ASIRobicon GT3000 Installation guide

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BASIC MANUAL MANUALE BASE
GT3000

BASIC MANUAL
GT3000
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GT3000 Basic Manual Table of contents
IMGT30003EN-September 2003 I
TABLE OF CONTENTS
TABLE OF CONTENTS .......................................................................................................................................................................... I
1 INTRODUCTION.................................................................................................................................................................................. 1
1.1. GENERAL OVERVIEW .............................................................................................................................................................. 1
1.2. GT 3000 POWER CIRCUITRY.................................................................................................................................................. 2
2 SPECIFICATIONS ............................................................................................................................................................................... 5
2.1. RECEIVING AND INSPECTION.................................................................................................................................................... 5
2.2. DRIVE IDENTIFICATION ............................................................................................................................................................ 5
2.3. DRIVE SPECIFICATIONS........................................................................................................................................................... 7
3 SAFETY ............................................................................................................................................................................................... 9
3.1. PERSONAL SAFETY PRECAUTIONS AND WARNINGS .......................................................................................................................... 9
3.2. POWER SOURCES IN THE GT 3000 ................................................................................................................................................ 9
3.3. TEST EQUIPMENT – AC/DC METER RATED AT 1000 VAC................................................................................................................ 9
3.4. VERIFICATION ............................................................................................................................................................................. 10
3.5. LOCK-OUT AND TAG-OUT ............................................................................................................................................................. 10
3.6. INPUT CONTACTORS.................................................................................................................................................................... 10
3.7. OUTPUT CONTACTORS AND BYPASS............................................................................................................................................. 10
3.8. DRIVE SAFETY ............................................................................................................................................................................ 10
4 INSTALLATION................................................................................................................................................................................. 11
4.1. INSTALLATION ............................................................................................................................................................................. 11
4.2. RUNNING CONDUIT INTO A SYSTEM CABINET ................................................................................................................................. 11
4.3. ISOLATION OF THE POWER WIRE AND CONTROL WIRING ................................................................................................................ 11
4.4. RUNNING THE POWER CABLES AND SIZING .................................................................................................................................... 11
4.5. RUNNING THE CONTROL WIRING ................................................................................................................................................... 11
4.6. POWER TERMINAL BLOCK............................................................................................................................................................ 11
4.7. POWER FUSES............................................................................................................................................................................ 11
4.8. AUXILIARY POWER SUPPLIES ....................................................................................................................................................... 11
5 KEYPAD & PC FUNCTIONS............................................................................................................................................................. 13
5.1. KEYPAD AND PC TOOL................................................................................................................................................................ 13
5.1.1. Keypad Key Functions ..................................................................................................................................................... 14
5.1.2. PC TOOL.......................................................................................................................................................................... 15
5.1.3. Programming using Keypad............................................................................................................................................. 16
6 FUNCTIONS OF PROGRAMMING LEVEL 1 ................................................................................................................................... 17
6.1. COMMISSIONING ......................................................................................................................................................................... 17
6.1.1. Programming levels.......................................................................................................................................................... 17
6.1.2. Control Modes .................................................................................................................................................................. 17
6.1.3. Standards ......................................................................................................................................................................... 17
6.1.4. Microprocessor Boards .................................................................................................................................................... 17
6.1.5. Motor Quick Start-Up........................................................................................................................................................ 17
6.2. INITIAL START/MOTOR OPERATION.................................................................................................................................... 19
6.2.1. V/Hz, SLS, and FOC Motor Direction Operation.............................................................................................................. 19
7 FUNCTONS OF PROGRAMMING LEVEL 2 .................................................................................................................................... 23
7.1. PROGRAMMING LEVEL 2 PARAMETERS ......................................................................................................................................... 23
7.2. MOTOR MENU MAIN SETTING....................................................................................................................................................... 31
7.3. MOTOR MENU MOTOR DATA........................................................................................................................................................ 31
7.4. MOTOR MENU V/HZ SETTING ....................................................................................................................................................... 31
7.5. DRIVE MENU DIGITAL OUTPUT ..................................................................................................................................................... 32
7.6. DRIVE MENU ANALOG INPUT ........................................................................................................................................................ 34
7.7. DRIVE MENU ANALOG OUTPUT..................................................................................................................................................... 35
7.8. DRIVE MENU STANDARD MACRO .................................................................................................................................................. 37
7.8.1. Critical Speed En.............................................................................................................................................................. 37
7.8.2. Curr Rollback En .............................................................................................................................................................. 38
7.8.3. VDC Rollback En.............................................................................................................................................................. 38
7.8.4. Flying Restart En.............................................................................................................................................................. 38

