Reliance electric GV3000 User manual

GV3000°® Version 4
Regulator Board Installation Instructions
Regulator Board P/N 0-56921-4xx
Regulator Upgrade Kit P/N K-690-AU
Regulator Board P/N 413338-5AU
Regulator Upgrade Kit P/N K-690-AV
Instruction ManualD2-3333
RELIANCE
ELECTRIC g

The information in this 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 THE VOLTAGE WITH A VOLTMETER TO
ENSURE THE D-C BUS CAPACITORS ARE DISCHARGED BEFORE TOUCHING ANY INTERNAL
COMPONENTS. FAILURETO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE BODILY
INJURY OR LOSS OF LIFE.
CAUTION: The Power Module identification procedure enabled in parameter P998 will clear the contents
of parameter P999. Only qualified electrical personnel who understand the potential hazards involved
should make modifications to parameters P998 and P999. Failure to observe this precaution could result
in damage to, or destruction of, the equipment.
CAUTION: Entering incorrect values into parameter P999 will configure the Regulator board incorrectly for
the connected Power Module. This parameter must be set by a qualified person who understands the
significance of setting it correctly. Failure to observe this precaution could result in damage to, or destruction
of, the equipment.
GV3000°2, AutoMax®, and Reliance® are registered trademarks of Reliance Electric Company
or its subsidiaries.
© Copyright Reliance Electric Industrial Company 1995.

Table of Contents
Preface ...... 00 ccc eee eee ees Hl
1.0 Installing Regulator Board P/N 0-56921-4xx in 1-5 HP and 7.5-10 HP Drives .............. 1-1
2.0 Installing Regulator Board P/N 0-56921-4xx in 15-25 HP Drives ..............000eeeeeees 2-1
3.0 ‘Installing Regulator Board P/N 413338-5AU in 25-50 HP Drives ...............0000eeeeee 3-1
4.0 Installing Regulator Board P/N 413338-5AU in 100-150 HP Drives .............00eseeeees 4-1
5.0 Clearing the PUn Alarm Code and Identifying the Power Module ............2...00eeeees 5-1
6.0 Restoring the Drive Configuration ............. 0 cece eee eee eens 6-1
7.0 Troubleshooting the Installation ............. cece eee eee eee ee ee ee enn eeees 7-1

PREFACE
The products described in this manual are manufactured or distributed by Reliance Electric Industrial
Company.
This manual provides instructions for replacingthe Regulator board in your installation with a GV3000®
Version 4 Regulator board. It is intended for qualified electrical personnel. The Regulator board is sold
individually as P/N 056921 -4xx or 413338-5AU and as part of Upgrade Kit P/N K-690-AU or K-690-AV.
You will need to refer to the following instruction manuals as you perform the installation procedure. These
manuals are shipped with the new Regulator board.
e@ D2-3323 GV3000 A-C General Purpose (Volts/Hertz) and Vector Duty Drive Software Start-Up and
Reference Manual
@ D2-3324 GV3000 A-C Power Modules Hardware Reference, Installation, and Troubleshooting
The installation procedure consists of replacing the Regulator board, identifying the Power Module to the
Regulator board, and restoring your configuration. Perform the instructions in the order in which they are
presented in this manual. The board replacement procedure differs depending on drivetype. Use the
following table to locate the appropriate installation procedure in this manual.
If your drive’s model number is not listed below,the regulator software may not be compatible for your drive.
Contact Reliance Renewal Parts for a compatible Regulator board.
For Drive Replace the Regulator Using the Procedure
Model Number... Board with Part Number... Beginning in Section...
1V41x0
4V44x0 0-5692 1 -4xx 1.0
2V41x0
1-5HP oVAdx0 0-5692 1 -4xx 1.0
3V41x0
3V44x0 0-5692 1 -4xx 1.0
5V41x0
5VA4x0 0-5692 1 -4xx 1.0
7V41x0
7.5-10HP 7V42x0 0-56921-Axx 10
10V41x0
410V42x0 0-5692 1 -4xx 1.0
15V41x0
15V42x0
0-5692 1 -4xx 2.0
20V41x0
15 - 25 HP 20V42x0 0-5692 1 -4xx 2.0
25G41x0
25G42x0
0-5692 1 -4xx 2.0
25 - 5S0HP 30R41x0 413338-5AU 3.0
50R41x0 413338-5AU Contact
40-100 HP 75R41x0 413338-5AU Reliance
100 - 150 HP 125R41x0 413338-5AU 4.0
NOTE: /f you are replacing the Regulator board in order to upgrade your system to Version 4, and you have
purchased the Configuration Executive (CE3000) software, saveyour configuration to a personal computer
before you begin the installation procedure if you have not done this previously. Refer to the CE3000
instruction manual (D2-3303) for this procedure.

