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Instruction Manual D2 3340

1. Figure 9 2 D C Bus Voltage Terminals 25 60 HP Drives 9 3 9 4 D C Bus Measuring Points Figure 9 3 D C Bus Voltage Terminals 60 100 HP Drives XXXXXX i xxxxxx Regulator Panel D C Bus Measuring Points Behind Regulator Panel on the Power Module Interface Board Power Module Interface Board D C Bus Measuring Points Figure 9 4 D C Bus Voltage Terminals 100 150 HP Drives 9 4 Checking the Power Modules with Input Power Use the following procedure to check the drive s Power Module circuitry with power off DANGER D C BUS CAPACITORS RETAIN HAZARDOUS VOLTAGES AFTER INPUT POWER HAS BEEN DISCONNECTED AFTER DISCONNECTING INPUT POWER WAIT FIVE 5 MINUTES FOR THE D C BUS CAPACITORS TO DISCHARGE AND THEN CHECK THE VOLTAGE WITH A VOLTMETER TO ENSURE THE D C 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 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Step 9 Step 10 Turn off and lock out input power Wait five minutes Remove the drive s cover Verify that there is no voltage at the drive s input power terminals Check the D C bus potential with a voltmeter as described in se
2. CURRENT FEEDBACK REGULATOR BOARD BOARD M N M N 1V4150 3V4150 1V4450 3V4450 2 4150 5V4150 2V4450 5V4450 Figure 2 2 1 5 HP Drive Components and Locations 2 3 2 4 BOARD HHH HHH CURRENT FEEDBACK BOARD 7V4150 7V4250 10V4150 10V4250 ASSEMBLY 9 a2 i FAN ASSEMBLY INTERNAL 3 MEMBRANE SWITCH 7 O KEYPAD BRACKET 2050000 REGULATOR BOARD Figure 2 3 7 5 10 HP Drive Components and Locations ASSEMBLY ASSEMBLY INTERNAL 9 a IGBT MODULE
3. 7 16 20 REGULATOR TERMINAL 66966569564 STRIP o POWER TERMINAL STRIP SIGNAL CONTRO GNAL CONTROL R TERMINAL STRIP SNUBBER RESISTOR BRAKING GROUND TERMINAL INPUT POWER AND MOTOR LEADS 4 CUSTOMER WIR ROUTINC M 3 1 2 14 PIPE THREADED CONDUIT HUBS NEMA 4X 12 3 875 22 2 mm DIA HOLES NEMA 1 Figure 4 1 Wire Routing Locations for 1 5 HP Drives 4 2 8888141 AUTO Forward 5 Bum ue Kw FORWARD TORQUE REVERSE CJ Password PROGRAM ENTER STOP Reser START REGULATOR TERMINAL 9 9 9 990 6 86 69966965559996596666 9 6 66 STRIP 16 20 os
4. 3 4 Figure 3 3 Single and Multiple Motor Lead Lengths 3 7 Figure 4 1 Wire Routing Locations for 1 5 HP Drives 4 2 Figure 4 2 Wire Routing Locations for 7 5 10 HP Drives 4 3 Figure 4 3 Wire Routing Locations for 15 25 HP Drives 4 4 Figure 4 4 Wire Routing Locations for 25 60 HP Drives 4 5 Figure 4 5 Wire Routing Locations for 60 100 HP 4 6 Figure 4 6 Wire Routing Locations for 100 150 HP 4 7 Figure 5 1 Typical A C Input Electrical Connections 5 2 Figure 5 2 Typical D C Bus Electrical 5 5 3 Figure 7 1 Two Wire Start Stop Sample Control Wiring 7 8 Figure 7 2 Three Wire Start Stop Sample Control Wiring 7 4 Figure 7 3 Wiring Connections for the Speed Feedback Device 7 6 Figure 9 1 D C Bus Voltage Terminals 1 25 HP Drives 9 2 Figure 9 2 D C Bus Voltage Terminals 25 60 HP Drives
5. 3 8 Table 5 1 Terminal Tightening Torques 5 4 Table 7 1 Wiring Signal and Control I O to the Terminal Strip 7 7 Table 9 1 Resistance Checks 9 6 Table 9 2 1 5 HP Drive Replacement Parts 9 8 Table 9 3 7 5 10 HP Drive Replacement Parts 9 8 Table 9 4 15 25 HP Drive Replacement Parts 9 9 Table 9 5 25 60 HP Drive Replacement Parts 9 10 Table 9 6 60 100 HP Drive Replacement Parts 9 11 Table 9 7 100 150 HP Drive Replacement Parts 9 12 Table A 1 Service Conditions A 1 Table 2 Ambient 2 2 4 A 1 Table Terminal Strip Input Specifications A 2 Table A 4 Terminal Strip Output Specifications A 2 Table A 5 RS 232 Specifications A 2 Table A 6 Speed Feedback Dev
6. DIODE BRIDGE POWER BOARD M N M N 15V4150 25G4150 15V4250 25G4250 20V4150 20V4250 POWER SUPPLY BOARD 5 components far side GU o gme 6 9 MEMBRANE SWITCH KEYPAD TOP BRACKET E REGULATOR BOARD Figure 2 4 15 25 HP Drive Components and Locations 2 4 25 60 GV3000 Drive Components and Locations The 25 60 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 7 Power Supply Board 1 Fan 2 Membrane Switch Keypad Bracket 3 Regulator Board 4 Bus Capacitors 10 IGBT Module 5 Not Used 11 Diode Bridge 6 Power Board 12 Wire Harness DIODE BRIDGE 8 Gate Driver Board 9 Internal Fa
7. o PIN 2 DATA IN RXD DATA IN TERMINAL 2 PIN 3 TXD DATA OUT COMMON COMMON TERMINAL 0 0 PIN 7 25 PIN D SHELL 08 5 9 0 5 WIRE LENGTH 50 FEET Wiring Pulse Tachometer Inputs 4 9 Pulse Tachometer Wiring See section 7 2 7 8 Table 7 1 Wiring Signal and Control I O to the Terminal Strip Continued Wiring Analog Outputs 0 10 VDC or 4 20 mA Analog Output Reference Regulator Common The setting of parameter P012 selects the terminal strip analog output source either speed or torque Jumper J17 must also be set See figure 2 11 The 4 20mA current 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 1 2 Meter or Analog Input 9 69 6 6 9 6 6 66 Connection to the negative side the power supply is only required when an external 15V power supply is used Table 7 1 Wiring Signal and Control I O to the Terminal Strip Continued Terminal Number Description Parameters Wiring Connections Wiring Analog Speed Reference Inputs Isolated Reference The following parameters must
8. Polarity of this point specifies the requested direction for driv 04 ing the FWD REV LEDs 016 Draw Ref 100 LIMIT w hysteresis MAX Invert Spd Ref H EN 14 REV DISABLE 9 0 Ne 015 P003 P027 100 Trim Ref Analog Input 1 Option Port ___ 2 FWD REV 0 1 P004 3 027 T le Ghent Fdbk 4 RMI Analog Input 5 RMI Freq Input 6 Switched RMI Analog Input or 7 Freq Input Outer Loop P1 8 Block RMI Mode 1 Outer Loop P1 9 Block RMI Mode 2 A C LINE INPUT SPEED SIGNALS S CURVE gt p CONTROLLER P019 S en VECTOR TORQUE DB KIT PWM dr DEG CONTROLLER Control INVERTER Accel time 001 FLUX A 4 gt P017 or P021 FIELD COMMAND gt CONTROLLER Decel time P002 P018 or P022 CURRENT FEEDBACK SPEED ROTOR PULSE FEEDBACK POSITION ENCODER DERIVATIVE 4 Figure B 2 Vector Regulation Block Diagram B 3 Compliance with 60204 1 1992 GV3000 complies with the following sections of standard EN 60204 1 1992 EN60204 1 Section Title 6 Protection against electrical shock 6 2 1 Protection by enclosure 6 2 3 Protection against residual voltages 6 3 1 Protec
9. View From Top PPS A C Ground Inputs View From Bottom Figure 4 6 Wire Routing Locations for 100 150 HP Drives PR 2 V Output Ground Signals Terminals 4 8 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 Step 2 Step 3 Step 4 Remove the drive s cover 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 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 Re attach 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 t
10. SIGNAL CONTROL BERE OPER TERMINAL STRIP SNUBBER RESISTOR BRAKING POWER TERMINAL STRIP GROUND TERMINALS MOTOR LEADS INPUT POWER AND MOTOR LEADS CUSTOMER WIRE ROUTING BASE 4 1 2 14 PIPE THREADED CONDUIT HUBS NEMA 4X 12 4 875 22 2 mm DIA HOLES NEMA 1 Figure 4 2 Wire Routing Locations for 7 5 10 HP Drives 4 3 REGULATOR TERMINAL STRIP POWER TERMINAL STRIP GROUND TERMINALS SIGNAL CONTROL TERMINAL STRIP CUSTOME INPUT POWER SNUBBER RESISTOR INPUT POWER BRAKING AND MOTOR LEADS R WIRE ROUTING 1 1 2 14 PIPE THREAD CONDUIT HUBS NEMA 12 1 875 22 2 mm HOLES NEMA 1 3 3 4 14 PIPE THREAD CONDUIT HUBS NEMA 12 3 1 094 27 8 mm DIA HOLES NEMA 1 Figure 4 3 Wire Routing Locations for 15 25 HP Drives 4 4 NI R RI TOR a
11. 60204 1 1992 7 5 7 2 Wiring the Speed Feedback Device Vector Regulation Only 7 5 7 3 Wiring the Signal and Control 7 7 Completing the Installation 8 1 8 1 Checking the Installation 8 1 8 2 Installing the Cover for NEMA 4X 12 Drives 8 2 8 3 Powering Up After Installation is Complete 8 2 Troubleshooting the Drive 9 1 9 1 Test Equipment Needed to Troubleshoot 9 1 9 2 Drive Alarms 5 9 1 9 3 Verifying That D C Bus Capacitors are Discharged 9 1 9 4 Checking Out the Power Modules with Input Power Off 9 6 9 5 Heplacemernt Parts Ran nest debet her des 9 8 Technical Specifications A 1 Appendix B Drive Regulation Overview ne B 1 Appendix C Compliance with EN 60204 1 1992 C 1
12. 9 3 Figure 9 3 D C Bus Voltage Terminals 60 100 HP Drives 9 4 Figure 9 4 D C Bus Voltage Terminals 100 150 HP Drives 9 5 Figure B 1 Volts Hertz Regulation Block Diagram B 2 Figure B 2 Vector Regulation Block Diagram B 3 List of Tables Table 2 1 Power and NEMA Enclosure Ratings 2 2 Table 2 2 Available Kits and Options 2 16 Table 3 1 Ambient Conditions 3 1 Table 3 2 Drive Dimensions and Weights 3 2 Table 3 3 Recommended Power Wire Sizes for 1 10 HP 3 5 Table 3 4 Recommended Power Wire Sizes for 15 25 HP Drives 3 5 Table 3 5 Recommended Power Wire Sizes for 25 60 HP Drives 3 6 Table 3 6 Recommended Power Wire Sizes for 60 100 HP Drives 3 6 Table 3 7 Recommended Power Wire Sizes for 100 150 HP Drives 3 6 Table 3 8 Recommended Terminal Strip Wire 5 3 6 Table 3 9 A C Input Line Fuse Selection Values
13. List of Figures Figure 2 1 Identifying the Drive Model 2 1 Figure 2 2 1 5 HP Drive Components and Locations 2 3 Figure 2 3 7 5 10 HP Drive Components and Locations 2 4 Figure 2 4 15 25 HP Drive Components Locations 2 5 Figure 2 5 25 60 HP Drive Components and Locations 2 6 Figure 2 6 60 100 HP Drive Components and Locations 2 7 Figure 2 7 100 150 HP Drive Components and Locations 2 8 Figure 2 8 1 60 HP Regulator Board Components and Locations 2 10 Figure 2 9 60 150 HP Regulator Board Components and Locations 2 11 Figure 2 10 Jumper J4 Settings for Analog Input Speed 2 12 Figure 2 11 Jumper J17 Settings for Analog Outputs 2 13 Figure 2 12 Typical Terminal Strip Connections 2 14 Figure 2 13 Keypad Display 2 15 Figure 3 1 Drive Dimensions 7 3 3 Figure 3 2 Recommended Air Flow Clearances
