Reliance electric GV3000SE User manual

GV3000/SE AC General Purpose and Vector Drive
Version 6.0
Instruction Manual
Manual P/N: 899.07.71
Firmware P/N: 790.46.00 / 790.51.60 Publication: GV3000-UM060K-EN-P
UL
CR

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INDEX OVERVIEW
PART 1: 49‘1327 GV3000/SE Power Units
1 - INTRODUCTION
2 - DESCRIPTION
3 - INSTALLATION
4 - MAINTENANCE
5 - ACCESSORIES
A - CE CONFORMITY
B - NEMA DESIGN INVERTERS 2 - 32 A
C - RFERENCE LIST
PART 2: 49‘1329 GV3000/SE Regulator
1 - REGULATOR OVERVIEW
2 - USE OF OPERATORS MANUAL
3 - USING THE GV3000 KEYPAD
4 - GENERAL PARAMETERS, DESCRIPTION
5 - V/HZ MODE REGULATION MODE
6 - VECTOR MODE REGULATION
7 - TROUBLE SHOOTING USING ERROR CODES
8 - PARAMETER QUICK REFERENCE GUIDE

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GV3000/SE Power Units
Instruction Manual
User Manual: 49‘1327e (11)

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TABLE OF CONTENTS
49'1327 e GV3000/SE I
Chapter/Topic Page
1. Introduction 1-1...1-2
Safety Instruction............................................................................................ 1-1
2. Description 2-1..2-22
Power Unit Functional Description .................................................................. 2-1
Specifications
Input Power Ratings, DC Bus................................................................ 2-13
Power Loss ........................................................................................... 2-15
Service Conditions................................................................................. 2-15
Power Connection Terminals................................................................. 2-16
Braking Unit........................................................................................... 2-17
Output Current Ratings ......................................................................... 2-18
Inverter Selection Tables....................................................................... 2-20
3. Installation 3-1...3-16
Power Unit Connection ................................................................................... 3-1
Regulator Connection..................................................................................... 3-4
Dimensions .................................................................................................... 3-10
4. Maintenance 4-1...4-10
Safety Precautions ......................................................................................... 4-1
Checking the Cooling Fans............................................................................. 4-1
Power Unit Function Check ............................................................................ 4-2
Replacement Parts ......................................................................................... 4-3
5. Accessories 5-1...5-2
AC Line Reactor ............................................................................................. 5-1
Radio Frequency Interference Filter ............................................................... 5-2
Appendix A CE-Conformity A-1...A-6
EMC Directive................................................................................................. A-1
General Wiring Instruction .............................................................................. A-2
Cabinet Mounted Inverters.............................................................................. A-3
Mounting Instruction .............................................................................. A-3
Wiring Instruction................................................................................... A-3
Installation of Standalone Drives IP20 ............................................................ A-5
Appendix B NEMA Design Inverters 2 to 32A B-1...B-8
Specifications and Principal Diagram .................................................................... B-1
Power Connections, Dimensions .......................................................................... B-6
Replacement Parts ................................................................................................ B-7
Radio Frequency Interference Filter ..................................................................... B-8
Appendix C Cross Reference List C-1...C-2

