DURAPULSE AC Drives – Introduction
Contents
1. Voltage Frequency Tolerance Voltage 10 Frequency 5 Wait Loss 100 I W 70 102 132 176 250 345 445 620 788 1290 1420 1680 n 39 44 4 1 94 132 135 144 26 5 26 5 26 5 772 712 Weight Ib kg 1759 1 994 1 8571 4 24 6 0021 6 106 6505 12 12 12 85 95 All 3 phase power sources must be symmetrical Do not connect any DURApulse drives to grounded center tapped delta transformers which are typically used for lighting circuits Book 2 14 1 www automationdirect com drives AC Drives e Prices as of April 16 2014 Check Web site for most current prices DURAPUuLSE AC Drives General Specifications General Specifications Control Characteristics Pulse Width Modulation Carrier frequency adjustable from 1k 15kHz depending on the model This system determines the control methods of the AC drive 00 V Hz open loop control 01 V Hz closed loop control 02 Sensorless Vector 03 Sensorless Vector with external feedback Rated Output Frequency 0 1 to 400 0 Hz Output Frequency Resolution 0 1 Hz Overload Capacity Torque Characteristics Braking Torque DC Braking Acceleration Deceleration Time Control System 150 of rated current for 1 minute Includes auto torque boost auto slip compensation starting torque 125 0 5 Hz 150 1 0 Hz 20 without braking resistor 125 with2. D2 260 CPU Port 2 HD15 0 HD15 RJ12 GS EDRV CBL 2 ZL CDM RJ12Xxx RJ12 o RJ12 FA ISOCO 5 pin Connector 0 5 pin plug Stellar Soft Starter SR44 Series RJ45 RS 485 Modbus RTU DLO6 PLCs D2 250 1 CPU D2 260 CPU Port 2 HD15 SRM 485 DI5 CBL2 0 HD15 ZL CDM RJ12Xxx RJ12 SR44 485RJ45 CBL 2 o RJ12 SRA4 RS485 SureServo IEEE1394 CN3 RS 232 Modbus RTU CLICK PLCs DLO5 PLCs Port 2 RJ12 DLO6 PLCs D2 250 1 CPU D2 260 CPU 2 HD15 D4 450 CPU 3 25 pin P3 550 CPU 2 RJ12 6 pin IEEE to RJ12 FA 15HD FA CABKIT RS 485 Modbus RTU DLO6 PLCs D2 260 CPU 2 HD15 SVC 85HDIS CB 2 6 pin IEEE to HD15 ZL CDM RJ12Xxx 2 SVC 485RJ12 CBL 2 6 pin IEEE to RJ12 USB 485M 5 SVC 485CFG CBL 2 6 pin IEEE to RJ45 SureStep RS 232 ASCII DLO6 PLCs D2 250 1 CPU D2 260 CPU Pori2 HD15 pin to RJ12 DLO5 PLCs CLICK PLCs RJ12 RJ12 to RJ12 When using the ZL CDM RJ12Xxx ZIPLink Communication Distribution Module replace the lowercase xx with the number of RJ12 ports i e 4 for four ports or 10 for ten ports ex ZL CDM RJ12X4 or ZL CDM RJ12X10 The SR44 RS485 Communications Adapter must be installed for RS 485 communications with the Stellar soft starters www automati
3. GS3 4020 GS3 4025 GS3 4030 GS3 4040 c ET Minimum Clearances and Air Flow GS3 4060 T Warning AC drives generate a large amount of heat which may damage the AC drive 150mm 6 inches Air Flow or more A 50mm 2 inches or more Enclosure 150mm 6 inches or more Auxiliary cooling methods are typically required in order not to exceed maximum ambient GS3 4075 temperatures GS3 4100 Warning Maximum ambient temperatures must not exceed 50 C 122 F or 40 C 104 F for models 7 5 hp 5 5 kW and higher Book 2 14 1 www automationdirect com drives AC Drives e Prices as of April 16 2014 Check Web site for most current prices DURApuLseE AC Drives Specifications Terminals Main Circuit Terminals Description Input Power AC Drive Output Braking Resistor Connection Under 20HP External Dynamic Brake Unit 20HP amp Over Terminal Symbol Ground Description Sa ara ars MOTOR GS3 4030 shown Control Circuit Terminals Remarks 24V DC Voltage Source 24V 20mA used only for AC drive digital inputs wired for source mode operation igital Input 1 Input 2 Input 3 Input 4 Input 5 Input 6 Input 7 Input 8 Input 9 Input 10 g g g g g ig g g g g Input 11 Sgielogsssgsossogo gital Common I
4. amp 20 braking torque without the addition of any external components The addition of optional braking may be required for applications that require rapid deceleration or high inertia loads Output Line Reactor Optional Refer to page DR 50 Output line reactors protect the motor insulation against AC drive short circuits and IGBT reflective wave damage and also smooth the motor current wave form allowing the motor to run cooler They are recommended for operating Motor grounding non inverter duty motors and when the length of wiring between the AC drive terminal and motor exceeds 75 feet Book 2 14 1 www automationdirect com drives AC Drives eDR Drives Prices as of April 16 2014 Check Web site for most current prices GS DURAPuLse Accessories Feedback Card 4 M A4 NES Ful e Phe t EESE sjy als JS a Feedback Card for DURAputse AC Drives Price Drive Model FOIL RAO 58 00 GS3 xXxxx The GS3 FB feedback card is for use only with DURApulse AC drives Description The GS3 FB card is used to add another layer of precision control to the already precise control algorithm utilized in the DURAPULSE drive series This added control is activated by selecting control Closed a Loop Diagram modes V Hz closed loop control or sensor Pees Es less vector with external feedback The y it feedback mechanism uses pulses gene
