Rockwell Automation Reliance electric GV3000/SE User manual

Hardware Reference, Installation, and Troubleshooting Manual D2-3392-7 RELIANCE
ELECTRICSL/
GV3000/SE AC Drive
30 - 200 HP, 460V AC
Version 6.07
@ Allen-Bradley - Rockwell Software Automation

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-L.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.
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 ahazard, 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 beon 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).
>
>|
i>
>
IMPORTANT _Identifies information that is critical for successful application and understanding of the product.
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.

Document Update
Document Update
Electronic Motor Overload This product does not offer speed-sensitive overload protection, thermal memory
Pr ot e cti on 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.

Document Update
Notes:

Summary of Changes
The information below summarizes the changes made to this manual since
its last release (June 2001).
Description of Changes Page
Added Document Update. After manual
front cover
Deleted the following statement: ‘The Motor Overload Enable parameter (P.040) can 6-1
beused in place of the electronic thermal overload relays in single motor
applications’.

soc-ii Summary of Changes
Notes:

CONTENTS
Chapter 1 Introduction
1.1. Related Publications 0.0.0... cc cccccsecscseeseeeseeenssesecancneanseseenneeessersenseaeenres 1-1
1.2 Getting Assistance from Reliance Electric 2.0.0.0... esseessseseeeenenssesnerseet 1-1
1.3 Notes on Handling the GV3000/SE Drive... eee eseenenaneaennenees 1-2
Chapter 2 About the Drive
2.1 Identify the Drive by Model NUMDET .............cessceeeessesesennesnernenesatsenenees 2-1
2.2 ENcClOSUIES .........cccssccececeesceeeeeneneeerensceeseeesscaseupeednessacsaauaceussadsassnseasnenanannes 2-2
2.3. 30-200 HP GV3000/SE Drive Component Locations ...............ccccccceescon 2-3
2.4 Regulator Board DeSCription............cccseeecsessrsceseneseeseseesereeeeaeneesansantonss 2-8
2.4.1 Jumper Locations and Settings 0.0.0... cscs sesensensesnesseneesees 2-10
2.4.1.1 Analog Input Speed Reference Jumper (J4)............cssseee 2-10
2.4.1.2 Analog Output Jumper (S17) «20... ee eeeeeecetseesetnenneneenensees 2-11
2.4.2 Wiring the Terminal Strip... sce cssscecsesetesseseseenereecseseeens 2-12
2.4.3 RS-232 Communication Port ........... ce ec seesessnseeeseceserseenseseeees 2-13
2.4.4 Option Board GCOmmnector ........cccsccsessecssscsesseesseenssnesseneesereecesates 2-13
2.4.5 Operator Interface Module Connector..........ececssesceeesseeseeneeeees 2-13
2.4.6 KeypPad/DISDlAaY .....ccceccsssssssscscesessneeesnsesesscerersaecenseesensesenseeeeseness 2-14
2.5 Jumpers on Base Board (PISC-60 and PISC-75/75A) 00... eecsssssersseees 2-14
2.6 Optional EquipMent .0........ ee ccs sesssceesesseenssessrnssenessesseressesneseesseesaeaees 2-16
Chapter 3 Planning Before Installing
3.1. General Requirements for the Installation Site... cc eeeeesteeesesseeteees 3-1
3.1.1. Making Sure Environmental Conditions are Met ........ccssesseee 3-1
3.1.2 Determining Total Area Required Based on Drive ,
DIMENSIONS ............ccccescceeeecccssedesssseceesccesnaasencnesseasecsueseeseenensnereered 3-2
3.1.3 Verifying the Site Provides for Recommended Air Flow
CICAPANCES. .........ecececseceseecetsrernenerereeeereseaanareeeneaneanenteeeseesenaaesersenens 3-5
3.1.4 Verifying Power Module AC input Ratings Match
Supplied POWeN........... cc ccssessssssasscssssceseussessecesavsasnenaseesseesoeenteneeees 3-6
3.2 Wiring Requirements for the Drive ou... ecseccescceeseneneeeesseeseesuscnaseanennens 3-6
3.2.1 Meeting Terminal Strip Input and Output Specifications ........... 3-6
3.2.2 Determining Wire Size Requirement ......... eee eeseeeseeneeeeneeees 3-6
3.2.2.1 Recommended Power Wire SiZe@S ...........seseesessseresseetaes 3-6
3.2.2.2 Recommended Control and Signal Wire Sizes .........0.... 3-7
3.2.2.3 Recommended Motor Lead Lengths .......... eee ee sceeeeccees 3-8
3.2.2.4 Recommended Serial Communication Cable Lengths ..... 3-9
3.2.3 Selecting AC Input Line Branch Circuit Fuses, Circuit
Breakers, and AC R@ACtOrs 20... ......ccccceeecesssesetnceceestneseeneneneneceaeee 3-10
3.2.4 Meeting Encoder Specifications (FVC Regulation Only) ........... 3-11
3.2.4.1 Encoder Wiring Guidelines 2.0.0... eee ceeeensseaneeenssensens 3-11
3.2.5 Verifying Power Module Output Current Rating is Greater
© Than Motor Full Load AMPS... csccssssssssssseseesesseeseesseessensasenees 3-11
Table of Contents |

