Hardware Reference, Installation, and Troubleshooting Manual D2-3427-3 GV3000/SE AC Bookshelf Drive Version 6.
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-1.1 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.
Document Update Document Update Electronic Motor Overload Protection This product does not offer speed-sensitive overload protection, thermal memory 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: 2
Summary of Changes The information below summarizes the changes made to this manual since its last release (December 2000). Description of Changes Page Added Document Update. After manual front cover Deleted the following statement: ‘The Motor Overload Enable parameter (P.040) can be used in place of the electronic thermal overload relays in single motor applications’.
soc-ii Notes: Summary of Changes
CONTENTS Contents Chapter 1 Introduction 1.1 Related Publications ........................................................................................ 1-1 1.2 Getting Assistance from Reliance Electric....................................................... 1-1 Chapter 2 About the Drive 2.1 Identifying the Drive......................................................................................... 2-1 2.2 Understanding the Enclosure Rating: IP20 .....................................................
Chapter 4 Mounting the Drive, Grounding, and Finding Wire Routing Locations 4.1 Mounting the Drive ...........................................................................................4-1 4.1.1 Verifying the Drive’s Watts Loss Rating.................................................4-1 4.2 Determining Input, Motor Output, Ground, and Control Wire Routing for the Drive......................................................................................................4-2 4.3 Grounding the Drive ......
List of Figures Figure 2.1 – Identifying the Drive Using the U. S. Model Number ............................ 2-1 Figure 2.2 – Identifying the Drive Using the European Stock Number ..................... 2-2 Figure 2.3 – 2 to 15 Amp Drive Component Locations............................................. 2-3 Figure 2.4 – 24 to 30 Amp Drive Component Locations........................................... 2-4 Figure 2.5 – 43 Amp Drive Component Locations....................................................
IV GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.
List of Tables Table 2.1 – Power Ratings ....................................................................................... 2-2 Table 2.2 – Standard Kits and Options .................................................................. 2-12 Table 3.1 – Environmental Conditions...................................................................... 3-2 Table 3.2 – Dimensions and Weights for 2 to 30 Amp Drives .................................. 3-3 Table 3.3 – Dimensions and Weight for 43 Amp Drives .........
VI GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.
CHAPTER 1 Introduction This instruction manual describes GV3000/SE Bookshelf drive hardware. It does not cover the GV3000/SE drive software. For software information, refer to the GV3000/SE AC General Purpose (V/Hz) and Vector Duty Bookshelf Drive Software Start-Up and Reference Manual (D2-3426). This manual is intended for qualified electrical personnel. It is organized according to a logical progression of steps to be followed to install and troubleshoot the drive.
1-2 GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.
CHAPTER 2 About the Drive This chapter provides an overview of the drive including how to identify the drive, a description of the Regulator board, and the identification of major components of the drive. The GV3000/SE AC Bookshelf drive is a PWM (pulse-width-modulated) drive that provides vector and general purpose regulation for a wide range of applications.
NNN . NN . NN 896 = GV3000/SE Power Module Size 11 = DC Bus Terminals and Braking Transistor Circuit 31 = DC Bus Terminals, Braking Resistor Circuit, and Built-In CE Filter Figure 2.2 – Identifying the Drive Using the European Stock Number Table 2.1 – Power Ratings Output Amps by Mode @ Carrier Frequency Power Loss Watts (Full Load) U.S. Model Number European Stock Number Input KVA 31ER40xx 31ET40xx 896.01.11 896.01.31 4.0 3.2 5 4 3.1 3.1 2.8 2.1 2.1 2.1 60 38ER40xx 38ET40xx 896.02.
2.3 2 to 15 Amp GV3000/SE Bookshelf Drive Component Locations The 2 to 15 amp GV3000/SE Bookshelf drives have the following main components. The numbered items listed below correspond to the numbers used in figure 2.3. Replacement parts are listed in chapter 10. 1. Regulator PCB 2. Fan 3. Output Relay Terminal Strip 4. Power PCB 5. Keypad/Display ➀ ➄ ➂ ➃ ➁ Front View Cover Removed Figure 2.
