Rockwell Automation Reliance electric SP600 Series User manual

Instruction Manual
SP600 AC Drive
User Manual
Version 2.0
0.5 to 10 HP @ 230 VAC
0.5 to 50 HP @ 460 VAC
0.5 to 20 HP @ 600 VAC
D2-3485-4
NEMA 4X/12 NEMA 1

©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.
SP600, VS Utilities, and Reliance are trademarks of Rockwell Automation.
!
ATTENTION:Only qualified personnel familiar with the
construction and operation ofthisequipment andthehazards
involved should install, adjust, operate, or service this
equipment. Readandunderstandthisdocumentinitsentirety
before proceeding. Failure to observe this precaution could
result in severe bodily injury or loss of life.
ATTENTION:DC bus capacitors retain hazardous voltages
afterinputpowerhasbeenremoved.Afterdisconnectinginput
power,waitfiveminutesfortheDCbuscapacitorstodischarge
and then check the voltage with a voltmeter to ensure the DC
bus capacitors are discharged before touching any internal
components.Failure to observethisprecaution couldresultin
severe bodily injury or loss of life.
ATTENTION:The drive can operate at and maintain zero
speed.The userisresponsibleforassuringsafeconditionsfor
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
precautionsarerequiredwheninstalling,testing,servicing, or
repairing the drive. Erratic machine operation and damage to,
or destruction of, equipment can result if this procedure is not
followed.Failureto observethisprecautioncanresult inbodily
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.

Contents I
CONTENTS
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.......................... 2-2
2.2 Identifying the Drive by Frame Size............................... 2-3
2.3 Power Enclosure Ratings .............................................. 2-3
2.4 Overview of SP600 Drive Features ............................... 2-7
2.4.1 Analog Inputs....................................................... 2-7
2.4.2 Analog Output...................................................... 2-7
2.4.3 Digital Outputs..................................................... 2-7
2.4.4 Multiple Control Modes........................................ 2-8
2.4.5 Multiple Stop Methods......................................... 2-8
2.4.6 Multiple Speed Control Methods ......................... 2-8
2.4.7 Auto/Manual Reference Selection....................... 2-9
2.4.8 Seven Preset Frequency Setpoints..................... 2-9
2.4.9 Motor-Operated Potentiometer (MOP) Function . 2-9
2.4.10Auto Restart (Reset/Run).................................... 2-9
2.4.11Autotune............................................................ 2-10
2.4.12Drive Protection Current Limit ........................... 2-11
2.4.13Drive Overload Protection ................................. 2-11
2.4.14Motor Overload Protection................................. 2-12
2.4.15Shear Pin Fault.................................................. 2-12
2.4.16Drive Peripheral Interface (DPI) ........................ 2-12
2.4.17Network Data Transfer via Datalinks................. 2-12
2.4.18Programmable Parameter Access Levels and
Protection.......................................................... 2-13
2.4.19User Sets........................................................... 2-13
2.4.19.1Normal Mode...................................... 2-13
2.4.19.2Dynamic Mode ................................... 2-14
2.4.20Process PI Loop................................................ 2-16
2.4.21S Curve.............................................................. 2-16
2.4.22Three Skip Bands (Avoidance Frequencies)..... 2-16
2.4.23Flying Start ........................................................ 2-17
2.4.24Voltage Class .................................................... 2-17
2.4.25Motor Cable Lengths......................................... 2-17
2.4.26Economizer Mode.............................................. 2-18
2.4.27Fan Curve.......................................................... 2-18
2.5 CE Conformity ............................................................. 2-18
2.5.1 Essential Requirements for CE Compliance ..... 2-19
2.6 Drive Connections ....................................................... 2-21
2.7 Drive Communication Options..................................... 2-23

