Reliance electric GV3000SE User manual

GV3000/SE AC Drive
30 - 100 HP, 230V AC
Version 6.04
Hardware Reference, Installation, and Troubleshooting Manual D2-3417-2

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 (August 1999).
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:

I
Table of Contents
CONTENTS
Chapter 1 Becoming Familiar with the Manual
1.1 Finding Information ................................................................................... 1-1
1.2 Assumptions About the Audience ............................................................. 1-2
1.3 Understanding Terms Used in this Manual .............................................. 1-2
1.4 If You Want to Know More ........................................................................ 1-2
1.5 Getting Assistance from Reliance Electric ............................................... 1-2
Chapter 2 About the Drive
2.1 Identify the Drive by Model Number ......................................................... 2-1
2.2 Enclosures ................................................................................................ 2-2
2.3 30-100 HP GV3000/SE Drive Components and Locations ...................... 2-3
2.4 Regulator Board Description..................................................................... 2-5
2.4.1 Jumper Locations and Settings ................................................... 2-7
2.4.1.1 Analog Input Speed Reference Jumper ............................ 2-7
2.4.1.2 Analog Output Jumper ...................................................... 2-8
2.4.2 Wiring the Terminal Strip ............................................................. 2-9
2.4.3 RS-232 Communication Port ....................................................... 2-10
2.4.4 Option Board Connector .............................................................. 2-10
2.4.5 Operator Interface Module Connector......................................... 2-10
2.4.6 Keypad/Display ............................................................................. 2-11
2.5 Jumpers on Base Board (PISC-40) .......................................................... 2-11
2.6 Drive Kit Options ....................................................................................... 2-13
Chapter 3 Planning Before Installing
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 Power Module AC 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 Recommended Power Wire Sizes .................................... 3-5
3.2.2.2 Recommended Control and Signal Wire Sizes ................. 3-6
3.2.2.3 Recommended Motor Lead Lengths ................................. 3-6
3.2.2.4 Recommended Serial Communication Cable Lengths ..... 3-8
3.2.3 Selecting AC Input Line Branch Circuit Fuses, Circuit
Breakers, and AC Reactors ......................................................... 3-8
3.2.4 Meeting Encoder Specifications (FVC Regulation Only) ........... 3-9
3.2.4.1 Encoder Wiring Guidelines .............................................. 3-9

II
GV3000/SE 230 VAC 30-100 HP Drive, Hardware Reference Version 6.04
3.2.5 Verifying Power Module Output Current Rating is Greater
Than Motor Full Load Amps......................................................... 3-9
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 Routing Input, Motor Output, Ground, and Control Wiring
for the Drive .............................................................................................. 4-1
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 ....................................................................................... 5-5
5.5 Installing Power Wiring from an External DC Bus to the
Drive's Internal DC Bus Terminals............................................................ 5-5
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 Terminal to the Motor ..... 6-1
Chapter 7 Wiring the Regulator Board Terminal Strip
7.1 Stopping the Drive .................................................................................... 7-6
7.2 Wiring the Encoder Feedback Device (FVC Regulation Only) ................. 7-6
7.3 Wiring the Signal and Control I/O ............................................................. 7-9
Chapter 8 Completing the Installation
8.1 Checking the Installation ........................................................................... 8-1
8.2 Powering Up After Installation is Complete .............................................. 8-2
Chapter 9 Troubleshooting the Drive
9.1 Test Equipment Needed to Troubleshoot ................................................. 9-1
9.2 Drive Alarms and Faults ........................................................................... 9-1
9.3 Verifying That DC Bus Capacitors are Discharged .................................. 9-1
9.4 Checking Out the Power Module with Input Power Off ............................ 9-2
9.5 Replacement Parts ................................................................................... 9-4
Appendix A Technical Specifications .................................................................................... A-1
Appendix B 30-100 HP GV3000/SE System Wiring Diagram ............................................... B-1

III
Table of Contents
List of Figures
Figure 2.1 – Identifying the Drive Model Number ............................................. 2-1
Figure 2.2 – 30 to 50 HP Drive Components and Locations ............................ 2-3
Figure 2.3 – 60 to 100 HP Drive Components and Locations .......................... 2-4
Figure 2.4 – Regulator Board Components and Locations .............................. 2-6
Figure 2.5 – Jumper J4 Settings for Analog Input Speed Reference ............... 2-8
Figure 2.6 – Jumper J17 Settings for Analog Outputs ..................................... 2-9
Figure 2.7 – Typical Terminal Strip Connections.............................................. 2-10
Figure 2.8 – Keypad/Display ............................................................................. 2-11
Figure 2.9 – Base Board Jumper Locations ..................................................... 2-12
Figure 3.1 – Drive Dimensions ......................................................................... 3-3
Figure 3.2 – Recommended Air Flow Clearances ............................................ 3-4
Figure 3.3 – How to Measure Motor Lead Lengths .......................................... 3-7
Figure 4.1 – Terminal Locations ....................................................................... 4-3
Figure 5.1 – Typical AC Input Electrical Connections ...................................... 5-3
Figure 5.2 – Typical DC Input Electrical Connections ...................................... 5-4
Figure 7.1 – Two-Wire Start/Stop Sample Control Wiring ................................ 7-4
Figure 7.2 – Three-Wire Start/Stop Sample Control Wiring ............................. 7-5
Figure 7.3 – Encoder Wiring Connections ........................................................ 7-8
Figure 9.1 – DC Bus Voltage Terminals ........................................................... 9-2

