Instruction Manual D2 3340
GV3000 AC Power Modules
Hardware Reference, Installation,
and Troubleshooting
Version 5.0
Instruction Manual D23340
The information in the user's manual is subject to change without notice.
DANGER
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.
DANGER
THE USER IS RESPONSIBLE FOR CONFORMING WITH ALL APPLICABLE LOCAL, NATIONAL, AND
INTERNATIONAL CODES. WIRING PRACTICES, GROUNDING, DISCONNECTS, AND
OVERCURRENT PROTECTION ARE OF PARTICULAR IMPORTANCE. FAILURE TO OBSERVE THIS
PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE.
DANGER
DĆC BUS CAPACITORS RETAIN HAZARDOUS VOLTAGES AFTER INPUT POWER HAS BEEN
DISCONNECTED. AFTER DISCONNECTING INPUT POWER, WAIT FIVE (5) MINUTES FOR THE DĆC
BUS CAPACITORS TO DISCHARGE AND THEN CHECK THE VOLTAGE WITH A VOLTMETER TO
ENSURE THE DĆC BUS CAPACITORS ARE DISCHARGED BEFORE TOUCHING ANY INTERNAL
COMPONENTS. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY
INJURY OR LOSS OF LIFE.
DANGER
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.
WARNING
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.
DeviceNett is a trademark of Open DeviceNet Vendor Association.
GV3000r, AutoMaxr, and Reliancer are registered trademarks of Reliance Electric Company or its subsidiaries.
E Copyright Reliance Electric Industrial Company 1995.
Manufacturer's Declaration
Manufacturer:
Reliance Electric Industrial Co.
24701 Euclid Avenue
Cleveland, Ohio 44117 - USA
declares that the product:
GV3000, AC Speed Controller for Electric Motors
is intended to be incorporated into machinery or to be assembled with other machinery to
constitute machinery covered by Directive 89/392/EEC, as amended;
and that
the following harmonized standards have been applied:
EN 602041: Electrical equipment of industrial machines - Part 1: General Requirements
and furthermore declares that the product covered by this Declaration must not be put into service
until the machinery into which it is to be incorporated or of which it is a component has been found
and declared to be in conformity with the provisions of Directive 89/392/EEC and with national
implementing legislation, i.e., as a whole, including the product referred to in this Declaration.
Authorized Representative of the Company:
Place:
Reliance Electric Industrial Co., Cleveland, Ohio 44117, USA
Date:
December 1, 1995
Signature:
Name:
Charles Janki
Position:
Product Development Safety Engineer
Table of Contents
1.0
Becoming Familiar with the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
1.1
1.2
1.3
1.4
1.5
1.6
2.0
Finding Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Assumptions About the Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Taking Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Understanding Terms Used in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
If You Want to Know More . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Getting Assistance from Reliance Electric . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
About the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
2.1
2.2
2.3
2.4
2.5
2.6
2.7
Identifying the Drive by Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
NEMA Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
125 HP GV3000 Drive Components and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2560 HP GV3000 Drive Components and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
60100 HP GV3000 Drive Components and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
100150 HP GV3000 Drive Components and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Regulator Board Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.1 Jumper Locations and Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.1.1 Analog Input Speed Reference Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.1.2 Analog Output Jumper . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.2 Wiring the Terminal Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.3 RS232 Communication Port . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.4 Option Board Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.5 Operator Interface Module Connector . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.6 Keypad/Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.8 Drive Kit Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.0
11
12
12
12
12
12
21
22
23
26
27
28
29
212
212
213
214
215
215
215
215
216
Planning Before Installing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
3.1 Requirements for the Installation Site . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.1 Making Sure Environmental Conditions are Met . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.1.2 Determining Total Area Required Based on Drive Dimensions . . . . . . . . . . . . . . . . . . . .
3.1.3 Verifying the Site Provides for Recommended Air Flow Clearances . . . . . . . . . . . . . . . .
3.1.4 Verifying Power Module Input Ratings Match Supplied Power . . . . . . . . . . . . . . . . . . . .
3.2 Wiring Requirements for the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.1 Meeting Terminal Strip Input and Output Specifications . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2 Determining Wire Size Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2.1 Conduit Entry Opening Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2.2 Recommended Power Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2.3 Recommended Control and Signal Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2.4 Recommended Motor Lead Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2.5 Recommended Serial Communication Cable Lengths . . . . . . . . . . . . . . . . . . . .
3.2.3 Selecting Input Line Branch Circuit Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.4 Meeting Pulse Tachometer Specifications (Vector Regulation Only) . . . . . . . . . . . . . . . .
3.2.5 Verifying Power Module Output Current Rating is Greater Than Motor Full
Load Amps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
31
31
32
34
35
35
35
35
35
35
36
36
37
37
38
38
I
4.0
Mounting the Drive, Grounding, and Finding Wire Routing Locations . . . . . . . . . . . . . . . . . . . 41
4.1 Mounting the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.1 Verifying the Drive's Watts Loss Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Routing Input, Motor Output, Ground, and Control Wiring for the Drive . . . . . . . . . . . . . . . . .
4.3 Grounding the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.0
Installing Input Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
5.1
5.2
5.3
5.4
5.5
6.0
41
41
41
48
Installing Transformers and Reactors (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Fuses for Branch Circuit Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing a Required External/Separate Input Disconnect . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing Power Wiring from the AC Input Line to the Drive's Power Terminals . . . . . . . . . . .
Installing Power Wiring from an External DC Bus to the Drive's Internal DC Bus
Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
51
51
54
54
55
Installing Output Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.1 Installing Output Contactors (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.2 Installing Mechanical Motor Overload Protection (Optional) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
6.3 Installing Output Wiring from the Drive Output Terminals to the Motor . . . . . . . . . . . . . . . . . . . 61
7.0
Wiring the Regulator Board Terminal Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
7.1 Stopping the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.1.1 Compliance with EN 602041: 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
7.2 Wiring the Speed Feedback Device (Vector Regulation Only) . . . . . . . . . . . . . . . . . . . . . . . . . .
7.3 Wiring the Signal and Control I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.0
75
75
75
77
Completing the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.1 Checking the Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
8.2 Installing the Cover for NEMA 4X/12 Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
8.3 Powering Up After Installation is Complete . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
9.0
Troubleshooting the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
9.1
9.2
9.3
9.4
9.5
II
Test Equipment Needed to Troubleshoot . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Drive Alarms and Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Verifying That DC Bus Capacitors are Discharged . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Checking Out the Power Modules with Input Power Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
91
91
91
96
98
Appendices
Appendix A
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1
Appendix B
Drive Regulation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B1
Appendix C
Compliance with EN 602041: 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C1
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Index1
III
List of Figures
Figure 2.1 Identifying the Drive Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Figure 2.2 15 HP Drive Components and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Figure 2.3 7.510 HP Drive Components and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Figure 2.4 1525 HP Drive Components and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Figure 2.5 2560 HP Drive Components and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Figure 2.6 60100 HP Drive Components and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Figure 2.7 100150 HP Drive Components and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Figure 2.8 160 HP Regulator Board Components and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
Figure 2.9 60150 HP Regulator Board Components and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Figure 2.10 Jumper J4 Settings for Analog Input Speed Reference . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 212
Figure 2.11 Jumper J17 Settings for Analog Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 213
Figure 2.12 Typical Terminal Strip Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Figure 2.13 Keypad/Display . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Figure 3.1 Drive Dimensions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Figure 3.2 Recommended Air Flow Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Figure 3.3 Single and Multiple Motor Lead Lengths . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Figure 4.1 Wire Routing Locations for 15 HP Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Figure 4.2 Wire Routing Locations for 7.510 HP Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Figure 4.3 Wire Routing Locations for 1525 HP Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Figure 4.4 Wire Routing Locations for 2560 HP Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Figure 4.5 Wire Routing Locations for 60100 HP Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Figure 4.6 Wire Routing Locations for 100150 HP Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Figure 5.1 Typical AC Input Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Figure 5.2 Typical DC Bus Electrical Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Figure 7.1 TwoWire Start/Stop Sample Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Figure 7.2 ThreeWire Start/Stop Sample Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Figure 7.3 Wiring Connections for the Speed Feedback Device . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Figure 9.1 DC Bus Voltage Terminals (125 HP Drives) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Figure 9.2 DC Bus Voltage Terminals (2560 HP Drives) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Figure 9.3 DC Bus Voltage Terminals (60100 HP Drives) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Figure 9.4 DC Bus Voltage Terminals (100150 HP Drives) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Figure B.1 Volts/Hertz Regulation Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B2
Figure B.2 Vector Regulation Block Diagram . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B3
IV
List of Tables
Table 2.1 Power and NEMA Enclosure Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Table 2.2 Available Kits and Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 216
Table 3.1 Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Table 3.2 Drive Dimensions and Weights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Table 3.3 Recommended Power Wire Sizes for 110 HP Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Table 3.4 Recommended Power Wire Sizes for 1525 HP Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Table 3.5 Recommended Power Wire Sizes for 2560 HP Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Table 3.6 Recommended Power Wire Sizes for 60100 HP Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Table 3.7 Recommended Power Wire Sizes for 100150 HP Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Table 3.8 Recommended Terminal Strip Wire Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Table 3.9 AC Input Line Fuse Selection Values . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Table 5.1 Terminal Tightening Torques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Table 7.1 Wiring Signal and Control I/O to the Terminal Strip . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Table 9.1 Resistance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Table 9.2 15 HP Drive Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Table 9.3 7.510 HP Drive Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Table 9.4 1525 HP Drive Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Table 9.5 2560 HP Drive Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 910
Table 9.6 60100 HP Drive Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 911
Table 9.7 100150 HP Drive Replacement Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 912
Table A.1 Service Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1
Table A.2 Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A1
Table A.3 Terminal Strip Input Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2
Table A.4 Terminal Strip Output Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2
Table A.5 RS232 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A2
Table A.6 Speed Feedback Device Specifications (Vector Regulation Only) . . . . . . . . . . . . . . . . . . . . . . . A2
Table A.7 Input Signal Response Times (Worst Case) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A3
V
1.0 BECOMING FAMILIAR WITH THE MANUAL
This chapter provides help in finding information in the manual and describes the intended audience.
Also included are references to other related publications and instructions on receiving assistance
from Reliance Electric.
1.1
Finding Information
This instruction manual describes the GV3000 drive's Power Module and regulator hardware. It does
not cover the GV3000 software. For additional software information, refer to the GV3000 AC General
Purpose (V/Hz) and Vector Duty Drive Software StartUp and Reference Manual (D23339).
As an aid in finding information in this manual, each chapter is briefly described below:
D Chapter 1
Becoming Familiar with the Manual
Provides information on how the manual is organized and where to find additional
information.
D Chapter 2
About the Drive
Identifies drive components and shows their locations.
D Chapter 3
Planning Before Installing
Presents information that must be considered when planning a drive installation.
D Chapter 4
Mounting the Drive, Grounding, and Finding Wire Routing Locations
Describes how to mount the drive and properly ground it.
D Chapter 5
Installing Input Power Wiring
Describes incoming AC and DC line components and how to properly connect
them.
D Chapter 6
Installing AC Output Power Wiring
Describes output AC line components and how to properly connect them to the
motor.
D Chapter 7
Wiring the Regulator Board Terminal Strip
Provides information on the I/O wiring that connects to the terminal strip on the
Regulator board.
D Chapter 8
Completing the Installation
Provides instructions on how to perform a final check of the installation before
power is applied.
D Chapter 9
Troubleshooting the Drive
Describes the equipment that is needed to troubleshoot the drive and how to
measure DC bus voltage. Replacement part lists are also provided.
D Appendix A Technical Specifications
Lists drive specifications in table form.
D Appendix B Drive Regulation Overview
Briefly describes volts/hertz and vector regulation.
D Appendix C Compliance with EN 602041: 1992
Lists the sections of standard EN 602041: 1992 that the GV3000 drive complies
with.
11
1.2
Assumptions About the Audience
This manual is intended for qualified electrical personnel. It is taskoriented and is organized
according to a logical progression of steps to be followed to install and troubleshoot the drive.
1.3
Taking Safety Precautions
Dangers, warnings, and cautions are used in this manual to point out potential problem areas. All
three types of precautions are enclosed in a box to call attention to them.