II SP600 AC Drive User Manual
2.8 Remote Operator Interface..........................................2-23
2.8.1 Connecting the Remote OIM or VS Utilities
to the Drive.......................................................2-23
2.9 PC-Based Utility...........................................................2-24
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................................................3-3
3.1.1.2 Input Power Conditioning......................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.......................................................3-12
3.2.1 Verifying the Drive’s Watts Loss Rating.............3-15
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.................................................4-5
4.3 Recommended Motor Lead Lengths..............................4-5
4.3.1 Reflected Wave Compensation ...........................4-7
4.4 Selecting Input Line Branch Circuit Protection...............4-9
Chapter 5 Finding Wire-Routing Locations and Grounding the Drive
5.1 Routing Input, Motor Output, Ground, and Control Wiring
for the Drive...................................................................5-1
5.2 Grounding the Drive.......................................................5-3
Chapter 6 Installing Power Wiring
6.1 Removing and Replacing the Cover..............................6-1
6.1.1 Removing and Replacing the Cover on NEMA 1
Drives ..................................................................6-1
6.1.2 Removing and Replacing the Cover on NEMA 4x/12
Drives ..................................................................6-2
6.1.2.1 Locking the Cover.................................6-4
6.2 Installing Output Power Wiring.......................................6-5
6.3 Installing Input Wiring.....................................................6-6
6.3.1 Installing an Optional Transformer and Reactor..6-6
6.3.2 Installing Branch Circuit Protection......................6-7
6.3.3 Installing the Required External/Separate Input
Disconnect...........................................................6-7
6.3.4 Installing Power Wiring from the AC Input Line to the
Drive’s Power Terminals .....................................6-7
6.4 Dynamic Braking Connections.......................................6-9

Contents III
Chapter 7 Installing Control Wiring
7.1 Stop Circuit Requirements............................................. 7-1
7.1.1 User-Initiated Stopping........................................ 7-2
7.2 Wiring the Signal and Control I/O.................................. 7-2
7.3 I/O Wiring Examples...................................................... 7-5
7.4 Wiring Diagram - Control and Motor.............................. 7-7
7.5 Speed Reference Control............................................ 7-10
7.5.1 Auto Reference Sources ................................... 7-10
7.5.2 Manual Reference Sources............................... 7-10
7.5.3 Changing Reference Sources ........................... 7-11
7.5.4 Auto/Manual Control.......................................... 7-11
7.6 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 LCD OIM
9.1 Connections................................................................... 9-1
9.2 Installing and Removing the Local LCD OIM (NEMA 1
Drives Only)................................................................... 9-2
9.2.1 Removing the Local LCD OIM While the Drive is
Powered.............................................................. 9-2
9.3 Display Description........................................................ 9-3
9.3.1 Key Descriptions.................................................. 9-4
9.4 LCD OIM Menu Structure.............................................. 9-5
9.5 Powering Up and Adjusting the LCD OIM ..................... 9-6
9.5.1 Selecting the Fast Power Up Feature.................. 9-6
9.5.2 Adjusting the Screen Contrast............................. 9-6
9.5.3 Resetting the Display........................................... 9-6
9.6 Selecting a Device in the System.................................. 9-6
9.7 Using the LCD OIM to Program the Drive ..................... 9-6
9.7.1 Viewing and Adjusting Parameters...................... 9-7
9.7.2 Loading and Saving User Sets............................ 9-8
9.8 Monitoring the Drive Using the Process Display
Screen on the LCD OIM.............................................. 9-10
9.8.1 Displaying and Changing the OIM Reference... 9-11
9.8.2 Customizing the Process Display Screen.......... 9-12
9.8.3 Customizing the Function Keys......................... 9-12
9.8.3.1 Customizing the Function Key
Label Text......................................... 9-15
9.8.4 Setting the Display Timeout Period................... 9-15
9.8.5 Selecting Reverse Video for the Process
Display Screen................................................. 9-16
9.9 Controlling the Drive From the LCD OIM..................... 9-16
9.9.1 Selecting the Logic and Reference Source....... 9-17
9.9.2 Starting the Drive............................................... 9-17
9.9.3 Stopping the Drive............................................. 9-17
9.9.4 Changing Motor Direction.................................. 9-18

