Rockwell Automation Reliance Electric GV3000 User manual

GV3000 115 VAC
Control Option Board
Installation Instructions
M/N 2LB3000
Instruction Manual D2-3376
6% Rockwell Automation
Reliance Electric

The information in this manual is subject to change without notice.
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.
CAUTION: 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.
GV3000® and Reliance® are registered trademarks of Reliance Electric Company or its subsidiaries.
©Copyright Reliance Electric Industrial Company 1996.

Table of Contents
Preface «20.0.0 c cee ee ee eee il
1.0 Installing the 115 VAC Control Option Board in 1-5 HP and 7.5-10 HP Drives ............. 1-1
2.0 ‘Installing the 115 VAC Control Option Board in 15-25 HP Drives.....0cccceceeeseuenenes 2-1
3.0 Installing the 115 VAC Control Option Board in 25-60 HP Drives.....00ccceceeeseueeenes 3-1
4.0 Installing the 115 VAC Control Option Board in 60-100 HP and 100-150 HP Drives ........ 4-1
5.0 Installing the 115 VAC Control Option Board in 200-400 HP Drives ..................++.. 5-1

Appendices
Appendix A
115 VAC Control Option Board Layout and Connections ............. 0.0 cece eee ee A-1
Appendix B
115 VAC Control Option Board Input and Output Wiring ...... 0... eee eee eee B-1

List of Figures
Figure A.1 - 115 VAC Control Option Board .............. 0.00 A-1
Figure A.2- 115 VAC Control Option Board Input and Output Connections ......................0.. A-2
List of Tables
Table 1 - 115 VAC Control Option Board Kit Contents ..........0. 000... cee IV
Table B.1 - AC Source Input 2.20.0... eee tne ete etnies B-1
Table B.2 - Control Option Board Wiring to GV3000 Regulator Board ........... ccc cee ees B-1

PREFACE
The preducts described in this instruction manual are manufactured or distributed by Reliance Electric
Industrial Company.
The 115 VAC Control Option board provides an interface between any of a number of external motor control
devices operating at 115 volts AC and a GV3000 AC drive. The Control Option board accepts input from
these devices and passes the signals to the drive’s Regulator board.
This manual is divided into five chapters and two appendices. Each chapter provides complete instructions
for installing a 115 VAC Control Option Board (M/N 2LB3000) on a specific range of GV3000® drives. The
appendices provide supporting board and input/output connection illustrations and information.
The chapters are organized as follows:
1.0 INSTALLING THE 115 VAC CONTROL OPTION BOARD IN 1-5 HP AND 7.5-10 HP DRIVES - The
instructions in this chapter pertain to GV3000 AC drives in the 1 to 5 horsepower and 7.5 to 10 horsepower
ranges only.
2.0 INSTALLING THE 115 VAC CONTROL OPTION BOARD IN 15-25 HP DRIVES - The instructions in this
chapter pertain to GV3000 AC drives in the 15 to 25 horsepower range only.
3.0 INSTALLING THE 115 VAC CONTROL OPTION BOARD IN 25-60 HP DRIVES - The instructions in this
chapter pertain to GV3000 AC drives in the 25 to 60 horsepower range only.
4.0 INSTALLING THE 115 VAC CONTROL OPTION BOARD IN 60-100 HP AND 100-150 HP DRIVES - The
instructions in this chapter pertain to GV3000 AC drives in the 60 to 100 horsepower and 100 to 150
horsepower ranges only.
5.0 INSTALLING THE 115 VAC CONTROL OPTION BOARD IN 200-400 HP DRIVES - The instructions in
this chapter pertain to GV3000 AC drives in the 200 to 400 horsepower range only.
Appendix A 115 VAC CONTROL OPTION BOARD LAYOUT AND CONNECTIONS - This appendix provides
illustrations of the Control Option board’s layout and of the input and output connections on theboard.
Appendix B 115 VAC CONTROL OPTION BOARD INPUT AND OUTPUT WIRING - The tables in this
appendix cetail the correct connections for AC input to the control option board and the control device input
and output connections on the Control Option board and the drive's Regulator board.
This manual is intended for qualified electrical personnel who are responsible for installing the GV3000 drive.
You will need to refer to instruction manual D2-3360 (GV3000 AC Power Modules Hardware Reference
Installation, and Troubleshooting) as you perform the installation procedure.
The installation procecure consists of installing the 115 VAC Control Option Board, wiring user control
devices to the board, and wiring the board to the existing control inputs on the GV3000 drive’s Regulator
board terminal strip.
The Control Option board’s component layout is shown in figure A-1 in Appendix A. Figure A-2 shows the
board's input and output connections.
No software configuration or parameter changes are necessary when installing a Control Option board. To
install theControl Option board in a GV3000 drive, go to the chapter that covers your specific drive and
perform the steps in the order in which they are presented in the chapter.
Table 1 - 115 VAC Control Option Board Kit Contents
Item No. Description Qty Part Number
1 115 VAC Control Option Board 1 3402R1B
2 M3 X 6 Self-Tapping Screw 4 419062-100PEE
3 M3 Flat Washer 4 419064-1SE
4 M3 Nuts 4 419063-1SE
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-RELIANCE.