DANGER
A DANGER ALERTS A PERSON OF A CONDITION WHICH COULD RESULT IN SEVERE BODILY
INJURY OR LOSS OF LIFE.
WARNING
A WARNING ALERTS A PERSON OF A CONDITION WHICH COULD RESULT IN POTENTIAL BODILY
INJURY IF PROCEDURES ARE NOT FOLLOWED.
CAUTION: A caution alerts a person of a condition which could result in damage to, or destruction of the
equipment.
1.4
Understanding Terms Used in this Manual
The following terms are defined according to the way they are used in this manual:
D GV3000 drives will typically be referenced by horsepower. If additional clarity is required, drive
model numbers will also be included.
D Parameters will be referenced either as parameter (P.030) or Elapsed Time Meter Reset (P.030).
1.5
If You Want to Know More
Refer to the following related publications as necessary for more information:
1.6
D D23339
GV3000 AC General Purpose (V/Hz) and Vector Duty Drive Software StartUp and
Reference Manual
D D23291
Snubber Resistor Braking Kit
D D23305
Motor Encoder Cable Kit
D D23308
AutoMax Network Communication Board
D D23348
Control and Configuration Software (CS3000)
D D23341
Remote Meter Interface
D D23342
Operator Interface Module
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 1800RELIANCE.
12
2.0 ABOUT THE DRIVE
This chapter describes how to identify the drive using the model number matrix and illustrates the
differences between the NEMA enclosures. Major components of each drive group are also shown.
The GV3000 AC drive is a PWM drive that provides vector and general purpose (volts/hertz or V/Hz)
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 using pulse tachometer
feedback.
Using general purpose (volts/hertz) regulation, the drive is suited for a broad range of applications
requiring adjustable speed control of motors.
2.1
Identifying the Drive by Model Number
Each GV3000 AC drive can be identified by its model number. See figure 2.1. This number appears
on the shipping label and on the drive's nameplate. The drive's model number includes the Power
Module and the regulator. Drive power ratings are provided in table 2.1.
NNN
A
N
N
NN
Horsepower Ratings
V = v 50 HP
GV3000 R = u 50 HP
G = V/Hz Only
Voltage
2 = 200*230V
4 = 380*460V
Enclosure
1 = NEMA 1
2 = NEMA 12 Only
4 = NEMA 4X (Indoor Only) or NEMA 12
Regulator Version
5.0 = Vector and V/Hz Regulator
Figure 2.1 Identifying the Drive Model Number
21
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Table 2.1 Power and NEMA Enclosure Ratings
Model
Number
1V4150
1V4450
2V4150
2V4450
3V4150
3V4450
5V4150
5V4450
7V4150
7V4250
10V4150
10V4250
15V4150
15V4250
20V4150
20V4250
25G4150
25G4250
25V4150
25V4250
30V4150
30V4250
40V4150
40V4250
50V4150
50V4250
50R4150
60G4150
60G4250
75R4150
125R4150
Selected
Regulation* and
Horsepower Rating
V/Hz or Vector
(1 HP)
V/Hz or Vector
(2 HP)
V/Hz or Vector
(3 HP)
V/Hz or Vector
(5 HP)
V/Hz or Vector
(7.5 HP)
V/Hz or Vector
(10 HP)
V/Hz or Vector
(15 HP)
V/Hz or Vector
(20 HP)
V/Hz
(25 HP)
V/Hz or Vector
(25 HP)
V/Hz or Vector
(30 HP)
V/Hz or Vector
(40 HP)
V/Hz or Vector
(50 HP)
Input
Voltage
(+/- 10%)
380-460 VAC
NEMA
Rating
1
4X/12
1
4X/12
1
4X/12
1
4X/12
1
12
1
12
1
12
1
12
1
12
1
12
1
12
1
12
1
12
Input
KVA
2.0
Input
Amps
2.5
Output
Amps
at 8 kHz
2.1
Power
Loss Watts
(Full Load)
60
3.3
4.2
3.4
100
5.1
6.4
5.3
140
7.9
9.9
8.2
180
10.7
13.4
11.1
210
13.4
16.8
14.2
250
20.2
25.4
21.0
375
26.1
32.7
27.0
600
29.5
37.0
30.4
600
30.2
38.0
34.5
750
35.0
44.0
39.0
800
46.2
58.0
54.0
960
57.3
72.0
67.0
1200
Vector (50 HP)
V/Hz (75 HP)
V/Hz
(60 HP)
Vector (60-75 HP)
V/Hz (100 HP)
Vector (100-125 HP)
V/Hz (125-150 HP)
380-460 VAC
1
70.0**
90.0**
78.0
380-460 VAC
1
12
1
81.0
102
90.0
1420
380-460 VAC
65.0
81.0
71.7
380-460 VAC
1
80.0
100
127
170
101
126
159
213
89.0**
116**
152**
210**
1400
1780
2410
3200
380-460 VAC
380-460 VAC
380-460 VAC
380-460 VAC
380-460 VAC
380-460 VAC
380-460 VAC
380-460 VAC
380-460 VAC
380-460 VAC
380-460 VAC
380-460 VAC
1200
*With V/Hz regulation, 110% continuous output current capability. With vector regulation, 150% output current capability for one
minute.
**At 2 kHz. For 4 kHz operation, derate by 20%. For 8 kHz operation, derate by 40%.
2.2
NEMA Enclosures
Each of the GV3000 Power Modules have one of following NEMA ratings:
D NEMA 1: Vented. Contains a communication access door that allows access to the
communication port without removing the cover. Intended for generalpurpose indoor
applications.
D NEMA 4X/12: Not vented. Supplied with base and keypad gaskets. Intended for use in indoor
environments that require a watertight/dusttight enclosure. An enclosure with this
NEMA rating encompasses both ratings (4X and 12).
D NEMA 12: Intended for use in indoor environments that require a dusttight/driptight enclosure.
See table 2.1 for a listing of the Power Modules and their individual NEMA ratings.
22
2.3
125 HP GV3000 Drive Components and Locations
The 125 HP GV3000 drives have the following main components. The identification numbers
provided correspond to the numbers used in figures 2.2 to 2.4. Replacement parts are listed in
chapter 9.
1. Fan/Fan Assembly
7. Power Supply PCB (1525 HP drives only)
2. Membrane Switch (Keypad/Bracket)
8. Gate Driver PCB (1525 HP drives only)
3. Regulator Printed Circuit Board (PCB)
9. Internal Fan Assembly
4. Capacitor PCB/Input Capacitors
10. IGBT Module
5. Current Feedback PCB
11. Diode Bridge
6. Power PCB (1525 HP drives only)
12. Fan Wire Harness
M/N
1V4150
1V4450
2V4150
2V4450
M/N
3V4150
3V4450
5V4150
5V4450
Figure 2.2 15 HP Drive Components and Locations
23
M/N
7V4150
7V4250
10V4150
10V4250
Figure 2.3 7.510 HP Drive Components and Locations
24
M/N
15V4150
15V4250
20V4150
20V4250
M/N
25G4150
25G4250
Figure 2.4 1525 HP Drive Components and Locations
25
2.4
2560 HP GV3000 Drive Components and Locations
The 2560 HP drives have the following main components. The identification numbers provided
correspond to the numbers used in figure 2.5. Replacement parts are listed in chapter 9.
1. Fan
7. Power Supply Board
2. Membrane Switch (Keypad/Bracket)
8. Gate Driver Board
3. Regulator Board
9. Internal Fan Assembly
4. Bus Capacitors
10. IGBT Module
5. Not Used
11. Diode Bridge
6. Power Board
12. Wire Harness
M/N
25V4150
25V4250
30V4150
30V4250
M/N
40V4150
40V4250
50V4150
50V4250
M/N
60G4150
60G4250
Figure 2.5 2560 HP Drive Components and Locations
26
2.5
60100 HP GV3000 Drive Components and Locations
The 60100 HP drives have the following main components. The identification numbers provided
correspond to the numbers used in figure 2.6. Replacement parts are listed in chapter 9.
9. Precharge Contactor
1. Regulator Printed Circuit Board (PCB)
2. Power Module Interface PCB
10. Current Transformer
3. Gate Driver PCB
11. Ground Fault Transformer
4. Bus Clamp PCB Right
12. Output Reactor
5. Bus Clamp PCB Left
13. Precharge Resistor
6. Intelligent Power Module PCB
14. Bus Discharge Resistor
7. Diode Bridge
15. 24 VDC Fan
8. DC Bus Fuse
16. Keypad
14
14
7
16
12
10
1
10
6
5
4
3
2
11
9
10
8
13
15
M/N
50R4150
75R4150
Figure 2.6 60100 HP Drive Components and Locations
27
2.6
100150 HP GV3000 Drive Components and Locations
The 100150 HP drive has the following main components. The identification numbers provided
correspond to the numbers used in figure 2.7. Replacement parts are listed in chapter 9.
1. Regulator Printed Circuit Board (PCB)
10. Current Transformer
2. Power Module Interface PCB
11. Ground Fault Transformer
3. Gate Driver PCB
12. Output Reactor
4. Bus Clamp PCB Right
13. Not Used
5. Bus Clamp PCB Left
14. Bus Discharge Resistor
6. Intelligent Power Module PCB
7. Thyristor Precharge Module
15. 24 VDC Fan
8. DC Bus Fuse
16. Keypad
9. Not Used
17. Thyristor Firing Pulse PCB
14
7
11
3
12
17
6
5
3
2
5
16
8
1
2
10
15
M/N
125R4150
Figure 2.7 100150 HP Drive Components and Locations
28
2.7
Regulator Board Description
GV3000 drive regulation is performed by a microprocessor on the Regulator board. See figures 2.8
and 2.9. Drive operation is adjusted by the parameters entered through the keypad. The Regulator
board accepts power circuit feedback signals, an external speed reference signal, and internal heat
sensor feedback, as well as data from a pulse tachometer that is attached to the motor when set up
for vector regulation. The Regulator board provides:
D 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 board to isolated drivers on the Gate Driver board. These drivers switch the
Insulated Gate Bipolar Transistors (IGBTs), producing a Pulse Width Modulated (PWM) waveform
that corresponds to the speed (vector regulation) or frequency (volts/hertz regulation) reference.
The IGBTs can be switched at either a 2, 4 or 8 kHz carrier frequency.
D Form A and B contacts for drive status indicators
The Form A and B contacts are under control of the user via programmable parameters. A Form A
or B transition can indicate drive status. The contacts are rated for 5 Amps resistive load at 250
VAC/ 30 VDC and are made available through the terminal strip.
D Display data for a fourcharacter display and fourteen indicator LEDs
The fourcharacter display is used to indicate drive parameters, parameter values, and fault
codes. The fourteen single LEDs indicate drive status and mode, as well as identifying drive
outputs whose values are displayed on the fourcharacter display.
D An analog output
The analog output is a scaled voltage (010 VDC) or current (420 mA) signal proportional to
either motor speed (RPM) or motor torque or current (%TORQUE). The current selection (via
jumper J17) requires a power supply for operation. The power can be sourced from the pulse
tachometer terminals (4 and 9) or from an external 15V power supply. See table 7.1, terminals 10
and 11, for more information. The analog output signal is available through the terminal strip.
D A snubber resistor braking signal
The 160 HP regulator provides a signal for use by an optional snubber resistor braking kit. The
signal goes through an isolating driver, made available through the terminal strip.
Two Regulator boards are used on the GV3000 drives: 160 HP Regulator boards are used with
160 HP drives; 60150 HP Regulator boards are used with 60150 HP drives. As shown in figures 2.8
and 2.9, the Regulator boards are similar but have different Power Module interface connectors.
