Rockwell Automation Reliance SP500 Installation And Operation Manual
SP500 AC Drive
Installation and Operation Manual
Version 3.1
Instruction Manual
D2-3356-5
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 equipment and 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
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...........................................................................................2-1
2.2 Drive Description ............................................................................................. 2-2
2.3 Identifying the Drive by Model Number ........................................................... 2-6
2.3.1 Power Ratings and NEMA Enclosure Ratings ...................................... 2-7
2.3.2 Enclosure Ratings and Sizes ................................................................ 2-8
2.4 Component Locations......................... ....... ...... ....... ....................................... .. 2-8
2.5 Option Kits..................................................................................................... 2-13
Chapter 3 SP500 System Planning
3.1 Installation Site Requirements......................................................................... 3-1
3.1.1 Determining the Total Area Required for Installation ............................ 3-2
3.1.2 Providing Proper Air Flow Clearances ..................................................3-4
3.1.3 Verifying the Drive’s Power Loss Rating ............................................... 3-4
3.2 Wiring Requirements .......................................................................................3-4
3.2.1 Verifying Conduit Sizes ......................................................................... 3-4
3.2.2 Recommended Power Wire Sizes......................................................... 3-4
3.2.3 Recommended Control and Signal Wire Sizes ..................................... 3-6
3.2.4 Recommended Motor Lead Lengths..................................................... 3-6
3.3 Selecting Input AC Line Branch Circuit Fuses.................................................3-8
3.4 Installing an Emergency Stop.......................................................................... 3-9
3.4.1 Complying with Machinery Safety Standard EN 60204-1:1992 ............3-9
3.5 Motor Considerations ......................................................................................3-9
3.5.1 Single-Motor Applications...................................................................... 3-9
3.5.2 Multiple-Motor Applications ....................................... ...... ....... ...... ....... 3-10
CONTENTS
Contents
Chapter 4 Installing the Drive
4.1 Mounting the Drive .......... ....... ...... ...... ....... ...... ....... ....................................... .. 4-1
4.2 Routing Wires.................................................................................................. 4-1
4.3 Installing External Components........................................... ...... ....... ...... ....... .. 4-6
4.3.1 Disconnects........................ ...... ....... ...... ....... ...... ....... ...... ....... ...............4-6
4.3.2 Input AC Line Branch Protection........................................................... 4-6
4.3.3 Transformers.........................................................................................4-6
4.3.4 Output Contactors................................................................................. 4-7
4.3.5 Mechanical Motor Overload Protection.................................................4-7
4.4 Setting the Analog Input Jumper on the Regulator Board............................... 4-7
4.5 Preparing the Motor.........................................................................................4-8
I
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.................................................................................5-4
5.2.4 Snubber Resistor Wiring........................................................................5-8
5.2.5 Output Status Relay Wiring .................................................................5-10
5.3 Output Power Wiring......................................................................................5-10
5.4 Grounding ......................................................................................................5-11
Chapter 6 Completing the Installation
6.1 Checking the Installation With the Power Off...................................................6-1
6.2 Checking Drive Operation................................................................................6-2
Chapter 7 Keypad and Display Operation
7.1 Display Description ..........................................................................................7-1
