Rockwell Automation Reliance SP500 User manual

RELIANCE
ELECTRIC S&S!
SP500 AC Drive
Installation and Operation Manual
Version 3.1
Instruction Manual D2-3356-5
Rockwell

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:
ATTENTION: Identifies information about practices or circumstances that can lead to personal
injury or death, property damage, or economic loss.
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: Only qualified electrical personnel familiar with the construction and operation of
this equipmentand the hazards involved should install, adjust, operate, and/or service this
equipment. Read and understand this manual in its entirety before proceeding.
Reliance, ReSource, and AutoMax are trademarks of Rockwell Automation.
©1999 Rockwell International Corporation

Introduction
1.1. Who Should Use This Manual .............:ccccccecceeeeeceeceeeeeeeeeeceaeeeseeeeseeeeetnneeeenees 1-4
1.2 Installation OVErVieW ............ecccceccccececeeceeeeeeceeeeeeeeeecaeeceeeesecaeeeeciaeeesereetineeesaes 1-1
1.3 Requesting Assistance from Reliance Electric .........0.....ccceeeeeceeeeeeeeeeeeeeteees 1-4
Learning About the SP500 Drive
2.1 Standard Features ...........eeccccceccececececeeceeeceeeeceeeceeeeeeseceeeeeeeeessueeeeeeeessaeeessieeens 2-1
2.2 Drive DOSCIIPTION ....... cee teeter eette tere rennet eee etntieee eet tnieeeeeeninineeeeennineeeesenaas 2-2
2.3 Identifying the Drive by Model NUmbet ...........0..ccccceececeeeeeeeeeeeeeteeeeeetnneeeeerenea 2-6
2.3.1 Power Ratings and NEMA Enclosure Ratings ......0......cccceceeseeeeeesiees 2-7
2.3.2 Enclosure Ratings and SIZeS ............c:cccccceeececeeeeeeeeceeeeseceeeeeeeeeentaeeesnees 2-8
2.4 Component Locations...........cccccccccccece cececeeceeeeee secre seeeseeeeeeseeeeseeeessiseeteneeees 2-8
2.5 Option Kits 22.2... cee ceccccec cece ceceeeececeeeeceeeeceaaeeecceeseaeeeesaaeeseeeeeseaeeeseeeeessueeessnees 2-13
SP500 System Planning
3.1. Installation Site Requirement .............::ccccecceecceeeeeeeeeeceeeeeeeeeseeeeeeeeeeteaeeeseneeees 3-1
3.1.1 Determining the Total Area Required for Installation ........0....cee 3-2
3.1.2 Providing Proper Air Flow Clearances, .........0...:ccccecccceeeceeesereetsteeeeeneees 3-4