29
J5
USER DISPLAY
26-Pin Ribbon Cable
34-Pin Ribbon Cable
J3
J9
J7
J8
J17
J4
USER I/O TERMINAL STRIP
J3 Option Board Connector
J8 RS232C Port
J4 Analog Input Jumper
J9 Keypad/Display Connector
J5 Power Module Feedback Cable
J17 Analog Output Jumper
J7 OIM (Optional) Connector
Figure 2.8 160 HP Regulator Board Components and Locations
210
60Pin Ribbon Cable
J16
USER DISPLAY
34Pin Ribbon Cable
J3
J9
J7
J17
J4
J8
USER I/O TERMINAL STRIP
J3 Option Board Connector
J9 Keypad/Display Connector
J4 Analog Input Jumper
J16 Power Module Feedback Cable
J7 OIM (Optional) Connector
J17 Analog Output Jumper
J8 RS232C Port
Figure 2.9 60150 HP Regulator Board Components and Locations
211
2.7.1 Jumper Locations and Settings
Jumpers J4 and J17 on the Regulator board are factoryset for voltage in and voltage out signals.
Refer to figures 2.8 and 2.9 for their locations on the Regulator boards. If you need to change the
jumpers' settings, use the following procedures.
CAUTION: 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.
2.7.1.1 Analog Input Speed Reference Jumper
Jumper J4 is the analog speed/torque (U.000) reference jumper. This jumper selects either
+/- 10 VDC or 020 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 instruction
manual D23339 for more information.
Use the following procedure to set jumper J4:
DANGER
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 input power to the drive and wait five minutes.
Step 2.
Remove the cover from the drive by unscrewing the four attaching screws.
Step 3.
Verify that the DC bus voltage is zero by following the procedure in section 9.3.
Step 4.
Locate jumper J4 on the Regulator board. Refer to figures 2.8 and 2.9.
Step 5.
Locate pin 1 on jumper J4. Move the jumper to the desired setting as shown in figure 2.10.
Step 6.
Reattach the cover.
Step 7.
Reapply input power.
Step 8.
Verify that Terminal Strip Analog Input Offset (P.009), Terminal Strip Analog Input Gain
(P.010), and Terminal Strip Analog Input Invert (P.011) are correctly set. Refer to instruction
manual D23339 for more information.
Voltage Input Option
Pins 23
Current Input Option
Pins 12
+10 VDC
020 mA
J4
J4
(default)
Figure 2.10 Jumper J4 Settings for Analog Input Speed Reference
212
2.7.1.2 Analog Output Jumper
Jumper J17 is the analog output jumper. This jumper selects either a 010 VDC or 420 mA scaled
signal output that is programmable for either speed or torque, parameter P.012. The jumper only
selects a 010 VDC source voltage or 420 mA sink current to represent speed or torque. Note that
the 420 mA current selection requires a power supply for operation as shown in table 7.1, terminals
10 and 11.
Use the following procedure to set jumper J17:
DANGER
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 input power to the drive and wait five minutes.
Step 2.
Remove the cover from the drive by unscrewing the four attaching screws.
Step 3.
Verify that the DC bus voltage is zero by following the procedure in section 9.3.
Step 4.
Locate jumper J17 on the Regulator board. Refer to figures 2.8 and 2.9.
Step 5.
Locate pin 1 on jumper J17. Move the jumper to the desired setting as shown in figure 2.11.
Step 6.
Reattach the cover.
Step 7.
Reapply input power.
Step 8.
Verify that parameter P.012 is set correctly for either speed or current.
Voltage Output Option
Pins 23
Current Output Option
Pins 12
+10 VDC
020 mA
J17
J17
(default)
Figure 2.11 Jumper J17 Settings for Analog Outputs
213
2.7.2 Wiring the Terminal Strip
The terminal strip on the Regulator board provides terminals for connecting customer I/O devices.
See figures 2.8, 2.9, and 2.12. The following terminals are provided:
D Terminals 13: RS232 connections
D Terminals 49: pulse tachometer connections
D Terminals 1011: analog output connections
D Terminals 1215: analog speed/torque reference connections
D Terminals 1625: 24V DC digital input connections (160 HP Regulator boards only)
D Terminals 2627: snubber resistor braking control connections (160 HP Regulator boards only)
DIGITAL INPUT 6 (FORWARD/REVERSE)
DIGITAL INPUT 7 (RAMP1/RAMP2)
DIGITAL INPUT 8 (REMOTE/LOCAL)
PHASE B NOT
D Terminals 2831: status relay connections
FACTORY
INSTALLED
PULSE TACHOMETER
CONNECTIONS
WIRES BETWEEN TERMINALS 16+16A AND
20 + 20A ARE NECESSARY FOR PROPER
OPERATION OF THE FUNCTION LOSS
INPUT. THEY SHOULD NOT BE REMOVED.
Figure 2.12 Typical Terminal Strip Connections
214
2.7.3 RS232 Communication Port
The Regulator board contains a 9pin Dshell RS232 communication port (J8). This port provides
RS232 communication between the GV3000 drive and a personal computer running the Control and
Configuration (CS3000) software. See figures 2.8 and 2.9. Refer to instruction manual D23348, for
more information.
2.7.4 Option Board Connector
The flatribbon cable connector (J3) on the left side of the Regulator board is a parallel bus
connection port that provides a means of attaching optional boards such as the DeviceNet board, the
RMI board, or the AutoMax Network Communication board to the GV3000 drive. See figures 2.8
and 2.9. The option board is mounted below the Regulator board inside the drive. Refer to the
appropriate board instruction manual for more information. Refer to section 2.7 of this manual for
more information on optional drive kits.
2.7.5 Operator Interface Module Connector
Flatribbon connector J7 provides a means of attaching the optional Operator Interface module
(OIM). The OIM is available for use as a remote keypad for the GV3000.
2.7.6 Keypad/Display
The front panel keypad/display is used to program and operate the GV3000 drive. See figure 2.13.
Refer to instruction manual D23339 for more information.
1. Applies power to the motor if the
keypad is selected as the control source.
1. Stops the drive.
2. Resets faults.
1. When this LED is on, parameters cannot be modified
from the keypad without entering the correct password
into P.051 (Programming Disable).
Figure 2.13 Keypad/Display
215
2.8
Drive Kit Options
Table 2.2 provides a listing of the available GV3000 kit options.
Table 2.2 Available Kits and Options
Kit Description
Snubber Resistor Braking
Low Energy Snubber Braking
Resistor(1)(2)
Snubber Transistor Only(1)(2)(3)
Line Regeneration Unit(1)(2)(3)
Motor Encoder Cable(1)(2)(3)(4)
AutoMax Network Communication
Board w/10 Feet of Cable(1)(2)(3)(4)
Remote Meter Interface (RMI)
DeviceNet Board
Operator Interface Module (OIM)
Control and Configuration Software
(CS3000)
Option Kit Model Number
2SR40400(1)
2SR40600(2)
2SR41200(2)
2SR41800(3)
2DB4010
2DB4020
2ST40027
1RG42008
1RG42015
1RG42045
2TC3025(5)
2TC3075(5)
2TC4025(5)
2TC4075(5)
2TC4100(6)
2TC4300(6)
Instruction Manual
D23179
D23291
N/A
D23305
2AX3000
D23308
2SI3000
2DV3000
2RK3000
D23341
HEHGV3DN
D23342
2CS3000
D23348
(1) 15 HP GV3000 Drives
(2) 7.510 HP GV3000 Drives
(3) 1560 HP GV3000 Drives
(4) 60150 HP GV3000 Drives
(5) For use with Reliance NEMA Vector Inverter Duty Motors (tachometer connector and exposed wire pairs).
(6) For use with Reliance NEMA Vector Inverter Duty Motors (exposed wire pairs on both ends).
216
D23291
3.0 PLANNING BEFORE INSTALLING
This chapter provides information that must be considered when planning a GV3000 drive
installation. Installation site requirements, drive requirements, and wiring requirements are presented.
DANGER
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.
DANGER
THE USER IS RESPONSIBLE FOR CONFORMING WITH ALL APPLICABLE LOCAL, NATIONAL, AND
INTERNATIONAL CODES. WIRING PRACTICES, GROUNDING, DISCONNECTS, AND
OVERCURRENT PROTECTION ARE OF PARTICULAR IMPORTANCE. FAILURE TO OBSERVE THIS
PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE.
CAUTION: 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.
3.1
Requirements for the Installation Site
It is important to properly plan before installing a GV3000 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:
D Verify that NEMA 1 drives can be kept clean, cool, and dry.
D The area chosen should allow the space required for proper air flow as defined in section 3.1.2.
D Be sure that NEMA 1 drives are away from oil, coolants, or other airborne contaminants.
D Do not install the drive above 1000 meters (3300 feet) without derating output power. For every
91.4 meters (300 feet) above 3300 feet, derate the output current 1%.
D Verify that the drive location will meet the environmental conditions specified in table 3.1.
Table 3.1 Ambient Conditions
Condition
Operating Temperature (Ambient)
Storage Temperature (Ambient)
Humidity
Specification
0r to +40r C (32r to 104rF)
-40rto +65rC (-40r to +149rF)
5 to 95% (noncondensing)
31
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 GV3000 drives.
Table 3.2 Drive Dimensions and Weights
32
GV3000 Drive
1V4150
1V4450
2V4150
2V4450
3V4150
3V4450
5V4150
5V4450
7V4150
7V4250
10V4150
10V4250
15V4150
15V4250
20V4150
20V4250
25G4150
25G4250
Dim. A
222.3 mm
8.75"
Dim. B
280.7 mm
11.05"
Dim. C
198.1 mm
7.80"
Dim D.
254.3 mm
10.01"
Dim. E
200.0 mm
7.87"
Weight
6.3 kg
14 lbs
280.6 mm
11.05"
11.05
338.4 mm
13.32"
13.32
248.0 mm
9.76"
9.76
309.1 mm
12.17"
12.17
200.0 mm
7.87"
7.87
9 kg
20 lbs
288.0 mm
11.34"
463.0 mm
18.23"
223.0 mm
8.78"
442.0 mm
17.40"
238.1 mm
9.37"
15.75 kg
35 lbs
25V4150
25V4250
30V4150
30V4250
40V4150
40V4250
50V4150
50V4250
60G4150
60G4250
50R4150
75R4150
125R4150
376.0 mm
14.80"
605.0 mm
23.82"
308.0 mm
12.13"
565.2 mm
22.25"
350.0 mm
13.78"
23.6 kg
52 lbs
376.0 mm
14.80"
605.0 mm
23.82"
308.0 mm
12.13"
565.2 mm
22.25"
350.0 mm
13.78"
25.8 kg
57 lbs
421.0 mm
16.60"
465.0 mm
18.30"
880.0 mm
34.65"
1457 mm
57.36"
360.0 mm
14.17"
330.0 mm
12.99"
850.0 mm
33.46"
1414 mm
55.66"
322.0 mm
12.68"
355.0 mm
13.97"
70 kg
154 lbs
96 kg
211 lbs
1-60 HP
60-150 HP
Figure 3.1 Drive Dimensions
33
3.1.3 Verifying the Site Provides for Recommended Air Flow Clearances
Be sure there is adequate clearance for air ventilation around the drive. For best air movement, do
not mount GV3000 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. Refer to figure 3.2 for
recommended air flow clearances.
1-60 HP
60-150 HP
*If adjacent to other drives.
Figure 3.2 Recommended Air Flow Clearances
34
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 GV3000 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, speed feedback (for vector regulation), and Estop 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, NEC/CEC regulations, and
applicable local codes.
DANGER
THE USER IS RESPONSIBLE FOR CONFORMING WITH ALL APPLICABLE LOCAL, NATIONAL, AND
INTERNATIONAL CODES. WIRING PRACTICES, GROUNDING, DISCONNECTS, AND
OVERCURRENT PROTECTION ARE OF PARTICULAR IMPORTANCE. FAILURE TO OBSERVE THIS
PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE.
3.2.2.1 Conduit Entry Opening Sizes
It is important to accurately 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 4.1
through 4.6.
3.2.2.2 Recommended Power Wire Sizes
Input power wiring should be sized according to applicable codes to handle the drive's
continuousrated input current. Output wiring should be sized according to applicable codes to
handle the drive's continuousrated output current. See tables 3.3 through 3.7 for recommended
power wire sizes.
