Reliance electric GV3000SE Programming manual

GV3000/SE AC Bookshelf Drive
Version 6.06
Hardware Reference, Installation, and Troubleshooting Manual D2-3427-3

Important User Information
Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety
Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from
your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some
important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference,
and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment
must satisfy themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the
use or application of this equipment.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
Allen-Bradley, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
IMPORTANT
Identifies information that is critical for successful application and understanding of the product.

1
Document Update
Document Update
Electronic Motor Overload
Protection
This product does not offer speed-sensitive overload protection, thermal memory
retention or provisions to act upon motor over-temperature sensing in motors. If
such protection is needed in the end-use product, it needs to be provided by
additional means.

2
Document Update
Notes:

Summary of Changes
The information below summarizes the changes made to this manual since
its last release (December 2000).
Description of Changes Page
Added Document Update. After manual
front cover
Deleted the following statement: ‘The Motor Overload Enable parameter (P.040) can
be used in place of the electronic thermal overload relays in single motor
applications’.
6-1

soc-ii Summary of Changes
Notes:

Contents
I
CONTENTS
Chapter 1 Introduction
1.1 Related Publications ........................................................................................ 1-1
1.2 Getting Assistance from Reliance Electric....................................................... 1-1
Chapter 2 About the Drive
2.1 Identifying the Drive......................................................................................... 2-1
2.2 Understanding the Enclosure Rating: IP20 ..................................................... 2-2
2.3 2 to 15 Amp GV3000/SE Bookshelf Drive Component Locations ................... 2-3
2.4 24 to 30 Amp GV3000/SE Bookshelf Drive Component Locations ................. 2-4
2.5 43 Amp GV3000/SE Bookshelf Drive Component Locations .......................... 2-5
2.6 Regulator Board Description ........................................................................... 2-6
2.6.1 Jumper Locations and Settings............................................................. 2-7
2.6.1.1 Setting the Analog Input Speed Reference Jumper (J4) ........ 2-7
2.6.1.2 Setting the Analog Output Jumper (J17)................................. 2-8
2.6.2 Terminal Strip...................................................................................... 2-10
2.6.3 RS-232 Communication Port............................................................... 2-10
2.6.4 Option Board Connector ..................................................................... 2-11
2.6.5 Operator Interface Module (OIM) Connector....................................... 2-11
2.7 Keypad/Display.............................................................................................. 2-11
2.8 Output Relay Terminal Strip .......................................................................... 2-12
2.9 Internal Braking Transistor ............................................................................ 2-12
2.10 Optional Internal AC Mains Filter................................................................... 2-12
2.11 Optional Equipment ....................................................................................... 2-12
Chapter 3 Planning Before Installing
3.1 General 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 ............ 3-3
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 ............. 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 for 24 to 43 Amp Bookshelf Drives 3-5
3.2.2.2 Recommended Power 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 ........... 3-8
3.2.3 Selecting Input Line Branch Circuit Fuses ............................................ 3-8
3.2.4 Meeting Encoder Specifications (FVC Regulation Only)....................... 3-9
3.2.4.1 Encoder Wiring Guidelines ..................................................... 3-9
3.2.5 Verifying Power Module Output Current Rating Is Greater Than
Motor Full Load Amps ........................................................................... 3-9

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GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
Chapter 4 Mounting the Drive, Grounding, and Finding Wire Routing Locations
4.1 Mounting the Drive ...........................................................................................4-1
4.1.1 Verifying the Drive’s Watts Loss Rating.................................................4-1
4.2 Determining Input, Motor Output, Ground, and Control Wire Routing
for the Drive......................................................................................................4-2
4.3 Grounding the Drive .........................................................................................4-2
Chapter 5 Installing Input Power Wiring
5.1 Installing Transformers and Reactors (Optional) .............................................5-1
5.2 Installing Fuses for Branch Circuit Protection ..................................................5-2
5.3 Installing a Required External/Separate Input Disconnect...............................5-2
5.4 Installing Power Wiring from the AC Input Line to the Drive’s Power Terminals .5-2
Chapter 6 Installing Output Power Wiring
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
Chapter 7 Wiring the Regulator Board Terminal Strip and the Output Relay Terminal Strip
7.1 Stopping the Drive............................................................................................7-4
7.1.1 Compliance with Machinery Safety Standard EN 60204-1:1992...........7-4
7.2 Wiring the Encoder Feedback Device (FVC Regulation Only).........................7-5
7.3 Wiring the Signal and Control I/O.....................................................................7-7
Chapter 8 Wiring Optional User-Supplied Braking Resistors
8.1 Installation Guidelines ......................................................................................8-1
8.2 Selecting a Braking Resistor ............................................................................8-3
8.3 Installing the Braking Resistor..........................................................................8-4
Chapter 9 Completing the Installation
9.1 Checking the Installation ..................................................................................9-1
9.2 Powering Up After Installation Is Complete......................................................9-2
Chapter 10 Troubleshooting the Drive
10.1 Test Equipment Needed To Troubleshoot .....................................................10-1
10.2 Drive Alarms and Faults.................................................................................10-1
10.3 Verifying That DC Bus Capacitors Are Discharged........................................10-1
10.4 Checking Out the Drive with Input Power Off.................................................10-4
10.5 Checking the Cooling Fans ............................................................................10-7
10.6 Replacement Parts.........................................................................................10-7
Appendix A Technical Specifications........................................................................................... A-1
Appendix B Compliance with Machinery Safety Standard EN 60204-1:1992 ............................. B-1
Appendix C Compliance with Electromagnetic Compatibility Standards ..................................... C-1
Index ...........................................................................................................................Index-1

