Yaskawa GPD503 User Manual

Magne

Tek

GPD 503 Technical Manual

GPD 503 SIMPLIFIED START-UP PROCEDURE

This procedure will quickly get you up and running by Digital Operator keypad or user supplied remote operator control. It assumes that the GPD 503 and motor are correctly wired (see pages 1-8 thru 1-15), and start-up is to be performed without any changes to factory set constants. Detailed information on the many other features of this drive will be found in later sections of this manual.

INSTALLATION

1. Be certain your input voltage source, motor, and drive name plates are all marked either 230V, 460V, or 575V. Other voltages can be used, but require additional programming, see Section

2.

2. Mount drive on a vertical surface with adequate space for air circulation.

3. Remove front cover, fit conduit to bottom plate, and connect power and ground wires as shown.

CAUTION

Be certain you connect input power to terminals L1, L2, and L3 only, or serious damage will result. Connect motor to terminals T1, T2, and T3 only.

KEYPAD OPERATION

1. Replace cover and apply input power - keypad display shows " STOP lampS are on. Press and hold JOG key, noting direction of motor rotation. If it is

incorrect, remove power, wait for “CHARGE” light to go out, then switch wires between terminals T1, and T2. Replace cover, and apply input power.

2. Run, Stop, and Frequency (Speed) - Here, the terms frequency and speed are used interchangeably. A value of 60.00 (Hz) in the “ for common motors. Press RUN key; RUN lamp lights, STOP lamp flashes (to indicate drive is running at zero speed). Note flashing "0" in “ to increase display frequency value to 10.00. Press DATA/ENTER key to enter speed data, noting that motor shaft begins to turn. Repeat this procedure using “up arrow”, “down arrow” and “right arrow” (RESET) keys to introduce various speeds, noting that the drive responds to each new value only after the DATA/ENTER key is pressed. The “ the frequency command the drive is looking at, whether it is running or not.

3. Reversing - can be selected while stopped, or while running. With the drive stopped, press FWD/REV key and note the REV lamp lights and FWD lamp goes out. If drive is running when this key is pressed, the drive will decelerate the motor to 0 Hz, then accelerate the motor to the same speed in the opposite direction. You can try this while running, provided your machine can be operated in reverse direction without damage.

4. Displays - With drive stopped, each time the DISPL (display) key is pressed, a different function appears. The first function on power up is the “ Press DISPL and “ recognized as the only display without alpha characters. The next is this display is output amps. For other display information, refer to Section 3.

0.00

” appears; this is a display of output frequency (speed) and is

F00.00

” display equals full speed (frequency)

” display. Press “up arrow” key one time

F00.00

” display, discussed above.

"; DRIVE, FWD, and

F00.00

” display indicates

“

0.0A

”; the “A” indicates

5. Faults - If an unacceptable operating condition such as code Ou (over voltage), Uu (under voltage), OC (over current), etc. occurs, the drive will trip, and the motor will coast to a stop. The appropriate fault code will be displayed. Examine fault code; consult Sections 6 & 7 for fault correction procedure.

- i -

INSTALLATION OF EXTERNAL RUN/STOP SWITCH AND SPEED POTENTIOMETERS

IMPORTANT: Complete the INSTALLATION and KEYPAD OPERATION instructions before attempting external control.

1. Disconnect power, remove cover, and wait for “CHARGE” light to go out.

2. Refer to the diagram below and connect a switch to terminals 1 and 11 using two conductor shielded wire. This circuit is 24Vdc, very low current; use a quality rotary or toggle switch (all wire should be 14-18AWG). Connect the shield to terminal 12 on the drive end only.

3. Install a single conductor “jumper” wire between drive terminals 5 and 11.

4. Connect a manual speed potentiometer rated 2000-3000 ohms, 1 watt minimum, using three conductor shielded wire, with shield connected at terminal 12. Connect wires to the potentiometer as shown, viewing potentiometer from the back. Trace wire shown closest to the top in diagram (right side of potentiometer) and connect to terminal 17. Trace center wire of potentiometer through and connect to terminal 16. The remaining wire will be connected to the trim pot in step 5.

5. Connect a trim potentiometer rated 2000-3000 ohms, 1 watt minimum, as close to the drive terminals as possible. Viewing the potentiometer from the back, connect a single conductor wire from the left terminal to terminal 15 of the drive. Connect a short jumper wire between the center and left terminals. Connect remaining wire from manual speed pot as shown.

1RH

MANUAL SPEED

POTENTIOMETER

(REAR VIEW)

STOP

S1

RUN

SHIELD

WIRES

1R

Trim Pot

11 12 13 14 15 16 17 25 26 27

1 2 3 4 5 6 7 8 21 22

"Jumper

wire"

Shield wire

termination

GPD 503 Control Board terminals

- ii -

IMPORTANT: Programming is required to set up the drive for operation from external terminals.

6. Replace cover, make sure remote switch S1 is in “Stop” position, then apply power. Note that the DRIVE lamp is on. Press DRIVE/PROGRAM key, noting the DRIVE lamp goes out, indicating drive is in the “Program mode”. The display will show “ (address). Press the “up arrow” (RESET) key three times to change constant to “ Press the DATA/ENTER key; the display will show “ Using the same procedure used in setting the speed in “KEYPAD OPERATION”, move to the first 1 and change it to 0; then move to the remaining 1 and also change it to 0. The display should now read “ Sn-04 to this new value. Display will momentarily show

7. Press DRIVE/PROGRAM key, noting DRIVE lamp turns on; you have returned to the “Drive mode”.

8. Calibrate manual speed pot for maximum speed at maximum rotation. With switch S1 in the “Stop” position, press DISPL key repeatedly, stopping at the “ will be indicating the combined setting of the trim, and manual speed pots. Turn manual speed pot (as viewed from the front) to the right (maximum) setting. Turn trim pot slowly until “

9. Press DISPL key to move to output frequency display, turn switch S1 to “Run”, and adjust motor speed with manual speed pot.

F59.00

0000

”. Press the DATA/ENTER key to change the contents of constant

” is displayed, then advance just enough to display “

0011

”, and the left 0 will be flashing.

"

End

Sn-01

".

FXX.XX

F60.00

”, which is a constant

Sn-04

” display. The display

”.

- iii -

QUICK REFERENCE FOR GPD 503 CONSTANTS (FACTORY SET)

CONSTANT FACTORY USER CONSTANT FACTORY USER CONSTANT FACTORY USER

NUMBER SETTING SETTING NUMBER SETTING SETTING NUMBER SETTING SETTING

An-01 0.00 An-02 0.00 An-03 0.00

An-04 0.00 An-05 0.00 An-06 0.00

An-07 0.00 An-08 0.00 An-09 6.00

bn-01 10.0 bn-02 10.0 bn-03 10.0

bn-04 10.0 bn-05 100.0 bn-06 0

bn-07 1.0 bn-08 0.0 bn-09 80

bn-10 1 bn-11 1.00 bn-12 0.50

Sn-01 Sn-02 01 Sn-03 0000

Sn-04 0011 Sn-05 0000 Sn-06 0000

Sn-07 0000 Sn-08 0100 Sn-09 0000

Sn-10 0000 Sn-11 0000 Sn-12 0100

Sn-13 0100 Sn-14 0000 Sn-15 03

Sn-16 04 Sn-17 06 Sn-18 08

Sn-19 00 Sn-20 00 Sn-21 01

(1)

Sn-22 02 Sn-23 00 Sn-24 00

Sn-25 0000 Sn-26 0000 Sn-27 0010

Sn-28 0100

Cn-01 230.0

Cn-02 Cn-03 Cn-04

Cn-05 Cn-06 Cn-07

Cn-08 Cn-09 Cn-10 1.5

Cn-11 50 Cn-12 0.0 Cn-13 0.0

Cn-14 100 Cn-15 0 Cn-16 0.0

Cn-17 0.0 Cn-18 0.0 Cn-19 1.0

Cn-20 0 Cn-21 0.0 Cn-22 2.0

Cn-23 Cn-24 Cn-25 00

Cn-26 160 Cn-27 0.1 Cn-28 170

(230V)

or 460.0

(460V)

or 575.0

(575V)

(2) (2) (2)

(2) (1)

(2)

(4) (4)

Cn-29 50 Cn-30 160 Cn-31

Cn-32 Cn-33 Cn-34 30

Cn-35 2.0 Cn-36 0 Cn-37

Cn-38 150 Cn-39 2.0 Cn-40

Cn-41 100 Cn-42 0.3

Un-01 N/A N/A Un-02 N/A N/A Un-03 N/A N/A

Un-04 N/A N/A Un-05 N/A N/A Un-06 N/A N/A

Un-07 N/A N/A Un-08 N/A N/A Un-09 N/A N/A

Un-10 N/A N/A

(4) (4)

(4)

(3)

(4)

(1)

Setting depends on GPD 503 rating. See Table A3-1.

