Reliance electric GV3000 User manual

GV3000 A-C Power Modules
Hardware Reference, Installation,
and Troubleshooting
Version 5.0
Instruction Manual D2-3340
RELIANCE
ELECTRICS

The information in the user’s manual is subject to change without notice.
ONLY QUALIFIED ELECTRICAL PERSONNEL FAMILIAR WITH THE CONSTRUCTION AND
OPERATION OF THIS EQUIPMENT AND THE HAZARDS INVOLVED SHOULD INSTALL, ADJUST,
OPERATE, OR SERVICE THIS EQUIPMENT. READ AND UNDERSTAND THIS MANUALAND OTHER
APPLICABLE MANUALS IN THEIR ENTIRETY BEFORE PROCEEDING. FAILURE TO OBSERVE THIS
PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE.
THE USER IS RESPONSIBLE FOR CONFORMING WITH ALL APPLICABLE LOCAL, NATIONAL, AND
INTERNATIONAL CODES. WIRING PRACTICES, GROUNDING, DISCONNECTS, AND
OVERCURRENT PROTECTION ARE OF PARTICULAR IMPORTANCE. FAILURE TO OBSERVE THIS
PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE.
D-C BUS CAPACITORS RETAIN HAZARDOUS VOLTAGES AFTER INPUT POWER HAS BEEN
DISCONNECTED. AFTER DISCONNECTING INPUT POWER, WAIT FIVE (5) MINUTES FOR THE D-C
BUS CAPACITORS TO DISCHARGE AND THEN CHECK THEVOLTAGE WITH A VOLTMETER TO
ENSURE THE D-C BUS CAPACITORS ARE DISCHARGED BEFORE TOUCHING ANY INTERNAL
COMPONENTS. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY
INJURY OR LOSS OF LIFE.
THE DRIVE IS CAPABLE OF OPERATING AT AND MAINTAINING ZERO SPEED. THE USER IS
RESPONSIBLE FOR ASSURING SAFE CONDITIONS FOR OPERATING PERSONNEL BY PROVIDING
SUITABLE GUARDS, AUDIBLE OR VISUAL ALARMS, OR OTHER DEVICES TO INDICATE THAT THE
DRIVE IS OPERATING OR MAY OPERATE AT OR NEAR ZERO SPEED. FAILURE TO OBSERVE THIS
PRECAUTION COULD RESULT IN SEVERE BODILY INJURY OR LOSS OF LIFE.
WARNING
THE USER MUST PROVIDE AN EXTERNAL, HARDWIRED EMERGENCY STOP CIRCUIT OUTSIDE OF
THE DRIVE CIRCUITRY. THIS CIRCUIT MUST DISABLE THE SYSTEM IN CASEOF IMPROPER
OPERATION. UNCONTROLLED MACHINE OPERATION MAY RESULT IF THIS PROCEDURE IS NOT
FOLLOWED. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN BODILY INJURY.
DeviceNet™ is atrademark of Open DeviceNet Vendor Association.
GV3000®, AutoMax®, and Reliance® are registered trademarks of Reliance Electric Company or its subsidiaries.
© Copyright Reliance Electric Industrial Company 1995.

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 withthe provisions of Directive 89/392/EEC and with national
implementing legislation, i.e., as a whole, including the product referred toin this Declaration.
Authorized Representative ofthe Company:
Place: Reliance Electric Industrial Co., Cleveland, Ohio 44117, USA
Date: December 1, 1995
signature: CO Mart. helec,
Name: Charles Jank
Position: Product Development Safety Engineer