Contents
III
List of Figures
Figure 2.1 – Identifying the Drive Using the U. S. Model Number ............................ 2-1
Figure 2.2 – Identifying the Drive Using the European Stock Number ..................... 2-2
Figure 2.3 – 2 to 15 Amp Drive Component Locations............................................. 2-3
Figure 2.4 – 24 to 30 Amp Drive Component Locations........................................... 2-4
Figure 2.5 – 43 Amp Drive Component Locations.................................................... 2-5
Figure 2.6 – Regulator Board Component Locations ............................................... 2-6
Figure 2.7 – Jumper J4 Settings for Analog Input Speed Reference ....................... 2-8
Figure 2.8 – Jumper J17 Settings for Analog Outputs.............................................. 2-9
Figure 2.9 – Typical Terminal Strip Connections.................................................... 2-10
Figure 2.10 – Keypad/Display................................................................................. 2-11
Figure 2.11 – Output Relay Terminal Strip ............................................................. 2-12
Figure 3.1 – Dimensions for 2 to 30 Amp Drives ...................................................... 3-3
Figure 3.2 – Dimensions for 43 Amp Drives ............................................................. 3-4
Figure 3.3 – How to Calculate Motor Lead Lengths ................................................. 3-7
Figure 4.1 – Wire Routing Locations for 2 to 15 Amp Drives.................................... 4-3
Figure 4.2 – Wire Routing Locations for 24 to 30 Amp Drives.................................. 4-4
Figure 4.3 – Wire Routing Locations for 43 Amp Drives........................................... 4-5
Figure 5.1 – Typical AC Input 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...................................... 7-3
Figure 7.3 – Encoder Wiring Connections ................................................................ 7-6
Figure 7.4 – Wiring the Terminal Strip - Detail.......................................................... 7-7
Figure 8.1 – Braking Resistor Wiring Connections ................................................... 8-4
Figure 10.1 – DC Bus Voltage Terminals (2 to 15 Amp Drives) ............................. 10-2
Figure 10.2 – DC Bus Voltage Terminals (24 to 30 Amp Drives) ........................... 10-3
Figure 10.3 – DC Bus Voltage Terminals (43 Amp Drives) .................................... 10-4

IV
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06

Contents
V
List of Tables
Table 2.1 – Power Ratings ....................................................................................... 2-2
Table 2.2 – Standard Kits and Options .................................................................. 2-12
Table 3.1 – Environmental Conditions...................................................................... 3-2
Table 3.2 – Dimensions and Weights for 2 to 30 Amp Drives .................................. 3-3
Table 3.3 – Dimensions and Weight for 43 Amp Drives ........................................... 3-4
Table 3.4 – Recommended Air Flow Clearances ..................................................... 3-4
Table 3.5 – Recommended Power Wire Sizes for 2 to 15 Amp Drives .................... 3-5
Table 3.6 – Recommended Power Wire Sizes for 24 to 43 Amp Drives .................. 3-6
Table 3.7 – Recommended Terminal Strip Wire Sizes............................................. 3-6
Table 3.8 – Recommended Motor Lead Lengths for Reliance Inverter Duty Motors.... 3-7
Table 3.9 – Compatible Reactors ............................................................................. 3-7
Table 3.10 – AC Input Fuse Selection Values ......................................................... 3-8
Table 7.1 – Encoder Connections (Regulator Terminals 4-9) .................................. 7-1
Table 7.2 – Analog Output Connections (Regulator Terminals 10 and 11) .............. 7-1
Table 7.3 – Analog Speed/Torque Reference Connections (Regulator
Terminals 12-15)................................................................................... 7-2
Table 7.4 – Digital Input Connections (Regulator Terminals 16-25)......................... 7-2
Table 7.5 – Status Relay Connections (Relay Terminals 28-31) on the
Output Relay Terminal Strip.................................................................. 7-2
Table 7.6 – Encoder Connections ............................................................................ 7-5
Table 7.7 – Wiring Signal and Control I/O to the Regulator Board Terminal Strip.... 7-7
Table 7.8 – Wiring the Output Relay Terminal Strip ............................................... 7-14
Table 8.1 – Cable Cross-Sections for External Braking Resistors ........................... 8-2
Table 8.2 – Selecting a Braking Resistor.................................................................. 8-3
Table 8.3 – Wiring Connections for External Braking Resistor................................. 8-4
Table 10.1 – Resistance Checks ............................................................................ 10-5
Table 10.2 – Replacement Parts ............................................................................ 10-7

