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Publication No. T1641Issue Date 05/99

Issue 05/99 ALSPA GD DELTA (T1641)ALSPA GD DELTA (T1641) Page i

ALSPA GD DELTAALSPA GD DELTA

Technical DataTechnical Data

and Assembly Instructionsand Assembly Instructions

Publication No. T1641

ALSTOM DRIVES & CONTROLSKidsgrove,

Stoke-on-Trent,Staffordshire, ST7 1TW

ENGLAND

Telephone: +44 (0) 1782) 781000 Fax: +44 (0) 1782) 781001

Latest Reprint: see page ii

Safety Instructions ALSPA GD DELTA

Page ii ALSPA GD DELTA (T1641)ALSPA GD DELTA (T1641) Issue 05/99

ISSUE INFORMATION

The issue of various chapters of the GD DELTA manual are individually controlled. The currentissue status of the manual is :-

18-95-99 Issue info., Appendix E,18-12-97 Index, Chapters 1, 2 & 3. Appendix E.08-04-97 Index, Appendix E.24-02-97 Chapter 4.21-01-97 Chapters 1, 2, Appendix D.06-12-96 Chapters 3, 5.08-05-96 Appendix A, B, C.05/99 All sections updated

ALSPA GD DELTA Safety Instructions

Issue 05/99 ALSPA GD DELTA (T1641) GD DELTA (T1641) Page iii

SAFETY INSTRUCTIONS1 General

Electrical equipment represents a risk to life.

Safety instructions are given on the product, in this manual and other relevant manuals referred to inthis manual.

Reference must be made to the instructions in this manual for any action taken when transporting,commissioning, operating, maintaining and disposing of the product.

Dangerous voltages appear on the circuitry. There can be moving parts and hot surfaces.Death, severe physical injury and extensive material damage can result if the instructionsgiven in this manual are not observed.

Local safety regulations must be observed during erection, commissioning and maintenance of theproduct. Persons performing this work must be suitably skilled and should have been trained in thatwork for these products.

Electrostatic sensitive components are used within this product. Static handling precautions inaccordance with Protection of Electrostatic Sensitive Devices, Part 1, General Requirements, EN100015 Pt.1:1992 (CECC 00015:1992) must be observed.

All products weighing in excess of 20 kg (44 lbs) should be moved by mechanical handlingequipment using the lifting points provided.

Radio transmitters (e.g. walkie talkies, mobile telephones) can cause incorrect operation.Transmitters with an output of more than 2 watts must not be used in the vicinity of the product.Transmitters with output power of 2 watts or less must not be used less than 2 metres (6 feet) fromthe product.

2 Intended use

These products are components designed for incorporation in installations, apparatus andmachines.

In the European Union, a machine should not be taken into service until the machine has beenproven to conform with the provisions of the Machinery (Safety) Directive, 89/392/EEC as amended.

In the European Union, the requirements of the EMC Directive, 89/336/EEC, and any amendmentsto that Directive should be established before any installation, apparatus or machine whichincorporates the product is taken into service.

The product complies with the requirements of the Low Voltage Directive, 73/23/EEC as amended.

The product complies with the safety and EMC standards listed in the Specifications section of themanual.

The technical data and the information concerning the supply conditions should be taken from therating plate and this manual, and must be strictly observed.

3 Transportation and storage.

Safety Instructions ALSPA GD DELTA

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The instructions for storage and transport specified on the packaging and in this manual must befollowed.

The climatic conditions should be within the limits specified in this manual.

4 Erection and commissioning.

Erection and commissioning of, and cooling medium flow to, the product should be in accordancewith the specifications given in the manual.

Erection and commissioning of the product must be carried out in line with any local electricalinstallation and wiring standards and IEC 364 or (in the United Kingdom) BS 7671.

The earth terminal must be connected to earth (safety ground) in accordance with local safetyregulations and IEC 364-5-54.

The products must be protected against excessive mechanical stresses. In particular, no componentmust be bent or isolation distances altered during the transportation, handling, installation ormaintenance of the product.