7.2 Key Descriptions ..............................................................................................7-2
7.3 LED Descriptions .............................................................................................7-3
7.4 Program Mode .................................................................................................7-4
7.5 Monitor Mode ...................................................................................................7-5
7.5.1 Displaying the Percent Selected Speed Reference...............................7-6
7.5.2 Scaling the RPM Display and Reference Using F-08............................7-6
7.6 Drive Control....................................................................................................7-6
7.6.1 Changing the Reference Using the Keypad ..........................................7-7
Chapter 8 Programming Reference
8.1 Displaying or Changing Parameter Values ......................................................8-1
8.2 Ensuring Program Security ........... ...... ...... ....... ...... ....................................... ...8-3
8.3 Parameter Descriptions....................................................................................8-5
Chapter 9 Troubleshooting Reference
9.1 Verifying DC Bus Voltage.................................................................................9-1
9.2 Troubleshooting the Drive Using Fault Codes .................................................9-3
9.3 Accessing and Clearing the Error Log .............................................................9-5
9.4 Checking the Drive’s Power Module Circuitry with the Power Off....................9-7
Appendix A Technical Specifications...........................................................................................A-1
Appendix B Record of User Settings........................................................................................... B-1
Appendix C Alphabetical Listi ng of Parameters..................... ....... ...... ....... .................................. C-1
Appendix D Compliance with Machinery Safety Standard EN-60204-1:1992.............................D-1
Appendix E Compliance with Electromagnetic Compatibility Standards..................................... E-1
Appendix F Replacement Parts ....... ...... ....... ...... ....... ...... ...... ....... ...... ....................................... .. F-1
Glossary ..................................... ...... ....... ...... ....... ...... ....................................... ...... ... Glossary-1
Index ..................................... ...... ....... ...... ....... ...... ....................................... ...... ....... ..Index-1
II
SP500 AC Drive Installation and Operation Manual Version 3.1
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 ......................................................2-9
Figure 2.6 – Enclosure B Component Locations ....................................................2-10
Figure 2.7 – Enclosure C Component Locations....................................................2-11
Figure 2.8 – Enclosure D Component Locations....................................................2-12
Figure 3.1 – Enclosure A Dimensions ......................................................................3-2
Figure 3.2 – Enclosure B Dimensions ......................................................................3-2
Figure 3.3 – Enclosure C Dimensions......................................................................3-3
Figure 3.4 – Enclosure D Dimensions......................................................................3-3
Figure 3.5 – How to Measure Motor Lead Lengths .................................................. 3-6
Figure 4.1 – Enclosure A Wire Routing Locations.................................................... 4-2
Figure 4.2 – Enclosure B Wire Routing Locations....................................................4-3
Figure 4.3 – Enclosure C Wire Routing Locations....................................................4-4
Figure 4.4 – Enclosure D Wire Routing Locations....................................................4-5
Figure 4.5 – Jumper J6 Settings for the Analog Input Speed Reference ................. 4-8
Figure 5.1 – Typical Electrical Connections.............................................................. 5-2
Figure 5.2 – Typical Control Terminal Strip Connections......................................... 5-3
Figure 5.3 – Analog Speed Reference Wiring Connections.....................................5-4
Figure 5.4 – Analog Output Wiring Connections ......................................................5-4
Figure 5.5 – Two-Wire Start/Stop Sample Control Wiring........................................5-5
Figure 5.6 – Three-Wire Start/Stop Sample Control Wiring.....................................5-5
