Hardware Reference, Installation, and Troubleshooting Manual D2-3340-1 GV3000 AC Power Modules Version 5.
Important User Information Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some important differences between solid-state equipment and hard-wired electromechanical devices.
Document Update Document Update Electronic Motor Overload Protection This product does not offer speed-sensitive overload protection, thermal memory retention or provisions to act upon motor over-temperature sensing in motors. If such protection is needed in the end-use product, it needs to be provided by additional means.
Document Update Notes: 2
Summary of Changes The information below summarizes the changes made to this manual since its last release (December 1995). Description of Changes Page Added Document Update. After manual front cover Deleted the following statement: ‘The Motor Overload Enable parameter (P.040) can be used in place of the electronic thermal overload relays in single motor applications’.
soc-ii Notes: Summary of Changes
Manufacturer's Declaration Manufacturer: Reliance Electric Industrial Co.
Table of Contents 1.0 Becoming Familiar with the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1Ć1 1.1 1.2 1.3 1.4 1.5 1.6 2.0 Finding Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Assumptions About the Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Taking Safety Precautions . . . . . . . . .
4.0 Mounting the Drive, Grounding, and Finding Wire Routing Locations . . . . . . . . . . . . . . . . . . . 4Ć1 4.1 Mounting the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.1.1 Verifying the Drive's Watts Loss Rating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2 Routing Input, Motor Output, Ground, and Control Wiring for the Drive . . . . . . . . . . . . . . . . . 4.
Appendices Appendix A Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . AĆ1 Appendix B Drive Regulation Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . BĆ1 Appendix C Compliance with EN 60204Ć1: 1992 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CĆ1 Index . . .
List of Figures Figure 2.1 Ć Identifying the Drive Model Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Ć1 Figure 2.2 Ć 1Ć5 HP Drive Components and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Ć3 Figure 2.3 Ć 7.5Ć10 HP Drive Components and Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Ć4 Figure 2.4 Ć 15Ć25 HP Drive Components and Locations . . . . . . . .
List of Tables Table 2.1 Ć Power and NEMA Enclosure Ratings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Ć2 Table 2.2 Ć Available Kits and Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2Ć16 Table 3.1 Ć Ambient Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3Ć1 Table 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.
1.2 Assumptions About the Audience This manual is intended for qualified electrical personnel. It is taskĆoriented and is organized according to a logical progression of steps to be followed to install and troubleshoot the drive. 1.3 Taking Safety Precautions Dangers, warnings, and cautions are used in this manual to point out potential problem areas. All three types of precautions are enclosed in a box to call attention to them.
2.0 ABOUT THE DRIVE This chapter describes how to identify the drive using the model number matrix and illustrates the differences between the NEMA enclosures. Major components of each drive group are also shown. The GV3000 AĆC drive is a PWM drive that provides vector and general purpose (volts/hertz or V/Hz) regulation for a wide range of applications.
ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁ ÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁ ÁÁÁÁ ÁÁÁ
2.3 1Ć25 HP GV3000 Drive Components and Locations The 1Ć25 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. ă1. Fan/Fan Assembly ă7. Power Supply PCB (15Ć25 HP drives only) ă2. Membrane Switch (Keypad/Bracket) ă8. Gate Driver PCB (15Ć25 HP drives only) ă3. Regulator Printed Circuit Board (PCB) ă9. Internal Fan Assembly ă4. Capacitor PCB/Input Capacitors 10.
M/N 7V4150 7V4250 10V4150 10V4250 Figure 2.3 Ć 7.
M/N 15V4150 15V4250 20V4150 20V4250 M/N 25G4150 25G4250 Figure 2.
2.4 25Ć60 HP GV3000 Drive Components and Locations The 25Ć60 HP drives have the following main components. The identification numbers provided correspond to the numbers used in figure 2.5. Replacement parts are listed in chapter 9. 1. Fan 7. Power Supply Board 2. Membrane Switch (Keypad/Bracket) 8. Gate Driver Board 3. Regulator Board 9. Internal Fan Assembly 4. Bus Capacitors 10. IGBT Module 5. Not Used 11. Diode Bridge 6. Power Board 12.