The degree of protection provided by the covers is for indoor use only.

Compliance with the requirements of EMC laws is the responsibility of the installer or themanufacturer of the machine. Instructions for erection and commissioning the product inaccordance with the EMC requirements of the European Union are given in the manual and must becomplied with. These instructions contain information on screening (shielding), earthing(grounding), wiring and relative positioning of electrical equipment.

Shrouds may be modified only as described in the manual.

5 Electrical connection

When working on the product, the local health and safety legislation must be observed.

Conductors, protective devices etc. should be provided in accordance with the requirements statedin the manual.

6 Operation

The product must not be used as a single item safety system. It may be used as a component in avoting safety system. Additional control and protective devices must be provided in accordance withthe safety requirements of the installation.

Changes by means of the application software are admissible.

Rotating motors are a source of energy and can apply high voltages to the circuitry.Capacitors can retain voltages and must be allowed to discharge. A minimum period of 5minutes must be observed after the input supply is disconnected and the rotating machineryhas stopped before access to live connections is permitted. In this respect warning labelsmust be observed.

ALSPA GD DELTA Safety Instructions

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When the product is configured for "auto start" (where relevant), it is possible that the motor mayturn without an operator command. Precautions must be taken to prevent injury to personnel.

During operation all covers and doors must be closed. If covers are removed and not replacedbefore power is reapplied there is danger of serious personal injury and damage to property. Yourattention is also drawn to the electromagnetic emission and susceptibility screening provided by theenclosure. These may be compromised when covers are removed or enclosure doors are open.

7 Maintenance and service

The information given in the documentation for maintaining and servicing the product must befollowed.

8 Disposal

Local regulations must be followed when disposing of the product.

This technical manual should be regarded as part of the product. It should be stored with theproduct and passed on to any subsequent owner or user of the product.

Any question or doubt should be referred to ALSTOM DRIVES & CONTROLS

COSHH ALSPA GD DELTA

Page vi ALSPA GD DELTA (T1641)ALSPA GD DELTA (T1641) Issue 05/99

CONTROL OF SUBSTANCES HAZARDOUS TO HEALTH

1. GENERAL

Care has been taken with selection of all components, interconnections, housing and packagingand in the design and manufacture of this equipment to minimize the risk to the health and safety ofall personnel who are in contact with this equipment during its life, when the equipment is properlyhandled and used.

Modern high technology materials have been used in the manufacture of the equipment to ensureoptimum performance. Some of these materials are toxic under certain conditions. Mechanical orelectrical damage is unlikely to give rise to any direct hazard, but toxic vapours may be generated ifthe materials are heated to destruction and it is important that the recommendations given below areobserved.

Care should be taken to ensure that all personnel who may handle, use or dispose of thisequipment are aware of the necessary precautions.

2. DISPOSAL

This equipment or any part of the equipment should be disposed of in accordance with the relevantlegislation; in the United Kingdom, disposal should therefore be carried out in accordance with theDeposit of Poisonous Waste Act 1972 and the Control of Pollution Act 1974, or with the latestlegislation.

Some devices within this equipment may contain beryllium oxide as an isolating barrier. Suchdevices must be disposed of as harmful waste.

3. FIRE

The products when used within the specified limits do not present a fire hazard.

Electronic devices within this equipment may contain arsenic, beryllium, lead, mercury, selenium,tellurium or similar hazardous materials or compounds which, if exposed to high temperature mayemit toxic or noxious fumes.

Most device encapsulation materials are flammable and care should be taken in the disposal of theequipment, and, in the event of a fire, the handling of damaged equipment. Toxic fumes may beemitted if the devices are burned.

4. HANDLING

Normal handling of the equipment is safe. However, care must be exercised with those devicesincorporating glass or plastic. If these devices are broken or damaged, precautions must be takenagainst the hazards that may arise.

For broken glass or ceramic protective clothing such as gloves must be worn.For toxic materials, vapour, skin contact and inhalation must be avoided.