3.1.3 Verifying the Drive’s Power Loss Rating ............:ccceeeeesseeeeeeeetteeeeeenees 3-4
3.2 Wiring Requirement .......... cece teeter eee eenneee eee enieeeeeetineeeeeeetiieeeeeetiieeeeertaa 3-4
3.2.1 Verifying Conduit SIZES ..0.... eee ccc ceeeeeeeceeceeeeeeeecaeeeseaeeesereeeestaeeesaees 3-4
3.2.2 Recommended Power Wire SiZ@S...........:::ccccceceeceeeceeeeseceeeeeeeeteteesenees 3-4
3.2.3 Recommended Control and Signal Wire SiZeS ..........0..eeeeeeteeeeeerees 3-6
3.2.4 Recommended Motor Lead Lengths ....00.......ccceeeeeereeeeeeteteeeeenteeeeeeenas 3-6
3.3 Selecting Input AC Line Branch Circuit FUS@S.........0...cccceeceeceeeeeeeeeeeeeeneeeeeeeees 3-8
3.4 Installing an Emergency Stop.........eccceccccecceeeceeeeeeeceeeeceeeeseneeeseneeseeeeeetnaeeesaees 3-9
3.4.1. Complying with Machinery Safety Standard EN 60204-1:1992 ............ 3-9
3.5 Motor Considerations ............cccccccccceeeeceeeceeeececeeeeneeeeeeeeeceeeseneeeesaeeeteueeeetiaeenes 3-9
3.5.1 Single-Motor Applications. ............ccccccceceeceeeceeceeeeeeeeceeeeseceeeeeeeeesntaeeesnees 3-9
3.5.2 Multiple-Motor Applications «2.0.0... ecccceeecteeeeeeeneeeeeeencieeeeeetneeeeeeeas 3-10
Installing theDrive
4.1. Mounting the Drive occ eer tree eerie reer eieeeeereiieeeeeeninineeeeennineeeeeenias 4-1
4.2 ROUTING WIPES 000... etree cette eee rete ee erent eee e tees eee tneeeeeeninineeeeennineeeesenias 4-1
4.3 Installing External Component. ............:::cccccceeceeeeeeceeeeeeeeeeeeseeeeeeeeetsaeeeteneeees 4-6
4.3.1 DISCONNECHS ..0.0.. ee eee teenie eee ener eee eeineeeeeeedieeeeseeinieeeeteniineeeesenas 4-6
4.3.2 Input AC Line Branch Protection .............c:cccceccceeeseeeeceeeeeeeeeereeessteeesnees 4-6
4.3.3 TransfOrMerS ........ 0c cece er ee eceee eee ecieeeeeencieeeeeeenieeeeeeeinineeeeeeineeeeenniees 4-6
4.3.4 Output Contactors ........eccccccccceeeceeceeeeeeeeeeeceeeeseeeeseceeseceeesereeesnneesenees 4-7
4.3.5 Mechanical Motor Overload Protection .............::c:cccceeceeeseeeeeeeeeeeeeeees 4-7
4.4 Setting the Analog Input Jumper on the Regulator Board ............::::ecceee 4-7
4.5 Preparing the MOtor......... ccc etter ee etieeeeeeeicieeeeetiieeeeeesieeeeesniineeeeeenaees 4-8
Contents

