Installation and Operation Manual D2-3356-6 SP500 AC Drive Version 3.
Important User Information Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some important differences between solid-state equipment and hard-wired electromechanical devices.
Document Update Document Update Electronic Motor Overload Protection This product does not offer speed-sensitive overload protection, thermal memory retention or provisions to act upon motor over-temperature sensing in motors. If such protection is needed in the end-use product, it needs to be provided by additional means.
Document Update Notes: 2
Summary of Changes The information below summarizes the changes made to this manual since its last release (July 1999). Description of Changes Page Added Document Update.
soc-ii Notes: Summary of Changes
CONTENTS Contents Chapter 1 Introduction 1.1 Who Should Use This Manual ......................................................................... 1-1 1.2 Installation Overview ....................................................................................... 1-1 1.3 Requesting Assistance from Reliance Electric ................................................ 1-1 Chapter 2 Learning About the SP500 Drive 2.1 Standard Features ..........................................................................
Chapter 5 Wiring the Drive 5.1 Input Power Wiring...........................................................................................5-1 5.2 Signal and Control Wiring ................................................................................5-3 5.2.1 Analog Speed Reference Wiring ...........................................................5-3 5.2.2 Analog Output Wiring.............................................................................5-4 5.2.3 Digital Input Wiring.....................
List of Figures Figure 2.1 – SP500 System Diagram ....................................................................... 2-3 Figure 2.2 – SP500 System Diagram (Continued) ................................................... 2-4 Figure 2.3 – Regulator Board Component Locations ............................................... 2-5 Figure 2.4 – Identifying the Drive Model Number ..................................................... 2-6 Figure 2.5 – Enclosure A Component Locations ................................
IV SP500 AC Drive Installation and Operation Manual Version 3.
List of Tables Table 2.1 – SP500 Model Number Notation ............................................................. 2-6 Table 2.2 – Power and NEMA Enclosure Ratings .................................................... 2-7 Table 2.3 – SP500 Option Kits ............................................................................... 2-13 Table 3.1 – Air Flow Clearances............................................................................... 3-4 Table 3.
VI SP500 AC Drive Installation and Operation Manual Version 3.
CHAPTER 1 Introduction This chapter describes the manual’s intended audience and provides an overview of the SP500 drive’s installation process. 1.1 Who Should Use This Manual This manual is intended for qualified electrical personnel responsible for installing, programming, starting up, and maintaining the SP500 drive. 1.2 Installation Overview This manual describes how to install and troubleshoot the SP500 drive.
1-2 SP500 AC Drive Installation and Operation Manual Version 3.
CHAPTER 2 Learning About the SP500 Drive This chapter describes the SP500 drive and how to identify it based on its model number. This chapter also provides power and enclosure rating information. 2.
• User-selectable relay contact for indications of drive running, drive faulted, or drive at selected speed • User-selectable power-up start, auto-restart, and coast-to-rest or ramp-to-rest stop functions • User-selectable local or remote operation • 29 user-adjustable software parameters 2.2 Drive Description The SP500 drive is an AC PWM (pulse-width-modulated) inverter that operates on single- or three-phase power. See figures 2.1 and 2.2. AC input power is applied to the drive’s input terminals.
. Figure 2.
Figure 2.2 – SP500 System Diagram (Continued) 2-4 SP500 AC Drive Installation and Operation Manual Version 3.
Figure 2.
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. Figure 2.
2.3.1 Power Ratings and NEMA Enclosure Ratings Table 2.2 provides SP500 drive power and NEMA enclosure ratings. Table 2.2 – Power and NEMA Enclosure Ratings Model Number 1SU11001 1SU14001 1SU21001 1SU24001 1SU21002 Input Power and Horsepower Rating* Single-Phase - 1 HP Single-Phase - Demo Input Amps 13.1 5.2 Input KVA 1.5 0.6 Output Amps* 6.8 2.0 Power Loss Watts*** 80 80 200-230 200-230 5.0 5.0 1.3 1.3 1.7 1.7 70 70 200-230 200-230 200-230 19.1 17.2 15.3 4.4 4.0 3.5 7.5 7.0 6.
Table 2.2 - Power and NEMA Enclosure Ratings (Continued) Model Number 1SU51002 1SU54002 1SU51003 1SU54003 1SU51005 1SU54005 1SU51007 1SU54007 1SU51010 1SU54010 Input Power and Horsepower Rating* Three-Phase - 2 HP Three-Phase - 2 HP Three-Phase - 3 HP Three-Phase - 3 HP Three-Phase - 5 HP Three-Phase - 5 HP Three-Phase - 7.5 HP Three-Phase - 7.
CONTROL STRIP TERMINAL REGULATOR PCB MEMBRANE SWITCH/ BRACKET ASSEMBLY INTERNAL FAN ASSEMBLY POWER TERMINAL STRIP POWER PCB GND CONNECTION Figure 2.
CONTROL TERMINAL STRIP REGULATOR PCB MEMBRANE SWITCH/ BRACKET ASSEMBLY INTERNAL FAN ASSEMBLY CAPACITOR PCB (3 & 5 HP ONLY) POWER PCB GND CONNECTION POWER TERMINAL STRIP Figure 2.6 – Enclosure B Component Locations 2-10 SP500 AC Drive Installation and Operation Manual Version 3.