ALSPA GD DELTA COSHH

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5. SUBSTANCES

Substances that may be included in this equipment are:-

ArsenicBoric acidEthylene GlycolPhosphoric acidPhthalic acidTributylamineTriethylamine

Certain substances such as those containing arsenic, indium, lead, lithium, selenium, tantalum, etcmay be toxic by ingestion or inhalation.

Electrolytic capacitors contain a non carcinogenic electrolyte which has a low acute toxicity whichmay cause slight irritation to the skin if contact is prolonged.

6. HAZARDOUS COMPONENTS

Components that may include hazardous substances are:-

Batteries LithiumOptical Devices ArsenicElectrolytic capacitors Electrolyte.All encapsulated Devices Plastic (generates an inhalation

risk in a fire).

7 PRECAUTIONS

Precautions to be followed in the event of damage to the equipment except where specialprecautions to be followed are listed above, include:-

After skin contact - wash thoroughly with soap and water. If contact is where the skin isbroken, medical advice should be sought.

After eye contact - wash immediately with copious amounts of water and seek medicaladvice.

After inhalation - seek medical advice.

Scope ALSPA GD DELTA

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Scope

This publication should be read in conjunction with the appropriate GD2000E, GD3000 andGD4000 technical manuals. This publication should be regarded as part of the Alspa GDDELTA product, it should be retained for the life of the product and passed on to anysubsequent owner or user.

This document provides assembly, installation, and commissioning instructions forAlspa GD DELTA power equipment when supplied in kitted form. The associated controlequipment is covered in the supplements to the GD2000E, GD3000, GD3000E and GD4000technical manuals.

ALSPA GD DELTA Scope

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Units Covered:

GDD000-4001 DELTA Mounting Frame 600W x 800DGDD000-4002 DELTA Mounting Frame 800W x 800DGDD000-4003 DELTA Mounting Frame 1000W x 800DGDD000-4004 DELTA Mounting Frame 1200W x 800DGDD000-4005 DELTA Mounting Frame 600W x 600DGDD000-4006 DELTA Mounting Frame 800W x 600DGDD000-4007 DELTA Mounting Frame 1000W x 600DGDD000-4008 DELTA Mounting Frame 1200W x 600DGDDRIT-46X6 DELTA Mounting Kit 600W x 600D (Rittal PS4000 cubicle)GDDRIT-48X6 DELTA Mounting Kit 800W x 600D (Rittal PS4000 cubicle)GDDRIT-40X6 DELTA Mounting Kit 1000W x 600D (Rittal PS4000 cubicle)GDDRIT-42X6 DELTA Mounting Kit 1200W x 600D (Rittal PS4000 cubicle)GDDRIT-46X8 DELTA Mounting Kit 600W x 800D (Rittal PS4000 cubicle)GDDRIT-48X8 DELTA Mounting Kit 800W x 800D (Rittal PS4000 cubicle)GDDRIT-40X8 DELTA Mounting Kit 1000W x 800D (Rittal PS 4000 cubicle)GDDRIT-42X8 DELTA Mounting Kit 1200W x 800D (Rittal PS 4000 cubicle)GDD282-4501 DELTA Transistor Bridge Module, 282AGDD300-4601 DELTA Transistor Bridge Module, 300AGDD377-4501 DELTA Transistor Bridge Module, 377AGDR391-4401 DELTA Rectifier Bridge Module 391A, -480VGDR391-4601 DELTA Rectifier Bridge Module 391A, -690VGDR633-4401 DELTA Rectifier Bridge Module 633A, -480VGDR633-4601 DELTA Rectifier Bridge Module 633A, -690VGDR721-4401 DELTA Rectifier Bridge Module 721A, -480VGDR721-4601 DELTA Rectifier Bridge Module 721A, -690VGDR872-4401 DELTA Rectifier Bridge Module 872A, -480VGDR872-4601 DELTA Rectifier Bridge Module 872A, -690VGDR1168-4401 DELTA Rectifier Bridge Module 1168A, -480VGDR1168-4601 DELTA Rectifier Bridge Module 1168A, -690V30V6500/10 DELTA 3 Phase Input Reactor 630A30V6700/10 DELTA 3 Phase Input Reactor 740A30V7000/10 GD2000E/GD3000 Switch Mode Power Supply, 380-480V30V7100/10 GD2000E/GD3000 Switch Mode Power Supply, 525V30V7200/10 GD2000E/GD3000 Switch Mode Power Supply, 690V30Z4592/10 2 Fan / Contactor Transformer - Standard 380-480V30Z4583/10 4 Fan / Contactor Transformer - Standard 380-480V30Z4584/10 6 Fan / Contactor Transformer - Standard 380-480V31V1900/20 DELTA Precharge Control Panel GD4282 - GD437731V1900/30 DELTA Precharge Control Panel GD4564 - GD475431V1900/40 DELTA Precharge Control Panel GD4864 - GD4113131V1900/50 DELTA Precharge Control Panel GD41508 - GD4226231V5200/10 DELTA Cooling System - Standard Version31V5400/10 DELTA Sharing Reactor 310A31V5500/10 DELTA Sharing Reactor 414A31V5800/10 DELTA Module Lower Guide Support Plate31V6900/10 DELTA Cooling System - High Performance Version33Z0314/10 Sinusoidal Input Line Reactor 377A, -480V33Z0315/10 Sinusoidal Input Line Reactor 564A, -480V33Z0316/10 Sinusoidal Input Line Reactor 754A, -480V33Z0317/10 Sinusoidal Input Line Reactor 846A, -480V33Z0327/10 DC Link Reactor (GD*282), -480V

