GV3000/SE AC Bookshelf Drive Hardware Reference, Installation

GV3000/SE AC Bookshelf Drive Hardware Reference, Installation
GV3000/SE AC Bookshelf Drive
Hardware Reference, Installation,
and Troubleshooting
Version 6.06
Instruction Manual D2-3427-2
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, or service this equipment.
Read and understand this manual and other applicable manuals in their entirety before
proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.
ATTENTION: Do not install or remove modification kits with power applied to the drive. Disconnect
and lock out incoming power before attempting such installation or removal. Failure to observe
this precaution could result in severe bodily injury or loss of life.
ATTENTION: DC bus capacitors retain hazardous voltages after input power has been
disconnected. After disconnecting input power, wait five (5) minutes for the DC bus capacitors
to discharge and then check the voltage with a voltmeter to ensure the DC bus capacitors are
discharged before touching any internal components. Failure to observe this precaution could
result in severe bodily injury or loss of life.
ATTENTION: The drive is capable of operating at and maintaining zero speed. The user is
responsible for assuring safe conditions for operating personnel by providing suitable guards,
audible or visual alarms, or other devices to indicate that the drive is operating or may operate
at or near zero speed. Failure to observe this precaution could result in severe bodily injury or
loss of life.
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. Failure to observe this precaution
could result in bodily injury.
ATTENTION: The drive contains ESD- (Electrostatic Discharge) sensitive parts and assemblies.
Static control precautions are required when installing, testing, servicing, or repairing the drive.
Erratic machine operation and damage to, or destruction of, equipment can result if this procedure
is not followed. Failure to observe this precaution can result in bodily injury.
ATTENTION: The user is responsible for conforming with all applicable local, national, and
international codes. Failure to observe this precaution could result in damage to, or destruction
of, the equipment.
DeviceNet is a trademark of Open DeviceNet Vendor Association.
ControlNet is a trademark of ControlNet International Ltd.
PROFIBUS is a trademark of PROFIBUS International.
GV3000, AutoMax, and Reliance are trademarks of Rockwell Automation.
©2000 Rockwell International Corporation
CONTENTS
Contents
Chapter 1
Introduction
1.1 Related Publications ........................................................................................ 1-1
1.2 Getting Assistance from Reliance Electric....................................................... 1-1
Chapter 2
About the Drive
2.1 Identifying the Drive......................................................................................... 2-1
2.2 Understanding the Enclosure Rating: IP20 ..................................................... 2-2
2.3 2 to 15 Amp GV3000/SE Bookshelf Drive Component Locations ................... 2-3
2.4 24 to 30 Amp GV3000/SE Bookshelf Drive Component Locations ................. 2-4
2.5 43 Amp GV3000/SE Bookshelf Drive Component Locations .......................... 2-5
2.6 Regulator Board Description ........................................................................... 2-6
2.6.1 Jumper Locations and Settings ............................................................. 2-7
2.6.1.1 Setting the Analog Input Speed Reference Jumper (J4) ........ 2-7
2.6.1.2 Setting the Analog Output Jumper (J17)................................. 2-8
2.6.2 Terminal Strip ...................................................................................... 2-10
2.6.3 RS-232 Communication Port............................................................... 2-10
2.6.4 Option Board Connector ..................................................................... 2-11
2.6.5 Operator Interface Module (OIM) Connector....................................... 2-11
2.7 Keypad/Display.............................................................................................. 2-11
2.8 Output Relay Terminal Strip .......................................................................... 2-12
2.9 Internal Braking Transistor ............................................................................ 2-12
2.10 Optional Internal AC Mains Filter................................................................... 2-12
2.11 Optional Equipment ....................................................................................... 2-12
Chapter 3
Planning Before Installing
3.1 General Requirements for the Installation Site ................................................ 3-1
3.1.1 Making Sure Environmental Conditions are Met ................................... 3-1
3.1.2 Determining Total Area Required Based on Drive Dimensions ............ 3-3
3.1.3 Verifying the Site Provides for Recommended Air Flow Clearances .... 3-4
3.1.4 Verifying Power Module Input Ratings Match Supplied Power ............. 3-5
3.2 Wiring Requirements for the Drive .................................................................. 3-5
3.2.1 Meeting Terminal Strip Input and Output Specifications ....................... 3-5
3.2.2 Determining Wire Size Requirements ................................................... 3-5
3.2.2.1 Conduit Entry Opening Sizes for 24 to 43 Amp Bookshelf Drives 3-5
3.2.2.2 Recommended Power Wire Sizes .......................................... 3-5
3.2.2.3 Recommended Control and Signal Wire Sizes ....................... 3-6
3.2.2.4 Recommended Motor Lead Lengths....................................... 3-6
3.2.2.5 Recommended Serial Communication Cable Lengths ........... 3-8
3.2.3 Selecting Input Line Branch Circuit Fuses ............................................ 3-8
3.2.4 Meeting Encoder Specifications (FVC Regulation Only)....................... 3-9
3.2.4.1 Encoder Wiring Guidelines ..................................................... 3-9
3.2.5 Verifying Power Module Output Current Rating Is Greater Than
Motor Full Load Amps ........................................................................... 3-9
I
Chapter 4
Mounting the Drive, Grounding, and Finding Wire Routing Locations
4.1 Mounting the Drive ...........................................................................................4-1
4.1.1 Verifying the Drive’s Watts Loss Rating.................................................4-1
4.2 Determining Input, Motor Output, Ground, and Control Wire Routing
for the Drive......................................................................................................4-2
4.3 Grounding the Drive .........................................................................................4-2
Chapter 5
Installing Input Power Wiring
5.1 Installing Transformers and Reactors (Optional) .............................................5-1
5.2 Installing Fuses for Branch Circuit Protection ..................................................5-2
5.3 Installing a Required External/Separate Input Disconnect...............................5-2
5.4 Installing Power Wiring from the AC Input Line to the Drive’s Power Terminals .5-2
Chapter 6
Installing Output Power Wiring
6.1 Installing Output Contactors (Optional) ............................................................6-1
6.2 Installing Mechanical Motor Overload Protection (Optional) ............................6-1
6.3 Installing Output Wiring from the Drive Output Terminals to the Motor............6-1
Chapter 7
Wiring the Regulator Board Terminal Strip and the Output Relay Terminal Strip
7.1 Stopping the Drive............................................................................................7-4
7.1.1 Compliance with Machinery Safety Standard EN 60204-1:1992...........7-4
7.2 Wiring the Encoder Feedback Device (FVC Regulation Only).........................7-5
7.3 Wiring the Signal and Control I/O.....................................................................7-7
Chapter 8
Wiring Optional User-Supplied Braking Resistors
8.1 Installation Guidelines ......................................................................................8-1
8.2 Selecting a Braking Resistor ............................................................................8-3
8.3 Installing the Braking Resistor..........................................................................8-4
Chapter 9
Completing the Installation
9.1 Checking the Installation ..................................................................................9-1
9.2 Powering Up After Installation Is Complete......................................................9-2
Chapter 10
Troubleshooting the Drive
10.1 Test Equipment Needed To Troubleshoot .....................................................10-1
10.2 Drive Alarms and Faults.................................................................................10-1
10.3 Verifying That DC Bus Capacitors Are Discharged........................................10-1
10.4 Checking Out the Drive with Input Power Off.................................................10-4
10.5 Checking the Cooling Fans ............................................................................10-7
10.6 Replacement Parts.........................................................................................10-7
Appendix A Technical Specifications........................................................................................... A-1
Appendix B Compliance with Machinery Safety Standard EN 60204-1:1992 ............................. B-1
Appendix C Compliance with Electromagnetic Compatibility Standards ..................................... C-1
Index
II
...........................................................................................................................Index-1
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
List of Figures
Figure 2.1 – Identifying the Drive Using the U. S. Model Number ............................ 2-1
Figure 2.2 – Identifying the Drive Using the European Stock Number ..................... 2-2
Figure 2.3 – 2 to 15 Amp Drive Component Locations............................................. 2-3
Figure 2.4 – 24 to 30 Amp Drive Component Locations........................................... 2-4
Figure 2.5 – 43 Amp Drive Component Locations.................................................... 2-5
Figure 2.6 – Regulator Board Component Locations ............................................... 2-6
Figure 2.7 – Jumper J4 Settings for Analog Input Speed Reference ....................... 2-8
Figure 2.8 – Jumper J17 Settings for Analog Outputs.............................................. 2-9
Figure 2.9 – Typical Terminal Strip Connections.................................................... 2-10
Figure 2.10 – Keypad/Display................................................................................. 2-11
Figure 2.11 – Output Relay Terminal Strip ............................................................. 2-12
Figure 3.1 – Dimensions for 2 to 30 Amp Drives ...................................................... 3-3
Figure 3.2 – Dimensions for 43 Amp Drives ............................................................. 3-4
Figure 3.3 – How to Calculate Motor Lead Lengths ................................................. 3-7
Figure 4.1 – Wire Routing Locations for 2 to 15 Amp Drives.................................... 4-3
Figure 4.2 – Wire Routing Locations for 24 to 30 Amp Drives.................................. 4-4
Figure 4.3 – Wire Routing Locations for 43 Amp Drives........................................... 4-5
Figure 5.1 – Typical AC Input Electrical Connections............................................... 5-3
Figure 7.1 – Two-Wire Start/Stop Sample Control Wiring ........................................ 7-3
Figure 7.2 – Three-Wire Start/Stop Sample Control Wiring...................................... 7-3
Figure 7.3 – Encoder Wiring Connections ................................................................ 7-6
Figure 7.4 – Wiring the Terminal Strip - Detail.......................................................... 7-7
Figure 8.1 – Braking Resistor Wiring Connections ................................................... 8-4
Figure 10.1 – DC Bus Voltage Terminals (2 to 15 Amp Drives) ............................. 10-2
Figure 10.2 – DC Bus Voltage Terminals (24 to 30 Amp Drives) ........................... 10-3
Figure 10.3 – DC Bus Voltage Terminals (43 Amp Drives) .................................... 10-4
Contents
III
IV
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
List of Tables
Table 2.1 – Power Ratings ....................................................................................... 2-2
Table 2.2 – Standard Kits and Options .................................................................. 2-12
Table 3.1 – Environmental Conditions...................................................................... 3-2
Table 3.2 – Dimensions and Weights for 2 to 30 Amp Drives .................................. 3-3
Table 3.3 – Dimensions and Weight for 43 Amp Drives ........................................... 3-4
Table 3.4 – Recommended Air Flow Clearances ..................................................... 3-4
Table 3.5 – Recommended Power Wire Sizes for 2 to 15 Amp Drives .................... 3-5
Table 3.6 – Recommended Power Wire Sizes for 24 to 43 Amp Drives .................. 3-6
Table 3.7 – Recommended Terminal Strip Wire Sizes............................................. 3-6
Table 3.8 – Recommended Motor Lead Lengths for Reliance Inverter Duty Motors.... 3-7
Table 3.9 – Compatible Reactors ............................................................................. 3-7
Table 3.10 – AC Input Fuse Selection Values ......................................................... 3-8
Table 7.1 – Encoder Connections (Regulator Terminals 4-9) .................................. 7-1
Table 7.2 – Analog Output Connections (Regulator Terminals 10 and 11) .............. 7-1
Table 7.3 – Analog Speed/Torque Reference Connections (Regulator
Terminals 12-15)................................................................................... 7-2
Table 7.4 – Digital Input Connections (Regulator Terminals 16-25)......................... 7-2
Table 7.5 – Status Relay Connections (Relay Terminals 28-31) on the
Output Relay Terminal Strip.................................................................. 7-2
Table 7.6 – Encoder Connections ............................................................................ 7-5
Table 7.7 – Wiring Signal and Control I/O to the Regulator Board Terminal Strip.... 7-7
Table 7.8 – Wiring the Output Relay Terminal Strip ............................................... 7-14
Table 8.1 – Cable Cross-Sections for External Braking Resistors ........................... 8-2
Table 8.2 – Selecting a Braking Resistor.................................................................. 8-3
Table 8.3 – Wiring Connections for External Braking Resistor................................. 8-4
Table 10.1 – Resistance Checks ............................................................................ 10-5
Table 10.2 – Replacement Parts ............................................................................ 10-7
Contents
V
VI
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
CHAPTER 1
Introduction
This instruction manual describes GV3000/SE Bookshelf drive hardware. It does not
cover the GV3000/SE drive software. For software information, refer to the
GV3000/SE AC General Purpose (V/Hz) and Vector Duty Bookshelf Drive Software
Start-Up and Reference Manual (D2-3426).
This manual is intended for qualified electrical personnel. It is organized according to
a logical progression of steps to be followed to install and troubleshoot the drive.
GV3000/SE Bookshelf drives will typically be referenced by amps. If additional clarity
is required, drive model numbers will also be included.
1.1
Related Publications
Refer to the following related publications as necessary for more information:
1.2
• D2-3426
GV3000/SE AC General Purpose (V/Hz) and Vector Duty Bookshelf
Drive Software Start-Up and Reference Manual
•
•
•
•
•
•
D2-3305
Motor Encoder Cable Kit
D2-3308
AutoMax Network Communication Option Board
D2-3348
Control and Configuration Software (CS3000)
D2-3341
Super Remote Meter Interface (RMI) Board
D2-3342
Operator Interface Module (OIM)
D2-3390
ControlNet Network Communication Option Board
Getting 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.
Introduction
1-1
1-2
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
CHAPTER 2
About the Drive
This chapter provides an overview of the drive including how to identify the drive, a
description of the Regulator board, and the identification of major components of the
drive.
The GV3000/SE AC Bookshelf drive is a PWM (pulse-width-modulated) drive that
provides vector and general purpose regulation for a wide range of applications.
Using vector regulation, the drive can provide high dynamic response, maintain full
rated motor torque to zero speed, and precisely control motor speed in both
directions. The drive can provide this functionality either with encoder feedback (flux
vector control or FVC) or without (sensorless vector control or SVC).
Using general purpose (volts/hertz or V/Hz) regulation, the drive is suited for a broad
range of applications requiring adjustable speed control of motors.
2.1
Identifying the Drive
Each GV3000/SE Bookshelf drive can be identified by its U.S. model number or the
European stock number. See figures 2.1 and 2.2. These numbers appear on the
shipping label and on the drive’s nameplate. Drive power ratings are provided in table
2.1.
NNN
AA
N
N
NN
V/Hz Current Ratings
(31 = 3.1 A, etc.)