5. 91 ZIP WK Wiring Solutions WVAUTOMATIONDIRECT Solution 4 Serial Communications Cables ZIPLink offers communications cables for use with Direc LOGIC CLICK and Productivity3000 CPUs that can also be used with other communica tions devices Connections include a 6 pin RJ12 or 9 pin 15 pin and 25 pin D sub connectors which can be used in conjunction with the RJ12 or D Sub Feedthrough modules Prices as of April 16 2014 Check Web site for most current prices Using the Serial Communications Cables selector table located in this section 1 Locate your connector type 2 Select a cable Solution 5 Specialty ZIPLink Modules For additional application solutions ZlPLink modules are available in a variety of configurations including stand alone relays 24VDC and 120VAC transorb modules D sub and RJI2 feedthrough modules communication port adapter and distribution modules and SureServo 50 pin I O interface connection Solution 6 ZIPLink Connector Modules to 3rd Party Devices If you need a way to connect your device to terminal blocks without all that wiring time then our pigtail cables with color coded soldered tip wires are a good solution Used in conjunction with any compatible ZIPLink Connector Modules a pigtail cable keeps wiring clean and easy and reduces troubleshooting time Book 2 14 1 eDR 92 AC Drives Using the ZIPLink Specialty Modules selector table located in this section 1 Loca
6. Check Web site for most current prices Automata DURAPuLsE Drives Specifications Installation Understanding the installation requirements for Drives your DURAPULSE AC drive will help to ensure that it operates within its environmental and electrical limits Environmental Specifications Note Never use only this catalog for installation instructions 7 T Protective Structure 1 IP20 or operation of equipment refer to the user manual GS3 M Ambient Operating Temperature 10 to 40 C 14 F to 104 F f Storage Temperature 3 20 to 60 C 4 F to 140 F Humidity To 9096 no condensation Py AFC 9 8 m s 19 less than 10 Hz Vibration 5 9 m s 0 60 10 to 60 Hz Altitude 1 000 m or less indoors no corrosive Localion gases liquids or dust 1 Protective structure is based upon EN60529 2 The ambient temperature must be in the range of 10 to 40 C If the range will be up to 50 C you will need to set the carrier fre quency to 2 1 kHz or less and derate the output current to 80 or less 3 The storage temperature refers to the short term temperature during transport Watt loss Chart 4 Conforms to the test method specified in JIS C0911 1984 GS3 Drive Model At full load GS3 21P0 60 GS3 22P0 82 GS3 23P0 130 GS3 25P0 194 GS3 27P5 301 GS3 2010 380 GS3 2015 660 GS3 2020 750 GS3 2025 920 GS3 2030 GS3 2040 GS3 2050 GS3 41P0 GS3 42P0 GS3 43P0 GS3 45P0 GS3 47P5 GS3 4010 GS3 4015
7. DULL LLDDOLDUDOODUOUL DODOOOCUOOCOOOODOCR GS3 2040 GS3 2050 GS3 4040 GS3 4050 GS3 4060 370 0 14 57 Sinis 190 01 260 0 10 24 335 0 13 19 Dia 18 0 0 71 Tues i o 18 0 0 71 SS 2 CJ Y fi X d O 132 5 5 22 _ J Dia 22 0 0 87 Dia 62 0 2 44 S R6 5 0 25 13 0 0 51 unit mm in Book 2 14 1 eDR 44 ACDrives 1 800 633 0405 Prices as of April 16 2014 Check Web site for most current prices Automation DURAPUuLSE AC Drives Dimensions GS3 4075 GS3 4100 n 3 c 425 0 16 73 m 264 0 10 39 385 0 15 16 SO Qo 2 18 0 0 7 T i 64 gu 59 g xs J oo o mMm o oO 18 0 0 71 Co A fud 4 Gl 130 4 5 13 A 280 0 11 02 Dia 22 0 0 87 _ Dia 74 8 2 94 5 Ea R E Al gt S R6 5 0 25 8 di amp 70707 7 7 BRTTRBESORTITRS DOBOpO D OS SEN AES B UH o FRED 13 0 0 51 LR unit mm in Book 2 14 1 www automationdirect com drives AC Drives e Prices as of April 16 2014 Check Web site for most current prices GS DURApuLseE Accessories Overview i GS 22P0 LR 3PH Accessories Part T numbering system Note With the exception of the EMI filters RF filters and LR series line reactors each accessory part n
8. Price DuRAPULSE Price SJ100 002NF 0 25 hp 113 00 158 00 GS3 21P0 242 00 SJ100 004NF 0 5 hp 117 00 158 00 242 00 SJ100 007NF 1 0 hp 134 00 177 00 242 00 SJ100 015NF 2 0 hp 164 00 251 00 293 00 SJ100 022NF 3 0 hp 309 00 347 00 SJ100 037LF 5 0 hp 363 00 400 00 SJ100 055LF 7 5 hp 465 00 549 00 SJ100 075LFl 10h 698 00 SJ100 004HF 05h 261 00 323 00 SJ100 007HF 10h 261 00 323 00 SJ100 015HF 20h 303 00 360 00 SJ 30h 357 00 385 00 SJ SJ 100 022HF 100 040HF 50h 410 00 427 00 75h i 586 00 613 00 10 hp B 725 00 734 00 Notes Replacement drives do not necessarily have the same physical dimensions mounting hole patterns or wiring terminal arrangements Replacement drive requires 3 phase input power Ensure that the existing application uses 3 phase input power or that 3 phase power is available Replacement drive is higher horsepower than existing drive Output power of new drive can be parameter limited to the smaller horsepower c IS ic ic ic ic IC IC IC Ic Ic Ic Ic lic 100 055HF SJ100 075HF e Book 2 14 1 www automationdirect com drives AC Drives eDR 9
9. connector at the other end is the best solution Using the PLC I O Modules to ZIPLink Connector Modules selector tables located in this section 1 Locate your I O module PLC 2 Select a ZIPLink Module 3 Select a corresponding ZIPLink Cable Solution 2 DirectLOGIC CLICK and Productivity3000 1 O Modules to 3rd Party Devices When wanting to connect I O to another device within close proximity of the I O modules no extra terminal blocks are necessary when using the ZIPLink Pigtail Cables ZIPLink Pigtail Cables are prewired to an I O terminal block with color coded pigtail with soldered tip wires on the other end Using the I O Modules to 3rd Party Devices selector tables located in this section 1 Locate your PLC I O module 2 Select a ZIPLink Pigtail Cable that is compatible with your 3rd party device Solution 3 GS Series and DURAPurse Drives Communication Cables Need to communicate via Modbus RTU to a drive or a network of drives ZIPLink cables are available in a wide range of configurations for connecting to PLCs and SureServo SureStep Stellar Soft Starter and AC drives Add a ZlPLink communications module to quickly and easily set up a multi device network www automationdirect com drives Using the Drives Communication selector tables located in this section 1 Locate your Drive and type of communications 2 Select a ZIPLink cable and other associated hardware Book 2 14 1 AC Drives eDR