Chapier 4
Mounting the Drive, Grounding, and Finding Wire Routing Locations
4.1. Mounting theDrive 0... eee eee seseeesecceeseaseeeessensenesesseesasnneesssaeaaseeneaes 4-1
4.1.1 Verifying the Drive's Watts Loss Rating .......0. 0 eeesereeeeeees 4-1
4.2 Routing Input, Motor Output, Ground, and Control Wiring
FOF thE Di iVe oe. ecsecesesssssesenceceeescesceseeesuenneenenseessseseeeeseaeenseenereeseeeeaeene 4-1
4.2.1 Replacing Conduit PIUQS ............. eee eseeeceeseeeeeeeseeseeenenoeneneeeneeens 4-2
4.3 Grounding the Drive 2... ecscsssessscecsseceseesnesnesceersesseensaceenseseseesatssecenves 4-2
Chapter 5 Installing Input Power Wiring
5.1Installing Transformers and Reactors (Optional) ....ccsssscsssesesenseeseereees 5-1
5.2 Installing Fuses for Branch Circuit Protection 00.0.0... ssesscssrceccenereseees 5-2
5.3 Installing a Required External/Separate Input Disconnect..............:cc0 5-2
5.4 Installing Power Wiring from the AC Input Line to the Drive's
POWer TOrmimallS ............sscsescssseessersersnssresnesssraccassensesseaseneusssecsassenseseseeasnens 5-5
5.5 Installing Power Wiring from an External DC Bus to the
Drive's Internal DC Bus Terminals ...........c:cccscesensssescessetsesecesseesnneseanersees 5-5
Chapter 6 Installing Output Power Wiring
6.1 Installing Output Contactors (Optional) ....0.... ec seseesseseeseeneeneeneesneeseee 6-1
6.2 Installing Mechanical Motor Overload Protection (Optional) .............0.0 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
7.1 Stopping the Drive... eceeccesescesseeceescensceeeeeeneesseneesanenansaneeeeeeeesanenatens 7-6
7.2 Wiring the Encoder Feedback Device (FVC Regulation Only) .....-- eee 7-7
7.3 Wiring the Signal and Control 1/0 ou... se seessnsssssrssesseenseseateasesseonneases 7-9
Chapter 8 Completing the Installation
8.1 Checking the Installation ........ cc cssesesseesssscrensacsenentearersstsesresenneessrsneees 8-1
8.2 Powering Up After Installation is Complete ............::ccssccessersessseessceenesees 8-2
Chapter 9 Troubleshooting the Drive ;
9.1 Test Equipment Needed to Troubleshoot ..0....... cece eens eeereneeeeneeeee 9-1
9.2 Drive Alarms and Faults ..........e eee eeseesececeseeceeseeeeesnesuaseeeeeseeseuenneeeseeenaes 9-1
9.3 Verifying That DC Bus Capacitors are Discharged ..........cssssseseeesees 9-1
9.4 Checking Out the Power Module withInput Power Off ......esseseseersescess 9-3
9.5 Replacement Parts ............esseccescccecsseeesssseseanerssenesssereneceesonneesseesanesenanees 9-5
Appendix A Technical Specifications ...............cssssssrssnseseseseessenesssensseecaesnesessnsseenensesesesees A-1
Appendix B 30-200 HP GV3000/SE System Wiring Diagram .........ssscsccsssessensessressessenanens B-1
Appendix C Compliance with Electromagnetic Compatibility Standards ..........ssssssereen C-1
GV3000/SE 460 VAC 30-200 HP Drive, Hardware Reference Version 6.07