Figure 5.7 – Multi-Speed Preset Sample Control Wiring.......................................... 5-6
Figure 5.8 – Terminal Usage During Multi-Speed Preset Operation ........................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
1SU5xxxx Drives................................................................................ 5-9
Figure 5.11 – Output Status Relay Wiring Connections.........................................5-10
Figure 7.1 – SP500 Keypad and Display..................................................................7-1
Figure 7.2 – SP500 Menu Structure......................................................................... 7-4
Figure 7.3 – Example of a Program Mode Display..................................................7-5
Figure 7.4 – Example of a Monitor Mode Display..................................................... 7-6
Figure 8.1 – Manual Torque Boost Adjustment Range.............................................8-7
Figure 8.2 – Volts/Hertz Curve .................................................................................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)................... ...... ....... ...... ....... ...... ....... ...............9-2
Figure 9.3 – DC Bus Terminals on Model 1SU4x015 and 1SU4x020 Drives........... 9-2
Contents
III
IV
SP500 AC Drive Installation and Operation Manual Version 3.1
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 3.2 – Recommended Power Wire Sizes for M/N 1SU1xxxx and
1SU2xxxx Drives...................................................................................3-5
Table 3.3 – Recommended Power Wire Sizes for M/N 1SU4xxxx and
1SU5xxxx Drives...................................................................................3-5
Table 3.4 – Recommended Power Wire Sizes for M/N 1SU4x015 and
1SU4x020 Drives.................................................................................. 3-5
Table 3.5 – Recommended Power Terminal Tightening Torque..............................3-5
Table 3.6 – Recommended Control and Signal Wire Sizes and Tightening Torque 3-6
Table 3.7 – Motor Lead Lengths...............................................................................3-7
Table 3.8 – Reactors ................................................................................................3-7
Table 3.9 – AC Input Line Fuse Selection Values.................................................... 3-8
Table 7.1 – Key Descriptions.................................................................................... 7-2
Table 7.2 – Drive Status LED Descriptions .............................................................. 7-3
Table 7.3 – Monitor Mode LED Descriptions............................................................ 7-3
Table 8.1 – Multi-Speed Presets Digital Inputs.......................................................8-15
Table 8.2 – Auto-Restartable Faults.......................................................................8-16
Table 9.1 – Drive Faults and Corrective Actions ......................................................9-3
Table 9.2 – Resistance Checks for Input Diodes......................................................9-8
Table 9.3 – Resistance Checks for IGBTs................................................................9-8
Contents
V
VI
SP500 AC Drive Installation and Operation Manual Version 3.1
This chapter describes the manual’s intended audience and provides an overview of
the SP500 d rive’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 Install at io n Overview
This manual describes how to install and troubleshoot the SP500 drive. Drive
installati on 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.
CHAPTER 1
Introduction
• 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 F lists the parts
of the drive that can be 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 keypad and the display, and Appendix A, which lists the
drive’s technical specifications.
1.3 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
1-2
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/Rev erse (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)
CHAPTER 2
• 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
(0 to 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
• 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 parameter s
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. 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 can be 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 can be 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 can be
viewed on the four-character display. After a fault, the STOP/RESET key or a
user-supplied IET RESET pushbutton must be pressed to reset the IET signal and
clear the fault from the drive.
2-2
SP500 AC Drive Installation and Operation Manual Version 3.1
.