CONTROL TERMINAL CONTROL TERMINAL STRIP STRIP REGULATOR REGULATORPCB PCB MEMBRANE MEMBRANESWITCH/ SWITCH/ BRACKETASSEMBLY ASSEMBLY BRACKET INTERNAL FAN INTERNAL FAN ASSEMBLY ASSEMBLY POWER TERMINAL POWER TERMINAL STRIP STRIP CAPACITOR CAPACITORPCB PCB GND GNDCONNECTIONS CONNECTIONS POWER PCB POWER PCB Figure 2.
Figure 2.8 – Enclosure D Component Locations 2-12 SP500 AC Drive Installation and Operation Manual Version 3.
2.5 Option Kits Table 2.3 provides a listing of the available SP500 option kits. Table 2.
2-14 SP500 AC Drive Installation and Operation Manual Version 3.
CHAPTER 3 SP500 System Planning This chapter provides information that you must consider when planning an SP500 drive installation. Installation site, wiring, and motor application requirements are included. ! ATTENTION: Only qualified electrical 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 manual and other applicable manuals in their entirety before proceeding.
3.1.1 Determining the Total Area Required for Installation Figures 3.1 to 3.4 provide drive dimensions for enclosures A through D as an aid in calculating the total area required by the SP500 drives. Appendix A lists drive weights 121.9 mm (4.8”) 20.7 mm (0.81”) 263.5 mm (10.37”) 304.8 mm (12.00”) 146.0 mm (5.57”) 73.0 mm (2.88”) Figure 3.1 – Enclosure A Dimensions . Figure 3.2 – Enclosure B Dimensions 3-2 SP500 AC Drive Installation and Operation Manual Version 3.
Figure 3.3 – Enclosure C Dimensions Figure 3.
3.1.2 Providing Proper Air Flow Clearances Be sure there is adequate clearance for air ventilation around the drive. For best air movement, do not mount SP500 drives directly above each other. Note that no devices are to be mounted behind the drive. This area must be kept clear of all control and power wiring. See table 3.1 for a listing of the recommended air flow clearances. Table 3.
. Table 3.2 – Recommended Power Wire Sizes for M/N 1SU1xxxx and 1SU2xxxx Drives Type of Wiring Terminals Size of Wire (maximum)* AC Input Power R, S, T 14 AWG, 2 (mm2) Output Power U, V, W 14 AWG, 2 (mm2) DC Bus –,+ 14 AWG, 2 (mm2) Ground GND 14 AWG, 2 (mm2) *Except for M/N 1SU21002 (single-phase input), 1SU21005, and 1SU24005, for which 12 AWG, 3 (mm2) wire is recommended. Table 3.
3.2.3 Recommended Control and Signal Wire Sizes Table 3.6 shows the recommended wire sizes to connect I/O signals to the terminal strip on the Regulator board. The minimum wire insulation rating is 600V. Operator controls can be up to 303 meters (1000 feet) from the SP500 drive. All signal wires should be twisted-pair. Table 3.6 – Recommended Control and Signal Wire Sizes and Tightening Torque Drives Terminals All 1–16 Minimum Wire Size Maximum Wire Size Maximum Tightening Torque 20 AWG, 0.
Table 3.7 – Motor Lead Lengths SP500 HP Rating Filter Type Maximum Lead Length in Feet with 230 VAC Motor Maximum Lead Length in Feet with 460 VAC Motor Maximum Lead Length in Feet with 575 VAC Motor Carrier Frequency Carrier Frequency Carrier Frequency 4 kHz 6 kHz 8 kHz 4 kHz 6 kHz 8 kHz 4 kHz 6 kHz 8 kHz 1 500 500 500 250 250 250 150 150 150 2 500 500 500 350 350 350 250 200 200 1000 1000 1000 400 400 400 250 200 200 1000 1000 1000 500 500 500 250 200 200 7.
3.3 Selecting Input AC Line Branch Circuit Fuses ! ATTENTION: Most codes require that upstream branch circuit protection be provided to protect input power wiring. Install the fuses recommended in table 3.9. Do not exceed the fuse ratings. Input line branch circuit protection fuses must be used to protect the input power lines. See figure 5.1. Table 3.9 shows recommended fuse values. These fuse ratings are applicable for one drive per branch circuit. No other load may be applied to that fused circuit.
3.4 Installing an Emergency Stop ! ATTENTION: The user must provide an external, hardwired emergency stop circuit outside of the drive circuitry. This circuit must disable the system in case of improper operation. Uncontrolled machine operation may result if this procedure is not followed.
If the motor will be operated below one-half of its rated speed, the motor overload relay may not protect the motor because of reduced cooling action due to the reduced speed. A motor thermostat, internal to the motor, should be installed to monitor the actual temperature of the windings. 3.5.2 Multiple-Motor Applications One drive can run two or more motors.
