Solar Turbine
Addendum
Ver sion 6.0
Instruction Manual
D2-3406
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: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. F ailure to observe this precaution
could result in bodily injury.
ATTENTION:The user is responsible for conforming with all applicable local, national, and
international codes. F ailure to observe this precaution could result in damage to, or destruction
of, the equipment.
Reliance is a trademark of Rockwell Automation.
©1999 Rockwell International Corporation
Chapter 1 Introduction
1.1 Intended Audience........................................................................................... 1-1
1.2 Other Required Manuals ................................................................................. 1-1
Chapter 2 About the Drive and Cabinet
2.1 Identifying the Solar Turbine Drive by Model Number and Ratings................. 2-1
2.2 Enclosure Rating .............................................................................................2-2
2.3 Identifying Solar Turbine Cabinet Components...............................................2-2
Chapter 3 Cabinet Mounting and Wire Routing
3.1 Mounting the Drive .... ...... ....... ...... ...... ....... ...... ....... ...... ....... ............................3-1
3.1.1 Verifying the Drive’s Watts Loss Rating ....................................... ....... .. 3-2
3.2 Cabinet Wire Routing ...................................................................................... 3-3
3.3 Grounding the Cabinet .................................................................................... 3-6
Chapter 4 Installing Power Wiring
4.1 Installing Fuses for Branch Circuit Protection.................................................. 4-1
4.2 Installing a Required External/Separate Input Disconnect ..............................4-1
4.3 Installing Power Wiring from the DC Power Supply to the Drive’s Internal
DC Bus Terminals ...........................................................................................4-3
4.4 Recommended Motor Lead Lengths...............................................................4-5
CONTENTS
Chapter 5 Troubleshooting the Drive
5.1 Verifying that DC Bus Capacitors are Discharged...........................................5-1
5.2 Replacement Parts....................................................... ....... ...... ....... ...............5- 1
Appendix A Solar Turbine Drive Parameters...............................................................................A-1
Contents
I
II
Solar Turbine Addendum
List of Figures
Figure 2.1 – Identifying the Drive Model Number .....................................................2-1
Figure 2.2 – Solar Turbine 1 HP Drive Component Locations..................................2-2
Figure 2.3 – Solar Turbine 5 HP Drive Component Locations..................................2-3
Figure 3.1 – Drive Dimensions .................................................................................3-2
Figure 3.2 – Wire Routing Locations for 1 HP Drive.................................................3-4
Figure 3.3 – Wire Routing Locations for 5 HP Drive.................................................3-5
Figure 4.1 – Typical Electrical Connections.............................................................. 4-2
Figure 4.2 – DC Input Terminals............................................................................... 4-4
Contents
III
IV
Solar Turbine Addendum
List of Tables
Table 2.1 – Drive Ratings .........................................................................................2-1
Table 3.1 – Drive Dimensions and Weights.............................................................. 3-1
Table 3.2 – Power and NEMA Enclosure Ratings.................................................... 3-2
Table 4.1 – Recommended Input Line Fuse Ratings ...............................................4-1
Table 4.2 – Recommended Power Wire Sizes......................................................... 4-3
Table 4.3 – Terminal Tightening Torques.................................................................4-4
Table 4.4 – Recommended Motor Lead Lengths .....................................................4-5
Table 5.1 – Solar Turbine Drive Replacement Parts ................................................5-2
Contents
V
VI
Solar Turbine Addendum
This addendum covers the features and specifications that are unique to the
GV3000/SE Solar Turbine drives. GV3000/SE Solar Turbine drives operate from a
120 VDC input, requiring a different power supply than standard GV3000/SE drives.
Only product information that is unique to Solar Turbine drives is covered in this
addendum. This addendum must be used along with the GV3000/SE software and
hardware instruction manuals listed in section 1.2.
1.1 Intended Audience
This addendum is intended for the following qualified personnel:
• Rockwell Automation Global Technical Service personnel who are familiar with the
features described.