Learning About the SP500 Drive
Figure 2.1 – SP500 System Diagram
2-3
Figure 2.2 – SP500 System Diagram (Continued)
2-4
SP500 AC Drive Installation and Operation Manual Version 3.1
Figure 2.3 – Regulator Board Component Locations
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.
2-6
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 ¼ - 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
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
Model
Number
Input Power
and Horsepower
Rating*
NEMA
Rating
Enclosure
Size**
AC Input
Volts
Input
Amps
Input
KV A
Output
Amps*
Power
Loss
Watts***
1SU11001 Single-Phase - 1 HP 1 A 115 13.1 1.5 6.8 80
1SU14001 Single-Phase - Demo ---- ---- 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 - 1 HP 4X/12 A 200-230 5.0 1.3 1.7 70
1SU21002 Single-Phase - 2 HP
4 kHz Carrier
6 kHz Carrier
8 kHz Carrier
1
A
200-230
200-230
200-230
19.1
17.2
15.3
4.4
4.0
3.5
7.5
7.0
6.5
120
120
120
1SU21001 Three-Phase - 1 HP 1 A 200-230 7.0 2.8 5.0 70
1SU24001 Three-Phase - 1 HP
4 kHz Carrier
6 kHz Carrier
8 kHz Carrier
1SU21002 Three-Phase - 2 HP
4 kHz Carrier
6 kHz Carrier
8 kHz Carrier
4X/12 A
1A
200-230
200-230
200-230
200-230
200-230
200-230
6.4
5.2
5.2
9.9
9.3
8.7
2.6
2.0
2.0
4.0
3.8
3.5
4.5
3.6
3.6
7.5
7.0
6.5
70
70
70
70
70
70
1SU24002 Three-Phase - 2 HP 4X/12 C 200-230 9.9 4.0 7.5 120
1SU21003 Three-Phase - 3 HP 1 C 200-230 12.5 5.0 10.6 210
1SU24003 Three-Phase - 3 HP 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 - 5 HP 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 - 1 HP 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 - 2 HP 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 - 3 HP 4X/12 B 380-460 6.4 5.1 5.3 140
1SU41005 Three-Phase - 5 HP 1 B 380-460 9.9 8.0 8.2 180
1SU44005 Three-Phase - 5 HP 4X/12 B 380-460 9.9 8.0 8.2 180
1SU41007 Three-Phase - 7.5 HP 1 C 380-460 13.4 10.7 11.1 210
1SU44007 Three-Phase - 7.5 HP 4X/12 C 380-460 13.4 10.7 11.1 210
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
1SU42015 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 - 1 HP 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)
Model
Number
Input Power
and Horsepower
Rating*
NEMA
Rating
Enclosure
Size**
AC Input
Volts
Input
Amps
Input
KV A
Output
Amps*
Power
Loss
Watts***
1SU51002 Three-Phase - 2 HP 1 B 575 3.4 3.3 2.7 90
1SU54002 Three-Phase - 2 HP 4X/12 B 575 3.4 3.3 2.7 90
1SU51003 Three-Phase - 3 HP 1 B 575 5.2 5.1 4.3 120
1SU54003 Three-Phase - 3 HP 4X/12 B 575 5.2 5.1 4.3 120
1SU51005 Three-Phase - 5 HP 1 B 575 7.5 7.5 6.2 150
1SU54005 Three-Phase - 5 HP 4X/12 B 575 7.5 7.5 6.2 150
1SU51007 Three-Phase - 7.5 HP 1 C 575 10.9 10.9 9.0 180
1SU54007 Three-Phase - 7.5 HP 4X/12 C 575 10.9 10.9 9.0 180
1SU51010 Three-Phase - 10 HP 1 C 575 14.5 14.4 12.0 250
1SU54010 Three-Phase - 10 HP 4X/12 C 575 14.5 14.4 12.0 250
* 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
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.
2-8
See table 2.2 for a 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.
2.4 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.
SP500 AC Drive Installation and Operation Manual Version 3.1
CONTROL STRIP
TERMINAL
REGULATOR PCB
MEMBRANE SWITCH/
BRACKET ASSEMBLY
INTERNAL FAN
ASSEMBLY
Learning About the SP500 Drive
POWER TERMINAL STRIP
POWER PCB
GND CONNECTION
Figure 2.5 – Enclosure A Component Locations
2-9
CONTROL TERMINAL STRIP
REGULATOR PCB
MEMBRANE SWITCH/
BRACKET ASSEMBLY
INTERNAL FAN
ASSEMBLY
2-10
CAPACITOR PCB
(3 & 5 HP ONLY)
Figure 2.6 – Enclosure B Component Locations
POWER PCB
GND CONNECTION
POWER TERMINAL STRIP
SP500 AC Drive Installation and Operation Manual Version 3.1
CONTROL TERMINAL
CONTROL TERMINAL STRIP
STRIP
REGULATOR PCB
REGULATOR PCB
MEMBRANE SWITCH/
MEMBRANE SWITCH/
BRACKET ASSEMBLY
BRACKET ASSEMBLY
INTERNAL FAN
INTERNAL FAN
ASSEMBLY
ASSEMBLY
CAPACITOR PCB
CAPACITOR PCB
GND CONNECTIONS
GND CONNECTIONS
Learning About the SP500 Drive
POWER PCB
POWER PCB
Figure 2.7 – Enclosure C Component Locations
POWER TERMINAL
POWER TERMINAL
STRIP
STRIP
2-11
Figure 2.8 – Enclosure D Component Locations
2-12
SP500 AC Drive Installation and Operation Manual Version 3.1
2.5 Option Kits
Table 2.3 provides a listing of the available SP500 option kits.
Table 2.3 – SP500 Option Kits
Option Kit Description
Low Energy Snubber Resistor Braking Kit for
Option Kit
Model Number
2DB2005 D2-3178
Instruction
Manual
M/N 1SU2xxxx Drives
Low Energy Snubber Resistor Braking Kit for
2DB4010 D2-3179
M/N 1SU4xxxx Drives*
Low Energy Snubber Resistor Braking Kit for
M/N 1SU4x015 and 1SU4x020 Drives
Low Energy Snubber Resistor Braking Kit for
2SR40700
D2-3291
2SR41800
2DB5010 D2-3180
M/N 1SU5xxxx Drives*
*Snubber resistor braking kits for M/N 1SU4xxxx and 1SU5xxxx drives require connection to the snubber
resistor braking 10V power supply. See section 5.2.4 for more information.