(2)

Initial value is related to V/f curve selected by Sn-02 setting.

(3)

Motor rated current (Cn-09) is set at 100% level. Setting range: 10 to 200% of GPD 503 rated capacity.

(4)

Initial value differs depending on GPD 503 capacity.

- iv -

Horsepower Range

RATED

INPUT

2 10 15 DS309 3 15 20 DS310 0 20 25 DS311 V 25 30 DS322

4 15 20 DS318 6 20 25 DS326 0 25 30 DS325 V 30 40 DS330

5 20 20 DS5022 7 25 25 DS5027 5 30 30 DS5032 V 40 40 DS5043

CT (150% OL) VT (125% OL)

HORSEPOWER

1 1 DS305 2 2 DS302 3 3 DS306 5 5 DS307

7.5 7.5/10 DS308

30 40 DS323 40 50 DS2040

40/50 50 GPD503-2L40

50 60 DS2050 60 60 GPD503-2L50 60 75 DS2060 60 75 GPD503-2L60 75 100 DS2075

75 100 GPD503-2L75 100 150 DS2100 100 125 GPD503-2L100

1 1 DS313 2 2 DS304 3 3 DS314 5 5 DS315

7.5 7.5/10 DS316

10 15 DS317

40 50 DS340

50 60 DS350

60 75 DS360

75 100 DS075

75/100 100 GPD503-4L75

100 150 DS100 100 150 GPD503-4L100 150 200 DS150 150 200 GPD503-4L150 200 250 DS200 200 250 GPD503-4L200 250 300 DS250 300 400 DS303 400 500 DS400

2 3 DS5003 3 3 DS5004 5 5 DS5006

7.5 7.5 DS5009

10 10 DS5012

15 15 DS5017

50 50 DS5054

60 60 DS5064

75 75 DS5081 100 100 DS5112 125 150 DS5130 150 200 DS5172 200 200 DS5202

MODEL

NO.

-v-

( "L" ) (04/27/95)

WARNING

Do not touch circuit components until main input power has been turned off and “CHARGE” lamp is extinguished. The capacitors are still charged and can be quite dangerous.

Do not connect or disconnect wires and connectors while power is applied to the circuit.

CAUTION

Know your application before using either Initialization function of Sn-03. This constant must be set to 0000 for Drive mode operation. (See paragraph 2.25 for additional information.)

1110 = Factory 2-Wire Control Initialization (Maintained RUN Contact)

1111 = Factory 3-Wire Control Initialization (Momentary START/STOP Contact) Entering either Initialization code resets all constants EXCEPT Sn-01 AND Sn-02 to factory settings, and automatically returns Sn-03 setting to 0000. If the GPD 503 is connected for 3-Wire control and this constant is set to 1110 (2-Wire Control Initialization), the motor may run in reverse direction WITHOUT A RUN COMMAND APPLIED. Equipment damage or personal injury may result.

IMPORTANT

Always ground the GPD 503 using ground terminal G ( E ). See paragraph 1.4.3, "Grounding".

Never connect main circuit output terminals T1, T2, and T3 to AC main circuit power supply.

All constants have been factory set. Do not change their settings unnecessarily. Do not perform a “HIPOT” voltage test on any part of the GPD 503. Equipment uses semi-

conductors and is vulnerable to high voltage. The Control PCB employs CMOS ICs which are easily damaged by static electricity. Use

proper electrostatic discharge (ESD) procedures when handling the Control PCB.

-vi-

Constant Torque – 150% OL ______ TEFC ___ or TENV ___ EPROMs ______________ Disconnect at Motor _______ I/O Boards ______________ Single/Multiple Motor _________ V/Hz Pattern ______________ Pulse Generator ______________ Speed/Torque Regulation _______ Location ______________ Pulse Generator Input __________ Number ______________ Thermal Motor Overload

Protection – Sn-14 ______

Motor Rated Current – Cn-09 _______

• Load / Machine: • Control: Torque Requirements as % of Controlled Variable (Pressure, Flow, Temp,

Full Load Torque: Level, etc.) ______________

Breakaway ______ Sensor ______________ Running ______ Location ______________

Peak ______ Number ______________ Speed Range ______________ Output ______________ Gear/Pulley Ratio _____________ Run/Stop: Speed/Torque Controlled ________ 2-Wire ___ or 3-Wire ___ Contro Accuracy Required _____________ Location(s) ______________ Inertia ______________ Numbers ______________ Location ______________ Speed Reference: 0-10 Vdc ___ Number ______________ or 4-20 mA ___

• Power Supply: • Auxiliary Devices: Circuit Breaker / Amps __________ Reactors

Disconnect / Fused __________ Input _______ Location _______________ Outptu _______ Number _______________ Filters Source _______________ Input _______ Voltage _______________ Output _______ Frequency _______________ Bypass _______ Quality _______________

- x -

TROUBLESHOOTING / MAINTENANCE REFERENCE SHEET

• Fault Code History:

Date Fault Cause Solution

_______ _________ ____________________ ___________________________ _______ _________ ____________________ ___________________________ _______ _________ ____________________ ___________________________ _______ _________ ____________________ ___________________________ _______ _________ ____________________ ___________________________ _______ _________ ____________________ ___________________________ _______ _________ ____________________ ___________________________ _______ _________ ____________________ ___________________________ _______ _________ ____________________ ___________________________ _______ _________ ____________________ ___________________________ _______ _________ ____________________ ___________________________ _______ _________ ____________________ ___________________________ _______ _________ ____________________ ___________________________ _______ _________ ____________________ ___________________________ _______ _________ ____________________ ___________________________

• Preventive Maintenance Log:

Date Action Person

_______ _____________________________ ___________________________ _______ _____________________________ ___________________________ _______ _____________________________ ___________________________ _______ _____________________________ ___________________________ _______ _____________________________ ___________________________ _______ _____________________________ ___________________________ _______ _____________________________ ___________________________ _______ _____________________________ ___________________________ _______ _____________________________ ___________________________

- xi -

Section 1. INSTALLATION

1.1 GENERAL

The GPD 503 is a high performance sine-coded pulse width modulated AC motor drive which generates an adjustable voltage/frequency three phase output for complete speed control of any conventional squirrel cage induction motor. Automatic stall prevention and voltage boost prevents nuisance tripping during load or line side transient conditions. The GPD 503 will not induce any voltage line notching distortion back to the utility line and maintains a displacement power factor of not less than 0.95 throughout its speed range.

When properly installed, operated and maintained, the GPD 503 will provide a lifetime of service. It is mandatory that the person who operates, inspects, or maintains this equipment thoroughly read and understand this manual before proceeding.

This manual primarily describes the GPD 503, but contains basic information for the operator control station as well. For details of the operation of other units in the drive system, refer to their respective manuals.

1.2 RECEIVING

The GPD 503 is thoroughly tested at the factory. After unpacking, verify the part numbers with the purchase order (invoice). Any damages or shortages evident when the equipment is received must be reported immediately to the commercial carrier who transported the equipment. Assistance, if required, is available from your sales representative.

1.3 PHYSICAL INSTALLATION

Location of the GPD 503 is important to achieve proper performance and normal operating life. The unit should be installed in an area where it will be protected from:

• Direct sunlight, rain or moisture.

• Corrosive gases or liquids.

• Vibration, airborne dust or metallic particles.

For effective cooling as well as proper maintenance, a wall mount style GPD 503 must be installed vertically to the ground using four mounting screws. There MUST be a MINIMUM 6 in. clearance above and below the GPD 503. A MINIMUM 2 in. clearance is required on each side on the GPD 503.

