Reliance electric GV3000 Instruction Manual Download Page 75

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Table 9.4 1525 HP Drive Replacement Parts

Quantity per Horsepower

Description*

Part Number

Fan Assembly

615161S

NEMA 1 Cover

8055471R

NEMA 12 Cover/Gasket

8055472R

Membrane Switch Keypad/Top Bracket

8055481R

Regulator PCB

0569215xx

Capacitor PCB

056948015
056948020

Power Board

056949020

Power Supply Board

056950015
056950020

Gate Driver Board

056947020

Internal Fan Assembly

6151591S

* Components are identified in figure 2.5.

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Summary of Contents for GV3000

Page 1: ...GV3000 A C Power Modules Hardware Reference Installation and Troubleshooting Version 5 0 Instruction Manual D2 3340 StockC heck com Downloaded from StockCheck com ...

Page 2: ...LIFE DANGER DĆC BUS CAPACITORS RETAIN HAZARDOUS VOLTAGES AFTER INPUT POWER HAS BEEN DISCONNECTED AFTER DISCONNECTING INPUT POWER WAIT FIVE 5 MINUTES FOR THE DĆC BUS CAPACITORS TO DISCHARGE AND THEN CHECK THE VOLTAGE WITH A VOLTMETER TO ENSURE THE DĆC BUS CAPACITORS ARE DISCHARGED BEFORE TOUCHING ANY INTERNAL COMPONENTS FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS...

Page 3: ...Part 1 General Requirements and furthermore declares that the product covered by this Declaration must not be put into service until the machinery into which it is to be incorporated or of which it is a component has been found and declared to be in conformity with the provisions of Directive 89 392 EEC and with national implementing legislation i e as a whole including the product referred to in ...

Page 4: ...ator Interface Module Connector 2 15 2 7 6 Keypad Display 2 15 2 8 Drive Kit Options 2 16 3 0 Planning Before Installing 3 1 3 1 Requirements for the Installation Site 3 1 3 1 1 Making Sure Environmental Conditions are Met 3 1 3 1 2 Determining Total Area Required Based on Drive Dimensions 3 2 3 1 3 Verifying the Site Provides for Recommended Air Flow Clearances 3 4 3 1 4 Verifying Power Module In...

Page 5: ... 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 Motor 6 1 7 0 Wiring the Regulator Board Terminal Strip 7 1 7 1 Stopping the Drive 7 5 7 1 1 Compliance with EN 60204 1 1992 7 5 7 2 Wiring the Speed Feedback Device Vector Regulation Only 7 5 7 3 Wiring the Signal and...

Page 6: ...II Appendices Appendix A Technical Specifications A 1 Appendix B Drive Regulation Overview B 1 Appendix C Compliance with EN 60204 1 1992 C 1 Index Index 1 StockC heck com Downloaded from StockCheck com ...

Page 7: ...ultiple 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 Drives 4 6 Figure 4 6 Wire Routing Locations for 100 150 HP Drives 4 7 Figure 5 1 Typical ...

Page 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 Dr...

Page 9: ... Chapter 4 Mounting the Drive Grounding and Finding Wire Routing Locations Describes how to mount the drive and properly ground it D Chapter 5 Installing Input Power Wiring Describes incoming A C and D C line components and how to properly connect them D Chapter 6 Installing A C Output Power Wiring Describes output A C line components and how to properly connect them to the motor D Chapter 7 Wirin...

Page 10: ...owing terms are defined according to the way they are used in this manual D GV3000 drives will typically be referenced by horsepower If additional clarity is required drive model numbers will also be included D Parameters will be referenced either as parameter P 030 or Elapsed Time Meter Reset P 030 1 5 If You Want to Know More Refer to the following related publications as necessary for more info...

Page 11: ... Using general purpose volts hertz regulation the drive is suited for a broad range of applications requiring adjustable speed control of motors 2 1 Identifying the Drive by Model Number Each GV3000 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 regulato...

