Rockwell Automation GV3000/SE 230 Installation and operation manual

Instruction Manual D2-3416-1
GV3000/SE 230 VAC 30-100 HP
General Purpose (Volts/Hertz)
and Vector Duty Drive
Software Start-Up and Reference Manual
Version 6.04

The information in this manual is subject to change without notice.
Throughout this manual, the following notes are used to alert you to safety considerations:
ATTENTION: Identifies information about practices or circumstances that can lead to personal
injury or death, property damage, or economic loss.
Important: Identifies information that is critical for successful application and understanding of the product.
ATTENTION: 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 manual and other applicable manuals in their entirety before
proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.
ATTENTION: DC bus capacitors retain hazardous voltages after input power has been
disconnected. After disconnecting input power, wait five (5) minutes for the DC bus capacitors
to discharge and then check the voltage with a voltmeter to ensure the DC bus capacitors are
discharged before touching any internal components. Failure to observe this precaution could
result in severe bodily injury or loss of life.
ATTENTION: The drive can operate at and maintain 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.
ATTENTION: Do not install modification kits with power applied to the drive. Disconnect and
lock out incoming power before attempting such installation or removal. Failure to observe this
precaution could result in severe bodily injury or loss of life.
ATTENTION: The user must provide an external, hardwired emergency stop circuit outside of
the drive circuitry. This circuit must disable the system in case of improper operation.
Uncontrolled machine operation may result if this procedure is not followed. Failure to observe
this precaution could result in bodily injury.
ATTENTION: The user is responsible for conforming with all applicable local, national, and
international codes. Failure to observe this precaution could result in damage to, or destruction
of, the equipment.
DeviceNet is a trademark of the Open DeviceNet Vendor Association.
ControlNet is a trademark of ControlNet International, Ltd.
PROFIBUS is a trademark of PROFIBUS International.
GV3000/SE, AutoMax, ControlNet, and Reliance are trademarks of Rockwell International.
© 1999 Rockwell International Corporation.
!
!

I
Table of Contents
CONTENTS
Preface .............................................................................................................................. VII
Chapter 1 Starting Up the Drive for Volts/Hertz Regulation
1.1 Preparing for Start Up (Volts/Hertz)......................................................... 1-2
1.2 Start-Up Procedure (Volts/Hertz)............................................................. 1-3
Chapter 2 Starting Up the Drive for Vector Regulation
2.1 Preparing for Start Up (Vector)................................................................ 2-2
2.2 Start-Up Procedure (Vector).................................................................... 2-3
Chapter 3 Using the Keypad/Display to Program, Monitor, and Control the Drive
3.1 Monitor Mode ........................................................................................... 3-2
3.1.1 Displaying the Selected Reference .............................................. 3-2
3.1.2 Entering the Manual Speed Reference ........................................ 3-3
3.2 Program Mode ......................................................................................... 3-3
3.3 Drive Control ............................................................................................ 3-4
3.4 The Display .............................................................................................. 3-4
3.4.1 Display Range .............................................................................. 3-4
3.4.2 Scaling the Manual Reference, Speed Display, and
Reference Display Using P.028 ................................................... 3-5
3.5 The Keypad.............................................................................................. 3-6
3.6 Drive Status LEDs ................................................................................... 3-8
Chapter 4 Programming Reference
4.1 Parameter Menus .................................................................................... 4-1
4.2 Parameter Types ..................................................................................... 4-2
4.3 Displaying or Changing Parameter Values ............................................. 4-3
4.4 Ensuring Program Security...................................................................... 4-5
4.5 First Menu Parameters ............................................................................ 4-6
4.5.1 First Menu General Parameter Descriptions (P.000 to P.006) .... 4-6
4.6 Second Menu Parameters ....................................................................... 4-11
4.6.1 Entering the Second Menu Password .......................................... 4-11
4.6.2 Second Menu General Parameter Descriptions (P.007
to P.099) ..................................................................................... 4-14
4.6.3 Second Menu V/Hz Parameter Descriptions (H.000 to
H.022) ..................................................................................... 4-57
4.6.4 Second Menu Vector Parameter Descriptions (U.000 to
U.048) ..................................................................................... 4-70
Chaoter 5 Troubleshooting the Drive Using Error Codes
5.1 Identifying Alarm Codes and Recovering ................................................ 5-2
5.2 Identifying Fault Codes and Recovering ................................................. 5-3
5.3 Accessing, Reading, and Clearing the Faults in the Error Log ............... 5-6
5.4 Identifying Fatal Fault Codes and Recovering ........................................ 5-9

II
GV3000/SE 230 VAC Drive, Software Reference Version 6.04
Appendix A Alphabetical Listing of Parameters................................................................... A-1
Appendix B Record of User Parameter Settings .................................................................. B-1
Appendix C Power Module-Dependent Parameter Default Values
(230 V Series)....................................................................................................... C-1
Appendix D European and Japanese Default Parameter Settings ..................................... D-1
Appendix E Configuring the Digital Inputs When the RMI Board is
Installed in the Drive........................................................................................... E-1
Appendix F Using the Terminal Strip Analog Input ............................................................. F-1
Appendix G Drive Regulation Overview ................................................................................ G-1