CHAPTER 4 Installing the Drive This chapter shows how to mount the SP500 drive and its external components. Also shown are the entry areas for routing wiring in and out of the drive. 4.1 Mounting the Drive Attach the drive to the selected flat, vertical surface using the mounting holes provided. Enclosure A drives have two mounting holes, which are accessible after the cover is removed. Enclosure B, C, and D drives have four mounting holes.
. Figure 4.1 – Enclosure A Wire Routing Locations 4-2 SP500 AC Drive Installation and Operation Manual Version 3.
Figure 4.
Figure 4.3 – Enclosure C Wire Routing Locations 4-4 SP500 AC Drive Installation and Operation Manual Version 3.
Figure 4.
4.3 Installing External Components Install the input power and output power components that are located outside of the SP500 enclosure. See figure 5.1. The following sections describe disconnect, transformer, and AC line branch protection installation. 4.3.1 Disconnects An input disconnect (for example, a switch or circuit breaker) must be installed in the line before the drive input terminals in accordance with local, national, and international codes (e.g., NEC/CEC).
• Do NOT use an input isolation transformer rated more than 100 KVA for 230 VAC (or 1000 KVA for 460 VAC) with less than 5% impedance directly ahead of the drive without additional impedance between the drive and the transformer. If your SP500 application requires the use of an output transformer, contact Reliance Electric for assistance. 4.3.
1 J6 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 0-20 mA 0-10 VDC Figure 4.5 – Jumper J6 Settings for the Analog Input Speed Reference Use the following procedure to set jumper J6: ! ATTENTION: DC bus capacitors retain hazardous voltages after input power has been disconnected.
• Verify that the motor is properly aligned with the application’s machine to minimize unnecessary motor loading due to shaft misalignment. • If the motor is accessible when it is running, install a protective guard around all exposed rotating parts.
4-10 SP500 AC Drive Installation and Operation Manual Version 3.
CHAPTER 5 Wiring the Drive This chapter describes how to wire the SP500 drive including: input wiring, control and signal wiring, output wiring, and grounding. 5.1 Input Power Wiring Use the following steps to connect AC input power to the drive: Step 1. Verify that the AC input power to the drive corresponds to the drive’s nameplate voltage and frequency. Step 2. Wire the AC input power leads by routing them according to the type of enclosure. See figures 4.1 through 4.4. See tables 3.2 through 3.
AC Input Voltage GND Manual Disconnect Fuse UserSupplied R/L1 S/L2 T/L3 GND ~ SP500 Drive - U U GND U U Motor Overload Relay (Optional if Electronic Overload is Used) U UserSupplied V/T2 W/T3 U U/T1 ~ M Figure 5.1 – Typical Electrical Connections 5-2 SP500 AC Drive Installation and Operation Manual Version 3.
5.2 Signal and Control Wiring The terminal strip on the Regulator board provides terminals for connecting signal (for example, external speed reference and analog output) and control (for example, stop, start, and function loss) wiring. See figure 5.2.
User-Supplied Speed Reference Input Signal User-Supplied Speed Reference Potentiometer 0-10 VDC or 0-20 mA +10 VDC 5kΩ or Figure 5.3 – Analog Speed Reference Wiring Connections 5.2.2 Analog Output Wiring Analog output wiring connects to terminals 4 and 5 on the Regulator board’s terminal strip. See figure 5.4.
Start and Stop Control Wiring Start and stop control wiring connects to terminals 6, 7, and 11. See figures 5.5 and 5.6. Note that these start/stop wiring connections are not to be used in multi-speed preset applications which are discussed in the following section. Start/ Stop IET Reset Fwd Rev Customer Interlock 24 VDC Common Function Loss Forward/Reverse IET Reset Start Stop Function Loss Figure 5.
Multi-Speed Preset Wiring Multi-speed preset wiring connects to terminals 6 through 8, and 11. See figure 5.7. When control type 3 is selected through parameter F-00, remote terminal strip control is enabled with multi-speed presets. This mode of operation changes the functionality of terminals 6 through 8 and may be used in place of 2- and 3-wire start/stop wiring. See figure 5.8.
F-00 = 0, 1, 2 Snubber Resistor Braking Signal 24 VDC Common Function Loss Forward/Reverse IET Reset Start Stop 24 VDC Common Analog Meter Output 4 F-00 = 3 (Multi-Speed Presets) Snubber Resistor Braking Signal 24 VDC Common Function Loss Forward/Reverse Multi-Speed Preset 1 Multi-Speed Preset 2 Start/Stop/IET Reset 24 VDC Common Analog Meter Output 4 Figure 5.
5.2.4 Snubber Resistor Wiring Snubber resistor wiring connects to terminals 12 and 13 on the Regulator board’s terminal strip. See figures 5.9 and 5.10.
Regulator Board +147 -45 24 VDC Common 12 13 Snubber Resistor Braking Signal Control Terminal Strip +1 -2 Snubber Resistor Braking Signal DC Bus Volts Snubber Resistor Power Terminal Strip + DC Bus Volts SP500 Drive Figure 5.
5.2.5 Output Status Relay Wiring Output status wiring connects to terminals 14 through 16 on the Regulator board’s terminal strip. See figure 5.11. Parameter F-09 specifies the type of status indication provided by the output relay. See the F-09 parameter description in section 8.3 for more information. USER-SUPPLIED LAMP USER-SUPPLIED 115 VAC / 24 VDC (10 mA Min.) N.O. 14 15 16 Figure 5.11 – Output Status Relay Wiring Connections 5.
