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

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
(0to 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
Learning About the SP500 Drive 2-1

2.2
* 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
Drive Description
The SP500 drive is an AC PWM (pulse-wicth-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 canbe 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 canbe 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 canbe
viewedon the four-character display. After a fault, the STOP/RESET key ora
user-supplied IET RESET pushbutton must be pressed to reset the IET signal and
clear the fault from the drive.
SP500 AC Drive Installation and Operation Manual Version 3.1

Learning
About
the
SP500
Drive
2-3
Figure
2.1
—
SP500
System
Diagram
LINE
INPUT
(200VAC — 230VAC)
OR
(380VAC
—
460VAC)
—LI
OR
(575VAC)
TO OPTIONAL
SNUBBER
RESISTOR
TO FIGURE 2.2
USER
SUPPLIED
=
*«
MODULE
DIODE (All except
1$U4x015,1SU4x020)
DC
CT
A
IGBT
MODULE
R|
Mov
V
jf.
+N
«KI + +
(1$U4x015
and
18U4x020
only)
DC
CT
€
AC
INDUCTION
MOTOR
tate
a
nd
10
VDC
(18U4x015
and
1SU4x020
only)
SWITCH
THERMAL
10 VDC_COMMON
24
Voc
24
VDC
COMMON
+15VDC
-15
vbc
BUS VOLTAGE
4 FEEDBACK
BUS CURRENT FEEDBACK
+5 VDC
REGULATOR
COMMON
GATE SIGNALS.
184:
[| THERMAL SWITCH
1 184: nil
(18U4x015, 1SU4x020 only)
POWER
SUPPLY

2-4
SP500
AC
Drive
Installation
and
Operation
Manual
Version
3.1
Figure
2.2
—
SP500
System
Diagram
(Continued)
+15VDC
1
1.87k
C
t-_LANALOG SPEED REFERENCE
REGULATOR BOARD
500
OHMS
REGULATOR
COMMON
10
0.1uf
10K
OHMS
CHASSIS
FUNCTION
LOSS
Ne
MICROPROCESSOR
FORWARD/REVERSE Ke
lET
RESET
he
START
Lc
11
) 2
STOP Np-
24V COM
24 VDC
24VDC COMMON
+15VDC
—15VvDC
BUS
VOLTAGE
FEEDBACK
J4
TO
FIGURE
2.1
BUS
CURRENT
FEEDBACK
+5 VDC
REGULATOR COMMON
GATE
SIGNALS
REGEN
_(1SU4x015,
1SU4x020
only)
THERMAL SWITCH (1SU4x015, 1SU 4x020 only)
ANALOG
METER
OUTPUT
bp
>
SNUBBER RESISTOR BRAKING CONTROL 24 COM
Ye
L— TO OPTIONAL
SNUBBER RESISTOR
24 COM
LOCAL OPERATOR
Np
IET/CONTROLLER
RUNNING
O
INTERFACE
co
RPM
1
%Load
C3
Volts
C3
Remote
AALALEY
(=I RUN
C4
Program
CI
Forward
Co Reverse

BQAAQGIAPPGACGOIAO QAO
12 3 45 6 7 89 10 11 1213141516
User I/O Terminal Strip
7-Pin J5
nN
>
u
S
a
ct
zs
6
Ss
Q
o
Ss
®
Figure 2.3 — Regulator Board ComponentLocations
Learning About the SP500 Drive 2-5

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.
Standard Model Number
iSU 2 1 001
Basic Catalog Number ———__! |
Labeling ——
U = UL Listed, IEC Certified
Voltage
1 = 115 VAC
2= 200-230 VAC
4= 380-460 VAC
5 =575 VAC
Enclosure
1 = NEMA 1 or Chassis
2 = NEMA 12 Only
4 = NEMA 4X (Indoor Only)/NEMA 12
Horsepower Rating
001 = 0.25 to 1.0 HP
002 = 2.0 HP
003 = 3.0 HP
005 = 5.0 HP
007 = 7.5 HP
010 = 10.0 HP
015 = 15.0 HP
020 = 20.0 HP
Figure 2.4 — Identifying the Drive Model Number
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.
Table 2.1 — SP500 Model Number Notation
Model Notation Input Voltage Horsepower
1SU1xxxx 115 VAC Y%- 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
2-6 SP500 AC Drive Installation and Operation Manual Version 3.1