Wiring theDrive
5.1 Input Power WING... ee eeccceeeee tire ee einieeeeerieeeeeeeeeeeeeniieeeeeetieeeeeeen 5-1
5.2 Signal and Control Wiring ...........cccccecccceeeeeeceeeeceeeceeeeeeeeeeceeesecaeeeeeeesseeeeesnnees 5-3
5.2.1 Analog Speed Reference Wiring ...........cccccccccecceeeceeeeeteeeeeeeeeeeeetsneeeeees 5-3
5.2.2 Amalog Output Wiring........0..cccccccecccceeececeeeeeeceeeeeeeeeeeseaeeeeeeeeeesureetnnaeeesees 5-4
5.2.3 Digital Input WING... cece ee encteee eee ttieeeeeesnnieeeeeetieeeeeetiieeeeereeea 5-4
5.2.4 Snubber Resistor Wiring ...........ccccccccccceceeecceeceeeeeeeeeeeeeeeeseeeeseeereesneesenees 5-8
5.2.5 Output Status Relay Wiring .............ccccceeecceeeeeeceeeeeeeeeteeeeeeeeeseeeetetaeeees 5-10
5.3 Output Power WING ..........cccceeeccecceecceeeeceeeeeeeeseeeeseaeeeseaeeeeceeeseseeeeeeeetsieeeseaes 5-10
Looe - © 10) 0] 010] 06 ee 5-14
Completing the Installation
6.1. Checking the Installation With the Power Off............::ccccsceeeeceeseeeeeeeeeeeeseeetenees 6-1
6.2 Checking Drive Operation ...........cccccccccecceceeeececeeeeeceeeeceeeseceeesecaeeeseeeteeeeetinees 6-2
Keypad and Display Operation
7.1 Display DeSCTIPTION .....0 eee etter eee ttee eee tnieeeeeeeeeeeeetiieeeeeeeneeeeeeetaa 7-1
7.2 Key DeSCTIPTIONS 00.0... eter eeeteee etree eee ee enneee eee tneeeeeeeieeeeeetiieeeeeetineeeenee 7-2
7.3 LED DeSCTIPTIONS «2... eect etter etter eter eine ee eee eieee eee eiaeeeeeesiieeeeeesiieeeeeeetaa 7-3
7.4 Program Mode .........ccccccccceeeeeceeeeeeeeineee ee eicieeeeeeiieeeeeesiieeeeeesinieeeseseiineeeeennaas 7-4
7.5 Monitor Mode ...00...... cece ee eecneee eee eeneeeeeeeenneeeeeesiieeeeeeeiiieeeeeesiieeeeeeeiieeeeeeetea 7-5
7.5.1 Displaying the Percent Selected Speed Reference...............:ceceeee 7-6
7.5.2 Scaling the RPM Display and Reference Using F-08...............::00cee 7-6
7.6 Drive Control .......ceeceececccecceceeeeeececceeeeeeeeecaaeeecaeeseaeeesaaeeseseeeseeeeseeeesnieeessneeens 7-6
7.6.1 Changing the Reference Using the Keypad .............::ccccesseeteeeeseeeeees 7-7
Programming Reference
8.1 Displaying or Changing Parameter ValUeS .............ccccceeceeeeeeceeeeeeeeeeeeeteteeeenees 8-1
8.2 Ensuring Program Security ...........ccccccccceceeececeeeeeeceeeeceeeseceeeesecaeeeeeeetseneeesnees 8-3
8.3 Parameter DeSCIIPtIONS........0.... cece terre ee eetteeeeeeetneeeeeeeiteeeeesnieeeeeeenieeeeeeenaas 8-5
Troubleshooting Reference
9.1 Verifying DC BUS Voltage. ...........cccccccceceeceeeeeeeeceeeeeceeeeseeeeseceeeeseeeeecureeteneenenees 9-1
9.2 Troubleshooting the Drive Using Fault Codes .............cccceeecseeeeeeeeeeeeeteseeeeseees 9-3
9.3 Accessing and Clearing the Error LOG .........:.cccccecceecceeeeeeeeeeeeeseceeeeseeeetsnaeenenees 9-5
9.4 Checking the Drive’s Power Module Circuitry with the Power Off................5 9-7
Technical Specifications............ccecccceceeccceecececeeeeeeeeeeeeeneeeeceeeeeeeeeeseaeeeceeeeessueeesneeeneas A-1
Record of User Settings ............:cceccccecceccceeeeeeeeeeeeeceeeeeeeeeeeseeeeeeeeeeseeeesceeetsareeessaeeees B-1
Alphabetical Listing of Parameters............. cc cceceeeeeeeeeeeeeteeeeenneeeeeeenieeeeeeeeieeeeeennaees C-1
Compliance with Machinery Safety Standard EN-60204-1:1992 0.0... cece D-1
Compliance with Electromagnetic Compatibility Standards ...........0...::::eeceeeeeees E-4
Replacement Parts............:cceecceereceeeeeereeeeecneeeeecneeeeeeicneeeseeecieeeeeeeieeesseeiiteeseniaees F-1
cee nee EE eens nieee eee eaeeeeeeeaaes Glossary-1
OE EE I I LIE nn LIU nee eaeeeeeeen eee tenennnaaeeas Index-1
SP500 AC Drive Installation and Operation Manual Version 3.1