5.4 Grounding ! ATTENTION: The user is responsible for conforming with all applicable local, national, and international codes. Use the following steps to ground the drive: Step 1. Remove the drive’s cover. Step 2. Run a suitable equipment grounding conductor unbroken from the drive’s ground terminal to the motor’s ground terminal and then to earth ground. See figures 4.1 through 4.4 and 5.1. Step 3. Connect a suitable grounding connector to the motor frame and transformer (if used).
5-12 SP500 AC Drive Installation and Operation Manual Version 3.
CHAPTER 6 Completing the Installation This chapter provides procedures to check the installation. ! 6.1 ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, and/or service this equipment. Read and understand this manual in its entirety before proceeding.
Step 9. Check that the wire sizes are within terminal specifications and that the terminals are tightened to the appropriate torque specifications. Refer to tables 3.2 through 3.6. Step 10. Check that the user-supplied branch circuit protection is installed and correctly rated. Step 11. Check that the incoming AC power is rated correctly. Step 12. Check the motor installation and length of motor leads. Step 13. Disconnect any power correction capacitors connected between the drive and the motor. Step 14.
Step 7. Verify the direction of the motor shaft rotation. If it is incorrect for your application, use the following procedure to change the direction of rotation. If it is correct, go to step 8. a. Press the STOP/RESET key to stop the drive. b. Wait until the motor has completely stopped. c. Turn off, lock out, and tag power to the drive. Wait five minutes. d. Remove the cover and check the DC bus potential with a voltmeter as described in section 9.1. Verify that the DC bus capacitors are discharged.
6-4 SP500 AC Drive Installation and Operation Manual Version 3.
CHAPTER 7 Keypad and Display Operation The front-panel keypad and display, shown in figure 7.1, are used to program, monitor, and control the drive. They operate in two modes: monitor mode and program mode. In monitor mode (the default mode), you can monitor specific drive outputs and the drive’s speed reference. In program mode, you can view and adjust drive parameter values and examine the error log.
7.2 Key Descriptions The keypad’s six membrane keys are used to monitor, program, and control the drive. Table 7.1 describes the keys. Table 7.1 – Key Descriptions Use the UP and DOWN arrow keys to: • Step through the drive parameters and error log when the drive is in program mode. • Increase or decrease a parameter’s numeric value or status in program mode. • Increase or decrease the internal speed reference when F-00 (Control Source Select) = 0 or 2. Hold down these keys to increase the scroll speed.
7.3 LED Descriptions The keypad area contains eight LEDs that indicate either drive status or which drive output value is displayed in monitor mode. Tables 7.2 and 7.3 describe the drive status LEDs and monitor mode LEDs, respectively. Table 7.2 – Drive Status LED Descriptions LED State Run On Off Description The drive is generating an output voltage and frequency. The drive is not generating an output voltage and frequency.
7.4 Program Mode Program mode allows you to display and modify drive parameter values when the drive is stopped. The following can be displayed in program mode: • Parameter numbers • Parameter values • Error log information To enter program mode: Step 1. Stop the drive (if it is running) by pressing the STOP/RESET key. Step 2. Press the MODE/ENTER key until the PROGRAM LED turns on. Parameter F-00 will be displayed. Use the key or key to scroll through the parameter list.
A sample program mode display is shown in figure 7.3. RPM %Load Volts Remote RUN Program Forward Reverse Mode Enter Forward Reverse STOP RESET START Figure 7.3 – Example of a Program Mode Display 7.5 For information about: Refer to section: Displaying or changing parameter values 8.1 Ensuring program security 8.2 Individual parameters 8.3 Accessing the error log 9.
A sample monitor mode display is shown in figure 7.4. RPM %Load Volts Remote RUN Program Forward Reverse Mode Enter Forward Reverse START STOP RESET Figure 7.4 – Example of a Monitor Mode Display 7.5.1 Displaying the Percent Selected Speed Reference To display the percent selected speed reference, parameter F-13 must be set to ON. Use the following procedure to display the percent selected speed reference: Step 1. Stop the drive (if it is running) by pressing the STOP/RESET key. Step 2.
The functions of the keypad keys are described in section 7.2. Refer to the F-00 Control Source Select parameter description in chapter 8 for more information on selecting a drive control source. 7.6.1 Changing the Reference Using the Keypad The speed reference can be increased or decreased using the or key when F-00 = 0 or 2. The display will show the internal speed reference in hertz (Hz) while the keys are pressed. There will be a slight delay before the display returns to the active monitor mode.
7-8 SP500 AC Drive Installation and Operation Manual Version 3.
CHAPTER 8 Programming Reference To program the SP500 drive for a specific application, you display the appropriate parameter and adjust it as required. The parameters specify characteristics of the drive. This chapter describes how to access, display, and modify parameters. Section 8.3 describes each parameter in detail. Appendix C lists the parameters in alphabetical order. 8.1 Displaying or Changing Parameter Values Use the following procedure to display or change parameter values: Step 1.