III
Table of Contents
List of Figures
Figure 3.1 – Keypad/Display ........................................................................... 3-1
Figure 3.2 – Example of a Monitor Mode Display ........................................... 3-2
Figure 3.3 – Example of a Program Mode Display ......................................... 3-4
Figure 4.1 – Parameter Menu Structure.......................................................... 4-2
Figure 4.2 – Analog Output Selection and Setting.......................................... 4-21
Figure 4.3 – Trim Reference Source Selection............................................... 4-22
Figure 4.4 – Draw and Trim Gain .................................................................... 4-23
Figure 4.5 – S-Curves ..................................................................................... 4-25
Figure 4.6 – Typical Preset Operation ............................................................ 4-34
Figure 4.7 – Drive Start, Stop, and Running Status when Configured for
Edge Control vs. Level Control ................................................... 4-44
Figure 4.8 – Sample Alarm Circuit for 30-100 HP Drives Using the Level
Sense Enable Feature ................................................................ 4-45
Figure 4.9 – Signal Selection for Network Output Registers .......................... 4-54
Figure 4.10 – Volts/Hertz Ratio ......................................................................... 4-57
Figure 4.11 – Torque Boost Voltage ................................................................. 4-59
Figure 4.12 – Avoidance Frequency Band........................................................ 4-63
Figure 4.13 – Volts/Hertz Curve Selection ........................................................ 4-67
Figure 4.14 – Motor Equivalent Circuit Diagram for Calculating Rotor Time
Constant...................................................................................... 4-82
Figure 4.15 – Outer Control Loop Proportional Trim......................................... 4-92
Figure F.1 – Terminal Strip Analog Input ........................................................ F-1
Figure F.2 – Analog Input Conversion Scaling (Speed and Trim Reference). F-3
Figure G.1 – Volts/Hertz Regulator Block Diagram ......................................... G-3
Figure G.2 – Flux Vector Control Block Diagram ............................................ G-4
Figure G.3 – Sensorless Vector Control Block Diagram.................................. G-4
Figure G.4 – Vector Regulator: Reference Detail ............................................ G-5
Figure G.5 – Vector Regulator: Speed Loop Detail ......................................... G-6
Figure G.6 – Vector Speed PI and Iq Reference Limit Selection .................... G-7
Figure G.7 – Outer Control Loop Block Diagram ............................................. G-8

V
Table of Contents
List of Tables
Table 3.1 – Display Range Examples ............................................................ 3-5
Table 3.2 – Drive Status LEDs....................................................................... 3-8
Table 3.3 – Monitor Mode LEDs .................................................................... 3-9
Table 4.1 – Speed Reference Source Based on P.000 and AUTO/MAN
Key Status................................................................................... 4-7
Table 4.2 – Function Selection for Digital Inputs 6, 7, and 8 ......................... 4-14
Table 4.3 – Acceptable P.007 and P.008 Selection Combinations ............... 4-18
Table 4.4 – Preset Speed Digital Inputs ........................................................ 4-33
Table 4.5 – Faults That Can Be Auto Reset .................................................. 4-37
Table 4.6 – AUTO/MAN Key Status Based on P.000 and P.052 .................. 4-41
Table 4.7 – STOP/RESET Key Status Based on P.000 and P.055 .............. 4-46
Table 5.1 – List of Alarm Codes..................................................................... 5-2
Table 5.2 – List of Fault Codes ...................................................................... 5-3
Table 5.3 – Fatal Fault Codes That Can Be Reset........................................ 5-9
Table F.1 – Analog Input Conversion Scaling for Speed or Trim Reference. F-2
Table F.2 – Analog Input Conversion Scaling for Torque Reference ............ F-4

VII
Preface
This manual is a start-up and programming reference guide for the version 6.04
GV3000/SE (Sensorless Enhanced) drive. The drive can be set up for either volts
per hertz (V/Hz) or vector regulation. This manual provides a start-up procedure for
both.
The start-up procedures are followed by reference information. This information
includes a complete list of all parameters and a description of the keypad/display.
• You will need to know to use the keypad to perform the start-up procedures
described in chapters 1 and 2. If you do not, refer to chapter 3 first.
• For drives that will be set up for V/Hz regulation, go to chapter 1 for the start-up
procedure.
• For drives that will be set up for vector regulation, go to chapter 2 for the start-up
procedure.
• For a description of all the parameters, go to chapter 4.
• For troubleshooting guidelines, go to chapter 5.
• For a description of the drive hardware, refer to the GV3000/SE 230 VAC Drive
Hardware Reference, Installation, and Troubleshooting instruction manual
(D2-3417-1).
New Features in Version 6.04
The GV3000/SE version 6.04 software includes support for the following features:
• Optional outer control loop without requiring an option board (vector control
only). See U.040 through U.048.
• Enhanced analog input configuration. See P.011 (Analog Input Configure).
• Enhanced output relay configuration. See P.013 (Output Relay Configuration).
Getting Assistance from Reliance Electric
If you have any questions or problems with the products described in this instruction
manual, contact your local Reliance sales office. For technical assistance, call
1-800-726-8112.
PREFACE