2.4 24 to 30 Amp GV3000/SE Bookshelf Drive Component Locations The 24 to 30 amp GV3000/SE Bookshelf drives have the following main components. The numbered items listed below correspond to the numbers used in figure 2.4. Replacement parts are listed in chapter 10. 1. Regulator PCB 2. Fan 3. Output Relay Terminal Strip 4. Power PCB 5. Keypad/Display ➄ ➀ ➂ Front View ➁ ➃ Cover Removed Figure 2.4 – 24 to 30 Amp Drive Component Locations 2-4 GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.
2.5 43 Amp GV3000/SE Bookshelf Drive Component Locations The 43 amp GV3000/SE Bookshelf drives have the following main components. The numbered items listed below correspond to numbers used in figure 2.5. Replacement parts are listed in chapter 10. 1. Regulator PCB 2. Fan 3. Output Relay Terminal Strip 4. Keypad/Display ➀ ➃ PE L1 L2 L3 45 47 48 U V W 28-31 ➂ ➁ Figure 2.
2.6 Regulator Board Description Drive regulation is performed by a microprocessor on the Regulator board. See figure 2.6. Drive operation is adjusted by the parameters entered through the keypad. The Regulator board accepts power circuit feedback signals and an external speed reference signal, as well as data from an encoder that is attached to the motor when set up for FVC regulation. The Regulator board provides PWM gating signals to the IGBT power devices.
2.6.1 Jumper Locations and Settings Jumpers J4 and J17 on the Regulator board are factory-set for voltage in and voltage out signals. Refer to figure 2.6 for their locations on the Regulator board. If you need to change the jumpers’ settings, use the following procedures. ! ATTENTION: Do not alter the setting of any jumper not described in this instruction manual. Failure to observe this precaution could result in damage to, or destruction of, the equipment. 2.6.1.
Step 7. Locate jumper J4 on the Regulator board. Refer to figure 2.6. Step 8. Locate pin 1 on jumper J4. Move the jumper to the desired setting as shown in figure 2.7. Voltage Input Option Pins 2-3 Current Input Option Pins 1-2 10 VDC 0-20 mA V In V In C In C In J4 J4 (Default) Figure 2.7 – Jumper J4 Settings for Analog Input Speed Reference Step 9. Reattach the cover. For 24 to 43 A drives, reattach the front panel before reattaching the cover.
Step 1. Disconnect, lock out, and tag all incoming power to the drive. Step 2. Wait five minutes for the DC bus capacitors to discharge. Step 3. Disconnect any wiring from the faceplate of the drive. Important: The cover is connected to the drive by the keypad/display cable. To disconnect the cover, use the procedure below. Do not remove the keypad/display. Step 4. Remove the cover as follows: a. Unscrew the attaching screw on the cover. b.
2.6.2 Terminal Strip The terminal strip on the Regulator board provides terminals for connecting customer I/O devices. See figures 2.6 and 2.9.
2.6.4 Option Board Connector The flat-ribbon cable connector (X3) on the bottom of the Regulator board is a parallel bus connection port that provides a means of attaching optional boards such as the DeviceNet Option board, the RMI board, the AutoMax Network Option board, or similar boards to the GV3000/SE drive. See figure 2.6. Refer to the appropriate board instruction manual for more information. Refer to section 2.11 of this manual for more information on optional drive kits. 2.6.
2.8 Output Relay Terminal Strip The output relay terminal strip, located on the Power board, provides a set of Form A and B contacts. These contacts are the under control of the user via programmable parameters. A Form A or B transition can be used to indicate drive status. The contacts are rated for 2 amps resistive load at 250 VAC/ 30 VDC. See figure 2.11 28 N. C. Relay Contact 29 N. C. Relay Common 30 N. O. Relay Contact 31 N. O. Relay Common Figure 2.11 – Output Relay Terminal Strip 2.
Table 2.
2-14 GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.
CHAPTER 3 Planning Before Installing This chapter describes how to plan a GV3000/SE Bookshelf drive installation. ! 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.
• Do not install the drive above 1000 meters (3300 feet) without derating output power. For every 91.4 meters (300 feet) above 1000 meters (3300 feet), derate the output current 1%. • Verify that the drive location will meet the environmental conditions specified in table 3.1. Table 3.1 – Environmental Conditions Condition Specification Operating Temperature (Ambient) 0° to +40°C (32° to 104°F) coolant air inlet temperature at heatsink Derating factor at 45°C (113°F) ambient: Output current by 7.