Table 3.3 Recommended Power Wire Sizes for 110 HP Drives
Type of Wiring
AC Input Power
Output Power
DC Input Power
Terminals
R/L1, S/L2, T/L3
U/T1, V/T2, W/T3
+, -
Size of Wire (Maximum)
12 AWG, 3 (mm2)
Table 3.4 Recommended Power Wire Sizes for 1525 HP Drives
Type of Wiring
AC Input Power
Output Power
DC Input Power
Terminals
R/L1, S/L2, T/L3
U/T1, V/T2, W/T3
+, -
Size of Wire (Maximum)
6 AWG, 13 (mm2)
35
Table 3.5 Recommended Power Wire Sizes for 2560 HP Drives
Type of Wiring
AC
A
C Input Power
Output Power
DC Input Power
Terminals
R/L1 S/L2,
R/L1,
S/L2 TL3
Size of Wire (Maximum)
U/T1, V/T2, W/T3
+, -
2/0
/ AWG ((2X),
), 185 ((mm2)
Table 3.6 Recommended Power Wire Sizes for 60100 HP Drives
Type of Wiring
Terminals
A C Input Power
AC
1L1, 1L2, 1L3
2L1, 2L2
U, V, W
PE
45, 47
Output Power
AC Ground
DC Input Power
Size of Wire (Maximum)
4/0 AWG, 95 (mm2)
2 AWG, 35 (mm2)
4/0 AWG, 95 (mm2)
6 AWG, 16 (mm2)
DC Ground
Table 3.7 Recommended Power Wire Sizes for 100150 HP Drives
Type of Wiring
Terminals
A C Input Power
AC
1L1, 1L2, IL3
2L1, 2L2
U, V, W
PE
45, 47
Output Power
AC Ground
DC Input Power
Size of Wire (Maximum)
2/0 AWG (2X), 185 (mm2)
4/0 AWG, 95 (mm2)
2 AWG, 35 (mm2)
6 AWG, 16 (mm2)
DC Ground
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 3.8. Recommend terminal tightening torque is 0.5 Newtonmeters (4.5 inlbs).
Table 3.8 Recommended Terminal Strip Wire Sizes
Terminals
1 to 31
Wire Size
20 to 14 AWG, 2 to 0.5 (mm2)
3.2.2.4 Recommended Motor Lead Lengths
The following motor lead lengths are recommended to reduce line disturbances and noise. See
figure 3.3.
For applications using one motor, motor lead length should not exceed 76 meters (250 feet).
For applications with multiple motors, total motor lead length should not exceed 76 meters
(250 feet).
When total lead length exceeds 76 meters (250 feet), nuisance trips can occur. These trips are
caused by capacitive current flow to ground. Note that these capacitivelycoupled currents should be
taken into consideration when working in areas where drives are running. If the motor lead length
must exceed these limits, output line reactors or other steps must be taken to correct the problem.
Note that drives set up for vector regulation can only be connected to one motor at a time.
36
GV3000
Drive
38 m (125')
GV3000
Drive
15 m (50')
38 m (125')
60 m (200')
60 m (200')
Motor
Motor
GV3000
Drive
Motor
8 m (25')
Motor
Motor
8 m (25')
Motor
GV3000
Drive
76 m (250')
Motor
Figure 3.3 Single and Multiple Motor Lead Lengths
3.2.2.5 Recommended Serial Communication Cable Lengths
Connector J8 on the Regulator boards is an RS232 serial communication port. This connector
allows the GV3000 drive to communicate with external devices such as a personal computer using
RS232 protocol. See table A.5. Two RS232 cables are available from Reliance: a 3.5 meter (12 feet)
Dshell 9pin to 9pin cable (M/N 6151841A) and a 0.3 meter (1 foot) Dshell 9pin to 25pin adaptor
cable (M/N 6151842A). Userconstructed cables can be up to 15 meters (50 feet) in length. Note that
for communication between a GV3000 drive and a personal computer, the Control and Configuration
software must also be used. Refer to instruction manual D23348 for more information.
The Regulator boards have one set of RS232 transmit/receive lines. These lines can be accessed by
only one device at a time: connector J8, the RS232 terminals (13) on the terminal strip, or an
Operator Interface module (OIM).
3.2.3 Selecting Input Line Branch Circuit Fuses
CAUTION: The NEC/CEC requires that upstream branch circuit protection be provided to protect input pow
er 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 figures
5.1 and 5.2. Recommended fuse values are shown in table 3.9. The input fuse ratings listed in table
3.9 are applicable for one drive per branch circuit. No other load may be applied to that fused circuit.
37
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Table 3.9 AC Input Line Fuse Selection Values
Model Number
1V4150
1V4450
2V4150
2V4450
3V4150
3V4450
5V4150
5V4450
7V4150
7V4250
10V4150
10V4250
15V4150
15V4250
20V4150
20V4250
25G4150
25G4250
25V4150
25V4250
30V4150
30V4250
40V4150
40V4250
50V4150
50V4250
50R4150
60G4150
60G4250
75R4150
125R4150
Horsepower Rating
1
Input Voltage
380460 VAC
Fuse Rating*
6A
2
380460 VAC
8A
3
380460 VAC
12A
5
380460 VAC
20A
7.5
380460 VAC
25A
10
380460 VAC
35A
15
380460 VAC
45A
20
380460 VAC
60A
25
380460 VAC
70A
25
380460 VAC
70A
30
380460 VAC
100A
40
380460 VAC
100A
50
380460 VAC
125A
Vector 50
V/Hz 75
60
380460 VAC
125A
380460 VAC
150A
Vector 6075
V/Hz 100
Vector 100125
V/Hz 125150
380460 VAC
125A
150A
250A
380460 VAC
*Recommended fuse type: UL Class J, 600V, time delay, or equivalent.
3.2.4 Meeting Pulse Tachometer Specifications (Vector Regulation Only)
GV3000 drives set up for vector regulation require a pulse tachometer for closed loop operation.
Pulse tachometer specifications are provided in table A.6. Drives set up for volts/hertz regulation do
not require a pulse tachometer for feedback because they operate in the open loop mode.
3.2.5 Verifying Power Module Output Current Rating is Greater Than Motor Full Load
Amps
Verify that the GV3000 output current rating is greater than the motor's full load current (amps).
Table 2.1 lists the output current values.
38
4.0 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 conduit entry
areas where wiring is to be routed in and out of the drive.
4.1
Mounting the Drive
Attach the drive to the vertical surface selected using the four (4) mounting holes provided. In order
to maintain a flat mounting surface and to ensure that bolt tightness is maintained, use washers
under the bolt heads. Refer to figure 3.2 and table 3.2 for drive mounting dimensions. Use the
following usersupplied mounting bolts and washers:
D 15HP drives: M6 (1/4"20 )
D 7.510HP drives: M8 (5/16"18 )
D 1560HP drives: M8 or M10 (3/8"16 )
D 60150HP drives: M8 (3/8" 16)
4.1.1 Verifying the Drive's Watts Loss Rating
When mounting the drive inside of another enclosure, you should examine the watts loss rating of the
drive as shown in table 2.1. This table lists the typical full load power loss watts value under all
operating carrier frequencies. Ensure adequate ventilation is provided based on the drive's watts loss
rating.
4.2
Routing Input, Motor Output, Ground, and Control Wiring for the
Drive
All wiring should be installed in conformance with the NEC/CEC and applicable local codes. 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 chaffing. Figures 4.1 through 4.6 show the wire routing,
grounding terminal, and power terminal strips of the GV3000 drives.
CAUTION: 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.
Note that in applications using GV3000 drives (75 HP and above), induced electrical noise may result
when the motor output leads from two or more drives are run together in the same conduit. It is
recommended that separate conduit be run from each drive to the motor it is operating.
41
Bottom View
Figure 4.1 Wire Routing Locations for 15 HP Drives
42
Bottom View
Figure 4.2 Wire Routing Locations for 7.510 HP Drives
43
Bottom View
Figure 4.3 Wire Routing Locations for 1525 HP Drives
44
Bottom View
Figure 4.4 Wire Routing Locations for 2560 HP Drives
45
Motor
Leads
AC
Input
Signals
DC Input
Terminals
and Ground
13/4"
45 47
View From Bottom
GND
(PE1)
IL1 IL2 IL3
GND
U
V W
AC Input Terminals
and Ground
AC Output Terminals
and Ground
Figure 4.5 Wire Routing Locations for 60100 HP Drives
46
DC Input
Terminals
and Ground
View From Top
AC Input
IL1
IL2
IL3
45 47
AC Input
Terminals
and Ground
11/2"
AC
Inputs
Ground
View From Bottom
7/8"
11/2"
Output
Ground
Terminals
U
V
Signals
W
AC Output
Terminals
and Ground
Figure 4.6 Wire Routing Locations for 100150 HP Drives
47
4.3
Grounding the Drive
DANGER
THE USER IS RESPONSIBLE FOR CONFORMING WITH ALL APPLICABLE LOCAL, NATIONAL, AND
INTERNATIONAL CODES. WIRING PRACTICES, GROUNDING, DISCONNECTS, AND
OVERCURRENT PROTECTION ARE OF PARTICULAR IMPORTANCE. FAILURE TO OBSERVE THIS
PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE.
Use the following steps to ground the drive:
Step 1.
Remove the drive's cover.
Step 2.
Run a suitable equipment grounding conductor unbroken from the drive's ground terminal
to the motor's ground terminal and then to earth ground. See figures 4.1 to 4.6, 5.1, and
5.2.
Step 3.
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.
Note that to conform with CSA requirements, when adding more than one grounding
conductor wire to a single chassis ground, twist the conductors together.
Step 4.
48
Reattach the drive's cover.
5.0 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:
D Damaging line voltage transients from reaching the drive.
D Line noise from the drive back to the incoming power source.
D Damaging currents that could develop if a point inside the drive becomes grounded.
Observe the following guidelines when installing an isolation transformer:
D A power disconnecting device must be installed between the power line and the primary of the
transformer.
D If the power disconnecting device is a circuit breaker, the circuit breaker trip rating must be
coordinated with the inrush current (10 to 12 times full load current) of the transformer.
D 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.
CAUTION: Distribution system capacity above the maximum recommended system KVA (1000 KVA for
460 VAC) requires the use of an isolation transformer, a line reactor, or other means of adding similar imped
ance to the drive power input. Failure to observe these precautions could result in damage to or destruction
of the equipment.
CAUTION: When the AC line is shared directly with other SCRrectified 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.
5.2
Installing Fuses for Branch Circuit Protection
Install the required, usersupplied branch circuit protection fuses according to NEC/CEC guidelines.
The fuses must be installed in the line before the drive input terminals. See figures 5.1 and 5.2. Fuse
value selections are provided in table 3.9.
WARNING
THE NEC/CEC REQUIRES 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.
51
3Phase AC
Input Voltage 460 V
181
182
183 GND
Manual
Disconnect
Fuse
UserSupplied
R
S
T
1L1
1L2
1L3
~ -
U
UserSupplied
Motor Overload Relay
(Optional if Electronic
Overload is Used)
~
V
u
Ũ
W
u
Ũ
GND
(PE)
GV 3000
Power Module
GND
u
Ũ
M
Figure 5.1 Typical AC Input Electrical Connections
52
DC Input
Voltage 620V Nominal
Manual
Disconnect
Fuse
UserSupplied
R
S
T
1L1
1L2
1L3
~ -
GND
(PE)
47
45
U
UserSupplied
Motor Overload Relay
(Optional if Electronic
Overload is Used)
~
V
u
Ũ
W
u
Ũ
GV 3000
Power Module
GND
u
Ũ
M
Figure 5.2 Typical DC Bus Electrical Connections
53
5.3
Installing a Required External/Separate Input Disconnect
An input disconnect must be installed in the line before the drive input terminals in accordance with
NEC/CEC guidelines. The disconnect should be sized according to the inrush current as well as any
additional loads the disconnect might supply. Note that the trip rating for the inrush current (1012
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
through 4.6. Tables 3.3 through 3.7 contain the recommended power wiring sizes.
On 15 HP drives, route the power leads through the bottom right opening of the drive base.
On 7.525 HP drives, route the power leads through the bottom middleright opening of the
drive base. If the snubber resistor braking option is used, route the power leads through the
bottom right opening.
On 2560 HP drives, route the power leads through top right or bottom right openings of the
drive base.