10. optional braking resistor braking circuit built in only for units under 20 hp Operation frequency 60 0 Hz 0 100 rated current Start time 0 0 5 0 seconds Stop time 0 0 25 0 seconds 0 1 to 600 seconds linear or non linear acceleration deceleration second acceleration deceleration available Settings available for Constant Torque low amp high starting torque Variable Torque low amp high starting torque and user configured 20 to 200 of rated current Operation Specifications Keypad _ Setting by UP or DOWN buttons Frequency Setting External Potentiometer 3 to 5 kQ 0 to 10 VDC input impedance 10 KQ 10 to 10 VDC 4 to 20 mA input impedance 2500 Signal 0 to 20 mA Multi Speed Inputs 1 to 4 RS 232C RS 485 communication interface Keypad Setting by RUN STOP lt JOG gt FWD REV buttons Operation Setting Bos Digital 11 user programmable FWD STOP REV STOP RUN STOP REV FWD RUN momentary N 0 STOP momentary N C Sink Source External Fault N O N C External Reset Multi Speed Bit 1 4 Manual Keyboard Control Jog External Base Block N 0 N C Second Accel Decel Time Speed Hold Increase Speed Decrease Speed Reset Speed to Zero PID Disable N O PID Input Selectable Disable N C Input Disable Terminals Voltage Frequency Pattern Stall Prevention Level Forward Stop Reverse Stop run stop fwd rev 3 wire control Serial Co
11. 15 3 7 6 22 155 206 26 34 50 60 75 Voltage Frequency Tolerance Voltage 10 Frequency 596 Watt Loss 100 I W 60 82 130 194 301 380 660 750 920 45 45 94 94 133 133 143 265 265 Weight Ib kg 2 034 2034 424 424 6031 6031 6487 12 DA utomati Direct Drives Maximum Motor Output Input Rated Voltage Frequency Rating All 3 phase power sources must be symmetrical Do not connect any DURApulse drives to grounded center tapped delta transformers which are typically used for lighting circuits 460V Class Three Phase Model Name GS3 xxx 41P0 42P0 43P0 45P0 47P5 4010 4015 4020 4025 4030 4040 4050 4060 4075 Price 323 00 360 00 385 00 427 00 613 00 734 00 957 00 1 165 00 1 383 00 1 570 00 2 001 00 2 436 00 2 788 00 3 130 00 Maximum Motor 1 2 3 5 75 10 15 20 25 30 40 50 60 75 Output 75 15 22 37 55 75 11 15 185 22 30 37 45 55 fee Output Current 57 43 55 as q3 18 a 32 38 45 60 73 91 110 Maximum Output g Voltage Three phase 380 to 480V proportional to input voltage Rated Frequency 0 1 to 400 Hz Rated Voltage Three phase Input Fri equency 380 400 415 440 460 480VAC 50 60Hz Raling ma Input Current l ue 4g
12. 5A AC Drive Running Multi function Digital Outputs 48VDC 250mA max AC Drive Fault 48VDC 50mA max At Speed 48VDC 250mA max Zero Speed Digital Frequency Output 1 1 Duty 50 Multi function Analog Output Potentiometer mH 8 5 kQ indicates Output Frequency Hz 0 10VDC 2mA RJ 12 Serial Comm Port Interface See Warning RS 485 Optional ZIPLink serial com 1 15V munication cables available 2 GND for plug and play connectivity 3 SG to AutomationDirect PLCs 4 SG See the comm cable selec 5 NC tion matrix on page DR 93 9 he Use wu Book 2 14 1 AC Drives eDR 41 Prices as of April 16 2014 Check Web site for most current prices DURApuLse AC Drives Dimensions GS3 21P0 GS3 22P0 GS3 41P0 GS3 42P0 118 0 4 65 160 0 6 30 r 108 0 4 25 Dia 5 5 0 22 Ann nan a Crete e N r NRT NTI oj Q eii N co UUU A YUU ful S y Dia 22 0 0 87 o o bia 28 0 1 10 2X Aon a e 2 i c B 118 0 4 65 145 0 5 71 a Rae Dia 5 5 0 22 ea dj i Se VE Od CHERSSEERS g EE o A G N man nnn BE eu U N o nnnn n wee A D
13. J300 015H 2 0 hp 303 00 360 00 357 00 385 00 F F 5J300 022HF 30 hp F 5 0 hp J300 040H 410 00 427 00 J300 055HFU 7 5 hp 586 00 613 00 J300 075HFI 10h 725 00 734 00 J300 110HFU 15h 957 00 1 165 00 p p J300 150HFU 20 hp J300 185HFU 25 hp 1 383 00 J300 220HFU 30 hp B 1 570 00 Notes Replacement drives do not necessarily have the same physical dimensions mounting hole patterns or wiring terminal arrangements All SJ300 drives are specified for use with 3 phase power but can be installed in single phase applications Replacement drive requires 3 phase power Ensure that the existing SJ application uses 3 phase input power or that 3 phase power is available Replacement drive is higher horsepower than existing drive Output power of new drive can be parameter limited to the smaller horse power Book 2 14 1 eDR 94 AC Drives 1 800 633 0405 Prices as of April 16 2014 Check Web site for most current prices Hitachi Drives Cross References To find a suitable replacement for an L100 Drives or SJ100 Hitachi drive use the chart to the Drive Volts Hz Sensorless Full Flux Series Vector Vector right to determine control mode s required and the tables below to determine pos L100 sible replacement part numbers Suggested SJ100 replacements do not necessaril