• Product end users
1.2 Other Required Manuals
CHAPTER 1
Introduction
This addendum must be used with the following publications:
• D2-3359 GV3000/SE AC General Purpose (Volts/Hertz) and Vector Duty Drive
Software Start-Up and Reference Manual
• D2-3360 GV3000/SE AC Power Modules Hardware Reference, Installation, and
Troubleshooting
Introduction
1-1
1-2
Solar Turbine Addendum
CHAPTER 2
About the Drive and Cabinet
This chapter describes how to identify the Solar Turbine drive and cabinet layout using
the Solar Turbine model number and drive power ratings. Internal cabinet component
drawings are also provided.
2.1 Identi fying the Solar Turbine Drive by Model Number
and Ratings
The Solar Turbine drive is available in 1 HP and 5 HP versions. Each drive can be
identified by its model number. See figure 2.1. This number appears on the shipping
label and on the drive’s nameplate. The drive’s model number includes the Power
Module and the Regulator. Drive power ratings are provided in table 2.1.
N NA N NN N
Horsepower Ratings
Drive
M/N
1G0160S NEMA 1
5G0160S NEMA 1
Enclosure
Type
IP20 V6.04
IP20 V6.04
Regulator Ty pe
G = V/Hz only
Voltage
0 = 120V DC
Enclosure
1 = NEMA 1
Regulator Version
60 = Version 6.0
Hardware Version
S =Special
Figure 2.1 – Identifying the Drive Model Number
Table 2.1 – Drive Ratings
Output
Power
1 HP 120 VDC 13.4 A 90 VAC 11.1 A 3 to 200 Hz
5 HP 120 VDC 37.0 A 90 VAC 30.4 A 3 to 200 Hz
Input
Volts
Input
Amps
Output
Volts
Output
Amps
Output
Frequency
About the Drive and Cabinet
2-1
2.2 Enclosure Rating
The Solar Turbine 1 HP and 5 HP cabinets have a NEMA 1 enclosure rating:
NEMA 1: Vented. Contains a communication access door that allows access to the
communication port without removing the cover. Intended for general-purpose indoor
applications.
2.3 Identifying Solar Turbine Cabinet Components
The Solar Turbine drive has the following main components. The identification
numbers provided correspond to the numbers used in figure 2.2 (1 HP) and figure 2.3
(5 HP).
1. Capacitor Board/Input Capacitors 6. Current Feedback Board
2. Fan Assembly 7. Regulator Board
Internal Fan Assembly
3.
4. Power Board 9. Signal Board
5. Membrane Switch (Keypad/Bracket) 10. Gate Driver Board
8. IGBT Module
1
6
MN
1G0160S
CURRENT FEEDBACK
BOARD
2
FAN ASSEMBLY
4
3
FAN ASSEMBLY
(INTERNAL)
5
MEMBRANE SWITCH
(KEYP AD/BRACKET)
7
REGULATOR
BOARD
2-2
Figure 2.2 – Solar Turbine 1 HP Drive Component Locations
Solar Turbine Addendum
2
3
9
10
FAN ASSEMBLY
4
POWER BOARD
MN
5G0160S
FAN ASSEMBLY
(INTERNAL)
1
Figure 2.3 – Solar Turbine 5 HP Drive Component Locations
SIGNAL BOARD
8
IGBT
MODULE
GATE DRIVER BOARD
5
MEMBRANE SWITCH
(KEYPAD/BRACKET)
7
REGULATOR BOARD
About the Drive and Cabinet
2-3
2-4
Solar Turbine Addendum
Cabinet Mounting and Wire Routing
This chapter provides information on how to mount the Solar Turbine drive. Also
shown are the entry areas where wiring is to be routed in and out of the drive.
Please refer to instruction manual D2-3360 for detailed information on planning your
drive installation and for further information on proper wiring routing of power and
signal wiring and grounding of GV3000/SE drives.
