Rockwell Automation Reliance electric 6SB401 Series User manual

Instruction Manual
SP600 AC Drive
User Manual
Version 3.0
6SB401 Series
20 HP to 200 HP @ 460 VAC
20 HP to 150 HP @ 575 VAC
D2-3501-5
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©2004 Rockwell Automation. All rights reserved.
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.
ControlNet is a trademark of ControlNet International Ltd.
DeviceNet is a trademark of Open DeviceNet Vendor Association.
SP600, VS Utilities, and Reliance are trademarks of Rockwell Automation.
!
ATTENTION: Only qualified personnel familiar with the
construction and operation of this equipment and the hazards
involved should install, adjust, operate, or service this
equipment. Read and understand this document in its entirety
before proceeding. Failure to observe this precaution could
result in severe bodily injury or loss of life.
ATTENTION: DC bus capacitors retain hazardous voltages
after input power has been removed. After disconnecting input
power, wait five 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. Failure to observe this precaution could result in
severe bodily injury or loss of life.
ATTENTION: The drive can operate at and maintain zero
speed. The user is responsible for assuring safe conditions for
operating personnel by providing suitable guards, audible or
visual alarms, or other devices to indicate that the drive is
operating, or may operate, at or near zero speed. Failure to
observe this precaution could result in severe bodily injury or
loss or life.
ATTENTION: The drive contains ESD- (Electrostatic
Discharge) sensitive parts and assemblies. Static control
precautions are required when installing, testing, servicing, or
repairing the drive. Erratic machine operation and damage to,
or destruction of, equipment can result if this procedure is not
followed. Failure to observe this precaution can result in bodily
injury.
ATTENTION: The user must provide an external, hardwired
emergency stop circuit outside of the drive circuitry. This
circuitry must disable the system in case of improper
operation. Uncontrolled machine operation may result if this
procedure is not followed. Failure to observe this precaution
could result in bodily injury.
ATTENTION: The user is responsible for conforming with all
applicable local and national codes. Failure to observe this
precaution could result in damage to, or destruction of, the
equipment.
Trademarks not belonging to Rockwell Automation are property of their
respective companies.
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Contents
I
C
ONTENTS
Chapter 1 Introduction
1.1 Manual Conventions ...................................................... 1-1
1.2 Getting Assistance from Reliance Electric..................... 1-1
Chapter 2 About the Drive
2.1 Identifying the Drive by Model Number.......................... 2-1
2.2 Power and NEMA Enclosure Ratings ............................ 2-2
2.3 Overview of SP600 Features......................................... 2-4
2.3.1 Analog Inputs....................................................... 2-4
2.3.2 Analog Outputs.................................................... 2-5
2.3.3 Digital Outputs ..................................................... 2-5
2.3.4 Multiple Control Modes........................................ 2-5
2.3.5 Multiple Stop Methods ......................................... 2-6
2.3.6 Multiple Speed Control Methods ......................... 2-6
2.3.7 Auto/Manual Reference Selection ....................... 2-6
2.3.8 Seven Preset Frequency Setpoints ..................... 2-7
2.3.9 Motor-Operated Potentiometer (MOP) Function . 2-7
2.3.10 Auto Restart (Reset/Run) .................................... 2-7
2.3.11 Autotune .............................................................. 2-8
2.3.12 Drive Protection Current Limit ............................. 2-8
2.3.13 Drive Overload Protection ................................... 2-9
2.3.14 Motor Overload Protection................................. 2-10
2.3.15 .Shear Pin Fault................................................. 2-10
2.3.16 .Drives Peripheral Interface (DPI)...................... 2-10
2.3.17 Network Data Transfer via Datalinks ................. 2-11
2.3.18Programmable Parameter Access Levels and
Protection .......................................................... 2-11
2.3.19 Process PI Loop ................................................ 2-11
2.3.20 S Curve.............................................................. 2-12
2.3.21Three Skip Bands (Avoidance Frequencies) ..... 2-12
2.3.22 Flying Start ........................................................ 2-12
2.3.23 Voltage Class .................................................... 2-12
2.3.24 Motor Cable Lengths ........................................ 2-13
2.3.25 Economizer Mode............................................. 2-13
2.3.26 Fan Curve ......................................................... 2-13
2.3.27Programmable Parameter Access Levels and
Protection .......................................................... 2-14
2.3.28 User Sets........................................................... 2-14
2.3.28.1Normal Mode...................................... 2-14