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GV3000/SE 230 VAC 30-100 HP Drive, Hardware Reference Version 6.04

V
Table of Contents
List of Tables
Table 2.1 – Power Ratings .............................................................................. 2-2
Table 2.2 – Settings of Jumpers on Base Board ............................................. 2-11
Table 2.3 – Available Kits and Options ........................................................... 2-13
Table 3.1 – Ambient Conditions ...................................................................... 3-2
Table 3.2 – Drive Dimensions and Weights .................................................... 3-2
Table 3.3 – Recommended Power Wire Sizes for 30 to 50 HP Drives ........... 3-5
Table 3.4 – Recommended Power Wire Sizes for 60 to 100 HP Drives ......... 3-6
Table 3.5 – Recommended Terminal Strip Wire Sizes ................................... 3-6
Table 3.6 – Motor Lead Lengths ...................................................................... 3-7
Table 3.7 – Reactors ....................................................................................... 3-7
Table 3.8 – AC Input Line Fuse Selection Values ........................................... 3-8
Table 3.9 – Circuit Breaker Selection Values .................................................. 3-9
Table 3.10 – AC Reactor Selection Values ....................................................... 3-9
Table 5.1 – AC Line Reactors ......................................................................... 5-2
Table 7.1 – RS-232 Connections (Terminals 1-3) ........................................... 7-1
Table 7.2 – Encoder Connections (Terminals 4-9).......................................... 7-1
Table 7.3 – Analog Output Connections (Terminals 10 and 11) ..................... 7-2
Table 7.4 – Analog Speed/Torque Reference Connections
(Terminals 12-15) ......................................................................... 7-2
Table 7.5 – Digital Input Connections (Terminals 16-25) ................................ 7-2
Table 7.6 – Snubber Resistor Braking Connections (Terminals 26 and 27) ... 7-3
Table 7.7 – Status Relay Connections (Terminals 28-31) .............................. 7-3
Table 7.8 – Wiring Signal and Control I/O to the Terminal Strip ..................... 7-9
Table 9.1 – Resistance Checks ....................................................................... 9-3
Table 9.2 – Replacement Parts for the GV3000/SE Drives ............................ 9-4
Table A.1 – Service Conditions ........................................................................ A-1
Table A.2 – Environmental Condition .............................................................. A-2
Table A.3 – Terminal Strip Input Specifications ............................................... A-2
Table A.4 – Terminal Strip Output Specifications ............................................ A-2
Table A.5 – Terminal Strip RS-232 Specifications........................................... A-3
Table A.6 – Encoder Feedback Device Specifications
(FVC Regulation Only) ................................................................. A-3
Table A.7 – Input Signal Response Times (Maximum) ................................... A-4

VI
GV3000/SE 230 VAC 30-100 HP Drive, Hardware Reference Version 6.04

1-1
Becoming Familiar with the Manual
CHAPTER 1
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/SE drive's Power Module and
regulator hardware. It does not cover the GV3000/SE software. For additional
software information, refer to the GV3000/SE 230 VAC General Purpose (V/Hz) and
Vector Duty Drive Software Start-Up and Reference Manual (D2-3416-1).
As an aid in finding information in this manual, each chapter is briefly described below:
• Chapter 1 - 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.
• Chapter 3 - 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 AC and DC line components and how to
properly connect them.
• Chapter 6 - Installing Output Power Wiring
Describes output AC 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 the terminal
strip on the Regulator board.
• Chapter 8 - Completing the Installation
Provides instructions on how to perform a final check of the
installation before power is applied.
• Chapter 9 - Troubleshooting the Drive

1-2
GV3000/SE 230 VAC 30-100 HP Drive, Hardware Reference Version 6.04
Describes the equipment that is needed to troubleshoot the drive
and how to measure DC bus voltage. A replacement part list is
also provided.
• Appendix A - Technical Specifications
Lists drive specifications in table form.
• Appendix B - 30-100 HP GV3000/SE System Wiring Diagram
Provides additional wiring information for the 30-100 HP drives.
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 Understanding Terms Used in this Manual
The following terms are defined according to the way they are used in this manual:
• GV3000/SE drives will typically be referenced by horsepower. If additional
clarity is required, drive model numbers will also be included.
• Parameters will be referenced either as parameter (P.030) or Elapsed Time
Meter Reset (P.030).
1.4 If You Want to Know More
Refer to the following related publications as necessary for more information:
• GV3000/SE 230 VAC General Purpose (Volts/Hertz) and Vector Duty Drive
Software Start-up and Reference manual (D2-3416-1).
• Instruction manuals listed in Table 2.3.
1.5 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.