14. Motor Rating Prices as of April 16 2014 Check Web site for most current prices DURAPpuLsE AC Drives Introduction DURApulse Drives Hp kW Single Three Phase Input 230V Three Phase 230VClass NN N ly I Overview The DURAPULSE series of AC drives offers all of the features of our GS2 series of drives including dynamic braking PID removable keypad and RS 485 Modbus communication The DURAPULSE AC drive also offers sensorless vector control with the option of encoder feedback for enhanced speed control The stan dard smart keypad or Human Interface Module is designed with defaults for the North American customer and allows you to configure the drive set the speed start and stop the drive and monitor critical parameters for your application In addi tion this keypad has internal memory that allows four complete programs to be stored and transferred to any DURAPULSE drive The DURAPULSE series offers three analog inputs eleven digital inputs and one SPDT relay output Three Phase 460V Class Features Simple Volts Hertz control Sensorless vector control with autotune Sensorless vector control with optional encoder feedback card for better speed control Sinusoidal pulse width modulation PWM e Variable carrier frequency depending on model IGBT technology Starting torque 125 0 5 Hz 150 1Hz 150 rated current for one minute Electro
15. NG ACCORDING TO THE CIRCUIT DIAGRAM SHOWN BELOW Multi function Digital Inputs Forward Stop p OO L gt Reverse Stop E oO x External Fault N O Po QU Multi Speed 1 od O O Multi Speed 2 E o Multi Speed 3 NE O O i H gt Multi speed 4 i o as JOG Hi o O _ External Reset i Second Accel Decel Time O O t T External Base Block N O i Analog Inputs Potentiometer 5kO kk FE T Frequency command source can be one of the three analog inputs up down keys on keypad or via the RS 485 serial comm port See parameter settings DURAPULSE AC Drive GS3 xxxx 24V Power Source 20mA max Input Mode Setting Sink lj sw Source Sink DI2 DIS DI4 DI5 DIG DI7 DI8 DI9 DI10 DI11 DCM Digital Signal Com D See Power Wiring Diag 10V Power Source 20mA max AH 0 to 10V Al2 0 20mA or 4 20mA Al3 10 to 10V ACM Analog Signal Common o See Power Wiring Diagram Factory default setting Factory default source of frequency command is via the keypad up down keys O Main circuit power terminals Control circuit terminal E Shielded leads WARNING Do not plug a modem or telephone into the DURAPULSsE RJ 12 Serial Comm Port or permanent damage may result www automationdirect com drives Digital Output Com Multi function Output Contact 120VAC 24VDC 95A 230VAC 2
16. ia 22 00 87 Dia 28 0 1 10 2X unit mm in Book 2 14 1 eDR 42 AC Drives 1 800 633 0405 Prices as of April 16 2014 Check Web site for most current prices Automation DURAputse AG Drives Dimensions GS3 23P0 GS3 25P0 GS3 45P0 X eS 150 0 5 91 m 135 0 5 32 Ke 160 2 6 31 d ga amp o 2 5 is alg 200 0 7 88 185 6 7 31 Ll c 303 0 11 94 323 0 12 73 Dia 22 0 0 87 Dia 42 6 1 68 1 7 0 0 28 DETAIL A unit mm in Book 2 14 1 AC Drives eDR 43 www automationdirect com drives Prices as of April 16 2014 Check Web site for most current prices DURApuLse AC Drives Dimensions GS3 2020 GS3 2025 GS3 2030 GS3 4020 GS3 4025 GS3 4030 250 0 9 84 Dia 10 0 0 39 226 0 8 90 205 4 8 08 ETE 384 0 15 12 403 8 15 90 Dia 28 0 1 1 Dia 42 0 1 65 2X ZOD El 10 0 0 39 LLDDOLDDDIEU
17. ion Level Over Torque Detection Time Over Current Stall Prevention during Acceleration Over Current Stall Prevention during Operation Protective Functions Operator Interface Operator Devices 9 key 2 line x 16 character LCD display 5 status LEDs Programming Parameter values for setup and review fault codes Status Display Output Frequency Motor Speed Scaled Frequency Output Current Motor Load Output Voltage DC Bus Voltage PID Setpoint PID Feedback Frequency Setpoint Key Functions RUN STOP RESET FWD REV PROGRAM DISPLAY UP DOWN ENTER Enclosure Rating Protected Chassis IP20 10 C to 40 C 14 F to 104 F 20 C to 60 C 4 F to 140 F during short term transportation period 20 to 90 RH non condensing 9 8 m s 1G less than 10 Hz 5 9 m s 0 6G 10 to 60 Hz Altitude 1000m or lower above sea level keep from corrosive gas liquid and dust Ambient Temperature Storage Temperature Ambient Humidity Vibration Installation Location Environment Noise filter input AC reactor output AC reactor cable for remote operator programming software dynamic braking resistor dynamic braking unit RF filter remote panel adapter Ethernet interface four and eight port RS 485 multi drop termination boards replacement keypads fuse kits and replacement fuses Book 2 14 1 eDR 34 AC Drives 1 800 633 0405 Prices as of April 16 2014
