Reliance electric GV3000 User manual

GV3000 AC Power Modules
Hardware Reference, Installation,
and Troubleshooting
Version 5.0
Instruction Manual D23340
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E Copyright Reliance Electric Industrial Company 1995.
DeviceNett is a trademark of pen DeviceNet V endor Association.
GV3000r , AutoMax r, and Reliancer are registered trademarks of Reliance Electric Company or its subsidiaries.
The information in the user's manual is subject to change without notice.
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 UNDERST AND THIS MANU AL AND OTHER
APPLICABLE MANU ALS IN THEIR ENTIRETY BEFORE PROCEEDING. F AIL URE TO OB SERVE THIS
PRECAUTION COULD RESULT IN SEVERE BODIL Y INJURY OR L OS S OF LIFE .
DANGER
THE USER IS RESPONSIBLE FOR CONFORMING WITH ALL APPLICABLE L OCAL , NA TIONAL, AND
INTERNATIONAL CODES. WIRING PRACTICES, GROUNDING, DISCONNECTS, AND
OVERCURRENT PROTECTION ARE OF PARTICULAR IMPORTANCE. FAILURE TO OBSERVE THIS
PRECAUTION COULD RESULT IN SEVERE BODIL Y INJURY OR L OS S OF LIFE .
DANGER
DĆC BUS CAPACITORS RETAIN HAZARDOUS VOLTAGES AFTER INPUT POWER HAS BEEN
DISCONNECTED.
AF TER DISCONNECTING INPUT POWER , W AIT FIVE (5) MINUTES FOR THE D ĆC
BUS CAPACITORS TO DISCHARGE AND THEN CHEC 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 LOS S OF LIFE .
DANGER
THE DRIVE IS CAPABLE OF OPERATING AT AND MAINTAINING ZERO SPEED. THE USER IS
RESPONSIBLE FOR AS SURING SAFE CONDITIONS FOR OPERA TING PERSONNEL B Y PRO VIDING
SUITABLE GU ARDS, A UDIBLE OR VISUAL ALARMS, OR OTHER DEVICES TO INDICA TE THA T THE
DRIVE IS OPERA TING OR MA Y OPERA TE A T OR NEAR ZERO SPEED . F AIL URE TO OB SERVE THIS
PRECAUTION COULD RESULT IN SEVERE BODIL Y INJURY OR L OS S OF LIFE .
WARNING
THE USER MUST PRO VIDE AN EXTERNAL , HARD WIRED EMERGENCY STOP CIRCUIT OUTSIDE OF
THE DRIVE CIRCUITRY. THIS CIRCUIT MUST DISABLE THE SYSTEM IN CASE OF IMPROPER
OPERATION. UNCONTROLLED MACHINE OPERA TION MA Y RESUL T IF THIS PROCEDURE IS NOT
FOLLOWED. F AILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODIL Y INJURY .
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Manufacturer's Declaration
Manufacturer:
Reliance Electric Industrial Co.
24701 Euclid Avenue
Cleveland, Ohio 44117 - USA
declares that the product:
GV3000, AC Speed Controller for Electric Motors
 is intended to be incorporated into machinery or to be assembled with other machinery to
constitute machinery covered by Directive 89/392/EEC, as amended;
and that
 the following harmonized standards have been applied:
EN 602041: Electrical equipment of industrial machines - 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 this Declaration.
Authorized Representative of the Company:
Place: Reliance Electric Industrial Co., Cleveland, Ohio 44117, USA
Date:
December 1, 1995
Signature:
Name: Charles Janki
Position: Product Development Safety Engineer
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I
Table of Contents
1.0 Becoming Familiar with the Manual 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.1 Finding Information 11. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.2 Assumptions About the Audience 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.3 Taking Safety Precautions 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.4 Understanding Terms Used in this Manual 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.5 If You Want to Know More 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
1.6 Getting Assistance from Reliance Electric 12. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.0 About the Drive 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.1 Identifying the Drive by Model Number 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.2 NEMA Enclosures 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.3 125 HP GV3000 Drive Components and Locations 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.4 2560 HP GV3000 Drive Components and Locations 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.5 60100 HP GV3000 Drive Components and Locations 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.6 100150 HP GV3000 Drive Components and Locations 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7 Regulator Board Description 29. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.1 Jumper Locations and Settings 212. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.1.1 Analog Input Speed Reference Jumper 212. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.1.2 Analog Output Jumper 213. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.2 Wiring the Terminal Strip 214. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.3 RS232 Communication Port 215. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.4 Option Board Connector 215. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
2.7.5 Operator 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 P ower Module Input Ratings Match Supplied Power 35. . . . . . . . . . . . . . . . . . . .