1.0
2.0
3.0
Table of Contents
Becoming Familiar with the Manual ........... 000. c cece eee eee eee eee eee eee eens 1-1
1.1 Finding Information ...... 00.00. eee eens 1-1
1.2 Assumptions About the Audience ......... 0... cece eect eens 1-2
1.3 Taking Safety Precautions ...... 2.0... teeta 1-2
1.4 Understanding Terms Used in this Manual ........... 00... c cece eee 1-2
1.5 If You Want to Know More ... 0... tenet eee teens 1-2
1.6 Getting Assistance from Reliance Electric .......... 0.00 c eect eee 1-2
About the Drive 0.0.0... 0.00 eee eee eee e eee e eee eaten 2-1
2.1 Identifying the Drive by Model Number ........... 0... cece tenes 2-1
2.2 NEMA EnclosureS ...... 0.0.00 e cc tte teen etnee tne nees 2-2
2.3 1-25 HP GV3000 Drive Components and Locations ............. 000: e eects 2-3
2.4 25-60 HP GV3000 Drive Components and Locations .......... 0.0: c cece ees 2-6
2.5 60-100 HP GV3000 Drive Components and Locations ............ 0... cece eee 2-7
2.6 100-150 HP GV3000 Drive Components and Locations ............. 0.0 cece eee 2-8
2.7 Regulator Board Description ........ 0... eect tet es 2-9
2.7.1 Jumper Locations and SettingS ......... 0... cece eens 2-12
2.7.1.1 Analog Input Speed Reference Jumper ......... 0.0: cece eee tees 2-12
2.7.1.2 Analog Output Jumper ..... 0... teens 2-13
2.7.2 Wiring the Terminal Strip 2.2.0... cece ents 2-14
2.7.3 RS-232 Communication Port .......... cece ete 2-15
2.7.4 Option Board Connector ..... 0... cee eee eens 2-15
2.7.5 Operator Interface Module Connector ......... 000: c cece eee 2-15
2.7.6 Keypad/Display ......... 0. cc teen eae 2-15
2.8 Drive Kit OPtiONS ... 6... nett eens 2-16
Planning Before Installing ......... 0... c cette nett eee e eens 3-1
3.1 Requirements for the Installation Site . 1.00... . tte es 3-1
3.1.1 Making Sure Environmental Conditions are Met ......... 00... cece ee eee 3-1
3.1.2 Determining Total Area Required Based on Drive Dimensions .................... 3-2
3.1.3 Verifying the Site Provides for Recommended Air Flow Clearances ................ 3-4
3.1.4 Verifying Power Module Input Ratings Match Supplied Power ..................4. 3-5
3.2 Wiring Requirements for the Drive ......... 0... eect tenes 3-5
3.2.1 Meeting Terminal Strip Input and Output Specifications ................. cee eee 3-5
3.2.2 Determining Wire Size Requirements .......... 0.00. c ccc eee 3-5
3.2.2.1 Conduit Entry Opening Sizes ....... 0.0... eee 3-5
3.2.2.2 Recommended Power Wire SiZ€S ....... eee tees 3-5
3.2.2.3 Recommended Control and Signal Wire Sizes ........... 0.0: e cece 3-6
3.2.2.4 Recommended Motor Lead Lengths ........... 0... cece eee es 3-6
3.2.2.5 Recommended Serial Communication Cable Lengths .................... 3-7
3.2.3 Selecting Input Line Branch Circuit Fuses ........ 0... 00sec eee ete ee 3-7
3.2.4 Meeting Pulse Tachometer Specifications (Vector Regulation Only) ................ 3-8
3.2.5 Verifying Power Module Output Current Rating is Greater Than Motor Full
Load AMPS ..... ee cece teen teeta 3-8