Page 13: ...1V4450 3V4450 2V4150 5V4150 2V4450 5V4450 1 Fan Fan Assembly 2 Membrane Switch Keypad Bracket 3 Regulator Printed Circuit Board PCB 4 Capacitor PCB Input Capacitors 5 Current Feedback PCB 6 Power PCB 15 25 HP drives only 7 Power Supply PCB 15 25 HP drives only 8 Gate Driver PCB 15 25 HP drives only 9 Internal Fan Assembly 10 IGBT Module 11 Diode Bridge 12 Fan Wire Harness Figure 2 2 1 5 HP Drive C...

Page 14: ...2 4 M N 7V4150 7V4250 10V4150 10V4250 Figure 2 3 7 5 10 HP Drive Components and Locations StockC heck com Downloaded from StockCheck com ...

Page 15: ...2 5 M N 15V4150 15V4250 20V4150 20V4250 M N 25G4150 25G4250 Figure 2 4 15 25 HP Drive Components and Locations StockC heck com Downloaded from StockCheck com ...

Page 16: ...ted in chapter 9 1 Fan 2 Membrane Switch Keypad Bracket 3 Regulator Board 4 Bus Capacitors 5 Not Used 6 Power Board 7 Power Supply Board 8 Gate Driver Board 9 Internal Fan Assembly 10 IGBT Module 11 Diode Bridge 12 Wire Harness M N 25V4150 25V4250 30V4150 30V4250 M N 40V4150 40V4250 50V4150 50V4250 M N 60G4150 60G4250 Figure 2 5 25 60 HP Drive Components and Locations StockC heck com Downloaded fr...

Page 17: ...ower Module Interface PCB 3 Gate Driver PCB 4 Bus Clamp PCB Right 5 Bus Clamp PCB Left 6 Intelligent Power Module PCB 7 Diode Bridge 8 D C Bus Fuse 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 2 14 7 12 10 13 11 10 6 5 3 9 4 8 1 10 14 15 16 M N 50R4150 75R4150 Figure 2 6 60 100 HP ...

Page 18: ...Module Interface PCB 3 Gate Driver PCB 4 Bus Clamp PCB Right 5 Bus Clamp PCB Left 6 Intelligent Power Module PCB 7 Thyristor Precharge Module 8 D C Bus Fuse 9 Not Used 10 Current Transformer 11 Ground Fault Transformer 12 Output Reactor 13 Not Used 14 Bus Discharge Resistor 15 24 VDC Fan 16 Keypad 17 Thyristor Firing Pulse PCB 2 14 7 12 2 8 11 15 5 6 3 3 5 1 10 17 16 M N 125R4150 Figure 2 7 100 15...

Page 19: ...at 250 VAC 30 VDC and are made available through the terminal strip D 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 D An analog o...

Page 20: ...ISPLAY J3 J7 J3 Option Board Connector J4 Analog Input Jumper J5 Power Module Feedback Cable J7 OIM Optional Connector J8 RS232C Port J9 Keypad Display Connector J17 Analog Output Jumper Figure 2 8 1 60 HP Regulator Board Components and Locations StockC heck com Downloaded from StockCheck com ...

Page 21: ...ption Board Connector J4 Analog Input Jumper J7 OIM Optional Connector J8 RS232C Port J9 Keypad Display Connector J16 Power Module Feedback Cable J17 Analog Output Jumper USER DISPLAY J7 Figure 2 9 60 150 HP Regulator Board Components and Locations StockC heck com Downloaded from StockCheck com ...

Page 22: ...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 ...

Page 23: ...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 secti...

Page 24: ...Terminals 16 25 24V D C digital input connections 1 60 HP Regulator boards only D Terminals 26 27 snubber resistor braking control connections 1 60 HP Regulator boards only D Terminals 28 31 status relay connections WIRES BETWEEN TERMINALS 16 16A AND 20 20A ARE NECESSARY FOR PROPER OPERATION OF THE FUNCTION LOSS INPUT THEY SHOULD NOT BE REMOVED PULSE TACHOMETER CONNECTIONS PHASE B NOT DIGITAL INPU...