ER = GV3000/SE Bookshelf Drive
without CE Filter
ET = GV3000/SE Bookshelf Drive
with CE Filter
Voltage
4 = 380 V to 460 V
Enclosure
0 = IP20
Regulator Version
60 = Vector and V/Hz Regulator Version 6.0 Firmware
Figure 2.1 – Identifying the Drive Using the U. S. Model Number
About the Drive
2-1
NNN
.
NN . NN
896 = GV3000/SE
Power Module Size
11 = DC Bus Terminals and
Braking Transistor Circuit
31 = DC Bus Terminals, Braking
Resistor Circuit, and Built-In CE Filter
Figure 2.2 – Identifying the Drive Using the European Stock Number
Table 2.1 – Power Ratings
Output Amps by Mode @ Carrier
Frequency
Power Loss
Watts
(Full Load)
U.S.
Model
Number
European
Stock
Number
Input
KVA
31ER40xx
31ET40xx
896.01.11
896.01.31
4.0
3.2
5
4
3.1
3.1
2.8
2.1
2.1
2.1
60
38ER40xx
38ET40xx
896.02.11
896.02.31
4.8
4.0
6
5
3.8
3.8
2.8
3.1
3.1
2.8
70
55ER40xx
55ET40xx
896.03.11
896.03.31
8.0
6.4
10
8
5.5
5.5
5.5
3.8
3.8
3.8
100
85ER40xx
85ET40xx
896.05.11
896.05.31
10.4
8.0
13
10
8.5
8.5
5.5
6.7
6.7
5.0
150
126ER40xx
126ET40xx
896.06.11
896.06.31
12.7
10.4
16
13
12.6
12.0
8.5
9.3
9.3
8.0
210
150ER40xx
150ET40xx
896.07.11
896.07.31
15.9
12.7
20
16
15.0
12.0
8.5
11.0
11.0
8.0
250
240ER40xx
240ET40xx
896.08.11
896.08.31
24.7
19.9
31
25
24.0
16.5
12.6
16.5
15.0
11.0
380
300ER40xx
300ET40xx
896.09.11
896.09.31
30.2
25.5
38
32
30.0
24.0
16.5
22.0
22.0
15.0
470
430ER40xx
430ET40xx
896.11.12
896.11.32
42.2
37.4
53
47
43.0
31.0
22.0
30.0
22.0
15.0
600
V/Hz**
Vector**
Input
Amps* 2 kHz 4 kHz 8 kHz 2 kHz 4 kHz 8 kHz
*
Input Voltage: 380 to 460 VAC (+/-10%)
**
With V/Hz regulation, 110% continuous output current capability. With vector regulation, 150% output
current capability for one minute.
2.2
Understanding the Enclosure Rating: IP20
GV3000/SE Bookshelf drives have an IP20 rating. An IP rating designates the
enclosure’s level of protection. The first number (2) indicates the enclosure protects
against solid objects greater than 12 mm. The second number (0) indicates that the
enclosure is not water-tight. Note that the drive is intended for use inside a larger,
user-supplied enclosure.
2-2
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
2.3
2 to 15 Amp GV3000/SE Bookshelf Drive Component
Locations
The 2 to 15 amp GV3000/SE Bookshelf drives have the following main components.
The numbered items listed below correspond to the numbers used in figure 2.3.
Replacement parts are listed in chapter 10.
1. Regulator PCB
2. Fan
3. Output Relay Terminal Strip
4. Power PCB
5. Keypad/Display
➀
➄
➂
➃
➁
Front View
Cover Removed
Figure 2.3 – 2 to 15 Amp Drive Component Locations
About the Drive
2-3
2.4
24 to 30 Amp GV3000/SE Bookshelf Drive
Component Locations
The 24 to 30 amp GV3000/SE Bookshelf drives have the following main components.
The numbered items listed below correspond to the numbers used in figure 2.4.
Replacement parts are listed in chapter 10.
1. Regulator PCB
2. Fan
3. Output Relay Terminal Strip
4. Power PCB
5. Keypad/Display
➄
➀
➂
Front View
➁
➃
Cover Removed
Figure 2.4 – 24 to 30 Amp Drive Component Locations
2-4
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
2.5
43 Amp GV3000/SE Bookshelf Drive Component
Locations
The 43 amp GV3000/SE Bookshelf drives have the following main components. The
numbered items listed below correspond to numbers used in figure 2.5. Replacement
parts are listed in chapter 10.
3. Output Relay Terminal Strip
4. Keypad/Display
1. Regulator PCB
2. Fan
➀
➃
PE L1 L2 L3
45 47 48 U V W
28-31
➂
➁
Figure 2.5 – 43 Amp Drive Component Locations
About the Drive
2-5
2.6
Regulator Board Description
Drive regulation is performed by a microprocessor on the Regulator board. See figure
2.6. Drive operation is adjusted by the parameters entered through the keypad. The
Regulator board accepts power circuit feedback signals and an external speed
reference signal, as well as data from an encoder that is attached to the motor when
set up for FVC regulation.
The Regulator board provides PWM gating signals to the IGBT power devices. Based
on the output of the control loop, the regulator sends PWM gating signals through the
current feedback section of the Power board to the isolated gate drivers. These drivers
switch the Insulated Gate Bi-polar Transistors (IGBTs), producing a PWM waveform
that corresponds to the speed (FVC regulation) or frequency (V/Hz regulation)
reference. The IGBTs can be switched at either a 2, 4, or 8 kHz carrier frequency.
The Regulator board components are shown in figure 2.6 and described in the
following sections.
OIM
Connector
(X7)
Power Module
Feedback Connector
(X16)
V
In
C
In
J17
RS-232C
Port (X8)
Keypad/Display
Cable Connector
(X9)
V
Out
C
Out
J4
Analog Output
Default: Voltage
Analog Input
Default: Voltage
Terminal Strip
(X1)
Option Board Connector
(X3)
Figure 2.6 – Regulator Board Component Locations
2-6
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
2.6.1 Jumper Locations and Settings
Jumpers J4 and J17 on the Regulator board are factory-set for voltage in and voltage
out signals. Refer to figure 2.6 for their locations on the Regulator board. If you need to
change the jumpers’ settings, use the following procedures.
!
ATTENTION: Do not alter the setting of any jumper not described in this
instruction manual. Failure to observe this precaution could result in
damage to, or destruction of, the equipment.
2.6.1.1 Setting the Analog Input Speed Reference Jumper (J4)
Jumper J4 is the analog speed/torque (U.000) reference jumper. This jumper selects
either +/-10 VDC or 0-20 mA input. Parameters P.009, P.010, and P.011 are used in
conjunction with the jumper.
Note that if the position of jumper J4 is changed after the parameters are
programmed, the software will not recognize that the input reference or polarity has
been changed. Be sure to verify that parameters P.009, P.010, and P.011 are correct
before starting the drive. Refer to the GV3000/SE Bookshelf Drive Software Start-Up
and Reference manual for more information about these parameters.
Use the following procedure to set jumper J4:
!
ATTENTION: DC bus capacitors retain hazardous voltages after input
power has been disconnected. After disconnecting input power, wait five
(5) minutes for the DC bus capacitors to discharge and then check the
voltage with a voltmeter to ensure the DC bus capacitors are discharged
before touching any internal components. Failure to observe this
precaution could result in severe bodily injury or loss of life.
Step 1. Disconnect, lock out, and tag all incoming power to the drive.
Step 2. Wait five minutes for the DC bus capacitors to discharge.
Step 3. Disconnect any wiring from the face of the drive.
Important: The cover is connected to the drive by the keypad/display cable. To
disconnect the cover, use the procedure below. Do not remove the
keypad/display.
Step 4. Remove the cover as follows:
a. Unscrew the attaching screw on the cover.
b. Lift the cover and carefully take it out of the heatsink as far as the flat
ribbon keypad cable will allow. This cable connects the display with the
Regulator board.
c. Use a screwdriver to slide the cable out of the connector on the Regulator
board to completely detach the cover.
Step 5. 24 to 43 A drives only: Remove the front panel by unscrewing the two
attaching screws.
Step 6. Verify that the DC bus voltage is zero before touching any internal
components by following the procedure in section 10.3.
About the Drive
2-7
Step 7. Locate jumper J4 on the Regulator board. Refer to figure 2.6.
Step 8. Locate pin 1 on jumper J4. Move the jumper to the desired setting as shown
in figure 2.7.
Voltage Input Option
Pins 2-3
Current Input Option
Pins 1-2
10 VDC
0-20 mA
V
In
V
In
C
In
C
In
J4
J4
(Default)
Figure 2.7 – Jumper J4 Settings for Analog Input Speed Reference
Step 9. Reattach the cover. For 24 to 43 A drives, reattach the front panel before
reattaching the cover.
Important: Check that the display cable is reconnected to the Regulator board. You
will need to fold and route the cable under the heatsink before replacing
the cover.
Step 10. Reconnect wiring to the faceplate of the drive.
Step 11. Reapply input power.
Step 12. Verify that Terminal Strip Analog Input Offset (P.009), Terminal Strip Analog
Input Gain (P.010), and Terminal Strip Analog Input Configure (P.011) are
correctly set.
Note that the jumper settings must match the software settings; otherwise,
the reference value may differ from what is expected. Refer to the
GV3000/SE Bookshelf Drive Software Start-Up and Reference manual for
more information.
2.6.1.2 Setting the Analog Output Jumper (J17)
Jumper J17 is the analog output jumper. This jumper selects either a 0-10 VDC or
4-20 mA scaled signal output that is programmable to be proportional to either speed
or torque using parameter P.012. Refer to the GV3000/SE Bookshelf Drive Software
Start-Up and Reference manual for more information about this parameter. The
analog output signal is available through the terminal strip.
The jumper only selects a 0-10 VDC source voltage or 4-20 mA sink current to
represent speed or torque. Note that the 4-20 mA current selection requires an
external 12 VDC power supply for operation as shown in table 7.6.
Use the following procedure to set jumper J17:
!
2-8
ATTENTION: DC bus capacitors retain hazardous voltages after input
power has been disconnected. After disconnecting input power, wait five
(5) minutes for the DC bus capacitors to discharge and then check the
voltage with a voltmeter to ensure the DC bus capacitors are discharged
before touching any internal components. Failure to observe this
precaution could result in severe bodily injury or loss of life.
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
Step 1. Disconnect, lock out, and tag all incoming power to the drive.
Step 2. Wait five minutes for the DC bus capacitors to discharge.
Step 3. Disconnect any wiring from the faceplate of the drive.
Important: The cover is connected to the drive by the keypad/display cable. To
disconnect the cover, use the procedure below. Do not remove the
keypad/display.
Step 4. Remove the cover as follows:
a. Unscrew the attaching screw on the cover.
b. Lift the cover and carefully take it out of the heatsink as far as the flat
ribbon keypad cable will allow. This cable connects the display with the
Regulator board.
c. Use a screwdriver to slide the cable out of the connector on the Regulator
board to completely detach the cover.
Step 5. 24 to 43 A drives only: Remove the front panel by unscrewing the two
attaching screws.
Step 6. Verify that the DC bus voltage is zero by following the procedure in section
10.3.
Step 7. Locate jumper J17 on the Regulator board. Refer to figure 2.6.
Step 8. Locate pin 1 on jumper J17. Move the jumper to the desired setting as shown
in figure 2.8.
Voltage Output Option
Pins 2-3
Current Output Option
Pins 1-2
10 VDC
4-20 mA
V
In
V
In
C
In
C
In
J17
(default)
J-17
Figure 2.8 – Jumper J17 Settings for Analog Outputs
Step 9. Reattach the cover. For 24 to 43 A drives, reattach the front panel before
reattaching the cover.
Important: Check that the display cable is reconnected to the Regulator board. You
will need to fold and route the cable under the heatsink before replacing
the cover.
Step 10. Reconnect wiring to the faceplate of the drive.
Step 11. Reapply input power.
Step 12. Verify that parameter P.012 is set correctly for either speed or current.
About the Drive
2-9
2.6.2 Terminal Strip
The terminal strip on the Regulator board provides terminals for connecting customer
I/O devices. See figures 2.6 and 2.9. The following terminals are provided:
• Terminals 4-9: Encoder connections
• Terminals 10-11: Analog output connections
• Terminals 12-15: Analog speed/torque reference connections
• Terminals 16-25: 24V DC digital input connections
Encoder
Feedback and
15 VDC Supply
+15 VDC
5
Phase A
6
Phase A Not
7
Phase B
8
Phase B Not
9
Regulator Common
10
0 to 10 VDC Meter
or Other Device
Reference Potentiometer
Digital Inputs
(6, 7, and 8 are
Software-Assignable)
Use with Digital Inputs 1-8
When Externally Powered
4
0 to 10 VDC Analog Output
11
Analog Output Return
12
Isolated Reference Voltage
13
+/- 10, 0 to 10 VDC Speed or Torque Reference
14
0/4 to 20 mA Speed or Torque Reference
15
Isolated Reference Ground
16
+24 VDC Supply
17
Digital Input 8 (Local/Remote)
18
Digital Input 7 (Ramp 1/ Ramp 2)
19
Digital Input 6 (Forward/Reverse)
20
Digital Input 5 (Function Loss)
21
Digital Input 4 (Run/Jog)
22
Digital Input 3 (Fault Reset)
23
Digital Input 2 (Stop)
24
Digital Input 1 (Start)
25
+24 VDC Common
Figure 2.9 – Typical Terminal Strip Connections
2.6.3 RS-232 Communication Port
The Regulator board contains a 9-pin D-shell RS-232 communication port (X8). See
figure 2.6. This port provides RS-232 communication between the GV3000/SE drive
and a personal computer running the Control and Configuration (CS3000) Software.
Refer to instruction manual D2-3348 for more information about the CS3000 software.
2-10
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
2.6.4 Option Board Connector
The flat-ribbon cable connector (X3) on the bottom of the Regulator board is a parallel
bus connection port that provides a means of attaching optional boards such as the
DeviceNet Option board, the RMI board, the AutoMax Network Option board, or
similar boards to the GV3000/SE drive. See figure 2.6. Refer to the appropriate board
instruction manual for more information. Refer to section 2.11 of this manual for more
information on optional drive kits.
2.6.5 Operator Interface Module (OIM) Connector
Flat-ribbon connector X7 provides a means of attaching the optional Operator
Interface Module (OIM). The OIM is available for use as a remote keypad for the drive.
Refer to the Operator Interface Module manual (D2-3342) for more information.
2.7
Keypad/Display
The front panel keypad/display is used to program and operate the drive. See figure
2.10. The four-character display is used to indicate drive parameters, parameter
values, and error codes. The fourteen single LEDs indicate drive status and operating
mode, as well as identify drive outputs whose values are displayed on the
four-character display.
Refer to the GV3000/SE Bookshelf Drive Software Start-Up and Reference manual
(D2-3426) for more information about the keypad/display.