A free-standing style GPD 503 must be installed with enough clearance for opening the door of the cabinet; this will ensure sufficient air space for cooling.

1-1

1.4 ELECTRICAL INSTALLATION

All basic interconnections (using the Digital Operator) are shown in Figures 1-3 through 1-6.

1.4.1 Main Circuit Input/Output

Complete wiring interconnections for the main circuit according to Tables 1-1 and 1-2, while observing the following:

CAUTION

Use only factory supplied instructions to install dynamic braking resistors. Failure to do so may cause equipment damage or personal injury.

• Use 600 V vinyl-sheathed wire or equivalent. Wire size should be determined

considering voltage drop of leads.

• NEVER connect AC main power to output terminals T1 ( U ), T2 ( V ), and T3 ( W ).

• NEVER allow wire leads to contact the GPD 503 enclosure. Short-circuit may result.

• NEVER connect power factor correction capacitors or noise filter to GPD 503 output.

• SIZE OF WIRE MUST BE SUITABLE FOR CLASS I CIRCUITS.

• Use UL listed closed loop connectors or CSA certified ring connectors sized for the

selected wire gauge. The connectors are to be installed using the correct crimp tool recommended by the connector manufacturer.

WIRE SIZE

AWG mm

20 0.5 M3.5 1.25 - 3.5 7.8 0.9 7.0 0.8 18 0.75 M4 1.25 - 4 13.0 1.5 10.4 1.2 16 1.25 M4 1.25 - 4 13.0 1.5 10.4 1.2

14 2 12 3.5 10 5.5

88 6 14 M6 14 - 6 40.9 34.8 4.8 4.1

4 22 M8 22 - 8 100.0 82.6 11.7 10.7 238

1/0 60 M10 60 - 10 182.6 156.5 21.4 18.4 3/0 80 M10 80 - 10 182.6 156.5 21.4 18.4

4/0 100

MCM300 150 M12 150 - 12 313.0 191.3 36.7 23.1 MCM400 200 M12 200 - 12 313.0 191.3 36.7 23.1 MCM650 325 M12 325 - 12 313.0 191.3 36.7 23.1

2 SCREW CONNECTOR

TERMINAL CLOSED-LOOP

M4 2 - 4 13.0 1.5 10.4 1.2 M5 2 - 5 26.1 20.9 3.1 2.4 M4 3.5 - 4 13.0 1.5 10.4 1.2 M5 3.5 - 5 26.1 20.9 3.1 2.4 M4 5.5 - 4 13.0 1.5 10.4 1.2 M5 5.5 - 5 26.1 20.9 3.1 2.4 M5 8 - 5 26.1 20.9 3.1 2.4 M6 8 - 6 40.9 34.8 4.8 4.1

M8 38 - 8 100.0 82.6 11.7 10.7

M10 38 - 10 182.6 156.5 21.4 18.4

M10 100 - 10 182.6 156.5 21.4 18.4 M12 100 - 12 313.0 191.3 36.7 23.1

CLAMPING TORQUE

STEEL COPPER

lb-in N-m lb-in N-m

1-2

Table 1-1. Wire Sizing For Main Circuit

SECTION A. 230V

DRIVE TERMINAL

HP TERMINAL WIRE SIZE

MODEL NO.

RATING TERMINAL SYMBOL SCREW AWG MM2

DS305 L1 (R),L2 (S),L3 (T),–, B1/+, B2, T1 (U), T2 (V),T3 (W),G (E) M4 14 - 10 2 - 5.5 DS302, L1 (R), L2 (S), L3 (T),–,B1/+, B2, T1 (U), T2 (V), T3 (W) M4 14 - 10 2 - 5.5

DS306 G (E) M4 12 - 10 3.5 - 5.5 DS307 L1 (R),L2 (S),L3 (T),–, B1/+, B2, T1 (U), T2 (V),T3 (W),G (E) M4 10 5.5 DS308, L1 (R), L2 (S), L3 (T), –, B1/+, B2, T1 (U), T2 (V), T3 (W) M5 8 8

DS309 G (E) M5 10 5.5 DS310 L1 (R), L2 (S), L3 (T), B0/–, B1/+, T1 (U), T2 (V), T3 (W) M6 4 22

DS311 L1 (R), L2 (S), L3 (T), B0/–, B1/+, T1 (U), T2 (V), T3 (W) M8 3 - 1/0 30 - 60

DS322 L1 (R), L2 (S), L3 (T), B0/–, B1/–, B1/+, T1 (U), T2 (V), T3 (W) M8 2 - 1/0 38 - 60

DS323 L1 (R), L2 (S), L3 (T), B0/–, B1/+, T1 (U), T2 (V), T3 (W) M8 1/0 60

DS2040 L1 (R), L2 (S), L3 (T), –, +1, +3, T1 (U), T2 (V), T3 (W) M10 2 - 4/0 38 - 100

GPD503-2L40

DS2050 L1 (R), L2 (S), L3 (T), –, +1, +3, T1 (U), T2 (V), T3 (W) M10 2 - 4/0 38 - 100

GPD503-2L50

DS2060 L1 (R), L2 (S), L3 (T), –, +1, +3, T1 (U), T2 (V), T3 (W) M10 2 - 4/0 38 - 100

GPD503-2L60

DS2075 L1 (R), L2 (S), L3 (T),–,+1, +3, T1 (U), T2 (V), T3 (W) M10 2 - 4/0 38 - 100

GPD503-2L75

DS2100 L1 (R), L2 (S), L3 (T),–,+1, +3, T1 (U), T2 (V), T3 (W) M12 4/0 -

GPD503-2L100

TERMINAL SYMBOL

G (E)

l

1 (r), l2 (s) M4 14 - 10 2 - 5.5

G (E)

l

1 (r), l2 (s) M4 14 - 10 2 - 5.5

G (E)

l

1 (r), l2 (s) M4 14 - 10 2 - 5.5

G (E)

l

1 (r), l2 (s) M4 14 - 10 2 - 5.5

G (E)

l

1 (r), l2 (s) M4 20 - 14 0.5 - 2

L1 (R), L2 (S), L3 (T), – (N), +3 (P3), T1 (U), T2 (V), T3 (W) M10 2 - 4/0 38 - 100 G (E)

l

1 (r), l2 (s) M4 20 - 14 0.5 - 2

G (E)

l

1 (r), l2 (s) M4 20 - 14 0.5 - 2

L1 (R), L2 (S), L3 (T), – (N), +3 (P3), T1 (U), T2 (V), T3 (W) M10 2 - 4/0 38 - 100 G (E)

l

1 (r), l2 (s) M4 20 - 14 0.5 - 2

G (E)

l

1 (r), l2 (s) M4 20 - 14 0.5 - 2

L1 (R), L2 (S), L3 (T), – (N), +3 (P3), T1 (U), T2 (V), T3 (W) M10 2 - 4/0 38 - 100 G (E)  4 - 2 22 - 38

l

1 (r), l2 (s) M4 20 - 14 0.5 - 2

G (E)

l

1 (r), l2 (s) M4 20 - 14 0.5 - 2

L1 (R), L2 (S), L3 (T), – (N), +3 (P3), T1 (U), T2 (V), T3 (W) M10 2 - 4/0 38 - 100 G (E)

l

1 (r), l2 (s) M4 20 - 14 0.5 - 2

G (E)

l

1 (r), l2 (s) M4 20 - 14 0.5 - 2

L1 (R), L2 (S), L3 (T), – (N), +3 (P3), T1 (U), T2 (V), T3 (W) M12 4/0 G (E)

l

1 (r), l2 (s) M4 20 - 14 0.5 - 2

SCREW AWG mm

 8 - 2 8 - 38

 6 - 2 14 - 38

 4 - 2 22 - 38

 3 - 2 30 - 38

 4 - 2 22 - 38

 1 - 2/0 50 - 67

WIRE SIZE

MCM400

100 - 200

2

 indicates terminal uses a pressure lug.

1-2.1

( "L" ) (06/22/95)

Table 1-1. Wire Sizing For Main Circuit - Continued

Section B. 460V

DRIVE TERMINAL

DRIVE TERMINAL WIRE SIZE

MODEL NO.