3.2 Wiring Requirements for the Drive 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.1 Meeting Terminal Strip Input and Output Specifications 35. . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2 Determining Wire Size Requirements 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2.1 Conduit Entry Opening Sizes 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2.2 Recommended P ower Wire Sizes 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2.3 Recommended Control and Signal Wire Sizes 36. . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2.4 Recommended Motor Lead Lengths 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.2.5 Recommended Serial Communication Cable Lengths 37. . . . . . . . . . . . . . . . . . . .
3.2.3 Selecting Input Line Branch Circuit Fuses 37. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
3.2.4 Meeting Pulse Tachometer Specifications (Vector Regulation Only) 38. . . . . . . . . . . . . . . .
3.2.5 Verifying P ower Module Output Current Rating is Greater Than Motor Full
Load Amps 38. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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II
4.0 Mounting the Drive, Grounding, and Finding Wire Routing Locations 41. . . . . . . . . . . . . . . . . . .
4.1 Mounting the Drive 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.1.1 Verifying the Drive's Watts Loss Rating 41. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4.2 Routing Input, Motor Output, Ground, and Control Wiring for the Drive 41. . . . . . . . . . . . . . . . .
4.3 Grounding the Drive 48. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.0 Installing Input Power Wiring 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.1 Installing Transformers and Reactors (Optional) 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.2 Installing F uses for Branch Circuit Protection 51. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.3 Installing a Required External/Separate Input Disconnect 54. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
5.4 Installing P ower Wiring from the AC Input Line to the Drive's Power Terminals 54. . . . . . . . . . .
5.5 Installing P ower Wiring from an External DC Bus to the Drive's Internal DC Bus
Terminals 55. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
6.0 Installing Output Power Wiring 6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 Control I/O 77. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.0 Completing the Installation 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.1 Checking the Installation 81. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.2 Installing the Cover for NEMA 4X/12 Drives 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8.3 Powering Up After Installation is Complete 82. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.0 Troubleshooting the Drive 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.1 Test Equipment Needed to Troubleshoot 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.2 Drive Alarms and Faults 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.3 Verifying That DC Bus Capacitors are Discharged 91. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.4 Checking Out the Power Modules with Input Power Off 96. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
9.5 Replacement P arts 98. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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III
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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IV
List of Figures
Figure 2.1  Identifying the Drive Model Number 21. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2.2  15 HP Drive Components and Locations 23. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2.3  7.510 HP Drive Components and Locations 24. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2.4  1525 HP Drive Components and Locations 25. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2.5  2560 HP Drive Components and Locations 26. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2.6  60100 HP Drive Components and Locations 27. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2.7  100150 HP Drive Components and Locations 28. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2.8  160 HP Regulator Board Components and Locations 210. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2.9  60150 HP Regulator Board Components and Locations 211. . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2.10  Jumper J4 Settings for Analog Input Speed Reference 212. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2.11  Jumper J17 Settings for Analog Outputs 213. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2.12  Typical Terminal Strip Connections 214. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 2.13  Keypad/Display 215. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3.1  Drive Dimensions 33. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3.2  Recommended Air Flow Clearances 34. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 3.3  Single and Multiple 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 AC Input Electrical Connections 52. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 5.2  Typical DC Bus Electrical Connections 53. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7.1  TwoWire Start/Stop Sample Control Wiring 73. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7.2  ThreeWire Start/Stop Sample Control Wiring 74. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 7.3  Wiring Connections for the Speed Feedback Device 76. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9.1  DC Bus Voltage Terminals (125 HP Drives) 92. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9.2  DC Bus Voltage Terminals (2560 HP Drives) 93. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9.3  DC Bus Voltage Terminals (60100 HP Drives) 94. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure 9.4  DC Bus Voltage Terminals (100150 HP Drives) 95. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure B.1  Volts/Hertz Regulation Block Diagram B2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Figure B.2  Vector Regulation Block Diagram B3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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V
List of Tables
Table 2.1  Power and NEMA Enclosure Ratings 22. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 2.2  Available Kits and Options 216. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 3.1  Ambient Conditions 31. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 3.2  Drive Dimensions and Weights 32. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 3.3  Recommended Power Wire Sizes for 110 HP Drives 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 3.4  Recommended Power Wire Sizes for 1525 HP Drives 35. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 3.5  Recommended Power Wire Sizes for 2560 HP Drives 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 3.6  Recommended Power Wire Sizes for 60100 HP Drives 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 3.7  Recommended Power Wire Sizes for 100150 HP Drives 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 3.8  Recommended Terminal Strip Wire Sizes 36. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table 3.9  AC Input Line Fuse Selection Values 3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 Drive Replacement Parts 912. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A.1  Service Conditions A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A.2  Ambient Conditions A1. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A.3  Terminal Strip Input Specifications A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A.4  Terminal Strip Output Specifications A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A.5  RS232 Specifications A2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table A.6  Speed Feedback Device Specifications (Vector Regulation Only) A2. . . . . . . . . . . . . . . . . . . . . . .
Table A.7  Input Signal Response Times (Worst Case) A3. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
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11
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. F or additional software information, refer to the GV3000 AC General
Purpose (V/Hz) and V ector Duty Drive Software Start Up and Reference Manual (D23339).
As an aid in finding information in this manual, each chapter is briefly described below:
D Chapter 1  Becoming Familiar with the Manual
Provides information on how the manual is organized and where to find additional
information.
D Chapter 2  About the Drive
Identifies drive components and shows their locations.
D Chapter 3  Planning Before Installing
Presents information that must be considered when planning a drive installation.
D Chapter 4  Mounting the Drive, Grounding, and Finding W ire Routing Locations
Describes how to mount the drive and properly ground it.
D Chapter 5  Installing Input P ower W iring
Describes incoming AC and D C line components and how to properly connect
them.
D Chapter 6  Installing AC Output P ower W iring
Describes output AC line components and how to properly connect them to the
motor.
D Chapter 7 W iring the Regulator Board T erminal Strip
Provides information on the I/O wiring that connects to the terminal strip on the
Regulator board.
D Chapter 8  Completing the Installation
Provides instructions on how to perform a final check of the installation before
power is applied.
D Chapter 9 T roubleshooting the Drive
Describes the equipment that is needed to troubleshoot the drive and how to
measure D C bus voltage. Replacement part lists are also provided.
DAppendix A  T echnical Specifications
Lists drive specifications in table form.
DAppendix B  Drive Regulation Overview
Briefly describes volts/hertz and vector regulation.
DAppendix C  Compliance with EN 602041: 1992
Lists the sections of standard EN 602041: 1992 that the GV3000 drive complies
with.
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12
1.2 Assumptions About the Audience
This manual is intended for qualified electrical personnel. It is task oriented 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.
DANGER
A DANGER ALERTS A PERSON OF A CONDITION WHICH COULD RESULT IN SEVERE BODILY
INJURY OR LOS S OF LIFE .
WARNING
A
W ARNING ALERTS A PERSON OF A CONDITION WHICH COULD RESUL T IN POTENTIAL B ODILY
INJURY IF PROCEDURES ARE NOT FOLLOWED.
CAUTION: A caution alerts a person of a condition which could result in damage to, or destruction of the
equipment.
1.4 Understanding Terms Used in this Manual
The following 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.
DP arameters will be referenced either as parameter (P .030) or Elapsed T ime Meter Reset (P .030).