4.0
5.0
6.0
7.0
8.0
9.0
Mounting the Drive, Grounding, and Finding Wire Routing Locations ................... 4-1
4.1 Mounting the Drive . 0.0... teeter tenn t ees 4-1
4.1.1 Verifying the Drive’s Watts Loss Rating ........... 0: ccc eee eens 4-1
4.2 Routing Input, Motor Output, Ground, and Control Wiring for the Drive ..............00.. 4-1
4.3 Grounding the Drive ....... 0... teeta es 4-8
Installing Input Power Wiring ........ 0. cece cette eee eee eens 5-1
5.1 Installing Transformers and Reactors (Optional) ........ 0.00... cece eee eee eee 5-1
5.2 Installing Fuses for Branch Circuit Protection .......... 0.0. c eects 5-1
5.3 Installing a Required External/Separate Input Disconnect ............. 000 cece eee eee 5-4
5.4 Installing Power Wiring from the A-C Input Line to the Drive’s Power Terminals ........... 5-4
5.5 Installing Power Wiring from an External D-C Bus to the Drive’s Internal D-C Bus
TerminalS 2... 0. . cette ener e een ees 5-5
Installing Output Power Wiring ........ 00.00 eee eens 6-1
6.1 Installing Output Contactors (Optional) . 0.0... . ces 6-1
6.2 Installing Mechanical Motor Overload Protection (Optional) .............. 00: cece eee eee 6-1
6.3 Installing Output Wiring from the Drive Output Terminals to the Motor................05. 6-1
Wiring the Regulator Board Terminal Strip ........... 00. cece cece eee eee 7-1
7.1 Stopping the Drive 1.1... ieee nett ene ees 7-5
7.1.1 Compliance with EN 60204-1: 1992 1.0... ck tae 7-5
7.2 Wiring the Speed Feedback Device (Vector Regulation Only) ............. 0: :eceeee eee 7-5
7.3 Wiring the Signal and Control 1/0 00... nett eens 7-7
Completing the Installation ......... 0000s cect eee eee eens 8-1
8.1 Checking the Installation ..... 0.0.0... cette nett 8-1
8.2 Installing the Cover for NEMA 4X/12 Drives .......... 0.00 cece tte 8-2
8.3 Powering Up After Installation is Complete .......... 0... cece tees 8-2
Troubleshooting the Drive ....... 00. ccc cece eee eee eee eee eee 9-1
9.1 Test Equipment Needed to Troubleshoot ........... 0... cece eee ees 9-1
9.2 Drive Alarms and Faults .... 00... cece teeta nees 9-1
9.3 Verifying That D-CBus Capacitors are Discharged ............ 00 cece eects 9-1
9.4 Checking Out the Power Modules with Input Power Off .......... 00... ccc eee eee eee 9-6
9.5 Replacement Parts ....... 0... cece ete ees 9-8

Appendices
Appendix A
Technical Specifications ©... 0... ke ete enn ete A-1
Appendix B
Drive Regulation Overview ....... 0. cece entree eee eens B-1
Appendix C
Compliance with EN 60204-1: 1992 0... tte eens C-1
Tao <>, Index-1