MODEL NO. TERMINAL SYMBOL SCREW AWG mm

DS313, DS304,

TERMINAL SYMBOL

SCREW AWG mm

L1 (R), L2 (S), L3 (T), –, B1/+, B2, T1 (U), T2 (V), T3 (W), G (E) M4 14 - 10 2 - 5.5

DS314

DS315 L1 (R), L2 (S), L3 (T), –, B1/+, B2, T1 (U), T2 (V), T3 (W) M4 14 - 10 2 - 5.5

G (E) M5 12 - 10 3.5 - 5.5

DS316 L1 (R), L2 (S), L3 (T), –, B1/+, B2, T1 (U), T2 (V), T3 (W) M4 12 - 10 3.5 - 5.5

G (E) M5 12 - 10 3.5 - 5.5

DS317 L1 (R), L2 (S), L3 (T), –, B1/+, B2, T1 (U), T2 (V), T3 (W) M4 10 5.5

G (E) M5 10 5.5

DS318, L1 (R), L2 (S), L3 (T), –, B1/+, B2, T1 (U), T2 (V), T3 (W) M5 8 8 DS326 G (E)  10 - 2 5.5 - 38

l

1 (r), l2 (s) M4 14 - 10 2 - 5.5

DS325 L1 (R), L2 (S), L3 (T), B0/–, B1/+, T1 (U), T2 (V), T3 (W) M6 6 - 4 14 - 22

G (E)  8 - 2 8 - 38

l

1 (r), l2 (s) M4 14 - 10 2 - 5.5

DS330 L1 (R), L2 (S), L3 (T), B0/–, B1/+, T1 (U), T2 (V), T3 (W) M6 4 22

G (E)  8 - 2 8 - 38

l

1 (r), l2 (s) M4 14 - 10 2 - 5.5

DS340 L1 (R), L2 (S), L3 (T), B0/–, B1/+, T1 (U), T2 (V), T3 (W) M8 3 - 1/0 30 - 60

G (E)  8 - 2 8 - 38

l

1 (r), l2 (s) M4 14 - 10 2 - 5.5

DS350 L1 (R), L2 (S), L3 (T), B0/–, B1/+, T1 (U), T2 (V), T3 (W) M8 2 - 1/0 38 - 60

G (E)  6 - 2 14 - 38

l

1 (r), l2 (s) M4 14 - 10 2 - 5.5

DS360 L1 (R), L2 (S), L3 (T), B0/–, B1/+, T1 (U), T2 (V), T3 (W) M8 1/0 60

G (E)  6 - 2 14 - 38

l

1 (r), l2 (s) M4 14 - 10 2 - 5.5

DS075, L1 (R), L2 (S), L3 (T), –, B1/+, B2, +3, T1 (U), T2 (V), T3 (W) M10 2 - 4/0 38 - 100 DS100 G (E)  4 - 2 22 - 38

l

1 (r), l2 200 (s200), l2 400 (s400), x, y M4 20 - 14 0.5 - 2

GPD503-4L75,

GPD503-4L100

L1 (R), L2 (S), L3 (T), – (N), +3 (P3), T1 (U), T2 (V), T3 (W) M10 2 - 4/0 38 - 100 G (E)  4 - 2 22 - 38

l

1 (r), l2 200 (s200), l2 400 (s400), x, y M4 20 - 14 0.5 - 2

DS150 L1 (R), L2 (S), L3 (T), –, B1/+, B2, +3, T1 (U), T2 (V), T3 (W) M10 2 - 4/0 38 - 100

G (E)  3 - 2 30 - 38

l

1 (r), l2 200 (s200), l2 400 (s400), x, y M4 20 - 14 0.5 - 2

GPD503-4L150

L1 (R), L2 (S), L3 (T), –, B1/+, B2, +3, T1 (U), T2 (V), T3 (W) M10 2 - 4/0 38 - 100 G (E)  3 - 2 30 - 38

l

1 (r), l2 200 (s200), l2 400 (s400), x, y M4 20 - 14 0.5 - 2

DS200 L1 (R), L2 (S), L3 (T), –, B1/+, B2, +3, T1 (U), T2 (V), T3 (W) M12 4/0-

G (E)  1 - 2/0 50 - 67

l

1 (r), l2 200 (s200), l2 400 (s400), x, y M4 20 - 14 0.5 - 2

GPD503-4L200

L1 (R), L2 (S), L3 (T), – (N), +3 (P3), T1 (U), T2 (V), T3 (W) M12 4/0 G (E)  1 - 2/0 50 - 67

l

1 (r), l2 200 (s200), l2 400 (s400), x, y M4 20 - 14 0.5 - 2

DS250, L1 (R), L2 (S), L3 (T), –, +1, +3, T1 (U), T2 (V), T3 (W) M12

MCM

DS303 G (E)  1/0 - 2/0 54 - 67

l

1 (r), l2 (s), x, y M4 20 - 14 0.5 - 2

DS400 L1 (R), L2 (S), L3 (T), –, +1, +3, T1 (U), T2 (V), T3 (W) M12

MCM

G (E)  2/0 67

l

1 (r), l2 (s), x, y M4 20 - 14 0.5 - 2

WIRE SIZE

MCM

400 100 - 200

MCM

400 100 - 200

650x2P325 x 2

650x2P325 x

2

P

2P

( "L" ) (04/27/95)

 indicates terminal uses a pressure lug.

1-2.2

Table 1-1. Wire Sizing For Main Circuit - Continued

Section C. 575V

DRIVE TERMINAL

DRIVE TERMINAL WIRE SIZE

MODEL NO.

MODEL NO. TERMINAL SYMBOL SCREW AWG mm

TERMINAL SYMBOL

SCREW AWG mm

DS5003, L1 (R), L2 (S), L3 (T), –, B1/+, B2, T1 (U), T2 (V), T3 (W) M4 14 - 10 2 - 5.5 DS5004 G (E) M4 14 - 10 2 - 5.5

DS5006 L1 (R), L2 (S), L3 (T), –, B1/+, B2, T1 (U), T2 (V), T3 (W) M4 14 - 10 2 - 5.5

G (E) M5 14 - 10 2 - 5.5

DS5009, L1 (R), L2 (S), L3 (T), –, B1/+, B2, T1 (U), T2 (V), T3 (W) M4 12 - 10 3.5 - 5.5 DS5012 G (E) M5 12 - 10 3.5 - 5.5