Page 25: ...w the Regulator board inside the drive Refer to the appropriate board instruction manual for more information Refer to section 2 7 of this manual for more information on optional drive kits 2 7 5 Operator Interface Module Connector 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 2 7 6 K...

Page 26: ... 2TC3025 5 2TC3075 5 2TC4025 5 2TC4075 5 2TC4100 6 2TC4300 6 D2 3305 AutoMax Network Communication Board w 10 Feet of Cable 1 2 3 4 2AX3000 D2 3308 Remote Meter Interface RMI 2SI3000 D2 3341 DeviceNet Board 2DV3000 HE HGV3DN Operator Interface Module OIM 2RK3000 D2 3342 Control and Configuration Software CS3000 2CS3000 D2 3348 1 1 5 HP GV3000 Drives 2 7 5 10 HP GV3000 Drives 3 15 60 HP GV3000 Driv...

Page 27: ...ve this precaution could result in damage to or destruction of the equipment 3 1 Requirements for the Installation Site It is important to properly plan before installing a GV3000 drive to ensure that the drive s environment and operating conditions are satisfactory Note that no devices are to be mounted behind the drive This area must be kept clear of all control and power wiring Read the followi...

Page 28: ...1 mm 12 17 200 0 mm 7 87 9 kg 20 lbs 7V4250 10V4150 10V4250 11 05 13 32 9 76 12 17 7 87 20 lbs 15V4150 15V4250 20V4150 288 0 mm 11 34 463 0 mm 18 23 223 0 mm 8 78 442 0 mm 17 40 238 1 mm 9 37 15 75 kg 35 lbs 20V4150 20V4250 25G4150 25G4250 25V4150 25V4250 30V4150 30V4250 40V4150 40V4250 376 0 mm 14 80 605 0 mm 23 82 308 0 mm 12 13 565 2 mm 22 25 350 0 mm 13 78 23 6 kg 52 lbs 50V4150 50V4250 60G415...

Page 29: ...3 3 1 60 HP 60 150 HP Figure 3 1 Drive Dimensions StockC heck com Downloaded from StockCheck com ...

Page 30: ...ment do not mount GV3000 drives directly above each other Note that no devices are to be mounted behind the drive This area must be kept clear of all control and power wiring Refer to figure 3 2 for recommended air flow clearances 1 60 HP 60 150 HP If adjacent to other drives Figure 3 2 Recommended Air Flow Clearances StockC heck com Downloaded from StockCheck com ...

Page 31: ...H ALL APPLICABLE LOCAL NATIONAL AND INTERNATIONAL CODES WIRING PRACTICES GROUNDING DISCONNECTS AND OVERCURRENT PROTECTION ARE OF PARTICULAR IMPORTANCE FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE 3 2 2 1 Conduit Entry Opening Sizes It is important to accurately determine the size of the conduit openings so that the wire planned for a specific entry point ...

Page 32: ...re 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 lbs Table 3 8 Recommended Terminal Strip Wire Sizes Terminals Wire Size 1 to 31 20 to 14 AWG 2 to 0 5 mm2 3 2 2 4 Recommended Motor Lead Lengths The following motor lead lengths are recommended to reduce line disturbances and noise See...

Page 33: ... 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 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 C...

Page 35: ...er 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...

Page 36: ...4 2 Bottom View Figure 4 1 Wire Routing Locations for 1 5 HP Drives StockC heck com Downloaded from StockCheck com ...

Page 37: ...4 3 Bottom View Figure 4 2 Wire Routing Locations for 7 5 10 HP Drives StockC heck com Downloaded from StockCheck com ...

Page 38: ...4 4 Bottom View Figure 4 3 Wire Routing Locations for 15 25 HP Drives StockC heck com Downloaded from StockCheck com ...

Page 39: ...4 5 Bottom View Figure 4 4 Wire Routing Locations for 25 60 HP Drives StockC heck com Downloaded from StockCheck com ...