Step 4. Press the MODE/ENTER key to display the parameter value. RPM %Load Volts Remote RUN Program Forward Reverse Mode Enter Forward Reverse START STOP RESET Step 5. Press the RPM %Load Volts Remote RUN Program Forward Reverse or Mode Enter Forward Reverse START STOP RESET key to change the value. Note that if programming has been disabled in parameter F-20 (Password Lockout Enable), the value will not change. Refer to section 8.2, Ensuring Program Security, for more information. Step 6.
8.2 Ensuring Program Security ATTENTION: It is the user’s responsibility to determine how to distribute the password. Reliance Electric is not responsible for unauthorized access violations within the user’s organization. ! Parameter values can be password-protected using parameter F-20 (Password Lockout Enable). When F-20 is set to ON, parameter values can be displayed but cannot be modified from the keypad unless the correct password is entered in F-20.
Step 3. Press the down the RPM %Load Volts Remote RUN Program Forward Reverse key until the password number, 257, is displayed. (Holding key increases the scroll speed.) Mode Enter Forward Reverse START STOP RESET Step 4. Press the MODE/ENTER key to save the password number. ON or OFF is displayed to indicate the current state of the password lockout. RPM %Load Volts Remote RUN Program Forward Reverse Mode Enter Forward Reverse START STOP RESET Step 5.
8.3 Parameter Descriptions F-00 Control Source Select This parameter selects Parameter Range: the drive control source and speed reference source.
F-02 Deceleration Time (continued) If the frequency requested from the keypad (using the and keys) is less than the maximum speed setting, the time to ramp to that frequency will be proportionally less than the actual rate setting. For example, if F-04 = 60Hz and F-02 = 4 seconds, it will take 2 seconds to ramp to a frequency reference of 0Hz from 30 Hz.
F-05 Current Limit This parameter limits motor output torque while it is running or accelerating. Parameter Range: 10% to 150% of rated drive current Default Setting: 150% Step Size: 1.0% When output current attempts to exceed the preset current limit, motor current will be maintained or reduced, or the acceleration / deceleration time will be extended. If current limit is set too low or too high relative to the required load, an overcurrent fault may occur (OC will be displayed).
F-07 V/Hz (Base Speed) (continued) The V/Hz curve allows the drive to maintain a constant V/Hz ratio, providing constant torque at any frequency. See figure 8.2. Output Voltage (%) Maxim um V / Hz 100 0 Base Frequency Mi n im V/ um Hz FREQUENCY (Hz) 240 Figure 8.2 – Volts/Hertz Curve F-08 RPM at Base Speed This parameter scales Parameter Range: the RPM display and Default Setting: the setpoint to a userspecified engineering Step Size: unit. 10 to 9999 1750 1.
F-09 Configurable Output Relay Select This parameter Parameter Range: specifies the type of status indication the output relay contacts provide (terminals 14, 15, and 16 on the drive terminal strip). 0 = Output relay is energized to show state of drive running. 1 = Output relay is energized to show state of active fault (IET). 2 = Output relay is energized to show state of drive running at speed. Default Setting: 0 Step Size: N/A If F-09 = 0, the output is energized only when the RUN LED is on.
F-11 Remote Reference Gain (continued) To calculate the scaled reference if you are using a 0 to 20 mA remote reference, use the following equation: Desired Maximum Reference (mA) x 100 = % gain (mA reference) Reference Range (20) Example If the remote speed reference is 0 to 20 mA and the maximum reference required is 19.2 mA, scale as follows: 19.
F-13 Percent Selected Speed Reference Display Enable This parameter enables or disables the fourth monitor mode display. Parameter Range: ON = Fourth monitor mode display is enabled. OFF = Fourth monitor mode display is disabled. Default Setting: OFF Step Size: N/A If F-13 = ON, the current value of the active speed reference can be displayed by pressing the MODE/ENTER key (while the drive is running) until all three monitor mode LEDs are on.
F-15 Electronic Thermal Overload Enable (continued) When F-15 = ON, the drive faults if it exceeds the thermal overload time (60 seconds at 150% of F-14). When an external thermal switch or other overtemperature monitoring device is connected to the function loss circuit (terminals 10 and 11), this parameter may be set ON or OFF. For multi-motor applications, set this parameter to OFF. The individual motors must have thermal switch protection.
F-18 RPM Setpoint Enable The parameter Parameter Range: enables the setpoint to be displayed in F-08 units. Default Setting: Step Size: OFF = Setpoint is displayed in hertz. ON = Setpoint is displayed in the units specified in F-08. ON N/A If F-18 = ON, pressing the and keys will change the setpoint in units of 1 between minimum speed in F-08 units and maximum speed in F-08 units. Note that this parameter only affects the setpoint, not the display.
F-20 Password Lockout Enable This parameter enables or disables parameter password protection. Parameter Range: OFF = Password lockout disabled (parameters can be modified) ON = Password lockout enabled (parameters cannot be modified) Default Setting: Step Size: ! OFF N/A ATTENTION: It is the user’s responsibility to determine how to distribute the password. Reliance Electric is not responsible for unauthorized access violations within the user’s organization.