DS5017 L1 (R), L2 (S), L3 (T), –, B1/+, B2, T1 (U), T2 (V), T3 (W) M5 10 - 8 5.5 - 8

G (E)  12 - 2 3.5 - 30

l

1 (r), l2 (s) M4 14 - 10 2 - 5.5

DS5022 L1 (R), L2 (S), L3 (T), –, B1/+, B2, T1 (U), T2 (V), T3 (W) M6 8 - 6 8 - 14

G (E)  12 - 2 3.5 - 30

l

1 (r), l2 (s) M4 14 - 10 2 - 5.5

DS5027 L1 (R), L2 (S), L3 (T), –, B1/+, B2, T1 (U), T2 (V), T3 (W) M6 8 - 6 8 - 14

G (E)  10 - 2 5.5 - 30

l

1 (r), l2 (s) M4 14 - 10 2 - 5.5

DS5032 L1 (R), L2 (S), L3 (T), B0/–, B1/+, B2, T1 (U), T2 (V), T3 (W) M6 8 - 6 8 - 14

G (E)  10 - 2 5.5 - 30

l

1 (r), l2 (s) M4 14 - 10 2 - 5.5

DS5043 L1 (R), L2 (S), L3 (T), B0/–, B1/+, T1 (U), T2 (V), T3 (W) M8 6 - 1 14 - 38

G (E)  10 - 2 5.5 - 30

l

1 (r), l2 (s), x, y M4 14 - 10 2 - 5.5

DS5054 L1 (R), L2 (S), L3 (T), B0/–, B1/+, T1 (U), T2 (V), T3 (W) M8 4 - 1 22 - 38

G (E)  8 - 2 8 - 30

l

1 (r), l2 (s), x, y M4 14 - 10 2 - 5.5

DS5064 L1 (R), L2 (S), L3 (T), B0/–, B1/+, T1 (U), T2 (V), T3 (W) M8 3 - 1/0 27 - 50

G (E)  8 - 2 8 - 30

l

1 (r), l2 (s), x, y M4 14 - 10 2 - 5.5

DS5081 L1 (R), L2 (S), L3 (T), B0/–, B1/+, T1 (U), T2 (V), T3 (W) M8 1 - 2/0 38 - 60

G (E)  8 - 2 8 - 30

l

1 (r), l2 (s), x, y M4 14 - 10 2 - 5.5

DS5112 L1 (R), L2 (S), L3 (T), B0/–, B1/+, T1 (U), T2 (V), T3 (W) M8 2/0 - 3/0 60 - 80

G (E)  6 - 2/0 14 - 60

l

1 (r), l2 (s), x, y M4 14 - 10 2 - 5.5

DS5130 L1 (R), L2 (S), L3 (T), B0/–, B1/+, T1 (U), T2 (V), T3 (W) M10 3/0 - 300 80 - 150

G (E)  6 - 2/0 14 - 60

l

1 (r), l2 (s), x, y M4 14 - 10 2 - 5.5

DS5172 L1 (R), L2 (S), L3 (T), –, B1/+, B2, +3, T1 (U), T2 (V), T3 (W) M12 3000 - 400 150 - 200

G (E)  4 - 2/0 22 - 60

l

1 (r), l2 (s), x, y M4 14 - 10 2 - 5.5

DS5202 L1 (R), L2 (S), L3 (T), –, B1/+, B2, +3, T1 (U), T2 (V), T3 (W) M12 300 - 400 177 - 200

G (E)  4 - 2/0 22 - 60

l

1 (r), l2 (s), x, y M4 14 - 10 2 - 5.5

WIRE SIZE

2

 indicates terminal uses a pressure lug.

1-2.3

Table 1-2. Terminal Functions and Voltages of Main Circuit

SECTION A. 230V

TERMINAL FUNCTION

TERMINAL

1 - 10HP (CT) 15 - 30HP (CT) 40 - 100HP (CT)

1 HP 3 TO 40 HP

FUNCTION

L1 (R) L2 (S) L3 (T)

T1 (U) T2 (V) T3 (W)

l

1 (r) Power for heat sink fan

l

2 (s)

B0/– B1/+ DB Unit terminals (B1/+ & B2) * DC bus terminals – – – – – – B2

– [ – (N) ]** DC bus terminals (B1/+ & –) +3 (P3) DB Unit terminals (+1 & –) +1 (P1) [ (+3 & –) ]**

x Power supply output for y

G (E) Ground terminal (100 ohms or less)

TERMINAL

TERMINAL FUNCTION 1 TO 60 HP

L1 (R) L2 (S) L3 (T)

– – – – – –

1 - 10HP (CT) 15 - 20HP (CT) 25 - 60HP (CT) 75 - 400HP (CT)

Three phase Main circuit input power supply 200 / 208 / 220V at 50 Hz; 200 / 208 / 220 / 230V at 60 Hz

Three phase AC output to motor 0V to max. input voltage level

200-230 Vac, single phase – two lines from input power DB Unit terminals *

– – – – – –

SECTION B. 460V

FUNCTION

Three phase Main circuit input power supply 380 / 400 / 415 / 460V at 50/60 Hz

DC bus terminals (+1 & –)

[ (+3 & – ) ]**

options (220 Vac, 30 VA)

T1 (U) T2 (V) T3 (W)

l

2 (s) Power for heat sink fan

l

1 (r)

l

2 200 (s200)

l

2 400 (s400)

B0/– B1/+ DB Unit terminals DB Unit terminals DC bus terminals – – – – – B2 (B1/+ & B2) * (B1/+ & B2)

– [ – (N) ]** +3 (P3) DC bus terminals

+1 (P1)

x Power supply output for

y G (E) Ground terminal (100 ohms or less)

( "L" ) (04/27/95)

– – – – –

DC bus terminals DC bus terminals

(B1/+ & –) (B1/+ & B0/–) (+1 & –) * [ (+3 & –) ]**

– – – – – indicates that terminals are not present.

* For installation of DB (Dynamic Braking) Units, see Appendix 7.

** indicates terminal marking or connection difference for units with "L" in Model No.

Three phase AC output to motor 0V to max. input voltage level

– – – – –

230 Vac single phase Power for heat sink fan:

l

1 to l2 200: 230 Vac

l

1 to l2 400: 460 Vac

DB Unit Terminals

(+1 & –) [ (+3 & –) ]**

options (220 Vac, 30 VA)

– – – – –

DB Unit Terminals *

– – – – –

1-2.4

Table 1-2. Terminal Functions and Voltages of Main Circuit - Continued

SECTION C. 575V

FUNCTION

TERMINAL

TERMINAL FUNCTION 1 HP 3 TO 40 HP

L1 (R) Three phase Main circuit L2 (S) input power supply L3 (T) 500 / 575 / 600V at 50/60 Hz

2-10HP (CT) 15 - 30HP (CT) 40 - 200HP

(CT)

T1 (U) T2 (V) T3 (W)

l

1 (r) Power for heat sink fan

l

2 (s)

B0/– B1/+ DB Unit (B1/+ & –) DB Unit terminals (B1/+ & B2) DC bus terminals B2 DB Resistor (B1/+ & B2) DC bus terminals (B1/+ * –)

– +3 (P3) +1 (P1)

x Power supply output for options

y G (E) Ground terminal (100 ohms or less)

– – – – – indicates that terminals are not present.

* For installation of DB (Dynamic Braking) Units, see Appendix 7.

Three phase AC output to motor 0V to max. input voltage level

– – – – –

230 Vac, single phase

DB Unit terminals *

– – – – –

(220 Vac, 30 VA)

1-3

1.4 ELECTRICAL INSTALLATION Continued

WRAP BOTH ENDS OF SHEATH WITH

INSULATING TAPE

CRIMP CONNECTION

OUTER JACKET

DO NOT CONNECT

TO EXTERNAL CIRCUIT

1.4.2 Control Circuit

All basic control circuit (signal) interconnections are shown in the appropriate diagram:

• Interconnections for external two-wire control in combination with the Digital Operator are shown in Figure 1-3 (for 230V or 460V rated drives) and Figure 1-5 (for 575V rated drives).

• Interconnections for external three-wire control in combination with the Digital Operator are shown in Figure 1-4 (for 230V or 460V rated drives) and Figure 1-6 (for 575V rated drives).

Make wiring connections according to Figures 1-1 thru 1-4 and Table 1-3, observing the following :

• Signal Leads : Terminals 1-8, 11-17, and 21-27.

• Control Leads : Terminals 9 & 10 and 18-20.

• Power Leads : Input Terminals L1 (R), L2 (S), and L3 (T), and Output Terminals T1 (U), T2 (V), and T3 (W).

• Use twisted shielded or twisted-pair shielded wire (20-14 AWG (0.5-2mm 1-60HP (CT); 18-14 AWG (0.75-2mm

2

)for 75-400HP (CT) ) for control and signal

2

)for

circuit leads. When using shielded wire, the shield sheath MUST be connected at the GPD 503 ONLY (terminal 12). The other end should be dressed neatly and left unconnected (floating). See Figure 1-1.

• Lead length should NOT EXCEED 164 feet (50 meters). Wire sizes should be determined considering the voltage drop.

SHIELD SHEATH

TO GPD 503 SIGNAL TERMINALS

TO SHIELD SHEATH TERMINAL (TERM. 12)

Figure 1-1. Shielded Sheath Termination

1-4

Table 1-3. Terminal Functions and Signals of Control Circuit

TERMINAL FUNCTIONS LEVELS

1 2-WIRE CONTROL: Forward Run / Stop signal Run at closed, stop at open (See NOTE 2)

(See NOTE 1) 3-WIRE CONTROL: Run signal Run at closed (See NOTE 2)

2 2-WIRE CONTROL: Reverse Run / Stop signal Run at closed, stop at open (See NOTE 2)

(See NOTE 1) 3-WIRE CONTROL: Stop signal Stop at open (See NOTE 2)

3 External fault input Fault at closed (see NOTE 2). When the External

Fault input is applied, the GPD 503’s Fault relay trips (shutdown) and the motor coasts to a stop.

