Answer Drives GT3000 Mounting instructions

GT3000
Hardware & Software Manual

www.answerdrives.com

Code: IMGT30017EN
Revision: 0.4
SW Version: 3G02.xxD1
3G2.xxE1
Date: May- 08
For further information and comment, please contact us at:
www.answerdrives.com
Answer Drives S.r.l. thanks you for choosing a product of the GT3000 family and for any useful advice aimed at the improvement of this manual.
GT3000
HARDWARE AND SOFTWARE MANUAL

IMGT30017EN i
Table of Contents
Table of contents.................................................................................................................................................... i
About this manual ..................................................................................................................................................................... v
THE GT3000 DRIVE
1A GT3000Overview and Installation Flowchart .....................................................................................................................1
1A.1.1Overview...............................................................................................................................................................1
1A.1.2 Notes about control modes.....................................................................................................................................1
1A.1.3 Installation Flowchart..............................................................................................................................................2
2A Technical Data................................................................................................................................................................3
2A..1 Identification code....................................................................................................................................................3
2A..2 Nameplate...............................................................................................................................................................4
2A..3Permissible environmentalconditions.......................................................................................................................5
2A..4Electricaldata..........................................................................................................................................................6
2A..5Switching frequency.................................................................................................................................................7
2A..6Generaldata............................................................................................................................................................8
2A..7Lossesand coolingdata...........................................................................................................................................9
2A..8Standards..............................................................................................................................................................10
2A..9Overalldimensionsandweights.............................................................................................................................11
3A Receiving and storing.................................................................................................................................................19
3A.1 Receiving, unloading, unpacking and inspecting the drive.................................................................................................19
3A.2 Storage...........................................................................................................................................................................20
3A.3 Installation......................................................................................................................................................................21
3A.3.1 MechanicalInstallation.......................................................................................................................................21
3A.3.2 Clearance around the drive....................................................................................................................21
3A.3.3 Dimensions...........................................................................................................................................23
3A.3.4 Accessing the terminals.........................................................................................................................24
3A.3.5 Frame VII VIII Installation.......................................................................................................................25
3A.4 Electrical Installation........................................................................................................................................................26
3A.4.1 Power wiring diagram.............................................................................................................................................27
3A.4.2.Power cables and power fuses...............................................................................................................................29
3A.4.3Auxiliaries Power Supply........................................................................................................................................31
3A.5 Reactors.........................................................................................................................................................................32
3A.6 Control section................................................................................................................................................................34
3A.7 Encoder Connection........................................................................................................................................................43
3A.8 Installation Checklist........................................................................................................................................................46
4A Maintenance..................................................................................................................................................................47
4A.1 Operating Principle..........................................................................................................................................................47
4A.2 Safety Precautions..........................................................................................................................................................48
4A.3 Preventative Maintenance...............................................................................................................................................50
4A.4 Disposal..........................................................................................................................................................................51
4A.5 Software download..........................................................................................................................................................52
5A Application Notes.........................................................................................................................................................53
5A.1 General Formulas describing a drive operation.................................................................................................................53
5A.2 Drive selection ................................................................................................................................................................54
5A.3 Application Notes............................................................................................................................................................54
5A.4 Application with specialmotors........................................................................................................................................54
5A.5 Motor selection................................................................................................................................................................54
6A Options...........................................................................................................................................................................57
6A.1 Introduction.....................................................................................................................................................................57
6A.2 Braking Unit....................................................................................................................................................................57
6A.3 Keypad Installation..........................................................................................................................................................60
6A.4 External Control power supply.........................................................................................................................................62
6A.5 “SIOVA”DigitalI/O expansion board................................................................................................................................68
6A.6 Safe StopBoard..............................................................................................................................................................71
6A.7 Sinus filter.......................................................................................................................................................................73
7A Spare parts....................................................................................................................................................................75
Appendix A1 – Terminal Boards and Powerschematics.......................................................................................................81
Appendix A2 - Mandatory Installation Instruction According to the EMC Directive................................................................ 103
Appendix A3 -Parallelunits...............................................................................................................................................111