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. If the product is still under warranty, you can also call the Customer
Response Center (CRC) at 1-800-726-8112. This is a toll-free call.
If the product is no longer under warranty, you have two options. You can call 1-900-230-6600. This is a toll
call for which you will be billed by the minute (the first two minutes are free). Alternately, you can call
1-900-346-3400. Calls to this number will be billed at a flat rate per call. If you think your problem will take
longer than 25 minutes to resolve, it will be more economical to contact Reliance at the second number.

1.0 INSTALLING REGULATOR BOARD P/N 0-56921-4XX
IN 1-5 HP AND 7.5-10 HP DRIVES
ONLY QUALIFIED PERSONNEL FAMILIAR WITH THE CONSTRUCTION AND OPERATION OF THIS
EQUIPMENT AND THE HAZARDS INVOLVED SHOULD INSTALL, ADJUST, OPERATE, AND/OR
SERVICE THIS EQUIPMENT. READ AND UNDERSTAND THIS INSTRUCTION MANUAL IN ITS
ENTIRETY BEFORE PROCEEDING. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN
SEVERE BODILY INJURY OR LOSS OF LIFE.
THE DRIVE IS AT LINE VOLTAGE WHEN CONNECTED TO INCOMING A-C POWER. DISCONNECT,
TAG, AND LOCKOUT ALL INCOMING POWER TO THE DRIVE BEFORE PERFORMING THE
FOLLOWING PROCEDURE. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE
BODILYINJURY 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 THE VOLTAGE 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.
Use the following procedure to replace the Regulator board (P/N 0-56921-4xx, individually, or as part
of Upgrade Kit P/N K-690-AU) in 1 to 5 HP and 7.5 to 10 HP GV3000 drives. Refer to figure 2.3 (1 to
5 HP) or figure 2.4 (7.5 to 10 HP) in instruction manual D2-3324 as you perform the procedure. Note
that if the Power Module has been panel-mounted, this procedure will be easier to perform if the
Power Module is removed from the panel.
Remove the Keypad Support Bracket from the Drive
Step 1. Disconnect, tag, and lockout power to the drive.
Step 2. Wait five (5) minutes for the D-C bus capacitors to discharge.
Step 3. Remove the cover by loosening the four (4) cover retaining screws.
Step 4. Using a voltmeter, verify that there is no voltage at the drive’s A-C input power terminals
(R/L1, S/L2, T/L3).
Step 5. Check the D-C bus potential (+, — terminals) with a voltmeter as described in section 9.3 of
D2-3324 to ensure that the D-C bus capacitors are discharged.
Caution: The drive contains printed circuit boards that are static-sensitive. An anti-static wrist band should
be worn by any person who touches the drive’s components, connectors, or leads. Failure to observe this
precaution may result in erratic machine operation and damage to, or destruction of, equipment.
1-1