IV SP600 AC Drive User Manual
9.9.5 Jogging the Drive...............................................9-18
Chapter 10 Starting Up the Drive Using the LCD OIM
10.1Preparing for Start-Up..................................................10-1
10.2Running the Start-Up Routines....................................10-2
10.3Other Start-Up Considerations.....................................10-5
10.3.1Sensorless Vector Performance........................10-5
10.3.2Operation Over Wide Speed Ranges (>120 Hz)10-5
10.3.3Start/Stop Control..............................................10-5
10.3.4Speed Reference Source ..................................10-6
Chapter 11 Programming Basics
11.1About Parameters........................................................11-1
11.2How Parameters are Organized ..................................11-2
11.3Accessing the Parameters...........................................11-3
11.3.1Accessing Parameters By Group.......................11-4
11.3.2Accessing Parameters by Number....................11-4
11.3.3Accessing Changed Parameters.......................11-4
11.3.4Selecting the Parameter Access Level..............11-5
11.3.5Using the Parameter Access Level Password to
Restrict Access to Other Parameter Levels.......11-6
11.4Using the Write-Protect Password to Ensure Program
Security........................................................................11-7
Chapter 12 Parameter Descriptions
Chapter 13 Troubleshooting the Drive
13.1Verifying that DC Bus Capacitors are Discharged Before
Servicing the Drive ......................................................13-1
13.2Determining Drive Status Using the Ready LED .........13-3
13.3About Alarms ...............................................................13-4
13.3.1Alarm Descriptions.............................................13-5
13.4About Faults.................................................................13-7
13.4.1About the Fault Queue.......................................13-9
13.4.2Clearing Faults.................................................13-10
13.4.3Fault Descriptions and Corrective Actions.......13-11
13.5Test Point Codes and Functions................................13-17
13.6Common Symptoms and Corrective Actions.............13-18
13.7Replacement Parts ....................................................13-23
13.8Troubleshooting the Drive Using the LCD OIM..........13-23
13.8.1Accessing the Fault Queue..............................13-24
13.8.2Accessing the Fault Parameters......................13-24
13.8.3Accessing the Drive Status Parameters..........13-25
13.8.4Accessing the List of Changed Parameters.....13-25
13.8.5Determining the Product Version.....................13-26
13.8.6Contacting Tech Support for Assistance .........13-28

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 (NEMA 1 Drives) .................................... 2-21
Figure 2.5 – Drive Connections (NEMA 4 Drives) .................................... 2-22
Figure 2.6 – DPI Port 2 on NEMA 4 Drives............................................... 2-24
Figure 3.1 – Typical Jumper Locations (C Frame Shown).......................... 3-3
Figure 3.2 – Phase-to-Ground MOV Removal............................................ 3-4
Figure 3.3 – Minimum Mounting Clearances.............................................. 3-6
Figure 3.4 – Panel-Mount Drive Dimensions.............................................. 3-7
Figure 3.5 – Flange-Mount Drive Dimensions ............................................ 3-8
Figure 3.6 – SP600 IP20/ Nema Type 1 Bottom View Dimensions............ 3-9
Figure 3.7 – SP600 IP66 (NEMA Type 4X/12) Bottom View Dimensions 3-10
Figure 3.8 – SP600 Flange-Mount Bottom View Dimensions................... 3-11
Figure 3.9 – A-Frame Flange-Mount Cutout Dimensions......................... 3-12
Figure 3.10 – B-Frame Flange-Mount Cutout Dimensions....................... 3-13
Figure 3.11 – C-Frame Flange-Mount Cutout Dimensions....................... 3-13
Figure 3.12 – D-Frame Flange-Mount Cutout Dimensions....................... 3-14
Figure 3.13 – E-Frame Flange-Mount Cutout Dimensions....................... 3-14
Figure 4.1 – How to Calculate 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 – Typical Wire Routing and Terminal Block Locations
(5 HP Drive Shown)............................................................. 5-2
Figure 5.2 – Typical Grounding................................................................... 5-3
Figure 5.3 – Single-Point Grounding/Panel Layout..................................... 5-3
Figure 6.1 – Removing the Drive Cover (NEMA 1 Drives).......................... 6-2
Figure 6.2 – Removing the Drive Cover (NEMA 4x/12 Drives)
Frames B4 and D4 shown. .................................................. 6-3
Figure 6.3 – Installing Plugs in Unused Holes in Conduit Entry Plate
on NEMA 4X/12 Drives........................................................ 6-4
Figure 6.4 – Location of Slots for User-Supplied Locks
on NEMA 4x/12 Drives......................................................... 6-4
Figure 6.5 – Power Terminal Block............................................................. 6-8
Figure 6.6 – Power Input Terminals on the Internal RFI Filter Option........ 6-8
Figure 6.7 – Simplified Dynamic Braking Schematic.................................. 6-9
Figure 6.8 – Protective Circuit for External Resistor Packages................ 6-10
Figure 7.1 – I/O Wiring Diagram................................................................. 7-7
Figure 7.2 – Wiring Diagram: Default Drive Configuration.......................... 7-9