3.1.2 Determining Total Area Required Based on Drive Dimensions Drive dimensions and weights are listed in table 3.2. Overall drive dimensions are illustrated in figure 3.1 as an aid in calculating the total area required by the drive. Table 3.2 – Dimensions and Weights for 2 to 30 Amp Drives U.S. Model Number 31ER40xx 31ET40xx 38ER40xx 38ET40xx 55ER40xx 55ET40xx 85ER40xx 85ET40xx 126ER40xx 126ET40xx 150ER40xx 150ET40xx 240ER40xx 240ET40xx 300ER40xx 300ET40xx European Stock Number 896.01.11 896.01.31 896.
Table 3.3 – Dimensions and Weight for 43 Amp Drives U.S. Model Number 430ER40xx 430ET40xx European Stock Number 896.11.12 896.11.32 Width Dim A mm (in) 214 (8.42 ) Physical Dimensions in mm (in) Mounting Height Dim B Width Dim C Height Dim D mm (in) mm (in) mm (in) 374 (14.72) 150 (5.90) Weight Depth Dim E mm (in) kg lb 200 (7.87) 16.5 36 422 (16.61) Ø 14 E D B C A Front View Side View Figure 3.2 – Dimensions for 43 Amp Drives 3.1.
3.1.4 Verifying Power Module Input Ratings Match Supplied Power It is important to verify that plant power will meet the input power requirements of the drive’s Power Module circuitry. Refer to table 2.1 for input power rating specifications. Be sure input power to the drive corresponds to the drive nameplate voltage and frequency. 3.2 Wiring Requirements for the Drive Certain drive requirements should be checked before continuing with the drive installation.
Table 3.6 – Recommended Power Wire Sizes for 24 to 43 Amp Drives Type of Wiring Terminals AC Input Power and Ground L1, L2, L3 PE Output Power and Ground U, V, W DC Bus Output, Braking Resistor 45(-), 47(+) 48(-), 47(+) Size of Wire (Maximum) 6 AWG, 16 mm2 3.2.2.3 Recommended Control and Signal Wire Sizes The recommended wire sizes to connect I/O signals to the terminal strip on the Regulator board are shown in table 3.7. Recommended terminal tightening torque is 9.5 Newton-meters (85 in-lb).
GV3000/SE Drive GV3000/SE Drive GV3000/SE Drive GV3000/SE Drive 15 m (50’) 38 m (125’) 61 m (200’) 38 m (125’) Motor Motor 76 m (250’) 61 m (200’) Motor 8 m (25’) Motor 8 m (25’) Motor Motor Motor This example shows how to measure various motor configurations when the maximum motor lead length is 76 m (250 ft). Note that drives using vector regulation can be connected to only one motor at a time. Figure 3.3 – How to Calculate Motor Lead Lengths Table 3.
3.2.2.5 Recommended Serial Communication Cable Lengths Connector X8 on the Regulator board is an RS-232 serial communication port. See figure 2.6. This connector allows the drive to communicate with external devices such as a personal computer using RS-232 protocol. Two RS-232 cables are available from Reliance: • 3 meter (10 feet) D-shell 9-pin to 9-pin cable (M/N 2CA3000) • 0.3 meter (1 foot) D-shell 9-pin to 25-pin adaptor cable (M/N 2CA3001).
Table 3.10 – AC Input Fuse Selection Values (Continued) U.S. Model Number European Stock Number Choke AC Input Current1 300ER40xx 896.09.11 No 38 A 300ET40xx 896.09.31 Yes 32 A 430ER40xx 896.11.12 No 53 A 430ET40xx 896.11.32 Yes 47 A External Fuse2 Nominal Maximum 50 A 50 A 63 A 63 A 1 AC line input current (RMS) is dependent on total line impedance. 2 Recommended type of external input fuse: AC line input: Branch circuit protection fuse, e.g.
3-10 GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.
CHAPTER 4 Mounting the Drive, Grounding, and Finding Wire Routing Locations This chapter shows how to mount the drive and properly ground it. Also shown are the entry areas where wiring is to be routed in and out of the drive. 4.1 Mounting the Drive The GV3000/SE Bookshelf drive is provided in an IP20 enclosure and is intended for use inside a larger, user-supplied enclosure. In order to maintain a flat mounting surface and to ensure that bolt tightness is maintained, use washers under the bolt heads.