1 - INTRODUCTION
49'1327 e GV3000/SE 1-1
This instruction manual provides a functional description of the Power Units for the PWM-Converters
Type GV3000 with circuit diagram and Specifications (Chapter 2), Installation Guidelines (Chapter 3),
general trouble shooting suggestions with spare parts lists (Chapter 4) and Accessories (Chapter 5).
Appendix A contains guidelines for installation to meet CE-Conformity and EMC Directive.
Appendix B describes the frequency converters in NEMA design type GV3000U-AC002 to 032
manufactured in USA, which are all UL, cUL and CE approved.
For Start-Up instructions please refer to the regulator manual.
Safety Instructions
DANGER, WARNING, and CAUTION point out potential trouble areas.
A DANGER alerts a person that high voltage is present which could result in severe bodily injury or
loss of life.
A WARNING alerts a person to potential bodily injury if procedures are not followed.
A CAUTION alerts a person that, if procedures are not followed, damage to, or destruction of
equipment could result.
DANGER:Before installing and/or operating this device, this manual must be understood by the
qualified electrical maintenance person who is familiar with this type of equipment and
the hazards involved. Failure to observe this precaution could result in bodily injury.
WARNING:Earth fault detection devices must not be used on this converter as the sole protection
measure against unintentional touching.
The DC-component in the earth fault current may inhibit the correct function of the fault
detector.
CAUTION:Electronic converters cause disturbances to the supply network. The basic version of
this converter does not include any harmonic filters and may not fulfill the limits of the
national recommendations. The harmonic voltage disturbances produced by the
converter are dependent on the supply network impedance.
Machinery Directive
CAUTION:This inverter device is a component intended for implementation in machines or
systems for the capital goods industry.
The start-up of the inverter in the European market is not permitted until it has been
confirmed that the machine into which the inverters are built is in conformance with the
regulations of the Council Directive Machinery 98/37/EWG.
WARNING:The built-in Stop function (control input at terminal 23 or 20) must not be used as an
emergency stop circuit. To inhibit uncontrolled machine operation in case of the
malfunction of the drive, the user must provide an external emergency stop circuit,
which ensures disconnection of the power source from the motor.
This circuit must be hardwired with electro-mechanic components and shall not depend
on electronic logic or software.The stopping device (e.g. mushroom head pushbutton
with lock) must be accessible to the operator.
Failure to observe this precaution could result in bodily injury or loss of life.

1 - INTRODUCTION
1-2 GV3000/SE 49'1327 e
Electromagnetic Compatibility (EMC-Directive)
CAUTION The operating of inverters in the European market is only permitted if the Council
Directive Electromagnetic Compatibility 89/336/EWG has been observed.
It is the responsibility of the manufacturer of the machine or system to observe the
immunity and emission limits, requested by the Council Directive EMC in the European
market. Guidelines for the installation according EMC-regulations - as shielding,
grounding, filter arrangement as well as wiring instructions - are summarized in
Appendix A, ‘CE-Conformance’ of this Instruction manual.
Hot Surface
WARNING This sign on the faceplate of the inverter alerts a person that high temperature is
present.
Do not touch the heatsink surface during operation of the drive or short after
disconnecting.

2 - DESCRIPTION
49'1327 e GV3000/SE 2-1
DESCRIPTION
Mechanical Arrangement and Options
The variable-voltage, variable-frequency power
inverters of the GV3000/SE series are ready for
installation and are available in different sizes
with output currents in the range 2 to 360 Amps.
They are designed to drive induction motors at
variable speeds using PWM technology.
The protective enclosure contains the Power
Module and the Control Unit with the Keypad.
Figure 2-1 shows the block diagram of the
inverter with specified options.
8
7
1
2
3
5
6
RC
47
48
47
45
+
_
L1 L2 L3
UVW
4
Figure 2-1: Block Diagram
1 Line Filter
The built-in option RFI- or HF-Filter limits
high frequency emission to permitted
values. See Selection Tables 2-8,
Chapter 5 and Appendix A.
2 Braking Unit (built-in on types 003-030,
039/044, option on 038/043, 058 - 240),
switches during motor regeneration the
externally mounted (user supplied)
braking resistors to the DC-bus and
prevents by that bus overvoltage.
3 DC-Bus Terminals
(option on type 038/043 and >058) e.g.
for connection of external braking unit.
On types >AC180 additional DC-Bus
bus-bar connections (145,147) are
available.
4 Diode Bridge (on types 003-170).
or Six Pulse Rectifier Bridge
controlled by the pulse firing card FPS
(on types 180-360).
5 Power semiconductors
IGBT (insulated gate bi-polar transistors)
or IPM (Intelligent Power Modules).
These are switched on and off by the
gate drivers to provide phases U,V,W to
the motor.
6 Gate Driver and Power Supply Card
Interface between the power modules
IGBT and power interface card.
7 Digital Regulator
Contains the terminal strip for the control
inputs (24V), the isolated analog inputs,
the tach input, relay outputs and
1 analog output.
8 Further Options
(See Regul. manual 49‘1329, page 1-2)
- Operator Interface Module (OIM) for
remote control, programming and display.
- RMI Card (Remote Meter Interface Card)
•3 isolated analog outputs for displaying,
•1 isolated analog input,
•4 programmable digital outputs,
•4 digital inputs,
•1 frequency input,
•3 relay outputs,
•1 frequency output.
- Communication Cards for
InterBus, Profibus DP,
DeviceNet, ControlNet and AutoMax.