Table Of Contents GT3000
ii IMGT30017EN
THE PROGRAMMING
1B Programming...............................................................................................................................................................119
2B Programming tools.........................................................................................................................................................121
2B.1 Introduction....................................................................................................................................................................121
2B.2 Basic Keypad "BF" and MenuSystem............................................................................................................................121
2B.3 Intermediate and advanced keyboard.............................................................................................................................127
2B.4 Menu System................................................................................................................................................................129
2B.5 PC Interface ..................................................................................................................................................................133
2B.6 GT3000PCTOOL: RS 485 Multi-Drop Functionality........................................................................................................134
2B.7 TELEASSISTANCE: Settings for the connection of the modem -GT3000 by phone connection......................................135
3B Programming levels and Motor Control Modes....................................................................................................145
3B.1 Programming levels.......................................................................................................................................................145
3B.2 Control Mode.................................................................................................................................................................145
3B.3 Programming levelsand Control Mode...........................................................................................................................146
3B.4 Factory settings (default values).....................................................................................................................................146
4B Level 1 - Quick Motor Start-Up procedure.............................................................................................................147
4B.1 Quick MotorStart-Up proceduredescription ...................................................................................................................147
4B.2 Quick MotorStart-Up Parameters...................................................................................................................................150
4B.3 Quick MotorStart-Up operation with Keypad...................................................................................................................151
4B.4 Quick MotorStart-Up Operation with PC Interface..........................................................................................................153
4B.5 Digital and analog I/O....................................................................................................................................................158
4B.6 Control Terminal Board..................................................................................................................................................159
4B.7 Protectionsand Alarms..................................................................................................................................................161
5B Level 2 - Quick Application Start-Up.......................................................................................................................163
5B.1 V/Hz Quick Application Start-Up.....................................................................................................................................163
5B.2 Sensorless (SLS) orField OrientedControl (FOC)Quick Application Start-Up.................................................................166
5B.3 Quick Application Start-Up (Settings for all controls)........................................................................................................168
5B.4 Parameters Tables ........................................................................................................................................................168
6B Level 3 - Advanced System Application.................................................................................................................169
6B.1 V/Hz Advanced Application Start-Up ..............................................................................................................................169
6B.2 AdvancedSystemApplications Start-Up - SLS o FOC....................................................................................................173
6B.3 Parameters Tables ........................................................................................................................................................176
6B.4 AdvancedApplication Start-Up - Settings for all controls.................................................................................................177
7B Standard macros........................................................................................................................................................179
7B.1 Speed Demand .............................................................................................................................................................179
7B.1.1Speed reference source selection.........................................................................................................................181
7B.1.2 Start command mode/Safety Start (FOC/SLS/VHz)...............................................................................................181
7B.1.3 Motor Minimum Operating Frequency...................................................................................................................182
7B.1.4 Rate of frequency change.....................................................................................................................................182
7B.1.5 Motor Maximum Operating Frequency ..................................................................................................................182
7B.1.6 Forward and Reverse Speed/frequency Reference Limits......................................................................................182
7B.2 Preset Speeds...............................................................................................................................................................183
7B.3 Digital Potentiometer......................................................................................................................................................184
7B.4 Speed Command Loss...................................................................................................................................................185
7B.5 CriticalSpeed Avoidance...............................................................................................................................................185
7B.6 Ramps ..........................................................................................................................................................................186
7B.7 VDCRollback................................................................................................................................................................188
7B.8 Current Rollback (V/Hz).................................................................................................................................................189
7B.9 Motor Overload Thermal Protection................................................................................................................................190
7B.10 Free Run Stop.............................................................................................................................................................191
7B.11 Auto Reset & Restart ..................................................................................................................................................191
7B.12 HOA/pulsed start stop ................................................................................................................................................192
7B.13 Auto On/Off.................................................................................................................................................................196
7B.14 Input Single Phasing....................................................................................................................................................198
7B.15 VDC Under voltage (Voltage Drop Control): Ride Through - (V/Hz, SLS, FOC)..............................................................200
7B.16 Flying restart (V/Hz).....................................................................................................................................................201
7B.17 Flying restart (SLS)......................................................................................................................................................202
7B.18 Energy Saver (SLS, FOC)............................................................................................................................................203
7B.19 ExternalPID Regulator (V/Hz, SLS, FOC)....................................................................................................................204