4.2 Determining Input, Motor Output, Ground, and Control Wire Routing for the Drive All wiring should be installed in conformance with the applicable local, national, and international codes (e.g., NEC/CEC). Signal wiring, control wiring, and power wiring must be routed in separate conduits to prevent interference with drive operation. Note that no wires are to be routed behind the drive. Use grommets, when hubs are not provided, to guard against wire chafing. Figures 4.1, 4.2, and 4.
Regulator Board Terminal Strip Output Relay Terminals AC Input Power Terminals (L1, L2, L3) Bus/Braking Resistor Terminals Motor Power Terminals (U, V, W) Ground Terminal All user wiring is external to the drive. Figure 4.
Bus/Braking Resistor Leads (29 mm dia.) Motor Leads (29 mm dia.) Ground Terminal Signal Wires (16 mm dia.) Input Power Leads (29 mm dia.) AC Input Power Terminals (L1, L2, L3) Bottom View Bus/Braking Resistor Terminals Regulator Board Terminal Strip Ground Terminal Output Relay Terminals Motor Power Terminals (U, V, W) Input Power Leads Bus/Braking Resistor Leads Signal Wires Motor Leads User Wire Routing Figure 4.
Signal Wires (16 mm dia.) Bus/Braking Resistor Leads (29 mm dia.) Motor Leads (38 mm dia.) Input Power Leads (38 mm dia.
4-6 GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.
CHAPTER 5 Installing Input Power Wiring This chapter describes incoming line components and how to install them. 5.1 Installing Transformers and Reactors (Optional) Input isolation transformers might be needed to help eliminate the following: • Damaging line voltage transients from reaching the drive. • Line noise from the drive back to the incoming power source. • Damaging currents that could develop if a point inside the drive becomes grounded.
For drives not equipped with an AC Mains Filter, the maximum line distribution system capacity is 315 KVA, three-phase with 10,000 amps symmetrical fault current capacity with a line impedance of less than 5%. 5.2 Installing Fuses for Branch Circuit Protection Install the required, user-supplied branch circuit protection fuses according to the applicable local, national, and international codes (e.g., NEC/CEC). The fuses must be installed in the line before the drive input terminals. See figure 5.1.
Input Voltage 460 V 181 182 183 GND Manual Disconnect Fuse UserSupplied R S T 1L1 1L2 1L3 ~ - GND (PE) GV3000/SE Power Module U UserSupplied ~ V W GND Motor Overload Relay (Optional if Electronic Overload is Used) M Figure 5.
5-4 GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.
CHAPTER 6 Installing Output Power Wiring This chapter provides instructions on wiring output contactors, motor overload protection, and output wiring to the motor. 6.1 Installing Output Contactors (Optional) Output contactors provide a positive means of disconnecting the motor from the drive. If the application requires the use of output contactors, contact Reliance Electric for assistance. 6.
! ATTENTION: Do not route signal and control wiring with power wiring in the same conduit. This can cause interference with drive operation. Failure to observe these precautions could result in damage to, or destruction of, the equipment ATTENTION: Unused wires in conduit must be grounded at both ends to avoid a possible shock hazard caused by induced voltages.
CHAPTER 7 Wiring the Regulator Board Terminal Strip and the Output Relay Terminal Strip This chapter describes how to wire the Regulator board terminal strip for stop, encoder feedback, and remote control signals. It also describes how to wire the output status relays on the output relay terminal strip. The signals available through the Regulator board terminal strip are shown in tables 7.1 to 7.4 and figures 7.1 and 7.2. Table 7.6 provides additional information.
Table 7.3 – Analog Speed/Torque Reference Connections (Regulator Terminals 12-15) Terminal # Signal 12 Isolated Reference Voltage 13 VDC Speed/Torque Reference 14 mA Speed/Torque Reference 15 Isolated Reference Common Notes: The analog speed/torque (P.008/U.000) reference is either +/-10 VDC or +/-20 mA, as determined by the setting of jumper J4 on the Regulator board. The analog reference can be adjusted using parameters P.009, P.010, and P.011.
Important: A maintained function loss switch should be used if P.054 (Level Sense Start Enable) = ON and P.026 (Function Loss Response) = 1.