On 60100 HP drives, route the power leads through the bottom left opening of the cover.
On 100150 HP drives, route the power leads through the top left opening of the cover.
CAUTION: 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 threephase AC input power leads (threewire 380460 VAC) to the proper
terminals according to drive type.
On 160 HP drives, connect the AC input power leads to terminals R/L1, S/L2, T/L3 on the
power terminal strip.
On 60150 HP drives, connect the AC input power leads to terminals 1L1, 1L2, and 1L3.
Step 3.
Tighten the AC input power terminals to the proper torque as shown in table 5.1.
Table 5.1 Terminal Tightening Torques
Drive
125HP
Terminals
All
Maximum Tightening Torque
1.08 Newtonmeters (9.5 inlbs)
25 60HP
2560HP
All
1L1, 1L2, 1L3
U V,
U,
V W
45,47
PE,
13 5 Newtonmeters
N t
t
(120 iinlbs)
lb )
13.5
1L1, 1L2, 1L3, PE
U, V, W
, 45, 47
10 Newtonmeters (88.5 inlbs)
60100HP
100150HP
54
10 Newton
Newtonmeters
meters (88
(88.5
5 in
inlbs)
lbs)
2.5 Newtonmeters (22.1 inlbs)
2.5 Newtonmeters (22.1 inlbs)
5.5
Installing Power Wiring from an External DC Bus to the Drive's
Internal DC Bus Terminals
Use the following steps to connect DC input power to the drive:
Step 1.
Wire the DC input power leads by routing them according to drive type. Refer to figures 4.1
through 4.6. Tables 3.3 through 3.7 contain the recommended power wiring sizes.
On 15 HP drives, route the power leads through the bottom right opening of the drive base.
On 7.525 HP drives, route the power leads through the bottom middleright opening of the
drive base. If the snubberresistor braking option is used, route the power leads through the
bottom right opening.
On 2560 HP drives, route the power leads through the top right or bottom right openings of
the drive base.
On 60100 HP drives, route the power leads through the bottom left opening of the cover.
On 100150 HP drives, route the power leads through the top left opening of the cover.
CAUTION: Do not route signal and control wiring in the same conduit with power wiring. This can cause
interference with drive operation. Failure to observe this precaution could result in damage to or destruction
of the equipment.
CAUTION: If the GV3000 drive is connected to an external DC bus, the user is responsible for DC bus
shortcircuit protection. Failure to observe this precaution could result in damage to or destruction of the
equipment.
Step 2.
Connect the DC input power leads (twowire 620 VDC nominal) to the proper terminals
according to drive type.
On 160 HP drives, connect the DC input power leads to terminals + and - on the power
terminal strip.
On 60150 HP drives, connect the DC input power leads to terminals 45 and 47.
Note that the maximum discharge rate of the DC bus supply should be 200V/second.
Step 3.
Tighten the DC input power terminals to the proper torque as shown in table 5.1.
Step 4.
On 60150 HP drives using volts/hertz regulation, set parameter H.017 to a value greater
than one to enable DC bus operation. Refer to the GV3000 Programming instruction
manual (D23339) for additional information.
55
6.0 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, the NEC requires that a motor thermostat, internal to
the motor, be installed or 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 the electronic 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 AĆC motors under all conditions. Parameter
P.040 must be enabled to provide overload protection. Refer to the GV3000 Programming Manual
(D2Ć3339) for more information.
In multiple motor applications (volts/hertz regulation only), each motor must have its own
userĆsupplied overload protection.
6.3
Installing Output Wiring from the Drive Output Terminals to the
Motor
Use the following steps to connect the AĆC output power wiring from the drive to the motor:
Step 1.
Wire the threeĆphase AĆC output power motor leads by routing them according to drive
type. Refer to figures 4.1 to 4.6. Tables 3.3 to 3.7 contain the recommended power wiring
sizes.
On 1Ć5 HP drives, route the motor leads through the bottom right opening of the drive base.
On 7.5Ć25 HP drives, route the motor leads through the bottom right opening of the drive
base.
On 25Ć60 HP drives, route the motor leads through the middle bottom opening of the drive
base.
On 60Ć100 HP drives, route the motor leads through the bottom right opening of the cover.
On 100Ć150 HP drives, route the motor leads through the three leftĆmost bottom openings
of the cover. Route the ground wire through the opening to the right of the motor leads.
CAUTION: 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.
Note that in applications using GV3000 drives (75 HP and above), induced electrical noise
may result when the motor output leads from two or more drives are run together in the
same conduit. It is recommended that separate conduit be run from each drive to the motor
it is operating.
6Ć1
Step 2.
Connect the threeĆphase AĆC output power motor leads to the proper output terminals
according to drive type.
On 1Ć60 HP drives, connect the motor leads to terminals U/T1, V/T2, W/T3 on the power
terminal strip.
On 60Ć150 HP drives, connect the motor leads to terminals U, V, and W.
Step 3.
6Ć2
Tighten the threeĆphase AĆC output power terminals to the proper torque according to drive
type as shown in table 5.1.
7.0 WIRING THE REGULATOR BOARD TERMINAL
STRIP
This chapter describes how to wire the Regulator board terminal strip for stop, speed feedback, and
remote control signals.
The terminal strip has the following signals available, as shown in figures 7.1 and 7.2. Table 7.1
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 instruction
manual D23339 for more information on how parameter P.000 is used to specify where the drive is
controlled from.
RS232 Connections (Terminals 13)
D Terminal 1: Transmit (Tx)
D Terminal 2: Receive (Rx)
D Terminal 3: Regulator Common
The RS232 terminals should only be used when the RS232 communication port (J8) or an Operator
Interface module (OIM) is not being used, as all three devices use the same transmit/receive lines.
Pulse Tachometer Connections (Terminals 49)
D Terminal 4: +15 VDC
D Terminal 5: Phase A
D Terminal 6: Phase A Not
D Terminal 7: Phase B
D Terminal 8: Phase B Not
D Terminal 9: Regulator Common
A speed feedback device (pulse tachometer) must be installed if vector regulation (P.048=1) is used.
Analog Output Connections (Terminals 10 and 11)
D Terminal 10: Analog Meter Output
D Terminal 11: Regulator Common
The output of this terminal is either 010 VDC or 420 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.
Analog Speed/Torque Reference Connections (Terminals 1215)
D Terminal 12: Isolated Reference Voltage
D Terminal 13: VDC Speed/Torque Reference
D Terminal 14: mA Speed/Torque Reference
D Terminal 15: Isolated Reference Ground
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 must also be programmed
via parameters P.009, P.010, and P.011.
71
Digital Input Connections (Terminals 1625)
D Terminal 16: +24 VDC (Current Limited) (For remote control digital inputs only)
D Terminal 17: Digital Input 8 (Remote/Local) Programmable
D Terminal 18: Digital Input 7 (Ramp1/Ramp2) Programmable
D Terminal 19: Digital Input 6 (Forward/Reverse) Programmable
D Terminal 20: Function Loss
D Terminal 21: Run/Jog
D Terminal 22: Reset
D Terminal 23: Stop
D Terminal 24: Start
D Terminal 25: +24 VDC Common
When a userinstalled function loss input, a coasttostop pushbutton, or another external interlock is
installed, the factorinstalled jumper connecting terminals 16 and 20 (or 16A and 20A) must be
removed so that a contact will open to 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 Programming Manual (D23339) for more information.
Snubber Resistor Braking Connections (Terminals 26 and 27)
D Terminal 26: Snubber Resistor Braking Signal (125HP Drives only)
D Terminal 27: +24 VDC Common
Status Relay Connections (Terminals 2831)
D Terminal 28: N.C Relay Contact
D Terminal 29: N.C. Relay Common
D Terminal 30: N.O. Relay Contact
D Terminal 31: N.O. Relay Common
Relay contact closure is programmable through parameter P.013. Refer to the GV3000 Programming
Manual (D23339) for more information.
72
DIGITAL INPUT 7 (RAMP1/RAMP 2)
DIGITAL INPUT 6 (FORWARD/REVERSE)
DIGITAL INPUT 8 (REMOTE/LOCAL)
PHASE B NOT
PHASE B
Remote 4-20 mA
Speed/Torque
Reference
*FOR 15-60 HP DRIVES, USE 16A INSTEAD OF 16 AND 20A INSTEAD OF 20. ALSO SEE FIGURE 2.12.
Figure 7.1 TwoWire Start/Stop Sample Control Wiring
73
DIGITAL INPUT 6 (FORWARD/REVERSE)
DIGITAL INPUT 7 (RAMP1/RAMP 2)
DIGITAL INPUT 8 (REMOTE/LOCAL)
PHASE B NOT
Remote 4-20 mA
Speed/Torque
Reference
*FOR 15-60 HP DRIVES, USE 16A INSTEAD OF 16 AND 20A INSTEAD OF 20. ALSO SEE FIGURE 2.12.
Figure 7.2 ThreeWire Start/Stop Sample Control Wiring
74
7.1
Stopping the Drive
WARNING
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 drive can be programmed to
provide either a coasttorest or a ramptorest operational stop without physical separation of the
power source from the motor. A coasttorest stop turns off the transistor power device drivers. A
ramptorest 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.
7.1.1 Compliance with EN 602041: 1992
This section applies to users who must comply with EN 602041: 1992, part 9.2.5.4, Emergency
Stop.
The GV3000 drive coasttorest stop is a category 0 operational stop. The ramptorest 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.
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 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
C for more information.
7.2
Wiring the Speed Feedback Device (Vector Regulation Only)
If the GV3000 drive is programmed to provide vector regulation, a speed feedback device (pulse
tachometer) must be installed. Drives using volts/hertz regulation do not require the use of a speed
feedback device. The pulse tachometer connects to terminals 4 to 9 of the terminal strip:
D Terminal 4: Pulse Tachometer Supply +15 VDC
D Terminal 5: Pulse Tachometer Phase A Differential Input
D Terminal 6: Pulse Tachometer Phase A Not Differential Input
D Terminal 7: Pulse Tachometer Phase B Differential Input
D Terminal 8: Pulse Tachometer Phase B Not Differential Input
D Terminal 9: Pulse Tachometer/Regulator Common
Use the following procedure to connect a pulse tachometer to the terminal strip:
Step 1.
Connect the pulse tachometer's wires to terminals 4 through 9 of the terminal strip. See
figure 7.3. See table A.6 for additional pulse tachometer specifications.
75
Figure 7.3 Wiring Connections for the Speed Feedback Device
Step 2.
Set the following parameters to establish the maximum motor speed:
D P.004: Maximum Speed
D U.001: Pulse Tach PPR
D U.002: Motor Poles
D U.003: Motor Nameplate Base Frequency
D U.005: Motor Nameplate RPM
D U.017: Motor Top Speed
Refer to the GV3000 Programming Manual (D23339) for more information.
76
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 table 7.1.
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Table 7.1 Wiring Signal and Control I/O to the Terminal Strip
Terminal
Number
1
2
3
Description
RS232 Transmit
RS232 Receive
RS232 Signal/Regulator
Common
Parameters/Wiring Connections
Wiring RS232 Signals
Note that RS232 communication between the GV3000
drive and a personal computer requires the use of the
Control and Configuration software. Refer to instruction
manual D23348 for more information.
These terminals should only be used when the RS232 port
(J8) or an Operator Interface module (OIM) are not being
used, as all three devices use the same transmit/receive
lines.
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ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
49
Wiring Pulse Tachometer Inputs
Pulse Tachometer Wiring
See section 7.2.
77
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ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Table 7.1 Wiring Signal and Control I/O to the Terminal Strip (Continued)
10
11
Wiring Analog Outputs
010 VDC or 420 mA
The setting of parameter P.012 selects the terminal strip
Analog Output Reference
analog output source (either speed or torque). Jumper J17
must also be set. See figure 2.11. The 420mA current
Regulator Common
selection requires a power supply for operation. The power
can be sourced from the pulse tachometer supply, terminal
4 (15VDC), or from an external 15V power supply. Note that
the maximum supply current from terminal 4 is 250mA
(pulse tachometer and current source) at 15V. Terminals 9
and 11 are internally connected.