GT3000 Table Of Contents
IMGT30017EN iii
8B Application Macros....................................................................................................................................................211
8B.1 DC Braking (V/Hz) ........................................................................................................................................................ 212
8B.2 Current Oscillation Compensation (V/Hz)....................................................................................................................... 213
8B.3 Jog ............................................................................................................................................................................ 214
8B.4 Speed External Limits.................................................................................................................................................... 214
8B.5 Under load......................................................................................................................................................................25
8B.6 Lossof Output Phase .................................................................................................................................................. 215
8B.8 Energy Saver -VHZ Curve Optimisation (V/Hz)..............................................................................................................215
8B.7 Emergency Stop............................................................................................................................................................216
8B.9 Helper (Master -Slave) (SLS,FOC)............................................................................................................................... 217
8B.10 Pope (SLS, FOC) .......................................................................................................................................................220
8B.11 Drooping (SLS,FOC)..................................................................................................................................................221
8B.12 Tension Regulator with Load Cells (SLS, FOC)............................................................................................................ 223
8B.13 Torque Control (SLS, FOC)......................................................................................................................................... 226
8B.14 Torque Limits Control (SLS, FOC)...............................................................................................................................227
8B.15 MotorStall(SLS, FOC)................................................................................................................................................ 229
8B.16 Speed Deviation .........................................................................................................................................................229
8B.17Torque Over boost (SLS, FOC) .................................................................................................................................... 230
8B.18TraceSettings .............................................................................................................................................................231
8B.19AND/OR Functions for DI/DO ....................................................................................................................................... 232
8B.20 Auto start.................................................................................................................................................................... 233
8B.21 Crane brake control (FOC/SLS/VHz)............................................................................................................................234
8B.22 Analog input user trip/Alarm (Motor PTC/NTC management)........................................................................................241
8B.23 Safety Override........................................................................................................................................................... 243
8B.24 Back-lack Compensation.............................................................................................................................................244
9B I/O Configuration........................................................................................................................................................ 245
9B.1igital Input Configuration................................................................................................................................................. 245
9B.2 Digital Output Configuration........................................................................................................................................... 245
9B.3 Analog Input Configuration............................................................................................................................................ 249
9B.4 Analog Output Configuration.......................................................................................................................................... 253
10B: Diagnostics, protections and troubleshooting ................................................................................................. 257
10B.1 Drive trips,alarmsand reset........................................................................................................................................ 258
10B.2 Fault/Alarmlog............................................................................................................................................................258
10B.3 Real Time Clock ......................................................................................................................................................... 259
10B.4 List of protections and alarms ..................................................................................................................................... 259
10B.5 Protection Menu.......................................................................................................................................................... 260
10B.6 Troubleshooting .......................................................................................................................................................... 261
10B.7 Monitor........................................................................................................................................................................ 265
Appendix B1 -Parameters -Programming level1............................................................................................................... 275
Appendix B2 -Parameters -Programming levels 1 & 2....................................................................................................... 277
Appendix B3 -Parameters -Programming levels 1, 2 & 3...................................................................................................285
Appendix B4 - Inputconfiguration for operating functions....................................................................................................309
Appendix B5 -Defaultvalues -Use of EU/NEMA ...............................................................................................................311
Appendix B6 -Drive variables refresh time.........................................................................................................................315
Appendix B7 - Menu System Flow Chart............................................................................................................................319
Answer Drives S.r.l shall not be liable for technical or editorial omissions or mistakes in this manual, nor shall it be liable for incidental or
consequentialdamages resulting from the use of information contained in this manual.