1.5 If You Want to Know More
Refer to the following related publications as necessary for more information:
DD23339 GV3000 AC General Purpose (V/Hz) and V ector Duty Drive Software Start Up and
Reference Manual
DD23291 Snubber Resistor Braking Kit
DD23305 Motor Encoder Cable Kit
DD23308 AutoMax Network Communication Board
DD23348 Control and Configuration Software (C S3000)
DD23341 Remote Meter Interface
DD23342 Operator Interface Module
1.6 Getting Assistance from Reliance Electric
If you have any questions or problems with the products described in this instruction manual, contact
your local Reliance Electric sales office. F or technical assistance, call 1800RELIANCE .
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21
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 AC drive is a P WM drive that provides vector and general purpose (volts/hertz or V/Hz)
regulation for a wide range of applications.
Using vector regulation, the drive can provide high dynamic response, maintain full rated motor
torque to zero speed, and precisely control motor speed in both directions using pulse tachometer
feedback.
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 P ower
Module and the regulator . Drive power ratings are provided in table 2.1.
V = v50 HP
R = u50 HP
G = V/Hz Only
Horsepower Ratings
GV3000
Voltage
2 = 200*230V
4 = 380 *460V
Enclosure
1 = NEMA 1
2 = NEMA 12 Only
4 = NEMA 4X (Indoor Only) or NEMA 12
Regulator Version
5.0 = Vector and V/Hz Regulator
NNN A N N NN
Figure 2.1  Identifying the Drive Model Number
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22
Table 2.1  P ower and NEMA Enclosure Ratings
ÁÁÁÁÁ
Á
ÁÁÁ
Á
Á
ÁÁÁ
Á
ÁÁÁÁÁ
Model
Number
ÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁ
Á
Á
ÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁÁ
Selected
Regulation* and
Horsepower Rating
ÁÁÁÁÁÁ
Á
ÁÁÁÁ
Á
Á
ÁÁÁÁ
Á
ÁÁÁÁÁÁ
Input
Voltage
(+/- 10%)
ÁÁÁÁ
Á
ÁÁ
Á
Á
ÁÁ
Á
ÁÁÁÁ
NEMA
Rating
ÁÁÁ
Á
Á
Á
Á
Á
Á
ÁÁÁ
Input
KVA
ÁÁÁ
Á
Á
Á
Á
Á
Á
ÁÁÁ
Input
Amps
ÁÁÁÁÁ
Á
ÁÁÁ
Á
Á
ÁÁÁ
Á
ÁÁÁÁÁ
Output
Amps
at 8 kHz
ÁÁÁÁÁ
Á
ÁÁÁ
Á
Á
ÁÁÁ
Á
ÁÁÁÁÁ
Power
Loss W atts
(F ull Load)
ÁÁÁÁÁ
ÁÁÁÁÁ
1V4150
1V4450
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
V/Hz
or V
ector
(1 HP)
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
380-460 VAC
ÁÁÁÁ
ÁÁÁÁ
1
4X/12
ÁÁÁ
ÁÁÁ
2.0
ÁÁÁ
ÁÁÁ
2.5
ÁÁÁÁÁ
ÁÁÁÁÁ
2.1
ÁÁÁÁÁ
ÁÁÁÁÁ
60
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
2V4150
2V4450
ÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁÁ
V/Hz or Vector
(2 HP)
ÁÁÁÁÁÁ
Á
ÁÁÁÁ
Á
ÁÁÁÁÁÁ
380-460 VAC
ÁÁÁÁ
Á
ÁÁ
Á
ÁÁÁÁ
1
4X/12
ÁÁÁ
Á
Á
Á
ÁÁÁ
3.3
ÁÁÁ
Á
Á
Á
ÁÁÁ
4.2
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
3.4
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
100
ÁÁÁÁÁ
ÁÁÁÁÁ
3V4150
3V4450
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
V/Hz or Vector