18. k 2 14 1 eDR 56 AC Drives 1 800 635 0405 Prices as of April 16 2014 Check Web site for most current prices Automation DURApuLsE AC Drives Basic Wiring Diagram B Power Wiring Diagram drives under 20 hp Drives Note Users MUST connect wiring according to the circuit diagram shown below Refer to user manual GS3 M for additional specific wiring information Note Refer to the following pages for explanations and information regarding feedback cards line reactors braking resistors EMI and RF filters and fuses DR 48 DR 50 DR 69 DR 74 DR 80 DR 81 Braking resistor optional Power Source 200 240V 10 50 60Hz 5 AC Motor T2 Motor mn 380 480V 10 50 60Hz 5 Use any two of L1 L2 L3 for 230V 1 phase models Note Grounding terminals og are internally connected D CX IE terminal Grounding resistance Mechanical less than 0 10 Coupling _ a GS3 FB optional Dw gt gt OC 12V V Factory Default DCM OC open collector TP totem pole 5 i Encoder Output 12VDC TP 5V O Main circuit power terminals Control circuit terminal f Shielded leads WAaRrNING Do not plug a modem or telephone into the GS3 DURAPutsE RJ 12 Serial Comm Port or permanent damage may result Terminals 2 and 5 should not be used as a power source for your communication connection Book 2 14 1 www automati
19. mmunication RS 232C amp RS 485 Modbus RTU 3 user configurable 0 to 10V input impedance 10 kQ Analog _ 0to 20 mA 4 to 20 mA input impedance 2500 10 bit resolution 10V to 10V 10 bit resolution Digital 4 user programmable Inverter Running Inverter Fault At Speed Zero Speed Above Desired Frequency Below Desired 3 transistors Frequency At Maximum Speed Over Torque Detected Above Desired Current Below Desired Current PID Deviation Alarm 1 relay Heatsink Overheat Warning OH Soft Braking Signal Above desired Frequency 2 Below desired Frequency 2 Encoder Loss Output 2 Terminals Digital Square Wave Analog 1 user programmable 0 to 10V 8 bit resolution frequency current process variable PV One digital square wave output representing drive frequency Automatic voltage regulation voltage frequency characteristics selection non linear acceleration deceleration upper and lower Operating Functions frequency limiters 15 stage speed operation adjustable carrier frequency 1 to 15 kHz PID control 5 skip frequencies analog gain amp bias adjustment jog electronic thermal relay automatic torque boost trip history software protection Electronic Thermal Overload Relay Auto Restart after Fault Momentary Power Loss Reverse Operation Inhibit Auto Voltage Regulation Over Voltage Stall Prevention Auto Adjustable Accel Decel Over Torque Detection Mode Over Torque Detect
20. mote panel adapter e Replacement keypad Keypad cables in 1 3 and 5 meter lengths Ethernet interface Four and eight port RS 485 multi drop termination boards e KEPDirect O or OPC Server GSoft drive configuration software GS3 FB feedback card GS 485HD15 CBL ZIPLink RS485 communication cable for connection to the DL06 and D2 260 15 pin ports USB 485M USB to RS 485 PC adapter see Communications Products chapter for detailed information Detailed descriptions and specifications for GS accessories are available in the GS DURAPULSE Accessories section Typical Applications e Conveyors Fans Pumps Compressors HVAC Material handling Mixing Shop tools e Extruding Grinding 1 800 635 0405 Prices as of April 16 2014 Check Web site for most current prices DURAPpuLse AC Drives Specifications 230V Class Model Name GS3 xxx 21PU 22P0 23P0 25P0 27P5 2010 2015 2020 2025 2030 2040 2050 Price 242 00 293 00 347 00 400 00 549 00 698 00 889 00 1 104 00 1 298 00 1 486 00 2 177 00 2 637 00 10 20 30 50 75 10 15 20 25 30 40 50 75 15 22 37 55 75 11 15 185 22 30 37 ped Rated Output Current A 5 7 11 17 25 33 49 65 75 90 120 145 Maximum Output Voltage Three phase 200 to 240V proportional to input voltage Rated Frequency 0 1 to 400 Hz Single Three phase Three phase 200 208 220 230 240 VAC 50 60Hz Rated Input Current A 11 9 5 7
21. nic overload protection e Stall prevention Adjustable accel and decel ramps with linear and S curve settings Automatic torque and slip compensation Internal dynamic braking circuit for mod els under 20 hp optional baking units available for models 20 hp and above e DC braking Five skip frequencies e Trip history Programmable jog speed Integral PID control Removable smart keypad with parameter upload download Keypad with memory to store up to four programs of any DURAPULSE drive Eleven programmable digital inputs Three programmable analog inputs Three digital and one SPDT relay programmable outputs One programmable analog output DURAPULSE part numbering system GS3 2 020 Applicable Motor Capacity 2P0 2HP 5P0 5HP 010 10HP 020 20HP 030 30HP 050 50HP 075 75HP 1P0 1HP 3P0 3HP 7P5 7 5HP 015 15HP 025 25HP 040 40HP 060 60HP 100 100HP Input Voltage 2 200 240VAC 4 380 480VAC Series Name Book 2 14 1 eDR 32 AC Drives 60 75 and 100HP models available in GS3 4xxx only One digital frequency output RS 485 Modbus communications Ethernet communication optional Two year warranty UL cUL CE listed Accessories AC line reactors EMI filters RF filter Braking resistors Braking units for models 20 hp and above Fuse kits and replacement fuses Replacement cooling fans e Re
22. nput Voltage Internally Supplied see Warning below Sink Mode Low active V Min OV Vip Max 15V lin Min 2 1mA p Max 7 0mA Source Mode High active V Min 8 5V V Max 24V lin Min 2 1mA lip Max 7 0mA Input response 12 15 msec Also see Basic Wiring Diagram on the next pages ternal Power Supply 10VDC 10mA maximum load nalog Input 0 to 10 V input only nalog Input 0 to 20mA 4 to 20mA input nalog Input 10 to 10 V input only nalog Common Relay Output 1 Normally Open Relay Output 1 Normally Closed Relay Output 1 Common Resistor Load 240VAC 5A N O 3A N C 24VDC 5A N 0 3A N C Inductive Load 240VAC 1 5A N O 0 5A N C 24VDC 1 5A N 0 0 5A N C See P 3 01 to P 3 03 Photocoupled digital output Photocoupled digital output Photocoupled digital output Digital Output Common Maximum 48VDC 50mA Analog Output 0 to 10 V 2mA Output Digital Frequency Output Square wave pulse train output AN WARNING Do NOT connect external voltage sources to the digital inputs Permanent damage may result NOTE USE TWISTED SHIELDED TWISTED PAIR OR SHIELDED LEAD WIRES FOR THE CONTROL SIGNAL WIRING IT IS RECOMMENDED TO RUN ALL SIGNAL WIRING IN A SEPARATE STEEL CONDUIT THE SHIELD WIRE SHOULD ONLY BE CONNECTED AT THE AC DRIVE Do NOT CONNECT SHIELD WIRE ON BOTH ENDS Boo