7.1 Stopping the Drive ! ATTENTION: When P.055 is set to ON, the STOP/RESET key is functional only from the selected control source. As a safety precaution, Reliance Electric recommends than an emergency stop push button be located near the drive in an easily accessible location. As a further safety precaution, the user should post a warning on the drive to alert personnel that the STOP/RESET key is not functional. Failure to observe this precaution could result in severe bodily injury or loss of life.
The required external hardwired emergency stop must be either a category 0 or 1 stop, depending on the user’s risk assessment of the associated machinery. In order to fully comply with machinery safety standard EN60204-1:1992, part 9.2.5.4, at least one of the two stop methods must be a category 0 stop. Refer to Appendix B for more information. 7.
Tamagawa-Style, 16-Pin MS Connector View of Encoder Cable MS Connector (Female) (M/N 2TC4025 and 2TC4075) Regulator Terminal Strip Connector/Cable End Terminal 6 Pin 1 Phase A Terminal 5 Pin 2 Phase A Not Terminal 4 Pin 6 0 VDC Terminal 9 Pin 12 +15 VDC Terminal 7 Pin 8 Phase B Terminal 8 Pin 9 Phase B Not Dynapar-Style, 10-Pin MS Connector View of Encoder Cable MS Connector (Female) (M/N 2TC3025 and 2TC3075) Regulator Terminal Strip A B I G C J F E F Connector/Cable End Termi
7.3 Wiring the Signal and Control I/O Wire the drive’s signal and control I/O to the terminal strip as shown in figure 7.4 and table 7.7. Use a small flat-head screwdriver. Insert wire Insert the screwdriver into the slot and press and hold down while inserting the wire into the corresponding hole. Important: Using the incorrect tool and exerting too much pressure may damage the terminal strip. Terminal Strip Figure 7.4 – Wiring the Terminal Strip - Detail Table 7.
Table 7.6 - Wiring Signal and Control I/O to the Regulator Board Terminal Strip (Continued) Terminal Number Description Parameters/Wiring Connections Wiring Analog Speed Reference Inputs 12 Isolated Reference Voltage (+10 VDC) 13 Analog Speed/Torque Reference Input Voltage (+/- 10 VDC) 14 Analog Speed/Torque Reference Input Current (0-20 mA) 15 Related parameters: P.000: Control Source P.009: Terminal Strip Analog Input Offset P.010: Terminal Strip Analog Input Gain P.
Table 7.6 - Wiring Signal and Control I/O to the Regulator Board Terminal Strip (Continued) Terminal Number Description Parameters/Wiring Connections Wiring a Remote/Local Input 16 +24 VDC Power Supply Current limited for remote input logic use only. 17 Digital Input 8 (Default - Remote/Local) Digital input 8 is control function programmable through parameter P.007.
Table 7.6 - Wiring Signal and Control I/O to the Regulator Board Terminal Strip (Continued) Terminal Number Description Parameters/Wiring Connections Wiring an Additional Ramp Input 18 Digital Input 7 (Default - Ramp 1/Ramp 2) Digital input 7 is control function programmable through parameter P.007. The following parameters must be set: • • • • • • • • P.000: Control Source P.001: Accel Time 1 (Ramp 1) P.002: Decel Time 1 (Ramp 1) P.006: Second Menu Password P.
Table 7.6 - Wiring Signal and Control I/O to the Regulator Board Terminal Strip (Continued) Terminal Number Description Parameters/Wiring Connections Wiring a Forward/Reverse Input 19 Digital Input 6 (Default - Forward/Reverse) Digital input 6 is control function programmable through parameter P.007. The following parameters must be set: • P.000: Control Source • P.006: Second Menu Password • P.
Table 7.6 - Wiring Signal and Control I/O to the Regulator Board Terminal Strip (Continued) Terminal Number Description Parameters/Wiring Connections Wiring a Function Loss Input 20 Digital Input 5 (Function Loss) The following parameters must be set: • P.026: Function Loss Response A signal must be present at terminal 20 for the drive to be able to start. See figures 7.1 and 7.2. The drive is shipped from the factory with a jumper between terminals 16 and 20 which provides the signal.