Figure 2.1 — SP500 System Diagram ............ccccccceccceeeceeeceeeeeeeeeeeeceeeeeceeeeeeereeseeeeesaes 2-3
Figure 2.2 — SP500 System Diagram (Continued) .............c:cceecceeeeeeeeseeeeeeeeeeeeenens 2-4
Figure 2.3 — Regulator Board Component Locations ...............:::cccceeeeeeeeeeteeseteeeeees 2-5
Figure 2.4 — Identifying the Drive Model NUMbE? ............:::cccccceeeeeeeeeeseeeteeeeseeenneees 2-6
Figure 2.5 — Enclosure A Component Locations ....0..... eect eereeeeeerereneeeneees 2-9
Figure 2.6 — Enclosure B Component Locations 0.0.0.0... ec eeceeeeeereeeereteneeeneenaes 2-10
Figure 2.7 — Enclosure C Component Locations .............c:cccccceeeeeceeeeeeteeeeeeesteeenees 2-11
Figure 2.8 — Enclosure D Component Locations ..............::cccecceeeeeeceeeeeeeeteeeeesteeenes 2-12
Figure 3.1 — Enclosure A DiMeNnsiOns ............ccccececeeereeeetteeeeeeeenneeeeeetnieeeeeetnneeeeeee 3-2
Figure 3.2 — Enclosure B DiMensiON .............ccccececeeeeeee teense ee eetneeeeeeenieeeeeetnneeeeee 3-2
Figure 3.3 — Enclosure C DIMENSIONS 0.0.0... ee eter reer tene en erentenntee 3-3
Figure 3.4 — Enclosure D Dimensions. ...........0. ee eee tee ee eee etter eet aee tense ee taeeneaees 3-3
Figure 3.5 — How to Measure Motor Lead Lengths ..........0. eee eects 3-6
Figure 4.1 — Enclosure A Wire Routing Locations ............:cccccceeesereeeeeeseeeeeeeeneneees 4-2
Figure 4.2 — Enclosure B Wire Routing Locations... cece eerste 4-3
Figure
4.3 — Enclosure C Wire Routing Locations ............0.:cccccsccceecereeeseeetsteeeeeneees 4-4
Figure 4.4 — Enclosure D Wire Routing Locations .............0. cee eee eee tee settee 4-5
Figure 4.5 — Jumper J6 Settings for the Analog Input Speed Reference ................. 4-8
Figure 5.1 — Typical Electrical Connections. ............ccccceececceceeeeeeceeeeteceeeeeeeeeseneeesaees 5-2
Figure
5.2 — Typical Control Terminal Strip Connections .............0.:ccceeeesseeeereeeees 5-3
Figure
5.3 — Analog Speed Reference Wiring Connections .........0...:.:ccecceeeeereerees 5-4
Figure 5.4 — Analog Output Wiring Connections ...........cccceeceeeeeeceeeeeeeeeeeeetsteeeeeees 5-4
Figure 5.5 — Two-Wire Start/Stop Sample Control Wiring ............0:::ccceeecseereereeees 5-5
Figure
5.6 — Three-Wire Start/Stop Sample Control Wiring............:.::ccccceeeeeeees 5-5
Figure 5.7 — Multi-Speed Preset Sample Control Wiring ..............:::cceeceeeeeteeeesteeeees 5-6
Figure
5.8 — Terminal Usage During Multi-Speed Preset Operation .........0....:0068 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
1 SU5XxxX DIVES 000... .eeceecece cececece ee ceeeeeeeeeeseaaeeeneeseseaeeeeseeeeseieeensaeenes 5-9
Figure
5.11 — Output Status Relay Wiring Connections .............:ccceeeeeeeeeeeeseeeees 5-10
Figure 7.1 — SP500 Keypad and Display.............c:cccecccceceeececeeeesecneeeseeeesecneesnneesenees 7-1
Figure 7.2 — SP500 Menu Structure ...........cccccecceeeceeeeceeeeeeeeseeeececaeeeseseesscaresneeessnees 7-4
Figure 7.3 — Example of a Program Mode Display ............c::cccccecceeeeetreeeeeettneeeeees 7-5
Figure 7.4 — Example of a Monitor Mode Display..............:c:cccccceeeeeeeeeeeeeeeeseeentneees 7-6
Figure 8.1 — Manual Torque Boost Adjustment Rangeé.......0....::cceccccsseeeeeeeettereeeeees 8-7
Figure 8.2 — Volts/HertzZ CUIV6 00... cee ee ren eeneen einen esi enneniietiieseresneereneee 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).... cece ce cecee cence ee ceaeeeeeeeeeeeaeeeeeeeeesseeeseeeeas 9-2
Figure 9.3 — DC Bus Terminals on Model 1SU4x015 and 1SU4x020 Drives........... 9-2
Contents Il