List of Figures
Figure 2.1 - Identifying the Drive Model Number .......... 0.00: cece tenet ees 2-1
Figure 2.2 - 1-5 HP Drive Components and Locations ........... 0.00. cece cece 2-3
Figure 2.3 - 7.5-10 HP Drive Components and Locations .......... 0.0: c cece eee ees 2-4
Figure 2.4 - 15-25 HP Drive Components and Locations ........... 0.0... cece eee ees 2-5
Figure 2.5 - 25-60 HP Drive Components and Locations ............ 0... c cece ees 2-6
Figure
2.6 - 60-100 HP Drive Components and Locations .......... 0.00: : cece eee 2-7
Figure 2.7 - 100-150 HP Drive Components and Locations ........... 0... cece cece 2-8
Figure 2.8 - 1-60 HP Regulator Board Components and Locations ................ ccc eee ees 2-10
Figure 2.9 - 60-150 HP Regulator Board Components and Locations ........... 0.00 cece eens 2-14
Figure 2.10 - Jumper J4 Settings for Analog Input Speed Reference .............. 0c cece eens 2-12
Figure 2.11 - Jumper J17 Settings for Analog Outputs 1.0.0.0... ee tees 2-13
Figure 2.12 - Typical Terminal Strip Connections .......... 0.0.0 c cece teens 2-14
Figure 2.13 - Keypad/Display ........ 2.0... ccc eee teeta es 2-15
Figure 3.1 - Drive Dimensions ..... 00... cere t nets 3-3
Figure 3.2 - Recommended Air Flow Clearances ......... 0.00. c cece tenes 3-4
Figure 3.3 - Single and Multiple Motor Lead Lengths ........... 0... c eet e eee 3-7
Figure 4.1 - Wire Routing Locations for 1-5 HP Drives ......... 0... ccc ees 4-2
Figure 4.2 - Wire Routing Locations for 7.5-10 HP Drives . 00... 0. ccc eee 4-3
Figure 4.3 - Wire Routing Locations for 15-25 HP Drives ......... 0... cece ees 4-4
Figure 4.4 - Wire Routing Locations for 25-60 HP Drives ... 0... 0. eee 4-5
Figure 4.5 - Wire Routing Locations for 60-100 HP Drives .. 0.0... .. ccc eee 4-6
Figure 4.6 - Wire Routing Locations for 100-150 HP Drives......... 0.0... cece ees 4-7
Figure 5.1 - Typical A-C Input Electrical Connections ............ 00. c eects 5-2
Figure 5.2 - Typical D-C Bus Electrical Connections ........ 0.00.0: ccc eens 5-3
Figure 7.1 - Two-Wire Start/Stop Sample Control Wiring ........... 00. c eee 7-3
Figure 7.2 - Three-Wire Start/Stop Sample Control Wiring ......... 0.0... cece eee ees 7-4
Figure 7.3 - Wiring Connections for the Speed Feedback Device .......... 0.00: cece eens 7-6
Figure 9.1 - D-C Bus Voltage Terminals (1-25 HP Drives) .......... 0.0: c cece eet 9-2
Figure 9.2 - D-C Bus Voltage Terminals (25-60 HP Drives) ......... 0.0: c cece eee eens 9-3
Figure 9.3 - D-C Bus Voltage Terminals (60-100 HP Drives) ......... 00... cece eee 9-4
Figure 9.4 - D-C Bus Voltage Terminals (100-150 HP Drives) ......... 00... cece eee eee eens 9-5
Figure B.1 - Volts/Hertz Regulation Block Diagram ......... 0.00: c cece ett ees B-2
FigureB.2- Vector Regulation Block Diagram ........ 00... cece eet ees B-3

List of Tables
Table 2.1 - Power and NEMA Enclosure RatingS ......... 0... cece eee ete teens 2-2
Table 2.2 - Available Kits and Options ......... 0.0... ccc cette nett ees 2-16
Table 3.1 - Ambient Conditions 2.0.0... 0... cece eet nett enn es 3-1
Table 3.2 - Drive Dimensions and Weights ......... 00... cece tte 3-2
Table 3.3 - Recommended Power Wire Sizes for 1-10 HP Drives ........... 000: c cece ees 3-5
Table 3.4 - Recommended Power Wire Sizes for 15-25 HP Drives .......... 00: cece eee eee ees 3-5
Table 3.5 - Recommended Power Wire Sizes for 25-60 HP Drives .......... 00: c cece eee ees 3-6
Table 3.6 - Recommended Power Wire Sizes for 60-100 HP Drives .......... 0.0... sce eee eee 3-6
Table 3.7 - Recommended Power Wire Sizes for 100-150 HP Drives ............ 0. ccc eee eee ees 3-6
Table 3.8 - Recommended Terminal Strip Wire Sizes... 2... tenes 3-6
Table 3.9 - A-C Input Line Fuse Selection Values ........... 00 cece eect eee es 3-8
Table 5.1 - Terminal Tightening TorqueS ...... 0... ccc cent teens 5-4
Table 7.1 - Wiring Signal and Control I/O to the Terminal Strip ....... 0.0... cee eee ees 7-7
Table 9.1 - Resistance Checks ........... 0c ccc ete eee teens 9-6
Table 9.2 - 1-5 HP Drive Replacement Parts ........... cece eet teens 9-8
Table 9.3 - 7.5-10 HP Drive Replacement Parts ........ 0... cece tte 9-8
Table 9.4 - 15-25 HP Drive Replacement Parts ........ 0... cece tte 9-9
Table 9.5 - 25-60 HP Drive Replacement Parts ........ 0... ccc cette 9-10
Table 9.6 - 60-100 HP Drive Replacement Parts ........ 0... cece cette 9-14
Table 9.7 - 100-150 HP Drive Replacement Parts ......... 0... cece teens 9-12
Table A.1 - Service Conditions 0... 0.0.0... tenet tenets A-1
Table A.2- Ambient Conditions ....... 0.0... ete e tte ees A-1
Table A.3 - Terminal Strip Input Specifications ..... 0.00... eee A-2
Table A.4 - Terminal Strip Output Specifications 2.0.0.0... ces A-2
Table A.5 - RS-232 Specifications . 0.0... 6. eee teens A-2
Table A.6 - Speed Feedback Device Specifications (Vector Regulation Only) ..................0000- A-2
Table A.7 - Input Signal Response Times (Worst Case) ....... 0. ccc cece eee eet e eens A-3