(3 HP)
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
380-460 VAC
ÁÁÁÁ
ÁÁÁÁ
1
4X/12
ÁÁÁ
ÁÁÁ
5.1
ÁÁÁ
ÁÁÁ
6.4
ÁÁÁÁÁ
ÁÁÁÁÁ
5.3
ÁÁÁÁÁ
ÁÁÁÁÁ
140
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
5V4150
5V4450
ÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁÁ
V/Hz or Vector
(5 HP)
ÁÁÁÁÁÁ
Á
ÁÁÁÁ
Á
ÁÁÁÁÁÁ
380-460 VAC
ÁÁÁÁ
Á
ÁÁ
Á
ÁÁÁÁ
1
4X/12
ÁÁÁ
Á
Á
Á
ÁÁÁ
7.9
ÁÁÁ
Á
Á
Á
ÁÁÁ
9.9
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
8.2
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
180
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
7V4150
7V4250
ÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁÁ
V/Hz or Vector
(7.5 HP)
ÁÁÁÁÁÁ
Á
ÁÁÁÁ
Á
ÁÁÁÁÁÁ
380-460 VAC
ÁÁÁÁ
Á
ÁÁ
Á
ÁÁÁÁ
1
12
ÁÁÁ
Á
Á
Á
ÁÁÁ
10.7
ÁÁÁ
Á
Á
Á
ÁÁÁ
13.4
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
11.1
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
210
ÁÁÁÁÁ
ÁÁÁÁÁ
10V4150
10V4250
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
V/Hz or Vector
(10 HP)
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
380-460 VAC
ÁÁÁÁ
ÁÁÁÁ
1
12
ÁÁÁ
ÁÁÁ
13.4
ÁÁÁ
ÁÁÁ
16.8
ÁÁÁÁÁ
ÁÁÁÁÁ
14.2
ÁÁÁÁÁ
ÁÁÁÁÁ
250
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
15V4150
15V4250
ÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁÁ
V/Hz or Vector
(15 HP)
ÁÁÁÁÁÁ
Á
ÁÁÁÁ
Á
ÁÁÁÁÁÁ
380-460 VAC
ÁÁÁÁ
Á
ÁÁ
Á
ÁÁÁÁ
1
12
ÁÁÁ
Á
Á
Á
ÁÁÁ
20.2
ÁÁÁ
Á
Á
Á
ÁÁÁ
25.4
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
21.0
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
375
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
20V4150
20V4250
ÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁÁ
V/Hz or Vector
(20 HP)
ÁÁÁÁÁÁ
Á
ÁÁÁÁ
Á
ÁÁÁÁÁÁ
380-460 VAC
ÁÁÁÁ
Á
ÁÁ
Á
ÁÁÁÁ
1
12
ÁÁÁ
Á
Á
Á
ÁÁÁ
26.1
ÁÁÁ
Á
Á
Á
ÁÁÁ
32.7
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
27.0
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
600
ÁÁÁÁÁ
ÁÁÁÁÁ
25G4150
25G4250
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
V/Hz
(25 HP)
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
380-460 VAC
ÁÁÁÁ
ÁÁÁÁ
1
12
ÁÁÁ
ÁÁÁ
29.5
ÁÁÁ
ÁÁÁ
37.0
ÁÁÁÁÁ
ÁÁÁÁÁ
30.4
ÁÁÁÁÁ
ÁÁÁÁÁ
600
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
25V4150
25V4250
ÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁÁ
V/Hz or Vector
(25 HP)
ÁÁÁÁÁÁ
Á
ÁÁÁÁ
Á
ÁÁÁÁÁÁ
380-460 VAC
ÁÁÁÁ
Á
ÁÁ
Á
ÁÁÁÁ
1
12
ÁÁÁ
Á
Á
Á
ÁÁÁ
30.2
ÁÁÁ
Á
Á
Á
ÁÁÁ
38.0
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
34.5
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
750
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
30V4150
30V4250
ÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁÁ
V/Hz or Vector
(30 HP)
ÁÁÁÁÁÁ
Á
ÁÁÁÁ
Á
ÁÁÁÁÁÁ
380-460 VAC
ÁÁÁÁ
Á
ÁÁ
Á
ÁÁÁÁ
1
12
ÁÁÁ
Á
Á
Á
ÁÁÁ
35.0
ÁÁÁ
Á
Á
Á
ÁÁÁ
44.0
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
39.0
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