14. dH 09 1 10 515 13 uononpul WMd a y SUeJ sdwy uoneuuo e npo y Mod S60d sued 4 joeles 89 gt gt ZLO H suonenb3 eDeyoA 016 0 90 2 sjeuBis 4 Daly uorees lt sng 2 0 t WMd dwog Ajuo se uq 000 A9 dH 091 09 5 gt yq oiny josey 5704 Aouenbal4 diis 4 0 600 H 5 peeds uondo Od 1 201 Figure B 1 Volts Hertz Regulation Block Diagram B 2
15. 6 1 Contacts Form A 2 9 7 15 Form B 2 9 7 15 Control source 7 1 7 3 to 7 4 7 7 PC 3 7 7 1 7 7 wiring 7 3 to 7 4 7 7 Control wiring 2 13 7 1 to 7 15 Current Feedback board 2 3 to 2 5 9 8 Current transformer 2 7 to 2 8 9 11 to 9 12 D D C bus input wiring 3 5 to 3 6 4 1 to 4 8 5 3 5 5 fuse 2 7 to 2 8 9 11 to 9 12 terminals 9 1 to 9 5 verifying capacitor voltage 9 1 to 9 5 Digital input wiring 2 14 7 2 to 7 4 7 10 to 7 14 8 remote local 7 2 to 7 4 7 10 ramp1 ramp2 7 2 to 7 4 7 11 6 forward reverse 7 2 to 7 4 7 12 5 function loss 7 2 to 7 4 7 13 4 run jog 7 2 to 7 4 7 13 3 reset 7 2 to 7 4 7 14 2 stop 7 2 to 7 4 7 14 1 start 7 2 to 7 4 7 14 Digital output wiring see Status Relays Dimensions 3 2 to 3 3 Disconnect installing A C input 5 2 to 5 4 Display see Keypad Display Distribution system capacity A C line maximum 5 1 Drive identifying 2 1 kits 2 16 Index 1 Emergency stop 7 5 EN 60204 1 compliance 7 5 C 1 to C 2 Enclosures NEMA 2 2 9 8 to 9 10 Environmental conditions 3 1 F Fan 2 3 to 2 8 9 8 to 9 12 Faults 9 1 Form A contacts see Status Relays Form B contacts see Status Relays Forward digital input 6 2 14 7 2 to 7 4 7 12 Frequency carrier 2 9 A 1 Frequency line 1 Function loss digital input 5 2 14 7 2 to 7 4 7 12 wiring 7 2 to 7 3 7 13 Fuse D C bus 2 7 to 2 9 9 9 to 9 11 to 9 12 A
16. Description Part Number 15 20 25 _ Tf 1 805547 1 NEMA 12 Cover Gasket 805547 2R Membrane Switch Keypad Top Bracket 805548 1R ae Regulator PCB 0 56921 5xx Capacitor PCB 0 56948 015 1 pore ees Power Supply Board 0 56950 015 rw 1 inal an sisiseis are identified in figure 2 5 9 9 Table 9 5 25 60 Drive Replacement Parts 2 Description Part Number 25 2 Fan Wire Harness 61519528 1 en Cov pev ecem mesmo pov s Membrane Switch Keypad 805548 1R Top Bracket Input Capacitor 600442 32A 2 0 56949 040 Power Supply PCB 0 56950 025 0 56950 030 0 56950 040 0 56950 050 Gate Driver PCB 0 56947 025 0 56947 040 0 56947 050 IGBT Module 602909 810AW 602909 811AW 602909 812AW Diode Bridge 701819 113BA 1 1 701819 114BA Internal Fan Assembly 615196 2R Components are identified in figure 2 5 9 10 Table 9 6 60 100 HP Drive Replacement Parts Description Part Number Quantity Regulator PCB Power Module Interface PCB Power Module Interface PCB Fuses Gate Driver PCB Bus Clamp PCB right Bus Clamp left Intelligent Power Module IPM PCB Diode Bridge MOV on Diode Bridge D C Bus Fuse Precharge Contactor Current Transformer Ground Fault Tr
17. Line Regeneration Unit kit 2 16 Local digital input 8 2 14 to 2 16 7 2 to 7 4 7 10 Loss function see Function Loss M Maximum A C line distribution system capacity 5 1 A 1 Mechanical motor overload protection 6 1 Meter output 2 14 7 1 7 8 Model numbers 2 1 to 2 2 MOP motor operated potentiometer 7 10 to 7 12 Motor Encoder Cable kit 2 16 lead lengths 3 6 to 3 7 overload protection mechanical 6 1 speed setting maximum 7 6 wiring 6 1 to 6 2 Mounting dimensions 3 2 to 3 3 NEMA enclosures 2 2 9 8 to 9 10 Network AutoMax Network Communication board 2 15 2 16 communication 2 15 3 7 Open loop see Volts Hertz Regulation Option kits see Kits Output analog see Analog Output contactors 6 1 digital see Status Relays inductor see Output Reactor reactor 2 7 to 2 8 9 11 to 9 12 specifications terminal strip A 2 Overload motor 6 1 5 location see Component Locations replacement 9 8 to 9 12 PC control see Control Source Planning drive clearances 3 4 location 3 1 Power board 2 5 2 6 9 9 9 10 output wiring 3 5 to 3 7 4 1 to 4 8 6 1 to 6 2 input wiring 3 5 to 3 6 3 7 to 3 8 4 1 to 4 7 5 1 to 5 5 Power Module checking 9 6 to 9 7 verifying output current rating 3 8 Power Supply board 2 5 2 6 9 9 9 10 Power terminals torque specifications 5 4 wiring 3 5 to 3 7 4 1 to 4 8 5 1 to 5 5 6 1 Precharge contactor 2 7 9 11 Precharge resistor 2
18. NEMA rating encompasses both ratings 4X and 12 NEMA 12 Intended for use in indoor environments that require dust tight drip tight enclosure See table 2 1 for a listing of the Power Modules and their individual NEMA ratings 2 3 1 25 HP GV3000 Drive Components and Locations The 1 25 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 15 25 HP drives only 2 Membrane Switch Keypad Bracket 8 Gate Driver PCB 15 25 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 15 25 HP drives only 12 Fan Wire Harness m a MEMBRANE SWITCH KEYPAD BRACKET 292000 2270 0 a8 oo al 5000 Sin
19. Refer to section 2 7 of this manual for more information on optional drive kits Operator Interface Module Connector Flat ribbon 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 Keypad Display The front panel keypad display is used to program and operate the GV3000 drive See figure 2 13 Refer to instruction manual D2 3339 for more information E STATUS L DISPLAY KE 001 MONITOR FORWARD REVERSE Password PROGRAM STOP RELIANCE RESET ELECTRIC START STOP RESEI K EY 1 Applies power to the motor if the keypad is selected as the control source PAS R 1 Stops the drive E D 2 Resets faults 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 2 16 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 Option Kit Model Number Instruction Manual P eese 2584060002 Snubber Resistor Brakin
20. resistance is Component is defective if 50 lt R lt 10 Megohm Continuity short circuit or open when the meter is connected with reversed polarity D C Bus Volts power terminal D C Bus Volts power terminal 60 150HP Drives Meter Connection Component is OK if resistance R is Component is defective if 1 47 W 0 3 kohm lt R lt 8 kohm Continuity short circuit or open when the meter is 2 47 V connected with reversed polarity 3 47 0 4 45 5 45 9 7 9 8 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 1 5 HP Drive Replacement Parts Quantity per Horsepower Description Part Number 1 Fan Assembly 615161 S NEMA 1 Cover 805531 1R NEMA 4X 12 Cover Gasket 805532 1R Membrane Switch Keypad Bracket 709576 1R Regulator PCB 0 56921 5xx Capacitor PCB 0 56928 30 0 56928 50 Current Feedback PCB 0 56926 20 0 56926 50 Internal Fan Assembly 615159 1R Components are identified in figure 2 3 Table 9 3 7 5 10 HP Drive Replacement Parts Quantity per Horsepower NEMA 12 Cover Gasket 805539 1R 1 1 1 Current Feedback PCB 0 56935 100 Internal Fan Assembly 615159 1R Components are identified in figure 2 4 ak Table 9 4 15 25 HP Drive Replacement Parts Quantity per Horsepower
21. 2 Connect the three phase A C input power leads three wire 380 460 VAC to the proper terminals according to drive type On 1 60 HP drives connect the A C input power leads to terminals R L1 S L2 T L3 on the power terminal strip On 60 150 HP drives connect the A C input power leads to terminals 1L1 1L2 and 1L3 Step Tighten the A C input power terminals to the proper torque as shown in table 5 1 Table 5 1 Terminal Tightening Torques Drive Terminals Maximum Tightening Torque 1 25HP All 1 08 Newton meters 9 5 in Ibs 25 60HP All 13 5 Newton meters 120 in Ibs 1L1 1L2 1L3 U V W 10 Newton meters 88 5 in Ibs 60 100 45 47 2 5 Newton meters 22 1 in Ibs 1L1 1L2 1L3 PE 10 Newton meters 88 5 in Ibs 100 150HP U V W L 45 47 2 5 Newton meters 22 1 5 5 Installing Power Wiring from an External D C Bus to the Drive s Internal D C Bus Terminals Use the following steps to connect D C input power to the drive Step 1 Wire the D C 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 1 5 HP drives route the power leads through the bottom right opening of the drive base On 7 5 25 HP drives route the power leads through the bottom middle right opening of the drive base If the snubber resistor braking option is used route the power leads
22. 2 5 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 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 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 user supplied mounting bolts and washers 1 5HP drives 1 4 20 7 5 10HP drives M8 5 16 18 e 15 60HP drives M8 or M10 3 8 16 60 150HP 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 l
23. 5 INPUT POWER SIGNALS CONTROL TERMINAL STRIP GROUND TERMINAL INPUT POWER TERMINALS WIRE ROUTING CHANNEL REGULATOR TERMINAL STRIP 1 OUTPUT POWER GROUND TERMINALS TERMINALS SIGNALS CONTROL INPUT POWER TERMINAL STRIP OR SNUBBER RESISTOR BRAKING MOTOR LEADS CUSTOMER WIRE ROUTING 3 4 3 1 174 CONDUIT HUBS NEMA 12 CONDUIT HUBS NEMA 12 1125 28 6mm DIA 2 000 50 8mm DIA HOLES NEMA 1 HOLES NEMA 1 BASE MOUNTING BRACKET 568 Figure 4 4 Wire Routing Locations for 25 60 HP Drives 4 5 4 6 D C Input Terminals Signals and Ground View From Bottom A C Input Terminals and Ground A C Output Terminals and Ground Figure 4 5 Wire Routing Locations for 60 100 HP Drives 1 Terminals Output Terminals and Ground D C Input Terminals and Ground
24. 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 4 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 311 Making Sure Environmental Conditions are Met Before deciding on an installation site consider the following guidelines Verify that NEMA 1 drives can be kept clean cool and dry The area chosen should allow the space required for proper air flow as defined in section 3 1 2 Be sure that NEMA 1 drives are away from oil coolants or other airborne contaminants Do not install the drive above 10
