Drive Installation and Operation Manual Version 3.1
Figure 2.2 – SP500 System Diagram (Continued)

Learning About the SP500 Drive 2-5
Figure 2.3 – Regulator Board Component Locations

2-6 SP500 AC Drive Installation and Operation Manual Version 3.1
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. 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 Number Notation
Model Notation Input Voltage Horsepower
1SU1xxxx 115 VAC ¼ - 1 HP
1SU2xxxx 208 - 230 VAC 1, 2, 3, 5, 7.5, 10 HP
1SU4xxxx 380 - 460 VAC 1, 2, 3, 5, 7.5, 10, 15, 20 HP
1SU5xxxx 575 VAC 1, 2, 3, 5, 7.5, 10 HP

Learning About the SP500 Drive 2-7
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
Model
Number
Input Power
and Horsepower
Rating* NEMA Rating Enclosure Size** AC Input Volts Input Amps Input KVA Output Amps*
Power
Loss
Watts***
1SU11001 Single-Phase - 1 HP 1 A 115 13.1 1.5 6.8 80
1SU14001 Single-Phase - Demo ---- ---- 115 5.2 0.6 2.0 80
1SU21001 Single-Phase - 1 HP 1 A 200-230 5.0 1.3 1.7 70
1SU24001 Single-Phase - 1 HP 4X/12 A 200-230 5.0 1.3 1.7 70
1SU21002 Single-Phase - 2 HP
4 kHz Carrier
6 kHz Carrier
8 kHz Carrier
1
A200-230
200-230
200-230
19.1
17.2
15.3
4.4
4.0
3.5
7.5
7.0
6.5
120
120
120
1SU21001 Three-Phase - 1 HP 1 A 200-230 7.0 2.8 5.0 70
1SU24001 Three-Phase - 1 HP
4 kHz Carrier
6 kHz Carrier
8 kHz Carrier
4X/12 A 200-230
200-230
200-230
6.4
5.2
5.2
2.6
2.0
2.0
4.5
3.6
3.6
70
70
70
1SU21002 Three-Phase - 2 HP
4 kHz Carrier
6 kHz Carrier
8 kHz Carrier
1A
200-230
200-230
200-230
9.9
9.3
8.7
4.0
3.8
3.5
7.5
7.0
6.5
70
70
70
1SU24002 Three-Phase - 2 HP 4X/12 C 200-230 9.9 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 3.3 3.4 100
1SU44002 Three-Phase - 2 HP 4X/12 B 380-460 4.2 3.3 3.4 100
1SU41003 Three-Phase - 3 HP 1 B 380-460 6.4 5.1 5.3 140
1SU44003 Three-Phase - 3 HP 4X/12 B 380-460 6.4 5.1 5.3 140
1SU41005 Three-Phase - 5 HP 1 B 380-460 9.9 8.0 8.2 180
1SU44005 Three-Phase - 5 HP 4X/12 B 380-460 9.9 8.0 8.2 180
1SU41007 Three-Phase - 7.5 HP 1 C 380-460 13.4 10.7 11.1 210
1SU44007 Three-Phase - 7.5 HP 4X/12 C 380-460 13.4 10.7 11.1 210
1SU41010 Three-Phase - 10 HP 1 C 380-460 17.2 13.7 14.2 250
1SU44010 Three-Phase - 10 HP 4X/12 C 380-460 17.2 13.7 14.2 250
1SU41015 Three-Phase - 15 HP 1 D 380-460 25.4 20.2 21.0 375
1SU42015 Three-Phase - 15 HP 12 D 380-460 25.4 20.2 21.0 375
1SU41020 Three-Phase - 20 HP 1 D 380-460 32.7 26.1 27.0 600
1SU42020 Three-Phase - 20 HP 12 D 380-460 32.7 26.1 27.0 600
1SU51001 Three-Phase - 1 HP 1 B 575 2.0 2.0 1.6 50
1SU54001 Three-Phase - 1 HP 4X/12 B 575 2.0 2.0 1.6 50

2-8 SP500 AC Drive Installation and Operation Manual Version 3.1
Table 2.2 - Power and NEMA Enclosure Ratings (Continued)
* To properly size the drive for motor nameplate horsepower and amps, refer to section 3.5 for more information. Derating for 4, 6, 8kHz
carrier frequencies is not required except for the units indicated.
** Refer to section 2.3.2 for more information on enclosure sizes.
*** Full-load at all carrier frequencies. Refer to section 3.1.3 for more information.
2.3.2 Enclosure Ratings and Sizes
Each of the SP500 drives have one of the following NEMA ratings:
See table 2.2 for a listing of drive model numbers and their individual NEMA ratings.
For clarity in this manual, SP500 drive enclosures are identified by size as enclosures
A through D. Refer to table 2.2 for a listing of the drive model numbers and their
individual enclosure sizes. Refer to section 3.1.1 for the dimensions of enclosures A
through D.
2.4 Component Locations
Figures 2.5 through 2.8 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
1SU54003 Three-Phase - 3 HP 4X/12 B 575 5.2 5.1 4.3 120
1SU51005 Three-Phase - 5 HP 1 B 575 7.5 7.5 6.2 150
1SU54005 Three-Phase - 5 HP 4X/12 B 575 7.5 7.5 6.2 150
1SU51007 Three-Phase - 7.5 HP 1 C 575 10.9 10.9 9.0 180
1SU54007 Three-Phase - 7.5 HP 4X/12 C 575 10.9 10.9 9.0 180
1SU51010 Three-Phase - 10 HP 1 C 575 14.5 14.4 12.0 250
1SU54010 Three-Phase - 10 HP 4X/12 C 575 14.5 14.4 12.0 250
NEMA
Rating Description
1 Vented. For general-purpose indoor applications.
4X/12 Not vented. Supplied with base and keypad gaskets. For use in indoor
environments that require a water-tight and dust-tight enclosure. An
enclosure with this NEMA rating encompasses both ratings (4X and 12).
12 Intended for use in indoor environments that require a dust-tight and
drip-tight enclosure.

Learning 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

2-10 SP500 AC Drive Installation and 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