Page 40: ...ls and Ground A C Output Terminals and Ground View From Bottom Signals 1 3 4 D C Input Terminals and Ground 45 47 GND GND PE1 IL1 IL2 IL3 U V W Figure 4 5 Wire Routing Locations for 60 100 HP Drives StockC heck com Downloaded from StockCheck com ...

Page 41: ... Ground A C Inputs Ground View From Top View From Bottom 1 1 2 Output Terminals Ground Signals 7 8 D C Input Terminals and Ground V U W 45 47 A C Input IL1 IL2 IL3 Figure 4 6 Wire Routing Locations for 100 150 HP Drives StockC heck com Downloaded from StockCheck com ...

Page 42: ...cover Step 2 Run a suitable equipment grounding conductor unbroken from the drive s ground terminal to the motor s ground terminal and then to earth ground See figures 4 1 to 4 6 5 1 and 5 2 Step 3 Connect a suitable grounding conductor to the motor frame the remote control station if used and the transformer Run each conductor unbroken to earth ground Note that to conform with CSA requirements wh...

Page 43: ...l impedance between the drive and the transformer CAUTION Distribution system capacity above the maximum recommended system KVA 1000 KVA for 460 VAC requires the use of an isolation transformer a line reactor or other means of adding similar imped ance to the drive power input Failure to observe these precautions could result in damage to or destruction of the equipment CAUTION When the A C line i...

Page 44: ...ut Voltage 460 V 181 182 183 GND R S T GND PE GND Motor Overload Relay Optional if Electronic Overload is Used User Supplied User Supplied Ũ u Ũ u Ũ u Manual Disconnect Figure 5 1 Typical A C Input Electrical Connections StockC heck com Downloaded from StockCheck com ...

Page 45: ...age 620V Nominal R S T GND PE GND Motor Overload Relay Optional if Electronic Overload is Used User Supplied User Supplied Ũ u Ũ u Ũ u Manual Disconnect 47 45 Fuse Figure 5 2 Typical D C Bus Electrical Connections StockC heck com Downloaded from StockCheck com ...

Page 46: ...hrough 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...

Page 47: ... 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...

Page 48: ... 3 Installing Output Wiring from the Drive Output Terminals to the Motor Use the following steps to connect the AĆC output power wiring from the drive to the motor Step 1 Wire the threeĆphase AĆC output power motor leads by routing them according to drive type Refer to figures 4 1 to 4 6 Tables 3 3 to 3 7 contain the recommended power wiring sizes On 1Ć5 HP drives route the motor leads through the...

Page 49: ...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 Tighten the threeĆphase AĆC output power terminals to the proper torque according to drive type as shown in table 5 1 StockC heck com Downloaded from StockCheck com ...

Page 50: ...ections Terminals 4 9 D Terminal 4 15 VDC D Terminal 5 Phase A D Terminal 6 Phase A Not D Terminal 7 Phase B D Terminal 8 Phase B Not D Terminal 9 Regulator Common A speed feedback device pulse tachometer must be installed if vector regulation P 048 1 is used Analog Output Connections Terminals 10 and 11 D Terminal 10 Analog Meter Output D Terminal 11 Regulator Common The output of this terminal i...

Page 51: ...and 20A must be removed so that a contact will open to stop the drive Terminals 17 18 and 19 remote control inputs 8 7 and 6 are programmed using parameters P 007 P 008 and P 031 through P 038 Factory default settings are shown here in parentheses Refer to the GV3000 Programming Manual D2 3339 for more information Snubber Resistor Braking Connections Terminals 26 and 27 D Terminal 26 Snubber Resis...

Page 52: ... ALSO SEE FIGURE 2 12 PHASE B NOT DIGITAL INPUT 8 REMOTE LOCAL DIGITAL INPUT 7 RAMP1 RAMP 2 DIGITAL INPUT 6 FORWARD REVERSE PHASE B Remote 4 20 mA Speed Torque Reference Figure 7 1 Two Wire Start Stop Sample Control Wiring StockC heck com Downloaded from StockCheck com ...