2.5 60Ć100 HP GV3000 Drive Components and Locations The 60Ć100 HP drives have the following main components. The identification numbers provided correspond to the numbers used in figure 2.6. Replacement parts are listed in chapter 9. 9. Precharge Contactor 1. Regulator Printed Circuit Board (PCB) 2. Power Module Interface PCB 10. Current Transformer 3. Gate Driver PCB 11. Ground Fault Transformer 4. Bus Clamp PCB Ć Right 12. Output Reactor 5. Bus Clamp PCB Ć Left 13. Precharge Resistor 6.
2.6 100Ć150 HP GV3000 Drive Components and Locations The 100Ć150 HP drive has the following main components. The identification numbers provided correspond to the numbers used in figure 2.7. Replacement parts are listed in chapter 9. 1. Regulator Printed Circuit Board (PCB) 10. Current Transformer 2. Power Module Interface PCB 11. Ground Fault Transformer 3. Gate Driver PCB 12. Output Reactor 4. Bus Clamp PCB Ć Right 13. Not Used 5. Bus Clamp PCB Ć Left 14. Bus Discharge Resistor 6.
2.7 Regulator Board Description GV3000 drive regulation is performed by a microprocessor on the Regulator board. See figures 2.8 and 2.9. Drive operation is adjusted by the parameters entered through the keypad. The Regulator board accepts power circuit feedback signals, an external speed reference signal, and internal heat sensor feedback, as well as data from a pulse tachometer that is attached to the motor when set up for vector regulation.
J5 USER DISPLAY 26-Pin Ribbon Cable 34-Pin Ribbon Cable J3 J9 J7 J8 J17 J4 USER I/O TERMINAL STRIP J3 Ć Option Board Connector J8 Ć RS232C Port J4 Ć Analog Input Jumper J9 Ć Keypad/Display Connector J5 Ć Power Module Feedback Cable J17 Ć Analog Output Jumper J7 Ć OIM (Optional) Connector Figure 2.
60ĆPin Ribbon Cable J16 USER DISPLAY 34ĆPin Ribbon Cable J3 J9 J7 J17 J4 J8 USER I/O TERMINAL STRIP J3 Ć Option Board Connector J9 Ć Keypad/Display Connector J4 Ć Analog Input Jumper J16 Ć Power Module Feedback Cable J7 Ć OIM (Optional) Connector J17 Ć Analog Output Jumper J8 Ć RS232C Port Figure 2.
2.7.1 Jumper Locations and Settings Jumpers J4 and J17 on the Regulator board are factoryĆset 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.
2.7.1.2 Analog Output Jumper Jumper J17 is the analog output jumper. This jumper selects either a 0Ć10 VDC or 4Ć20 mA scaled signal output that is programmable for either speed or torque, parameter P.012. The jumper only selects a 0Ć10 VDC source voltage or 4Ć20 mA sink current to represent speed or torque. Note that the 4Ć20 mA current selection requires a power supply for operation as shown in table 7.1, terminals 10 and 11.
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.
2.7.3 RSĆ232 Communication Port The Regulator board contains a 9Ćpin DĆshell RSĆ232 communication port (J8). This port provides RSĆ232 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 D2Ć3348, for more information. 2.7.
2.8 Drive Kit Options Table 2.2 provides a listing of the available GV3000 kit options. Table 2.
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.
3.1.2 Determining Total Area Required Based on Drive Dimensions Drive dimensions and weights are listed in table 3.2. Overall drive dimensions are illustrated in figure 3.1 as an aid in calculating the total area required by the GV3000 drives. Table 3.2 Ć Drive Dimensions and Weights 3Ć2 GV3000 Drive 1V4150 1V4450 2V4150 2V4450 3V4150 3V4450 5V4150 5V4450 7V4150 7V4250 10V4150 10V4250 15V4150 15V4250 20V4150 20V4250 25G4150 25G4250 Dim. A 222.3 mm 8.75" Dim. B 280.7 mm 11.05" Dim. C 198.1 mm 7.
1-60 HP 60-150 HP Figure 3.
3.1.3 Verifying the Site Provides for Recommended Air Flow Clearances Be sure there is adequate clearance for air ventilation around the drive. For best air movement, do not mount GV3000 drives directly above each other. Note that no devices are to be mounted behind the drive. This area must be kept clear of all control and power wiring. Refer to figure 3.2 for recommended air flow clearances. 1-60 HP 60-150 HP *If adjacent to other drives. Figure 3.