1-2
Installing Regulator Board P/N 0-56921-4xx in 1-5 HP and 7.5-10 HP Drives (Continued)
Step 6. Note the cable lead connections to the Regulator board terminal strip. If these connections
are not documented elsewhere, record them now. Then disconnect these cable leads from
the Regulator board terminal strip.
If the drive hasan option board, such as the AutoMax® Network Communication option
board, installed below the Regulator board, continue to step 7. Otherwise, proceed to
step 8.
Step 7. (Drives with option boards only) Note the cable connections to the option board terminals. If
these connections arenot documented elsewhere, record them now. Then disconnect
these leads from the option board terminal strip.
Step 8. Disconnect the green-striped keypad ribbon cable from the Regulator board. The cable is
located on the right-hand side of the drive. The cable connector is held in place bya small
retaining clip at its center. Insert a small screwdriver inside the cable loop, and press in on
the retaining clip while pulling out the connector.
Step 9. Remove the three (3) M4 x 10 screws that fasten the bottom of the support bracket to the
drive’s heat sink.
Step 10. Disconnect the 26-conductor Regulator board ribbon cable from the Current Feedback
board located on the right-handside below the keypad. The connector is held in place by
retaining clips at its edges. Spread these clips apart to release theconnector.
Step 11. Move the support bracket aside and carefully pull out the Current Feedback board to
expose the internal fan assembly connector plug. Use a small pair of pliers to pinch the
center retaining clip that holds the Current Feedback board in place.
Step 12. Unplug the internal fan assembly power connector from the drive.
For 7.5 to 10 HP drives, continue to step 13.
For 1 to 5 HP drives containing an option board, proceed to step 14.
For 1 to 5 HP drives with no option board, proceed to step 16.
Remove the Regulator Board from the Keypad Support Bracket
Step 13. (7.5 to 10 HP drives only) Loosen the thumb screw on the left side of the keypad support
bracket to release the top of the bracket from the bottom. Grasp the bracket on the
left-hand side and lift it up and to the left to separate the top bracket from the bottom.
If the drive hasan option board, continue to step 14. If there is no option board, proceed to
step 16.
Step 14. (Drives with option boards only) Remove the option board from the support bracket. The
option board is held in place by two metal screws with lock washers and two plastic rivets.
To remove a plastic rivet, pull the post from the rivet body and then remove the body of the
rivet. Use a small pair of wire cutters or a similar tool to pry these pieces loose. NOTE: Do
not cut the rivets.
Set the plastic rivets, metal screws, and lock washers aside for later use.
Step 15. (Drives with option boards only) Remove the Regulator board ribbon connector from the
option board. The connector is held in place by retaining clips at its ends. Spread these
clips apart to release the connector. Set the option board aside.
Step 16. Remove the old Regulator board from the support bracket. The Regulator board is held in
place by two metal screws with lock washers and two plastic rivets. To remove a plastic
rivet, pull the post from the rivet body and then remove the body of the rivet. Use a small
pair of wire cutters or a similar tool to pry these pieces loose. NOTE: Do not cut the rivets.
Set the plastic rivets, metal screws, and lock washers aside for later use. Then slide the old
Regulator board out of the bracket.