2 - DESCRIPTION
2-2 GV3000/SE 49'1327 e
Electrical Description
As shown in Figures 2-2, three phase input
power is applied to terminals L1, L2, and L3 via
external standard input fuses or fused isolator.
Power is then fed to the precharge circuitry
through the optional input filter circuit. This filter
keeps conducted emissions in the high
frequency range within the limits as per EMC
product standards. The current transformer T4
senses ground fault currents (on types 038/043
and 058 - 360).
The internal switching power supply develops
the isolated DC 24 V control voltage and
different supply voltages (DC ±5 to 24V) for the
controller operation.
An optional, user supplied AC-line input reactor
allows the Power Module to be operated on any
supply line also with high fault level (refer to
chapter 5, Accessories).
On types GV3000E-AC003 - 030 and 039/044
the inductance of the optional RFI filter allows
connection to supply transformers with a fault
level up to 29 kA (e.g. 1000 kVA) after which a
choke should be fitted.
When line voltage (or DC-bus voltage on type
DC240 and DC360) is applied at the input
terminals (external main contactor has picked
up), the DC-bus begins charging.
The DC-bus voltage increases to a value 1.4
times the no-load three-phase line voltage on
types AC003 - 170 resp. to the value of the
applied DC-voltage on type DC240 and DC360.
Precharge resistors limit the DC-bus capacitors'
charging current. When the DC-bus reaches
95% of its rated voltage, the parallel connected
precharge contactors close and bypass the
resistors.
On types AC180 - 360 the DC-bus is charged
through a six pulse rectifier bridge controlled by
the pulse firing card FPS.
Discharge resistors on the DC-bus capacitors
can discharge the capacitors down to 50 V
within approximately 60 sec. after power is
removed from the input terminals.
The inverter circuitry converts the DC-bus
voltage into a variable voltage, variable-
frequency at the output to the motor (terminals
U, V, W). The inverter's phase transistors
(IPM, IGBT) are switched by the Gate Driver
cards. Two current transformer devices (T1,T2)
provide current feedback to the regulator
through the Power Interface card. Power output
AC-chokes on types 038/043 and 058 - 360 or
current compound chokes on types 003-030 and
039/044 limit the magnitude of dv/dt in the
motor.
In summary, a constant DC voltage is deve-
loped by rectifying and filtering the incoming AC
power line voltage. A PWM three-phase voltage
is then produced from this constant voltage
using an IGBT inverter corresponding to the
variable voltage and frequency selected for the
motor.

2 - DESCRIPTION
49'1327 e GV3000/SE 2-3
PE
/1 Equipment according to spare parts list Chapter 4
Figure 2-2a: Typical System Block Diagram, Type GV3000/SE AC003 to 015

2 - DESCRIPTION
2-4 GV3000/SE 49'1327 e
PE
Figure 2-2b: Typical System Block Diagram, Type GV3000/SE AC024 and 030

2 - DESCRIPTION
49'1327 e GV3000/SE 2-5
PE
1
EMC-Filter
/1 On Units with RFI filter only
Figure 2-2c: Block diagram of the power units, GV3000/SE Type AC039 and 044

2 - DESCRIPTION
2-6 GV3000/SE 49'1327 e
1
2
321
4
F2
F1
C5C3 C4C2
1413
R1
R5
PIS
R6
F8
J
V10
V3V2V1
10
744594
X2
5
3
1514121
X6
8
12
M1
~ ~
18172019
INTERFACE
POWER
~
3
1
X4
2
1
X1
X6
5 3
1
REGULATOR CARD GVD
X7 X7
+24V
1615
X2 X1
10
9
X3
101 1
X2
21
X2X4X5
X1
876
5
4
3
IPA37
X1X2X3
X1
X4
V11
RFI
PE
1L3
1L2
1L1
T4
K2 K1
F10
BUA
K1
K2
45 4847
V6V5V4
X5X7X9 X6X8X10
W
V U
L3 L2
L1
X1
X1
T1
T2
5
SCN
5
C10 C11
6
F20
6
SCN
5
V20-23
/1 On Units 896’xx-10/ -11/ -80/ -81 only /3 On Units 896’xx-80/ -81 only /5 On GV3000 UL Units only
/2 On Units 896’xx-10/ -11/ -31 only /4 On Units with RFI filter only /6 Not used on GV3000 UL Units
Figure 2-2d: Block diagram of the power units, Type GV3000/SE AC038/ 043/ 058/ 070 and 085