Display
5
Monitor Mode LEDs
Password LED
STOP/RESET Key
RPM
RUN
V
REM
A
JOG
Hz
AUTO
kW
FWD
TRQ
REV
PASS
PROG
STOP
RESET
START
AUTO
MAN
FWD
REV
PROG
RUN
JOG
Drive Status LEDs
START Key
Keypad
ENTER
Figure 2.10 – Keypad/Display
About the Drive
2-11
2.8
Output Relay Terminal Strip
The output relay terminal strip, located on the Power board, provides a set of Form A
and B contacts. These contacts are the under control of the user via programmable
parameters. A Form A or B transition can be used to indicate drive status. The
contacts are rated for 2 amps resistive load at 250 VAC/ 30 VDC. See figure 2.11
28
N. C. Relay Contact
29
N. C. Relay Common
30
N. O. Relay Contact
31
N. O. Relay Common
Figure 2.11 – Output Relay Terminal Strip
2.9
Internal Braking Transistor
An internal braking transistor connects externally mounted, user-supplied braking
resistors to the DC bus and prevents DC bus overvoltage faults. The resistor switches
on during motor regeneration. See chapter 8 for more information.
2.10 Optional Internal AC Mains Filter
A built-in line filter limits radio frequency emission to EMC permitted values. It provides
the same function as a line reactor.
An AC Mains Filter is required if the installation must be in compliance with the
European Community Electromagnetic Compatibility Standard. See Appendix C for
more information.
2.11 Optional Equipment
Table 2.2 lists standard GV3000/SE kits and options.
Table 2.2 – Standard Kits and Options
Description
2-12
Model Number
Instruction Manual
Motor Encoder Cable
2TC3025
2TC3075
2TC4025
2TC4075
2TC4100
2TC4300
D2-3305
ControlNet Network Option Board
2CN3000
D2-3390
InterBus Network Option Board
2NB3000
49’1333
AutoMax Network Option Board with
762mm (30”) of Cable
2AX3000
D2-3308
AutoMax RS-232 Adapter Cable
2CA3001
D2-3348
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
Table 2.2 – Standard Kits and Options (Continued)
Description
About the Drive
Model Number
Instruction Manual
Super Remote Meter Interface (RMI)
2SI3000E
D2-3341
DeviceNet Network Option Board
2DV3000
MAN0096-03
Operator Interface Module (OIM)
2RK3000
D2-3342
CS3000 Control and Configuration
Software
2CS3000
D2-3348
CS3000 RS-232 Computer Cable
2CA3000
D2-3348
115 VAC Interface Option Board
2LB3000
D2-3376
PROFIBUS
2PB3000
49’1355
Network Option Board
2-13
2-14
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
CHAPTER 3
Planning Before Installing
This chapter describes how to plan a GV3000/SE Bookshelf drive installation.
!
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. Failure to observe this precaution could result in
severe bodily injury or loss of life.
ATTENTION: When the level-sense start feature is enabled
(P.054 = ON), the user must ensure that automatic start up of the driven
equipment will not cause injury to operating personnel or damage to the
driven equipment. In addition, the user is responsible for providing
suitable audible or visual alarms or other devices to indicate that this
function is enabled and the drive may start at any moment. Refer to the
GV3000/SE Bookshelf Drive Software Start-Up and Reference manual
(D2-3426) for additional information. Failure to observe this precaution
could result in severe bodily injury or loss of life.
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. Failure to observe this precaution could result in
damage to, or destruction of, the equipment.
ATTENTION: The user is responsible for conforming with all applicable
local, national, and international codes. Failure to observe this precaution
could result in damage to, or destruction of, the equipment.
3.1
General Requirements for the Installation Site
It is important to properly plan before installing a GV3000/SE Bookshelf 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
drive installation.
3.1.1 Making Sure Environmental Conditions are Met
Before deciding on an installation site, consider the following guidelines:
• Verify that drives can be kept clean, cool, and dry.
• The area chosen should allow the space required for proper air flow as defined in
section 3.1.3.
• Be sure that drives are away from oil, coolants, or other airborne contaminants.
Planning Before Installing
3-1
• 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 1%.
• Verify that the drive location will meet the environmental conditions specified in table
3.1.
Table 3.1 – Environmental Conditions
Condition
Specification
Operating Temperature (Ambient)
0° to +40°C (32° to 104°F) coolant air
inlet temperature at heatsink
Derating factor at 45°C (113°F)
ambient: Output current by 7.5%
Derating factor at 50°C (122°F)
ambient: Output current by 15%
Storage Temperature (Ambient)
-25°C to +55°C (-77° to +131°F)
Transportation Temperature (Ambient)
-25°C to +70°C (-77° to +158°F)
(+70°C (+158°F) during max. 24 hrs)
Humidity
Maximum: 50% at 40°C (104°F)
unlimited
Maximum: 90% at 20°C (68°F) during
maximum 30 days/year
75% average
No condensation
3-2
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
3.1.2 Determining Total Area Required Based on Drive Dimensions
Drive dimensions and weights are listed in table 3.2. Overall drive dimensions are
illustrated in figure 3.1 as an aid in calculating the total area required by the drive.
Table 3.2 – Dimensions and Weights for 2 to 30 Amp Drives
U.S.
Model
Number
31ER40xx
31ET40xx
38ER40xx
38ET40xx
55ER40xx
55ET40xx
85ER40xx
85ET40xx
126ER40xx
126ET40xx
150ER40xx
150ET40xx
240ER40xx
240ET40xx
300ER40xx
300ET40xx
European
Stock
Number
896.01.11
896.01.31
896.02.11
896.02.31
896.03.11
896.03.31
896.05.11
896.05.31
896.06.11
896.06.31
896.07.11
896.07.31
896.08.11
896.08.31
896.09.11
896.09.31
Width Dim A
mm (in)
Physical Dimensions in mm (in)
Mounting
Height Dim B Width Dim C Height Dim D
mm (in)
mm (in)
mm (in)
Weight
Depth Dim E
mm (in)
kg
lb
95 (3.74)
378 (14.88)
38 (1.50)
422 (16.61)
200 (7.87)
5.5
12
95 (3.74)
378 (14.88)
38 (1.50)
422 (16.61)
200 (7.87)
5.5
12
95 (3.74)
378 (14.88)
38 (1.50)
422 (16.61)
200 (7.87)
5.5
12
95 (3.74)
378 (14.88)
38 (1.50)
422 (16.61)
200 (7.87)
5.5
12
95 (3.74)
378 (14.88)
38 (1.50)
422 (16.61)
200 (7.87)
5.5
12
95 (3.74)
378 (14.88)
38 (1.50)
422 (16.61)
200 (7.87)
5.5
12
195 (7.68)
374 (14.72)
61 (2.40)
422 (16.61)
200 (7.87)
10
22
195 (7.68)
374 (14.72)
61 (2.40)
422 (16.61)
200 (7.87)
10
22
E
D
B
C
A
Front View
Side View
Figure 3.1 – Dimensions for 2 to 30 Amp Drives
Planning Before Installing
3-3
Table 3.3 – Dimensions and Weight for 43 Amp Drives
U.S.
Model
Number
430ER40xx
430ET40xx
European
Stock
Number
896.11.12
896.11.32
Width Dim A
mm (in)
214 (8.42 )
Physical Dimensions in mm (in)
Mounting
Height Dim B Width Dim C Height Dim D
mm (in)
mm (in)
mm (in)
374 (14.72)
150 (5.90)
Weight
Depth Dim E
mm (in)
kg
lb
200 (7.87)
16.5
36
422 (16.61)
Ø 14
E
D
B
C
A
Front View
Side View
Figure 3.2 – Dimensions for 43 Amp Drives
3.1.3 Verifying the Site Provides for Recommended Air Flow Clearances
Be sure there is adequate clearance for air circulation around the drive. For best air
movement, do not mount GV3000/SE Bookshelf 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.
When mounting the drive within a cabinet, maintain the minimum clearances shown in
table 3.4 to allow adequate air circulation around and through the drive.
Table 3.4 – Recommended Air Flow Clearances
Minimum Clearance
3-4
Above and below the Bookshelf drive
100 mm
4 in
Between the Bookshelf drive and side cabinet
walls
20 mm
.75 in
Between Bookshelf drives
5 mm
.25 in
Between other larger drives or heat-producing
devices
40 mm
1.5 in
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
3.1.4 Verifying Power Module Input Ratings Match Supplied Power
It is important to verify that plant power will meet the input power requirements of the
drive’s Power Module circuitry. Refer to table 2.1 for input power rating specifications.
Be sure input power to the drive corresponds to the drive nameplate voltage and
frequency.
3.2
Wiring Requirements for the Drive
Certain drive requirements should be checked before continuing with the drive
installation. Wire sizes, branch circuit protection, encoder feedback (for FVC
regulation), and E-stop wiring (see chapter 7) are all areas that need to be evaluated.
3.2.1 Meeting Terminal Strip Input and Output Specifications
The terminal strip on the Regulator board provides terminals for 24 VDC power for the
eight remote control inputs. Refer to tables A.3 and A.4 for control input and output
specifications.
3.2.2 Determining Wire Size Requirements
Wire size should be determined based on the size of conduit openings, and applicable
local, national, and international codes (e.g., NEC/CEC regulations).
!
ATTENTION: The user is responsible for conforming with all applicable
local, national, and international codes. Failure to observe this precaution
could result in damage to, or destruction of, the equipment.
3.2.2.1 Conduit Entry Opening Sizes for 24 to 43 Amp Bookshelf Drives
It is important to determine the size of the conduit openings so that the wire planned
for a specific entry point will fit through the opening. Conduit opening sizes are shown
in figures 4.2 and 4.3.
3.2.2.2 Recommended Power Wire Sizes
Input power wiring should be sized according to applicable codes to handle the drive’s
continuous-rated input current. Output wiring should be sized according to applicable
codes to handle the drive’s continuous-rated output current. See tables 3.5 and 3.6 for
recommended power wire sizes.
Table 3.5 – Recommended Power Wire Sizes for 2 to 15 Amp Drives
Planning Before Installing
Type of Wiring
Terminals
AC Input Power
L1, L2, L3, PE
Output Power
U, V, W
DC Bus Output
45(-), 47(+), 48
Ground
PE
Size of Wire (Maximum)
12 AWG, 6 mm2
3-5
Table 3.6 – Recommended Power Wire Sizes for 24 to 43 Amp Drives
Type of Wiring
Terminals
AC Input Power
and Ground
L1, L2, L3
PE
Output Power
and Ground
U, V, W
DC Bus Output,
Braking Resistor
45(-), 47(+)
48(-), 47(+)
Size of Wire (Maximum)
6 AWG, 16 mm2
3.2.2.3 Recommended Control and Signal Wire Sizes
The recommended wire sizes to connect I/O signals to the terminal strip on the
Regulator board are shown in table 3.7. Recommended terminal tightening torque is
9.5 Newton-meters (85 in-lb). Operator controls can be up to 303 meters (1000 feet)
from the drive.
Table 3.7 – Recommended Terminal Strip Wire Sizes
Terminals
Wire Size
4-25 (Regulator Board Terminal Strip)
28-31 (Output Relay Terminal Strip)
20 AWG to 14 AWG, 0.5 to 2 mm2
3.2.2.4 Recommended Motor Lead Lengths
To reduce line disturbances and noise, motor lead length should not exceed 76 meters
(250 feet) for any non-Reliance Electric motor or any non-inverter duty motor.
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. Refer to table 3.9 for a list of
compatible reactors.
For Reliance Electric inverter duty motors, use the recommended lead lengths shown
in table 3.8 as a guideline.
Your application may be restricted to a shorter lead length due to:
• the type of wire
• the placement of wire (for example, in conduit or a cable tray)
• the type of line reactor
• the type of motor.
Figure 3.3 illustrates how to calculate motor lead lengths.
3-6
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
GV3000/SE
Drive
GV3000/SE
Drive
GV3000/SE
Drive
GV3000/SE
Drive
15 m (50’)
38 m (125’)
61 m (200’)
38 m (125’)
Motor
Motor
76 m (250’)
61 m (200’)
Motor
8 m (25’)
8 m (25’)
Motor
Motor
Motor
Motor
This example shows how to measure various motor configurations when the maximum motor lead length is 76 m (250 ft). Note that drives using
vector regulation can be connected to only one motor at a time.
Figure 3.3 – How to Calculate Motor Lead Lengths
Table 3.8 – Recommended Motor Lead Lengths for Reliance Inverter Duty Motors
Maximum Lead Length in Feet with
460 VAC Motor
GV3000/SE
Amp Rating
Carrier Frequency
Filter Type
2 kHz
4 kHz
8 kHz
500
500
500
500
500
500
750
500
500
24 to 43
800
500
500
3.1 to 3.8
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
1000
3.1 to 3.8
5.5 to 8.5
None
12.6 to 15
5.5 to 8.5
A 5% reactor/filter
at the drive.
12.6 to 15
24 to 43
Table 3.9 – Compatible Reactors
GV3000/SE
Amp Rating
480 Volt
5% Reactor
3.1
RL-00202
3.8
RL-00403
5.5
RL-00403
8.5
RL-00803
12.6
RL-01203
15
RL-01803
24
RL-02503
30
RL-03503
43
RL-04503
Standard reactors can be used on GV3000/SE drives with carrier frequency settings up to 8 kHz.
All reactors listed are UL-recognized (UL-506 File #E53094) and CSA certified (CSA File # LR29753).
Planning Before Installing
3-7
3.2.2.5 Recommended Serial Communication Cable Lengths
Connector X8 on the Regulator board is an RS-232 serial communication port. See
figure 2.6. This connector allows the drive to communicate with external devices such
as a personal computer using RS-232 protocol.
Two RS-232 cables are available from Reliance:
• 3 meter (10 feet) D-shell 9-pin to 9-pin cable (M/N 2CA3000)
• 0.3 meter (1 foot) D-shell 9-pin to 25-pin adaptor cable (M/N 2CA3001).
User-constructed cables can be up to 15 meters (50 feet) in length.
Note that for communication between a GV3000/SE drive and a personal computer,
the Control and Configuration Software (2CS3000) must also be used. Refer to
instruction manual D2-3348 for more information about the CS3000 software.
The Regulator board has one set of RS-232 transmit/receive lines. These lines can be
accessed by only one device at a time: connector J8 or an Operator Interface Module
(OIM).
3.2.3 Selecting Input 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. Failure to observe this
precaution could result in damage to, or destruction of, the equipment.
Input line branch circuit protection fuses must be used to protect the input power lines.