Table of contents GT3000 Basic Manual
II IMGT30003EN-September 2003
7.8.5. Motor Pot Enable.............................................................................................................................................................. 38
7.8.6. VDC Undervolt En ............................................................................................................................................................ 39
7.8.7. Free Run Stop .................................................................................................................................................................. 39
7.8.8. HOA\Pulsed StartStop...................................................................................................................................................... 39
7.8.9. Auto-reset & Start Enb ..................................................................................................................................................... 40
7.8.10. AUTO ON/OFF............................................................................................................................................................... 40
7.8.11. Input Single Phasing ...................................................................................................................................................... 40
7.8.12. EXTERNAL PID REGULATOR...................................................................................................................................... 40
7.9. AUTO MENU,SPEED DEMAND SETUP ........................................................................................................................................... 42
7.9.1. Rate of frequency change ................................................................................................................................................ 43
7.9.2. Forward and Reverse Speed (or Frequency) Reference Limits ...................................................................................... 43
7.9.3. Ramps, Acceleration and Deceleration Times, Jerk time (or S-shaped ramp)................................................................ 44
7.10. PROTECT MENU, MOTOR THERMAL PROT [P66.00] ..................................................................................................................... 45
7.11. PROTECT MENU, ALARM SETTING [P68.00]................................................................................................................................ 46
7.12. PROTECT MENU, PROTECTIONS [P69.00]................................................................................................................................... 46
7.13. PROTECT MENU, AUTO-RESET & RESTART................................................................................................................................. 46
8 ALARMS AND FAULTS.................................................................................................................................................................... 47
8.1. MONITOR OVERVIEW................................................................................................................................................................... 47
8.2. ALARMS ..................................................................................................................................................................................... 49
8.3. FAULTS ...................................................................................................................................................................................... 50
9 MAINTENANCE................................................................................................................................................................................. 53
9.1. SAFETY PRECAUTIONS ................................................................................................................................................................ 53
9.2. PREVENTIVE MAINTENANCE (PM) SCHEDULE................................................................................................................................ 53
9.2.1. PM System and Performance Checklist........................................................................................................................... 53
10 SYSTEM OPTIONS ......................................................................................................................................................................... 55
10.1. GENERAL OVERVIEW................................................................................................................................................................. 55
10.2. SYSTEM OPTIONS DESCRIPTION................................................................................................................................................. 59
APPENDIX A - CHASSIS ..................................................................................................................................................................... 63
APPENDIX B - SYSTEM OPTIONS ..................................................................................................................................................... 75
APPENDIX C - MICROPROCESSOR BOARDS ................................................................................................................................. 81
APPENDIX - LIST................................................................................................................................................................................. 85

GT3000 Basic Manual Introduction
IMGT30003EN-September 2003 1
1 INTRODUCTION
1.1 General Overview
Variable Frequency Drives (VFD) are utilized to control many processes and require various control capabilities based upon the
application. The GT 3000 contains a wide range of features enabling it to meet the demands of many types of industrial applications.
The GT 3000 complete family of VFDs runs from 2HP- 900 HP and 1.5kW – 650kW. VFDs are designed to fulfill many applications
including the following:
• Pumps – centrifugal, positive displacement
• Fans – Forced and induced draft, centrifugal, axial, evaporators
• Mixers, Agitators, Conveyors, Winders, Centrifuges, Extruders, Compressors
• Machinery for paper, steel and textile industries
• Lifts, elevators, cranes and hoists
Standard features of the GT 3000 are:
• Control capabilities
• V/Hz mode – utilized for multiple motor applications
• Sensorless Vector mode – provides torque when required; ultimate control without encoder feedback
• Field-Oriented Control mode – used for applications requiring tight torque/speed control
• Auto Tuning – tunes the VFD to the motor specifications and the load
• Speed Profile – controls the minimum/maximum speed profile per requirements
• Critical Speed Avoidance – eliminates the drive from running at critical speeds
• PID Control – controls process with an internal PID loop controller
• Energy Saver – saves energy at lower speeds of operation
• Overload setting – protection designed to protect the motor
• Flying Re-Start – function used to catch a spinning motor
• Free Run Stop – stops firing of IGBTs
• Fast Stop – fast deceleration of the motor per fast stop ramp rate
• Three (3) adjustable ramp rates – controls acceleration/deceleration of the motor with the process
• Auto On/Off- via the input control signal, the drive can be started/stopped
• Auto Reset and Auto Restart
• Voltage boost – provides additional voltage to motor for sticky loads at low speeds
• S-curve of Acceleration/Deceleration
• Jog function – control the speed for low speed process control
• Minimum/Maximum speed setting
• Preset Speeds/Monitor and Hold
Options of the GT 3000 are:
• Input Reactor – protects and filters input power circuitry
• Output Reactor – for long lead lengths
• DC Braking – for applications which require a fast deceleration
• Enclosures – Nema 1, Nema 12
• Input devices – circuit breaker, non-fused disconnect, fuses
• Clean Power capability – to minimize harmonic effect on input power
• Output Contactors - for use with VFD and/or for Bypass capabilities
• Temperature Overload Relays – for motor protection
• Pressure Transducer – for control feedback
• Encoder – for Vector Control operations
• RFI filters – to reduce noise injection to the power supply