1.0 INSTALLING THE 115 VAC CONTROL OPTION
BOARD 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 AND OTHER
APPLICABLE MANUALS IN THEIR 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 AC POWER. DISCONNECT,
LOCK OUT, AND TAG ALL INCOMING POWER TO THE DRIVE BEFORE PERFORMING THE
FOLLOWING PROCEDURE. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE
BODILY INJURY OR LOSS OF LIFE.
DC BUS CAPACITORS RETAIN HAZARDOUS VOLTAGES AFTER INPUT POWER HAS BEEN
DISCONNECTED. AFTER DISCONNECTING INPUT POWER, WAIT FIVE (5) MINUTES FORTHE 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.
CAUTION: Do not route signal wiring with power wiring in the same conduit. This may cause interference
with drive operation. Route signal and power wiring in separate conduit. Failure to observe this precaution
could result in damage to, or destruction of, the equipment.
Use the following procedure to install a 115 VAC Control Option board(M/N 2LB3000} in 1 to 5 HP
and 7.5 to 10 HP GV3000 drives. Refer to the instruction manual for your GV3000 drive as you
perform this procedure.
NOTE: Read and understand the warning labels on the drive before proceeding.
Remove the Keypad Support Bracket from the Drive
Step 1. Disconnect, lock out, and tag power to the drive.
Step 2. Wait five (5) minutes for the DC 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 AC input power terminals
(R/L1, S/L2, T/L3).
Step 5. Check the DC bus potential (+, — terminals) with a voltmeter as described in the instruction
manual for your drive to ensure that the DC bus capacitorsare discharged.
1-1