Terminal
Strip
Load
(Meter or Analog Input)
+
+
+
Connection to the negative side of the
power supply is only required
when an external 15V power supply is used.
78
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ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
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ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Table 7.1 Wiring Signal and Control I/O to the Terminal Strip (Continued)
Terminal
Number
12
13
14
15
Description
Parameters/Wiring Connections
Wiring Analog Speed Reference Inputs
Isolated Reference
The following parameters must be set:
Voltage (+15VDC)
P.000: Control Source
Analog Speed/Torque
Reference Input Voltage
P.009: Terminal Strip Analog Input Offset
(+/- 10 VDC)
P.010: Terminal Strip Analog Input Gain
Analog Speed/Torque
P.011: Terminal Strip Analog Input Invert
Reference Input Current
(020mA)
Refer to the GV3000 Programming instruction manual
Isolated Speed/Torque
(D23339) for additional parameter information.
Reference Common
(Voltage/Current)
Jumper J4 must also be set. See figure 2.10.
79
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ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Table 7.1 Wiring Signal and Control I/O to the Terminal Strip (Continued)
Terminal
Number
16
17
Description
Parameters/Wiring Connections
Wiring a Remote/Local Input
+24 VDC Power Supply
Current limited for remote input logic use only.
Digital Input 8
Digital input 8 is control function programmable through
(Default Remote/Local)
parameter P.007.
WARNING
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 18
Refer to the GV3000 Programming instruction manual
(D23339) for additional information.
Terminal 17 On = Local Control
Diagram shows factory setting.
710
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Table 7.1 Wiring Signal and Control I/O to the Terminal Strip (Continued)
Terminal
Number
18
Description
Parameters/Wiring Connections
Wiring an Additional Ramp Input
Digital Input 7
Digital input 7 is control function programmable through
(Default Ramp1/Ramp2)
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 18
Refer to the GV3000 Programming instruction manual
(D23339) for additional information.
Terminal 18 On = Ramp 2
Diagram shows factory setting.
711
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Table 7.1 Wiring Signal and Control I/O to the Terminal Strip (Continued)
Terminal
Number
19
Description
Parameters/Wiring Connections
Wiring a Forward/Reverse Input
Digital Input 6
Digital input 6 is control function programmable through
(Default Forward/Reverse) 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: Reverse Disable
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 18
Refer to the GV3000 Programming instruction manual
(D23339) for additional information.
Terminal 19 On = Reverse Direction
Diagram shows factory setting. From the pulse tachometer
end of the motor, clockwise rotation indicates forward mo
tor movement.
712
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Table 7.1 Wiring Signal and Control I/O to the Terminal Strip (Continued)
Terminal
Description
Parameters/Wiring Connections
Number
Wiring a Function Loss Input
20
Digital Input 5
The following parameters must be set:
(Function Loss)
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. See figure 2.12.
(or from 16A and 20A on 15-60HP drives)
Terminal 20 On = No Function Loss
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21
Digital Input 4
(Run/Jog)
Wiring a Run/Jog Input
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
713
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ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
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ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Table 7.1 Wiring Signal and Control I/O to the Terminal Strip (Continued)
Terminal
Number
22
Description
Digital Input 3
(Reset)
Parameters/Wiring Connections
Wiring the Reset Input
The following parameter must be set:
P.000: Control Source
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ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Terminal 22 On = Reset
23
24
Digital Input 2
(Stop)
Digital Input 1
(Start)
Wiring the Stop/Start Inputs
The following parameter must be set:
P.000: Control Source
P.025: Stop Type
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ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
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ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
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ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Terminal 23 Off = Stop
Terminal 24 On Transition = Start
25
26
27
714
24 VDC Isolated Common
Wiring the Snubber Resistor
Snubber Resistor Braking
Used with Snubber Resistor Braking Kit M/N 2DB4010.
Control Signal
Refer to the kit's instruction manual for installation
instructions.
+24 VDC Isolated Common
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ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ
Table 7.1 Wiring Signal and Control I/O to the Terminal Strip (Continued)
Terminal
Number
28
29
30
31
Description
Parameters/Wiring Connections
Wiring the Output Status Relays
NormallyClosed Contact
Both Form A and Form B contacts are rated for
(Form B)
250 VAC/30 VDC at 5 amps resistive or 2 amps inductive
load.
NormallyClosed Contact
Common (Form B)
The following parameter must be set:
NormallyOpen Contact
(Form A)
P.013: Output Relay Configuration
NormallyOpen Contact
Common (Form A)
Note that depending on the setting of parameter P.013, the
relay coil will energize (the normallyopen contact will close
and the normallyclosed contact will open). Refer to the
GV3000 Programming instruction manual (D23339) for
more information.
28 29 30 31
715
8.0 COMPLETING THE INSTALLATION
This chapter provides instructions on how to perform a final check of the installation before power is
applied to the drive.
DANGER
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.
8.1
Checking the Installation
Use the following procedure to verify the condition of the installation:
DANGER
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 9.3.
Step 3.
If a function loss coaststop pushbutton has been installed, verify that it has been wired
correctly. Be sure the factoryinstalled jumper at terminals 16 and 20 (or 16A and 20A) has
been removed so that the coaststop pushbutton will work.
WARNING
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 the wiring to the terminal strip and the power terminals is correct.
Step 7.
Check that the wire size is within terminal specification and that the wires are tightened
properly.
Step 8.
Check that usersupplied branch circuit protection is installed and correctly rated.
Step 9.
Check that the incoming power is rated correctly.
Step 10. Check the motor installation and length of motor leads.
Step 11. Disconnect any power correction capacitors connected between the drive and the motor.
Step 12. Check that the rating of the transformer (if used) matches the drive requirements and is
connected properly.
81
Step 13. Verify that a properlysized 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 14. Uncouple the motor from any driven machinery to initially start the drive.
8.2
Installing the Cover for NEMA 4X/12 Drives
In order to maintain the integrity of the NEMA 4X/12 enclosures, care must be taken when
reinstalling the covers. Use the following steps to reinstall the covers:
8.3
Step 1.
Before installing the cover, check that the gaskets on the cover are flat and within the gasket
channels.
Step 2.
Position the cover and sequentially tighten the four (4) captive screws to ensure even
compression of the gaskets. Do not exceed 2.2 Nm (20 inlbs) of torque on these screws.
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:
82
Step 1.
Turn the drive's input power disconnect to the On position.
Step 2.
Apply power to the drive.
Step 3.
Follow the startup procedure in instruction manual D23339.
9.0 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.
9.1
Test Equipment Needed to Troubleshoot
An isolated multimeter will be needed to measure DC bus voltage and to make resistance checks.
9.2
Drive Alarms and Faults
The drive will display alarm and fault codes to assist in troubleshooting when a problem develops
during selftuning or drive operation.
If an alarm condition occurs, the drive will continue to run and a 2 or 3digit alarm code will flash on
the display.
If a fault occurs, the drive will coasttostop and a 2 or 3digit fault code will flash on the display.
Refer to the GV3000 Software StartUp and Reference Manual (D23339) for more information on
drive alarms and faults.
9.3
Verifying That DC Bus Capacitors are Discharged
DANGER
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 GV3000 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.
Turn off and lock out input power. Wait five minutes.
Step 2.
Remove the drive's cover.
Step 3.
Verify that there is no voltage at the drive's input power terminals.
Step 4.
Measure the DC bus potential with a voltmeter.
For 160 HP drives, measure the DC bus potential at the DC bus power terminals. See
figures 9.1 and 9.2.
For 60100HP drives, while standing on a nonconductive surface and wearing insulated
gloves (600V), remove the top two screws of the regulator panel and tilt the panel forward.
See figure 9.3. Measure the DC bus potential at the diode bridge as shown. Reattach the
regulator panel.
91
For 100150HP drives, while standing on a nonconductive surface and wearing insulated
gloves (600V), remove the top two screws of the regulator panel and tilt the panel forward.
See figure 9.4. Measure the DC bus potential at the bottom of the fuse holders on the
Power Module Interface board on the back of the regulator panel. Take care not to touch
any conductive traces. Reattach the regulator panel.
Step 5.
Once the drive has been serviced, reattach the drive's cover.
Step 6.
Reapply input power.
Figure 9.1 DC Bus Voltage Terminals (125 HP Drives)
92
Figure 9.2 DC Bus Voltage Terminals (2560 HP Drives)
93
(-)
DC Bus
Measuring Points
(+)
45 47
1L1 1L2 1L3
U
V W
Figure 9.3 DC Bus Voltage Terminals (60100 HP Drives)
94
AC Input
1L1
1L2 1L3
4547
Regulator Panel
(DC Bus Measuring Points
Behind Regulator Panel on
the Power Module Interface
Board)
Power Module Interface Board
Fuses
(-)(+)
DC Bus Measuring Points
U
V
W
Figure 9.4 DC Bus Voltage Terminals (100150 HP Drives)
95
9.4
Checking Out the Power Modules with Input Power Off
Use the following procedure to check the drive's Power Module circuitry with power off:
DANGER
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 and lock out input power. Wait five minutes.
Step 2.
Remove the drive's cover.
Step 3.
Verify that there is no voltage at the drive's input power terminals.
Step 4.
Check the DC bus potential with a voltmeter as described in section 9.3 to ensure that the
DC bus capacitors are discharged.
Step 5.
Disconnect the motor from the drive.
Step 6.
Check all AC line and DC bus fuses.
Step 7.
If a fuse is blown, use a multimeter to check the input diodes and output IGBTs. See table
9.1.
Note that 110HP drives do not have replaceable transistor modules: the entire drive must
be replaced if a transistor malfunctions. Intelligent Power Modules (IPM) may be replaced if
they fail in a 60150HP drive.
Step 8.
Reconnect the motor to the drive.
Step 9.
Reattach the drive's cover.
Step 10. Reapply input power.
Table 9.1 Resistance Checks
160HP Drives
Input
Meter
Diode
Connection
No. (+)
(-)
1
*
R/L1
2
*
S/L2
3
*
T/L3
4
R/L1
**
5
S/L2
**
6
T/L3
**
Component is OK if
resistance (R) is:
50 < R < 10 Megohm
* (+) DC Bus Volts power terminal
** (-) DC Bus Volts power terminal
96
Component is defective if:
Continuity (short circuit) or open when the meter is
connected with reversed polarity
Table 9.1 Resistance Checks (Continued)
60100HP Drives
Input
Meter
Diode
Connection
No. (+)
(-)
1
47
1L1
2
47
1L2
3
47
1L3
4
1L1
45
5
1L2
45
6
1L3
45
Component is OK if
resistance (R) is:
0.3 kohm <R< 8 kohm
Component is defective if:
Continuity
y (short
(
circuit)) or open
p when the meter is
connected
d with
i h reversed
d polarity
l i
100150HP Drives
Input
Meter
Diode
Connection
No. (+)
(-)
1
47
1L1
2
47
1L2
3
47
1L3
4
1L1
45
5
1L2
45
6
1L3
45
Component is OK if
resistance (R) is:
R> 100 kohm
Component is defective if:
Continuity
y ((short circuit))
160HP Drives
IGBT
No.
Meter
Connection
Component is OK if
(+)
(-)
resistance (R) is:
50 <R< 10 Megohm
g
1
*
W/T3
2
*
V/T2
3
*
U/T1
4
W/T3 **
5
V/T2
**
6
U/T1 **
* (+) DC Bus Volts power terminal
Component is defective if:
Continuity
y (short
(
circuit)) or open
p when the meter is
connected
d with
i h reversed
d polarity
l i
** (-) DC Bus Volts power terminal
60150HP Drives
IGBT
No.
1
2
3
4
5
6
Meter
Connection
(+)
(-)
47
W
47
V
47
U
W
45
V
45
U
45
Component is OK if
resistance (R) is:
0.3 kohm <R< 8 kohm
Component is defective if:
Continuity
circuit)) or open
y (short
(
p when the meter is
d with
i h reversed
d polarity
l i
connected
97
9.5
Replacement Parts
Tables 9.2 to 9.7 list the replacement parts that are available from Reliance Electric. See figures 2.3 to
2.8 for the location of the parts.