2.3.28.2Dynamic Mode ................................... 2-15
2.4 CE Conformity ............................................................. 2-17
2.4.1 Essential Requirements for CE Compliance ..... 2-18
2.5 Drive Connections ....................................................... 2-19
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SP600 AC Drive User Manual
2.6 Drive Communication Options ..................................... 2-21
2.7 Remote Operator Interface .......................................... 2-21
2.7.1 Connecting the Remote OIM or VS Utilities
to the Drive................................................................... 2-21
2.8 PC-Based Utility........................................................... 2-22
Chapter 3 Mounting the Drive
3.1 General Requirements for the Installation Site .............. 3-2
3.1.1 Verifying Power Module AC Input Ratings Match
Available Power................................................... 3-2
3.1.1.1 Unbalanced or Ungrounded Distribution
Systems ................................................ 3-2
3.1.1.2 Input Power Conditioning...................... 3-4
3.1.1.3 AC Input Phase Selection (60HP and
Larger) .................................................. 3-4
3.1.1.4 Selecting/Verifying Fan Voltage (60HP and
Larger) .................................................. 3-4
3.1.2 Making Sure Environmental Conditions are Met . 3-5
3.1.3 Minimum Mounting Clearances ........................... 3-6
3.1.4 Drive Dimensions and Weights............................ 3-7
3.2 Mounting the Drive....................................................... 3-11
3.2.1 Verifying the Drive’s Watts Loss Rating............. 3-11
Chapter 4 Wiring Requirements for the Drive
4.1 Power Wiring.................................................................. 4-1
4.1.1 Power Wire Sizes ................................................ 4-3
4.1.2 Using Input/Output Contactors ............................ 4-4
4.2 Control and Signal Wire Sizes ....................................... 4-5
4.3 Recommended Motor Lead Lengths.............................. 4-5
4.3.1 Reflected Wave Compensation ........................... 4-6
4.4 Selecting Input Line Branch Circuit Protection............... 4-9
4.5 Verifying Power Module Output Current Rating
is Greater than Motor Full Load Amps........................... 4-9
Chapter 5 Finding Wire-Routing Locations and Grounding
5.1 Routing Input, Motor Output, Ground, and Control Wiring
for the Drive................................................................... 5-1
5.2 Grounding the Drive....................................................... 5-4
Chapter 6 Installing Power Wiring
6.1 Opening the Cover......................................................... 6-1
6.2 Installing Output Power Wiring....................................... 6-2
6.3 Installing Input Wiring..................................................... 6-3
6.3.1 Installing an Optional Transformer and Reactor .. 6-3
6.3.2 Installing Fuses for Branch Circuit Protection...... 6-4
6.3.3 Installing the Required Input Disconnect ............. 6-4
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Contents
III
6.3.4 Installing Power Wiring from the AC Input Line to the
Drive’s Power Terminals ..................................... 6-4
Chapter 7 Installing Control Wiring
7.1 Stop Circuit Requirements............................................. 7-1
7.1.1 User-Initiated Stopping ........................................ 7-2
7.2 Control and Signal Inputs .............................................. 7-2
7.3 Removing the I/O Terminal Block.................................. 7-2
7.4 Wiring the Signal and Control I/O .................................. 7-2
7.5 I/O Wiring Examples ...................................................... 7-6
7.6 Wiring Diagram - Control and Motor .............................. 7-7
7.7 Speed Reference Control ............................................ 7-10
7.7.1 Auto Reference Sources ................................... 7-10
7.7.2 Manual Reference Sources ............................... 7-10
7.7.3 Changing Reference Sources ........................... 7-11
7.7.4 Auto/Manual Control.......................................... 7-11
7.8 Remote OIM Configuration .......................................... 7-12
Chapter 8 Completing the Installation
8.1 Checking the Installation................................................ 8-1
8.2 Powering Up after Installation is Complete.................... 8-2
Chapter 9 Using the Start-Up Routines on the LCD OIM
9.1 Preparing for Start-Up.................................................... 9-1
9.2 Running the Start-Up Routines...................................... 9-2
9.2.1 Sensorless Vector Performance.......................... 9-4
9.2.2 High Speed Operation (>120 Hz) ........................ 9-5
9.3 Start/Stop Control .......................................................... 9-5
9.4 Speed Reference........................................................... 9-6
9.5 Changing the Speed of the Drive (Setpoint Control) ..... 9-6
Chapter 10 Programming Basics
10.1 About Parameters........................................................ 10-1
10.2 How Parameters are Organized .................................. 10-2