VI
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06

Introduction
1-1
CHAPTER 1
Introduction
This instruction manual describes GV3000/SE Bookshelf drive hardware. It does not
cover the GV3000/SE drive software. For software information, refer to the
GV3000/SE AC General Purpose (V/Hz) and Vector Duty Bookshelf Drive Software
Start-Up and Reference Manual (D2-3426).
This manual is intended for qualified electrical personnel. It is organized according to
a logical progression of steps to be followed to install and troubleshoot the drive.
GV3000/SE Bookshelf drives will typically be referenced by amps. If additional clarity
is required, drive model numbers will also be included.
1.1 Related Publications
Refer to the following related publications as necessary for more information:
1.2 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
1-800-726-8112.
•D2-3426 GV3000/SE AC General Purpose (V/Hz) and Vector Duty Bookshelf
Drive Software Start-Up and Reference Manual
•D2-3305 Motor Encoder Cable Kit
•D2-3308 AutoMax Network Communication Option Board
•D2-3348 Control and Configuration Software (CS3000)
•D2-3341 Super Remote Meter Interface (RMI) Board
•D2-3342 Operator Interface Module (OIM)
•D2-3390 ControlNet Network Communication Option Board

1-2
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06

About the Drive
2-1
CHAPTER 2
About the Drive
This chapter provides an overview of the drive including how to identify the drive, a
description of the Regulator board, and the identification of major components of the
drive.
The GV3000/SE AC Bookshelf drive is a PWM (pulse-width-modulated) drive that
provides vector and general purpose 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. The drive can provide this functionality either with encoder feedback (flux
vector control or FVC) or without (sensorless vector control or SVC).
Using general purpose (volts/hertz or V/Hz) regulation, the drive is suited for a broad
range of applications requiring adjustable speed control of motors.
2.1 Identifying the Drive
Each GV3000/SE Bookshelf drive can be identified by its U.S. model number or the
European stock number. See figures 2.1 and 2.2. These numbers appear on the
shipping label and on the drive’s nameplate. Drive power ratings are provided in table
2.1.
Figure 2.1 – Identifying the Drive Using the U. S. Model Number
V/Hz Current Ratings
(31 = 3.1 A, etc.)
ER = GV3000/SE Bookshelf Drive
without CE Filter
ET = GV3000/SE Bookshelf Drive
with CE Filter
Voltage
4 = 380 V to 460 V
Enclosure
0 = IP20
Regulator Version
60 = Vector and V/Hz Regulator Version 6.0 Firmware
NNN AA N N NN