VI SP600 AC Drive User Manual
Figure 7.3 – Speed Reference Control Flowchart.....................................7-11
Figure 7.4 – Speed Reference Selection..................................................7-13
Figure 9.1 – SP600 LCD OIM.....................................................................9-1
Figure 9.2 – Installing and Removing the Local LCD OIM (NEMA 1 Only).9-2
Figure 9.3 – The Display (Main Menu Shown)............................................9-3
Figure 9.4 – LCD OIM Menu Structure.......................................................9-5
Figure 9.5 – Adjusting Parameters..............................................................9-7
Figure 9.6 – Save to User Set.....................................................................9-8
Figure 9.7 – Assigning a Custom Name to a User Set...............................9-9
Figure 9.8 – Load From User Set..............................................................9-10
Figure 9.9 – Process (User) Display Screen.............................................9-11
Figure 9.10 – OIM Reference Displayed...................................................9-11
Figure 9.11 – Customizing the Process Display Screen...........................9-12
Figure 9.12 – Accessing the Function Key Configuration Screens...........9-13
Figure 9.13 – Customizing the Function Key Label Text ..........................9-15
Figure 9.14 – Selecting Reverse Video for the Process Display Screen..9-16
Figure 9.15 – Selecting the Control and Reference Source......................9-17
Figure 10.1 – Accessing the Start-Up Routines........................................10-2
Figure 10.2 – Start-Up Menu.....................................................................10-2
Figure 10.3 – Start/Stop Control using the Local OIM ..............................10-5
Figure 10.4 – Two-Wire and Three-Wire Start/Stop Control.....................10-6
Figure 10.5 – Analog Speed Reference....................................................10-6
Figure 11.1 – Example of Parameter Organization...................................11-2
Figure 11.2 – Accessing the Parameters Using the LCD OIM..................11-3
Figure 11.3 – Parameter Access Levels...................................................11-5
Figure 11.4 – Selecting the Parameter Access Level...............................11-5
Figure 11.5 – Setting the Access Level Password....................................11-6
Figure 11.6 – Setting the Write-Protect Password....................................11-7
Figure 12.1 – Motor OL Hertz (47)..........................................................12-11
Figure 12.2 – Custom V/Hz Curve..........................................................12-12
Figure 12.3 – Fan/Pump Curve...............................................................12-13
Figure 12.4 – Speed Limits.....................................................................12-13
Figure 12.5 – Compensation (56) ...........................................................12-14
Figure 12.6 – Speed Control Method......................................................12-18
Figure 12.7 – Speed Limits.....................................................................12-19
Figure 12.8 – Skip Freq Band (87)..........................................................12-20
Figure 12.9 – Logic Source Sel (89) .......................................................12-22
Figure 12.10 – Reference Selection........................................................12-24
Figure 12.11 – Trim Input Select.............................................................12-27
Figure 12.12 – Trim Out Select (118)......................................................12-28
Figure 12.13 – PI Configuration (124).....................................................12-30
Figure 12.14 – PI Control (125)...............................................................12-32
Figure 12.15 – PI Regulator....................................................................12-32
Figure 12.16 – PI Preload Value.............................................................12-35