3.1 Mounting the Drive
Attach the drive to the vertical surface selected using the four (4) mounting holes
provided. In order to maintain a flat mounting surface and to ensure that bolt tightness
is maintained, use washers under the bolt heads. Refer to table 3.1 and figure 3.1 for
mounting dimensions. Use the following user-supplier mounting bolts and washers:
1 HP Solar Turbine Drives: M8 (5/16”)
5 HP Solar Turbine drives: M8 or M10 (5/16” or 3/8”)
CHAPTER 3
Table 3.1 – Drive Dimensions and Weights
HP Rating Dim. A Dim. B Dim. C Dim. D Dim E. Weight
1 HP 280.6 mm
11.05"
5 HP 288.0 mm
11.34"
338.4 mm
13.32"
463.0 mm
18.23"
248.0 mm
9.76"
223.0 mm
8.78"
309.1 mm
12.17"
442.0 mm
17.40"
200.0 mm
7.87"
238.1 mm
9.37"
9 kg
20 lbs
15.75 kg
35 lbs
Cabinet Mounting and Wire Routing
3-1
A
C
E
D
Figure 3.1 – Drive Dimensions
B
3.1.1 Verifying t h e Drive’s Watts Loss Rating
When mounting the drive inside another enclosure, you should determine the watts
loss rating of the drive from table 3.2. Ensure adequate ventilation is provided based
on the drive’s watts loss rating.
Table 3.2 – Power and NEMA Enclosure Ratings
Output
HP
Rating
1 HP 1 120 13.4 11.1 11.1 11.1 210
5 HP 1 120 37.0 30.4 30.4 30.4 600
3-2
NEMA
Rating
Input
Volts
Input
Amps
Amps at
2kHz
Output
Amps at 4
kHz
Output
Amps at 8
kHz
Power Loss Watts
(Full Load)
Solar Turbine Addendum
3.2 Cabinet Wire Routing
All wiring should be installed in conformance with the applicable local, national, and
international codes (for example, NEC/CEC). Signal wiring, control wiring, and power
wiring must be routed in separate conduits to prevent interference with drive
operation. Figures 3.2 and 3.3 show the wire routing of the cabinet for 1 HP and 5 HP
drives, respectively.
ATTENTION:Do not route signal and control wiring with power wiring in
the same conduit. This can cause interference with drive operation.
!
Refer to instruction manual D2-3360 for detailed instructions on cabinet wire routing.
Failure to observe this precaution could result in damage to, or
destruction of, the equipment.
Cabinet Mounting and Wire Routing
3-3
Regulator Terminal Strip
Power Strip Terminals
Ground Terminals
Signal Control
(Terminal Strip)
Input Power
or
Snubber Resistor
Braking
User Wire Routing
Motor Leads
or
Input Power
and Motor Leads
Cover
Base
(4) .875 [22/2 mm] diameter
Holes (Nema 1)
3-4
Figure 3.2 – Wire Routing Locations for 1 HP Drive
Solar Turbine Addendum
Regulator Terminal Strip
Power Strip Terminals
Ground Terminals
Signal Control
(Terminal Strip)
Input Power
Snubber Resistor
or
Braking
User Wire Routing
(1) .875 [22.2mm] diameter
Hole (NEMA 1)
Bottom View
Motor Leads
or
Input Power
and Motor Leads
Cover
Base
(3) 1.094 [27.8mm] diameter
Holes (Nema 1)
Cabinet Mounting and Wire Routing
Figure 3.3 – Wire Routing Locations for 5 HP Drive
3-5
3.3 Grounding the Cabinet
ATTENTION:The user is responsible for conforming with all applicable
local, national, and international codes. Failure to observe this precaution
!
The Solar Turbine drive should be grounded in accordance with the instructions given
for mounting a GV3000/SE drive in instruction manual D2-3360.
could result in damage to, or destruction of, the equipment.
3-6
Solar Turbine Addendum
CHAPTER 4
Installing Power Wiring
This chapter describes how to connect 120 volt DC input power to a 1 HP or 5 HP
GV3000/SE Solar Turbine drive. Guidelines for motor lead lengths are also provided.
Please refer to instruction manual D2-3360 for complete information on wiring a
GV3000/SE drive.
4.1 Installing Fuse s for Branch Circuit Protection
ATTENTION:Most codes require that upstream branch protection be
provided to protect input power wiring. Failure to observe this precaution
!
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 4.1. Fuse value
recommendations are provided in table 4.1.
could result in severe bodily injury or loss of life.
Table 4.1 – Recommended Input Line Fuse Ratings
Drive HP Rating Input Voltage (+/- 10%) Fuse Rating
1 HP 120 VDC 25A
5 HP 120 VDC 70A
1.Recommended fuse type: UL Class J, 600V, time delay, or equiv alent.