800
ÁÁÁÁÁ
ÁÁÁÁÁ
40V4150
40V4250
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
V/Hz or Vector
(40 HP)
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
380-460 VAC
ÁÁÁÁ
ÁÁÁÁ
1
12
ÁÁÁ
ÁÁÁ
46.2
ÁÁÁ
ÁÁÁ
58.0
ÁÁÁÁÁ
ÁÁÁÁÁ
54.0
ÁÁÁÁÁ
ÁÁÁÁÁ
960
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
50V4150
50V4250
ÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁÁ
V/Hz or Vector
(50 HP)
ÁÁÁÁÁÁ
Á
ÁÁÁÁ
Á
ÁÁÁÁÁÁ
380-460 VAC
ÁÁÁÁ
Á
ÁÁ
Á
ÁÁÁÁ
1
12
ÁÁÁ
Á
Á
Á
ÁÁÁ
57.3
ÁÁÁ
Á
Á
Á
ÁÁÁ
72.0
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
67.0
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
1200
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
50R4150
ÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁÁ
V ector (50 HP)
V/Hz (75 HP)
ÁÁÁÁÁÁ
Á
ÁÁÁÁ
Á
ÁÁÁÁÁÁ
380-460 VAC
ÁÁÁÁ
Á
ÁÁ
Á
ÁÁÁÁ
1
ÁÁÁ
Á
Á
Á
ÁÁÁ
65.0
81.0
ÁÁÁ
Á
Á
Á
ÁÁÁ
81.0
102
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
70.0**
90.0**
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
1420
ÁÁÁÁÁ
ÁÁÁÁÁ
60G4150
60G4250
ÁÁÁÁÁÁÁÁÁ
ÁÁÁÁÁÁÁÁÁ
V/Hz
(60 HP)
ÁÁÁÁÁÁ
ÁÁÁÁÁÁ
380-460 VAC
ÁÁÁÁ
ÁÁÁÁ
1
12
ÁÁÁ
ÁÁÁ
71.7
ÁÁÁ
ÁÁÁ
90.0
ÁÁÁÁÁ
ÁÁÁÁÁ
78.0
ÁÁÁÁÁ
ÁÁÁÁÁ
1200
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
75R4150
ÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁÁ
Vector (60-75 HP)
V/Hz (100 HP)
ÁÁÁÁÁÁ
Á
ÁÁÁÁ
Á
ÁÁÁÁÁÁ
380-460 VAC
ÁÁÁÁ
Á
ÁÁ
Á
ÁÁÁÁ
1
ÁÁÁ
Á
Á
Á
ÁÁÁ
80.0
100
ÁÁÁ
Á
Á
Á
ÁÁÁ
101
126
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
89.0**
116**
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
1400
1780
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
125R4150
ÁÁÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁ
Á
ÁÁÁÁÁÁÁÁÁ
Vector (100-125 HP)
V/Hz (125-150 HP)
ÁÁÁÁÁÁ
Á
ÁÁÁÁ
Á
ÁÁÁÁÁÁ
380-460 VAC
ÁÁÁÁ
Á
ÁÁ
Á
ÁÁÁÁ
1
ÁÁÁ
Á
Á
Á
ÁÁÁ
127
170
ÁÁÁ
Á
Á
Á
ÁÁÁ
159
213
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
152**
210**
ÁÁÁÁÁ
Á
ÁÁÁ
Á
ÁÁÁÁÁ
2410
3200
*With V/Hz regulation, 110% continuous output current capability. With vector regulation, 150% output current capability for one
minute.
**At 2 kHz. For 4 kHz operation, derate by 20%. For 8 kHz operation, derate by 40%.
2.2 NEMA Enclosures
Each of the GV3000 P ower Modules have one of following NEMA ratings:
D NEMA 1: V ented. Contains a communication access door that allows access to the
communication port without removing the cover . Intended for generalpurpose indoor
applications.
DNEMA 4X/12: Not vented. Supplied with base and keypad gaskets. Intended for use in indoor
environments that require a water tight/dust tight enclosure. An enclosure with this
NEMA rating encompasses both ratings (4X and 12).
D NEMA 12: Intended for use in indoor environments that require a dust tight/driptight enclosure.
See table 2.1 for a listing of the P ower Modules and their individual NEMA ratings.