Scope ALSPA GD DELTA

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33Z0328/10 DC Link Reactor (GD*377/282), -480V33Z0329/10 DC Link Reactor (GD*564/377), -480V33Z0330/10 DC Link Reactor (GD*754/564), -480V33Z0331/10 DC Link Reactor (GD*846/754), -480V33Z0333/10 DC Link Reactor (GD*1131/846), -480V33Z0350/10 Interbridge Transformer (GD*282), -480V33Z0351/10 Interbridge Transformer (GD*377/282), -480V33Z0352/10 Interbridge Transformer (GD*564/377), -480V33Z0353/10 Interbridge Transformer (GD*754/564), -480V33Z0354/10 Interbridge Transformer (GD*846/754), -480V33Z0355/10 Interbridge Transformer (GD*1131/846), -480V33Z0361/10 Sinusoidal Input Line Reactor 1131A, -480V50Z0015/01 Sinusoidal Input Line Reactor 282A, -480V50Z0018/01 2 Fan / Contactor Transformer - High Performance 380-500V50Z0018/02 4 Fan / Contactor Transformer - High Performance 380-500V50Z0018/03 6 Fan / Contactor Transformer - High Performance 380-500V50Z0019/01 DC Link Reactor (GD*1131), -480V50Z0021/01 Interbridge Transformer (GD*1131), -480V50Z0031/01 Sinusoidal Input Line Reactor 335A, -690V50Z0031/02 Sinusoidal Input Line Reactor 670A, -690V50Z0031/03 Sinusoidal Input Line Reactor 1005A, -480V50Z0036/01 2 Fan / Contactor Transformer - Standard 525-690V50Z0036/02 4 Fan / Contactor Transformer - Standard 525-690V50Z0036/03 6 Fan / Contactor Transformer - Standard 525-690V50Z0037/01 2 Fan / Contactor Transformer - High Performance 525-690V50Z0037/02 4 Fan / Contactor Transformer - High Performance 525-690V50Z0037/03 6 Fan / Contactor Transformer - High Performance 525-690V50Z0038/01 DC Link Reactor (GD*300), -690V50Z0038/02 DC Link Reactor (GD*600), -690V50Z0038/03 DC Link Reactor (GD*900), -690V50Z0042/01 Sigma Power Supply Step Down Transformer50Z0043/01 Interbridge Transformer (GD*300), -690V50Z0043/02 Interbridge Transformer (GD*600), -690V50Z0043/03 Interbridge Transformer (GD*900), -690V84041/512 Precharge Contactor for GDD28284041/712 Precharge Contactor for GDD377