See figure 5.1. Recommended fuse values are shown in table 3.10. The input fuse
ratings listed in table 3.10 are applicable for one drive per branch circuit. No other load
may be applied to that fused circuit.
Table 3.10 – AC Input Fuse Selection Values
3-8
U.S.
Model
Number
European
Stock
Number
Choke
AC Input
Current1
31ER40xx
896.01.11
No
5A
31ET40xx
896.01.31
Yes
4A
38ER40xx
896.02.11
No
6A
38ET40xx
896.02.31
Yes
5A
55ER40xx
896.03.11
No
10 A
55ET40xx
896.03.31
Yes
8A
85ER40xx
896.05.11
No
13 A
85ET40xx
896.05.31
Yes
10 A
126ER40xx
896.06.11
No
16 A
126ET40xx
896.06.31
Yes
13 A
150ER40xx
896.07.11
No
20 A
150ET40xx
896.07.31
Yes
16 A
240ER40xx
896.08.11
No
31 A
240ET40xx
896.08.31
Yes
25 A
External Fuse2
Nominal
Maximum
6A
25 A
10 A
25 A
16 A
25 A
16 A
25 A
20 A
25 A
25 A
25 A
40 A
50 A
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
Table 3.10 – AC Input Fuse Selection Values (Continued)
U.S.
Model
Number
European
Stock
Number
Choke
AC Input
Current1
300ER40xx
896.09.11
No
38 A
300ET40xx
896.09.31
Yes
32 A
430ER40xx
896.11.12
No
53 A
430ET40xx
896.11.32
Yes
47 A
External Fuse2
Nominal
Maximum
50 A
50 A
63 A
63 A
1
AC line input current (RMS) is dependent on total line impedance.
2
Recommended type of external input fuse:
AC line input: Branch circuit protection fuse, e.g., IEC 269-1/gG, EN 60269-1, VDE 0636/gL, UL Class
J, or equivalent.
DC bus input: Semiconductor protection fuse, 660 V or 750 V, superfast, e.g., A70P500, VDE 0636/aR,
or equivalent.
3.2.4 Meeting Encoder Specifications (FVC Regulation Only)
GV3000/SE drives set up for FVC regulation require an encoder for closed-loop
operation. Refer to table A.5 for specifications. Drives set up for V/Hz or SVC
regulation do not require an encoder for feedback.
3.2.4.1 Encoder Wiring Guidelines
Encoder connections are considered signal level wiring and, therefore, must be run
separate from control and power wiring. Reliance Electric recommends 18 AWG
unshielded twisted pair wires with 2-3 twists per inch for applications to a maximum
distance of 303 meters (1000 feet). The recommended Reliance Electric part number
is 417900-207CG; 18 AWG, 6 conductor (3 twisted pairs).
3.2.5 Verifying Power Module Output Current Rating Is Greater Than
Motor Full Load Amps
Verify that the GV3000/SE output current rating is greater than the motor’s full load
current (amps). Table 2.1 lists the output current values.
Planning Before Installing
3-9
3-10
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
CHAPTER 4
Mounting the Drive, Grounding, and
Finding Wire Routing Locations
This chapter shows how to mount the drive and properly ground it. Also shown are the
entry areas where wiring is to be routed in and out of the drive.
4.1
Mounting the Drive
The GV3000/SE Bookshelf drive is provided in an IP20 enclosure and is intended for
use inside a larger, user-supplied enclosure.
In order to maintain a flat mounting surface and to ensure that bolt tightness is
maintained, use washers under the bolt heads. Use M6 (1/4”) mounting bolts and
washers.
2 to 30 Amp Drives
Refer to figure 3.1 and table 3.2 in chapter 3 for drive mounting dimensions. Attach the
drive to the vertical surface selected using the two (2) mounting brackets provided.
The brackets slide into the wide channel of the aluminum heat sink on the back of the
drive. Slide one bracket into the top of the channel and the other bracket into the
bottom of the channel. Note that the upper mounting bracket is not fixed and,
therefore, cannot support the unit alone.
43 Amp Drives
Refer to figure 3.2 and table 3.3 in chapter 3 for drive mounting dimensions. Attach the
drive to the vertical surface selected using the built-in mounting brackets.
4.1.1 Verifying the Drive’s Watts Loss Rating
When mounting the drive inside of another enclosure, you should determine the watts
loss rating of the drive from table 2.1. This table lists the typical full load power loss
watts value under all operating carrier frequencies. Ensure that the enclosure is
adequately ventilated with 0° to 40°C ambient air based on the drive’s watts loss
rating.
Mounting the Drive, Grounding, and Finding Wire Routing Locations
4-1
4.2
Determining Input, Motor Output, Ground, and
Control Wire Routing for the Drive
All wiring should be installed in conformance with the applicable local, national, and
international codes (e.g., NEC/CEC). Signal wiring, control wiring, and power wiring
must be routed in separate conduits to prevent interference with drive operation. Note
that no wires are to be routed behind the drive. Use grommets, when hubs are not
provided, to guard against wire chafing. Figures 4.1, 4.2, and 4.3 show the wire
routing, grounding terminal, and power terminal strips of the GV3000/SE Bookshelf
drives.
!
ATTENTION: Do not route signal and control wiring with power wiring in
the same conduit. This can cause interference with drive operation.
Failure to observe this precaution could result in damage to, or
destruction of, the equipment.
Do not route more than three sets of motor leads through a single conduit. This will
minimize cross-talk that could reduce the effectiveness of noise reduction methods. If
more than three drive/motor connections per conduit are required, shielded cable
must be used. If possible, each conduit should contain only one set of motor leads.
!
4.3
ATTENTION: Unused wires in conduit must be grounded at both ends
to avoid a possible shock hazard caused by induced voltages. Also, if a
drive sharing a conduit is being serviced or installed, all drives using this
conduit should be disabled to eliminate the possible shock hazard from
cross-coupled motor leads. Failure to observe these precautions could
result in bodily injury.
Grounding the Drive
!
ATTENTION: The user is responsible for conforming with all applicable
local, national, and international codes. Failure to observe this precaution
could result in damage to, or destruction of, the equipment.
On 2 to 15 A drives, the grounding terminal is located on the drive faceplate (refer to
figure 4.1). On 24 to 43 A drives, you will need to remove the drive faceplate and cover
to access the grounding terminal (refer to figure 4.2 or 4.3).
Use the following steps to ground the drive:
Step 1. 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, 4.2, or 4.3.
Step 2. Connect a suitable grounding conductor to the motor frame, the remote
control station (if used), and the transformer. Run each conductor unbroken
to earth ground.
When adding more than one grounding conductor wire to a single chassis
ground, twist the conductors together.
Step 3. 24 to 43 A drives only: Reattach the front panel and then the cover.
4-2
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
Regulator Board
Terminal Strip
Output Relay
Terminals
AC Input Power
Terminals
(L1, L2, L3)
Bus/Braking Resistor
Terminals
Motor Power
Terminals
(U, V, W)
Ground
Terminal
All user wiring is
external to the drive.
Figure 4.1 – Wire Routing Locations for 2 to 15 Amp Drives
Mounting the Drive, Grounding, and Finding Wire Routing Locations
4-3
Motor Leads
(29 mm dia.)
Bus/Braking
Resistor Leads
(29 mm dia.)
Ground
Terminal
Signal
Wires
(16 mm dia.)
Input Power
Leads
(29 mm dia.)
AC Input Power
Terminals
(L1, L2, L3)
Bottom View
Bus/Braking
Resistor
Terminals
Regulator Board
Terminal Strip
Ground
Terminal
Output Relay
Terminals
Motor Power Terminals
(U, V, W)
Input Power
Leads
Bus/Braking
Resistor Leads
Signal Wires
Motor Leads
User Wire Routing
Figure 4.2 – Wire Routing Locations for 24 to 30 Amp Drives
4-4
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
Signal
Wires
(16 mm dia.)
Bus/Braking
Resistor Leads
(29 mm dia.)
Motor
Leads
(38 mm dia.)
Input Power
Leads
(38 mm dia.)
AC Input Power
Terminals*
(L1, L2, L3)
Bottom View
Regulator Board
Terminal Strip
PE L1 L2 L3
Motor Power
Terminals*
(U, V, W)
45 47 48 U V W
28-31
Bus/Braking
Resistor Leads*
Output Relay
Terminals*
3 x M3
Ground terminal for AC input power*
(Provided only on units without AC Mains Filter)
Ground terminal for output power*
*Terminals are located behind cover and
front panel.
Figure 4.3 – Wire Routing Locations for 43 Amp Drives
Mounting the Drive, Grounding, and Finding Wire Routing Locations
4-5
4-6
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
CHAPTER 5
Installing Input Power Wiring
This chapter describes incoming line components and how to install them.
5.1
Installing Transformers and Reactors (Optional)
Input isolation transformers might be needed to help eliminate the following:
• Damaging line voltage transients from reaching the drive.
• Line noise from the drive back to the incoming power source.
• Damaging currents that could develop if a point inside the drive becomes grounded.
Observe the following guidelines when installing an isolation transformer:
• A power disconnecting device must be installed between the power line and the
primary of the transformer.
• If the power disconnecting device is a circuit breaker, the circuit breaker trip rating
must be coordinated with the in-rush current (10 to 12 times full load current) of the
transformer.
• For drives equipped with an AC Mains Filter, an input isolation transformer rated
more than 1000 KVA for 460 VAC with less than 5% impedance should NOT be
used directly ahead of the drive without additional impedance between the drive and
the transformer.
• For drives not equipped with an AC Mains Filter, an input isolation transformer rated
more than 315 KVA for 460 VAC with less than 5% impedance should NOT be used
directly ahead of the drive without additional impedance between the drive and the
transformer.
!
ATTENTION: Distribution system capacity above the maximum
recommended system KVA (1000 KVA for 460 VAC for drives equipped
with an AC Mains Filter, 315 KVA for 460 VAC for drives not equipped
with an AC Mains Filter) requires the use of an isolation transformer, a
line reactor, or other means of adding similar impedance to the drive
power input. Failure to observe these precautions could result in damage
to, or destruction of, the equipment.
ATTENTION: When the AC line is shared directly with other
SCR-rectified drives, an optional snubber resistor braking kit might be
required to alleviate excess DC bus voltage. Failure to observe these
precautions could result in damage to, or destruction of, the equipment.
For drives equipped with an AC Mains Filter, the maximum AC line distribution system
capacity is 1000 KVA, three-phase with 30,000 amps symmetrical fault current
capacity with a line impedance of less than 5%.
Installing Input Power Wiring
5-1
For drives not equipped with an AC Mains Filter, the maximum line distribution system
capacity is 315 KVA, three-phase with 10,000 amps symmetrical fault current capacity
with a line impedance of less than 5%.
5.2
Installing Fuses for Branch Circuit Protection
Install the required, user-supplied branch circuit protection fuses according to the
applicable local, national, and international codes (e.g., NEC/CEC). The fuses must
be installed in the line before the drive input terminals. See figure 5.1. Fuse value
selections are provided in table 3.10.
!
5.3
ATTENTION: Most codes require that upstream branch protection be
provided to protect input power wiring. Failure to observe this precaution
could result in severe bodily injury or loss of life.
Installing a Required External/Separate Input
Disconnect
An input disconnect must be installed in the line before the drive input terminals in
accordance with local, national, and international codes (e.g., NEC/CEC). The
disconnect should be sized according to the in-rush current as well as any additional
loads the disconnect might supply. The trip rating for the inrush current (10-12 times
full load current) should be coordinated with that of the input isolation transformer, if
used. Refer to section 5.1 for additional information.
5.4
Installing Power Wiring from the AC Input Line to the
Drive’s Power Terminals
Use the following steps to connect AC input power to the drive:
Step 1. Wire the AC input power leads by routing them according to drive type. Refer
to figures 4.1, 4.2, or 4.3. Tables 3.5 and 3.6 contain the recommended
power wiring sizes.
!
ATTENTION: Do not route signal and control wiring with power wiring in
the same conduit. This can cause interference with drive operation.
Failure to observe this precaution could result in damage to, or
destruction of, the equipment.
Step 2. Connect the three-phase AC input power leads (three-wire 380-460 VAC) to
terminals L1, L2, L3.
Step 3. Tighten the AC input power terminals to 1.4 Nm (12 in-lb).
5-2
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
Input Voltage 460 V
181
182
183
GND
Manual
Disconnect
Fuse
UserSupplied
R
S
T
1L1
1L2
1L3
~
GND
(PE)
GV3000/SE
Power
Module
~
U
UserSupplied
V
W
GND
Motor Overload
Relay (Optional if
Electronic
Overload is Used)
M
Figure 5.1 – Typical AC Input Electrical Connections
Installing Input Power Wiring
5-3
5-4
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
CHAPTER 6
Installing Output Power Wiring
This chapter provides instructions on wiring output contactors, motor overload
protection, and output wiring to the motor.
6.1
Installing Output Contactors (Optional)
Output contactors provide a positive means of disconnecting the motor from the drive.
If the application requires the use of output contactors, contact Reliance Electric for
assistance.
6.2
Installing Mechanical Motor Overload Protection
(Optional)
To provide the motor with overload protection, local, national, and international codes
(e.g., NEC/CEC) require one of the following:
• A motor thermostat be installed internal to the motor.
• An electronic thermal motor overload relay, sized to protect the motor, be installed
between the motor and the drive’s output terminals.
The Motor Overload Enable parameter (P.040) can be used in place of thermal motor
overload relays in single motor applications. Note, however, that temperature
measuring devices integral to the motor are the best way to thermally protect AC
motors under all conditions. Parameter P.040 must be enabled to provide overload
protection. Refer to the GV3000/SE Bookshelf Software Start-Up and Reference
manual for more information.
In multiple-motor applications (V/Hz regulation only), each motor must have its own
user-supplied overload protection.
6.3
Installing Output Wiring from the Drive Output
Terminals to the Motor
Use the following steps to connect the AC output power wiring from the drive to the
motor:
Step 1. Wire the three-phase AC output power motor leads by routing them
according to drive type. Refer to figures 4.1, 4.2, or 4.3. Tables 3.5 and 3.6
contain the recommended power wiring sizes.
Do not route more than three sets of motor leads through a single conduit.
This will minimize cross-talk that could reduce the effectiveness of noise
reduction methods. If more than three drive/motor connections per conduit
are required, shielded cable must be used. If possible, each conduit should
contain only one set of motor leads.
Installing Output Power Wiring
6-1
!
ATTENTION: Do not route signal and control wiring with power wiring in
the same conduit. This can cause interference with drive operation.