Table 7.6 - Wiring Signal and Control I/O to the Regulator Board Terminal Strip (Continued) Terminal Number Description Parameters/Wiring Connections Wiring the Reset Input 22 Digital Input 3 (Reset) The following parameter must be set: • P.000: Control Source Terminal 22 On = Reset Wiring the Stop/Start Inputs 23 24 Digital Input 2 (Stop) Digital Input 1 (Start) The following parameter must be set: • P.000: Control Source • P.
Table 7.8 – Wiring the Output Relay Terminal Strip Terminal Number Description Parameters/Wiring Connections Wiring the Output Status Relays 28 Normally-Closed Contact (Form B) 29 Normally-Closed Contact Common (Form B) 30 Normally-Open Contact (Form A) 31 Normally-Open Contact Common (Form A) Both Form A and Form B contacts are rated for 250 VAC/30 VDC at 5 amps resistive or 2 amps inductive load. The following parameter must be set: • P.
CHAPTER 8 Wiring Optional User-Supplied Braking Resistors This chapter describes how to select and wire optional user-supplied braking resistors. ! 8.1 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.
. Table 8.1 – Cable Cross-Sections for External Braking Resistors Maximum Continuous Braking Current (A rms) Minimum Cable Cross-Section 31ER40xx 31ET40xx 6 1 mm2 (16 AWG) 38ER40xx 38ET40xx 6 1 mm2 (16 AWG) 55ER40xx 55ET40xx 6 1 mm2 (16 AWG) 85ER40xx 85ET40xx 6 1 mm2 (16 AWG) 126ER40xx 126ET40xx 10 1 mm2 (16 AWG) 150ER40xx 150ET40xx 10 1 mm2 (16 AWG) 240ER40xx 240ET40xx 15 1.5 mm2 (16 AWG) 300ER40xx 300ET40xx 20 2.
8.2 Selecting a Braking Resistor The maximum braking power is defined by the maximum braking current and the maximum DC voltage (750 V). To determine the correct braking resistor for your drive, refer to table 8.2. Table 8.2 – Selecting a Braking Resistor Maximum Braking Current Power Module Input Voltage Turn-On Voltage Turn-Off Voltage Minimum Allowed External Braking Resistor Braking Power1 Drive M/N Continuous 25% Duty Cycle 31ER40xx 31ET40xx 4.5 kW 4.5 kW 6A 460 V 750 V 720 V 125.
8.3 Installing the Braking Resistor To prevent possible damage due to an overload on the braking resistors, install a thermal protection device according to figure 8.1 and table 8.3. 1L1 PE 1L2 1L3 If the resistor overheats, this contact operates a disconnect that removes AC power1 6from 2the 0 drive. - + 47 DBU T 48 45 47 U V W M 3- . Figure 8.1 – Braking Resistor Wiring Connections Table 8.
CHAPTER 9 Completing the Installation This chapter provides instructions on how to perform a final check of the installation before power is applied to the drive. ! 9.1 ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should start and adjust it. Read and understand this manual in its entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or loss of life.
Step 10. Check that the incoming power is rated correctly. Step 11. Check the motor installation and length of motor leads. Step 12. Disconnect any power correction capacitors connected between the drive and the motor. Step 13. Check that the rating of the transformer (if used) matches the drive requirements and is connected properly. Step 14. Verify that a properly-sized ground wire is installed and a suitable earth ground is used.
CHAPTER 10 Troubleshooting the Drive This chapter describes how to troubleshoot the drive and the equipment that is needed to do so. Also provided are replacement part lists and information on clearing faults. 10.1 Test Equipment Needed To Troubleshoot An isolated multimeter will be needed to measure DC bus voltage and to make resistance checks. Note that dedicated troubleshooting test points are not provided. 10.
To remove the cover: a. Unscrew the attaching screw on the cover. b. Lift the cover and carefully take it out of the heatsink as far as the flat ribbon cable, which connects the display with the Regulator board, allows. c. Use a screwdriver to slide the cable out of the connector on the Regulator board to completely detach the cover. Step 4. Use a voltmeter to verify that there is no voltage at the drive’s AC input power terminals (R/L1, S/L2, T/L3). Refer to figure 10.1, 10.2, or 10.
AC Input Power Terminals (L1, L2, L3) DC Bus Measuring Points (-)45, (+)47 Cover Removed Figure 10.