23. ondirect com drives AC Drives Book 2 14 1 eDR 93 To find a suitable replacement for an SJ300 Hitachi drive use the chart to the right to determine control mode s required and the tables below to determine possible replace ment part numbers Suggested replace ments do not necessarily have all control modes of the original so appropriate drives will be application dependent Please call Tech Support if there are any replacement questions Hitachi S J300 Cross Reference Hitachi SJ300 AC Drives Part No Horsepower GS1 Price Drive Series Prices as of April 16 2014 Check Web site for most current prices Hitachi Drives Cross References Volts Hz Sensorless Full Flux Vector Vector L100 SJ100 GS1 GS2 DURAPULSE GS3 J300 Possible Replacements Price DURAPust GS3 Price SJ300 004LFI 0 5 hp GS1 20P5 117 00 158 00 242 00 SJ300 007LFI 1 0 hp GS1 21P0 134 00 177 00 242 00 SJ300 015LFI 2 0 hp GS1 22P0 164 00 251 00 293 00 SJ300 022LFI 3 0 hp 2 309 00 347 00 J300 037LF 5 0 hp B 363 00 400 00 SJ300 055LFI 7 5 hp B 465 00 549 00 300 075LF 10 hp 698 00 300 110LF 15 hp 889 00 1 104 00 300 185LF 25 hp 1 298 00 SJ SJ SJ300 150LFI 20 hp SJ SJ 300 220LF 30 hp 1 486 00 J300 007H 1 0 hp 261 00 323 00
24. ondirect com drives AC Drives eDR 3 Prices as of April 16 2014 Check Web site for most current prices DURApuLse AC Drives Basic Wiring Diagram Power Wiring Diagram 20 to 30 hp 230 VAC amp 20 to 60 hp 460 VAC Note Users MUST connect wiring according to the circuit diagram shown below Refer to user manual GS3 M for additional specific wiring information Note Refer to the following pages for explanations and information regarding feedback cards line reactors braking units and resistors EMI and RF filters and fuses DR 48 DR 50 DR 67 DR 69 DR 74 DR 80 DR 81 Dynamic BR F4 Brake Unit Braking resistor optional optional optional Power Source 3 phase 200 240V 10 50 60Hz4 5 6 AC Motor DURAPULSE GS3 xxxx D AA T3O Motor 380 480V 10 50 60Hz 5 Note Grounding terminals OQ are internally connected o CX b terminal Grounding resistance less than 0 10 Cousins Ww GS3 FB optional nw gt gt OC 12V VP Factory Default DCM OC open collector TP totem pole TR SV u Encoder Output 12VDC O Main circuit power terminals Control circuit terminal ze Shielded leads WanNiNG Do not plug a modem or telephone into the GS3 DURAputseE RJ 12 Serial Comm Port or permanent damage may result Terminals 2 and 5 should not be used as a power source f
25. one into the GS3 DURAPutsE RJ 12 Serial Comm Port or permanent damage may result Terminals 2 and 5 should not be used as a power source for your communication connection AN Book 2 14 1 AC Drives eDR 3 9 www automationdirect com drives Automation LUCHI Drives Prices as of April 16 2014 Check Web site for most current prices DURApuLseE AC Drives Control Wiring Diagram DI Connection to Sinking Outputs Control Wiring Diagram Digital Input Connections to Sinking Output Devices NOTE USERS MUST CONNECT WIRING ACCORDING TO THE CIRCUIT DIAGRAM SHOWN BELOW DURAPUuLSsE AC Drive Multi function Digital Inputs GS3 xxxx Multi function Output Contact x 24V Power Source R1 20mA XFoardiStop ED RICA 230VAC 25A hReverse Stop Er Input Mode Setting O i AC Drive Bufming O O DI2 Sink O R10 External Fault N O Dod F sw o 0o DI3 A Multi Speed 1 Source Bos Multi function Digital Outputs 0 6 DI4 XSink 48VDC 50mA max Multi Speed 2 Pod E Bi ED KAC Drive Fault amp Multi Speed 3 Od o 6 3 DI6 DO2 Multi speed 4 Pod 48VDC 50mA max o 6 DI7 At X JoG 3 ED Kt Spesa OO DI8 External Reset Pod o 6 3 DI9 48VDC 50mA max Second Accel Decel Time Zero Speed OO DI10 xX External Base Block N O E OO DI11 pod DCM Digital Output Com e Digital Signal Com Digital Fre
26. or your communication connection Book 2 14 1 eDR 38 AC Drives 1 800 633 0405 Prices as of April 16 2014 Check Web site for most current prices DURApuLse AC Drives Basic Wiring Diagram Power Wiring Diagram 40 to 50 hp 230 VAC amp 75 to 100 hp 460 VAC Note Users MUST connect wiring according to the circuit diagram shown below Refer to user manual GS3 M for additional specific wiring information Note Refer to the following pages for explanations and information regarding feedback cards line reactors braking units and resistors EMI and RF filters and fuses DR 48 DR 50 DR 67 DR 69 DR 74 DR 80 DR 81 Dynamic r 1 BR F4 Brake Unit p m tional Braking resistor l l optional l I Dynamic F 3 1 BR L4 Brake Unit 7 JUMPER amp optional e Braking resistor optional AC Motor 200 240V 10 50 60Hz 5 DURAPULSE GS3 xxxx Motor 380 480V 10 50 60Hz 5 Note Grounding terminals are internally connected N e terminal Grounding resistance Mechanical less than 0 10 Coupling GS3 FB optional nwo gt gt OC 12V VP Factory Default DCM e OC open collector Fp 5y Encoder TP totem pole Output 12VDC amp Shielded leads Control circuit terminal O Main circuit power terminals WARNING Do not plug a modem or teleph