EF3

The Digital Operator displays “

4 Fault Reset input (external) Fault Reset at closed (see NOTE 2). The Fault

Reset input will reset the Fault relay, if the GPD 503 is in “stopped” condition. Both Forward Run/Stop signal and Reverse Run/Stop signal must be OPEN.

5 - 8 External signal inputs (see NOTE 2); functions as defined by settings of system constants Sn-15 thru Sn-18.

See MULTI-FUNCTION INPUT TERMINALS in the PROGRAMMABLE FEATURES section of this manual.

” failure.

9, 10 Multi-function contact output. Contact capacity:

One of 18 functions are available, by setting 250 Vac at 1A or below of system constant Sn-20. (N.O.) 30 Vdc at 1A or below

11 Sequence control input common Sequence control input 0 V

for terminals (1 - 8).

12 Connection for shield sheath of signal leads – – – –

13 0 to +10V (20K ohms)

Auto frequency reference input

14 4-20 mA (250 ohms)

15 Manual frequency reference power supply +15V (Control power supply for frequency setting:

max 20 mA)

16 Multi-function analog input; function of input signal 0 to +10V/100% (20K ohms)

is selected by setting of system constant Sn-19

17 Multi-function analog input common 0 V

18 Closed at fault

Fault contact output

19 (N.O./N.C.) Open at fault 250 Vac at 1A or below 20 Common

Contact capacity:

30 Vdc at 1A or below

1-5

Table 1-3. Terminal Functions and Signals of Control Circuit - Continued

TERMINAL FUNCTIONS LEVELS

21 Multi-function analog monitor (+) Output current or Type of analog signal (operating parameter) to be

output frequency output is selected by setting of constant bn-13.

22 Multi-function analog monitor (-) is selectable Monitor output: 0 to +11V; 2 mA maximum

25 Multi-function open One of 18 functions Photocoupler insulation output: +48V, 50mA

collector output 1 are available, by or less

setting of system

26 Multi-function open constants Sn-21

collector output 2 and Sn-22.

27 Multi-function open collector output common 0V

NOTES:

1. When Forward Run and Reverse Run inputs are both closed for more than 500 ms, the Digital Operator flashes “ condition is not stored by the GPD 503 (on Digital Operator, red lamp at STOP key does not light);

IF ONE OF THE INPUTS IS OPENED, THE MOTOR WILL IMMEDIATELY START UP

AGAIN.

2. Terminals 1-8 source +24 Vdc and operate in a Low = True (ON) configuration when connected to terminal 11.

When using relays for input to terminals 1-8, use relays with highly reliable contacts (for very small current) with a capacity of 30 Vdc or more and rated current of 100mA or higher. When using transistor (open collector) input, use transistors with rated voltage of 35 Vdc or more and rated current of 100mA or more.

EF

” and the motor (if rotating) is decelerated by the GPD 503 to a stop. This stop

1.4.3 Grounding

• The GPD 503 must be solidly grounded using main circuit ground terminal G (E). Ground resistance should be 100 ohms or less. Select lead size suitable for size of terminal screw. Make the length as short as possible.

• NEVER ground the GPD 503 in common with welding machines, motors, or other large-current electrical equipment.

• Where several GPD 503s are used, ground each directly or daisy-chain to the ground pole(s). DO NOT FORM A LOOP WITH THE GROUND LEADS.

•• •

•

CORRECT CORRECT NOT

ACCEPTABLE

1-6

1.4 ELECTRICAL INSTALLATION Continued

INPUT

RFI FILTER

L1

X3X2X1

B2

A1(L1)

(L3)C2

(L2)B2

(L1)A2

L I N E

L O A D

EARTH GROUND

SEE NOTE 2

(G)

L2

L1T3T2

T1

INPUT

OUTPUT

MagneTek Drive

EARTH GROUND

SEE NOTE 1

SEE NOTES 3, 4

OUTPUT

RFI FILTER

TO CASE

EARTH GROUND SEE NOTE 2

SEE NOTES 3, 4

A.C. MOTOR

12345

6

OUT

T3T2T1C1B1A1C2B2A2

EARTH GROUND

SEE NOTE 2

SEE NOTE 6

1.4.4 Auxiliary Input and Output Power Option Devices

Figure 1-2 is a factory guideline for proper wiring practices and relative locations within the electrical path from the line to the load. It does not imply what devices are needed for a particular application, nor does it show what devices were shipped with a particular order. Therefore, disregard those items in the diagram which are not being used in your installation.

Mount all power option devices as close to the drive, and keep electrical connections as short as possible.

DO NOT run input and output wiring in the same conduit.

CUSTOMER'S

3Ø A.C. LINE

POWER

SUPPLY

L3 L2

NOTES

1. Connect drive ground terminal or panel to

earth ground. Always use low impedance paths and connections.

2. Mount input and output RFI filters

physically close to the drive as possible (on the same panel, if possible). Filters should have a solid connection from filter case or ground terminal to drive panel or ground terminal (conduit with good bare metal to bare metal connections may serve as the path). If multiple input or output RFI filters are used, they must be wired in parallel.

3. Shield conductors with metallic conduit.

4. Connect output conduit in a manner that allows it to act as an unbroken shield from the drive panel to the motor casing.

5. RF noise filter (different from RFI filter) part no. 05P00325-0023 is a delta wye capacitor network which is wired in parallel with the drive input terminals. On the smaller drives with die cast chassis, it must be mounted externally. On the larger drives with sheet metal chassis, it may be mounted inside the area where the input power wiring enters the drive. On units equipped with bypass, it may be wired to the primary side of the circuit breaker and mounted to the bypass panel or sidewall.

6. Connection points:

Drive w/o Bypass Drive w/ Bypass

Input

Output

L1, L2, L3

T1, T2, T3

Ckt BrkrL1, L2, L3

Unwired side of

Overload relay

ISOLATION

TRANSFORMER

H3 H2

H1

as

REACTOR

C1 B1

A1

RF NOISE

FILTER

INPUT

OUTPUT

REACTOR

C2

A2

SEE NOTE 5

GND

C1(L3) B1(L2)

SEE NOTE 3

L3

IN

Figure 1-2. Customer Connection Diagram For Isolation Transformers,

Input Reactors, Input RFI Filters, Output Reactors and Output RFI FIlters

1-7

NOTES FOR FIGURE 1-3

✱ – Indicates components not supplied.

■ – Indicates customer connection terminal. Wire only to terminals shown.

( ) – Indicates alternate terminal marking, i.e., (R) and L1.

▲ – Function labels shown for these terminals are determined by factory settings of System Constants

Sn–15 through Sn-18.

● – Function labels shown for these terminals are determined by factory settings of System Constants

Sn–20 through Sn-22.

■ – Function labels shown for these terminals are determined by factory setting of System Constant

Sn-05 ( X X X X ).

 – Function label shown for this terminal is determined by factory setting of System Constant Sn-19.

1. If only a remote Manual Speed pot (1RH) is used, 3SS is not needed; in that case, a jumper must be added between terminals 5 and 11. This jumper will override both the Auto and Digital Operator frequency references, regardless of the programming of Sn-04 X X X X. If you are using a remote speed command or the Digital Operator, DO NOT install this jumper.

2. The GPD 503 Electronic Thermal Overload function (Sn-17, Cn-09) meets standards set by UL and CSA for motor thermal overload protection. If local code requires separate mechanical overload protection, an overload relay should be installed, interlocked with the GPD 503 as shown. It should be the manual reset type to prevent automatic restart following a motor fault and subsequent contact reclosure after cool down.

3. Insulated twisted shielded wire is required.

2-conductor #18 GA. (Beldon #8760 or equivalent). 3-conductor #18 GA. (Beldon #8770 of equivalent).

Connect shield ONLY AT GPD 503 END. Stub and isolate other end.