List of Figures
Figure 2.1 — Identifying the Drive Model NUMDET .............c.:ccceseseeetsseeteseeseenees 2-1
Figure 2.2 — 30 and 40 HP Drive Component Locations ...........cccscseseeseeeees 2-3
Figure 2.3 — 50 and 60 HP Drive Component Locations .............ccsssseseneesens 2-4
Figure 2.4 — 75 and 100 HP Drive Component Locations ...........cccsseceeesseees 2-5
Figure 2.5 — 125 HP Drive Component Locations ........csceesesenestreseeensereess 2-6
Figure 2.6 — 150 and200 HP Drive Component Locations ........scessssseserees 2-7
Figure 2.7 — Regulator Board Component Locations ............cccseesseesneeeneeees 2-9
Figure 2.8 — Jumper J4 Settings for Analog Input Speed Reference............... 2-11
Figure 2.9 — Jumper J17 Settings for Analog Outputs ......... ce seeseeeeseeteeeeres 2-12
Figure 2.10 — Typical Terminal Strip COMMGCtIONS........cesssstereteneneneeeneees 2-13
Figure 2.11 — Keypad/Display .............cccsesssessseseseeessssenseneenssesesneneeannsensensaenes 2-14
Figure 2.12 — Base Board Jumper Locations ...........ccscsesereeneeenssetsesenersenes 2-15
Figure 3.1 — Dimensions of 30 HP and 40 HP Drives .........::cssssssseseseersees 3-3
Figure 3.2 — Dimensions of 50 HP to 200 HP Drives ...........ccseessereresereseeeeees 3-4
Figure 3.3 — Recommended Air Flow Clearances .......ccesscsesescneersnn neers 3-5
Figure 3.4 — How to Calculate Motor Lead Lengths ........cseecessssssntesssertnerners 3-8
Figure 4.1 — Terminal Locations of 30 HP and 40 HP Drives..........cssseseereers 4-3
Figure 4.2 — Terminal Locations of 50 HP to 200 HP Drives............ccssseesees 4-4
Figure 5.1 — Typical AC Input Electrical Connections ............scscssecseresreeeees 5-3
Figure 5.2 — Typical DC Bus Electrical Comme ction ........ccsssessssessneseeseeseeees 5-4
Figure 7.1 — Two-Wire Start/Stop Sample Control Wiring ........--.::::ceeeeeeeteeees 7-4
Figure 7.2 — Three-Wire Start/Stop Sample Control Wiring ............cseereees 7-5
Figure 7.3 — Encoder Wiring Connections ............scececesseeceeensenseesneesenseeesenaas 7-8
Figure 9.1 - DC Bus Voltage Terminals of 30 HP and 40 HP Drives .............. 9-2
Figure 9.1 — DC Bus Voltage Terminals of 50 HP to 200 HP Drives ............... 9-2
Figure B.1 — 30-40 HP GV3000/SE System Wiring Diagram... B-1
Figure B.2 — 50-60 HP GV3000/SE System Wiring Diagram .......scseseeeees B-2
Figure B.3 — 75-200 HP GV3000/SE System Wiring Diagram ..............se B-3
Table of Contents

Figure C.1 — Outline Dimensions of AC Mains Filters of Schaffner
for Model 30V4060 to 125V4060 Drives .0...... eee eeeeeees C-3
Figure C.2 — Outline Dimensions of Model FN359H250/99 AC Mains Filters
of Schaffner for Model 150V4060 and 200V4060 Drives.............. C-4
Figure C.3 ~ Outline Dimensions of AC Mains Filters of Soshin Electric
for Model 30V4060 and 100V4060 Drives .......2.... cee eeeseeeeereeeee C-5
Figure C.4 — Outline Dimensions of AC Mains Filters of Soshin Electric
for Model 125V4060 to 200V4060 Drives .......... es eeseeseceeesereesee C-6
Figure C.5 — Outline Dimensions of Common Mode Output Cores
of Hitachi Ferrite Electronics and Hitachi Metals for
Output Power Cable of Model 30V4060 to 200V4060 Drives...... C-7
Figure C.6 — Outline Dimensions of Common Mode Output Cores of
Soshin Electric for Output Power Cable of
Model 30V4060 to 200V4060 Dives .........:-..ecceescesseeserereeeeeneeeees C-8
Figure C.7 — Cabinet Mounted GV3000/SE Wiring Example............sseserees C-9
Figure C.8 — Typical Three-Phase Connections for AC Mains Filter ................ C-10
Figure C.9 — 1/0 Signals Cable... cccsseeeseeserceeeeensenenteenannsneeesesensenstenees C-11
GV3000/SE 460 VAC 30-200 HP Drive, Hardware Reference Version 6.07