27. quency Output FO vie e See Power i n Wiring Diag EO 1 1 Duty 50 Analog Inputs t DCM 10V Power Source 20mA max Multi function Analog Output Potentiometer t AM dy od n 0 to 10V D C Le a Wiese put tok 0 20mA or 4 20mA ACM T AG 0 10VDC 2mA 10 to 10V t ACM RJ 12 Serial Comm Port o Analog Signal Common Interface See Warning t Frequency command source RS 485 beusey can be one of the three analog So BOWE 1 15V P atr inputs up down keys on keypad Wiring Diagram 2 GND E or via the RS 485 serial comm 3 SG 2 ort See parameter settings 1 IN P P g TA CONNECTIONSYSTEMS Factory default setting Factory default source of frequency command is via the keypad up down keys O Main circuit power terminals Control circuit terminal Shielded leads Optional ZIPLink serial com munication cables available for plug and play connectivity to AutomationDirect PLCs See the comm cable selec tion matrix on page DR 93 ZEN WARNING Do not plug a modem or telephone into the DURAPULsE RJ 12 Serial Comm Port or permanent damage may result Book 2 14 1 eDR 40 AC Drives 1 800 635 0405 Control Wiring Diagram Digital Input Connections to Sourcing Output Devices Prices as of April 16 2014 Check Web site for most current prices DURAPpuLse AC Drives Control Wiring Diagram DI Connections to Sourcing Outputs Drives NOTE Users MUST CONNECT WIRI
28. r ated by an external encoder or pulse generator Unlike other feedback types P Gain B a the GS3 FB accommodates the four most 10 02 BACH common encoder signal types output voltage open collector line driver and complimentary PG Gain Feedback 10 03 v SW1 and SW switches Types of Encoders 5V 12V o D OC12V OC12V gt d 8 TP 5V TP 5V O 6 VCC 2 8 OC12V OC12V 8 op E TP 5V TP 5V Q O ov o Q OC12V OC12V em o 5 a TP5V TP 5V VCC ren S 5 OC12V OC12V E O P a E TP5V TP5V fe oO Book 2 14 1 e DR 48 AC Drives 1 800 633 0405 Prices as of April 16 2014 Check Web site for most current prices GS DURAPuLse Accessories Feedback Card Wi ring Diag rams Power Source 3 phase 200 240V 10 o 000 OL1 T1 50 60Hz 5 DURAPULSE 380 480V 10 id as GS3 xxxx i Drives AC Motor 50 60Hz 5 N p WOOL3 T3c Note Grounding terminals Motor JM are internally connected e C terminal Grounding resistance less than 10 Mechanical Coupling 2 Open Collector GS3 FB Pulse Generator type Encoder OC 12V Fact aon un z Gpaichem pole TP SV UH 2VDC Terminal Power Source 3 phase AC Motor Description pM Symbols d Gee
29. rges Disconnect switch short circuits and ground faults They are recommended for all installations and may be required for UL listed installations Contactor Optional Refer to the Motor Controls section Do not use a contactor or disconnect switch for run stop control of the AC drive and motor This will reduce the operating life cycle of the AC drive Cycling a power circuit switching device while the AC drive is in run mode should be done only in emergency situations 4 Input Line Reactor Optional Refer to page DR 50 Input line reactors protect the AC drive from transient overvoltage conditions typically caused by utility capacitor switching The input line reactor also reduces O O i the harmonics associated with AC drives Input line reactors are recommended for all installations EMI filter Optional Refer to page DR 74 Input EMI filters reduce electromagnetic interference or noise on the input side of the AC drive They are required for CE compliance and recommended for instal lations prone to or sensitive to electromagnetic interference DURAPULSE 424 Aan FF filter Optional Refer to page DR 80 RF filters reduce the radio frequency interference or noise on the input or output side of the inverter Braking Unit amp Braking Resistor Optional eg DR 67 Dynamic braking allows the AC drive to produce additional braking stopping torque AC drives can typically produce between 15
30. s cm DURAPUsE 7 NP WOOL2 2 Power source of GS3 FB CERES ane Anne GS3 xxxx I EN SW1 can be switched to 12V or 5V Output Voltage us m Al 12VDC 5 200mA or 5VDC 2 mel are O ential 400mA ERNEUT UT Mechanical Power source VP and input signal A B e Mu commen Outputsvoc Input signal from Encoder Input type is i selected by SW2 Maximum 500kp sec GS3 FB A ae GS3 FB output signal for use with RPM B Cee Meter Open Collector Maximum DC24V B 100mA Line Driver type ocv ype GS3 FB output signal A O B O common Encoder with RPM il Dom Meter Oo cpon collector PEV di totem pole A O REEN 3 5 nnn 5 o SM OUUU COM Li RPM meter Power Source 3 phase AC Motor N moe 9 97 DURAPuLsE T IM 380 480V 10 i 5 GS3 xxxx E 3 Control Terminals 60 60H2 5 o p rm OLs T3 Ss Block Designations Motor J Note Grounding terminals e JE are internally connected terminal Grounding resistance H Mechanical less than 0 10 i Coupling Fj1_ Connect to GS3 O A O DH series control board BO Turri niaaa n BEEN DEM HE com Output Voltage or mm A Wiring Terminals A a VP Complementary type Generator SW1 SW2 GS3 FB pad DCM Encoder B Select the power A OC 12V vp source and encoder A I A i A DCM B output type TP 5V B OC open collector Fp cy Encoder B TF