4. Digital Operator is standard on every GPD 503. Remote operators, as shown, may not be required.

5. Customer to connect terminal G (E) to earth ground.

6. Wire only one Auto Reference input.

7. If the Dynamic Braking (DB) option is used, wire per Appendix 7 instructions.

1-8

L1 L2 L3

1516171214

13

V/HZ PROFILE

+15Vdc (20mA MAX)

FWD

▲

●

FWD

RUN/STOP

COM

SHIELD

4-20mA (250

DIGITAL

OPERATOR

PRGM DRIVE

0 TO 10Vdc (20K

SEE

NOTE 4

REMOTE DRIVE FWD REV SEQ REF

DSPL

4-20mA

0-10V

EXT. FAULT ✱

SEE NOTE 3

JOG

MAN SPEED

AUTO

MAN

SEE NOTE 1

7

REV

AUTO/MAN

MULTI-STEP FREQ

SELECT

FAULT

CONTACTS

RY2

19

20

ANALOG OUTPUT (0-10 Vdc)

OPEN

COLLECTOR

CIRCUIT

25

26

RESET

FWD REV

RUN

RY CONTACTS CAPACITY: 1A AT 250Vac 1A AT 30Vdc

MULTI-FUNCTION MONITOR OUTPUT 0 - +10V 2mA MAX.

MULTIFUNCTION OPEN COLLECTOR OUTPUTS CAPACITY: 50mA AT 48Vdc MAX.

(T2)

(T1) (T3)

200V 380V 440V

220/ 400/ 460V 230V 415V

VOLTAGE SELECTOR

(460V, 15HP (CT) AND ABOVE)

FACTORY SET FOR 460V

EARTH

GROUND

SEE NOTE 5

1OL ✱

SEE NOTE 2

(R) (S) (T)

(E)

(U) (V) (W)

2SS ✱

REV

RUN/STOP

■



B1 or B0/–

B2 or B1/+

1

2

COOLING

FAN

POWER

(15HP (CT) AND ABOVE)

1RH ✱

2K / 2.5K

SEE NOTE 1

1R ✱

3ø POWER SUPPLY (SEE NAMEPLATE DATA)

L1 L2 L3

1CB ✱

2K

▲

1SS ✱

1

MAN REF. IN (0 TO 10Vdc)

VOLTAGE

OUTPUT

(%)

GPD 503

OUTPUT FREQUENCY

(HZ)

EXT. FAULT

FAULT RESET

▲

2

3

4

5

6

TO

TERM. 12

EXT. FAULT RESET

1PB ✱

3SS ✱

1OL ✱

SEE NOTE 2

ISOLATED AUTO REFERENCE ✱ SEE NOTE 6

FOR WIRING DYNAMIC BRAKING OPTION

SEE NOTE 7

FOR UNITS WITH "L" IN MODEL NO.

– (N)

+3

(P3)

STOP

DATA

ENTER

COAST STOP (BASE BLOCK)

RUN CONTACT

OPEN

COLLECTOR

CIRCUIT

JOG SPEED

0 VOLTS

RY1

RY2

8

11

●

9

10

TERMINALS 1-8: IF INPUT FROM RELAY CONTACTS: RATED 30Vdc OR MORE, 100mA OR MORE IF OPEN COLLECTOR INPUT: RATED 35Vdc OR MORE, 100mA OR MORE

18

21 22

●

27

G

Figure 1-3. 230V or 460V Interconnections - 2-Wire Control

GPD 503 BASIC INTERCONNECT DIAGRAM FOR 2-WIRE CONTROL

T1 T2 T3

AC MOTOR ✱

(with constant Sn-04 set to 0000, Sn-15 set to 03,

Sn-16 set to 04, Sn-17 set to 06, and Sn-18 set to 08 )

1-9

( "L" ) (04/27/95)

NOTES FOR FIGURE 1-4

✱ – Indicates components not supplied.

■ – Indicates customer connection terminal. Wire only to terminals shown.

( ) – Indicates alternate terminal marking, i.e., (R) and L1.

▲ – Function labels shown for these terminals are determined by 3-Wire Control settings of System

Constants Sn-16 through Sn-18: Sn-16 =

03

, Sn-17 = 04, Sn-18 = 06.

● – Function labels shown for these terminals are determined by factory settings of System Constants

Sn–20 through Sn-22.

■ – Function labels shown for these terminals are determined by factory setting of System Constant

Sn-05 ( X X X X ).

 – Function label shown for this terminal is determined by factory setting of System Constant Sn-19.

1. If only a remote Manual Speed pot (1RH) is used, 2SS is not needed; in that case, a jumper must be added between terminals 6 and 11. This jumper will override both the Auto and Digital Operator frequency references, regardless of the programming of Sn-04 X X X X. If you are using a remote speed command or the Digital Operator, DO NOT install this jumper.

2. The GPD 503 Electronic Thermal Overload function (Sn-17, Cn-09) meets standards set by UL and CSA for motor thermal overload protection. If local code requires separate mechanical overload protection, an overload relay should be installed, interlocked with the GPD 503 as shown. It should be the manual reset type to prevent automatic restart following a motor fault and subsequent contact reclosure after cool down.

3. Insulated twisted shielded wire is required.

2-conductor #18 GA. (Beldon #8760 or equivalent). 3-conductor #18 GA. (Beldon #8770 or equivalent).

Connect shield ONLY AT GPD 503 END. Stub and isolate other end.

4. Digital Operator is standard on every GPD 503. Remote operators, as shown, may not be required.

5. Customer to connect terminal G (E) to earth ground.

6. Wire only one Auto Reference input.

7. If the Dynamic Braking (DB) option is used, wire per Appendix 7 instructions.

CAUTION

Before running, Sn-03 must be set to "0000". Resetting drive constant Sn-03 to "1110" may cause the motor to run in the reverse direction WITHOUT A RUN COMMAND, and possibly result in damage to the equipment or personal injury.

1-10

GPD 503

15

16

MAN REF. IN (0 TO 10Vdc)

RUN

▲

SEE

NOTE 4

2PB ✱

MAN SPEED 1RH ✱

2K / 2.5K

AUTO

MAN

1SS ✱

SEE NOTE 1

1

MULTI-STEP

FREQ

SELECT

MULTIFUNCTION OPEN COLLECTOR OUTPUTS CAPACITY: 50mA AT 48Vdc MAX.

AC MOTOR ✱

(T2)

(T1) (T3)

G

220/ 400/ 460V 230V 415V

VOLTAGE SELECTOR

GPD 503 BASIC INTERCONNECT DIAGRAM FOR 3-WIRE CONTROL

TERMINALS 1-8: IF INPUT FROM RELAY CONTACTS: RATED 30Vdc OR MORE, 100mA OR MORE; IF OPEN COLLECTOR INPUT: RATED 35Vdc OR MORE, 100mA OR MORE

SEE NOTE 1

ISOLATED AUTO REFERENCE ✱ SEE NOTE 6

1R ✱

4-20mA

0-10V

FOR WIRING DYNAMIC BRAKING OPTION

SEE NOTE 7

FOR UNITS WITH "L" IN MODEL NO.

– (N)

+3

(P3)

3ø POWER SUPPLY (SEE NAMEPLATE DATA)

L1 L2 L3

1CB ✱

2K

+15Vdc (20mA MAX)



17

COM

SHIELD

12

4-20mA

14

(250

0 TO 10Vdc

13

(20K

B1 or

L1 L2 L3

(R) (S) (T)

V/HZ PROFILE

OUTPUT

VOLTAGE

(%)

OUTPUT FREQUENCY

REMOTE DRIVE FWD REV SEQ REF

PRGM DRIVE

JOG

FWD REV

RUN

(HZ)

DIGITAL

OPERATOR

DSPL

DATA

ENTER

RESET

STOP

1

COOLING

FAN

POWER

B0/–

B2 or B1/+

(460V, 15HP (CT) AND ABOVE)

FACTORY SET FOR 460V

200V 380V 440V

ANALOG OUTPUT (0-10 Vdc)

(15HP (CT) AND ABOVE)

2

STOP

EXT. FAULT

FAULT RESET

FWD/REV

AUTO/MAN

JOG SPEED

0 VOLTS

RUN CONTACT

RY1

FAULT

CONTACTS

RY2

▲

2

3

4

5

6

7

8

11

●

9

10

18

19

20

■

21 22

TO

TERM. 12

STOP

EXT. FAULT RESET

RY CONTACTS CAPACITY: 1A AT 250Vac 1A AT 30Vdc

RUN

1PB ✱

1OL ✱

EXT. FAULT ✱

3PB ✱

SEE NOTE 3

FWD

REV

2SS ✱

MULTI-FUNCTION MONITOR OUTPUT 0 - +10V 2mA MAX.