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.
Table 3.5 Ć Recommended Power Wire Sizes for 25Ć60 HP Drives Type of Wiring AĆC A C Input Power Output Power DĆC Input Power Terminals R/L1, S/L2, R/L1 S/L2 TL3 Size of Wire (Maximum) U/T1, V/T2, W/T3 +, - 2/0 / AWG ((2X), ), 185 ((mm2) Table 3.
GV3000 Drive 38 m (125') GV3000 Drive 15 m (50') 38 m (125') 60 m (200') 60 m (200') Motor Motor GV3000 Drive Motor 8 m (25') Motor Motor 8 m (25') Motor GV3000 Drive 76 m (250') Motor Figure 3.3 Ć Single and Multiple Motor Lead Lengths 3.2.2.5 Recommended Serial Communication Cable Lengths Connector J8 on the Regulator boards is an RSĆ232 serial communication port. This connector allows the GV3000 drive to communicate with external devices such as a personal computer using RSĆ232 protocol.
ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁ ÁÁ
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.
BV Figure 4.
BV Figure 4.2 Ć Wire Routing Locations for 7.
BV Figure 4.
BV Figure 4.
Motor Leads AĆC Input Signals DĆC Input Terminals and Ground 1Ć3/4" 45 47 View From Bottom GND (PE1) IL1 IL2 IL3 GND U V W AĆC Input Terminals and Ground AĆC Output Terminals and Ground Figure 4.
DĆC Input Terminals and Ground View From Top AĆC Input IL1 IL2 IL3 45 47 AĆC Input Terminals and Ground 1Ć1/2" AĆC Inputs Ground View From Bottom 7/8" 1Ć1/2" Output Ground Terminals U V Signals W AĆC Output Terminals and Ground Figure 4.
4.3 Grounding the Drive DANGER THE USER IS RESPONSIBLE FOR CONFORMING WITH ALL APPLICABLE LOCAL, NATIONAL, AND INTERNATIONAL CODES. WIRING PRACTICES, GROUNDING, DISCONNECTS, AND OVERCURRENT PROTECTION ARE OF PARTICULAR IMPORTANCE. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE. Use the following steps to ground the drive: Step 1. Remove the drive's cover. Step 2.
5.0 INSTALLING INPUT POWER WIRING This chapter describes incoming line components and how to install them. 5.1 Installing Transformers and Reactors (Optional) Input isolation transformers might be needed to help eliminate the following: D Damaging line voltage transients from reaching the drive. D Line noise from the drive back to the incoming power source. D Damaging currents that could develop if a point inside the drive becomes grounded.
3ĆPhase AĆC Input Voltage 460 V 181 182 183 GND Manual Disconnect Fuse UserĆSupplied R S T 1L1 1L2 1L3 ~ - U UserĆSupplied Motor Overload Relay (Optional if Electronic Overload is Used) ~ V u W u GND (PE) GV 3000 Power Module GND u M Figure 5.
DĆC Input Voltage 620V Nominal Manual Disconnect Fuse UserĆSupplied R S T 1L1 1L2 1L3 ~ - GND (PE) 47 45 U UserĆSupplied Motor Overload Relay (Optional if Electronic Overload is Used) ~ V u W u GV 3000 Power Module GND u M Figure 5.
5.3 Installing a Required External/Separate Input Disconnect An input disconnect must be installed in the line before the drive input terminals in accordance with NEC/CEC guidelines. The disconnect should be sized according to the inĆrush current as well as any additional loads the disconnect might supply. Note that the trip rating for the inrush current (10Ć12 times full load current) should be coordinated with that of the input isolation transformer, if used. Refer to section 5.
5.5 Installing Power Wiring from an External DĆC Bus to the Drive's Internal DĆC Bus Terminals Use the following steps to connect DĆC input power to the drive: Step 1. Wire the DĆC 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 1Ć5 HP drives, route the power leads through the bottom right opening of the drive base. On 7.
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.