1-1
Starting Up the Drive for Volts/Hertz Regulation
CHAPTER 1
Starting Up the Drive
for Volts/Hertz Regulation
This chapter describes the basic start-up procedure for drives which utilize open-loop
V/Hz regulation. V/Hz regulation is the default method of regulation. You do not
need to select it.
If you are starting up a drive which will perform vector regulation, refer to the vector
start-up procedure in chapter 2.0 instead. Do not perform the start-up procedure in
this chapter.
The start-up procedure below provides step-by-step instructions for:
• powering up
• checking monitor mode displays
• accessing program mode
• configuring General parameters (designated with a "P")
• configuring specific V/Hz parameters (designated with an "H")
• checking motor rotation direction
• running the drive
This start-up procedure describes how to program the minimum set of parameters
that usually need to be programmed for applications using V/Hz regulation. Once
you program these parameters, their values are retained even if power is lost. You
only need to re-program them if you want to change how the drive operates.
Your application may require programming other parameters in addition to the ones
described in this start-up procedure. Refer to chapter 4 for a description of all the
parameters to verify whether you need to program any additional parameters as
well. Appendix A provides a list of parameters listed alphabetically.
Throughout this manual, you will see references to parameter names and the
numbers that identify them for the drive. This manual uses the same format that will
be shown on the keypad/display to refer to parameters:
P.nnn
U.nnn
H.nnn
r.nnn
where: nnn is a number
P designates General parameters
U designates Vector parameters
H designates Volts/Hertz parameters
r designates optional RMI parameters

1-2
GV3000/SE 230 VAC Drive, Software Reference Version 6.04
1.1 Preparing for Start Up (Volts/Hertz)
Read through the following sections to prepare for the start-up procedure.
What You Need To Know:
• You must be qualified to perform the procedure and be familiar with V/Hz
regulation.
• You should be familiar with the keypad/display. If you are not familiar with the
keypad/display, refer to chapter 3, which describes it.
What You Need To Do:
• Complete all hardware installation as described in the hardware reference
manual. This includes connecting input power, input transformers (if required),
disconnects, fuses, and the terminal strip on the drive.
• Record the following motor data from each motor nameplate for use during the
procedure. Space is provided for recording information from three motors:
Motor rated amps:
Motor rated volts:
Motor base frequency:
Motor rated amps:
Motor rated volts:
Motor base frequency:
Motor rated amps:
Motor rated volts:
Motor base frequency:
• Connect the drive to the motor.
• Check that you have not been prevented from programming the drive. If the
PASSWORD LED on the keypad is on, programming has been prevented in
parameter P.051, Programming Disable. Refer to section 4.4 in this manual for
the procedure to enable programming.
If You Have a Problem:
To Exit:
During most of the start-up procedure, you will be in program mode, which is used
to program parameters. If you want to stop programming parameters, you can exit
program mode. You can do this by pressing the PROGRAM key until the
PROGRAM LED turns off. This will place the keypad/display in monitor mode, the
default. You can read more about these modes in chapter 3.

1-3
Starting Up the Drive for Volts/Hertz Regulation
To Restore a Default Parameter Value after Writing over It:
If you enter the wrong value while programming parameters, you can restore the
default if you have not yet pressed the ENTER key. To do so:
1. Press the PROGRAM key.
2. Press the ENTER key. The default value of the parameter will be displayed
again. You can select it with ENTER or enter a new one and press ENTER.
To Restore All the Default Values to General (P) Parameters:
If you need to restore all the default values for General (P) parameters after
programming them, you can do so using the Restore Defaults parameter (P.050).
1.2 Start-Up Procedure (Volts/Hertz)
This section describes the start-up procedure for drives set up for V/Hz regulation.
Before using this procedure, you should have read section 1.1 for information you
need to know before working with the drive.
Step 1. Power Up the Drive
This step verifies that the drive powers up and passes the power-up diagnostics.
After the drive passes the diagnostics, the keypad/display automatically enters
monitor mode, with speed displayed.
Turn power on.
AUTO
MAN Forward Reverse
PROGRAM
RUN
JOG
STOP
RESET
START
ENTER
SPEED
VOLTS
AMPS
Hz
Kw
TORQUE
Password
RUNNING
REMOTE
JOG
AUTO
FORWARD
REVERSE
PROGRAM
The initial display shows SELF, with all
monitor mode and status LEDs on, indicating
the drive is performing power-up
diagnostics.
After diagnostics are complete (5-6
seconds), the SPEED LED is on and the
keypad/display is in monitor mode. The
displayed value is zero. You can move
through the five items accessible in monitor
mode - Speed, Volts, Amps, Hz, and Kw - by
pressing the ENTER key.
AUTO
MAN Forward Reverse
PROGRAM
RUN
JOG
STOP
RESET
START
ENTER
SPEED
VOLTS
AMPS
Hz
Kw
TORQUE
Password
RUNNING
REMOTE
JOG
AUTO
FORWARD
REVERSE
PROGRAM