1.0 BECOMING FAMILIAR WITH THE MANUAL
This chapter provides help in finding information in the manual and describes the intended audience.
Also included are references to other related publications and instructions on receiving assistance
from Reliance Electric.
1.1. Finding Information
This instruction manual describes the GV3000 drive’s Power Module and regulator hardware. It does
not cover the GV3000 software. For additional software information, refer to the GV3000 A-C General
Purpose (V/Hz) and Vector 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:
@ Chapter1 -Becoming Familiar with the Manual
Provides information on how the manual is organized and where to find additional
information.
@ Chapter 2 - About the Drive
Identifies
drive components and shows their locations.
@ Chapter3 - Planning Before Installing
Presents information that must be considered when planning a drive installation.
@ Chapter 4 - Mounting the Drive, Grounding, and Finding Wire Routing Locations
Describes how to mount the drive and properly ground it.
@ Chapter 5 Installing Input Power Wiring
Describes incoming A-C and D-C line components and how to properly connect
them.
@ Chapter6 Installing A-C Output Power Wiring
Describes output A-C line components and how to properly connect them to the
motor.
@ Chapter 7 - Wiring the Regulator Board Terminal Strip
Provides information on the I/O wiring that connects to the terminal strip on the
Regulator board.
@ Chapter8 - Completing the Installation
Provides instructions on how to perform final check of the installation before
power is applied.
@ Chapter9 - Troubleshooting 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.
@ Appendix A - Technical Specifications
Lists drive specifications in table form.
@ Appendix B - Drive Regulation Overview
Briefly describes volts/hertz and vector regulation.
@ Appendix C - Compliance with EN 60204-1: 1992
Lists the sections of standard EN 60204-1: 1992 that the GV3000 drive complies
with.
1-1

1-2
1.2
1.3
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.
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.
A DANGER ALERTS A PERSON OF A CONDITION WHICH COULD RESULT IN SEVERE BODILY
INJURY OR LOSS OF LIFE.
WARNING
A WARNING ALERTS A PERSON OF A CONDITION WHICH COULD RESULT IN POTENTIAL BODILY
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
1.5
1.6
Understanding Terms Used in this Manual
The following terms aredefined according to the way they are used in this manual:
e GV3000 drives will typically be referenced by horsepower. If additional clarity is required, drive
model numbers will also be included.
e@ Parameters will be referenced either as parameter (P030) or Elapsed Time Meter Reset (P.030).
If You Want to Know More
Refer to the following related publications as necessary for more information:
e@ D2-3339 GV3000 A-C General Purpose (V/Hz) and Vector Duty Drive Software Start-Up and
Reference Manual
e@ D2-3291 Snubber Resistor Braking Kit
@ D2-3305 Motor Encoder Cable Kit
@ D2-3308 AutoMax Network Communication Board
e@ D2-3348 Control and Configuration Software (CS3000)
@ D2-3341 Remote Meter Interface
® D2-3342 Operator Interface Module
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. For technical assistance, call 1-800-RELIANCE.