*AC Input Power Terminals (L1, L2, L3) PE L1 L2 L3 28-31 45 47 48 U V W *Terminals are located behind the cover and front panel. *DC Bus Measuring Points (-)45, (+)47 Figure 10.3 – DC Bus Voltage Terminals (43 Amp Drives) 10.4 Checking Out the Drive with Input Power Off Use the following procedure to check the drive circuitry with power off: ! ATTENTION: DC bus capacitors retain hazardous voltages after input power has been disconnected.
Important: The cover is connected to the drive by the keypad/display cable. To disconnect the cover, use the following procedure. Do not remove the keypad/display. To remove the cover: a. Unscrew the attaching screw on the cover. b. Lift the cover and carefully take it out of the heatsink as far as the flat ribbon cable, which connects the display with the Regulator board, allows. c. Use a screwdriver toslide the cable out of the connector on the Regulator board to completely detach the cover. Step 4.
IGBT No. Meter Connection (+) (-) V6 47* W(T3) V5 47* V(T2) V4 47* U(T1) V3 W(T3) 45* V2 V(T2) 45* V1 U(T1) 45* Component is OK if resistance (R) is: 0.3 < R < 8K ohm Component is defective if: Continuity (short circuit) or open when the meter is connected with reversed polarity *If the optional terminals 45 and 47 are not fitted (e.g., on drives with built-in chopper option), remove cover and connect the meter to the measuring points according to the procedure in section 10.3.
10.5 Checking the Cooling Fans On a regular basis, visually check the cooling fans on the base of the unit. If a fan is binding, clogged with dust, or is not functioning, it must be replaced. The replacement part number for the fan is shown in table 10.2. 10.6 Replacement Parts Table 10.2 lists the replacement parts that are available from Reliance Electric. See figures 2.3, 2.4, and 2.5 for the location of the parts. Table 10.
10-8 GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.
APPENDIX A Technical Specifications Table A.1 – Service Conditions AC Line Distribution System Capacity (Maximum) for 460 VAC Units • Units Not Equipped with an AC Mains • 315 KVA, three-phase with 10,000 amps symmetrical fault • Units Equipped with an AC Mains Filter • 1000 KVA, three-phase with 30,000 amps symmetrical fault Control Method All-digital vector, sinusoidal pulse-width-modulated (PWM) Displacement Power Factor 0.
Table A.2 – Environmental Condition Condition Specification 0° to +40°C (32° to 104°F) coolant air inlet temperature at heatsink Operating Temperature (Ambient) Derating factor at 45°C ambient: 7.5% Derating factor at 50°C ambient: 15% Storage Temperature (Ambient) -25°C to +55°C Transportation Temperature (Ambient) -25°C to +70°C (+70°C during a maximum 24 hours) Table A.
Table A.5 – Flux Vector Regulation Specifications Specification Rating Motor Poles 2, 4, 6, or 8 poles Overcurrent IET 200% load (based on drive nameplate rating) Overload Current Rating 150% for 1 minute (based on drive nameplate rating) Speed Control Range 1:600 with 1024 PPR Speed Control Response 15 Hz (typical) Encoder Feedback 15 V differential quadrature, encoder incremental (512 PPR, 1024 PPR, 2048 PPR, 4096 PPR) Service Factor 1.0 ) Table A.
A-4 GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.
APPENDIX B Compliance with Machinery Safety Standard EN 60204-1:1992 The GV3000/SE Bookshelf drive complies with the following sections of machinery safety standard EN 60204-1:1992. EN60204-1 Section Title 6 Protection against electrical shock 6.2.1 - Protection by enclosure 6.2.3 - Protection against residual voltages 6.3.1 - Protection by automatic disconnect of supply 6.4 - Protection by the use of PELV (Protective Extra Low Voltage) 7 Protection of equipment 7.
EN60204-1 Section Title 9.2.6 - Combined start and stop controls 9.3 - Protective interlocks 9.3.5 - Reverse current braking 9.4 - Control functions in case of failure 9.4.2.1 - Use of proven circuit techniques and components 9.4.3 - Provisions for redundancy 9.4.3.1 - Earth faults 9.4.3.2 - Voltage interruption 10 Operator interface and machine mounted control devices 10.2.1 - Pushbutton colors 10.8 - Displays 11 Control interfaces 11.