2-2
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
2.2 Understanding the Enclosure Rating: IP20
GV3000/SE Bookshelf drives have an IP20 rating. An IP rating designates the
enclosure’s level of protection. The first number (2) indicates the enclosure protects
against solid objects greater than 12 mm. The second number (0) indicates that the
enclosure is not water-tight. Note that the drive is intended for use inside a larger,
user-supplied enclosure.
Figure 2.2 – Identifying the Drive Using the European Stock Number
NNN . NN . NN
896 = GV3000/SE
Power Module Size
11 = DC Bus Terminals and
Brakin
g
Transistor Circuit
31 = DC Bus Terminals, Brakin
g
Resistor Circuit, and Built-In CE Filter
Table 2.1 – Power Ratings
U.S.
Model
Number
European
Stock
Number
Input
KVA
Input
Amps*
Output Amps by Mode @ Carrier
Frequency
Power Loss
Watts
(Full Load)
V/Hz** Vector**
2 kHz 4 kHz 8 kHz 2 kHz 4 kHz 8 kHz
31ER40xx
31ET40xx
896.01.11
896.01.31
4.0
3.2
5
43.1 3.1 2.8 2.1 2.1 2.1 60
38ER40xx
38ET40xx
896.02.11
896.02.31
4.8
4.0
6
53.8 3.8 2.8 3.1 3.1 2.8 70
55ER40xx
55ET40xx
896.03.11
896.03.31
8.0
6.4
10
85.5 5.5 5.5 3.8 3.8 3.8 100
85ER40xx
85ET40xx
896.05.11
896.05.31
10.4
8.0
13
10 8.5 8.5 5.5 6.7 6.7 5.0 150
126ER40xx
126ET40xx
896.06.11
896.06.31
12.7
10.4
16
13 12.6 12.0 8.5 9.3 9.3 8.0 210
150ER40xx
150ET40xx
896.07.11
896.07.31
15.9
12.7
20
16 15.0 12.0 8.5 11.0 11.0 8.0 250
240ER40xx
240ET40xx
896.08.11
896.08.31
24.7
19.9
31
25 24.0 16.5 12.6 16.5 15.0 11.0 380
300ER40xx
300ET40xx
896.09.11
896.09.31
30.2
25.5
38
32 30.0 24.0 16.5 22.0 22.0 15.0 470
430ER40xx
430ET40xx
896.11.12
896.11.32
42.2
37.4
53
47 43.0 31.0 22.0 30.0 22.0 15.0 600
*Input Voltage: 380 to 460 VAC (+/-10%)
**With V/Hz regulation, 110% continuous output current capability. With vector regulation, 150% output
current capability for one minute.

About the Drive
2-3
2.3 2 to 15 Amp GV3000/SE Bookshelf Drive Component
Locations
The 2 to 15 amp GV3000/SE Bookshelf drives have the following main components.
The numbered items listed below correspond to the numbers used in figure 2.3.
Replacement parts are listed in chapter 10.
1. Regulator PCB 4. Power PCB
2. Fan 5. Keypad/Display
3. Output Relay Terminal Strip
Figure 2.3 – 2 to 15 Amp Drive Component Locations
Front View Cover Removed
➀
➃
➂
➄
➁

2-4
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
2.4 24 to 30 Amp GV3000/SE Bookshelf Drive
Component Locations
The 24 to 30 amp GV3000/SE Bookshelf drives have the following main components.
The numbered items listed below correspond to the numbers used in figure 2.4.
Replacement parts are listed in chapter 10.
1. Regulator PCB 4. Power PCB
2. Fan 5. Keypad/Display
3. Output Relay Terminal Strip
Figure 2.4 – 24 to 30 Amp Drive Component Locations
Cover Removed
➀
➃
➂
Front View ➁
➄

About the Drive
2-5
2.5 43 Amp GV3000/SE Bookshelf Drive Component
Locations
The 43 amp GV3000/SE Bookshelf drives have the following main components. The
numbered items listed below correspond to numbers used in figure 2.5. Replacement
parts are listed in chapter 10.
1. Regulator PCB 3. Output Relay Terminal Strip
2. Fan 4. Keypad/Display
Figure 2.5 – 43 Amp Drive Component Locations
PE L1 L2 L3 45 47 48 U V W
28-31
➁
➀
➂
➃

2-6
GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.06
2.6 Regulator Board Description
Drive regulation is performed by a microprocessor on the Regulator board. See figure
2.6. Drive operation is adjusted by the parameters entered through the keypad. The
Regulator board accepts power circuit feedback signals and an external speed
reference signal, as well as data from an encoder that is attached to the motor when
set up for FVC regulation.
The Regulator board provides PWM gating signals to the IGBT power devices
.
Based
on the output of the control loop, the regulator sends PWM gating signals through the
current feedback section of the Power board to the isolated gate drivers. These drivers
switch the Insulated Gate Bi-polar Transistors (IGBTs), producing a PWM waveform
that corresponds to the speed (FVC regulation) or frequency (V/Hz regulation)
reference. The IGBTs can be switched at either a 2, 4, or 8 kHz carrier frequency.
The Regulator board components are shown in figure 2.6 and described in the
following sections.
Figure 2.6 – Regulator Board Component Locations
J17
J4
V Out
C Out
V In
C In
OIM
Connector
(X7)
RS-232C
Port (X8)
Ter mi nal S t rip
Power Module
Feedback Connector
(X16)
Keypad/Display
Cable Connector
(X9)
Analog Output
Default: Voltage
Analog Input
Default: Voltage
Option Board Connector
(X3)
(X1)