10.3 Accessing the Parameters........................................... 10-3
10.3.1 Selecting the Parameter Access Level.............. 10-4
10.3.2 Restricting Access to Other Parameter Levels.. 10-5
10.4 Ensuring Program Security.......................................... 10-6
Chapter 11 Parameter Descriptions
Chapter 12 Troubleshooting the Drive
12.1 Verifying that DC Bus Capacitors are Discharged
Before Servicing the Drive ......................................... 12-1
12.2 Determining Precharge Board Status Using the LED
Indicators (Frames 5 & 6 Only) ................................... 12-3
12.3 Determining Drive Status Using the Ready LED ......... 12-4
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SP600 AC Drive User Manual
12.4 About Alarms ............................................................... 12-5
12.4.1 About the Alarm Queue ..................................... 12-5
12.4.2 Alarm Descriptions............................................. 12-6
12.5 About Faults................................................................. 12-9
12.5.1 About the Fault Queue..................................... 12-10
12.5.2 Clearing Faults................................................. 12-11
12.5.3 Fault Descriptions and Corrective Actions....... 12-12
12.6 Common Symptoms and Corrective Actions ............. 12-19
12.7 Replacement Parts .................................................... 12-23
12.8 Troubleshooting the Drive Using the LCD OIM.......... 12-23
12.8.1 Accessing the Fault Queue.............................. 12-24
12.8.2 Accessing the Fault Parameters...................... 12-25
12.8.3 Accessing the Drive Status Parameters .......... 12-25
12.8.4 Determining the Product Version..................... 12-26
12.8.5 Contacting Tech Support for Assistance ......... 12-28
Appendix A Technical Specifications
Appendix B Using the LCD OIM
Appendix C Parameters Cross-Referenced by Name
Appendix D Analog Input Selection Path
Appendix E Process PI Block Diagram
Appendix F Record of User Settings: Advanced Access Level
Index
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Contents
V
List of Figures
Figure 2.1 – Identifying the Drive by Model Number................................... 2-2
Figure 2.2 – Normal Mode Operation ....................................................... 2-14
Figure 2.3 – Dynamic Mode Operation..................................................... 2-16
Figure 2.4 – Drive Connections ................................................................ 2-20
Figure 3.1 – Typical Jumper Locations ...................................................... 3-3
Figure 3.2 – Selecting Input Phase and Fan Voltage (60HP and Larger)... 3-5
Figure 3.3 – Minimum Mounting Clearances .............................................. 3-6
Figure 3.4 – Panel-Mount Drive Dimensions - Frames 2 and 3.................. 3-7
Figure 3.5 – Panel Mount Drive Dimensions - Frame 4.............................. 3-8
Figure 3.6 – Panel-Mount Drive Dimensions - Frame 5.............................. 3-9
Figure 3.7 – Panel-Mount Drive Dimensions - Frame 6............................ 3-10
Figure 4.1 – How to Calculate Typical Motor Lead Lengths ....................... 4-6
Figure 4.2 – Inverter and Motor Line-to-line Voltages................................. 4-7
Figure 4.3 – Motor Overvoltage as a Function of Cable Length ................. 4-8
Figure 5.1 – Wire Routing and Terminal Block Locations
(Frame 2 Shown) .................................................................. 5-2
Figure 5.2 – Wire Routing and Terminal Block Locations
(Frame 5 Shown) .................................................................. 5-3
Figure 5.3 – Typical Grounding................................................................... 5-4
Figure 5.4 – Single-Point Grounding/Panel Layout..................................... 5-5
Figure 6.1 – Opening the Drive Cover ........................................................ 6-1
Figure 6.2 – Power Terminal Block............................................................. 6-5
Figure 7.1 – Typical Wiring Diagram........................................................... 7-7
Figure 7.2 – Wiring Diagram - Default Drive Configuration......................... 7-9
Figure 7.3 – Speed Reference Control Flowchart..................................... 7-11
Figure 7.4 – Speed Reference Selection.................................................. 7-13
Figure 9.1 – Accessing the Start-Up Routines............................................ 9-2
Figure 9.2 – Start-Up Menu ........................................................................ 9-2
Figure 9.3 – Start/Stop Control using the Local OIM .................................. 9-5
Figure 9.4 – Two-Wire and Three-Wire Start/Stop Control......................... 9-5
Figure 9.5 – Analog Speed Reference........................................................ 9-6
Figure 10.1 – Example of Parameter Organization................................... 10-2
Figure 10.2 – Accessing the Parameters Using the LCD OIM.................. 10-3
Figure 10.3 – Selecting the Parameter Access Level............................... 10-4
Figure 10.4 – Setting the Access Level Password.................................... 10-5
Figure 10.5 – Setting the Write-Protect Password.................................... 10-6