1-2
installing the 115 VAC Control Option Board in 1-5 HP and 7.5-10 HP Drives (continued)
WARNING
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. ERRATIC MACHINE OPERATION AND DAMAGE TO, OR DESTRUCTION
OF, EQUIPMENT MAY RESULT IF THIS PROCEDURE IS NOT FOLLOWED. FAILURE TO OBSERVE
THIS PRECAUTION MAY RESULT IN BODILY INJURY.
Step 6.
Step 7.
Note the cable lead connections to the Regulator board terminal strip. Record these
connections now. Then disconnect these cable leacs from the Regulator board terminal
strip.
Remove the three (3) M4 x 10 screws that fasten the bottom of the support bracket to the
drive’s heat sink.
NOTE: The bracket is connected to the drive by wiring. Do not attempt to lift the bracket out
completely as this may Gamage or pull out the wiring.
Step 8.
Step 9.
Step 10.
Step 11.
Step 12.
Step 13.
Locate theControl Option board support tabs on the support bracket. They are below and
behind the Regulator board. The Control Option board is attached to these tabs using the
four screws and nuts provided.
Place a washer on each of the screws provided with the kit.
Hold the 115 VAC Control Option boardso the row of connectors is at the same end and
faces the same direction as the row of connectors on the Regulator board.
Working from below the support tabs, line up the holes in theControl Option Board with the
holes in the support tabs.
Insert one screw from below through the hole in theControl Option board and thehole in
the support tab, and then thread a nut on the end of the screw. Repeat this procedure for
the remaining three screws.
Hand tighten the screws and nuts holding theControl Option board in place until they are
snug.
Reinstall the Support Bracket
Step
14. Align the support bracket with the mounting holes in the drive heat sink. Fasten the bracket
with the three (3) M4 x10 screws removed in step 7.
Wire the Control Option and Regulator Boards
Step 15.
Step 16.
Step 17.
Wireyour 115 VAC supply to the correct TB1 terminals on the Control Option board. Refer
to table B.1 and to figure A.1. Route the wire through the left-hand wire-routing hole at the
bottom of the drive.
Wireyour 115 VAC control devices to theControl Option board’s TB1 terminals and then
wire the Control Option board’s TB2 terminals to the corresponding terminals on the drive’s
Regulator board. Refer to table B.2, and figures A.1 and A.2 in this instruction manual, and
to the instruction manual for your drive. Route the wire through the left-hand wire-routing
hole at the bottom of the drive.
Reconnect all cable leads to the appropriate terminals on the Regulator board. Refer to the
terminal connections documented in step 6 or to the appropriate instruction manual for the
speed feedback device being used. Route the wire through the left-hand wire-routing hole
at the bottom of the drive.

installing the 115 VAC Control Option Board in 1-5 HP and 7.5-10 HP Drives (continued)
Reinstall the Cover and Apply Power
Step 18. Reinstall the cover. Align all cover screws into the heat sink before tightening any of them.
(For NEMA 4X/12 covers, refer to the appropriate section in your drive’s installation
manual.)
Step 19. Remove thelockout and tag. Apply power to the drive. SELF will be displayed while the
drive performs power-up diagnostics.
Hardware installation of the 115 VAC Control Option board is complete.
1-3

2.0 INSTALLING THE 115 VAC CONTROL OPTION
BOARD IN 15-25 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 AND OTHER
APPLICABLE MANUALS IN THEIR 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 AC POWER. DISCONNECT,
LOCK OUT, AND TAG ALL INCOMING POWER TO THE DRIVE BEFORE PERFORMING THE
FOLLOWING PROCEDURE. FAILURE TO OBSERVE THIS PRECAUTION COULD RESULT IN SEVERE
BODILY INJURY OR LOSS OF LIFE.
DC BUS CAPACITORS RETAIN HAZARDOUS VOLTAGES AFTER INPUT POWER HAS BEEN
DISCONNECTED. AFTER DISCONNECTING INPUT POWER, WAIT FIVE (5) MINUTES FORTHE 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.
CAUTION: Do not route signal wiring with power wiring in the same conduit. This may cause interference
with drive operation. Route signal and power wiring in separate conduit. Failure to observe this precaution
could result in damage to, or destruction of, the equipment.
Use the following procedure to install a 115 VAC Control Option board(M/N 2LB3000) in 15 to 25 HP
GV3000 drives. Refer to the instruction manual for your drive as you perform this procedure.
NOTE: Read and understand the warning labels on the drive before proceeding.
Remove the Keypad Support Bracket from the Drive
Step 1. Disconnect, lock out, and tag power to the drive.
Step 2. Wait five (5) minutes for the DC 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 AC input power terminals
(R/L1, S/L2, T/L3).
Step 5. Check the DC bus potential (+, — terminals) with a voltmeter as described in your drive’s
instruction manual to ensure that the DC bus capacitorsare discharged.
2-1