Failure to observe these precautions could result in damage to, or
destruction of, the equipment
ATTENTION: Unused wires in conduit must be grounded at both ends
to avoid a possible shock hazard caused by induced voltages. Also, if a
drive sharing a conduit is being serviced or installed, all drives using this
conduit should be disabled to eliminate the possible shock hazard from
cross-coupled motor leads. Failure to observe these precautions could
result in bodily injury.
Step 2. Connect the three-phase AC output power motor leads to terminals U, V, and
W.
Step 3. Tighten the three-phase AC output power terminals to 1.4 Nm (12 in-lb).
6-2
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
CHAPTER 7
Wiring the Regulator Board
Terminal Strip and the
Output Relay Terminal Strip
This chapter describes how to wire the Regulator board terminal strip for stop,
encoder feedback, and remote control signals. It also describes how to wire the output
status relays on the output relay terminal strip.
The signals available through the Regulator board terminal strip are shown in tables
7.1 to 7.4 and figures 7.1 and 7.2. Table 7.6 provides additional information.
Note that when the Control Source parameter (P.000) is set to remote (rE), the drive
will be controlled by the signals connected to the terminal strip. Refer to the
GV3000/SE Bookshelf Drive Software Start-Up and Reference manual for more
information on how parameter P.000 is used to specify where the drive is controlled
from.
The signals available through the output relay terminal strip are shown in table 7.5.
Table 7.7 provides additional information.
Table 7.1 – Encoder Connections (Regulator Terminals 4-9)
Terminal #
Signal
4
+15 VDC
5
Phase A
6
Phase A Not
7
Phase B
8
Phase B Not
9
Regulator Common
Notes: An encoder feedback device must be installed if FVC regulation is used.
Table 7.2 – Analog Output Connections (Regulator Terminals 10 and 11)
Terminal #
Signal
10
Analog Meter Output
11
Analog Output Return
Notes: The output of this terminal is either 0-10 VDC or 4-20 mA as determined by the
setting of jumper J17 on the Regulator board. The analog output must also be
programmed via parameter P.012 for an indication of speed and direction or percent of
torque.
Wiring the Regulator Board Terminal Strip and the Output Relay Terminal Strip
7-1
Table 7.3 – Analog Speed/Torque Reference Connections (Regulator Terminals 12-15)
Terminal #
Signal
12
Isolated Reference Voltage
13
VDC Speed/Torque Reference
14
mA Speed/Torque Reference
15
Isolated Reference Common
Notes: The analog speed/torque (P.008/U.000) reference is either +/-10 VDC or
+/-20 mA, as determined by the setting of jumper J4 on the Regulator board. The
analog reference can be adjusted using parameters P.009, P.010, and P.011.
Refer to Appendix G in the GV3000/SE Bookshelf Drive Software Start-Up and
Reference manual for more information about the analog input.
.
Table 7.4 – Digital Input Connections (Regulator Terminals 16-25)
Terminal #
Signal
16
+24 VDC (Current Limited) (For remote control digital inputs only)
17
Digital Input 8 (Remote/Local) - Programmable
18
Digital Input 7 (Ramp 1/Ramp 2) - Programmable
19
Digital Input 6 (Forward/Reverse) - Programmable
20
Function Loss
21
Run/Jog
22
Reset
23
Stop
24
Start
25
+24 VDC Common
Notes: When a user-installed function loss input, a coast-to-stop pushbutton, or
another external interlock is installed, the factory-installed jumper connecting terminals
16 and 20 must be removed so that a contact, when open, will stop the drive.
Terminals 17, 18, and 19 (remote control inputs 8, 7, and 6) are programmed using
parameters P.007, P.008, and P.031 through P.038. Factory default settings are shown
here in parentheses. Refer to the GV3000/SE Bookshelf Drive Software Start-Up and
Reference manual for more information.
Table 7.5 – Status Relay Connections (Relay Terminals 28-31) on the Output Relay Terminal Strip
Terminal #
Signal
28
N.C Relay Contact
29
N.C. Relay Common
30
N.O. Relay Contact
31
N.O. Relay Common
Notes: Relay contact closure is programmable through parameter P.013. Refer to the
GV3000/SE Bookshelf Drive Software Start-Up and Reference manual for more
information.
7-2
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
Important: A maintained function loss switch
should be used if P.054 (Level Sense Start
Enable) = ON and P.026 (Function Loss
Response) = 1.
4
+15 VDC
5
Phase A
6
Phase A Not
7
Phase B
8
Phase B Not
9
Regulator Common
10
0 to 10 VDC Analog Output
11
Analog Output Return
12
Isolated Reference Voltage
13
+/- 10, 0 to 10 VDC Speed or Torque Reference
REV
FWD
Reset
Run
Jog
Start/Stop
Function Loss
14
0/4 to 20 mA Speed or Torque Reference
15
Isolated Reference Ground
16
+24 VDC Supply
17
Digital Input 8 (Local/Remote)
18
Digital Input 7 (Ramp 1/ Ramp 2)
19
Digital Input 6 (Forward/Reverse)
20
Digital Input 5 (Function Loss)
21
Digital Input 4 (Run/Jog)
22
Digital Input 3 (Fault Reset)
23
Digital Input 2 (Stop)
24
Digital Input 1 (Start)
25
+24 VDC Common
Figure 7.1 – Two-Wire Start/Stop Sample Control Wiring
Important: A maintained function loss switch
should be used if P.054 (Level Sense Start
Enable) = ON and P.026 (Function Loss
Response) = 1.
4
+15 VDC
5
Phase A
6
Phase A Not
7
Phase B
8
Phase B Not
9
Regulator Common
10
0 to 10 VDC Analog Output
11
Analog Output Return
12
Isolated Reference Voltage
13
+/- 10, 0 to 10 VDC Speed or Torque Reference
REV
FWD
Reset
Run
Jog
Stop
Function Loss
14
0/4 to 20 mA Speed or Torque Reference
15
Isolated Reference Ground
16
+24 VD C Suppl y
17
Digital Input 8 (Local/Remote)
Start
18
Digital Input 7 (Ramp 1/ Ramp 2)
19
Digital Input 6 (Forward/Reverse)
20
Digital Input 5 (Function Loss)
21
Digital Input 4 (Run/Jog)
22
Digital Input 3 (Fault Reset)
23
Digital Input 2 (Stop)
24
Digital Input 1 (Start)
25
+24 VDC Common
Figure 7.2 – Three-Wire Start/Stop Sample Control Wiring
Wiring the Regulator Board Terminal Strip and the Output Relay Terminal Strip
7-3
7.1
Stopping the Drive
!
ATTENTION: When P.055 is set to ON, the STOP/RESET key is
functional only from the selected control source. As a safety precaution,
Reliance Electric recommends than an emergency stop push button be
located near the drive in an easily accessible location. As a further safety
precaution, the user should post a warning on the drive to alert personnel
that the STOP/RESET key is not functional. Failure to observe this
precaution could result in severe bodily injury or loss of life.
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. Failure to observe this
precaution could result in bodily injury.
Depending upon the requirements of the application, the GV3000/SE Bookshelf drive
can be programmed to provide either a coast-to-rest or a ramp-to-rest operational stop
without physical separation of the power source from the motor.
A coast-to-rest stop turns off the transistor power device drivers. A ramp-to-rest stop
fires the transistor power device drivers until the motor comes to a stop, and then turns
off the power devices.
The user can also program zero speed with power maintained to the motor, but in this
condition, the drive is not actually stopped.
See the description of terminals 23 and 24 or Stop Type (P.025) for more information
on how to program the operational stop.
In addition to the operational stop, the user must provide a hardwired emergency stop
external to the drive. The emergency stop circuit must contain only hardwired
electromechanical components. Operation of the emergency stop must not depend on
electronic logic (hardware or software) or on the communication of commands over an
electronic network or link.
Parameter P.055 (STOP/RESET Key Disable) can be used to change the operation of
the STOP/RESET key. See the P.055 parameter description in the software manual for
more information.
Note that the user-installed hardwired emergency stop may be used at any time to
stop the drive.
7.1.1 Compliance with Machinery Safety Standard EN 60204-1:1992
This section applies to users who must comply with machinery safety standard
EN 60204-1:1992, part 9.2.5.4, Emergency Stop.
The GV3000/SE drive coast-to-rest stop is a category 0 operational stop. The
ramp-to-rest stop is a category 1 operational stop. In addition, it is possible to
implement a category 2 stop, with power maintained to the motor at zero speed.
7-4
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
The required external hardwired emergency stop must be either a category 0 or 1
stop, depending on the user’s risk assessment of the associated machinery. In order
to fully comply with machinery safety standard EN60204-1:1992, part 9.2.5.4, at least
one of the two stop methods must be a category 0 stop. Refer to Appendix B for more
information.
7.2
Wiring the Encoder Feedback Device
(FVC Regulation Only)
If the GV3000/SE drive is programmed to provide FVC regulation, an encoder must be
installed on the motor. Drives using V/Hz or SVC regulation do not require the use of
an encoder feedback device. The encoder connects to terminals 4 through 9 of the
Regulator board terminal strip as shown in table 7.6:
Table 7.6 – Encoder Connections
Terminal
Encoder Connection
4
Encoder Supply +15 VDC (250 mA capacity)
5
Encoder Phase A Differential Input
6
Encoder Phase A Not Differential Input
7
Encoder Phase B Differential Input
8
Encoder Phase B Not Differential Input
9
Encoder/Regulator Common
Use the following procedure to connect an encoder to the Regulator board terminal
strip:
Step 1. Connect the encoder’s wires to terminals 4 through 9 of the terminal strip.
See figure 7.3. Refer to section 3.2.4.1 for encoder wiring guidelines.
Step 2. Set the following parameters to establish the maximum motor speed:
• P.004: Maximum Speed
• U.001: Encoder PPR
• U.002: Motor Poles
• U.003: Motor Nameplate Base Frequency
• U.005: Motor Nameplate RPM
• U.017: Motor Top Speed
Refer to the GV3000/SE Bookshelf Drive Software Start-Up and Reference manual for
parameter descriptions.
Wiring the Regulator Board Terminal Strip and the Output Relay Terminal Strip
7-5
Tamagawa-Style, 16-Pin MS Connector
View of Encoder Cable MS Connector (Female)
(M/N 2TC4025 and 2TC4075)
Regulator
Terminal Strip
Connector/Cable End
Terminal 6
Pin 1
Phase A
Terminal 5
Pin 2
Phase A Not
Terminal 4
Pin 6
0 VDC
Terminal 9
Pin 12
+15 VDC
Terminal 7
Pin 8
Phase B
Terminal 8
Pin 9
Phase B Not
Dynapar-Style, 10-Pin MS Connector
View of Encoder Cable MS Connector (Female)
(M/N 2TC3025 and 2TC3075)
Regulator
Terminal Strip
A
B
I
G
C
J
F
E
F
Connector/Cable End
Terminal 6
Pin A
Phase A
Terminal 5
Pin H
Phase A Not
Terminal 4
Pin F
0 VDC
Terminal 9
Pin D
+15 VDC
Terminal 7
Pin B
Phase B
Terminal 8
Pin I
Phase B Not
Lakeshore-Style, 10-Pin MS Connector
View of Encoder Cable MS Connector (Female)
(Lakeshore M/N SL56 Slim-Tach Encoder)
Regulator
Terminal Strip
H
1
2
3
4
5
6
7
8
9
10
Connector/Cable End
Terminal 6
Pin 3
Phase A
Terminal 5
Pin 8
Phase A Not
Terminal 4
Pin 1
0 VDC
Terminal 9
Pin 6
+15 VDC
Terminal 7
Pin 2
Phase B
Terminal 8
Pin 7
Phase B Not
Figure 7.3 – Encoder Wiring Connections
7-6
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
7.3
Wiring the Signal and Control I/O
Wire the drive’s signal and control I/O to the terminal strip as shown in figure 7.4 and
table 7.7.
Use a small flat-head screwdriver.
Insert
wire
Insert the screwdriver into the slot and
press and hold down while inserting the
wire into the corresponding hole.
Important: Using the incorrect tool and
exerting too much pressure may damage
the terminal strip.
Terminal
Strip
Figure 7.4 – Wiring the Terminal Strip - Detail
Table 7.7 – Wiring Signal and Control I/O to the Regulator Board Terminal Strip
Terminal
Number
Description
Parameters/Wiring Connections
Wiring Encoder Inputs
4-9
Encoder Wiring
See section 7.2.
Wiring Analog Outputs
10
0-10 VDC or 4-20 mA
Analog Output Reference
The setting of parameter P.012 selects the terminal strip analog
output source (either speed or torque). Jumper J17 must also be
set. See figure 2.8.
11
Analog Output Return
The 4-20 mA current selection requires a power supply for
operation. The power must be sourced from an external 12 V
power supply.
Terminals 9 and 11 are internally connected.
Load
(Meter or Analog Input)
≤500 Ohm
Terminal Strip
+
+
P/S
+
+
-
Wiring the Regulator Board Terminal Strip and the Output Relay Terminal Strip
7-7
Table 7.6 - Wiring Signal and Control I/O to the Regulator Board Terminal Strip (Continued)
Terminal
Number
Description
Parameters/Wiring Connections
Wiring Analog Speed Reference Inputs
12
Isolated Reference
Voltage (+10 VDC)
13
Analog Speed/Torque
Reference Input Voltage
(+/- 10 VDC)
14
Analog Speed/Torque
Reference Input Current
(0-20 mA)
15
Related parameters:
P.000: Control Source
P.009: Terminal Strip Analog Input Offset
P.010: Terminal Strip Analog Input Gain
P.011: Terminal Strip Analog Input Configure
•
•
•
•
Refer to the GV3000/SE Bookshelf Drive Software Start-Up
and Reference manual for additional parameter information.
Jumper J4 must also be set. See figure 2.7.
Isolated Speed/Torque
Reference Common
(Voltage/Current)
Refer to Appendix G of the GV3000/SE Bookshelf Drive
Software Start-Up and Reference manual for more
information about the analog input.
7-8
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
Table 7.6 - Wiring Signal and Control I/O to the Regulator Board Terminal Strip (Continued)
Terminal
Number
Description
Parameters/Wiring Connections
Wiring a Remote/Local Input
16
+24 VDC Power Supply
Current limited for remote input logic use only.
17
Digital Input 8
(Default - Remote/Local)
Digital input 8 is control function programmable through
parameter P.007.
!
ATTENTION: If a maintained start contact is used when the control source = rE, switching
from local to remote from the terminal strip will cause power to be applied to the motor if
the remote start contact is closed. Stay clear of rotating machinery in this case. Failure to
observe this precaution could result in bodily injury.