F-22 Avoidance Bandwidth (continued) Example Assume: Minimum Speed (F-03) = 3 Hz Maximum Speed (F-04) = 60.0 Hz Avoidance Frequency (F-21) = 32.2 Hz Avoidance Bandwidth (F-22) = 4 Hz Avoidance Band = 30.2 to 34.2 Hz Requested Output Frequency 25.0 Hz Output Frequency After Avoidance Band Correction 25.0 Hz 30.0 Hz 30.0 Hz 31.0 Hz 30.2 Hz 32.0 Hz 30.2 Hz 34.0 Hz 30.2 Hz 34.2 Hz 30.2 Hz 34.3 Hz 34.3 Hz 35.0 Hz 35.
F-26 Auto-Restart Number of Attempts This parameter selects Parameter Range: the number of times Default Setting: the drive will attempt to restart after certain Step Size: faults have shut down the drive. ! 0 to 10 0 N/A ATTENTION: If parameter F-26 ≠ 0, the drive will attempt to restart automatically after auto-restartable drive faults (see table 8.2) have shut down the drive.
F-27 Auto-Restart Retry Wait Time This parameter specifies the amount of time the drive will wait between autorestart attempts. Parameter Range: 1 to 30 seconds Default Setting: 1 Step Size: 1.0 second This parameter is used with parameter F-26 (Auto-Restart Number of Attempts). Refer to the F-26 parameter description for information regarding this feature. F-28 Drive Voltage Selection This parameter displays the drive’s voltage rating.
8-18 SP500 AC Drive Installation and Operation Manual Version 3.
CHAPTER 9 Troubleshooting Reference ! ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, and/or service this equipment. Read and understand this manual in its entirety before proceeding. The SP500 drive is monitored by internal diagnostics. If a fault occurs, the drive displays a two-digit fault code to identify the problem.
. (T1) (T2) AC POWER INPUT LEADS* (T3) MOTOR LEADS DC BUS VOLTS (SNUBBER RESISTOR BRAKING) *For single-phase units, connect AC input power to terminals R and S. Figure 9.1 – DC Bus Terminals on Model 1SU1xxxx and 1SU2xxxx Drives AC POWER INPUT LEADS DC BUS (SNUBBER VOLTS RESISTOR (SNUBBER BRAKING RESISTOR 10V SUPPLY) MOTOR LEADS BRAKING) Figure 9.
9.2 Troubleshooting the Drive Using Fault Codes Table 9.1 defines the fault codes for user-correctable faults, lists possible causes, and suggests actions to take to correct the problem. All other faults require replacement of the drive. If a fault occurs, do the following: Step 1. Try to clear the fault first by pressing the STOP/RESET key or asserting the IET reset input (remote operation). If the fault reoccurs, continue with step 2. Step 2. Refer to table 9.
LU = LOW BUS VOLTAGE The DC bus voltage has fallen below the electronic trip low threshold level. Note that the fault will not clear until the linput line voltage is within the proper range. This may take a few seconds. Important: If a line dip or momentary power loss occurs and the DC bus is able to rise back to the proper level within 500 ms, the drive will automatically restart (if the drive was running when the fault occurred). Possible Cause Corrective Action Loss of input power.
0L = ELECTRONIC THERMAL OVERLOAD The electronic thermal overload trip level has been exceeded. This fault protects the drive motor from overheating due to excessive current within a specified period. Note that the fault will not clear until the input line voltage is within the proper range. This may take a few seconds. Possible Cause Corrective Action The current limit setting in F-05 is incorrect. If the current limit level is too low relative to the load, increase the current level in F-05.
Use the following procedure to access the error log: : Step 1. Enter program mode by pressing the MODE/ENTER key until the PROGRAM LED turns on. RPM %Load Volts Remote RUN Program Forward Reverse Mode Enter Forward Reverse START STOP RESET Step 2. Press the key until ERR is displayed. The error log precedes parameter F-00 and follows F-49. (Sample Display) RPM %Load Volts Remote RUN Program Forward Reverse Mode Enter Forward Reverse START STOP RESET Step 3.
Step 5. Press the STOP/RESET key to clear the log. The display will return to the active monitor display. RPM %Load Volts Remote 9.4 RUN Program Forward Reverse Mode Enter Forward Reverse START STOP RESET Checking the Drive’s Power Module Circuitry with the Power Off ! ATTENTION: DC bus capacitors retain hazardous voltages after input power has been disconnected.
. Table 9.2 – Resistance Checks for Input Diodes Meter Connection Input Diode No. (+) (-) Component is OK if resistance (R) is: 1 * R/L1 50 < R < 10 Megohm 2 * S/L2 3 * T/L3 4 R/L1 ** 5 S/L2 ** 6 T/L3 ** Component is defective if: Continuity (short circuit) or open when the meter is connected with reversed polarity. * (+) DC bus volts power terminal ** (–) DC bus volts power terminal Table 9.3 – Resistance Checks for IGBTs Meter Connection IGBT No.
APPENDIX A Technical Specifications Table A.