Step 2. Connect the threeĆphase AĆC output power motor leads to the proper output terminals according to drive type. On 1Ć60 HP drives, connect the motor leads to terminals U/T1, V/T2, W/T3 on the power terminal strip. On 60Ć150 HP drives, connect the motor leads to terminals U, V, and W. Step 3. 6Ć2 Tighten the threeĆphase AĆC output power terminals to the proper torque according to drive type as shown in table 5.1.
7.0 WIRING THE REGULATOR BOARD TERMINAL STRIP This chapter describes how to wire the Regulator board terminal strip for stop, speed feedback, and remote control signals. The terminal strip has the following signals available, as shown in figures 7.1 and 7.2. Table 7.1 provides additional information. Note that when the Control Source parameter (P.000) is set to remote (rE), the drive will be controlled by the signals connected to the terminal strip.
Digital Input Connections (Terminals 16Ć25) D Terminal 16: +24 VDC (Current Limited) (For remote control digital inputs only) D Terminal 17: Digital Input 8 (Remote/Local) Ć Programmable D Terminal 18: Digital Input 7 (Ramp1/Ramp2) Ć Programmable D Terminal 19: Digital Input 6 (Forward/Reverse) Ć Programmable D Terminal 20: Function Loss D Terminal 21: Run/Jog D Terminal 22: Reset D Terminal 23: Stop D Terminal 24: Start D Terminal 25: +24 VDC Common When a userĆinstalled function loss input, a coastĆtoĆsto
DIGITAL INPUT 7 (RAMP1/RAMP 2) DIGITAL INPUT 6 (FORWARD/REVERSE) DIGITAL INPUT 8 (REMOTE/LOCAL) PHASE B NOT PHASE B Remote 4-20 mA Speed/Torque Reference *FOR 15-60 HP DRIVES, USE 16A INSTEAD OF 16 AND 20A INSTEAD OF 20. ALSO SEE FIGURE 2.12. Figure 7.
DIGITAL INPUT 6 (FORWARD/REVERSE) DIGITAL INPUT 7 (RAMP1/RAMP 2) DIGITAL INPUT 8 (REMOTE/LOCAL) PHASE B NOT Remote 4-20 mA Speed/Torque Reference *FOR 15-60 HP DRIVES, USE 16A INSTEAD OF 16 AND 20A INSTEAD OF 20. ALSO SEE FIGURE 2.12. Figure 7.
7.1 Stopping the Drive WARNING THE USER MUST PROVIDE AN EXTERNAL, HARDWIRED EMERGENCY STOP CIRCUIT OUTSIDE OF THE DRIVE CIRCUITRY. THIS CIRCUIT MUST DISABLE THE SYSTEM IN CASE OF IMPROPER OPERATION. UNCONTROLLED MACHINE OPERATION MAY RESULT IF THIS PROCEDURE IS NOT FOLLOWED. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY.
Figure 7.3 Ć Wiring Connections for the Speed Feedback Device Step 2. Set the following parameters to establish the maximum motor speed: D P.004: Maximum Speed D U.001: Pulse Tach PPR D U.002: Motor Poles D U.003: Motor Nameplate Base Frequency D U.005: Motor Nameplate RPM D U.017: Motor Top Speed Refer to the GV3000 Programming Manual (D2Ć3339) 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. ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Table 7.
ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Table 7.1 Ć Wiring Signal and Control I/O to the Terminal Strip (Continued) 10 11 Wiring Analog Outputs 0Ć10 VDC or 4Ć20 mA The setting of parameter P.012 selects the terminal strip Analog Output Reference analog output source (either speed or torque). Jumper J17 must also be set. See figure 2.11. The 4Ć20mA current Regulator Common selection requires a power supply for operation.
ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Table 7.1 Ć Wiring Signal and Control I/O to the Terminal Strip (Continued) Terminal Number 12 13 14 15 Description Parameters/Wiring Connections Wiring Analog Speed Reference Inputs Isolated Reference The following parameters must be set: Voltage (+15VDC) Analog Speed/Torque P.000: Control Source Reference Input Voltage P.
ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ
ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Table 7.1 Ć Wiring Signal and Control I/O to the Terminal Strip (Continued) Terminal Number 18 Description Parameters/Wiring Connections Wiring an Additional Ramp Input Digital Input 7 Digital input 7 is control function programmable through (Default Ć Ramp1/Ramp2) parameter P.007. The following parameters must be set: P.
ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Table 7.1 Ć Wiring Signal and Control I/O to the Terminal Strip (Continued) Terminal Number 19 Description Parameters/Wiring Connections Wiring a Forward/Reverse Input Digital Input 6 Digital input 6 is control function programmable through (Default Ć Forward/Reverse) parameter P.007. The following parameters must be set: P.
ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Table 7.1 Ć Wiring Signal and Control I/O to the Terminal Strip (Continued) Terminal Description Parameters/Wiring Connections Number Wiring a Function Loss Input 20 Digital Input 5 The following parameters must be set: (Function Loss) P.026: Function Loss Response A signal must be present at terminal 20 for the drive to be able to start. See figures 7.1 and 7.2.
ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Table 7.1 Ć Wiring Signal and Control I/O to the Terminal Strip (Continued) Terminal Number 22 Description Digital Input 3 (Reset) Parameters/Wiring Connections Wiring the Reset Input The following parameter must be set: P.
ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ Table 7.1 Ć Wiring Signal and Control I/O to the Terminal Strip (Continued) Terminal Number 28 29 30 31 Description Parameters/Wiring Connections Wiring the Output Status Relays NormallyĆClosed Contact Both Form A and Form B contacts are rated for (Form B) 250 VAC/30 VDC at 5 amps resistive or 2 amps inductive load.
8.0 COMPLETING THE INSTALLATION This chapter provides instructions on how to perform a final check of the installation before power is applied to the drive. DANGER ONLY QUALIFIED ELECTRICAL PERSONNEL FAMILIAR WITH THE CONSTRUCTION AND OPERATION OF THIS EQUIPMENT AND THE HAZARDS INVOLVED SHOULD START AND ADJUST IT. READ AND UNDERSTAND THIS MANUAL IN ITS ENTIRETY BEFORE PROCEEDING. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE. 8.
Step 13. Verify that a properlyĆsized ground wire is installed and a suitable earth ground is used. Check for and eliminate any grounds between the motor frame and the motor power leads. Verify that all ground leads are unbroken. Step 14. Uncouple the motor from any driven machinery to initially start the drive. 8.2 Installing the Cover for NEMA 4X/12 Drives In order to maintain the integrity of the NEMA 4X/12 enclosures, care must be taken when reĆinstalling the covers.
9.0 TROUBLESHOOTING THE DRIVE This chapter describes how to troubleshoot the drive and the equipment that is needed to do so. Also provided are replacement part lists and information on clearing faults. 9.1 Test Equipment Needed to Troubleshoot An isolated multimeter will be needed to measure DĆC bus voltage and to make resistance checks. 9.2 Drive Alarms and Faults The drive will display alarm and fault codes to assist in troubleshooting when a problem develops during selfĆtuning or drive operation.
For 100Ć150HP drives, while standing on a nonĆconductive 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 DĆC 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. ReĆattach the regulator panel. Step 5. Once the drive has been serviced, reĆattach the drive's cover. Step 6. ReĆapply input power.
Figure 9.
(-) DĆC Bus Measuring Points (+) 45 47 1L1 1L2 1L3 U V W Figure 9.
AĆC Input 1L1 1L2 1L3 4547 Regulator Panel (DĆC Bus Measuring Points Behind Regulator Panel on the Power Module Interface Board) Power Module Interface Board Fuses (-)(+) DĆC Bus Measuring Points U V W Figure 9.
9.4 Checking Out the Power Modules with Input Power Off Use the following procedure to check the drive's Power Module circuitry with power off: DANGER DĆC BUS CAPACITORS RETAIN HAZARDOUS VOLTAGES AFTER INPUT POWER HAS BEEN DISCONNECTED. AFTER DISCONNECTING INPUT POWER, WAIT FIVE (5) MINUTES FOR THE DĆC BUS CAPACITORS TO DISCHARGE AND THEN CHECK THE VOLTAGE WITH A VOLTMETER TO ENSURE THE DĆC BUS CAPACITORS ARE DISCHARGED BEFORE TOUCHING ANY INTERNAL COMPONENTS.