Page 53: ... 20 ALSO SEE FIGURE 2 12 DIGITAL INPUT 8 REMOTE LOCAL DIGITAL INPUT 7 RAMP1 RAMP 2 DIGITAL INPUT 6 FORWARD REVERSE PHASE B NOT Remote 4 20 mA Speed Torque Reference Figure 7 2 Three Wire Start Stop Sample Control Wiring StockC heck com Downloaded from StockCheck com ...

Page 54: ...is 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 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 o...

Page 55: ...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 D2 3339 for more information StockC heck com Downloaded from StockCheck com ...

Page 56: ...232 Signals 1 2 3 RS 232 Transmit RS 232 Receive RS 232 Signal Regulator Common Note that RS 232 communication between the GV3000 drive and a personal computer requires the use of the Control and Configuration software Refer to instruction 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 th...

Page 57: ...so 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 Load Meter or Analog Input Conn...

Page 58: ... 15 Isolated Reference Voltage 15VDC Analog Speed Torque Reference Input Voltage 10 VDC Analog Speed Torque Reference Input Current 0 20mA Isolated Speed Torque Reference Common Voltage Current The following parameters must be set P 000 Control Source P 009 Terminal Strip Analog Input Offset P 010 Terminal Strip Analog Input Gain P 011 Terminal Strip Analog Input Invert Refer to the GV3000 Program...

Page 59: ...ÁÁÁÁÁÁÁÁ WARNING IF A MAINTAINED START CONTACT IS USED WHEN THE CONTROL SOURCE rE SWITCHING FROM LOCAL TO REMOTE FROM THE TERMINAL STRIP WILL CAUSE POWER TO BE APPLIED TO THE MOTOR IF THE REMOTE START CONTACT IS CLOSED STAY CLEAR OF ROTATING MACHINERY IN THIS CASE FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY The following parameters must be set P 000 Control Source Only active ...

Page 60: ... P 002 Decel Time 1 Ramp 1 P 006 Second Menu Password P 007 Terminal Strip Digital Inputs Configure Selects and assigns a control function to digital inputs 6 to 8 P 008 Terminal Strip Speed Reference Source Analog Motor Operated Potentiometer MOP or Preset Speeds P 017 Accel Time 2 Ramp 2 P 018 Decel Time 2 Ramp 2 Note that based on the settings of parameters P 000 P 007 P 008 and r 030 if an RMI...

Page 61: ...nal Strip Digital Inputs Configure Selects and assigns a control function to digital inputs 6 to 8 P 008 Terminal Strip Speed Reference Source Analog Motor Operated Potentiometer MOP or Preset Speeds P 027 Reverse Disable Note that based on the settings of parameters P 000 P 007 P 008 and r 030 if an RMI board is used the following parameters can affect digital input 6 P 023 MOP Accel Decel Time P...

Page 62: ...es 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 20 On No Function Loss or from 16A and 20A on 15 60HP drives ÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁÁ ÁÁÁÁÁÁÁ...

Page 64: ...rm 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 P 013 Output Relay Configuration Note that depending on the setting of parameter P 013 the relay coil will energize the normally open contact will clo...

Page 65: ...a function loss coast stop pushbutton has been installed verify that it has been wired correctly Be sure the factory installed jumper at terminals 16 and 20 or 16A and 20A has been removed so that the coast stop pushbutton will work WARNING THE USER MUST PROVIDE AN EXTERNAL HARDWIRED EMERGENCY STOP CIRCUIT OUTSIDE OF THE DRIVE CIRCUITRY THIS CIRCUIT MUST DISABLE THE SYSTEM IN CASE OF IMPROPER OPER...

Page 66: ...teps 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 8 3 Powering Up After Installation is Complete Use the following procedure to verif...

Page 67: ...OWER 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 voltag...

Page 68: ...re 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 6 Re apply input power Figure 9 1 D C Bus Voltage Terminals 1 25 HP Drives StockC heck com Downloaded from StockCheck com ...

Page 69: ...9 3 Figure 9 2 D C Bus Voltage Terminals 25 60 HP Drives StockC heck com Downloaded from StockCheck com ...