25. HP Regulator Board Components and Locations 60 Ribbon Cable USER DISPLAY J7 34 Ribbon Cable 0 00 00 O JO USER TERMINAL STRIP 9 6 6 GC 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 1 2 3 4 5 6 7 8 9 10 11 12 15 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 43 Option Board Connector 49 Keypad Display Connector J4 Analog Input Jumper J16 Power Module Feedback Cable J7 OIM Optional Connector 417 Analog Output Jumper J8 RS232C Port Figure 2 9 60 150 HP Regulator Board Components and Locations 2 7 1 Jumper Locations and Settings Jumpers J4 and J17 on the Regulator board are factory set for voltage in and voltage out signals Refer to 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 0 20 mA input Parameters P009 P010 and P011 are used in conjunction with the jumper Note that if the pos
26. Intelligent Power Module PCB 7 Diode Bridge 8 D C Bus Fuse ee 828152648524 i Su 50R4150 75R4150 9 Precharge Contactor 10 Current Transformer 11 Ground Fault Transformer 12 Output Reactor 13 Precharge Resistor 14 Bus Discharge Resistor 15 24 VDC Fan 16 Keypad 5 5 Figure 2 6 60 100 HP Drive Components and Locations 2 7 2 8 2 6 100 150 HP GV3000 Drive Components and Locations The 100 150 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 3 Gate Driver PCB 4 Bus Clamp PCB Right 5 Bus Clamp PCB Left 6 Intelligent Power Module PCB 11 Ground Fault Transformer 12 Output Reactor 13 Not Used 14 Bus Discharge Resistor 7 Thyristor Precharge Module 15 24 VDC Fan 8 D C Bus Fuse 16 Keypad 9 Not Used 17 Thyristor Firing Pulse PCB Pi 5 ae M N 125R4150 Figure 2 7 100 150 HP Drive Components and Locations 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 int
27. 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 coast to rest or a ramp to rest operational stop without physical separation of the power source from the motor A coast to rest stop turns off the transistor power device drivers A ramp to rest stop fires the transistor power device drivers until the motor comes to a stop and then turns off the power devices The user can also program zero speed with power maintained to the motor but in this condition the drive is not actually stopped See the description of terminals 23 and 24 or Stop 25 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 11 Compliance with EN 60204 1 1992 This section applies to users who must comply with EN 60204 1 1992 part 9 2 5 4 Emergency Stop The GV3000 drive coast to rest stop is a category 0 operational stop The ramp to rest stop is a category 1 operational stop
28. and the normally closed contact will open Refer to the GV3000 Programming instruction manual 02 3339 for more information NC 0 COM CUM USER SUPPLIED DEVICE PARAMETER 013 SELECTS OUTPUT CATION 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 81 Checking the Installation Use the following procedure to verify the condition of the installation DANGER D C BUS CAPACITORS RETAIN HAZARDOUS VOLTAGES AFTER INPUT POWER HAS BEEN DISCONNECTED AFTER DISCONNECTING INPUT POWER WAIT FIVE 5 MINUTES FOR THE D C BUS CAPACITORS TO DISCHARGE AND THEN CHECK THE VOLTAGE WITH A VOLTMETER TO ENSURE THE D C 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 D C bus voltage is zero Refer to section 9 3 Step 3 If a funct
29. 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 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 re installing the covers Use the following steps to re install the covers 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 in lbs 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 Step 1 Turn the drive s input power disconnect to the On position Step 2 Apply power to the drive Step 3 Follow the start up procedure in instruction manual D2 3339 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 91 Test Equipment Needed to Troubleshoot An isolated multimeter will be needed to measure D C bus voltage and to make resistance checks 9 2 Drive Alarms and Faults The drive will display alarm and fault codes to assi
30. be set Voltage 15VDC Analog Speed Torque P 000 Control Source Reference Input Voltage P 009 Terminal Strip Analog Input Offset 10 VDC 010 Terminal Strip Analog Input Gain Analog Speed Torque 011 Terminal Strip Analog Input Invert Reference Input Current 0 20mA Isolated Speed Torque Reference Common Voltage Current Refer to the GV3000 Programming instruction manual D2 3339 for additional parameter information Jumper J4 must also be set See figure 2 10 10V OV 20 OV 12 13 14 15 12 13 14 15 OO OS OO 00 SK 10VDC SPEE Number Table 7 1 Wiring Signal and Control I O to the Terminal Strip Continued Description Parameters Wiring Connections Wiring a Remote Local Input 16 24 VDC Power Supply Current limited for remote input logic use only 17 Digital Input 8 Default Remote Local Digital input 8 is control function programmable through parameter 007 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 whe
31. conductive 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 D C bus potential at the diode bridge as shown Re attach the regulator panel 9 1 100 150HP drives while standing a non conductive 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 D C 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 Re attach the regulator panel Step 5 Once the drive has been serviced re attach the drive s cover Step Re apply input power 9 9 ev e Ie R AT S 2 10 COM U T V T2 W T3 BUS MOTOR DS VOUS Al U T1 2 W T3 S L2 1 15 Figure 9 1 D C Bus Voltage Terminals 1 25 HP Drives
32. jumper to the desired setting as shown in figure 2 11 Step 6 Re attach the cover Step 7 Re apply input power Step 8 Verify that parameter P012 is set correctly for either speed or current Voltage Output Option Current Output Option Pins 2 3 Pins 1 2 10 VDC 0 20 mA 417 default Figure 2 11 Jumper J17 Settings for Analog Outputs 2 13 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 Terminals 1 3 RS 232 connections e Terminals 4 9 pulse tachometer connections e Terminals 10 11 analog output connections Terminals 12 15 analog speed torque reference connections Terminals 16 25 24V D C digital input connections 1 60 HP Regulator boards only Terminals 26 27 snubber resistor braking control connections 1 60 HP Regulator boards only Terminals 28 31 status relay connections R OUTPUT REGULATOR COMMON 15 VDC PHASE A PHASE A NOT PHASE B PHASE B NOT REGULATOR COMMON ANALOG METI REGULATOR COMMON SOLATED REFERENCE VOLTAGE VDC SPEED REFERENCE mA SPEED REFERENCE SOLATED REFERENCE GND 24 VDC DIGITAL INPUT 8 REMOTE LOCAL DIGITAL INPUT 7 RAMP1 RAMP2 DIGITAL INPUT 6 FORWARD REVERSE FUNCTION LOSS 24 COMMON SNUBBER RESISTOR BRAKING SIGNAL 24 VDC COMMON N C RELAY CONTACT N C RELAY
33. power terminal strip On 60 150 HP drives connect the motor leads to terminals U V and W Step 3 Tighten the three phase A C 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 00 is set to remote rE the drive will be controlled by the signals connected to the terminal strip Refer to instruction manual D2 3339 for more information on how parameter is used to specify where the drive is controlled from RS 232 Connections Terminals 1 3 e Terminal 1 Transmit Tx Terminal 2 Receive Rx Terminal 3 Regulator Common The RS 232 terminals should only be used when the RS 232 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 4 9 Terminal 4 15 VDC Terminal 5 Phase Terminal 6 Phase Not Terminal 7 Phase Terminal 8 Phase Not Terminal 9 Regulator Common A speed feedback device pulse tachometer must be installed if vector regulation PO48 1 is used Analog Ou
34. 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 3 6 GV3000 GV3000 GV3000 Drive Drive Drive 15 m 50 38 m 125 38 m 1257 60 m 200 60 200 8 25 8 25 GV3000 Drive 76 250 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 RS 232 serial communication port This connector allows the GV3000 drive to communicate with external devices such as a personal computer using RS 232 protocol See table A 5 Two RS 232 cables are available from Reliance a 3 5 meter 12 feet D shell 9 pin to 9 pin cable M N 615184 1 and a 0 3 meter 1 foot D shell 9 pin to 25 pin adaptor cable M N 615184 2 User constructed 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 D2 3348 for more information The Regulator boards have one set of RS 232 transmit receive lines These lines can be accessed by only one device at a time connector J8
35. through the bottom right opening On 25 60 HP drives route the power leads through the top right or bottom right openings of the drive base On 60 100 HP drives route the power leads through the bottom left opening of the cover On 100 150 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 D C bus the user is responsible for D C bus short circuit protection Failure to observe this precaution could result in damage to or destruction of the equipment Step 2 Connect the D C input power leads two wire 620 VDC nominal to the proper terminals according to drive type On 1 60 HP drives connect the D C input power leads to terminals and on the power terminal strip On 60 150 HP drives connect the D C input power leads to terminals 45 and 47 Note that the maximum discharge rate of the D C bus supply should be 200V second Step Tighten the D C input power terminals to the proper torque as shown in table 5 1 Step 4 On 60 150 HP drives using volts hertz regulation set parameter H 017 to a value greater than one to enable D C bus operation Refer to the GV3000 Programming instruction manual D2 3339 for additional in