2-1
About the Drive
Figure 2.1 - Identifying the Drive Model Number
CHAPTER 2
About the Drive
This chapter describes how to identify the drive using the model number matrix.
Major components of each drive are also shown.
The GV3000/SE AC drive is a PWM (Pulse-Width-Modulation) 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 Identify the Drive by Model Number
Each GV3000/SE AC 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 Power Module and the regulator. Drive power
ratings are provided in table 2.1.
Horsepower Ratings
30 = 30 HP
40 = 40 HP
50 = 50 HP
60 = 60 HP
75 = 75 HP
100 = 100 HP
GV3000/SE
V = V/Hz or Vector
Voltage
2 = 200 - 230 VAC
Enclosure
0 = Chassis
Regulator Version
60 = Vector and V/Hz Regulator
NNN V2 0NN

2-2
GV3000/SE 230 VAC 30-100 HP Drive, Hardware Reference Version 6.04
Table 2.1 - Power Ratings
Model
Number
30V2060
40V2060
50V2060
60V2060
75V2060
100V2060
Input Volts
(AC)
200-230 VAC
+/– 10%
200-230 VAC
+/– 10%
200-230 VAC
+/– 10%
200-230 VAC
+/– 10%
200-230 VAC
+/– 10%
200-230 VAC
+/– 10%
Input
KVA
41.8
53.8
59.8
77.7
97.6
109.6
Input Amps
(Maximum)
105 A
135 A
150 A
195 A
245 A
275 A
Output Amps
(Maximum) (1) (2)
105 A
135 A
150 A
195 A
245 A
275 A
Power Loss Watts
(Full Load)
660
900
1100
1350
1650
2250
(1) With vector regulation, 150% output current capability for one minute.
(2) These values are for operation with 4 kHz carrier frequency. For operation with 8 kHz carrier frequency, derating by 20% is required.
2.2 Enclosures
This manual describes GV3000/SE chassis style drives. These drives should be
installed in cabinets.

2-3
About the Drive
▲
▲
AUTO
MAN
Forward
Reverse
PROGRAM
RUN
JOG
ENTER
STOP
RESET
START
SPEED
VOLTS
AMPS
Hz
Kw
TORQUE
Password
RUNNING
REMOTE
JOG
AUTO
FORWARD
REVERSE
PROGRAM
.
2
3
4
6
5
1
7
2.3 30-100 HP GV3000/SE Drive Components and Locations
The 30-100 HP GV3000/SE drives have the following main components. The
identification numbers provided correspond to the number used in figures 2.2 and
2.3. Replacement parts are listed in chapter 9.
1. Fan Assembly
2. Membrane Switch (Keypad/Bracket)
3. Regulator Printed Circuit Board
4. Base Board (PISC Board)
5. Bus Capacitor
6. Internal Fan Assembly.
7. Cover
Figure 2.2 - 30 to 50 HP Drive Components and Locations

2-4
GV3000/SE 230 VAC 30-100 HP Drive, Hardware Reference Version 6.04
Figure 2.3 - 60 to 100 HP Drive Components and Locations
▲
▲
AUTO
MAN
Forward
Reverse
PROGRAM
RUN
JOG
ENTER
STOP
RESET
START
SPEED
VOLTS
AMPS
Hz
Kw
TORQUE
Password
RUNNING
REMOTE
JOG
AUTO
FORWARD
REVERSE
PROGRAM
.
2
3
4
6
5
1
7

2-5
About the Drive
2.4 Regulator Board Description
GV3000/SE drive regulation is performed by a microprocessor on the Regulator
board. See figure 2.4. 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 board to isolated drivers on the Gate Driver
board. These drivers switch the Insulated Gate Bi-polar Transistors (IGBTs),
producing a pulse-width-modulated (PWM) waveform that corresponds to the
speed (FVC regulation) or frequency (volts/hertz regulation) reference. The
IGBTs can be switched at either a 2, 4 or 8 kHz carrier frequency.
• Form A and B contacts for drive status indicators
The Form A and B contacts are under control of the user via programmable
parameters. A Form 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.
• 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.
• An 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 signal selection (via jumper J17) requires a power supply for
operation. The power can be sourced from the encoder terminals (4 and 9) or
from an external 15V power supply. See table 7.8, terminals 10 and 11, for
more information. The analog output signal is available through the terminal
strip.
• A snubber resistor braking signal
The Regulator board provides a signal for use by an optional snubber resistor
braking kit. The signal is available through the terminal strip.

2-6
GV3000/SE 230 VAC 30-100 HP Drive, Hardware Reference Version 6.04
Figure 2.4 - Regulator Board Components and Locations
USER DISPLAY
12345678910111213141516171819202122232425262728293031
34-Pin Ribbon Cable
J3
J8
J7
J17 J4 USER I/O TERMINAL STRIP
J9
J5
26-Pin Ribbon Cable
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