2 - DESCRIPTION
49'1327 e GV3000/SE 2-7
1 2
31
F2
C3..C9 C2..C8
PIS
INTERFACE
POWER
R1 R8
K4
K1
R5
K3
SCM
SCM
K4 K3
V13
V12
F18
M1
14
13
R2
R6
R7
F8
V10
V3V2V1
10
SCM
SCM
74
4594
X2
53
15
1
4
1
2
1
X6
812
M2
~ ~
18
17
2019
F1
~
3 1
X4
2
1
X1
X6
5 3
1
REGULATOR CARD GVD
X7 X7
+24V
16
15
X2 X1
10
9
X3
101 1
X2
21
X2X4X5
X1
8
7
65
4
3
IPA75
X1X2X3
X1
X4
V11
K2 K1
BUA
K2
45 4847
V6V5V4
X5X7X9 X6X8X10
W
V U
L3 L2 L1
T1
T2
T4
4
RFI
PE
1L3
1L2
1L1
F20
2
C10.. C14
6
55
F11
F10
5
6
4
HF
V20-23
/1 On Units 896’xx-10/ -11/ -80/ -81/ -97 only /3 On Units 896’xx-80/ -81/ -97 only /5 On GV3000 UL Units only
/2 On Units 896’xx-10/ -11/ -31/ -37 only /4 On Units with RFI- or HF-filter only /6 Not used on GV3000 UL Units
Figure 2-2e: Block diagram of the power unit, Type GV3000/SE AC089/ 106/ 140 and 170

2 - DESCRIPTION
2-8 GV3000/SE 49'1327 e
2HF
MOV 1- 4
/1 On Units 896’xx-10/ -11/ -17 with Braking Unit only /2 On Units 896’xx-07/ -17 with HF-filter only
Figure 2-2f: Block diagram power unit, Type GV3000/SE AC180/ 210/ 240 (896.xy-00/01/07, -10/11/17)

2 - DESCRIPTION
49'1327 e GV3000/SE 2-9
1
HF
/1 On Units 896’xx-87 with HF-filter only
Figure 2-2g: Block diagram of the power unit, Type GV3000/SE AC180/ 210/ 240 (896.xy-80/ -81/ -87)

2 - DESCRIPTION
2-10 GV3000/SE 49'1327 e
CFI
CFI
T2
T1
L1 L2 L3
U V W
PE
V4
X2
X7
X7
REGULATOR CARD GVD M
X6
C2..C9
R3 R4 R1 R2
F10 F11 F12 F13
X32
C10..C17
V1
X31
GDA
812345678
91045 12345678
V2 V5
1234567812
F18F8
56 78
MMM
11 12 13 14 15 1920
X1
1
2 3 4
5
1 2 3 4 5 6 7
16 17
X4
4321
X2
X13X4X5
X5 X4 X12X5 X4 X11X2X2
X3 X8
F2 F1
POWER INTERFACE PIP
CDA
X1
1 2
1 2 3 44
3 2 1
2 11
2
1 2 3 4
V6
4 3 2 1
2 1
GDA
X31 X32
1 2
1 2 3 4
SNU
4 3 2 1
2 1
V3
813'28-00
C47
E
SNU
813'28-00
SNU
813'28-01
SNU
813'28-01
E
C
45
X2-20POL X3-5POL X4-10POL X5-8POL X6-12POL X8-15POL X11-8POL X12-8POL X13-8POL
1 2 3 6 7 8
K2
K1
T4
R6 R7 R8
K2
R11 R10 R9
K2 T4
12345678
K1
K1
K1
K2
K2
X31 X32
X31 X32
X32
X31
X32 X31
10 12
X2
451
90
78
X6
135 1234 8 9 10 11 12 13 14 15
X8
X1-4POL
145 147
Figure 2-2h: Block diagram of the power unit, GV3000/SE Type DC240