Table A.4 – Drive Inputs Analog Speed Reference 0 to 10 VDC or 0 to 20 mA Start Edge-sensitive signal that must see an open-to-closed contact transition. This transition may be a momentary or fixed closure. Stop An open contact that must be closed when the drive is running. The drive will remain off as long as the contact is open. IET Reset Edge-sensitive signal that must see an open-to-closed contact transition. This transition may be a momentary or fixed closure.
APPENDIX B Record of User Settings Parameter No. Parameter Name Range Step Size Default Setting F-00 Control Source Select 0, 1, 2, 3 N/A 0 F-01 Accel Time (seconds) 0.5 - 90.0 0.10 5.0 F-02 Decel Time (seconds) 0.5 - 90.0 0.10 5.0 F-03 Minimum Speed (Hz) 0.5 - 30.0 0.10/0.25 5.0 F-04 Maximum Speed (Hz) 30.0 - 240.0 0.10/0.25 60.0 F-05 Current Limit (%) 10 - 150 1.0 150 F-06 Manual Torque Boost (%) 2 - 10 1.0 2 F-07 V/Hz Base Speed (Hz) 3 - 240 1.
Parameter No. Parameter Name Range Step Size Default Setting F-26 Auto-Restart Number of Attempts 0 - 10 0 = disabled N/A 0 F-27 Auto-Restart Retry Wait Time (seconds) 1 - 30 1.0 1 F-28 Drive Voltage Selection F-29 Analog Output Select F-49 Version Information B-2 Setting Date This parameter is set at the factory. Do not change the setting. SPd LOAd UOL rEF N/A SPd x.xx N/A Read Only SP500 AC Drive Installation and Operation Manual Version 3.
APPENDIX C Alphabetical Listing of Parameters Acceleration Time ..................................................................................................F-01 Analog Output Select.............................................................................................F-29 Auto-Restart Number of Attempts..........................................................................F-26 Auto-Restart Retry Wait Time................................................................................
Remote Reference Gain........................................................................................ F-11 Remote Reference Offset...................................................................................... F-12 Reverse Disable .................................................................................................... F-17 RPM at Base Speed.............................................................................................. F-08 RPM Setpoint Enable .......................
APPENDIX D Compliance with Machinery Safety Standard EN-60204-1:1992 The SP500 AC Speed Controller for Electric Motors complies with the following sections of Machinery Safety Standard EN-60204-1:1992. EN-60204-1 Section Title 6 6.2.1 Protection against electrical shock - Protection by enclosure 6.2.3 6.4 - Protection against residual voltages - Protection by automatic disconnect of supply - Protection by the use of PELV (Protective Extra Low Voltage) 7 7.
EN-60204-1 Section 9.3 9.3.5 9.4 9.4.2.1 9.4.3 9.4.3.1 9.4.3.2 10 10.8 11 11.2 11.2.1 11.2.2 11.3 11.3.1 11.5 12 12.2.2 12.2.3 12.3 12.3.1 12.3.2 12.3.3 12.3.4 12.3.5 13 13.2.3 13.4 15 15.1.1 15.1.3 15.2.2 18 18.2 18.4 19 19.
APPENDIX E Compliance with Electromagnetic Compatibility Standards E.
• be installed according to the instructions in this appendix. Note that when using 15 – 20 HP SP500 drives, a special cover is required. The model number of the SP500 cover kit is M/N 2CK4120. Follow the instructions provided with the kit when replacing the cover. The instructions in this appendix assume that the drive has the correct cover on it. E.2 Installing the AC Mains Filter This section describes how to identify and install the AC Mains Filters.
Top View (Filter Only, Cover Removed) H M5 Nuts J G K, Conduit Entry F L1 D L2 E G L3 E(GND) AC Mains Filter AC Mains Filter CB SP500 Drive Mounts on Top of Mains Filter (Screws Provided) Flexible Conduit (Provided) E F D A Side View (Filter and Drive) Front View (Filter Only) See table E.2 for dimensions. Figure E.
Table E.2 - AC Mains Filter Mounting Dimensions and Weights Dimension A B C D E F G H J K Filter Weight AC Mains Filter M/N 2DF2282 146 mm 5.7" 407 mm 16" 382 mm 15" 104 mm 4.1" 9 mm 0.35" 21 mm 0.83" 63 mm 2.5" 118 mm 4.6" 25 mm 1" 22 mm 0.87" 2.5 kg 5.5 lb AC Mains Filter M/N 2DF4283 217 mm 8.5" 387mm 15.25" 362 mm 14.25" 174 mm 6.9" 9 mm 0.35" 21.5 mm 0.85" 53 mm 2.1" 180 mm 7.1" 18 mm 0.71" 22 mm 0.87" 3.2 kg 7 lb AC Mains Filter M/N 2DF4284 272 mm 10.7" 441 mm 17.4" 415 mm 16.3" 230 mm 9.1" 9 mm 0.
• When the drive is connected to three-phase AC input power, the three output leads from the filter should be connected to the drive’s AC input power terminals as shown in figure E.3. • Connect the filter ground wire (green/yellow) to the drive ground. . A B L1 L2 FILTER’S AC INPUT POWER L 3 E(GND) AC MAINS FILTER GREEN/ REDYELLOW BLUE YELLOW DRIVE’S AC INPUT POWER R S T GND SP500 U V W GND MOTOR Figure E.