36. 0 40V4250 50V4150 376 0 mm 605 0 mm 308 0 mm 565 2 mm 350 0 mm 25 8 kg 50V4250 14 80 23 82 12 13 22 25 13 78 57 Ibs 60G4150 60G4250 50R4150 421 0 mm 880 0 mm 360 0 mm 850 0 mm 322 0 mm 70 kg 75R4150 16 60 34 65 14 17 33 46 12 68 154 Ibs 125R4150 465 0 mm 1457 mm 330 0 mm 1414 mm 355 0 mm 96 kg 18 30 57 36 12 99 55 66 13 97 211 Ibs 60 150 KA a o Figure 3 1 Drive Dimensions 3 4 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 10 cm 4 in 25 10 in I 10 4 25 cm 10 10cm 47 60 150 0 87 0 87 4 1 6 4cm
37. 00 meters 3300 feet without derating output power For every 91 4 meters 300 feet above 3300 feet derate the output current 1 Verify that the drive location will meet the environmental conditions specified in table 3 1 Table 3 1 Ambient Conditions Condition Specification Operating Temperature Ambient 09 to 409 C 329 to 1049F Storage Temperature Ambient 406to 65 409 to 149 F Humidity 5 to 95 non condensing 3 1 3 2 3 1 2 Determining Total Area Required Based 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 GV3000 Drive Dim A Dim B Dim C Dim D Dim E Weight 1V4150 222 3 mm 280 7 mm 198 1 mm 254 3 mm 200 0 mm 6 3 kg 1V4450 8 75 11 05 7 80 10 01 7 87 14 Ibs 2V4150 2V4450 3V4150 3V4450 5V4150 5V4450 7V4150 280 6 mm 338 4 mm 248 0 mm 309 1 mm 200 0 mm 9kg 7V4250 11 05 13 32 9 76 12 17 7 87 20 Ibs 10V4150 10V4250 15V4150 288 0 mm 463 0 mm 223 0 mm 442 0 mm 238 1 mm 15 75 kg 15V4250 11 34 18 23 8 78 17 40 9 37 35 Ibs 20V4150 20V4250 25G4150 25G4250 25V4150 376 0 mm 605 0 mm 308 0 mm 565 2 mm 350 0 mm 23 6 kg 25V4250 14 80 23 82 12 13 22 25 13 78 52 16 30V4150 30V4250 40V415
38. 1 3 1 2 Determining Total Area Required Based on Drive Dimensions 3 2 3 1 3 Verifying the Site Provides for Recommended Air Flow Clearances 3 4 3 1 4 Verifying Power Module Input Ratings Match Supplied Power 3 5 3 2 Wiring Requirements for the 3 5 3 2 1 Meeting Terminal Strip Input and Output Specifications 3 5 3 2 2 Determining Wire Size Requirements 3 5 3 2 2 1 Conduit Entry Opening 3 5 3 2 2 2 Recommended Power Wire Sizes 3 5 3 2 2 3 Recommended Control and Signal Wire Sizes 3 6 3 2 2 4 Recommended Motor Lead Lengths 3 6 3 2 2 5 Recommended Serial Communication Cable Lengths 3 7 3 2 3 Selecting Input Line Branch Circuit Fuses 3 7 3 2 4 Meeting Pulse Tachometer Specifications Vector Regulation 3 8 3 2 5 Verifying Power Module Output Current Rating is Greater Than Motor Full Load AMPS 56 y be 3 8 4 0 5 0 6 0 7 0 8 0 9 0 Mounting the Drive Grounding and Finding Wire Routing Locations 4 1 4 1 Mounting the Drive rec x hha ne ea ERG Me
39. 1 67 10 4 If adjacent to other drives Figure 3 2 Recommended Air Flow Clearances 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 E stop wiring see chapter 7 are all areas that need to be evaluated 3 2 1 Meeting Terminal Strip Input and Output Specifications The terminal strip on the Regulator board provides terminals for 24 VDC power for the eight remote control inputs Refer to tables A 3 and A 4 for control input and output specifications 3 2 2 Determining Wire Size Requirements Wire size should be determined based on the size of conduit openings 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 BODIL
40. 35 61 NOWWOO 5304911934 1 Remote 4 20 mA Speed Torque Reference FUNCTION LOSS START STOP FOR 15 60 HP DRIVES USE 16A INSTEAD OF 16 AND 20A INSTEAD OF 20 ALSO SEE FIGURE 2 12 Figure 7 1 Two Wire Start Stop Sample Control Wiring 7 3 NONNWOO AVI LOVLNOD AVI NONWOO AVI3M AVI3M NOWWOO 20 vc 9NDIVH8 30191535 H388nNS OGA vZ 1815 4015 13538 90P NnN 5501 NOILONN4S 5 9 LOdNI TVLIDIG WVLISIC 8 WLIDIG 20 2 QNO 3ON333434 03191051 3ON3N3J3M 03395 39 343334 03395 32 34343 4 1 105 NONNOO YOLVINDAY 104100 N313A SOIWNV NONNOO YOLVINDAY LON 8 5 8 5 LON 3SVHd V 3SVHd 61 NOWWOO YOLVINDSY 1 4 20 Speed Torque Reference 17 o E 2 gt 15 60 HP DRIVES 16 INSTEAD 16 20 INSTEAD OF 20 ALSO SEE FIGURE 2 12 Figure 7 2 Three Wire Start Stop Sample Control Wiring 7 4 7 1 Stopping the Drive THE USER MUST PROVIDE AN EXTERNAL HARDWIRED EMERGENCY STOP CIRCUIT OUTSIDE OF THE DRIVE CIRCUITRY THIS CIRCUIT MUST DISABLE THE SYSTEM IN CASE
41. 7 9 11 Protection mechanical motor overload 6 1 Publications related 1 2 Pulse tachometer specifications A 2 wiring 2 14 7 1 7 5 to 7 6 see also Speed Feedback R Ramp1 ramp2 digital input 7 2 14 7 2 to 7 4 7 11 Ratings A C input 2 2 fuse 3 8 NEMA 2 2 output 2 2 power loss 2 2 Regulation drive vector block diagram B 3 volts hertz block diagram B 2 Regulator boards 2 3 to 2 15 Relays output status see Status Relays Remote digital input 8 2 14 7 2 to 7 4 7 10 Replacement parts 9 8 to 9 12 Reset digital input 3 2 14 7 2 to 7 4 7 14 Resistor bus discharge location 2 7 to 2 8 Snubber Braking kit see Kits Reverse digital input 6 2 14 7 2 to 7 4 7 12 Routing wiring 4 1 to 4 7 RS 232 cable length 3 7 7 7 communication port J8 3 7 specifications A 2 wiring 2 15 3 7 7 1 7 7 Run digital input 4 2 14 7 2 to 7 4 7 13 5 Selecting operation see Control Source Serial communication see RS 232 Site requirements 3 1 Snubber resistor braking 2 9 2 14 5 1 A 2 kit 2 16 low energy kit 2 16 wiring 2 14 7 2 to 7 4 7 14 Snubber Transistor Only kit 2 16 Specifications conduit opening sizes 4 2 to 4 7 dimensions 3 2 to 3 3 environmental 3 1 inputs terminal strip A 2 outputs terminal strip A 2 speed feedback A 2 torque ratings 5 4 wire sizes 3 5 to 3 6 Index 3 Speed feedback specifications A 2 wiring 2 14 7 1 7 5 to 7 7 see also Pulse Tachometer Sp
42. C input 3 7 to 3 8 5 1 to 5 2 G Gate Driver board 2 5 to 2 8 9 9 to 9 12 Ground fault transformer 2 7 to 2 8 9 11 to 9 12 Grounding 4 2 to 4 8 5 2 to 5 3 H Humidity 3 1 A 1 IGBT power devices 2 9 testing resistance checks 9 6 to 9 7 Inductor output see Output Reactor Input specifications terminal strip A 2 Input A C see A C Input Input digital see Digital Input Wiring Installation A C input disconnect 5 2 to 5 4 checking 8 1 to 8 2 completing 8 1 to 8 2 fuses A C input line branch circuit 3 7 to 3 8 5 1 to 5 2 input isolation transformer 5 1 mechanical motor overload protection 6 1 output contactors 6 1 planning 3 1 to 3 8 requirements 3 1 to 3 8 transformers and reactors 5 1 Index 2 Intelligent Power Module IPM board 2 7 to 2 8 9 11 to 9 12 J Jog digital input 4 2 14 7 2 to 7 4 7 13 Jumpers J4 2 10 to 2 12 J17 2 10 to 2 11 2 13 location of 2 10 to 2 11 settings for 2 12 to 2 13 K Keypad display 2 3 to 2 8 2 16 Kits AutoMax Network Communication board 2 16 DeviceNet Board 2 16 Line Regeneration Unit 2 16 Low Energy Snubber Resistor Braking 2 16 Motor Encoder Cable 2 16 Operator Interface Module 2 16 Remote Meter Interface 2 16 Snubber Resistor Braking 2 16 Snubber Transistor Only 2 16 L Lead lengths motor 3 6 to 3 7 LEDs 2 9 2 15 Line branch circuit fuses A C input 3 7 to 3 8 5 1 to 5 2 Line frequency A 1 Line noise avoiding 5 1
43. COMMON RELAY CONTACT N O RELAY COMMON 9 66 9 6 66 1 21 22 23 24 30 31 FACTORY INSTALLED CONFIGURABLE RS 232 PULSE TACHOMETER ANALOG ANALOG SPEED STATUS RELAYS CONNECTIONS CONNECTIONS OUTPUT REFERENCE SNUBBER RESISTOR DIGITAL INPUTS BRAKING CONTROL ISOLATED 24 VDC oo GV3000 460 15 60 HP ONLY FUNCTION LOSS INPUT 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 2 14 2 7 3 2 7 4 2 7 5 2 7 6 RS 232 Communication Port The Regulator board contains a 9 pin D shell RS 232 communication port J8 This port provides RS 232 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 D2 3348 for more information Option Board Connector The flat ribbon 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
44. Drive Components and Locations 2 3 2 4 25 60 HP GV3000 Drive Components and Locations 2 6 2 5 60 100 HP GV3000 Drive Components and Locations 2 7 2 6 100 150 HP GV3000 Drive Components and Locations 2 8 2 7 Regulator Board Description 2 9 2 7 1 Jumper Locations and Settings 2 12 2 7 1 1 Analog Input Speed Reference Jumper 2 12 2 7 1 2 Analog Output Jumper 2 13 2 7 2 Wiring the Terminal Strip 2 14 2 7 3 RS 232 Communication Port 2 15 2 7 4 Option Board Connector 2 15 2 7 5 Operator Interface Module Connector 2 15 2 7 6 KeypadiDisplay bete Pee 2 15 2 8 Drive Kit OptiONS E EUER VEL p M 2 16 Planning Before Installing 3 1 3 1 Requirements for the Installation Site 3 1 3 1 1 Making Sure Environmental Conditions are Met 3
45. GV3000 A C Power Modules Hardware Reference Installation and Troubleshooting Version 5 0 Instruction Manual D2 3340 RELIANCE ELECTRIC MLI 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 D C BUS CAPACITORS RETAIN HAZARDOUS VOLTAGES AFTER INPUT POWER HAS BEEN DISCONNECTED AFTER DISCONNECTING INPUT POWER WAIT FIVE 5 MINUTES FOR THE D C BUS CAPACITORS TO DISCHARGE AND THEN CHECK THE VOLTAGE WITH A VOLTMETER TO ENSURE THE D C 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 PERSONNE
46. 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 Terminal 4 Pulse Tachometer Supply 15 VDC Terminal 5 Pulse Tachometer Phase A Differential Input Terminal 6 Pulse Tachometer Phase A Not Differential Input Terminal 7 Pulse Tachometer Phase Differential Input Terminal 8 Pulse Tachometer Phase Not Differential Input 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 7 5 7 6 WHITE