Contents VII
Figure 12.17 – PI Status (134)................................................................ 12-36
Figure 12.18 – Selecting Stop Mode B................................................... 12-40
Figure 12.19 – Coast to Stop (Stop Mode A = 0).................................... 12-41
Figure 12.20 – Ramp Stop (Stop Mode A = 1) ....................................... 12-41
Figure 12.21 – Ramp to Hold (Stop Mode A = 2) ................................... 12-42
Figure 12.22 – DC Brake (Stop Mode A = 3).......................................... 12-42
Figure 12.23 – Selecting Bus Reg Mode B............................................. 12-46
Figure 12.24 – Protective Circuit for External Resistor Packages.......... 12-47
Figure 12.25 – Save OIM Ref (192)........................................................ 12-54
Figure 12.26 – Save MOP Ref (194)...................................................... 12-55
Figure 12.27 – Configuring Digital Inputs for MOP Inc and MOP Dec.... 12-55
Figure 12.28 – Dyn UserSet Cnfg........................................................... 12-59
Figure 12.29 – DynUsrSetSel................................................................. 12-60
Figure 12.30 – Drive Status 1 (209)........................................................ 12-61
Figure 12.31 – Drive Status 2 (210)........................................................ 12-62
Figure 12.32 – Drive Alarm 1 (211)......................................................... 12-63
Figure 12.33 – Drive Alarm 2 (212)......................................................... 12-63
Figure 12.34 – Start Inhibits (214).......................................................... 12-64
Figure 12.35 – Dig In Status (216).......................................................... 12-65
Figure 12.36 – Dig Out Status (217)....................................................... 12-66
Figure 12.37 – Status 1 @ Fault (227) ................................................... 12-68
Figure 12.38 – Status 2 @ Fault (228) ................................................... 12-68
Figure 12.39 – Alarm 1 @ Fault (229).................................................... 12-69
Figure 12.40 – Alarm 2 @ Fault (230).................................................... 12-69
Figure 12.41 – Fault Config 1 (238)........................................................ 12-71
Figure 12.42 – Alarm Config 1 (259)....................................................... 12-72
Figure 12.43 – Drive Logic Rslt (271)..................................................... 12-73
Figure 12.44 – Manual Mask (286)......................................................... 12-74
Figure 12.45 – Stop Owner..................................................................... 12-75
Figure 12.46 – Manual Owner ................................................................ 12-75
Figure 12.47 – Data Received By the Drive From the Network.............. 12-76
Figure 12.48 – Data Sent By the Drive To the Network.......................... 12-78
Figure 12.49 – Anlg In Config (320)........................................................ 12-79
Figure 12.50 – Anlg In Sqr Root (321).................................................... 12-80
Figure 12.51 – Analog Input Scaling Example........................................ 12-81
Figure 12.52 – Anlg Out Absolute (341)................................................. 12-85
Figure 12.53 – Dig Out1 OffTime (383) .................................................. 12-97
Figure 12.54 – Dig Out2 OffTime (387) ................................................ 12-101
Figure 13.1 – Location of DC Bus Voltage Measuring Points................... 13-2
Figure 13.2 – Location of the Ready LED................................................. 13-3
Figure 13.3 – Sample Fault Screen on the LCD OIM............................... 13-9
Figure 13.4 – Accessing the Fault Queue............................................... 13-24

VIII SP600 AC Drive User Manual
Figure 13.5 – Sample Fault Queue Entry................................................13-24
Figure 13.6 – Accessing the Fault Parameters.......................................13-24
Figure 13.7 – Accessing the Drive Status Parameters ...........................13-25
Figure 13.8 – Accessing the List of Changed Parameters......................13-25
Figure 13.9 – Accessing the Device Version Information .......................13-26
Figure 13.10 – Device Version Screens at Product and
Component Levels.......................................................13-26
Figure 13.11 – Accessing the OIM Version Information..........................13-27
Figure 13.12 – OIM Version Screens at the Product and
Component Levels.......................................................13-27
Figure 13.13 – Accessing the Device Item Information...........................13-27