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VI
SP600 AC Drive User Manual
Figure 11.1 – Motor Overload Hertz........................................................ 11-11
Figure 11.2 – Custom V/Hz Curve .......................................................... 11-12
Figure 11.3 – Fan/Pump Curve............................................................... 11-13
Figure 11.4 – Speed Limits ..................................................................... 11-13
Figure 11.5 – Compensation (56) ........................................................... 11-14
Figure 11.6 – Speed Control Method...................................................... 11-19
Figure 11.7 – Speed Limits ..................................................................... 11-20
Figure 11.8 – Trim Input Select............................................................... 11-26
Figure 11.9 – Trim Out Select (118)........................................................ 11-27
Figure 11.10 – PI Configuration (124)..................................................... 11-29
Figure 11.11 – PI Control (125)............................................................... 11-31
Figure 11.12 – PI Preload Value............................................................. 11-34
Figure 11.13 – PI Status (134)................................................................ 11-35
Figure 11.14 – Save OIM Ref (192)........................................................ 11-51
Figure 11.15 – Save MOP Ref (194)....................................................... 11-52
Figure 11.16 – Dyn UserSet Cnfg........................................................... 11-56
Figure 11.17 – DynUsrSetSel ................................................................. 11-57
Figure 11.18 – Drive Status 1 (209)........................................................ 11-58
Figure 11.19 – Drive Status 2 (210)........................................................ 11-59
Figure 11.20 – Drive Alarm 1 (211)......................................................... 11-60
Figure 11.21 – Drive Alarm 2 (212)......................................................... 11-60
Figure 11.22 – Start Inhibits (214)........................................................... 11-61
Figure 11.23 – Dig In Status (216).......................................................... 11-62
Figure 11.24 – Dig Out Status (217) ....................................................... 11-63
Figure 11.25 – Status 1 @ Fault (227).................................................... 11-65
Figure 11.26 – Status 2 @ Fault (228).................................................... 11-65
Figure 11.27 – Alarm 1 @ Fault (229) .................................................... 11-66
Figure 11.28 – Alarm 2 @ Fault (230) .................................................... 11-66
Figure 11.29 – Fault Config 1 (238) ........................................................ 11-68
Figure 11.30 – Alarm Config 1 (259)....................................................... 11-69
Figure 11.31 – Drive Logic Rslt (271) ..................................................... 11-70
Figure 11.32 – Manual Mask (286) ......................................................... 11-71
Figure 11.33 – Stop Owner ..................................................................... 11-72
Figure 11.34 – Manual Owner................................................................. 11-72
Figure 11.35 – Anlg In Config (320)........................................................ 11-76
Figure 11.36 – Anlg In Sqr Root (321) .................................................... 11-76
Figure 11.37 – Analog Out Config........................................................... 11-80
Figure 11.38 – Anlg Out Absolute (341).................................................. 11-80
Figure 12.1 – Location of DC Bus Voltage Measuring Points................... 12-2
Figure 12.2 – Location of Precharge Status LED...................................... 12-3
Figure 12.3 – Location of the Ready LED................................................. 12-4
Figure 12.4 – Sample Fault Screen on the LCD OIM ............................. 12-10
Figure 12.5 – Accessing the Fault Queue............................................... 12-24
Figure 12.6 – Sample Fault Queue Entry................................................ 12-24
Figure 12.7 – Accessing the Fault Parameters....................................... 12-25
Figure 12.8 – Accessing the Drive Status Parameters ........................... 12-25
Figure 12.9 – Accessing the Device Version Information ....................... 12-26
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Contents
VII
Figure 12.10 – Device Version Screens at Product
and Component Levels............................................... 12-26
Figure 12.11 – Accessing the OIM Version Information ......................... 12-27
Figure 12.12 – OIM Version Screens at the Product
and Component Levels............................................... 12-27
Figure 12.13 – Accessing the Device Item Information .......................... 12-27
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VIII
SP600 AC Drive User Manual
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