Units Covered in Appendix A

GDR391-4001 DELTA Rectifier Bridge Module 391A, 380-480V, Single Bridge.GDR633-4001 DELTA Rectifier Bridge Module 633A, 380-480V, Double Bridge.GDR721-4001 DELTA Rectifier Bridge Module 721A, 380-480V, Single Bridge.GDR872-4001 DELTA Rectifier Bridge Module 872A, 380-480V, Single Bridge.GDR1168-4001 DELTA Rectifier Bridge Module 1168A, 380-480V, Double Bridge.GDD282-4001 DELTA Transistor Bridge Module 282A, 380-480V.GDD282-4002 DELTA Transistor Bridge Module 282A, 380-480V.GDD282-4004 DELTA Transistor Bridge Module 282A, 380-480V.GDD377-4001 DELTA Transistor Bridge Module 377A, 380-480V.GDD377-4002 DELTA Transistor Bridge Module 377A, 380-480V.GDD377-4004 DELTA Transistor Bridge Module 377A, 380-480V.

ALSPA GD DELTA Contents

Issue 05/99 ALSPA GD DELTA (T1641)ALSPA GD DELTA (T1641) Page xi

Contents

Section Page

Issue Information.....................................................................................iiSafety Instructions .................................................................................iiiControl of Substances Hazardous to Health ........................................viScope of this Manual............................................................................ viiiUnits Covered .........................................................................................ixContents..................................................................................................xi

1 INTRODUCTION...........................................................................1-11.1 General Description ............................................................................ 1-11.1.1 About This Manual .......................................................................... 1-21.2 Features ............................................................................................... 1-21.3 DELTA System Description ................................................................ 1-21.3.1 System Overview ............................................................................ 1-31.3.2 Basic System .................................................................................. 1-31.3.3 Alspa GD2000E/GD3000/GD3000E Standard 6 Pulse Input Drive. 1-31.3.4 Alspa GD4000 Sinusoidal Input AC Drive ....................................... 1-41.3.5 Parallel Transistor Bridges .............................................................. 1-51.3.6 12 Pulse Input Rectifier ................................................................... 1-61.3.7 Parallel Rectifier Input ..................................................................... 1-61.4 Mechanical Description....................................................................... 1-71.5 Cooling ................................................................................................. 1-91.6 Reactors............................................................................................. 1-101.7 Modules .............................................................................................. 1-121.7.1 Rectifier Bridge Modules ............................................................... 1-121.7.2 Cubicle Busbars for Rectifier Modules .......................................... 1-151.7.3 Transistor Bridge Module .............................................................. 1-171.7.4 3-Phase AC Line Reactors 282A and 377A.................................. 1-191.7.5 3-Phase AC Line Reactors 630A and 754A.................................. 1-211.7.6 DELTA Cooling System ................................................................ 1-231.7.7 Lower Guide Plate Sub-assembly................................................. 1-251.7.8 DELTA Precharge Control Panel .................................................. 1-261.7.9 Fan/Contactor Supply Transformer............................................... 1-271.7.10 DELTA Mounting Kit...................................................................... 1-281.7.11 SIGMA Switch Mode Power Supply Step-Down Transformer ....... 1-291.7.12 GD2000E / GD3000 / GD3000E Switch Mode Power Supply....... 1-29

2 SPECIFICATION...........................................................................2-12.1 Alspa DELTA Components (General Environment) .......................... 2-12.1.1 Atmosphere (Operational) ..................................................................... 2-12.1.2 Atmosphere (Storage, transport)........................................................... 2-12.1.3 Mechanical ............................................................................................ 2-22.1.4 Miscellaneous Data............................................................................... 2-32.2 Rectifier Bridge Modules..................................................................... 2-42.2.1 Current Ratings............................................................................... 2-4