47. L 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 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 DeviceNet is a trademark of Open DeviceNet Vendor Association GV30006 AutoMax and Reliance are registered trademarks of Reliance Electric Company or its subsidiaries 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 A C 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 as amended and that the following harmonized standards have been applied EN 60204 1 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 incorpora
48. LED FORWARD DIRECTION ONLY Terminal 19 On Reverse Direction Diagram shows factory setting From the pulse tachometer end of the motor clockwise rotation indicates forward mo tor movement Table 7 1 Wiring Signal and Control I O to the Terminal Strip Continued Terminal Number Description Parameters Wiring Connections Wiring a Function Loss Input Digital Input 5 Function Loss The following parameters must be set 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 TERMINAL STRI 161718 19 2021 161718 00900 090900 ae eid SAFETY INTERLOCKS REMOVE FACTORY FUNCTION FUNCTION LOSS COAST STOP LOSS JUMPER HERE PUSHBUTTON or from 16A and 20A on 15 60HP drives Terminal 20 On No Function Loss Wiring a Run Jog Input Digital Input 4 Run Jog The following parameters must be set 000 Control Source P 020 Jog Speed Reference P021 Jog Ramp Accel Time 022 Jog Ramp Decel Time 16 JOG Terminal 21 On Jog Operation 7 13 7 14 N
49. LOSS OF LIFE 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 e QGV3000 drives will typically be referenced by horsepower If additional clarity is required drive model numbers will also be included e Parameters will be referenced either as parameter P030 or Elapsed Time Meter Reset P030 If You Want to Know More Refer to the following related publications as necessary for more information e 02 3339 GV3000 A C General Purpose V Hz and Vector Duty Drive Software Start Up and Reference Manual e 02 3291 Snubber Resistor Braking Kit e D2 3305 Motor Encoder Cable Kit e 02 3308 AutoMax Network Communication Board e D2 3348 Control and Configuration Software CS3000 e D2 3341 Remote Meter Interface e D2 3342 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 1 800 RELIANCE 2 0 ABOUT THE DRIVE This chapter describes how to identify the drive using the model number matrix and illustrates the differences betwee
50. ORANGE 1 PHASE SORE 2 PHASE RED 6 0 VDC WHITE RED 12 15 VDC BROWN 8 PHASE 9 PHASE WHITE BROWN Figure 7 3 Wiring Connections for the Speed Feedback Device Step 2 Set the following parameters to establish the maximum motor speed P004 Maximum Speed U 001 Pulse Tach PPR U 002 Motor Poles U 003 Motor Nameplate Base Frequency U 005 Motor Nameplate RPM U 017 Motor Top Speed Refer to the GV3000 Programming Manual D2 3339 for more information 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 Table 7 1 Wiring Signal and Control I O to the Terminal Strip Terminal Number Description Parameters Wiring Connections Wiring RS 232 Signals 1 RS 232 Transmit Note that RS 232 communication between the GV3000 2 RS 232 Receive drive and a personal computer requires the use of the 3 RS 232 Signal Regulator Control and Configuration software Refer to instruction Common manual D2 3348 for more information These terminals should only be used when the RS 232 port J8 or an Operator Interface module OIM are not being used as all three devices use the same transmit receive lines PERSONAL COMPUTER TERMINAL STRIP 25 PIN D SHELL MALE OR 9 PIN 0 5 PLUG 1 1 2 3 200 o TXD DATA OUT TERMINAL 1 O
51. Pushbutton colors 10 8 Displays 11 Control interfaces 11 2 Digital input output interfaces 11 2 1 Inputs 11 2 2 Outputs 11 3 Drive interfaces with analog inputs 11 3 1 Separation between control and electric drives 11 5 Communications 12 Electronic equipment 12 2 2 Electronic control equipment 12 2 3 Equipotential bonding 12 3 Programmable equipment 12 3 1 Programmable controllers 12 3 2 Memory retention and protection 12 3 3 Programming equipment 12 3 4 Software verification 12 3 5 Use in safety related functions 13 Controlgear Location mounting and enclosures 13 2 3 Heating effects 13 4 Enclosures doors and openings 15 Wiring practices 15 1 1 General requirements 15 1 3 Conductors of different circuits 15 2 2 Identification of the protective conductor 18 Warning signs and item identification 18 2 Warning signs 18 4 Marking of control equipment 19 Technical documentation 19 1 General C 2 Reliance Electric 24703 Euclid Avenue Cleveland Ohio 44117 216 266 7000 RELIANCE ELECTRIC M Printed in U S A D2 3340 December 1995
52. 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 Table 7 Input Signal Response Times Worst Case These are maximum times from transitioning the input to the drive reacting to the input Signal and Source Volts Hertz Regulation Vector Regulation Keypad START 150 milliseconds 130 milliseconds Terminal Strip 126 milliseconds 105 milliseconds STOP RESET FL 75 milliseconds 75 milliseconds Preset Speeds 75 milliseconds 75 milliseconds Analog Speed Trim 16 milliseconds 5 milliseconds Reference N A Analog Torque Reference 0 5 milliseconds 46 milliseconds network 25 milliseconds network transport time transport time STOP RESET FL 26 milliseconds network 25 milliseconds network transport time transport time Analog Speed Trim 5 milliseconds network 5 milliseconds network Reference transport time transport time Torque Reference N A 0 5 milliseconds network transport time A 3 Drive Regulation Overview The GV3000 is a digital drive that provides closed loop vector or open loop volts hertz regulation of A C motors The Volts Hertz or Vector Regulation parameter 48 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 provid
53. Vector 380 460 VAC 1 3 4 100 2V4450 2 HP ub 3V4150 V Hz or Vector 380 460 VAC 3V4450 8 HP ax 12 5V4150 V Hz or Vector 380 460 VAC 5V4450 5 HP ax 12 7 4150 V Hz or Vector 380 460 VAC 7V4250 7 5 HP 10V4150 V Hz or Vector 380 460 VAC 10V4250 10 HP 15V4150 V Hz or Vector 15V4250 15 HP 20V4150 V Hz or Vector 20V4250 20 HP 25V4150 a or 380 460 25 4250 25 30 4150 V Hz or Vector 380 460 VAC 30V4250 30 HP 40V4150 V Hz or Vector 380 460 VAC 40V4250 40 HP 50V4150 V Hz or Vector 380 460 VAC 50V4250 50 HP 50R4150 Vector 50 HP 380 460 VAC V Hz 75 HP 60G4150 380 460 VAC 60G4250 75R4150 Vector 60 75 HP 380 460 VAC V Hz 100 HP 125R4150 Vector 100 125 HP 380 460 VAC V Hz 125 150 HP 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 e NEMA 1 Vented Contains a communication access door that allows access to the communication port without removing the cover Intended for general purpose indoor applications e NEMA 4X 12 Not vented Supplied with base and keypad gaskets Intended for use in indoor environments that require a water tight dust tight enclosure An enclosure with this
54. Y 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 continuous rated input current Output wiring should be sized according to applicable codes to handle the drive s continuous rated output current See tables 3 3 through 3 7 for recommended power wire sizes Table 3 3 Recommended Power Wire Sizes for 1 10 HP Drives Type of Wiring Terminals Size of Wire Maximum A C Input Power R L1 S L2 T L3 Output Power U T1 V T2 W T3 12 AWG D C Input Power du Table 3 4 Recommended Power Wire Sizes for 15 25 HP Drives Type of Wiring Terminals Size of Wire Maximum A C Input Power R L1 S L2 T L3 Output Power U T1 V T2 W T3 6 AWG 13 mm D C Input Power 3 5 Table 3 5 Recommended Power Wire Sizes for 25 60 HP Drives Type of Wiring Terminals Size of Wire Maximum A C Input Power R L1 S L2 TL3 Output Power U T1 V T2 W T3 2 0 AWG 2X 185 D C Input Power Ta Table 3 6 Recommended Power Wire Sizes for 60 100 HP Drives Type of Wiring Terminals Size
55. alling A C Output Power Wiring Describes output A C line components and how to properly connect them to the motor e Chapter7 Wiring the Regulator Board Terminal Strip Provides information on the 1 wiring that connects to the terminal strip on the Regulator board e Chapter8 Completing the Installation Provides instructions on how to perform a final check of the installation before power is applied e Chapter9 Troubleshooting the Drive Describes the equipment that is needed to troubleshoot the drive and how to measure D C bus voltage Replacement part lists are also provided Appendix A Technical Specifications Lists drive specifications in table form e Appendix B Drive Regulation Overview Briefly describes volts hertz and vector regulation e Appendix C Compliance with EN 60204 1 1992 Lists the sections of standard EN 60204 1 1992 that the GV3000 drive complies with 1 2 1 2 1 3 Assumptions About the Audience This manual is intended for qualified electrical personnel It is task oriented and is organized according to a logical progression of steps to be followed to install and troubleshoot the drive 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
56. ansformer Output Reactor Precharge Resistor 18 ohms Bus Discharge Resistor 1 5K ohms 24V D C Fan Components are identified in figure 2 7 mam 413338 5AX 1 413338 5E 2 413338 5K 3 413338 5R 2 413338 5V 2 11 Table 9 7 100 150 HP Drive Replacement Parts Description Part Number Quantity Regulator PCB 413338 5AU Lb hM Ij Power Module Interface PCB 413338 5AV Power Module Interface PCB Fuses 413338 5AB 413338 5AX E 3 Bus Clamp PCB right 413338 5AE 2 mengem Power Module PM POB f 8 Thyristor Precharge Module 413338 5AJ _ 2 Ground _ 3 _ SUM Reactor 413338 5AR Bus Discharge 4 woon Thyristor Firing Pulse PCB 413338 5AG D cw g Thyristor Firing Pulse PCB Fuses 15 413338 1 5 Components identified in figure 2 8 t is recommended that the Gate Driver PCB be replace at the same time as the IPM A BR BRI A C input diodes checking 9 6 to 9 7 disconnect installing 5 2 to 5 4 isolation transformer 5 1 line branch circuit fuses 3 7 to 3 8 5 1 to 5 3 ratings 2 2 wire sizes 3 5 to 3 6 wiring 3 5 to 3 7 4 1 to 4 8 5 1 to 5 5 voltage transients avoiding 5 1 A C output wiring 3 5 to 3 7 4 1 to 4 8 6 1 to 6 2 Air flow 3 1 3 4 Ala