Page 70: ...9 4 D C Bus Measuring Points 45 47 1L1 1L2 1L3 U V W Figure 9 3 D C Bus Voltage Terminals 60 100 HP Drives StockC heck com Downloaded from StockCheck com ...

Page 71: ...Interface Board Regulator Panel D C Bus Measuring Points Behind Regulator Panel on the Power Module Interface Board 4547 1L1 1L2 1L3 U V W A C Input Figure 9 4 D C Bus Voltage Terminals 100 150 HP Drives StockC heck com Downloaded from StockCheck com ...

Page 72: ... in section 9 3 to ensure that the D C bus capacitors are discharged Step 5 Disconnect the motor from the drive Step 6 Check all A C line and D C bus fuses Step 7 If a fuse is blown use a multimeter to check the input diodes and output IGBTs See table 9 1 Note that 1 10HP drives do not have replaceable transistor modules the entire drive must be replaced if a transistor malfunctions Intelligent Po...

Page 73: ...uit 2 47 1L2 y 3 47 1L3 4 1L1 45 5 1L2 45 6 1L3 45 1 60HP Drives IGBT No Meter Connection Component is OK if resistance R is Component is defective if 1 W T3 50 R 10 Megohm Continuity short circuit or open when the meter is d i h d l i 2 V T2 g y p connected with reversed polarity 3 U T1 4 W T3 5 V T2 6 U T1 D C Bus Volts power terminal D C Bus Volts power terminal 60 150HP Drives IGBT No Meter Co...

Page 74: ...x 1 1 1 1 Capacitor PCB 0 56928 30 0 56928 50 1 1 1 1 Current Feedback PCB 0 56926 20 0 56926 50 1 1 1 1 Internal Fan Assembly 615159 1R 1 1 1 1 Components are identified in figure 2 3 Table 9 3 7 5 10 HP Drive Replacement Parts Quantity per Horsepower Description Part Number 7 5 10 Fan Assembly 615161 S 2 2 NEMA 1 Cover 805538 1R 1 1 NEMA 12 Cover Gasket 805539 1R 1 1 Membrane Switch Keypad Brack...

Page 75: ... 805547 2R 1 1 1 Membrane Switch Keypad Top Bracket 805548 1R 1 1 1 Regulator PCB 0 56921 5xx 1 1 1 Capacitor PCB 0 56948 015 0 56948 020 1 1 1 Power Board 0 56949 020 1 1 1 Power Supply Board 0 56950 015 0 56950 020 1 1 1 Gate Driver Board 0 56947 020 1 1 1 Internal Fan Assembly 615159 1S 1 1 1 Components are identified in figure 2 5 StockC heck com Downloaded from StockCheck com ...

Page 76: ... Regulator PCB 0 56921 5xx 1 1 1 1 1 Input Capacitor 600442 32A 600442 33A 2 2 2 4 4 Power PCB 0 56949 040 0 56949 050 1 1 1 1 1 Power Supply PCB 0 56950 025 0 56950 030 0 56950 040 0 56950 050 1 1 1 1 1 Gate Driver PCB 0 56947 025 0 56947 040 0 56947 050 1 1 1 1 1 IGBT Module 602909 810AW 602909 811AW 602909 812AW 3 3 3 3 3 Diode Bridge 701819 113BA 701819 114BA 1 1 1 1 1 Internal Fan Assembly 61...

Page 77: ...left 413338 5E 413338 5F 2 2 Intelligent Power Module IPM PCB 413338 5J 3 Diode Bridge 413338 5K 3 MOV on Diode Bridge 413338 5L 3 D C Bus Fuse 413338 5M 2 Precharge Contactor 413338 5N 4 Current Transformer 413338 5R 2 Ground Fault Transformer 413338 5Q 1 Output Reactor 413338 5S 3 Precharge Resistor 18 ohms 413338 5T 4 Bus Discharge Resistor 1 5K ohms 413338 5V 2 24V D C Fan 413338 5W 2 Componen...