Table 9.2 15 HP Drive Replacement Parts
Quantity per Horsepower
Description*
Part Number
1
2
3
5
1
1
Fan Assembly
615161S
NEMA 1 Cover
8055311R
1
1
1
1
NEMA 4X/12 Cover/Gasket
8055321R
1
1
1
1
Membrane Switch Keypad/Bracket
7095761R
1
1
1
1
Regulator PCB
0569215xx
1
1
1
1
Capacitor PCB
05692830
05692850
1
1
1
05692620
05692650
1
6151591R
1
Current Feedback PCB
Internal Fan Assembly
1
1
1
1
1
1
1
* Components are identified in figure 2.3.
Table 9.3 7.510 HP Drive Replacement Parts
Quantity per Horsepower
Part Number
7.5
10
Fan Assembly
615161S
2
2
NEMA 1 Cover
8055381R
1
1
NEMA 12 Cover/Gasket
8055391R
1
1
Membrane Switch Keypad/Bracket
8055481R
1
1
Regulator PCB
0569215xx
1
1
Capacitor PCB
056934100
1
1
Current Feedback PCB
056935100
1
1
Internal Fan Assembly
6151591R
1
1
Description*
* Components are identified in figure 2.4.
98
Table 9.4 1525 HP Drive Replacement Parts
Quantity per Horsepower
Part Number
15
20
25
Fan Assembly
615161S
2
2
2
NEMA 1 Cover
8055471R
1
1
1
NEMA 12 Cover/Gasket
8055472R
1
1
1
Membrane Switch Keypad/Top Bracket
8055481R
1
1
1
Regulator PCB
0569215xx
1
1
1
Capacitor PCB
056948015
056948020
1
1
1
Power Board
056949020
1
1
1
Power Supply Board
056950015
056950020
1
1
1
056947020
1
1
1
6151591S
1
1
1
Description*
Gate Driver Board
Internal Fan Assembly
* Components are identified in figure 2.5.
99
Table 9.5 2560 HP Drive Replacement Parts
Quantity per Horsepower
Part Number
25
30
40
50
60
Fan
6973948A
2
2
2
2
2
Fan Wire Harness
6151952R
1
1
1
1
1
NEMA 1 Cover
80553411R
1
1
1
1
1
NEMA 12 Cover/Gasket
80553412R
1
1
1
1
1
Membrane Switch Keypad/
Top Bracket
8055481R
1
1
1
1
1
Regulator PCB
0569215xx
1
1
1
1
1
Input Capacitor
60044232A
60044233A
2
4
4
056949040
056949050
1
1
1
056950025
056950030
056950040
056950050
1
1
1
056947025
056947040
056947050
1
1
1
602909810AW
602909811AW
602909812AW
3
3
3
701819113BA
701819114BA
1
1
1
6151962R
1
1
1
Description*
Power PCB
Power Supply PCB
Gate Driver PCB
IGBT Module
Diode Bridge
Internal Fan Assembly
* Components are identified in figure 2.5.
910
2
2
1
1
1
1
1
3
1
1
1
3
1
1
Table 9.6 60100 HP Drive Replacement Parts
Part Number
Quantity
Regulator PCB
4133385AU
1
Power Module Interface PCB
4133385AW
1
Power Module Interface PCB Fuses
4133385AB
2
Keypad
4133385AX
1
Gate Driver PCB
4133385D
1
Bus Clamp PCB (right)
Bus Clamp PCB (left)
4133385E
4133385F
2
2
Intelligent Power Module (IPM) PCB
4133385J
3
Diode Bridge
4133385K
3
MOV on Diode Bridge
4133385L
3
DC Bus Fuse
4133385M
2
Precharge Contactor
4133385N
4
Current Transformer
4133385R
2
Ground Fault Transformer
4133385Q
1
Output Reactor
4133385S
3
Precharge Resistor (18 ohms)
4133385T
4
Bus Discharge Resistor (1.5K ohms)
4133385V
2
24V DC Fan
4133385W
2
Description*
* Components are identified in figure 2.7.
911
Table 9.7 100150 HP Drive Replacement Parts
Part Number
Quantity
Regulator PCB
4133385AU
1
Power Module Interface PCB
4133385AV
1
Power Module Interface PCB Fuses
4133385AB
2
Keypad
4133385AX
1
Gate Driver PCB
4133385AC
6
Bus Clamp PCB (right)
Bus Clamp PCB (left)
4133385AE
4133385AF
2
2
Intelligent Power Module (IPM) PCB **
4133385AH
6
Thyristor Precharge Module
4133385AJ
3
DC Bus Fuse
4133385AK
4
Current Transformer
4133385R
2
Ground Fault Transformer
4133385Q
1
Output Reactor
4133385AR
3
Bus Discharge Resistor (1.5K ohms)
4133385V
4
24V DC Fan
4133385W
4
Thyristor Firing Pulse PCB
4133385AG
1
Thyristor Firing Pulse PCB Fuses (15A)
4133381JS
3
Description *
* Components are identified in figure 2.8.
**It is recommended that the Gate Driver PCB be replace at the same time as the IPM PCB.
912
Index
A
AC input
diodes, checking, 96 to 97
disconnect, installing, 52 to 54
isolation transformer, 51
line branch circuit fuses, 37 to 38, 51 to 53
ratings, 22
wire sizes, 35 to 36
wiring, 35 to 37, 41 to 48, 51 to 55
voltage transients, avoiding, 51
AC output
wiring, 35 to 37, 41 to 48, 61 to 62
Air flow, 31, 34
Alarms, 91
Altitude requirements, 31
Ambient conditions, 31, A1
Analog output, 29
010 VDC (J17), 29 to 211, 213, A2
420 mA (J17), 29 to 211, 213, A2
wiring, 214, 71, 73 to 74, 78
Analog input speed reference
input current, wiring, 214, 71, 73 to 74, 79,
A2
input voltage, wiring, 214, 71, 73 to 74, 79,
A2
010 VDC (J4), 210 to 212, 71
420 mA (J4), 210 to 212, 71
Area required, 32 to 34
Audience, intended, 12
B
Block diagram
vector regulation, B3
volts/hertz regulation, B2
Board
Bus Clamp, 27 to 28, 911 to 912
Capacitor, 23 to 25, 98 to 99
Current Feedback, 23 to 25, 98
Gate Driver, 25 to 28, 99 to 912
Intelligent Power Module (IPM), 27 to 28, 911
to 912
Option, 215, 216
Power, 25, 26, 99, 910
Power Supply, 25, 26, 99, 912
Regulator, 23 to 214, 37, 98 to 910
Thyristor Precharge, 28, 912
Braking, snubber resistor, 29, 216, 51, A2
wiring, 214, 72 to 74, 714
Bus clamp board, 27 to 28, 911 to 912
C
Capacitor board, 23 to 25, 98 to 99
Capacitors, DC bus, 91 to 95
Carrier frequency, 29, A1
CS3000, see Control and Configuration Software
Closed loop, see Vector Regulation
Communication port (J8), 210 to 211, 215, 37,
71, 77
Communication, network, 215, 37
Component locations, 23 to 28
Conduit size, 42 to 47
Control and Configuration Software, 12, 216, 37,
77
Contacting Reliance, 12
Contactors, installing output, 61
Contacts
Form A, 29, 715
Form B, 29, 715
Control source, 71, 73 to 74, 77
PC, 37, 71, 77
wiring, 73 to 74, 77
Control, wiring, 213, 71 to 715
Current Feedback board, 23 to 25, 98
Current transformer, 27 to 28, 911 to 912
D
DC bus
input wiring, 35 to 36, 41 to 48, 53, 55
fuse, 27 to 28, 911 to 912
terminals, 91 to 95
verifying capacitor voltage, 91 to 95
Digital input wiring, 214, 72 to 74, 710 to 714
8 (remote/local), 72 to 74, 710
7 (ramp1/ramp2), 72 to 74, 711
6 (forward/reverse), 72 to 74, 712
5 (function loss), 72 to 74, 713
4 (run/jog), 72 to 74, 713
3 (reset), 72 to 74, 714
2 (stop), 72 to 74, 714
1 (start), 72 to 74, 714
Digital output wiring, see Status Relays
Dimensions, 32 to 33
Disconnect, installing AC input, 52 to 54
Display, see Keypad/Display
Distribution system capacity, AC line maximum, 51
Drive,
identifying, 21
kits, 216
Index1
E
Emergency stop, 75
EN602041 compliance, 75, C1 to C2
Enclosures, NEMA, 22, 98 to 910
Environmental conditions, 31
F
Fan, 23 to 28, 98 to 912
Faults, 91
Form A contacts, see Status Relays
Form B contacts, see Status Relays
Forward (digital input 6), 214, 72 to 74, 712
Frequency, carrier, 29, A1
Frequency, line, A1
Function loss (digital input 5), 214, 72 to 74, 712
wiring, 72 to 73, 713
Fuse
DC bus, 27 to 29, 99 to 911 to 912
AC input, 37 to 38, 51 to 52
G
Gate Driver board, 25 to 28, 99 to 912
Ground fault transformer, 27 to 28, 911 to 912
Grounding, 42 to 48, 52 to 53
Humidity, 31, A1
H
I
IGBT power devices, 29
testing, resistance checks, 96 to 97
Inductor, output, see Output Reactor
Input specifications, terminal strip, A2
Input, AC, see AC Input
Input, digital, see Digital Input Wiring
Installation
AC input disconnect, 52 to 54
checking, 81 to 82
completing, 81 to 82
fuses, AC input line branch circuit, 37 to 38,
51 to 52
input isolation transformer, 51
mechanical motor overload protection, 61
output contactors, 61
planning, 31 to 38
requirements, 31 to 38
transformers and reactors, 51
Index2
Intelligent Power Module (IPM) board, 27 to 28,
911 to 912
J
Jog (digital input 4), 214, 72 to 74, 713
Jumpers
J4, 210 to 212
J17, 210 to 211, 213
location of, 210 to 211
settings for, 212 to 213
K
Keypad/display, 23 to 28, 216
Kits
AutoMax Network Communication board, 216
DeviceNet Board 216
Line Regeneration Unit, 216
Low Energy Snubber Resistor Braking, 216
Motor Encoder Cable, 216
Operator Interface Module, 216
Remote Meter Interface, 216
Snubber Resistor Braking, 216
Snubber Transistor Only, 216
L
Lead lengths, motor, 36 to 37
LEDs, 29, 215
Line branch circuit fuses, AC input, 37 to 38, 51
to 52
Line frequency, A1
Line noise, avoiding, 51
Line Regeneration Unit kit, 216
Local (digital input 8), 214 to 216, 72 to 74, 710
Loss, function, see Function Loss
M
Maximum AC line distribution system capacity, 51,
A1
Mechanical motor overload protection, 61
Meter output, 214, 71, 78
Model numbers, 21 to 22
MOP (motor operated potentiometer), 710 to 712
Motor
Encoder Cable kit, 216
lead lengths, 36 to 37
overload protection, mechanical, 61
speed, setting maximum, 76
wiring, 61 to 62
Mounting dimensions, 32 to 33
N
NEMA enclosures, 22, 98 to 910
Network
AutoMax Network Communication board, 215,
216
communication, 215, 37
O
Open loop, see Volts/Hertz Regulation
Option kits, see Kits
Output
analog, see Analog Output
contactors, 61
digital, see Status Relays
inductor, see Output Reactor
reactor, 27 to 28, 911 to 912
specifications, terminal strip, A2
Overload, motor, 61
P
Parts
location, see Component Locations
replacement, 98 to 912
PC control, see Control Source
Planning
drive clearances, 34
location, 31
Power
board, 25, 26, 99, 910
output, wiring, 35 to 37, 41 to 48, 61 to 62
input, wiring, 35 to 36, 37 to 38, 41 to 47,
51 to 55
Power Module
checking, 96 to 97
verifying output current rating, 38
Power Supply board, 25, 26, 99, 910
Power terminals
torque specifications, 54
wiring, 35 to 37, 41 to 48, 51 to 55, 61
Precharge contactor, 27, 911
Precharge resistor, 27, 911
Protection, mechanical motor overload, 61
Publications, related, 12
Pulse tachometer
specifications, A2
wiring, 214, 71, 75 to 76
see also Speed Feedback
R
Ramp1/ramp2 (digital input 7), 214, 72 to 74,
711
Ratings
AC input, 22
fuse, 38
NEMA, 22
output, 22
power loss, 22
Regulation, drive
vector, block diagram, B3
volts/hertz, block diagram, B2
Regulator boards, 23 to 215
Relays, output status, see Status Relays
Remote (digital input 8), 214, 72 to 74, 710
Replacement parts, 98 to 912
Reset (digital input 3), 214, 72 to 74, 714
Resistor
bus discharge, location, 27 to 28
Snubber, Braking kit, see Kits
Reverse (digital input 6), 214, 72 to 74, 712
Routing, wiring, 41 to 47
RS232
cable length, 37, 77
communication port (J8), 37
specifications, A2
wiring, 215, 37, 71, 77