4.2 Installing a Required External/Separate Input
Disconnect
An input disconnect must be installed in the line before the drive input terminals in
accordance with local, national, and international codes (e.g., NEC/CEC). The
disconnect should be sized according to the in-rush current as well as any additional
loads the disconnect might supply. The trip rating for the inrush current (10-12 times
full load current) should be coordinated with that of the input isolation transformer, if
used. Refer to instruction manual D2-3360 for additional information.
1
Installing Power Wiring
4-1
User
Supplied
User’s 120 VD C
Supply
_
+
Manual
Disconnect
DC Fuses
User
S u p p lie d
5 HP Drive: Terminals B1 and B2
*
1 HP Drive: Terminals (+) and (–)
Motor Overload Relay
(If Electronic O verload
Is Not Used)
B1
(+)
*
B2
(–)
~
UVW
T2 T3
T1
M
*
Solar Turbine
Power Module
GND
PE
4-2
Figure 4.1 – Ty pical Electrical Connections
Solar Turbine Addendum
4.3 Installing Power Wiring from the DC Power Suppl y to
the Drive’s Internal DC Bus Terminals
ATTENTION:Do not route signal and control wiring in the same conduit
with power wiring. This can cause interference with drive operation.
!
Use the following steps to connect DC input power to the drive:
Step 1. Wire the DC input power leads by routing them according to drive type. Refer
Type of Wiring Terminals Size of Wire (Maximum)
Output Power U/T1, V/T2, W/T3
DC Input Power +, –
Failure to observe this precaution could result in damage to, or
destruction of, the equipment.
ATTENTION:If the GV3000/SE drive is connected to an external DC
bus, the user is responsible for DC bus short-circuit protection. Failure
to observe this precaution could result in damage to, or destruction of,
the equipment.
to figures 3.2 and 3.3. Table 4.2 contains the recommended power wiring
sizes.
Table 4.2 – Recommended Power Wire Sizes
2
(1 HP)
2
(5 HP)
Ground
12 AWG, 3 mm
6 AWG, 13 mm
Step 2. Connect the DC input power leads to terminals + and – (1 HP drive) or B1
and B2 (5 HP drive) on the power terminal strip (see figure 4.2).
ATTENTION:On the 5 HP Solar T urbine drive, the positive DC input must
be connected to the (+) terminal. The negative DC input must be
!
connected to the (–) terminal. These terminals cannot be interchanged.
Failure to observe this precaution could result in damage to, or
destruction of, the equipment.
Installing Power Wiring
4-3
ATTENTION:On the 5 HP Solar T urbine drive, the positive DC input must be connected to the
(+) terminal. The negative DC input must be connected to the (–) terminal. These terminals
!
cannot be interchanged. Failure to observe this precaution could result in damage to, or
destruction of, the equipment.
1 HP Drive
U/T1
B1 B2
(+) (-)
DC Inputs
W/T3V/T2
DC Bus
U/T110V 10 COM
Motor Leads
Volts
5 HP D rive
W/T3V/T2
4-4
Motor Leads
Step 3. Tighten the DC input power terminals to the proper torque, as listed in
DC P ositive
Input
Figure 4.2 – DC Input Terminals
DC Negative
Input
table 4.3.
Table 4.3 – Terminal Tightening Torques
Drive Terminals Maximum Tightening Torque
1 HP All 1.08 Newton-meters (9.5 in-lbs)
5 HP All 13.5 Newton-meters (10 ft-lbs)
Solar Turbine Addendum
4.4 Recommended Motor Lead Lengths
The following motor lead lengths are recommended to reduce line disturbances and
noise.
Table 4.4 – Recommended Motor Lead Lengths
Maximum Lead Length in Feet
Carrier Frequency
Drive Power Rating
1 HP 500 500 500
5 HP 800 500 500
Refer to instruction manual D2-3360 for detailed instructions on installing output
power wiring.