E.3.2 Motor Leads The motor leads must be run in continuous, rigid, conductive conduit, continuously-screened armored cable, or equivalent. Note that the use of flexible metal conduit, open wire, or wire in trays is not acceptable. Many flexible metal conduit products have not been designed for RF containment and are not adequate to maintain compliance. All motor leads should have the same cross-sectional area.The maximum allowable motor lead length from the drive to the motor is 76 m (250 feet).
3 EN-60204-1, Part 15.2.2: Identification of the Protective Conductor For insulated conductors, the two-color combination of green and yellow should meet the following criteria for any given 15 mm length: one of the colors should cover at least 30% and no more than 70% of the surface, with the other color covering the remainder of the surface. E.3.5 Operator Control Stations The enclosure of an operator’s control station must be constructed of a conductive metal.
E-8 SP500 AC Drive Installation and Operation Manual Version 3.
APPENDIX F Replacement Parts The following tables list the replacement parts available from Reliance Electric. Replacement parts are not available for 1 and 2 HP drives (M/N 1SU1xxxx and 1SU2xxxx). For M/N 1SU24002, use the replacement parts listed for the 3 HP drive. Table F.
Table F.3 – Replacement Parts List for Model 1SU5xxxx Drives Description Fan Assembly NEMA 4X Cover/Gasket NEMA 1 Cover Membrane Switch Keypad/Bracket Regulator PCB Capacitor PCB Fan Assembly (Internal) F-2 Part Number 615161-S 805512-1R 805522-1R 805504-7R 805508-9R 709507-1R 709511-1R 56953-3xx 56954-3xx 56922-055 56939-105 615159-1R 1 HP – 1 – 1 – 1 – 1 – – – – Quantity per Horsepower 2 HP 3 HP 5 HP 7.
GLOSSARY accelerating torque - an increase in torque (force) generated by a motor in order to achieve running speed. base speed - the manufacturer’s nameplate rating at which point the motor will develop rated horsepower at rated load and voltage. base frequency - the motor nameplate frequency rating. carrier frequency - the switching frequency at which an IGBT inverter bridge converts a DC voltage into a pulse-width modulated (PWM) voltage.
overcurrent - a current greater than a specified maximum current value. overload capacity - the ability of the drive to withstand currents beyond the system’s continuous rating. It is normally specified as a percentage of full load current for a specified time period. overtemperature - a temperature greater than the specified (rated) temperature limit. power factor - a measurement of the time phase difference between the voltage and current in an AC circuit.
INDEX A D Acceleration Time (F-01), 8-5 AC input diodes, checking, 9-7 to 9-8 line branch circuit fuses, 3-8, 4-6, 5-2 ratings, 2-7 to 2-8 wire sizes, 3-4 to 3-5 wiring, 3-4 to 3-5, 3-8, 4-1 to 4-6, 5-1 to 5-2 AC line distribution capacity, A-1 AC mains filter, E-1 to E-6 AC output wiring, 3-4 to 3-7, 4-1 to 4-5, 4-7 to 4-9, 5-2, 5-10 Air flow, 3-1, 3-4 Altitude requirements, 3-1, A-1 Analog input jumper (J6), 4-7 to 4-8 Analog Output Select (F-29), 8-17 Analog output wiring, 5-4 Analog speed reference wi
G Grounding, 2-9 to 2-12, 5-11 H Humidity, 3-1, A-1 I IET reset, digital input, 5-5, 5-7 IGBT power devices, 2-2 checking, 9-7 to 9-8 Input, AC, see AC input Input, digital, see Digital Input Wiring Installation checking with power off, 6-1 to 6-2 checking with power on, 6-2 to 6-3 completing, 6-1 to 6-3 disconnects, 4-6 output contactors, 4-7 planning, 3-1 to 3-10 requirements, 3-1 transformers, 4-6 to 4-7 J Jumper (J6) location of, 4-7 to 4-8 K Key descriptions, 7-1 to 7-2 Keypad and display operation
Power-Up Start Enable (F-19), 8-13 Program mode, 7-4 to 7-5 R Ratings AC input, 2-7 to 2-8 NEMA, 2-7 to 2-8 power, 2-7 to 2-8 power loss, 2-7 to 2-8 Regulator board, 2-9 to 2-12, F-1 to F-2 Remote Reference Gain (F-11), 8-9 to 8-10 Remote Reference Offset (F-12), 8-10 Replacement parts, F-1 to F-2 Reset, digital input, 5-3, 5-7 Resistor, snubber braking, 2-13, 4-2 to 4-5, 5-8 to 5-9, A-2 Reverse, digital input, 5-3, 5-7 Reverse Disable (F-17), 8-12 Routing, wire, 4-1 to 4-5 RPM at Base Speed (F-08), 8-8 RP
Index-4 SP500 AC Drive Installation and Operation Manual Version 3.
U.S. Allen-Bradley Drives Technical Support - Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: support@drives.ra.rockwell.com, Online: www.ab.com/support/abdrives www.rockwellautomation.com Power, Control and Information Solutions Headquarters Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.