57. ch Circuit Protection Install the required user supplied 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 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 5 1 3 Input Voltage 460 V 181 182 183 GND 9 9 29 Disconnect 2 User Supplied GV 3000 Power Module Motor Overload Relay User Supplied Optional if Electronic Overload is Used Figure 5 1 Typical A C Input Electrical Connections User Supplied Manual Disconnect Fuse User Supplied Figure 5 2 Typical D C Bus Electrical Connections D C Input Voltage 620V Nominal O GV 3000 Power Module Motor Overload Relay Optional if Electronic Overload is Used 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 shou
58. ction 9 3 to ensure that the D C bus capacitors are discharged Disconnect the motor from the drive Check all A C line and D C bus fuses If a fuse is blown use a multimeter to check the input diodes and output IGBTs See table 9 1 Note that 1 10HP 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 60 150HP drive Re connect the motor to the drive Re attach the drive s cover Re apply input power Table 9 1 Resistance Checks 1 60HP Drives Meter Connection Component is OK if resistance is Component is defective if R L1 50 lt lt 10 Continuity short circuit or open when the meter is S L2 connected with reversed polarity T L3 R L1 5 512 Bus Volts power terminal D C Bus Volts power terminal 9 6 Table 9 1 Resistance Checks Continued 60 100HP Drives Meter Connection Component is OK if resistance is Component is defective if 0 3 kohm lt R lt 8 kohm Continuity short circuit or open when the meter is connected with reversed polarity 100 150HP Drives Input Meter Diode Connection Component is OK if No resistance is Component is defective if 1 47 1L1 R 100 kohm Continuity short circuit 1 60HP Drives Connection Component is OK if
59. ee 4 1 4 1 1 Verifying the Drive s Watts Loss Rating 4 1 4 2 Routing Input Motor Output Ground and Control Wiring for the Drive 4 1 4 3 Grounding the Drive esau ev ev wed ee dees NE es 4 8 Installing Input Power Wiring 5 1 5 1 Installing Transformers and Reactors 5 1 5 2 Installing Fuses for Branch Circuit Protection 5 1 5 3 Installing a Required External Separate Input Disconnect 5 4 5 4 Installing Power Wiring from the A C Input Line to the Drive s Power Terminals 5 4 5 5 Installing Power Wiring from an External D C Bus to the Drive s Internal D C Bus TermirialS z t hace NP ER EA d Rb UOI 5 5 Installing Output Power Wiring 6 1 6 1 Installing Output Contactors Optional 6 1 6 2 Installing Mechanical Motor Overload Protection Optional 6 1 6 3 Installing Output Wiring from the Drive Output Terminals to the 6 1 Wiring the Regulator Board Terminal Strip 7 1 7 1 Stopping the Drive b ee CERE E a REG dae 7 5 7 1 1 Compliance with
60. eed maximum setting 7 6 Start digital input 1 2 14 7 2 to 7 4 7 14 Status relays Form A B 2 9 2 14 7 2 to 7 4 7 15 Stop digital input 2 2 14 7 2 to 7 4 7 14 Stopping the drive 7 5 Switch membrane see Keypad Display T Tachometer pulse see Pulse Tachometer Terminal strip wiring 2 14 3 6 7 1 to 7 15 input specifications A 2 output specifications A 2 torque specifications 5 4 wire sizes 3 5 to 3 6 Testing IGBT 9 6 to 9 7 Thyristor precharge board 2 8 9 12 Transformer current 2 7 to 2 8 9 11 to 9 12 ground fault 2 7 to 2 8 9 9 to 9 11 isolation input installing 5 1 Transients A C line voltage 5 1 V Vector regulation B 1 block diagram B 3 Ventilation see Air Flow Volts hertz regulation B 1 block diagram B 2 Watts loss rating 2 2 4 1 Weights 3 2 Index 4 Technical Specifications Table A 1 Service Conditions A C Line Distribution System Capacity maximum 1000KVA three phase with 25 000 amps symmetrical for 460 VAC Units fault current capacity with a line impedance of less than 8 Control Method All digital vector sinusoidal pulse width modulated PWM Line Frequency 50 60Hz 2 Hz Line Voltage Variation 1096 to 10 Line Dip Ride Through Maximum 500 milliseconds vector Adjustable up to 999 9 seconds See P042 V Hz Motor Lead Lengths 76 meters 250 feet total Acceleration Adjustment Range 0 1 to 999 9 seconds within
61. ernal 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 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 Bi polar 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 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 Display data for a four character display and fourteen indicator LEDs The four character 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 four character display An analog output The analog output is a scaled voltage 0 10 VDC or current 4 20 mA signal proportional to either motor speed RPM or motor torque or current TORQUE The cu
62. es general purpose open loop A C 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 user specified motor characteristics The control loop output switches the power device gates generating a pulse width modulated PWM waveform to the motor Vector Regulation Vector regulation allows dynamic closed loop performance in an A C drive similar to that achieved with a D C 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 user specified Torque Reference Source parameter for the torque control loop An internally generated 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 pulse width modulated PWM waveform to the motor B 1 OOOEA
63. formation 5 5 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 P040 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 A C motors under all conditions Parameter P040 must be enabled to provide overload protection Refer to the GV3000 Programming Manual D2 3339 for more information In multiple motor applications volts hertz regulation only each motor must have its own user supplied overload protection 6 3 Installing Output Wiring from the Drive Output Terminals to the Motor Use the following steps to connect the A C output power wiring from the drive to the motor Step 1 W
64. g 25 412000 02 3291 2SR41800 9 Low Energy Snubber Braking 2DB4010 5 Resisto rA 2DB4020 D2 3179 Snubber Transistor Only 1 2 2ST40027 D2 3291 1RG42008 Line Regeneration Unit 2 3 1RG42015 N A 1RG42045 2TC3025 9 2TC3075 9 2TC4025 9 1 2 3 4 Motor Encoder Cable 2 3 4 276407505 02 3305 27041006 2TC4300 9 AutoMax Network Communication Board w 10 Feet of Cable 1 2 9 4 ZAAO UR Remote Meter Interface RMI 2513000 02 3341 DeviceNet Board 2DV3000 HE HGV3DN Operator Interface Module OIM 2RK3000 D2 3342 Control and Configuration Software 2 CS3000 2CS3000 D2 3348 1 5 HP GV3000 Drives 7 5 10 HP GV3000 Drives 15 60 HP GV3000 Drives 60 150 HP GV3000 Drives For use with Reliance NEMA Vector Inverter Duty Motors tachometer connector and exposed wire pairs For use with Reliance NEMA Vector Inverter Duty Motors exposed wire pairs on both ends 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
65. ice Specifications Vector Regulation Only A 2 Table A 7 Input Signal Response Times Worst Case A 3 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 A C General Purpose V Hz and Vector Duty Drive Software Start Up and Reference Manual 02 3339 As an aid in finding information in this manual each chapter is briefly described below e Chapter1 Becoming Familiar with the Manual Provides information on how the manual is organized and where to find additional information e Chapter2 Aboutthe Drive Identifies drive components and shows their locations e Chapter3 Planning Before Installing Presents information that must be considered when planning a drive installation e Chapter4 Mounting the Drive Grounding and Finding Wire Routing Locations Describes how to mount the drive and properly ground it e Chapter5 Installing Input Power Wiring Describes incoming A C and D C line components and how to properly connect them e Chapter6 Inst
66. information Voltage Input Option Current Input Option Pins 2 3 Pins 1 2 10 VDC 0 20 mA O O J4 default Figure 2 10 Jumper J4 Settings for Analog Input Speed Reference 2 7 1 2 Jumper 17 is the analog output jumper This jumper selects either 0 10 VDC or 4 20 mA scaled signal output that is programmable for either speed or torque parameter 012 The jumper only selects a 0 10 VDC source voltage or 4 20 mA sink current to represent speed or torque Note that the 4 20 mA current selection requires a power supply for operation as shown in table 7 1 terminals 10 and 11 Use the following procedure to set jumper J17 DANGER D C BUS CAPACITORS RETAIN HAZARDOUS VOLTAGES AFTER INPUT POWER HAS BEEN DISCONNECTED AFTER DISCONNECTING INPUT POWER WAIT FIVE 5 MINUTES FOR THE D C BUS CAPACITORS TO DISCHARGE AND THEN CHECK THE VOLTAGE WITH A VOLTMETER TO ENSURE THE D C 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 D C 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