Table 9.1 Ć Resistance Checks (Continued) 60Ć100HP Drives Input Meter Diode Connection No. (+) (-) 1 47 1L1 2 47 1L2 3 47 1L3 4 1L1 45 5 1L2 45 6 1L3 45 Component is OK if resistance (R) is: 0.3 kohm
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.
Table 9.
Table 9.
Table 9.
Table 9.
Index A AĆC input diodes, checking, 9Ć6 to 9Ć7 disconnect, installing, 5Ć2 to 5Ć4 isolation transformer, 5Ć1 line branch circuit fuses, 3Ć7 to 3Ć8, 5Ć1 to 5Ć3 ratings, 2Ć2 wire sizes, 3Ć5 to 3Ć6 wiring, 3Ć5 to 3Ć7, 4Ć1 to 4Ć8, 5Ć1 to 5Ć5 voltage transients, avoiding, 5Ć1 AĆC output wiring, 3Ć5 to 3Ć7, 4Ć1 to 4Ć8, 6Ć1 to 6Ć2 Air flow, 3Ć1, 3Ć4 Alarms, 9Ć1 Altitude requirements, 3Ć1 Ambient conditions, 3Ć1, AĆ1 Analog output, 2Ć9 0Ć10 VDC (J17), 2Ć9 to 2Ć11, 2Ć13, AĆ2 4Ć20 mA (J17), 2Ć9 to 2Ć11, 2Ć13, AĆ2 wi
E Emergency stop, 7Ć5 ENĆ60204Ć1 compliance, 7Ć5, CĆ1 to CĆ2 Enclosures, NEMA, 2Ć2, 9Ć8 to 9Ć10 Environmental conditions, 3Ć1 F Fan, 2Ć3 to 2Ć8, 9Ć8 to 9Ć12 Faults, 9Ć1 Form A contacts, see Status Relays Form B contacts, see Status Relays Forward (digital input 6), 2Ć14, 7Ć2 to 7Ć4, 7Ć12 Frequency, carrier, 2Ć9, AĆ1 Frequency, line, AĆ1 Function loss (digital input 5), 2Ć14, 7Ć2 to 7Ć4, 7Ć12 wiring, 7Ć2 to 7Ć3, 7Ć13 Fuse DĆC bus, 2Ć7 to 2Ć9, 9Ć9 to 9Ć11 to 9Ć12 AĆC input, 3Ć7 to 3Ć8, 5Ć1 to 5Ć2 G Gate
N NEMA enclosures, 2Ć2, 9Ć8 to 9Ć10 Network AutoMax Network Communication board, 2Ć15, 2Ć16 communication, 2Ć15, 3Ć7 O Open loop, see Volts/Hertz Regulation Option kits, see Kits Output analog, see Analog Output contactors, 6Ć1 digital, see Status Relays inductor, see Output Reactor reactor, 2Ć7 to 2Ć8, 9Ć11 to 9Ć12 specifications, terminal strip, AĆ2 Overload, motor, 6Ć1 P Parts location, see Component Locations replacement, 9Ć8 to 9Ć12 PC control, see Control Source Planning drive clearances, 3Ć4 loc
Speed feedback, specifications, AĆ2 wiring, 2Ć14, 7Ć1, 7Ć5 to 7Ć7 see also Pulse Tachometer Speed, maximum setting, 7Ć6 Start (digital input 1), 2Ć14, 7Ć2 to 7Ć4, 7Ć14 Status relays, Form A/B, 2Ć9, 2Ć14, 7Ć2 to 7Ć4, 7Ć15 Stop (digital input 2), 2Ć14, 7Ć2 to 7Ć4, 7Ć14 Stopping the drive, 7Ć5 Switch, membrane, see Keypad/Display T Tachometer, pulse, see Pulse Tachometer Terminal strip wiring, 2Ć14, 3Ć6, 7Ć1 to 7Ć15 input specifications, AĆ2 output specifications, AĆ2 torque specifications, 5Ć4 wire sizes, 3
Appendix A Technical Specifications Table A.1 Ć Service Conditions AĆC Line Distribution System Capacity (maximum) for 460 VAC Units 1000KVA, threeĆphase with 25,000 amps symmetrical fault current capacity with a line impedance of less than 8% Control Method AllĆdigital vector, sinusoidal pulseĆwidthĆmodulated (PWM) Displacement Power Factor 0.96 Line Frequency 50/60Hz (+2 Hz) Line Voltage Variation -10% to +10% Line Dip Ride Through Maximum 500 milliseconds Ć vector Adjustable up to 999.