Table Of Contents GT3000
iv IMGT30017EN

IMGT30017EN - v -
☞
CAUTION !
ABOUT THIS MANUAL
This manual provides detailed information on the installation and start up procedures for GT3000 drives. It also describes all
safety precautions necessary for easy and safe operation.
The manual wasprepared for qualified personnel involved with GT3000 drives assembly, installation, start-up and maintenance.
The manual contains three different kinds of safety labels and related symbols to indicate information that requires special
attention:
Indicates potentially dangerous situations that could lead to death or serious injury to
operators and / or maintenance personnel.
Highlights potential dangers to personnel and/or to equipment.
Highlights potential dangers to personnel from electrically live parts or components.
Shows a procedure that should be followed or avoided in order to carry out correct
installation, repair or replacement operations without damaging the drive.
Shows operations where electrostatic charges should be avoided.
General WARNING symbol
Is used to explain an instruction, a repair operation orother.
3
General NOTE symbol
DOCUMENTATION STRUCTURE
The GT3000 documentation includes the following manuals:
BASIC MANUAL - MANUALE BASE : IMGT30016EN
HARDWARE AND SOFTWARE MANUAL : IMGT30017EN
COMMUNICATION MANUAL : IMGT30005EN
GT3000 AFE HARDWARE AND SOFTWARE MANUAL IMGT30007EN
STAND ALONE BRAKING UNIT MANUAL IMGT30006EN/IT
Make sure to thoroughly read and fully understand this MANUAL before performing any
operation on GT3000 drives.
WARNING
NOTE
CAUTION !

General Safety Precautions
-vi IMGT30017EN
GENERAL SAFETY PRECAUTIONS
This section provides information related to the safety issues of which all personnel working with the GT3000 must be aware.
The information is general and concerns the risks associated with both the operation and the maintenance of the drive. Failure
to comply with the safety precautions may lead to personnel injury or death and to damage to the drive, the motor or the
machine.
♠All electrical maintenance and installation operations on GT3000 must be performed by
qualified technicians.
♠All standard electrical safety procedures must be followed:
¾Never touch anything within the drive until you check that it is not hotand/or live.
¾Always wear insulated or rubber safety shoes, and safety goggles.
¾Never work alone.
¾Never connect any grounded meters or oscilloscopes to the system.
¾Never remove safety shields.
¾Always use extreme caution when handling components or taking measurements
inside the enclosure.
¾DANGER! RISK OF FIRE, HEAVY DAMAGE OR INJURIES! Never operate the drive without line fuses or using line
fuses different from the ones specified for it (see Chapter 3A for size and type). Wrong fuses may cause fire, injuries to
personnel or heavy damage to equipment and/or nearby connected parts. Some units need separate line fusing for fans
and auxiliary circuits.
¾Do not apply power to the drive if any moisture, dust or caustic/corrosive chemicals may have entered the enclosure or
internal components.
¾DANGER! RISK OF FIRE, HEAVY DAMAGE OR INJURIES! GT3000 drives are open type devices and must be installed
strictly as instructed in the GT3000 HARDWARE MANUAL, and in full compliance with existing industry standards and
regulations.
¾DANGER! GT3000 and all connected devices MUST BE SUITABLY GROUNDED.
¾DANGER! RISK OF FIRE, HEAVY DAMAGE OR INJURIES! The voltages on the output terminals of GT3000 are
dangerous when the drive is energized, even if the drive is not running. Again, be aware that the motor could spin at any
time as soon as the power supply is connected and capacitorbank is charged.
¾If installed in an enclosure, never run the drive with cabinet doors open.
¾DANGER! RISK OF DEATH OR ELECTRICAL SHOCK! The following safety instructions must be strictly obeyed before
servicing the unit:
♦Perform supply power lockout/tagoutprocedure, and open the main
disconnect to the drive.
♦Make sure that allpower supplies coming into GT3000 (main supply and
auxiliaries supply) are disconnected before servicing the drive.
♦Before servicing the drive or accessing the motor terminals wait at least ten
(10) minutes after disconnecting all input power supplies. Verify that the DC
link voltage is less than 40 Volts before proceeding. Use a multimeter rated for
1000 volts DC or more. Refer to the safety label that is placed on every drive.
♦The DC voltages at the brake switch terminals are dangerous (higher than
500V).
DANGER! RISK OF FIRE, HEAVY DAMAGE OR INJURIES! Never store
flammable materialin,onornear thedriveenclosure.
GT3000 is provided with many automatic reset and restart functions. Such
functions may restart the unit automatically. Do not activate these functions if
danger situations may arise.
¾Do not change the insulation distances or remove insulating materials andcoverings.
CAUTION !
CAUTION !
☞
DANGER