31. te the type of application 2 Select a ZIPLink module Uuu P Using the Universal Connector Modules and Pigtail Cables table located in this section 1 Select module type 2 Select the number of pins 3 Select cable 1 800 633 0405 WVAUTOMATIONDIRECT Prices as of April 16 2014 Check Web site for most current prices ZIP Motor Controller Communication Drive Motor Controller GS DURAPutse SureServo SureStep Stellar ZIPLink Selector Communications Drive Motor Controller Controller Comm Port Type Network Protocol Connects to Comm Port Type Cable 2 meter length ZIPLink Cable Cable Connectors Automation Birecti Drives Other Hardware Required RS 485 Modbus RTU DL06 PLCs D2 260 CPU Port 2 HD15 RJ12 to HD15 GS EDRV100 RJ12 GS EDRV CBL 2 ZL CDM RJ12Xxx RJ12 RJ12 to RJ12 FA ISOCON 5 pin Connector RJ12 to 5 pin plug RS 232 Modbus RTU CLICK PLCs DLOS PLCs Port 2 RJ12 DLO6 PLCs D2 250 1 CPU D2 260 CPU Port 2 HD15 D4 450 CPU Port 3 25 pin P3 550 CPU Port 2 RJ12 GS RJ12 CBL 2 RJ12 to RJ12 FA 15HD FA CABKIT RS 485 Modbus RTU DLO6 PLCs D2 260 CPU Port 2 HD15 0 HD15 RJ12 GS EDRV CBL 2 ZL CDM RJ12Xxx RJ12 0 RJ12 FA ISOCO 5 pin Connector 0 5 pin plug DuraPulse 653 RS 485 Modbus RTU DL06 PLCs
32. totem pole Output 12VDC Book 2 14 1 www automationdirect com drives AC Drives eDR 49 Prices as of April 16 2014 Check Web site for most current prices Automation ZIP INK Wiring Solutions WAUTOMATIONDIRECT Drives Wiring Solutions using the ZIPLink Wiring System ZIPLinks eliminate the normally tedious process of wiring between devices by utilizing prewired cables and DIN rail mount connector modules It s as simple as plugging ina cable connector at either end or terminating wires at only one end Prewired cables keep installation clean and efficient using half the space at a fraction of the cost of standard terminal blocks There are several wiring solutions available when using the ZIPLink System ranging from PLC O to ZIPLink Connector Modules that are ready for field termination options for connecting to third party devices GS DuraPulse and SureServo Drives and specialty relay transorb and communications modules Pre printed O specific adhesive label strips for quick marking of ZlPLink modules are provided with ZIPLink cables See the following solutions to help determine the best ZIPLink system for your application Solution 1 DirectLOGIC CLICK and Productivity3000 1 O Modules to ZIPLink Connector Modules When looking for quick and easy O to field termination a ZIPLink connector module used in conjunction with a prewired ZlPLink cable consisting of an I O terminal block at one end and a multi pin
33. umber begins with GS followed by the AC Drive rating and then the relevant accessory code Following the accessory code you will find a description code when applicable The diagram at right shows the accessory part numbering system Under 20hp From power supply Y 7 Disconnect switch o GS and B1 DURAPULSE AC Drive GSx xxxx NS Motor grounding terminal Book 2 14 1 eDR 46 AC Drives Description Code optional 1PH Single phase 3PH Three phase ENC Enclosure Blank For reactor blank 3 phase Accessory Code BR Braking resistor BZL Bezel CBL Cable DBU Dynamic Brake Unit EDRV Ethernet board FB Feedback board FKIT Fuse Kit FUSE Replacement fuses for FKIT KPD Keypad LR Line reactor legacy RS Recommended Standard Horsepower Rating Example 2P0 2 0hp 7P5 7 5hp 010 10hp Voltage Rating 1 115V 2 230V 4 460V 5 575V Series GS All GS and DURApulse Series Drives GS1 GS1 Series GS2 GS2 Series GS3 DURApulse Series LR Newer line reactor series 1 800 633 0405 Prices as of April 16 2014 Check Web site for most current prices GS DURApuLsE Accessories Overview 20hp amp Over Power Supply DURAPULSE only Please follow the specific power supply requirements shown in Chapter 1 of the DURAPULSE AC Drives User Manual From power supply 9 Fuses Refer to page DR 81 Input fuses protect the AC drive from excessive input current due to line su
34. y have all GS1 control modes of the original so appropri GS2 ate drives will be application dependent DURAPULSE Please call Tech Support if there are any 51300 replacement questions Hitachi L100 Cross Reference Hitachi L100 AC Drives Possible Replacements Part No Horsepower Price Price DURAPULSE Price L100 002NFU 0 25 hp 113 00 158 00 GS3 21P0 242 00 L100 004NFU 05h 117 00 158 00 242 00 L100 007NFU 10h 134 00 177 00 242 00 L100 015NFU 20h 164 00 251 00 293 00 L100 022NFU 30h 309 00 347 00 L100 037LFU 50h 363 00 400 00 L100 055LFU 75h 465 00 549 00 L100 075LFU 10h 698 00 L100 004HFU 0 5 261 00 323 00 L100 007HFU 10h 261 00 323 00 L100 015HFU 20h 303 00 360 00 L100 022HFU 30h 357 00 385 00 L100 040HFU 50h 410 00 427 00 L100 055HFU 75h 586 00 613 00 L100 075HFU 10h 725 00 734 00 Notes Replacement drives do not necessarily have the same physical dimensions mounting hole patterns or wiring terminal arrangements Replacement drive requires 3 phase input power Ensure that the existing application uses 3 phase input power or that 3 phase power is available Replacement drive is higher horsepower than existing drive Output power of new drive can be parameter limited to the smaller horsepower c G S S S G SIS S G B S S o Hitachi SJ100 AC Drives Part No Horsepower Price
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