Table A.3 Ć Terminal Strip Input Specifications Signal Type Terminal(s) Speed Reference Input 12Ć15 Digital Inputs (1 Ć 8) Specification 10 V (@ 50K ohm input impedance or 20 mA) 16 +24 VDĆC Isolated Supply 17 Remote/Local (Default) 18 Ramp1/Ramp2 (Default) 19 Forward/Reverse (Default) 20 Function Loss 21 Run/Jog 22 Reset 23 Stop 24 Start Table A.
Table A.7 Ć Input Signal Response Times (Worst Case) These are the maximum times from transitioning the input to the drive reacting to the input. Signal Type and Source Volts/Hertz Regulation Vector Regulation 150 milliseconds 130 milliseconds START 126 milliseconds 105 milliseconds STOP, RESET, FL 75 milliseconds 75 milliseconds Preset Speeds 75 milliseconds 75 milliseconds Analog Speed/Trim Reference 16 milliseconds 5 milliseconds N/A 0.
Appendix B Drive Regulation Overview The GV3000 is a digital drive that provides closed loop vector or open loop volts/hertz regulation of AĆC motors. The Volts/Hertz or Vector Regulation parameter (P.048) is used to select the type of regulation for the application. See figures B.1 and B.2 for block diagrams of both regulators. Volts/Hertz Regulation Volts/hertz regulation provides general purpose open loop AĆC drive control. It does not use a speed feedback device.
BĆ2 Figure B.1 Ć Volts/Hertz Regulation Block Diagram P.043 Fault Auto Reset Attempts P.044 Fault Auto Reset Time Line Voltage fbk Local Remote Host PC Option P.000 P.016 Draw Gain Speed Ref. SelecĆ tion Speed Ref P.014 P.015 P.020 H.004 Trim Ref Rate Selection H.009 to H.015 + + + (60Ć150 HP GV3000 Drives Only) DC-Bus Voltage Comp. SĆCurve Frequency Reference Avoid Freq. Overload Jog Ref DĆC Bus Voltage Search Mot. Freq.
P.016 100 LIMIT (w/ hysteresis) ) Spd Ref Analog Input 1 Option Port 2 P.004 3 Torque Current Fdbk 4 RMI Analog Input 5 RMI Freq. Input 6 Switched RMI Analog Input or Freq. Input 0 ) ) P.015 100 MAX IN Invert OUT MIN P.014 0 P.004 Draw Ref Polarity of this point specifies the requested direction for drivĆ ing the FP FWD/REV LEDs EN REV DISABLE P.003 P.027 Trim Ref FWD/REV (0/1) Open when P.
Appendix C Compliance with EN 60204Ć1: 1992 The GV3000 complies with the following sections of standard EN 60204Ć1: 1992. EN60204Ć1 Section 6 6.2.1 6.2.3 6.3.1 6.4 7 7.2 7.2.3 7.2.6 7.5 8 8.2.1 8.2.2 8.2.3 8.2.7 8.3 8.4 8.5 8.6 9 9.1.1 9.1.3 9.1.4 9.2 9.2.1 9.2.2 9.2.3 9.2.5 9.2.5.3 9.2.5.6 9.2.6 9.3 9.3.5 9.4 9.4.2.1 9.4.3 9.4.3.1 9.4.3.
Appendix C Compliance with EN 60204Ć1: 1992 (Continued) EN60204Ć1 Section 10 10.2.1 10.8 11 11.2 11.2.1 11.2.2 11.3 11.3.1 11.5 12 12.2.2 12.2.3 12.3 12.3.1 12.3.2 12.3.3 12.3.4 12.3.5 13 13.2.3 13.4 15 15.1.1 15.1.3 15.2.2 18 18.2 18.4 19 19.
U.S. Allen-Bradley Drives Technical Support - Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: support@drives.ra.rockwell.com, Online: www.ab.com/support/abdrives www.rockwellautomation.com Power, Control and Information Solutions Headquarters Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.