Contents ALSPA GD DELTA

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2.2.2 Phase Rotation ................................................................................2-62.2.3 Input Phase Voltage ........................................................................2-62.2.4 Output DC Link Voltage ...................................................................2-62.2.5 Environment.....................................................................................2-72.2.6 Thermal Protection...........................................................................2-72.2.7 Precharge ........................................................................................2-72.2.8 Terminations ....................................................................................2-82.2.9 Weight .............................................................................................2-92.3 Transistor Modules ............................................................................2-102.3.1 AC Phase Current Ratings.............................................................2-102.3.2 Phase Voltage ...............................................................................2-102.3.3 DC Link Voltage.............................................................................2-102.3.4 Weight ...........................................................................................2-112.3.5 Environment...................................................................................2-112.3.6 Terminations ..................................................................................2-112.4 3 Phase Sharing Reactors.................................................................2-112.5 Sinusoidal Input Line Reactors .........................................................2-122.5.1 GD4000 Applications .....................................................................2-122.5.2 Losses ...........................................................................................2-132.6 3 Phase Input Line Reactors .............................................................2-132.7 DC Link Reactors ...............................................................................2-152.7.1 Losses ...........................................................................................2-152.8 Interbridge Transformers...................................................................2-162.8.1 Losses ...........................................................................................2-172.9 DELTA Cooling System...................................................................... 2-182.9.1 DELTA Cooling System - Standard Version ..................................2-182.9.2 DELTA Cooling System - High Performance Version ....................2-182.10 Fan/Contactor Supply Transformers ................................................2-192.10.1 For Standard DELTA Cooling Systems..........................................2-192.10.2 For High performance DELTA Cooling Systems............................2-212.11 Miscellaneous Equipment Weights ................................................... 2-232.11.1 DELTA mounting frames................................................................2-232.11.2 DELTA Module Lower Guide Support Plate...................................2-232.11.3 Cubicle Busbars for rectifier Bridge Modules .................................2-242.12 Components For GD4000 Only .........................................................2-242.12.1 DELTA Precharge Control Panels .................................................2-242.12.2 Precharge Contactors (GD4000 only)............................................2-242.12.3 GD4000 Sigma Power Supply Step Down Transformer ................2-242.13 Components For GD2000E / GD3000 / GD3000E Only ....................2-262.13.1 GD2000E / GD3000 Switch Mode Power Supply ..........................2-26

3 MECHANICAL INSTALLATION................................................... 3-13.1 Introduction ..........................................................................................3-13.2 Receipt of Equipment ..........................................................................3-13.3 Cooling Requirements .........................................................................3-23.4 Frame Mounting Dimensions...............................................................3-23.5 Assembling Module Frames ................................................................3-43.5.1 General ............................................................................................3-43.5.2 Side Supports ..................................................................................3-43.5.3 Cross Members................................................................................3-43.5.4 Assembly Rittal PS4000 Module Frames.........................................3-6


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3.5.5 Side Supports ....................................................................................... 3-63.5.6 Cross Members ..................................................................................... 3-63.6 Fans...................................................................................................... 3-83.7 Lower Guide Support Plates............................................................. 3-113.8 Fitting Sharing Reactors ................................................................... 3-113.9 Dirty Air Intake Duct .......................................................................... 3-133.10 Phase Busbars for Rectifier Bridge Modules .................................. 3-143.10.1 GDR721 Phase Busbars............................................................... 3-143.10.2 GDR872 Phase Busbars............................................................... 3-153.10.3 GDR1168 Phase Busbars............................................................. 3-173.11 Modules .............................................................................................. 3-193.11.1 DELTA Lifting Frame..................................................................... 3-223.12 Precharge Panel ................................................................................ 3-233.13 Precharge Control Contactor ........................................................... 3-243.14 GD2000E / GD3000 Switch Mode Power Supply ............................. 3-24