APPENDIX C Compliance with Electromagnetic Compatibility Standards C.1 Introduction This appendix provides information on the GV3000/SE Bookshelf drive’s compliance with European community electromagnetic compatibility standards and covers the following: • requirements for standards compliance • instructions on how the drive must be wired.
C.3 Wiring Practices This section describes how the GV3000/SE drive must be wired to conform to the standards listed in section C.1. Figure C.1 shows a typical wiring configuration for a GV3000/SE Bookshelf drive if an AC Mains Filter is used.
C.3.1 Motor Leads The motor leads must be run in continuous, rigid, conductive conduit, continuously-screened armored cable, or equivalent. Note that the use of flexible metal conduit, open wire, or wire in trays is not acceptable. Many flexible metal conduit products have not been designed for RF containment and are not adequate to maintain compliance. All motor leads should have the same cross-sectional area. The maximum allowable motor lead length from the drive to the motor is 250’ (76m).
C.3.3 I/O Signals Control (I/O) and signal wiring must be run in continuous, rigid, conductive conduit or continuously-screened cable as shown in figure C.2. Note that the use of flexible metal conduit, open wire, or wire in trays is not acceptable. Many flexible metal conduit products have not been designed for RF containment and are not adequate to maintain compliance.
C.3.6 Encoder Cabling Use only the Reliance Electric encoder cables listed in table C.1. Table C.
C-6 GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.
INDEX A C AC input diodes, checking, 10-4 to 10-6 disconnect, installing, 5-2 isolation, transformer, 5-1 to 5-2 line branch circuit fuses, 3-8 to 3-9, 5-2 ratings, 2-2 wire sizes, 3-5 to 3-6 wiring, 3-5 to 3-6, 4-1 to 4-5, 5-1 to 5-3 voltage transients, avoiding, 5-1 AC Mains Filter, 2-12, 5-1, C-1, C-2 AC output wiring, 3-5 to 3-6, 4-1 to 4-5, 6-1 to 6-2 Air flow, 3-1, 3-4 Alarms, 10-1 Altitude requirements, 3-2 Ambient conditions 3-2, A-2 Analog input jumper location, 2-6 jumper settings, 2-7 to 2-8 sp
E Electromagnetic compatibility standards, drive compliance with, C-1 to C-5 Emergency stop, 7-4 EN-60204-1 compliance, 7-4 to 7-5, B-1 to B-2 Enclosure, 2-2 Encoder wiring, 3-9, 7-5 to 7-6 Environmental conditions, 3-2, A-2 European stock number, 2-1 to 2-2 F Fan checking, 10-7 location, 2-3 to 2-5 part number, 10-7 Faults, 10-1 Flux vector control, 2-1 Flux vector regulator specifications, A-3 Form A/B contacts, see Status Relays Forward (digital input 6), 2-10, 7-2, 7-11 Frequency, line, A-1 Function lo
N Network AutoMax Network Option board, 2-11, 2-12 communication, 2-11 ControlNet Network Option board, 2-12 DeviceNet Network Option board, 2-11, 2-13 Profibus Network Option board, 2-13 O Open loop control, see Volts/Hertz Regulation Operator Interface Module, 2-13 Operator Interface Module connector, 2-11 Option kits, see Kits Option board connector, 2-6, 2-11 Output analog, see analog Output contactors, 6-1 digital, see Status Relays specifications, terminal strip, A-2 Output relay terminal strip, 2-3,
W Watts loss rating, 2-2, 4-1 Weight, 2 to 30 amp drives, 3-3 43 amp drives, 3-4 Wire routing, 4-2 to 4-5 Wire sizes, 3-5, 3-6, 3-8, 3-9 Index-4 GV3000/SE AC Bookshelf Drive Hardware Reference, Version 6.
U.S. Allen-Bradley Drives Technical Support - Tel: (1) 262.512.8176, Fax: (1) 262.512.2222, Email: support@drives.ra.rockwell.com, Online: www.ab.com/support/abdrives www.rockwellautomation.com Power, Control and Information Solutions Headquarters Americas: Rockwell Automation, 1201 South Second Street, Milwaukee, WI 53204-2496 USA, Tel: (1) 414.382.2000, Fax: (1) 414.382.