Page 78: ...wer Module IPM PCB 413338 5AH 6 Thyristor Precharge Module 413338 5AJ 3 D C Bus Fuse 413338 5AK 4 Current Transformer 413338 5R 2 Ground Fault Transformer 413338 5Q 1 Output Reactor 413338 5AR 3 Bus Discharge Resistor 1 5K ohms 413338 5V 4 24V D C Fan 413338 5W 4 Thyristor Firing Pulse PCB 413338 5AG 1 Thyristor Firing Pulse PCB Fuses 15A 413338 1JS 3 Components are identified in figure 2 8 It is ...

Page 79: ...g 2 14 7 2 to 7 4 7 14 Bus clamp board 2 7 to 2 8 9 11 to 9 12 C 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 Configurati...

Page 80: ... 6 1 planning 3 1 to 3 8 requirements 3 1 to 3 8 transformers and reactors 5 1 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...

Page 81: ...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 ...

Page 82: ...meter 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 Ventilat...

Page 83: ... seconds within 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 50 to 110 based on drive nameplate rating V Hz Service Factor 1 0 Speed Adjustable Range From 0 RPM to maximum speed Speed Regulation Vector 0 01 long term steady state V Hz motor slip dependent Speed Reference Resolution 1 RPM ...

Page 84: ...Used with Snubber Resistor Braking Kits Refer to Instruction Manual D2 3179 Table A 5 RS 232 Specifications Signal Type Terminal s Specification RS 232 Communications 1 XMIT 2 RECV 3 COMMON Table A 6 Speed Feedback Device Specifications Vector Regulation Only Specification Rating Motor Poles 2 4 6 or 8 poles Overcurrent IET 200 load based on drive nameplate rating Overload Current Rating 150 for 1...

Page 85: ...econds Preset Speeds 75 milliseconds 75 milliseconds Analog Speed Trim Reference 16 milliseconds 5 milliseconds Analog Torque Reference N A 0 5 milliseconds Network START 46 milliseconds network transport time 25 milliseconds network transport time STOP RESET FL 26 milliseconds network transport time 25 milliseconds network transport time Analog Speed Trim Reference 5 milliseconds network transpor...

Page 86: ...wer device gates generating a pulseĆwidthĆmodulated PWM waveform to the motor Vector Regulation Vector regulation allows dynamic closedĆloop performance in an AĆC drive similar to that achieved with a DĆC drive Torque is constant across the motor s base speed range in both forward and reverse directions The drive uses two digital control loops speed and torque to obtain vector performance The spee...

Page 87: ... w1 VD VQ PWM Controller Forward TransĆ formation Reverse TransĆ formation P 043 Fault Auto Reset Attempts P 044 Fault Auto Reset Time Line Voltage fbk A D Converter A D Converter A D Converter DC Bus Voltage Comp Gate Signals P 047 P 095 PWM Inverter AĆC Induction Motor H 017 DB Select Remote Braking Resistor 60Ć150 HP GV3000 Drives Only 1Ć60 HP GV3000 Drives Only Carrier Freq Power Module Output...

Page 88: ...P 001 P 017 or P 021 Decel time P 002 P 018 or P 022 SPEED REFERENCE SPEED CONTROLLER FIELD CONTROLLER DERIVATIVE VECTOR TORQUE CONTROLLER TORQUE COMMAND FLUX COMMAND PWM INVERTER GATE SIGNALS DB KIT CONTROL AĆC MOTOR CURRENT FEEDBACK PULSE ENCODER ROTOR POSITION AĆC LINE INPUT SPEED FEEDBACK Invert P 027 5 6 7 8 9 RMI Analog Input RMI Freq Input Switched RMI Analog Input or Freq Input Outer Loop ...

Page 89: ...ints 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 Contr...

Page 90: ...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 dif...

Page 91: ...Reliance Electric 24703 Euclid Avenue Cleveland Ohio 44117 216 266Ć7000 Printed in U S A December 1995 D2Ć3340 StockC heck com Downloaded from StockCheck com ...

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Reliance electric GV3000, Instruction Manual

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