2 kHz 4 kHz 8 kHz
Installing Power Wiring
4-5
4-6
Solar Turbine Addendum
CHAPTER 5
Tr oubleshooting the Drive
The GV3000/SE Solar Turbine drive displays alarm and fault codes to signal a
problem detected during self tuning or drive operation. These codes are described in
instruction manual D2-3359. This chapter provides general troubleshooting safety
guidelines and replacement part information that is unique to a 1 HP or 5 HP
GV3000/SE Solar Turbine drive. Refer to D2-3359 and to D2-3360 for detailed
instructions about troubleshooting a GV3000/SE drive and obtaining standard
replacement parts.
5.1 Verifying that DC Bus Capacitors are Discharged
ATTENTION:DC bus capacitors retain hazardous voltages after input
power has been disconnected. After disconnecting input power, wait fiv e
!
Step 1. Place the input disconnect in the Off position and lock out drive power. Wait
(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.
five minutes.
Step 2. Remove the drive’s cover.
Step 3. Verify that there is no voltage at the drive’s input power terminals (refer to
figure 4.2). This ensures that the DC bus capacitors are discharged.
Step 4. Once the drive has been serviced, reattach the drive’s cover.
Step 5. Reapply input power.
5.2 Replacement Parts
Table 5.1 lists the replacement parts that are available from Reliance Electric. See
figures 2.2 and 2.3 for component locations.
Troubleshooting the Drive
5-1
Table 5.1 – Solar Turbine Drive Replacement Parts
Description
1
Drive HP Part Number Quantity
1
NEMA 1 Fan Assembly
52
615161-V
1 805538-1S 1
NEMA 1 Cover
5 805547-1S 1
1
Membrane Switch Keypad/Bracket
51
805548-1R
1
Regulator Printed Circuit Board
51
O-56975-200
Capacitor Printed Circuit Board 1 179210 1
Current Feedback Printed Circuit Board 1 O-56935-100 1
1 179211 1
Power Printed Circuit Board
5 O-56973 1
IGBT Module 5 602909-813AW 3
Signal Printed Circuit Board 5 O-56974 1
Gate Driver Board
2
5 O-5 6960 1
1 615159-1R 1
Internal Fan Assembly
1
Components are identified in figure 2.3.
2
Replace the Gate Driver board when the IGBT modules are replaced.
5 615159-1S 1
1
1
1
5-2
Solar Turbine Addendum
APPENDIX A
Solar Turbine Drive Parameters
For Solar Turbine drives the following parameters have different default values than
standard GV3000/SE drives:
Solar Turbine
Parameter
P.048 V/Hz
H.000 90
H.017 3
H.021 85
Please refer to Instruction Manual D2-3359 for detailed descriptions of drive
parameters.
Default Setting
Solar Turbine Drive Parameters
A-1
A-2
Solar Turbine Appendix
INDEX
A
About the drive and cabinet, 2-1 to 2-4
B
Branch circuit protection, 4-1
C
Cabinet components, 2-2 to 2-4
Cabinet mounting, 3-1 to 3-3
Component locations
1 HP drive, 2-2
5 HP drive, 2-3
Components
identifying, 2-2
D
Dimensions, 3-1 to 3-2
Drive parameters, default settings, A-1
Drive ratings, 2-1
Identifying drive by model number and ratings, 2-1
Input disconnect, 4-1
Input terminal identification, 4-4
Intended audience, 1-1
Introduction, 1-1
M
Model number, 2-1
Mounting, 3-1
P
Power wiring, 4-1 to 4-5
DC input, 4-2
motor lead lengths, 4-5
recommended wire sizes, 4-3
R
Replacement parts, 5-1 to 5-2
Required manuals, 1-1
E
Electrical connections, typical, 4-2
Enclosure rating, 2-2, 3-2
F
Fuses, 4-1
I
Identifying, 2-1
Index
T
Terminal tightening torques, 4-4
Troubleshooting, 5-1 to 5-2
verifying DC bus capacitors are discharged, 5-1
W
Watts loss rating, verifying, 3-2
Weight of drive, 3-1
Wire routing, 3-1 to 3- 3
cabinet, 3-3
Index-1
Index-2
Solar Turbine Addendum
U.S. 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
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Publication D2-3406-September 1999 Copyright © 1999 Rockwell Automation, Inc. All Rights Reserved. Printed in USA.
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