The following parameters must be set:
• P.000: Control Source (Only active when P.000 = rE)
• P.006: Second Menu Password
• P.007: Terminal Strip Digital Inputs Configure (Selects and
assigns a control function to digital inputs 6 to 8)
• P.008: Terminal Strip Speed Reference Source
(Analog, Motor Operated Potentiometer (MOP), or
Preset Speeds)
Note that based on the settings of parameters P.000, P.007,
P.008, and r.030 if an RMI board is used, the following
parameters can affect digital input 8:
• P.023: MOP Accel/Decel Time
• P.024: MOP Reset Configuration
• P.031 to P.038: Preset Speeds 1-8
Refer to the GV3000/SE Bookshelf Drive Software Start-Up
and Reference manual for additional information.
Terminal 17 On = Local Control
Diagram shows factory setting.
Wiring the Regulator Board Terminal Strip and the Output Relay Terminal Strip
7-9
Table 7.6 - Wiring Signal and Control I/O to the Regulator Board Terminal Strip (Continued)
Terminal
Number
Description
Parameters/Wiring Connections
Wiring an Additional Ramp Input
18
Digital Input 7
(Default - Ramp 1/Ramp 2)
Digital input 7 is control function programmable through
parameter P.007. The following parameters must be set:
•
•
•
•
•
•
•
•
P.000: Control Source
P.001: Accel Time 1 (Ramp 1)
P.002: Decel Time 1 (Ramp 1)
P.006: Second Menu Password
P.007: Terminal Strip Digital Inputs Configure (Selects and
assigns a control function to digital inputs 6 to 8)
P.008: Terminal Strip Speed Reference Source (Analog
Motor Operated Potentiometer (MOP), or Preset
Speeds)
P.017: Accel Time 2 (Ramp 2)
P.018: Decel Time 2 (Ramp 2)
Note that based on the settings of parameters P.000, P.007,
P.008, and r.030 if an RMI board is used, the following
parameters can affect digital input 7:
• P.023: MOP Accel/Decel Time
• P.024: MOP Reset Configuration
• P.031 to P.038: Preset Speeds 1-8
Refer to the GV3000/SE Bookshelf Drive Software Start-Up
and Reference manual for additional information.
Terminal 18 On = Ramp 2
Diagram shows factory setting.
7-10
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
Table 7.6 - Wiring Signal and Control I/O to the Regulator Board Terminal Strip (Continued)
Terminal
Number
Description
Parameters/Wiring Connections
Wiring a Forward/Reverse Input
19
Digital Input 6
(Default - Forward/Reverse)
Digital input 6 is control function programmable through
parameter P.007. The following parameters must be set:
• P.000: Control Source
• P.006: Second Menu Password
• P.007: Terminal Strip Digital Inputs Configure (Selects and
assigns a control function to digital inputs 6 to 8)
• P.008: Terminal Strip Speed Reference Source
•
(Analog, Motor Operated Potentiometer (MOP), or
Preset Speeds)
P.027: Forward/Reverse Configuration
Note that based on the settings of parameters P.000, P.007,
P.008, and r.030 if an RMI board is used, the following
parameters can affect digital input 6:
• P.023: MOP Accel/Decel Time
• P.024: MOP Reset Configuration
• P.031 to P.038: Preset Speeds 1-8
Refer to the GV3000/SE Bookshelf Drive Software Start-Up
and Reference manual for additional information.
If P.027 = 1
Forward Direction Only
Terminal 19 On = Reverse Direction
Diagram shows factory setting. From the encoder end of the
motor, clockwise rotation indicates forward motor movement.
Wiring the Regulator Board Terminal Strip and the Output Relay Terminal Strip
7-11
Table 7.6 - Wiring Signal and Control I/O to the Regulator Board Terminal Strip (Continued)
Terminal
Number
Description
Parameters/Wiring Connections
Wiring a Function Loss Input
20
Digital Input 5
(Function Loss)
The following parameters must be set:
• P.026: Function Loss Response
A signal must be present at terminal 20 for the drive to be
able to start. See figures 7.1 and 7.2.
The drive is shipped from the factory with a jumper between
terminals 16 and 20 which provides the signal. The function
loss input should be in series with the drive’s external
interlocks. In this case, the jumper must be removed before
the connections are made.
Terminal 20 On = No Function Loss
Important: A maintained function loss switch should be
used if P.054 (Level Sense Start Enable) = ON
and P.026 (Function Loss Response) = 1.
Wiring a Run/Jog Input
21
Digital Input 4
(Run/Jog)
The following parameters must be set:
•
•
•
•
P.000: Control Source
P.020: Jog Speed Reference
P.021: Jog Ramp Accel Time
P.022: Jog Ramp Decel Time
Terminal 21 On = Jog Operation
7-12
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
Table 7.6 - Wiring Signal and Control I/O to the Regulator Board Terminal Strip (Continued)
Terminal
Number
Description
Parameters/Wiring Connections
Wiring the Reset Input
22
Digital Input 3
(Reset)
The following parameter must be set:
• P.000: Control Source
Terminal 22 On = Reset
Wiring the Stop/Start Inputs
23
24
Digital Input 2
(Stop)
Digital Input 1
(Start)
The following parameter must be set:
• P.000: Control Source
• P.025: Stop Type
Terminal 23 Off = Stop
Terminal 24 On Transition = Start
25
24 VDC Isolated Common
Wiring the Regulator Board Terminal Strip and the Output Relay Terminal Strip
7-13
Table 7.8 – Wiring the Output Relay Terminal Strip
Terminal
Number
Description
Parameters/Wiring Connections
Wiring the Output Status Relays
28
Normally-Closed Contact
(Form B)
29
Normally-Closed Contact
Common (Form B)
30
Normally-Open Contact
(Form A)
31
Normally-Open Contact
Common (Form A)
Both Form A and Form B contacts are rated for
250 VAC/30 VDC at 5 amps resistive or 2 amps inductive
load.
The following parameter must be set:
• P.013: Output Relay Configuration
Note that depending on the setting of parameter P.013, the
relay coil will energize (the normally-open contact will close
and the normally-closed contact will open). Refer to the
GV3000/SE Bookshelf Drive Software Start-Up and
Reference manual for more information.
28 29 30 31
7-14
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
CHAPTER 8
Wiring Optional User-Supplied
Braking Resistors
This chapter describes how to select and wire optional user-supplied braking
resistors.
!
8.1
ATTENTION: The user is responsible for conforming with all applicable
local, national, and international codes. Failure to observe this precaution
could result in damage to, or destruction of, the equipment.
Installation Guidelines
Use the following guidelines when installing braking resistors:
• The cable length of the connection between the braking unit and the resistor must
not exceed 2.5 m (8 ft).
• Provide ground connections as shown in figure 8.1.
• The conductors should be twisted together and run separate from other conductors.
• If the braking resistor is mounted in a separate enclosure, this must be metallic
conductive and the diameter of ventilation holes should not exceed 6 mm (.236 in).
• Heat-resistant cables and cable sockets (minimum 90° C) must be used to connect
the braking resistor.
• Wire rated at a minimum of least 600 volts for 460 VAC must be used. Refer to table
8.1 for cable cross-section specifications.
!
ATTENTION: It is important to use wire rated at 600 volts for 460 VAC
because this wiring may make contact with uninsulated 460 VAC
components. Failure to observe this precaution could result in damage
to, or destruction of, the equipment.
• If the drive installation must be in compliance with the European community
electromagnetic compatibility standards, refer to Appendix C.
Wiring Optional User-Supplied Braking Resistors
8-1
.
Table 8.1 – Cable Cross-Sections for External Braking Resistors
Maximum Continuous
Braking Current (A rms)
Minimum Cable
Cross-Section
31ER40xx
31ET40xx
6
1 mm2 (16 AWG)
38ER40xx
38ET40xx
6
1 mm2 (16 AWG)
55ER40xx
55ET40xx
6
1 mm2 (16 AWG)
85ER40xx
85ET40xx
6
1 mm2 (16 AWG)
126ER40xx
126ET40xx
10
1 mm2 (16 AWG)
150ER40xx
150ET40xx
10
1 mm2 (16 AWG)
240ER40xx
240ET40xx
15
1.5 mm2 (16 AWG)
300ER40xx
300ET40xx
20
2.5 mm2 (12 AWG)
430ER40xx
430ET40xx
30
6 mm2 (12 AWG)
Drive M/N
8-2
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
8.2
Selecting a Braking Resistor
The maximum braking power is defined by the maximum braking current and the
maximum DC voltage (750 V). To determine the correct braking resistor for your drive,
refer to table 8.2.
Table 8.2 – Selecting a Braking Resistor
Maximum
Braking
Current
Power
Module Input
Voltage
Turn-On
Voltage
Turn-Off
Voltage
Minimum
Allowed
External
Braking
Resistor
Braking Power1
Drive M/N
Continuous
25% Duty
Cycle
31ER40xx
31ET40xx
4.5 kW
4.5 kW
6A
460 V
750 V
720 V
125.0 Ω
38ER40xx
38ET40xx
4.5 kW
4.5 kW
6A
460 V
750 V
720 V
125.0 Ω
55ER40xx
55ET40xx
4.5 kW
4.5 kW
6A
460 V
750 V
720 V
125.0 Ω
85ER40xx
85ET40xx
4.5 kW
4.5 kW
6A
460 V
750 V
720 V
125.0 Ω
126ER40xx
126ET40xx
7.5 kW
7.5 kW
10 A
460 V
750 V
720 V
75.0 Ω
150ER40xx
150ET40xx
7.5 kW
7.5 kW
10 A
460 V
750 V
720 V
75.0 Ω
240ER40xx
240ET40xx
11 kW
11 kW
15 A
460 V
750 V
720 V
50.0 Ω
300ER40xx
300ET40xx
15 kW
15 kW
20 A
460 V
750 V
720 V
37.5 Ω
430ER40xx
430ET40xx
22 kW
22 kW
30 A
460 V
750 V
720 V
25.0 Ω
1
The turn-on and the turn-off voltage and the braking power is proportional to the AC line voltage (specified
in parameter H.021 or U.018).
Wiring Optional User-Supplied Braking Resistors
8-3
8.3
Installing the Braking Resistor
To prevent possible damage due to an overload on the braking resistors, install a
thermal protection device according to figure 8.1 and table 8.3.
1L1
PE
1L2
1L3
If the resistor overheats,
this contact operates a
disconnect that removes
AC power1 6from 2the
0 drive.
-
+
47
DBU
T
48
45
47
U
V
W
M
3-
Figure 8.1 – Braking Resistor Wiring Connections
.
Table 8.3 – Wiring Connections for External Braking Resistor
Terminal
47
48
Description
External Braking Resistor
Ground
8-4
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
CHAPTER 9
Completing the Installation
This chapter provides instructions on how to perform a final check of the installation
before power is applied to the drive.
!
9.1
ATTENTION: Only qualified electrical personnel familiar with the
construction and operation of this equipment and the hazards involved
should start and adjust it. Read and understand this manual in its entirety
before proceeding. Failure to observe this precaution could result in
severe bodily injury or loss of life.
Checking the Installation
Use the following procedure to verify the condition of the installation:
!
ATTENTION: DC bus capacitors retain hazardous voltages after input
power has been disconnected. After disconnecting input power, wait five
(5) minutes for the DC bus capacitors to discharge and then check the
voltage with a voltmeter to ensure the DC bus capacitors are discharged
before touching any internal components. Failure to observe this
precaution could result in severe bodily injury or loss of life.
Step 1. Turn off, lock out, and tag the input power to the drive. Wait five minutes.
Step 2. Verify that the DC bus voltage is zero. Refer to section 10.3.
Step 3. If a function loss coast-stop pushbutton has been installed, verify that it has
been wired correctly. Be sure the factory-installed jumper at terminals 16 and
20 has been removed so that the coast-stop pushbutton will work.
!
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. Failure to observe this
precaution could result in bodily injury.
Step 4. Remove any debris, such as metal shavings, from around the drive.
Step 5. Check that there is adequate clearance around the drive.
Step 6. Verify that there is nothing mounted behind the drive.
Step 7. Verify that the wiring to the terminal strip and the power terminals is correct.
Step 8. Check that the wire size is within terminal specification and that the wires are
tightened properly.
Step 9. Check that user-supplied branch circuit protection is installed and correctly
rated.
Completing the Installation
9-1
Step 10. Check that the incoming power is rated correctly.
Step 11. Check the motor installation and length of motor leads.
Step 12. Disconnect any power correction capacitors connected between the drive
and the motor.
Step 13. Check that the rating of the transformer (if used) matches the drive
requirements and is connected properly.
Step 14. Verify that a properly-sized ground wire is installed and a suitable earth
ground is used. Check for and eliminate any grounds between the motor
frame and the motor power leads. Verify that all ground leads are unbroken.
Step 15. Uncouple the motor from any driven machinery to initially start the drive.
9.2
Powering Up After Installation Is Complete
Use the following procedure to verify that the drive is installed correctly and is
receiving the proper line voltage:
Step 1. Turn the drive’s input power disconnect to the On position.
Step 2. Apply power to the drive.
Step 3. Follow the start-up procedure in the GV3000/SE Bookshelf Drive Software
Start-Up and Reference manual.
9-2
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
CHAPTER 10
Troubleshooting the Drive
This chapter describes how to troubleshoot the drive and the equipment that is
needed to do so. Also provided are replacement part lists and information on clearing
faults.
10.1 Test Equipment Needed To Troubleshoot
An isolated multimeter will be needed to measure DC bus voltage and to make
resistance checks. Note that dedicated troubleshooting test points are not provided.
10.2 Drive Alarms and Faults
The drive will display alarm and fault codes to assist in troubleshooting when a
problem develops during self-tuning or drive operation.
If an alarm condition occurs, the drive will continue to run and a 2- or 3-digit alarm
code will flash on the display.
If a fault occurs, the drive will coast-to-rest stop and a 2- or 3-digit fault code will flash
on the display.
Refer to the GV3000/SE Bookshelf Drive Software Start-Up and Reference manual for
more information on drive alarms and faults.
10.3 Verifying That DC Bus Capacitors Are Discharged
!
ATTENTION: DC bus capacitors retain hazardous voltages after input
power has been disconnected. After disconnecting input power, wait five
(5) minutes for the DC bus capacitors to discharge and then check the
voltage with a voltmeter to ensure the DC bus capacitors are discharged
before touching any internal components. Failure to observe this
precaution could result in severe bodily injury or loss of life.
The drive’s DC bus capacitors retain hazardous voltages after input power has been
disconnected. Perform the following steps before touching any internal components:
Step 1. Disconnect, lock out, and tag all incoming power to the drive.
Step 2. Wait five minutes for the DC bus capacitors to discharge.