SEE NOTE 2

●

(E)

(U) (V) (W) T1 T2 T3

OPEN

COLLECTOR

CIRCUIT

OPEN

COLLECTOR

CIRCUIT

25

●

26

27

EARTH

GROUND

SEE NOTE 5

Figure 1-4. 230V or 460V Interconnections - 3-Wire Control

(with constant Sn-04 set to 0000, Sn-15 set to 00,

Sn-16 set to 03, Sn-17 set to 04, and Sn-18 set to 06 )

1-11

1OL ✱

SEE NOTE 2

( "L" ) (04/27/95)

NOTES FOR FIGURE 1-5

✱ – Indicates components not supplied.

■ – Indicates customer connection terminal. Wire only to terminals shown.

( ) – Indicates alternate terminal marking, i.e., (R) and L1.

▲ – Function labels shown for these terminals are determined by factory settings of System Constants

Sn–15 through Sn-18.

● – Function labels shown for these terminals are determined by factory settings of System Constants

Sn–20 through Sn-22.

■ – Function labels shown for these terminals are determined by factory setting of System Constant

Sn-05 ( X X X X ).

 – Function label shown for this terminal is determined by factory setting of System Constant Sn-19.

1. If only a remote Manual Speed pot (1RH) is used, 3SS is not needed; in that case, a jumper must be added between terminals 5 and 11. This jumper will override both the Auto and Digital Operator frequency references, regardless of the programming of Sn-04 X X X X. If you are using a remote speed command or the Digital Operator, DO NOT install this jumper.

2. The GPD 503 Electronic Thermal Overload function (Sn-17, Cn-09) meets standards set by UL and CSA for motor thermal overload protection. If local code requires separate mechanical overload protection, an overload relay should be installed, interlocked with the GPD 503 as shown. It should be the manual reset type to prevent automatic restart following a motor fault and subsequent contact reclosure after cool down.

3. Insulated twisted shielded wire is required.

2-conductor #18 GA. (Beldon #8760 or equivalent). 3-conductor #18 GA. (Beldon #8770 of equivalent).

Connect shield ONLY AT GPD 503 END. Stub and isolate other end.

4. Digital Operator is standard on every GPD 503. Remote operators, as shown, may not be required.

5. Customer to connect terminal G (E) to earth ground.

6. Wire only one Auto Reference input.

7. If the Dynamic Braking (DB) option is used, wire per Appendix 7 instructions.

1-12

L1 L2 L3

+15Vdc (20mA MAX)

MAN REF. IN (0 TO 10Vdc)

FWD

▲▲▲

OUTPUT

VOLTAGE

(%)

SHIELD

4-20mA (250

OUTPUT FREQUENCY

(HZ)

4-20mA

1OL ✱

EXT. FAULT ✱

EXT. FAULT RESET

1PB ✱

SEE NOTE 3

TO

TERM. 12

JOG

1R ✱

SEE NOTE 1

AUTO

MAN

3SS ✱

1SS ✱

6

7

FAULT RESET

AUTO/MAN

FAULT

CONTACTS

RY2

OPEN

COLLECTOR

CIRCUIT

212225

26

RUN

RY CONTACTS CAPACITY: 1A AT 250Vac 1A AT 30Vdc

MULTIFUNCTION OPEN COLLECTOR OUTPUTS CAPACITY: 50mA AT 48Vdc MAX.

5000V

575/600V

VOLTAGE SELECTOR

(15HP AND ABOVE)

FACTORY SET FOR 575/600V

(R) (S) (T)

REV

RUN/STOP



TERMINALS 1-8: IF INPUT FROM RELAY CONTACTS: RATED 30Vdc OR MORE, 100mA OR MORE IF OPEN COLLECTOR INPUT: RATED 35Vdc OR MORE, 100mA OR MORE

FOR WIRING DYNAMIC BRAKING OPTION

SEE NOTE 7

3ø POWER SUPPLY (SEE NAMEPLATE DATA)

L1 L2 L3

1CB ✱

(15HP AND ABOVE)

FWD

RUN/STOP

MAN SPEED 1RH ✱

2K / 2.5K

ISOLATED AUTO REFERENCE ✱ SEE NOTE 6

0-10V

2K

15

GPD 503

V/HZ PROFILE

17

16

COM

12

COOLING

FAN

POWER

REV

EXT. FAULT

▲

1

▲

2

3

2SS ✱

SEE NOTE 2

4

SELECT

JOG SPEED

0 VOLTS

RY1

RY2

▲

5

SEE NOTE 1

8

11

●

9

10

18

19

20

■

MULTI-FUNCTION MONITOR OUTPUT 0 - +10V 2mA MAX.

12

14

13

B1 or B0/–

B2 or B1/+

SEE

NOTE 4

0 TO 10Vdc (20K

REMOTE DRIVE FWD REV SEQ REF

DIGITAL

OPERATOR

PRGM DRIVE

FWD REV

DSPL

STOP

DATA

ENTER

RESET

MULTI-STEP FREQ

COAST STOP (BASE BLOCK)

RUN CONTACT

ANALOG OUTPUT (0-10 Vdc)

●

OPEN

COLLECTOR

CIRCUIT

●

27

(E)

G

EARTH

GROUND

SEE NOTE 5

Figure 1-5. 575V Interconnections - 2-Wire Control

GPD 503 BASIC INTERCONNECT DIAGRAM FOR 2-WIRE CONTROL

(U) (V) (W) T1 T2 T3

(T2)

(T1) (T3)

AC MOTOR ✱

1OL ✱

SEE NOTE 2

(with constant Sn-04 set to 0000, Sn-15 set to 03,

Sn-16 set to 04, Sn-17 set to 06, and Sn-18 set to 08 )

1-13

NOTES FOR FIGURE 1-6

✱ – Indicates components not supplied.

■ – Indicates customer connection terminal. Wire only to terminals shown.

( ) – Indicates alternate terminal marking, i.e., (R) and L1.

▲ – Function labels shown for these terminals are determined by 3-Wire Control settings of System

Constants Sn-16 through Sn-18: Sn-16 =

03

, Sn-17 = 04, Sn-18 = 06.

● – Function labels shown for these terminals are determined by factory settings of System Constants

Sn–20 through Sn-22.

■ – Function labels shown for these terminals are determined by factory setting of System Constant

Sn-05 ( X X X X ).

 – Function label shown for this terminal is determined by factory setting of System Constant Sn-19.

1. If only a remote Manual Speed pot (1RH) is used, 2SS is not needed; in that case, a jumper must be added between terminals 6 and 11. This jumper will override both the Auto and Digital Operator frequency references, regardless of the programming of Sn-04 X X X X. If you are using a remote speed command or the Digital Operator, DO NOT install this jumper.

2. The GPD 503 Electronic Thermal Overload function (Sn-17, Cn-09) meets standards set by UL and CSA for motor thermal overload protection. If local code requires separate mechanical overload protection, an overload relay should be installed, interlocked with the GPD 503 as shown. It should be the manual reset type to prevent automatic restart following a motor fault and subsequent contact reclosure after cool down.

3. Insulated twisted shielded wire is required.

2-conductor #18 GA. (Beldon #8760 or equivalent). 3-conductor #18 GA. (Beldon #8770 or equivalent).

Connect shield ONLY AT GPD 503 END. Stub and isolate other end.

4. Digital Operator is standard on every GPD 503. Remote operators, as shown, may not be required.

5. Customer to connect terminal G (E) to earth ground.

6. Wire only one Auto Reference input.

7. If the Dynamic Braking (DB) option is used, wire per Appendix 7 instructions.

CAUTION

Before running, Sn-03 must be set to "0000". Resetting drive constant Sn-03 to "1110" may cause the motor to run in the reverse direction WITHOUT A RUN COMMAND, and possibly result in damage to the equipment or personal injury.

1-14

Yaskawa GPD503 User Manual

GPD 503 SIMPLIFIED START-UP PROCEDURE

Horsepower Range

CONTENTS

Section 1. INSTALLATION

1.1 GENERAL

1.2 RECEIVING

1.3 PHYSICAL INSTALLATION

1.4 ELECTRICAL INSTALLATION

1.4.1 Main Circuit Input/Output

1.4.2 Control Circuit

1.4.3 Grounding

1.4.4 Auxiliary Input and Output Power Option Devices