67. ion loss coast stop pushbutton has been installed verify that it has been wired correctly Be sure the factory installed jumper at terminals 16 and 20 or 16A and 20A has been removed so that the coast stop pushbutton will work 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 user supplied 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 8 1 8 2 8 2 8 3 Step 13 Verify that properly sized ground wire is installed and suitable earth ground is used Check for and eliminate
68. ire the three phase A C 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 1 5 HP drives route the motor leads through the bottom right opening of the drive base On 7 5 25 HP drives route the motor leads through the bottom right opening of the drive base On 25 60 HP drives route the motor leads through the middle bottom opening of the drive base On 60 100 HP drives route the motor leads through the bottom right opening of the cover On 100 150 HP drives route the motor leads through the three left most 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 6 1 6 2 Step 2 Connect the three phase output power motor leads to the proper output terminals according to drive type On 1 60 HP drives connect the motor leads to terminals U T1 V T2 W T3 on the
69. ition 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 P009 P010 and P011 are correct before starting the drive Refer to instruction manual D2 3339 for more information Use the following procedure to set jumper J4 DANGER D C BUS CAPACITORS RETAIN HAZARDOUS VOLTAGES AFTER INPUT POWER HAS BEEN DISCONNECTED AFTER DISCONNECTING INPUT POWER WAIT FIVE 5 MINUTES FOR THE D C BUS CAPACITORS TO DISCHARGE AND THEN CHECK THE VOLTAGE WITH A VOLTMETER TO ENSURE THE D C 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 Step 2 Step 3 Step 4 Step 5 Step 6 Step 7 Step 8 Turn off input power to the drive and wait five minutes Remove the cover from the drive by unscrewing the four attaching screws Verify that the D C bus voltage is zero by following the procedure in section 9 3 Locate jumper J4 on the Regulator board Refer to figures 2 8 and 2 9 Locate pin 1 on jumper J4 Move the jumper to the desired setting as shown in figure 2 10 Re attach the cover Re apply input power Verify that Terminal Strip Analog Input Offset 009 Terminal Strip Analog Input Gain P010 and Terminal Strip Analog Input Invert P011 are correctly set Refer to instruction manual D2 3339 for more
70. ld be sized according to the in rush current as well as any additional loads the disconnect might supply Note that the trip rating for the inrush current 10 12 times full load current should be coordinated with that of the input isolation transformer if used Refer to section 5 1 for additional information 5 4 Installing Power Wiring from the A C Input Line to the Drive s Power Terminals Use the following steps to connect A C input power to the drive Step 1 Wire the A C 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 1 5 HP drives route the power leads through the bottom right opening of the drive base On 7 5 25 HP drives route the power leads through the bottom middle right opening of the drive base If the snubber resistor braking option is used route the power leads through the bottom right opening On 25 60 HP drives route the power leads through top right or bottom right openings of the drive base On 60 100 HP drives route the power leads through the bottom left opening of the cover On 100 150 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
71. ls 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 007 P 008 and P031 through P038 Factory default settings are shown here in parentheses Refer to the GV3000 Programming Manual 02 3339 for more information Snubber Resistor Braking Connections Terminals 26 and 27 e Terminal 26 Snubber Resistor Braking Signal 1 25HP Drives only e Terminal 27 24 VDC Common Status Relay Connections Terminals 28 31 e Terminal 28 N C Relay Contact e Terminal 29 N C Relay Common e Terminal 30 N O Relay Contact e Terminal 31 N O Relay Common Relay contact closure is programmable through parameter P013 Refer to the GV3000 Programming Manual D2 3339 for more information NOWWOO AVI3M AVI3M NOWWOO AVI3H AVI3M NONWWOO vo t IWNSIS S9NDIVH8 YOLSISSY YAEENNs NONWOO LYVLS 4015 13534 90 5501 14 6 9 TWLIDIG 7 LAdNI TVLIOIQ OVOOVALOWAY 8 TWLIDIG 20 39343333 319105 39 343333 9334 3ON333434 9334 20 39 343334 03191051 NOWWOO 5901911934 104100 N313W 5 NONWOO 301911934 LON 8 5 8 LON 3SVHd V
72. n Assembly GATE DRIVER BOARD i IGBT MODULE 0 709579 1 opp 00 POWER BOARD M N M N M N 25V4150 25V4250 30V4150 30V4250 2 6 40V4150 60G4150 40 4250 6064250 50V4150 50V4250 Figure 2 5 25 60 HP Drive Components and Locations 0000000 25 p em MEMBRANE SWITCH KEYPAD TOP BRACKET 5 REGULATOR BOARD 2 5 60 100 GV3000 Drive Components and Locations The 60 100 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 1 Regulator Printed Circuit Board PCB 2 Power Module Interface PCB 3 Gate Driver PCB 4 Bus Clamp PCB Right 5 Bus Clamp PCB Left 6
73. n P000 rE P006 Second Menu Password P007 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 P000 P007 P008 and r 030 if RMI board is used the following parameters can affect digital input 8 P 023 MOP Accel Decel Time P024 Reset Configuration P031 to P038 Preset Speeds 1 8 Refer to the GV3000 Programming instruction manual D2 3339 for additional information Terminal 17 On Local Control Diagram shows factory setting 7 10 Number Table 7 1 Wiring Signal and Control I O to the Terminal Strip Continued Description Parameters Wiring Connections Wiring an Additional Ramp Input 18 Digital Input 7 Default Ramp1 Ramp2 Digital input 7 is control function programmable through parameter 007 The following parameters must be set 000 Control Source 001 Accel Time 1 Ramp 1 002 Decel Time 1 Ramp 1 006 Second Menu Password P007 Terminal Strip Digital Inputs Configure Selects and assigns a control function to digital inputs 6 to 8 P008 Terminal Strip Speed Reference Source Analog Motor Operated Potentiometer MOP or Preset Speeds P017 Accel Time 2 Ramp 2 P018 Decel Time 2 Ram
74. n the NEMA enclosures Major components of each drive group are also shown The GV3000 A C 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 21 Identifying the Drive by Model Number Each GV3000 A C 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 Horsepower Ratings lt 50 HP gt 50 HP V Hz Only V Gv3000 Voltage 2 200 230V 4 380 460V Enclosure 1 1 2 12 4 NEMA Indoor Only NEMA 12 Regulator Version 5 0 Vector and V Hz Regulator Figure 2 1 Identifying the Drive Model Number 2 1 2 2 Table 2 1 Power NEMA Enclosure Ratings Selected Input Output Model Regulation and Voltage Amps Number Horsepower Rating 10 1V4150 V Hz or Vector 380 460 VAC 1V4450 1 HP 2V4150 V Hz or
75. o help eliminate the following Damaging line voltage transients from reaching the drive e Line noise from the drive back to the incoming power source Damaging currents that could develop if a point inside the drive becomes grounded Observe the following guidelines when installing an isolation transformer A power disconnecting device must be installed between the power line and the primary of the transformer e lf the power disconnecting device is a circuit breaker the circuit breaker trip rating must be coordinated with the in rush current 10 to 12 times full load current of the transformer e 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 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 A C line is shared directly with other SCR rectified drives an optional snubber resistor braking kit might be required to alleviate excess D C bus voltage Failure to observe these precautions could result in damage to or destruction of the equipment 5 2 Installing Fuses for Bran
76. of Wire Maximum 1L1 1L2 113 A C Input Power 211 212 4 0 AWG 95 mm Output Power U V W A C Ground PE 2 AWG 35 D C Input Power 45 47 4 0 AWG 95 D C Ground 6 AWG 16 Table 3 7 Recommended Power Wire Sizes for 100 150 HP Drives Type of Wiring Terminals Size of Wire Maximum 111 112 IL3 A C Input Power i p 211 212 2 0 AWG 2X 185 Output Power U V W A C Ground PE 4 0 AWG 95 D C Input Power 45 47 2 AWG 35 D C Ground 6 AWG 16 mm 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 Newton meters 4 5 in Ibs Table 3 8 Recommended Terminal Strip Wire Sizes Terminals Wire Size 1 to 31 20 to 14 AWG 2 to 0 5 mm 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 capacitively coupled currents
77. oss 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 4 1
78. p 2 Note that based on the settings of parameters P000 P007 P008 and r 030 if an RMI board is used the following parameters can affect digital input 7 023 Accel Decel Time P024 Reset Configuration P031 to P038 Preset Speeds 1 8 Refer to the GV3000 Programming instruction manual D2 3339 for additional information Terminal 18 On Ramp 2 Diagram shows factory setting 7 12 Number Table 7 1 Wiring Signal and Control to the Terminal Strip Continued Description Parameters Wiring Connections Wiring a Forward Reverse Input 19 Digital Input 6 Default Forward Reverse Digital input 6 is control function programmable through parameter 007 The following parameters must be set 000 Control Source 006 Second Menu Password P007 Terminal Strip Digital Inputs Configure Selects and assigns a control function to digital inputs 6 to 8 P008 Terminal Strip Speed Reference Source Analog Motor Operated Potentiometer MOP or Preset Speeds P027 Reverse Disable Note that based on the settings of parameters P000 P007 P008 r 030 if an RMI board is used the following parameters can affect digital input 6 023 Accel Decel Time P024 MOP Reset Configuration P031 to P038 Preset Speeds 1 8 Refer to the GV3000 Programming instruction manual D2 3339 for additional information EV 027 ENAB