Introduction GT3000 Basic Manual
2 IMGT30003EN-September 2003
1.2 GT 3000 Power Circuitry
The VFD consists of a converter, a pre-charge, a DC bus and an inverter circuit:
Converter
• Takes a fixed frequency (50/60Hz) on the input to the drive and converts it into a fixed DC voltage
DC Bus and Pre-Charge
• The bus is charged through a pre-charge network in all HP ranges
• On drives ranging from sizes OP3F to 121F (2HP/1.5Kw – 125HP/9kW), the contactor is picked up to bypass the pre-
charge circuit
• On drives ranging from sizes 152F to 780F (150HP/110kW – 900HP/650kW), three (3) SCRs are utilized in the positive
bridge and are turned on when the capacitors have been pre-charged
Inverter
• Takes the DC voltage - sequencing frequency controls the rpm of the motor.
• The number of pulses and duty cycle of the IGBTs controls the voltage applied to the motor
• Although drives vary in size, some key components are common. These components include the following:
Power Circuitry Control Boards
• Input diodes/SCRs • Microprocessor Basic/Plus
• Pre-charge or control • Gate Driver/interface
• DC bus capacitors • Keypad – Basic/Intermediate/Advanced
• Bleeder resistors
• IGBT modules
See Appendix A – Table A.1 for kW and HP ratings
Figure 1-1 Diagram of Drive (0P3F – 121F)
NOTE

GT3000 Basic Manual Introduction
IMGT30003EN-September 2003 3
Figure 1-2 Diagram of Drive (105K – 480K)
Figure 1-3 Diagram of Drive (520F – 960K)

Introduction GT3000 Basic Manual
4 IMGT30003EN-September 2003
Figure 1-4 Clean Power Drive Configuration (NAFTA Market)
GE
C
GE
C
GE
GE
C
GE
C
GE
C
MOTOR
CONVERTER (AC TO DC) DC BUS INVERTER (DC TO AC)
OUTPUT POWER IGBTS
INPUT DIODE RECTIFIERS
F11 L1
F12
F13
LINE
REACTOR
DC BUS
CAPS
PRECHARGE
RESISTORS
BYPASS
VDC
TRANSFORMER
+
-
C
CONTACTOR