Learning About the SP500 Drive
2-13
2-14
SP500 AC Drive Installation and Operation Manual Version 3.1
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
!
3.1 Installation Site Requir em e nt s
should install, adjust, operate, or service this equipment. Read and
understand this manual and other applicable manuals in their entirety
before proceeding.
ATTENTION:Use of power correction capacitors on the output of the
drive can result in erratic operation of the motor, nuisance tripping,
and/or permanent damage to the drive. Remove power correction
capacitors before proceeding.
ATTENTION:The user is responsible for conforming with all applicable
local, national, and international codes.
CHAPTER 3
It is important to properly plan before installing an SP500 drive to ensure that the
drive’s environment and operating conditions are satisfactory . Note that no devices are
to be mounted behind the drive. This area must be kept clear of all control and power
wiring. Read the following recommendations before continuing with the drive
installation.
Before deciding on an installation site, consider the following guidelines:
• The area chosen should allow the space required for proper airflow as specified in
sections 3.1.1 and 3.1.2.
• Do not install the drive above 1000 meters (3300 feet) without derating output
power. For every 91.4 meters (300 feet) above 1000 meters (3300 feet), derate the
output current by 1%.
• Verify that the drive location will meet the following environmental conditions:
Operating temperature (ambient): 0 to +40°C (32 to 104°F)
Storage temperature (ambient): –40 to +65°C (–40 to +149°F)
Humidity: 5 to 95% (non-condensing)
• Verify that NEMA 1 drives can be kept clean, cool, and dry.
• Be sure NEMA 1 drives are located away from oil, coolants, or other airborne
contaminants.
• Verify that the AC power distribution system meets the service conditions specified
in table A.1.
SP500 System Planning
3-1
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”)146.0 mm (5.57”)
263.5 mm (10.37”)
20.7 mm (0.81”)
73.0 mm (2.88”)
.
Figure 3.1 – Enclosure A Dimensions
304.8 mm (12.00”)
3-2
Figure 3.2 – Enclosure B Dimensions
SP500 AC Drive Installation and Operation Manual Version 3.1
Figure 3.3 – Enclosure C Dimensions
SP500 System Planning
Figure 3.4 – Enclosure D Dimensions
3-3
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 3.1 – Air Flow Clearances
Enclosure
ABCD
Minimum distance from the sides of the drive if adjacent to non-heat
producing equipment
Minimum distance from the top and bottom of the drive if adjacent to
non-heat producing equipment
Minimum distance from the sides of the drive if adjacent to other drives 51 mm
Minimum distance from the top and bottom of the drive if adjacent to
other drives
51 mm
”
)
(2
102 mm
(4”)
(2”)
254 mm
(10”)
3.1.3 Verifying the Drive’s Power Loss Rating
When installing an SP500 drive inside of another enclosure, you should consider the
drive’s watts loss rating shown in table 2.2. This table lists the typical full load power
loss watts value under all operating carrier frequencies. Ensure adequate ventilation is
provided based on the drive’s watts loss rating.
3.2 Wiring Requirements
Evaluate the following areas of drive wiring before you do the installation: size of
available conduit, size of power and control wiring, and motor lead lengths.
102 mm
(4”)
102 mm
(4”)
102 mm
(4”)
254 mm
(10”)
102 mm
(4”)
102 mm
(4”)
102 mm
(4”)
254 mm
(10”)
102 mm
(4”)
102 mm
(4”)
102 mm
(4”)
102 mm
(4”)
3-4
3.2.1 Verifying Conduit Sizes
It is important to determine the size of the conduit openings accurately so that the wire
planned for a specific entry point will fit through the opening. Figures 4.1 through 4.4
show conduit opening sizes.