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23
2.3 125 HP GV3000 Drive Components and Locations
The 125 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.
M/N M/N
1V4150 3V4150
1V4450 3V4450
2V4150 5V4150
2V4450 5V4450
1. Fan/Fan Assembly
2. Membrane Switch (K eypad/Bracket)
3. Regulator Printed Circuit Board (PCB)
4. Capacitor PCB/Input Capacitors
5. Current F eedback 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 F an Assembly
10. IGBT Module
11. Diode Bridge
12. Fan W
ire Harness
Figure 2.2  15 HP Drive Components and Locations
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24
M/N
7V4150
7V4250
10V4150
10V4250
Figure 2.3  7.510 HP Drive Components and Locations
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25
M/N
15V4150
15V4250
20V4150
20V4250
M/N
25G4150
25G4250
Figure 2.4  1525 HP Drive Components and Locations
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26
2.4 2560 HP GV3000 Drive Components and Locations
The 2560 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
2. Membrane Switch (K eypad/Bracket)
3. Regulator Board
4. Bus Capacitors
5. Not Used
6. P ower Board
7. Power Supply Board
8. Gate Driver Board
9. Internal F an Assembly
10. IGBT Module
11. Diode Bridge
12. W ire 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
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27
2.5 60100 HP GV3000 Drive Components and Locations
The 60100 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.
1. Regulator Printed Circuit Board (PCB)
2. P ower Module Interface PCB
3. Gate Driver PCB
4. Bus Clamp PCB  Right
5. Bus Clamp PCB  Left
6. Intelligent P ower Module PCB
7. Diode Bridge
8. DC Bus Fuse
9. Precharge Contactor
10. Current T ransformer
11. Ground F ault T ransformer
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 Drive Components and Locations
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28
2.6 100150 HP GV3000 Drive Components and Locations
The 100150 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)
2. P ower Module Interface PCB
3. Gate Driver PCB
4. Bus Clamp PCB  Right
5.
Bus Clamp PCB  Left
6. Intelligent P ower Module PCB
7. Thyristor Precharge Module
8. DC Bus Fuse
9. Not Used
10. Current T ransformer
11.
Ground F ault T ransformer
12. Output Reactor
13. Not Used
14. Bus Discharge Resistor
15. 24 VDC Fan
16. Keypad
17.
Thyristor Firing P ulse 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150 HP Drive Components and Locations
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29
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. The Regulator board provides:
DP WM gating signals to the IGBT power devices
Based on the output of the control loop, the regulator sends P WM gating signals through the
Current F eedback board to isolated drivers on the Gate Driver board. These drivers switch the
Insulated Gate Bipolar T ransistors (IGBT s), producing a P ulse W idth Modulated (P
WM) waveform
that corresponds to the speed (vector regulation) or frequency (volts/hertz regulation) reference.
The IGBT
s can be switched at either a 2, 4 or 8 kHz carrier frequency .
DF orm A and B contacts for drive status indicators
The F
orm A and B contacts are under control of the user via programmable parameters. A F
orm A
or B transition can indicate drive status. The contacts are rated for 5 Amps resistive load 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 .
DAn analog output
The analog output is a scaled voltage (010 VDC) or current (420 mA) signal proportional to
either motor speed (RPM) or motor torque or current (%TORQUE). The current selection (via
jumper J17) requires a power supply for operation. The power can be sourced from the pulse
tachometer terminals (4 and 9) or from an external 15V power supply . See table 7.1, terminals 10
and 11, for more information. The analog output signal is available through the terminal strip.
D A snubber resistor braking signal
The 160 HP regulator provides a signal for use by an optional snubber resistor braking kit. The
signal goes through an isolating driver , made available through the terminal strip.
Two Regulator boards are used on the GV3000 drives: 160 HP Regulator boards are used with
160 HP drives; 60150 HP Regulator boards are used with 60150 HP drives. As shown in figures 2.8
and 2.9, the Regulator boards are similar but have different P ower Module interface connectors.
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210
34-Pin Ribbon Cable
J8
J17 J4 USER I/O TERMINAL STRIP
26-Pin Ribbon Cable
J5
J9
USER DISPLAY
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
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