GT3000 Basic Manual Specifications
IMGT30003EN-September 2003 5
2 SPECIFICATIONS
2.1 Receiving and Inspection
All systems are fully inspected and tested prior to packing and shipment from the factory. Upon receipt, the system should be
inspected for any signs of visible damage that may have occurred during transit. The packing slips should be carefully checked to
ensure that all components, including outline and schematic drawings of the equipment have been received. If any parts are
damaged or missing, the purchaser should immediately present a claim to the carrier and then notify the factory.
Figure 2-1 Methods of Unloading and Lifting Drives
After initial inspection, the equipment should be promptly moved to the final installation position or to a dry, weather-protected and
temperature-controlled storage area per specifications. The drive is not weatherproof and must never be stored in an outdoor area.
2.2 Drive Identification
The following are examples of the nameplates. These can be found on every drive. They represent rated values.
Chassis Nameplate System Options Nameplate (NAFTA Market)
1. Drive Type
2. Serial Number
3. Product test date
4. Input voltage
5. Input frequency
6. Number of input phases
18. Input current VT(cl.1)
19. Maximum symmetrical short
circuit current
20. Aux. Control voltage
21. Number of aux phases
22. Aux. Control current
23. Aux. Protecting devices (not incl on
chassis)
7. Rated output [kVA]
16. Motor power kW-VT (@400V)
17. Motor power HP-VT (@400V)
10. Output current (VT or cl.1)
14. Motor power kW-CT (@400V)
15. Motor power HP-CT (@460V)
13. Output current (CT or cl.1)
11. SAP Code
12. Bar code
SVGT VT/CT XXXXHP
SYSTEM P/N 3000XXXX.00
INPUT: 460VAC, 60Hz, 3 PH, XX.A
OUTPUT: 0 – 460 VAC, 0 – 60 HZ, 3 PH, CT-XXA, VT-XXA
S.O. HR91 XXXXXX.XX
DATE CODE: ENG: XXXXXX
New Kensington, PA 15068 B
1
23
465
7
10
11
12
13
14 15
16 17
18 19
20
22 23
21

Specifications GT3000 Basic Manual
6 IMGT30003EN-September 2003
Table 2-1 Part Number, Model Number (1-13 Chassis only, 14-28 System Options*)
1,2,3,4 SVGT
5,6,7 042 Rated Power in HP (See table of electric data in Appendix A*)
8 F Input Voltage F = 380 – 480 Volt AC
G = 500 Volt AC
K = 525 – 690 Volt AC
Y = 510 – 650 Volt DC
Z = 675 Volt DC
J = 705 – 930 Volt DC
9 D Control Board N= Not Installed
D= Microprocessor Basic
E= Microprocessor Plus
10 B Dynamic Braking N = Not Installed B= Installed
11 F RFI Filter N = Not Installed F= Installed
12 H Keypad N= Not Installed
B= Basic
I= Intermediate
H= Advanced
13 P Communication N = Not Installed
F = FAN Net Board
P= Profibus
C = Canbus
M= Modbus
O = Modbus +
D = Device Net
14 1 Enclosure 1= Nema 1 2= Nema 12 ventilated
15 1 Main Input
Device
1 =Fuses
2 =Non-Fused Disc. Sw.
3 = Non-Fused Disc. Sw. w/fuses
4 = 25KA CB
5 = 50KA CB
6 = 65KA CB
7= 85KA CB
8= 100KA CB
16 0 Input Magnetics 0= None
1= 2.5%
2= 5.0%
3= Clean Power
17 0 Contactor 0= None
1= One contactor - MVS
2= Two contactors - MCS
3= Three contactors – Drive Input Isolation
4= Two contactors (mechanically interlocked)
5= Three contactors (2 mechanically interlocked)
6= Two contactors w/auto bypass
7= Three contactors w/auto bypass
8= Two contactors mechanically interlocked and auto bypass
9= Three contactors (2 mechanically interlocked and auto bypass)
18, 19 0,0 1st TOL, 2nd TOL
(1st & 2nd
Thermal
Overloads)
0= None
A= 1 HP (amp range)
B= 2 HP (amp range)
C= 3 HP (amp range)
D= 5 HP (amp range)
E= 7.5 HP (amp range)
F= 10 HP (amp range)
G= 15 HP (amp range)
H= 20 HP (amp range)
J= 25 HP (amp range)
K= 30 HP (amp range)
L= 40 HP (amp range)
M= 50 HP (amp range)
N= 60 HP (amp range
0= None
A= 1 HP (amp range)
B= 2 HP (amp range)
C= 3 HP (amp range)
D= 5 HP (amp range)
E= 7.5 HP (amp range)
F= 10 HP (amp range)
G= 15 HP (amp range)
H= 20 HP (amp range)
J= 25 HP (amp range)
K= 30 HP (amp range)
20 0 PTD - Pressure
Transducer
0= None
1= 3-15 PSI
21 0 Control 0= None (Future)
22 1 Door Control 0= None
1= HOA
2= LOR
4= HOA_Start_Stop
5= LOR_Start_Stop
8= HOA_Start_Stop_SpeedPot
9= LOR_Start_Stop_SpeedPot
23 5 System Voltage 5= 480V – 60 Hz
24-27 V040 VT/CT (See table of electric data in Appendix A*)
* See Chapter 10 and Appendix B for System Options – North America Free Trade Agreement (NAFTA)