Step 3. 24 to 43 A drives only: Disconnect all wiring from the face of the drive. Then
remove the cover and the front panel.
Important: The cover is connected to the drive by the keypad/display cable. To
disconnect the cover, use the following procedure. Do not remove the
keypad/display.
Troubleshooting the Drive
10-1
To remove the cover:
a. Unscrew the attaching screw on the cover.
b. Lift the cover and carefully take it out of the heatsink as far as the flat
ribbon cable, which connects the display with the Regulator board, allows.
c. Use a screwdriver to slide the cable out of the connector on the Regulator
board to completely detach the cover.
Step 4. Use a voltmeter to verify that there is no voltage at the drive’s AC input power
terminals (R/L1, S/L2, T/L3). Refer to figure 10.1, 10.2, or 10.3 for the
location of these terminals.
Step 5. Ensure that the DC bus capacitors are discharged. To check DC bus
potential:
a. Stand on a non-conductive surface and wear insulated gloves.
b. Use a voltmeter to measure the DC bus potential at the DC bus power
terminals ((-)45, (+)47) shown in figure 10.1, 10.2, or 10.3.
Step 6. 24 to 43 A drives only: Reattach the drive’s cover and front panel. Reconnect
all wiring to the face of the drive.
Important: When replacing the cover on 24 to 43 A drives, check that the display
cable is reconnected to the Regulator board. You will need to fold and
route the cable under the heatsink before replacing the cover.
Step 7. Reapply input power.
AC Input Power
Terminals
(L1, L2, L3)
DC Bus
Measuring Points
(-)45, (+)47
Figure 10.1 – DC Bus Voltage Terminals (2 to 15 Amp Drives)
10-2
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
AC Input Power
Terminals
(L1, L2, L3)
DC Bus
Measuring Points
(-)45, (+)47
Cover Removed
Figure 10.2 – DC Bus Voltage Terminals (24 to 30 Amp Drives)
Troubleshooting the Drive
10-3
*AC Input Power
Terminals
(L1, L2, L3)
PE L1 L2 L3
45 47 48 U V W
*Terminals are located
behind the cover and
front panel.
28-31
*DC Bus
Measuring Points
(-)45, (+)47
Figure 10.3 – DC Bus Voltage Terminals (43 Amp Drives)
10.4 Checking Out the Drive with Input Power Off
Use the following procedure to check the drive circuitry with power off:
!
ATTENTION: DC bus capacitors retain hazardous voltages after input
power has been disconnected. After disconnecting input power, wait five
(5) minutes for the DC bus capacitors to discharge and then check the
voltage with a voltmeter to ensure the DC bus capacitors are discharged
before touching any internal components. Failure to observe this
precaution could result in severe bodily injury or loss of life.
Step 1. Disconnect, lock out, and tag all incoming power to the drive.
Step 2. Wait five minutes for the DC bus capacitors to discharge.
Step 3. 24 to 43 A drives only: Remove all wiring from the face of the drive. Then
remove the drive’s cover and front panel.
10-4
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
Important: The cover is connected to the drive by the keypad/display cable. To
disconnect the cover, use the following procedure. Do not remove the
keypad/display.
To remove the cover:
a. Unscrew the attaching screw on the cover.
b. Lift the cover and carefully take it out of the heatsink as far as the flat
ribbon cable, which connects the display with the Regulator board, allows.
c. Use a screwdriver toslide the cable out of the connector on the Regulator
board to completely detach the cover.
Step 4. Use a voltmeter to verify that there is no voltage at the drive’s input power
terminals.
Step 5. Check the DC bus potential with a voltmeter as described in section 9.3 to
ensure that the DC bus capacitors are discharged.
Step 6. Disconnect the motor from the drive.
Step 7. Check all AC line fuses.
Step 8. If a fuse is open, use a multimeter to check the input diodes and output
IGBTs. See table 10.1.
Note that Bookshelf drives do not have replaceable transistor modules. The
entire drive must be replaced if a transistor malfunctions.
Step 9. Reconnect the motor to the drive.
Step 10. 24 to 43 A drives only: Reattach the drive’s cover and front panel. Reconnect
all wiring to the face of the drive.
Step 11. Reapply input power.
Table 10.1 – Resistance Checks
Input
Diode
No.
Meter
Connection
(+)
(-)
1
47*
1L1(R)
2
47*
1L2(S)
3
47*
1L3(T)
4
1L1(R) 45*
5
1L2(S)
45*
6
1L3(T)
45*
Component is OK if
resistance (R) is:
0.3 < R < 8K ohm
Component is defective if:
Continuity (short circuit) or
open when the meter is
connected with reversed
polarity
*If the optional terminals 45 and 47 are not fitted (e.g., on drives with built-in chopper option), remove
cover and connect the meter to the measuring points according to the procedure in section 10.3.
Troubleshooting the Drive
10-5
IGBT
No.
Meter
Connection
(+)
(-)
V6
47*
W(T3)
V5
47*
V(T2)
V4
47*
U(T1)
V3
W(T3)
45*
V2
V(T2)
45*
V1
U(T1)
45*
Component is OK if
resistance (R) is:
0.3 < R < 8K ohm
Component is defective if:
Continuity (short circuit) or
open when the meter is
connected with reversed
polarity
*If the optional terminals 45 and 47 are not fitted (e.g., on drives with built-in chopper option), remove
cover and connect the meter to the measuring points according to the procedure in section 10.3.
10-6
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
10.5 Checking the Cooling Fans
On a regular basis, visually check the cooling fans on the base of the unit. If a fan is
binding, clogged with dust, or is not functioning, it must be replaced. The replacement
part number for the fan is shown in table 10.2.
10.6 Replacement Parts
Table 10.2 lists the replacement parts that are available from Reliance Electric. See
figures 2.3, 2.4, and 2.5 for the location of the parts.
Table 10.2 – Replacement Parts
Quantity per Drive
55ER40xx
55ET40xx
85ER40xx
85ET40xx
126ER40xx
126ET40xx
150ER40xx 240ER40xx 300ER40xx 430ER40xx
150ET40xx 240ET40xx 300ET40xx 430ET40xx
Description
Part
Number
31ER40xx
31ET40xx
38ER40xx
38ET40xx
Regulator PCB
814.61.001
1
1
1
1
1
1
Keypad/Display
PCB
814.63.00
1
1
1
1
1
1
Fan
922.67.05
922.68.05
12
-
1
-
2
-
2
-
2
2
Cover
957.85.00
957.85.10
1
-
1
-
1
-
1
1
1
Troubleshooting the Drive
1
Specify firmware version 790.46.00A when ordering the Regulator PCB.
2
On M/N 38ET40xx only (with AC Mains Filter)
10-7
10-8
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
APPENDIX A
Technical Specifications
Table A.1 – Service Conditions
AC Line Distribution System Capacity
(Maximum) for 460 VAC Units
• Units Not Equipped with an AC Mains
Filter
• Units Equipped with an AC Mains Filter
• 315 KVA, three-phase with 10,000 amps symmetrical fault
current capacity with a line impedance of less than 5%.
• 1000 KVA, three-phase with 30,000 amps symmetrical fault
current capacity with a line impedance of less than 5%.
Control Method
All-digital vector, sinusoidal pulse-width-modulated (PWM)
Displacement Power Factor
0.96
Line Frequency
50/60Hz (+2 Hz)
Line Voltage Variation
-10% to +10%
Line Dip Ride-Through
FVC: Maximum 500 milliseconds
V/Hz, SVC: Adjustable up to 999.9 seconds (See P.042)
Motor Lead Lengths
76 meters (250 feet) typical (refer to section 3.2.2.4)
Remote Operator Control Wire Length
Up to 303 meters (1000 feet) from the drive
Analog Speed Reference Resolution
1/1024 (10 bits) 0.1%
Acceleration Adjustment Range
0.1 to 999.9 seconds (within the ability of current)
Carrier Frequency
2 kHz, 4 kHz, or 8 kHz, software-selectable
Current Limit Adjustment
Vector: U.006 to 150% (based on motor nameplate rating)
V/Hz: 50% to 110% (based on drive nameplate rating)
Service Factor
1.0
Speed Adjustable Range
From 0 RPM to maximum speed (vector)
Speed Regulation
Vector: 0.01% FVC, 0.5% SVC (steady state)
V/Hz: Motor slip dependent
Speed Reference Resolution
1 RPM with local keypad, -4095 to +4095 counts with a network
or serial reference
Torque Control Response
180 to 220 Hz
Torque Linearity
+3% with optimal parameter setting (typical) (see parameter
U.005)
Technical Specifications
A-1
Table A.2 – Environmental Condition
Condition
Specification
0° to +40°C (32° to 104°F) coolant air inlet
temperature at heatsink
Operating Temperature (Ambient)
Derating factor at 45°C ambient: 7.5%
Derating factor at 50°C ambient: 15%
Storage Temperature (Ambient)
-25°C to +55°C
Transportation Temperature (Ambient)
-25°C to +70°C (+70°C during a maximum
24 hours)
Table A.3 – Terminal Strip Input Specifications
Signal Type
Terminal(s)
Speed Reference Input
Digital Inputs (1 - 8)
12-15
Specification
10 V (@ 50K ohm input
impedance or 20 mA)
16
+24 VDC Isolated Supply
17
Remote/Local (Default)
18
Ramp 1/Ramp 2 (Default)
19
Forward/Reverse (Default)
20
Function Loss
21
Run/Jog
22
Reset
23
Stop
24
Start
Table A.4 – Terminal Strip Output Specifications
Signal Type
Analog Output
A-2
Terminal(s)
Specification
10 -11
scaled signal
0-10 VDC (maximum 4
mA, 2.5K ohm impedance)
or 4-20 mA
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
Table A.5 – Flux Vector Regulation Specifications
Specification
Rating
Motor Poles
2, 4, 6, or 8 poles
Overcurrent IET
200% load (based on drive nameplate
rating)
Overload Current Rating
150% for 1 minute (based on drive
nameplate rating)
Speed Control Range
1:600 with 1024 PPR
Speed Control Response
15 Hz (typical)
Encoder Feedback
15 V differential quadrature, encoder
incremental (512 PPR, 1024 PPR, 2048
PPR, 4096 PPR)
Service Factor
1.0
)
Table A.6 – Input Signal Response Times (Maximum)
Signal Type and Source
Volts/Hertz Regulation*
Vector Regulation*
150 milliseconds
130 milliseconds
START
126 milliseconds
105 milliseconds
STOP, RESET, FL
75 milliseconds
75 milliseconds
Preset Speeds
75 milliseconds
75 milliseconds
Analog Speed/Trim
Reference
16 milliseconds
5 milliseconds
N/A
0.5 milliseconds
START
46 milliseconds + network
transport time
25 milliseconds + network
transport time
STOP, RESET, FL
26 milliseconds + network
transport time
25 milliseconds + network
transport time
Analog Speed/Trim
Reference
5 milliseconds +
network transport time
5 milliseconds +
network transport time
Torque Reference
N/A
0.5 milliseconds +network
transport time
Keypad START
Terminal Strip:
Analog Torque
Reference
Network:
*These are the maximum times from transitioning the input to the drive reacting to the input.
Technical Specifications
A-3
A-4
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
APPENDIX B
Compliance with Machinery Safety
Standard EN 60204-1:1992
The GV3000/SE Bookshelf drive complies with the following sections of machinery
safety standard EN 60204-1:1992.
EN60204-1
Section
Title
6
Protection against electrical shock
6.2.1
-
Protection by enclosure
6.2.3
-
Protection against residual voltages
6.3.1
-
Protection by automatic disconnect of supply
6.4
-
Protection by the use of PELV (Protective Extra Low Voltage)
7
Protection of equipment
7.2
-
Overcurrent protection
7.2.3
-
Control circuits
7.2.6
-
Transformers
7.5
-
Protection against supply interruption or voltage reduction and subsequent restoration
8
Equipotential bonding
8.2.1
-
General (the PE terminal)
8.2.2
-
Protective conductors (connection points)
8.2.3
-
Continuity of the protective bonding circuit
8.2.7
-
Protective conductor connecting points
8.3
-
Bonding to the protective bonding circuit for operational purposes
8.4
-
Insulation failures
8.5
-
Bonding to a common reference potential
8.6
-
Electrical interferences
9
Control circuit and control functions
9.1.1
-
Control circuit supply
9.1.3
-
Protection
9.1.4
-
Connection of control devices
9.2
-
Control functions
9.2.1
-
Start function
9.2.2
-
Stop function
9.2.3
-
Operating modes
9.2.5
-
Operation
9.2.5.3
-
Stop
9.2.5.6
-
Hold-to-run controls
Compliance with Machinery Safety Standard EN 60204-1:1992
B-1
EN60204-1
Section
Title
9.2.6
-
Combined start and stop controls
9.3
-
Protective interlocks
9.3.5
-
Reverse current braking
9.4
-
Control functions in case of failure
9.4.2.1
-
Use of proven circuit techniques and components
9.4.3
-
Provisions for redundancy
9.4.3.1
-
Earth faults
9.4.3.2
-
Voltage interruption
10
Operator interface and machine mounted control devices
10.2.1
-
Pushbutton colors
10.8
-
Displays
11
Control interfaces
11.2
-
Digital input/output interfaces
11.2.1
-
Inputs
11.2.2
-
Outputs
11.3
-
Drive interfaces with analog inputs
11.3.1
-
Separation between control and electric drives
11.5
-
Communications
12
Electronic equipment
12.2.2
-
Electronic control equipment
12.2.3
-
Equipotential bonding
12.3
-
Programmable equipment
12.3.1
-
Programmable controllers
12.3.2
-
Memory retention and protection
12.3.3
-
Programming equipment
12.3.4
-
Software verification
12.3.5
-
Use in safety-related functions
13
Controlgear: Location, mounting and enclosures
13.2.3
-
Heating effects
13.4
-
Enclosures, doors and openings
15
Wiring practices
15.1.1
-
General requirements
15.1.3
-
Conductors of different circuits
15.2.2
-
Identification of the protective conductor
18
Warning signs and item identification
18.2
-
Warning signs
18.4
-
Marking of control equipment
19
Technical documentation
19.1
-
General
Copies of this standard can be purchased from the American National Standards
Institute at www.ansi.org.
B-2
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
APPENDIX C
Compliance with Electromagnetic
Compatibility Standards
C.1 Introduction
This appendix provides information on the GV3000/SE Bookshelf drive’s compliance
with European community electromagnetic compatibility standards and covers the
following:
• requirements for standards compliance
• instructions on how the drive must be wired.