Run (digital input 4), 214, 72 to 74, 713
S
Selecting operation, see Control Source
Serial communication, see RS232
Site requirements, 31
Snubber resistor braking, 29, 214, 51, A2
kit, 216
low energy kit, 216
wiring, 214, 72 to 74, 714
Snubber Transistor Only kit, 216
Specifications
conduit opening sizes, 42 to 47
dimensions, 32 to 33
environmental, 31
inputs, terminal strip, A2
outputs, terminal strip, A2
speed feedback, A2
torque ratings, 54
wire sizes, 35 to 36
Index3
Speed feedback,
specifications, A2
wiring, 214, 71, 75 to 77
see also Pulse Tachometer
Speed, maximum setting, 76
Start (digital input 1), 214, 72 to 74, 714
Status relays, Form A/B, 29, 214, 72 to 74, 715
Stop (digital input 2), 214, 72 to 74, 714
Stopping the drive, 75
Switch, membrane, see Keypad/Display
T
Tachometer, pulse, see Pulse Tachometer
Terminal strip
wiring, 214, 36, 71 to 715
input specifications, A2
output specifications, A2
torque specifications, 54
wire sizes, 35 to 36
Testing, IGBT, 96 to 97
Thyristor precharge board, 28, 912
Transformer
current, 27 to 28, 911 to 912
ground fault, 27 to 28, 99 to 911
isolation input, installing, 51
Transients, AC line voltage, 51
V
Vector regulation, B1
block diagram, B3
Ventilation, see Air Flow
Volts/hertz regulation, B1
block diagram, B2
W
Watts loss rating, 22, 41
Weights, 32
Index4
Appendix A
Technical Specifications
Table A.1 Service Conditions
AC Line Distribution System Capacity (maximum)
for 460 VAC Units
1000KVA, threephase with 25,000 amps symmetrical
fault current capacity with a line impedance of less
than 8%
Control Method
Alldigital vector, sinusoidal pulsewidthmodulated
(PWM)
Displacement Power Factor
0.96
Line Frequency
50/60Hz (+2 Hz)
Line Voltage Variation
-10% to +10%
Line Dip Ride Through
Maximum 500 milliseconds vector
Adjustable up to 999.9 seconds (See P.042) V/Hz
Motor Lead Lengths
76 meters (250 feet) total
Analog Speed Reference Accuracy
0.5%
Acceleration Adjustment Range
0.1 to 999.9 seconds (within the ability of current)
Carrier Frequency
2 Hz, 4 Hz, or 8 Hz, softwareselectable
Current Limit Adjustment
U.006 to 150% (based on drive nameplate rating) vector
50% to 110% (based on drive nameplate rating) V/Hz
Service Factor
1.0
Speed Adjustable Range
From 0 RPM to maximum speed
Speed Regulation
Vector 0.01% long term 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)
Table A.2 Ambient Conditions
Condition
Specification
Operating Temperature (Ambient)
0_ to +40_ C (32_ to 104_F)
Storage Temperature (Ambient)
-40_to +65_C (-40_ to +149_F)
Humidity
5 to 95% (noncondensing)
A1
Table A.3 Terminal Strip Input Specifications
Signal Type
Terminal(s)
Speed Reference Input
1215
Digital Inputs (1 8)
Specification
10 V (@ 50K ohm input
impedance or 20 mA)
16
+24 VDC Isolated Supply
17
Remote/Local (Default)
18
Ramp1/Ramp2 (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
Terminal(s)
10 11
scaled signal
Snubber Resistor
26 27
Specification
010 VDC or 420 mA
Used with Snubber Resistor
Braking Kits Refer to Instruction
Manual D23179.
Table A.5 RS232 Specifications
Signal Type
RS 232 Communications
Terminal(s)
Specification
1
XMIT
2
RECV
3
COMMON
Table A.6 Speed Feedback Device Specifications (Vector Regulation Only)
Specification
A2
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)
Speed Feedback
15 V differential quadrature, pulse tachometer
incremental (512 PPR, 1024 PPR, 2048 PPR,
4096 PPR)
Service Factor
1.0
Table A.7 Input Signal Response Times (Worst Case)
These are the maximum times from transitioning the input to the drive reacting to the input.
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
Keypad START
Terminal Strip:
Analog Torque Reference
Network:
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 +
Torque Reference
N/A
network
transport time
0.5 milliseconds + network
transport time
A3
Appendix B
Drive Regulation Overview
The GV3000 is a digital drive that provides closed loop vector or open loop volts/hertz regulation of AĆC
motors. The Volts/Hertz or Vector Regulation parameter (P.048) is used to select the type of regulation for the
application. See figures B.1 and B.2 for block diagrams of both regulators.
Volts/Hertz Regulation
Volts/hertz regulation provides general purpose open loop AĆC drive control. It does not use a speed
feedback device. In this type of control, the regulator maintains a programmed ratio of voltage to an output
frequency, which provides constant or variable motor torque across a wide speed range. An internal function
generator calculates the output motor voltage based on requested frequency and userĆspecified motor
characteristics. The control loop output switches the power device gates, generating a
pulseĆwidthĆmodulated (PWM) waveform to the motor.
Vector Regulation
Vector regulation allows dynamic closedĆloop performance in an AĆC drive similar to that achieved with a DĆC
drive. Torque is constant across the motor's base speed range in both forward and reverse directions. The
drive uses two digital control loops, speed and torque, to obtain vector performance.
The speed loop reference can be an internal or an external source. Speed loop feedback is provided by a pulse
tachometer attached to the motor's shaft. A trim parameter is summed with the speed reference to provide a
torque reference, or to adjust a userĆspecified Torque Reference Source parameter, for the torque control loop.
An internallyĆgenerated flux reference is also fed to the torque loop. The torque will vary to maintain the motor
at the requested speed. The torque control loop output switches the power device gates, generating a
pulseĆwidthĆmodulated (PWM) waveform to the motor.
BĆ1
Figure B.1 Ć Volts/Hertz Regulation Block Diagram
BĆ2
PC Option
Host
Remote
Local
Speed
Ref.
SelecĆ
tion
P.000
H.004
P.020
P.015
P.014
P.016
Slip Comp
Jog Ref
Trim Ref
Speed Ref
Draw Gain
Avoid
Freq.
Rate Selection
Ride Thru
Current fbk
DĆC Bus Voltage
Search Mot. Freq.
Overload
+ +
H.009
to
H.015
+
SĆCurve
V/Hz
Generator
Voltage
Equations
Frequency Reference
VQ
VD
w1
Reverse
TransĆ
formation
Forward
TransĆ
formation
PWM
Controller
A/D Converter
A/D Converter
P.047 Carrier Freq.
P.095 Power Module
Output Amps
PWM
Inverter
AĆC Induction Motor
A/D Converter
Gate Signals
(60Ć150 HP GV3000
Drives Only)
DC-Bus Voltage Comp.
Line Voltage fbk
Remote
Braking
Resistor
(1Ć60 HP
GV3000
Drives Only)
DB
Select
H.017
P.043 Fault Auto Reset Attempts
P.044 Fault Auto Reset Time
P.016
100
LIMIT (w/ hysteresis)
)
Spd Ref
Analog Input
1
Option Port
2
P.004
3
Torque
Current Fdbk
4
RMI Analog
Input
5
RMI Freq. Input
6
Switched RMI
Analog Input or
Freq. Input
0
)
)
P.015
100
MAX
IN
Invert
OUT
MIN
P.014
0
P.004
Draw Ref
Polarity of this point specifies
the requested direction for drivĆ
ing the FP FWD/REV LEDs
EN
REV DISABLE
P.003
P.027
Trim Ref
FWD/REV
(0/1)
Open when
P.027 = OFF
7
Outer Loop P1
Block (RMI) Mode 1
8
Outer Loop P1
Block (RMI) Mode 2
9
AĆC LINE INPUT
SPEED
REFERENCE )
P.019
SĆCURVE
S_en
ACC
SPEED
CONTROLLER
TORQUE
COMMAND
DEC
Accel time (P.001,
P.017, or P.021)
Decel time (P.002,
P.018, or P.022)
GATE
SIGNALS
VECTOR
PWM
TORQUE
DB KIT
CONTROLLER CONTROL INVERTER
FLUX
COMMAND
FIELD
CONTROLLER
CURRENT
FEEDBACK
AĆC
MOTOR
SPEED
FEEDBACK
DERIVATIVE
ROTOR
POSITION
PULSE
ENCODER
Figure B.2 Ć Vector Regulation Block Diagram
BĆ3
Appendix C
Compliance with EN 602041: 1992
The GV3000 complies with the following sections of standard EN 602041: 1992.
EN602041
Section
6
6.2.1
6.2.3
6.3.1
6.4
7
7.2
7.2.3
7.2.6
7.5
8
8.2.1
8.2.2
8.2.3
8.2.7
8.3
8.4
8.5
8.6
9
9.1.1
9.1.3
9.1.4
9.2
9.2.1
9.2.2
9.2.3
9.2.5
9.2.5.3
9.2.5.6
9.2.6
9.3
9.3.5
9.4
9.4.2.1
9.4.3
9.4.3.1
9.4.3.2
Title
Protection against electrical shock
Protection by enclosure
Protection against residual voltages
Protection by automatic disconnect of supply
Protection by the use of PELV (Protective Extra Low Voltage)
Protection of equipment
Overcurrent protection
Control circuits
Transformers
Protection against supply interruption or voltage reduction and subsequent restoration
Equipotential bonding
General (the PE terminal)
Protective conductors (connection points)
Continuity of the protective bonding circuit
Protective conductor connecting points
Bonding to the protective bonding circuit for operational purposes
Insulation failures
Bonding to a common reference potential
Electrical interferences
Control circuit and control functions
Control circuit supply
Protection
Connection of control devices
Control functions
Start function
Stop function
Operating modes
Operation
Stop
Holetorun controls
Combined start and stop controls
Protective interlocks
Reverse current braking
Control functions in case of failure
Use of proven circuit techniques and components
Provisions for redundancy
Earth faults
Voltage interruption
C1
Appendix C
Compliance with EN 602041: 1992 (Continued)
EN602041
Section
10
10.2.1
10.8
11
11.2
11.2.1
11.2.2
11.3
11.3.1
11.5
12
12.2.2
12.2.3
12.3
12.3.1
12.3.2
12.3.3
12.3.4
12.3.5
13
13.2.3
13.4
15
15.1.1
15.1.3
15.2.2
18
18.2
18.4
19
19.1
C2
Title
Operator interface and machine mounted control devices
Pushbutton colors
Displays
Control interfaces
Digital input/output interfaces
Inputs
Outputs
Drive interfaces with analog inputs
Separation between control and electric drives
Communications
Electronic equipment
Electronic control equipment
Equipotential bonding
Programmable equipment
Programmable controllers
Memory retention and protection
Programming equipment
Software verification
Use in safetyrelated functions
Controlgear: Location, mounting and enclosures
Heating effects
Enclosures, doors and openings
Wiring practices
General requirements
Conductors of different circuits
Identification of the protective conductor
Warning signs and item identification
Warning signs
Marking of control equipment
Technical documentation
General
Reliance Electric / 24703 Euclid Avenue / Cleveland, Ohio 44117 / (216) 266Ć7000
Printed in U.S.A.
D2Ć3340
December 1995
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