3.2.2 Recommended Power Wire Sizes
Size input power wiring according to applicable codes to handle the drive’s
continuous-rated input current. Size output wiring according to applicable codes to
handle the drive’s continuous-rated output current. Tables 3.2, 3.3, and 3.4 provide
recommended power wiring sizes. Use only copper wire with a minimum temperature
rating of 60/75°C. Table 3.5 contains the recommended tightening torque values for all
power wiring terminals.
SP500 AC Drive Installation and Operation Manual Version 3.1
.
Table 3.2 – Recommended Power Wire Sizes for M/N 1SU1xxxx and 1SU2xxxx Drives
Type of Wiring Terminals
AC Input Po wer R, S, T
Output Power U, V, W
DC Bus – , +
Ground GND
*Except for M/N 1SU21002 (single-phase input), 1SU21005, and 1SU24005, for which 12 AWG, 3 (mm2)
wire is recommended.
Table 3.3 – Recommended Power Wire Sizes for M/N 1SU4xxxx and 1SU5xxxx Drives
Type of Wiring Terminals
AC Input Po wer R(L1), S(L2), T(L3)
Output Power U(T1), V(T2), W(T3)
DC Bus – , +
Snubber Resistor +10 VDC, 10 COM
Ground GND
2
* Except for M/N 1SU41010 and 1SU44010, for which 12 AWG, 3 (mm
) wire is recommended.
Size of Wire
(maximum)*
14 AWG, 2 (mm
14 AWG, 2 (mm
14 AWG, 2 (mm
14 AWG, 2 (mm
Size of Wire
(maximum)*
14 AWG, 2 (mm
14 AWG, 2 (mm
14 AWG, 2 (mm
14 AWG, 2 (mm
14 AWG, 2 (mm
2
)
2
)
2
)
2
)
2
)
2
)
2
)
2
)
2
)
Table 3.4 – Recommended Power Wire Sizes for M/N 1SU4x015 and 1SU4x020 Drives
Type of Wiring Terminals
AC Input Po wer R/L1, S/L2, T/L3
Output Power U/T1, V/T2, W/T3
DC Bus – , +
Snubber Resistor –, +
Ground GND
Table 3.5 – Recommended Power Terminal Tightening Torque
Size of Wire
(maximum)
12 AWG, 3 (mm
12 AWG, 3 (mm
12 AWG, 3 (mm
12 AWG, 3 (mm
12 AWG, 3 (mm
Drives Terminals Maximum Tightening Torque
All All power wires 1.08 Newton-meters (9.5 in-lb)
2
)
2
)
2
)
2
)
2
)
SP500 System Planning
3-5
3.2.3 Recommen ded 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
Minimum
Wire Size
Maximum
All 1–16 20 AWG,
2
0.5 (mm
)
3.2.4 Recommended Motor Lead Lengths
The following motor lead lengths are recommended to reduce line disturbances and
noise. See figure 3.5.
• For applications using one motor, motor lead length should not exceed 76 meters
(250 feet).
• For applications with multiple motors, total motor lead length should not exceed 76
meters (250 feet).
When total lead length exceeds 76 meters (250 feet), nuisance trips can occur,
caused by capacitive current flow to ground. Note that these capacitively-coupled
currents should be taken into consideration when working in areas where drives are
running. If the motor lead length must exceed these limits, the addition of output line
reactors or other steps must be taken to correct the problem. See tables 3.7 and 3.8.
Note that the motor lead lengths shown in table 3.7 are maximum distances. Your
application may be restricted to a shorter motor lead length due to:
• the type of wire
Wire Size
14 AWG,
2 (mm2)
Maximum
Tightening Torque
0.5 Newton-meters
(4.5 in-lb)
• the placement of the wire (for example, in conduit or a cable tray)
• the type of line reactor
• the type of motor
SP500 Drive
38m (125’)
Motor
Motor
All examples represent 76m (250’) of motor lead length.
3-6
38m (125’)
15m (50’)
Motor
61m (200’)
8m (25’)
Motor
Figure 3.5 – How to Measure Motor Lead Lengths
SP500 AC Drive Installation and Operation Manual Version 3.1
61m (200’)
8m (25’)
Motor Motor
SP500 DriveSP500 DriveSP500 Drive
76m (250’)
Motor
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