The GV3000/SE drives listed on the Declaration of Conformity (DOC) have been
tested and are in compliance with the following standards:
• EN50081-2 (1993)
Electromagnetic compatibility - Generic emission standard
Part 2: Industrial
• EN50082-2 (1995)
Electromagnetic compatibility - Generic immunity standard
Part 2: Industrial
Note that the conformity of the GV3000/SE Bookshelf drive to the above standards
does not guarantee that the entire installation will be in conformance.
Copies of the Declaration of Conformity (DOC) may be obtained by contacting the
Rockwell AutoFax service at 440-646-7777.
C.2 Compliance Requirements
In order for the GV3000/SE Bookshelf drive to conform to the standards listed in
section C.1, the drive must:
• be specified by model number on the DOC.
• have a CE mark. This mark is found on the drive’s certification label.
• include an AC Mains Filter.
• be installed according to the instructions in this appendix.
Compliance with Electromagnetic Compatibility Standards
C-1
C.3 Wiring Practices
This section describes how the GV3000/SE drive must be wired to conform to the
standards listed in section C.1. Figure C.1 shows a typical wiring configuration for a
GV3000/SE Bookshelf drive if an AC Mains Filter is used.
Cabinet
GV3000/SE Drive
Panel
Built-In
AC Mains
Filter
U,V,W
L1, L2, L3
PE
PE
Terminals for 4-wire AC-input cable
(L1,L2,,L3, PE)
Cabinet-protection ground bus bar
1
2
1
Cable bracket
2
Screen
3
Screened 4-wire motor cable
4
Screened signal conductor cable
(feedback, reference)
5
EMC-tested armored cable gland at
terminal box
3
4
5
PE
U,V,W
G
MOTOR
Figure C.1 – Cabinet Mounted GV3000/SE Wiring Example
C-2
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
C.3.1 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 250’ (76m).
A ground (earth) lead, equivalent in size to the motor leads, must be run with the
motor leads from the motor to the drive. Terminate this lead in the drive at the ground
terminal.
Proper glands must be used to terminate the motor conduit/cable. The gland must
secure the cable screen to the conductive surfaces of the drive and motor. A full 360°
screen termination is preferred.
Follow all instructions supplied with the motor.
C.3.2 Grounding the Drive
Connect the drive/filter assembly to earth ground at the terminal provided (see figures
4.1 and 4.2. The ground wire should be sized per EN-60204-1, Part 5.21, for copper
conductors and EN-60204-1, Part 8.2.2.22, for non-copper conductors. European
Union standards require that the ground wire must be green/yellow according to
EN-60204-1, Part 15.2.2.3
1
EN-60204-1, Part 5.2: Minimum Cross-Sectional Area of the External Protective
Copper Conductor
Cross-Sectional Area of Phase
Conductors Supplying the Equipment
(S) (mm2)
Minimum Cross-Sectional Area of the
External Protective Conductor (mm2)
S < 16
S
16 < S < 35
16
S > 35
S/2
2
EN-60204-1, Part 8.2.2.2: Protective Conductors
Copper conductor should be used. If a material other than copper is used, its electrical
resistance per unit length should not exceed that of copper. Non-copper conductors
should not be less than 16 mm2 in cross-sectional area.
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.
Compliance with Electromagnetic Compatibility Standards
C-3
C.3.3 I/O Signals
Control (I/O) and signal wiring must be run in continuous, rigid, conductive conduit or
continuously-screened cable as shown in figure C.2. 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.
Stranded copper wire
Plastic insulation
Inner plastic sheath
Compact screen of galvanized (tinned) copper or steel braid
Outer plastic jacket
Figure C.2 – I/O Signal Cable
C.3.4 Operator Control Stations
The enclosure of an operator’s control station must be constructed of a conductive
metal. The cover of the enclosure should be bonded to the case and not rely on the
hinge for bonding. Standard industrial operator devices, e.g., pushbuttons, switches,
and meters, may be used.
The wiring connecting the operator’s devices to the drive 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.
Proper glands must be used to terminate the operator’s control station conduit/cable
at the station and the drive. The gland must secure the cable screen to the conductive
surfaces of the drive and station enclosure. A full 360° screen termination is preferred.
Screen pigtails are not permitted.
C.3.5 Connecting to the AutoMax Network
GV3000/SE drive connections to an AutoMax network require the use of coaxial cable
as described in instruction manuals J2-3001 and D2-3308. The coaxial cable must be
run in continuous, rigid, conductive conduit.
Proper glands must be used to terminate the conduit at the AutoMax enclosure and
the GV3000/SE drive. The gland must secure the cable screen to the conductive
surfaces of the drive and AutoMax enclosure. A full 360° screen termination is
preferred. Screen pigtails are not permitted.
C-4
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
C.3.6 Encoder Cabling
Use only the Reliance Electric encoder cables listed in table C.1.
Table C.1 – Encoder Cabling
Cable Type
Cable Length
Cable Model Number
MS connector on encoder end
25’
2TC4025
MS connector on encoder end
75’
2TC4075
Bare wire on both ends
100’
2TC4100
Bare wire on both ends
300’
2TC4300
Compliance with Electromagnetic Compatibility Standards
C-5
C-6
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
INDEX
A
C
AC input
diodes, checking, 10-4 to 10-6
disconnect, installing, 5-2
isolation, transformer, 5-1 to 5-2
line branch circuit fuses, 3-8 to 3-9, 5-2
ratings, 2-2
wire sizes, 3-5 to 3-6
wiring, 3-5 to 3-6, 4-1 to 4-5, 5-1 to 5-3
voltage transients, avoiding, 5-1
AC Mains Filter, 2-12, 5-1, C-1, C-2
AC output
wiring, 3-5 to 3-6, 4-1 to 4-5, 6-1 to 6-2
Air flow, 3-1, 3-4
Alarms, 10-1
Altitude requirements, 3-2
Ambient conditions 3-2, A-2
Analog input
jumper location, 2-6
jumper settings, 2-7 to 2-8
specifications, A-2
terminal strip connection, 2-10, 7-2
wiring, 3-5, 7-8
Analog output
jumper location, 2-6
jumper settings, 2-8 to 2-9
specifications, A-2
terminal strip connection, 2-10, 7-1
wiring, 3-6, 7-7
Assistance, technical, 1-1
AutoMax Network Option board, 2-11, 2-12
Capacitors, DC bus, 10-1 to 10-4
Carrier frequency, 2-2, A-1
Closed loop control, see Vector Regulation
Communication, network, 2-11
Communication port (X8), see RS-232
Conduit size
24 to 30 amp drives, 4-4
43 amp drives, 4-5
Contactors, installing output, 6-1
Contacts, Form A/B, 2-10, 7-14
Control and Configuration Software, 1-1, 2-10,
2-13, 3-8
Control source, 7-1, 7-9
Control wiring, 2-10, 7-1 to 7-13
Cover
part number, 10-7
removing, 10-1 to 10-2
CS3000, see Control and Configuration Software
B
Board
Keypad/Display, 10-7
Option, 2-11, 2-12 to 2-13
Power, 2-3, 2-4, 2-5, 2-6
Regulator, 2-3, 2-4, 2-5, 2-6 to 2-11, 10-7
Braking resistor
selecting, 8-3
wiring user-supplied, 8-1 to 8-2, 8-4
Braking transistor, internal, 2-12
Index
D
DC bus
input wiring, 3-5 to 3-6, 4-3, 4-4, 4-5
terminals, 10-2 to 10-4
verifying capacitor voltage, 10-1 to 10-4
Declaration of Conformity, C-1
DeviceNet Network Option board, 2-11, 2-13
Digital input wiring, 2-10, 7-2, 7-9 to 7-13
Digital output wiring, see Status Relays
Dimensions,
2 to 30 amp drives, 3-3
43 amp drives, 3-4
Disconnect, installing input, 5-2
Display, see Keypad/Display
Distribution system capacity, AC line, 5-1, A-1
Drive,
checking, 10-3 to 10-6
component locations, 2-3 to 2-5
identifying, 2-1 to 2-2
kits, 2-12 to 2-13
software, 1-1
verifying output current rating, 3-5
Index-1
E
Electromagnetic compatibility standards, drive
compliance with, C-1 to C-5
Emergency stop, 7-4
EN-60204-1 compliance, 7-4 to 7-5, B-1 to B-2
Enclosure, 2-2
Encoder wiring, 3-9, 7-5 to 7-6
Environmental conditions, 3-2, A-2
European stock number, 2-1 to 2-2
F
Fan
checking, 10-7
location, 2-3 to 2-5
part number, 10-7
Faults, 10-1
Flux vector control, 2-1
Flux vector regulator specifications, A-3
Form A/B contacts, see Status Relays
Forward (digital input 6), 2-10, 7-2, 7-11
Frequency, line, A-1
Function loss (digital input 5), 2-10, 7-2, 7-12
Fuse
AC input, 3-8 to 3-9, 5-2 to 5-3
FVC, see Flux Vector Control
output contactors, 6-1
planning, 3-1 to 3-9
requirements, 3-1 to 3-5
transformers and reactors, 5-1 to 5-2
IP20 enclosure, 2-2
J
Jog (digital input 4), 2-10, 7-2, 7-12
Jumpers
J4, 2-6, 2-7 to 2-8
J17, 2-6, 2-8 to 2-9
location of 2-6
settings for, 2-8, 2-9
K
Keypad/display, 2-3, 2-4, 2-5, 2-11, 10-7
Kits, 2-12 to 2-13
L
Lead lengths, motor, 3-6 to 3-7
LEDs, 2-11
Line branch circuit fuses, AC input, 3-8 to 3-9, 5-2
Line frequency, A-1
Line noise, avoiding, 5-1
Local (digital input 8), 2-10, 7-2, 7-9
G
Grounding, 4-2 to 4-5, 5-3
H
Humidity, 3-2, A-2
I
IGBT power devices, 2-6
testing, resistance checks, 10-5 to 10-6
Input, AC, see AC Input
Input, digital, see Digital Input Wiring
Input signal response times, A-3
Input specifications, terminal strip, A-2
Installation
AC input disconnect, 5-2
checking, 9-1 to 9-2
completing, 9-1 to 9-2
fuses, AC input line branch circuit, 3-8 to 3-9,
5-2
input isolation transformer, 5-1 to 5-2
mechanical motor overload protection, 6-1
Index-2
M
Machinery Safety Standard EN 60204-1:1992,
compliance with, 7-4 to 7-5, B-1 to B-2
Mains filter, 2-12, 5-1, C-1, C-2
Mechanical motor overload protection, 6-1
Meter output, 2-12, 7-1, 7-7
Model number, 2-1
MOP (motor operated potentiometer), 7-9 to 7-11
Motor
Encoder Cable kit, 2-12
lead lengths, 3-6 to 3-7
overload protection, mechanical, 6-1
speed, setting maximum, 7-5
wiring, 6-1 to 6-2
Mounting dimensions
2 to 30 amp drives, 3-3
43 amp drives, 3-4
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
N
Network
AutoMax Network Option board, 2-11, 2-12
communication, 2-11
ControlNet Network Option board, 2-12
DeviceNet Network Option board, 2-11, 2-13
Profibus Network Option board, 2-13
O
Open loop control, see Volts/Hertz Regulation
Operator Interface Module, 2-13
Operator Interface Module connector, 2-11
Option kits, see Kits
Option board connector, 2-6, 2-11
Output
analog, see analog Output
contactors, 6-1
digital, see Status Relays
specifications, terminal strip, A-2
Output relay terminal strip, 2-3, 2-4, 2-5, 2-12, 3-6,
7-2, 7-14
Overload, motor, 6-1
P
Parts
location, see Component Locations
replacement, 10-7
PC control, see Control Source
Power board, 2-3, 2-4, 2-5, 2-6
Power ratings, 2-2
Power terminals
torque specifications, 5-2
wiring, 3-5 to 3-6, 4-2 to 4-5, 5-1 to 5-3, 6-1 to
6-2
Profibus Network Option board, 2-13
Protection, mechanical motor overload, 6-1
Publications, related, 1-1
R
Ramp 1/Ramp 2 (digital input 7), 2-10, 7-2, 7-10
Rating
AC input, 2-2
enclosure, 2-2
fuse, 3-8 to 3-9
output, 2-2
power loss, 2-2
Regulator board, 2-3, 2-4, 2-5, 2-6 to 2-11, 7-1 to
7-3, 7-7 to 7-13, 10-7
Relays, output status, see Status Relays
Index
Reliance, getting assistance from, 1-1
Remote (digital input 8), 2-10, 7-2, 7-9
Remote Meter Interface board, 2-13
Removing cover, 10-1 to 10-2
Replacement parts, 10-5
Reset (digital input 3), 2-10, 7-2, 7-13
Reverse (digital input 6), 2-10, 7-2, 7-11
RS-232
cable length, 3-8
communication port (X8), 2-6, 2-10, 3-8
Run (digital input 4), 2-10, 7-2, 7-12
S
Selecting operation, see Control Source
Sensorless vector control, 2-1
Serial communication, see RS-232
Site requirements, 3-1 to 3-2
Software, drive, 1-1
Space requirements,
2 to 30 amp drives, 3-3
43 amp drives, 3-4
Specifications, technical, A-1 to A-3
Speed, maximum setting, 7-5
Start (digital input 1), 2-10, 7-2, 7-13
Status relays, Form A/B, 2-12, 7-2, 7-14
Stop (digital input 2), 2-10, 7-2, 7-13
Stopping the drive, 7-4 to 7-5
Super Remote Meter Interface board, 2-13
SVC, see Sensorless Vector Control
Switch, membrane, see Keypad/Display
T
Tachometer, pulse, see Encoder
Terminal strip,
input specifications, A-2
output specifications, A-2
output relay, 2-3, 2-4, 2-5, 2-12, 7-2, 7-14
Regulator board, 2-6, 2-10, 7-1 to 7-13
torque specifications, 3-6
wiring, 2-10, 3-6, 7-1 to 7-14
Testing, IGBT, 10-4 to 10-6
Transformer, installing isolation input, 5-1
Transients, AC line voltage, 5-1
V
Vector regulation, 2-1
Ventilation, see Air Flow
Volts/hertz regulation, 2-1
Index-3
W
Watts loss rating, 2-2, 4-1
Weight,
2 to 30 amp drives, 3-3
43 amp drives, 3-4
Wire routing, 4-2 to 4-5
Wire sizes, 3-5, 3-6, 3-8, 3-9
Index-4
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
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Technical Documentation
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Fax: 216.266.7785
Publication Name: GV3000/SE AC Bookshelf Drive Hardware Reference, Installation,
and Troubleshooting Version 6.06
Publication Number: D2-3427-2
Publication Date: December 2000
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 2000 Rockwell International Corporation. All rights reserved. Printed in USA.
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