Installing Regulator Board P/N 0-56921-4xx in 1-5 HP and 7.5-10 HP Drives (Continued)
Step 17. Note the settings of jumpers J4 and J17 on the old Regulator board. These jumpers are
located alongside the center of the terminal strip. Figure 2.9 in D2-3324 shows the location
of these jumpers.
Install the New Regulator Board in the Keypad Support Bracket
Step 18. Remove the new Regulator board from its anti-static wrapper and verify that the jumper
settings on the new Regulator board are identical to those on the old board. Slide the new
board into the keypad support bracket. Position the boardso that the seven-segment
displays appear in the display window in the keypad.
Step 19. Connect the new Regulator board to the support bracket using the fasteners removed in
step 16. Observe that two corners of the board have metal-plated grounding pads. In order
to properly ground the Regulator board, use the metal screws and lock washers to mount
the corners that have the grounding pads. Mount the other two corners of the board by
inserting the plastic rivet bodies into the mounting holes and then pressing the posts into
the rivet bodies. NOTE: Improper grounding ofthe Regulator board may result in erratic
operation of the drive.
If the drive has an option board, continue to step 20.
For 7.5 to 10 HP drives without an option board, proceed to step 22.
For 1 to 5 HP drives without an option board, proceed to step 23.
Step 20. (Drives with option boards only) Align the key on the Regulator board’s 34-conductor
ribbon cable connector with the slot in the option board’s connector and press the ribbon
cable connector in until it locks into position.
Step 21. (Drives with option boards only) Reconnect the option board to the support bracket using
the fasteners removed in step 14. Observe that two of the corners of the board have
metal-plated grounding pads. In order to properly ground the option board, use the metal
screws and lock washers to mount the corners that have the grounding pads. Mount the
other two corners of the board by inserting the plastic rivet bodies into the mounting holes
and then pressing the posts into the rivet bodies. NOTE: Improper grounding ofthe option
board may result in erratic operation ofthe drive.
For 7.5 to 10 HP drives, continue to step 22.
For 1 to 5 HP drives, proceed to step 23.
Step 22. (7.5 to 10 HP drives only) Reconnect the top of the keypad support bracket to the bottom
by inserting the mounting tabs into the slots in the bottom of the bracket and tightening the
thumbscrew.
Reinstall the Support Bracket in the Drive
Step 23. Reconnect the internal fan assembly power connector to the drive. Align the key on the
connector with the slot in the receptacle, and press the connector into position.
WARNING
PROPER ALIGNMENT OF THE CURRENT FEEDBACK BOARD DURING INSTALLATION IS CRITICAL.
VERIFY THAT THE CONNECTOR PINS ON THE CURRENT FEEDBACK BOARD ARE CORRECTLY
ALIGNED WITH THEIR CORRESPONDING CONNECTOR BLOCKS ON THE DRIVE. FAILURE TO
OBSERVE THIS PRECAUTION MAY RESULT IN BODILY INJURY.
Step 24. Reinstall the Current Feedback board. Carefully align the two sets of connector pins on the
Current Feedback board with their matching connector blocks on the drive. Then gently
press the board into place. The board should go in easily. If any resistance is met, it may be
due to a bent or misaligned pin. After inserting the board, inspect the installation thoroughly
with a light source for bent or misaligned pins.
1-3

1-4
Installing Regulator Board P/N 0-56921-4xx in 1-5 HP and 7.5-10 HP Drives (Continued)
Step 25.
Step 26.
Step 27.
Step 28.
Step 29.
Step 30.
Step 31.
Align the support bracket with the mounting holes in the drive heat sink. Fasten the bracket
with the three (3) M4 x 10 screws removed in step 9.
Connect the green-striped keypad ribbon cable to the new Regulator board. Align the
ribbon cable connector with the Regulator board connector and carefully push the
keyboard cable connector in until it snaps into place. Verify that it is locked into position by
gently tugging on the cable.
Align the Regulator board’s 26-conductor ribbon cable connector (located on the right-hand
side below the keypad) with the Current Feedback board’s connector and press it in until it
locks into position.
If an option board has been installed, continue to step 28. Otherwise, proceed to step 29.
(Drives with option boards only) Connect the option board cable leads to the appropriate
option board terminals. Route the wire through the left-hand wire-routing hole at the bottom
of the drive. Refer to the terminal connections documented in step 7 or to the appropriate
instruction manual for the option board that is being used.
Connect all Regulator board cable leads to the appropriate terminals on the Regulator
board terminal strip. Route the wire through the left-hand wire-routing hole at the bottom of
the drive. Refer to the terminal connections documented in step 6 or to the appropriate
instruction manual for the speed feedback device that is being used.
Reinstall the cover. Align all cover screws into the heat sink before tightening any of them.
(For NEMA 4X/12 covers, refer to section 8.2 in D2-3324.)
Remove the lockout and tag, and apply power to the drive. SELF will be displayed while the
drive performs power-up diagnostics. After the diagnostics are complete, the alarm code
PUn will be displayed.
This completes the hardware installation portion of the Regulator board replacement procedure. Go
to Chapter 5 for the procedure to clear the PUn alarm code.