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
Input PowerPower
Model and Horsepower NEMA |Enclosure| AC InputInputInput Output Loss
Number Rating* Rating Size** Volts Amps KVA Amps* Watts***
1SU11001 Single-Phase -1 HP 1 A 115 13.41.5 6.8 80
1SU14001 Single-Phase - Demo a+ ---- 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-1HP 4X/12 A 200-230 5.0 1.3 1.7 70
1SU21002 Single-Phase - 2 HP 1 A
4 kHz Carrier 200-230 19.1 44 7.5 120
6 kHz Carrier 200-230 17.2 4.0 7.0 120
8 kHz Carrier 200-230 15.3 3.5 6.5 120
1SU21001 Three-Phase -1 HP 1 A 200-230 7.02.8 5.0 70
1SU24001 Three-Phase-1HP 4X/12 A
4 kHz Carrier 200-230 6.4 2.64.5 70
6 kHz Carrier 200-230 5.2 2.03.6 70
8 kHz Carrier 200-230 5.2 2.03.6 70
1SU21002 Three-Phase - 2 HP 1 A
4 kHz Carrier 200-230 9.94.0 7.5 70
6 kHz Carrier 200-230 9.3 3.8 7.0 70
8 kHz Carrier 200-230 8.7 3.5 6.5 70
1SU24002 Three-Phase-2HP 4X/12 C 200-230 9.94.0 7.5 120
1SU21003 Three-Phase - 3 HP 1 C 200-230 12.5 5.0 10.6 210
1SU24003 Three-Phase-3HP 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-5HP 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-1HP 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-2HP 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-3HP 4X/12 B 380-460 6.4 5.1 5.3 140
1SU41005 Three-Phase - 5 HP 1 B 380-460 9.9 8.08.2 180
1SU44005 Three-Phase-5 HP 4X/12 B 380-460 9.9 8.08.2 180
1SU41007 Three-Phase - 7.5 HP 1 C 380-460 13.410.7 11.4 210
1SU44007 Three-Phase - 7.5 HP 4xX/12 C 380-460 13.410.7 11.4 210
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
18U42015 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-1HP 4X/12 B 575 2.0 2.0 1.6 50
Learning About the SP500 Drive 2-7

Table 2.2 - Power and NEMA Enclosure Ratings (Continued)
Input PowerPower
Model and Horsepower NEMA Enclosure AC Input} InputInput Output}; Loss
Number Rating* Rating Size** Volts Amps KVA_ Amps*| Watts***
1SU51002 Three-Phase - 2 HP 1 B 575 3.4 3.3 2.7 90
1SU54002 Three-Phase - 2 HP 4Xx/12 B 575 3.4 3.3 2.7 90
1SU51003 Three-Phase - 3 HP 1 B 575 5.2 5.1 43 120
1SU54003 Three-Phase - 3 HP 4x/12 B 575 5.2 5.1 4.3 120
1SU51005 Three-Phase - 5 HP 1 B 575 7.57.56.2 150
1SU54005 Three-Phase - 5 HP 4x/12 B 575 7.57.56.2 150
1SU51007 Three-Phase - 7.5 HP 1 Cc 575 10.910.9 9.0 180
1SU54007 Three-Phase-7.5HP 4X/12 Cc 575 10.910.9 9.0 180
1SU51010 Three-Phase - 10 HP 1 Cc 575 14.514.412.0 250
1SU54010 Three-Phase-10HP 4X/12 Cc 575 14.514.412.0 250
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
2.4
Each of the SP500 drives have one of the following NEMA ratings:
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.
See table 2.2 for 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.
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.
2-8 SP500 AC Drive Installation and Operation Manual Version 3.1

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[1] Fiovranared
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_. CONTROL STRIP
Pl TERMINAL
__-—» REGULATOR PCB
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a BRACKET ASSEMBLY
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~~ ASSEMBLY
_~ POWER TERMINAL STRIP
___-— POWER PCB
__~— GND CONNECTION
Learning About the SP500 Drive
Figure 2.5 — Enclosure A Component Locations
2-9

CONTROL TERMINAL STRIP
-— REGULATOR PCB
____ MEMBRANE SWITCH/
/~” BRACKET ASSEMBLY
\ INTERNAL FAN
| ASSEMBLY
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CAPACITOR PCB POWER PCB
(3 & 5 HP ONLY)
} GND CONNECTION
t POWER TERMINAL STRIP
Figure 2.6 — Enclosure B Component Locations
2-10 SP500 AC Drive Installation and Operation Manual Version 3.1