SP500 AC Drive Installation and Operation Manual Version 3.1

Table 2.1 — SP500 Model Number Notation .....0......0.cce cc ccceecec eee s ee eeeeeeecesaeeeeeeeeseeas 2-6
Table 2.2 — Power and NEMA Enclosure RatingS ...........cc:cccesceeceeeesetereeeeeentreeeeeeneas 2-7
Table 2.3 — SP500 Option Kits ........ cc ceccececceeeceeeeceeeeseceeeeeeeeseeeeeseeeeeseeeeeseeessees 2-13
Table 3.1 — Air Flow Clearances.........cccccccccccecceccecsneeeececenneeeeeecseeeeeecnnieeeeessseeeessnaees 3-4
Table 3.2 — Recommended Power Wire Sizes for M/N 1SU1xxxx and
1SU2XXxX DIVES... cece cee enneeeeeeceseeeeeesseeeeeesnseeeessesieeeessnnseeeesenea 3-5
Table 3.3 — Recommended Power Wire Sizes for M/N 1SU4xxxx and
1SU5XXXxX DIVES... cece ccecnneeeeeeennneeeeeecsneeeeesseseeeeeseneeeessneeeeeseea 3-5
Table 3.4 — Recommended Power Wire Sizes for M/N 1SU4x015 and
1SU4x020 DIive ......0 cc cceccccceeeeeeeeeeesneeeeeessneeeeeeseneeeessesneeeeessnseeeeness 3-5
Table 3.5 — Recommended Power Terminal Tightening Torque .............:::ccceeeeee 3-5
Table 3.6 — Recommended Control and Signal Wire Sizes and Tightening Torque 3-6
Table 3.7 — Motor Lead Lengths...........ccececececeeeeteeeeeeeecneeeeeeenneeeeeesitneeeeesnineeeeeenes 3-7
Table 3.8 — REACtOIs 200.0... . ccc cceeececececee cee ee erect ee teeeeeaaecaeeeeeeeeeseccancaecaeeeeeeeeeeeteteesennaneees 3-7
Table 3.9 — AC Input Line Fuse Selection Values .............cccccceeeeeeeeceeeeseeeeteteeeeeneees 3-8
Table 7.1 — Key DeSCIiptions ............cecceeececeeeeeeeeeecneeeeeenieeeeeetnneeeeeeetnieeeeeetineeeeertea 7-2
Table 7.2 — Drive Status LED Descriptions .0............ccceccccceeececeeeeeteeeeeeeeeeeteneeeetnaeenes 7-3
Table 7.3 — Monitor Mode LED Descriptions ............c ec cciceceeeeeeeeeeeeeeeteeeeeetnteeeeerenee 7-3
Table 8.1 — Multi-Speed Presets Digital INPUtS...............c:cceccceeeeeeceeeeeeeeeeeeeeteeeeeeees 8-15
Table 8.2 — Auto-Restartable Faults ..............ccececceeccecceceeeeeeeeeeeceaccueeeeeeeeeeeeeseneeeenas 8-16
Table 9.1 — Drive Faults and Corrective ACtiOns «0.00... ccccccccccseecececssteeeeesssneeeeeeeneas 9-3
Table 9.2 — Resistance Checks for Input Diodes...........0....:ccceeececeeeeeeeeeteeeteteeeeeneeees 9-8
Table 9.3 — Resistance Checks for IGBTS.....0.....cccccccecesseeeeeecsneeeeecesneeeeesssieeeeesenaees 9-8
Contents V

Vi SP500 AC Drive Installation and Operation Manual Version 3.1

1.1
1.2
1.3
Introduction
This chapter describes the manual’s intended audience and provides an overview of
the SP500 drive’s installation process.
Who Should Use This Manual
This manual is intended for qualified electrical personnel responsible for installing,
programming, starting up, and maintaining the SP500 drive.
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 lists theparts
of the drive that canbe 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 keypadand the display, and Appendix A, which lists the
drive’s technical specifications.
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).
Introduction 1-1

SP500 AC Drive Installation and Operation Manual Version 3.1