79. rms 9 1 Altitude requirements 3 1 Ambient conditions 3 1 A 1 Analog output 2 9 0 10 VDC J17 2 9 to 2 11 2 13 A 2 4 20 mA J17 2 9 to 2 11 2 13 A 2 wiring 2 14 7 1 7 3 to 7 4 7 8 Analog input speed reference eaten wiring 2 14 7 1 7 3 to 7 4 7 9 input voltage wiring 2 14 7 1 7 3 to 7 4 7 9 A 2 0 10 VDC J4 2 10 to 2 12 7 1 4 20 mA J4 2 10 to 2 12 7 1 Area required 3 2 to 3 4 Audience intended 1 2 Block diagram vector regulation B 3 volts hertz regulation B 2 Board Bus Clamp 2 7 to 2 8 9 11 to 9 12 Capacitor 2 3 to 2 5 9 8 to 9 9 Current Feedback 2 3 to 2 5 9 8 Gate Driver 2 5 to 2 8 9 9 to 9 12 Intelligent Power Module IPM 2 7 to 2 8 9 11 to 9 12 Option 2 15 2 16 Power 2 5 2 6 9 9 9 10 Power Supply 2 5 2 6 9 9 9 12 Regulator 2 3 to 2 14 3 7 9 8 to 9 10 Thyristor Precharge 2 8 9 12 Braking snubber resistor 2 9 2 16 5 1 A 2 wiring 2 14 7 2 to 7 4 7 14 Bus clamp board 2 7 to 2 8 9 11 to 9 12 Capacitor board 2 3 to 2 5 9 8 to 9 9 Capacitors D C bus 9 1 to 9 5 Carrier frequency 2 9 A 1 CS3000 see Control and Configuration Software Closed loop see Vector Regulation Communication port J8 2 10 to 2 11 2 15 3 7 7 1 7 7 Communication network 2 15 3 7 Component locations 2 3 to 2 8 Conduit size 4 2 to 4 7 Control and Configuration Software 1 2 2 16 3 7 Contacting Reliance 1 2 Contactors installing output
80. rrent 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 snubber resistor braking signal The 1 60 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 1 60 HP Regulator boards are used with 1 60 HP drives 60 150 HP Regulator boards are used with 60 150 HP drives As shown in figures 2 8 and 2 9 the Regulator boards are similar but have different Power Module interface connectors 2 9 c 7 USER DISPLAY uoqq y uld 9c ooooooooon 34 Ribbon Cable 00000 Ji7 J4 USER I O TERMINAL STRIP S 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 6 1 2 3 4 5 6 7 8 9 10 11 12 15 14 15 16 17 18 19 20 21 22 25 24 25 26 27 28 29 30 31 43 Option Board Connector J8 RS232C Port 44 Analog Input Jumper J9 Keypad Display Connector J5 Power Module Feedback Cable J17 Analog Output Jumper J7 OIM Optional Connector Figure 2 8 1 60
81. st in troubleshooting when a problem develops during self tuning or drive operation If an alarm condition occurs the drive will continue to run and a 2 or 3 digit alarm code will flash on the display If a fault occurs the drive will coast to stop and a 2 or 3 digit fault code will flash on the display Refer to the GV3000 Software Start Up and Reference Manual D2 3339 for more information on drive alarms and faults 9 3 Verifying That D C Bus Capacitors are Discharged DANGER D C BUS CAPACITORS RETAIN HAZARDOUS VOLTAGES AFTER INPUT POWER HAS BEEN DISCONNECTED AFTER DISCONNECTING INPUT POWER WAIT FIVE 5 MINUTES FOR THE D C BUS CAPACITORS TO DISCHARGE AND THEN CHECK THE VOLTAGE WITH A VOLTMETER TO ENSURE THE D C 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 D C 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 D C bus potential with a voltmeter For 1 60 HP drives measure the D C bus potential at the D C bus power terminals See figures 9 1 and 9 2 For 60 100HP drives while standing on a non
82. ted 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 Qf at Name Charles Jank Position Product Development Safety Engineer 1 0 2 0 3 0 Table of Contents Becoming Familiar with the Manual 1 1 1 1 INfOrMation PA ee a A BUA e ed antes 1 1 1 2 Assumptions About the Audience 1 2 1 3 Taking Safety Precautions 1 2 1 4 Understanding Terms Used in this Manual 1 2 1 5 If You Want to Know More 2 14 1 4 1 2 1 6 Getting Assistance from Reliance Electric 1 2 About the Drive sciri agen moe E oe E 2 1 2 1 Identifying the Drive by Model Number 2 1 2 2 NEMA EnclosUres nn yen PIXG 2 2 2 3 1 25 HP GV3000
83. the RS 232 terminals 1 3 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 3 7 3 8 Table 3 9 A C Input Line Fuse Selection Values Model Number Horsepower Rating Input Voltage Fuse Rating 1V4150 380 460 VAC 1V4450 2V4150 380 460 VAC 2V4450 3V4150 3 380 460 VAC 12A 3V4450 5V4150 5 380 460 VAC 20A 5V4450 7V4150 7 5 380 460 25 7 4250 10V4150 380 460 VAC 10V4250 15V4150 380 460 VAC 15V4250 20V4150 380 460 VAC 20V4250 25G4150 25 380 460 VAC 25 4150 25 380 460 30 4150 30 380 460 40V4150 40 380 460 VAC 50V4150 50 380 460 VAC 50R4150 Vector 50 380 460 VAC 60G4150 380 460 VAC 60G4250 75R4150 Vector 60 75 380 460 VAC 125R4150 380 460 VAC V Hz 125 150 Recommended fuse type UL Class J 600V time delay or equivalent 3 2 4 3
84. the ability of current Carrier Frequency 2 Hz 4 Hz or 8 Hz software selectable Current Limit Adjustment U 006 to 150 based on drive nameplate rating vector 5096 to 11096 based on drive nameplate rating V Hz 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 Operating Temperature Ambient 0 to 40 32 to 10492 Storage Temperature Ambient 40710 65 40 to 149 F 9995 fnorccondensing A 1 2 Table Terminal Strip Input Specifications Signal Type Terminal s Specification impedance or 20 mA Table A 4 Terminal Strip Output Specifications Analog Output 10 11 0 10 VD C 4 20 mA scaled signal Snubber Resistor 26 27 Used with Snubber Resistor Braking Kits Refer to Instruction Manual D2 3179 Table A 5 RS 232 Specifications Table A 6 Speed Feedback Device Specifications Vector Regulation Only 5 2 200 load based drive nameplate rating 150 for 1 minute based on drive nameplate rating Speed Control Range 1 600 with 1024 PPR
85. tion by automatic disconnect of supply 6 4 Protection by the use of PELV Protective Extra Low Voltage 7 Protection of equipment 7 2 Overcurrent protection 7 2 3 Control circuits 7 2 6 Transformers 7 5 Protection against supply interruption or voltage reduction and subsequent restoration 8 Equipotential bonding 8 2 1 General the PE terminal 8 2 2 Protective conductors connection points 8 2 3 Continuity of the protective bonding circuit 8 2 7 Protective conductor connecting points 8 3 Bonding to the protective bonding circuit for operational purposes 8 4 Insulation failures 8 5 Bonding to a common reference potential 8 6 Electrical interferences 9 Control circuit and control functions 9 1 1 Control circuit supply 9 1 3 Protection 9 1 4 Connection of control devices 9 2 Control functions 9 2 1 Start function 9 2 2 Stop function 9 2 3 Operating modes 9 2 5 Operation 9 2 5 3 Stop 9 2 5 6 Hole to run controls 9 2 6 Combined start and stop controls 9 3 Protective interlocks 9 3 5 Reverse current braking 9 4 Control functions in case of failure 9 4 2 1 Use of proven circuit techniques and components 9 4 3 Provisions for redundancy 9 4 3 1 Earth faults 9 4 3 2 Voltage interruption C 1 Compliance with EN 60204 1 1992 Continued EN60204 1 Section Title 10 Operator interface and machine mounted control devices 10 2 1
86. tput Connections Terminals 10 and 11 e Terminal 10 Analog Meter Output e Terminal 11 Regulator Common The output of this terminal is either 0 10 VDC or 4 20 mA as determined by the setting of jumper J17 on the Regulator board The analog output must also be programmed via parameter P012 for an indication of speed and direction or percent of torque Analog Speed Torque Reference Connections Terminals 12 15 e Terminal 12 Isolated Reference Voltage e Terminal 13 VDC Speed Torque Reference e Terminal 14 mA Speed Torque Reference e 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 P009 P010 and P011 7 1 7 2 Digital Input Connections Terminals 16 25 Terminal 16 24 VDC Current Limited For remote control digital inputs only Terminal 17 Digital Input 8 Remote Local Programmable Terminal 18 Digital Input 7 Ramp1 Ramp2 Programmable Terminal 19 Digital Input 6 Forward Reverse Programmable Terminal 20 Function Loss Terminal 21 Run Jog Terminal 22 Reset Terminal 23 Stop Terminal 24 Start Terminal 25 24 VDC Common When a user installed function loss input a coast to stop pushbutton or another external interlock is installed the factor installed jumper connecting termina
87. umber Table 7 1 Wiring Signal and Control I O to the Terminal Strip Continued Description Parameters Wiring Connections Wiring the Reset Input Digital Input 3 Reset The following parameter must be set P000 Control Source Terminal 22 On Reset Wiring the Stop Start Inputs Digital Input 2 Stop Digital Input 1 Start The following parameter must be set P000 Control Source P025 Stop Type Terminal 23 Off Stop Terminal 24 On Transition Start 24 VDC Isolated Common Wiring the Snubber Resistor Snubber Resistor Braking Control Signal 24 VDC Isolated Common Used with Snubber Resistor Braking Kit M N 2DB4010 Refer to the kit s instruction manual for installation instructions Number Table 7 1 Wiring Signal and Control I O to the Terminal Strip Continued Description Parameters Wiring Connections Wiring the Output Status Relays Normally Closed Contact Form B Normally Closed Contact Common Form B Normally Open Contact Form A Normally Open Contact Common Form A Both Form A and Form B contacts are rated for 250 VAC 30 VDC at 5 amps resistive or 2 amps inductive load The following parameter must be set P013 Output Relay Configuration Note that depending on the setting of parameter P013 the relay coil will energize the normally open contact will close

Instruction Manual D2 3340

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