4 ELECTRICAL INSTALLATION ....................................................4-14.1 Introduction ......................................................................................... 4-24.2 Rectifier Bridge Module Terminals..................................................... 4-24.2.1 Control Terminals............................................................................ 4-24.2.2 Power Terminals for GDR391 Rectifier Bridge Module ................... 4-54.2.3 Power Terminals for GDR633 Rectifier Bridge Module ................... 4-64.2.4 Power Terminals for GDR721 Rectifier Bridge Module ................... 4-74.2.5 Power Terminals for GDR872 Rectifier Bridge Module ................... 4-84.2.6 Power Terminals for GDR1168 Rectifier Bridge Module ................. 4-94.2.7 Cabling of Phase Power Terminals GDR721 - GDR1168 ............. 4-104.3 Transistor Module Terminals............................................................ 4-104.3.1 Control Terminals.......................................................................... 4-104.3.2 Gate Drive Links / Connectors ...................................................... 4-114.3.2 Power Terminals ........................................................................... 4-124.4 Power Module Earthing Requirements ............................................ 4-134.5 DELTA Precharge Control Panel...................................................... 4-134.6 Line Contactors and Relays ............................................................. 4-144.7 Fans.................................................................................................... 4-144.7.1 Standard Cooling Systems............................................................ 4-144.7.2 High Performance Cooling System ............................................... 4-154.8 Reactors............................................................................................. 4-174.9 GD2000E / GD3000 / GD3000E Switch Mode Power Supply .......... 4-17

5 CUBICLE PLANNING ........................................................................... 5-15.1.1 Guidance Sequence............................................................................ 5-15.1.2 Additional Requirements for Electro-Magnetic Compatibility .......... 5-25.2 Example 1 - GD2282 6 Pulse Input Drive ........................................... 5-45.2.1 Component List............................................................................... 5-45.2.2 Cubicle Layout ................................................................................ 5-45.3 Example 2 - GD4754 Sinusoidal Input................................................ 5-85.3.1 Component List............................................................................... 5-85.3.2 Cubicle Layout ................................................................................ 5-85.4 600mm (23.6") Deep Enclosures ...................................................... 5-115.4.1 Position of GD2000E / GD3000 Control Module ........................... 5-115.4.2 Position of GD4000 Controller ...................................................... 5-125.4.3 Position of GD2000E / GD3000 SMPS ......................................... 5-12


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5.4.4 Double Door Flanges.....................................................................5-125.5 Additional Information ........................................................................5-155.6 Outline Drawings................................................................................ 5-165.6.1 Rectifier Bridge Module GDR391...................................................5-165.6.2 Rectifier Bridge Module GDR633...................................................5-175.6.3 Rectifier Bridge Module GDR721

(with cubicle bus-bar assembly).....................................................5-185.6.4 Rectifier Bridge Module GDR721

(without cubicle bus-bar assembly)................................................5-195.6.5 Rectifier Bridge Module GDR872


(without cubicle bus-bar assembly)................................................5-215.6.7 Rectifier Bridge Module GDR1168


(without cubicle bus-bar assembly)................................................5-235.6.9 DELTA Transistor Bridge ...............................................................5-245.6.10 282/377 Amp Reactor Box.............................................................5-265.6.11 Sinusoidal Input Line Reactors ......................................................5-275.6.12 630 Amp Input Line Reactor ..........................................................5-305.6.13 754 Amp Input Line Reactor ..........................................................5-315.6.14 DC Link Reactors...........................................................................5-325.6.15 Interbridge Transformer .................................................................5-355.6.16 DELTA Cooling System - Standard Version ..................................5-375.6.17 DELTA Cooling system - High Performance Version.....................5-385.6.18 Fan/Contactor Transformer for Standard Cooling System.............5-395.6.19 Fan/Contactor Transformer for High Performance

Cooling system ...................................................................... 5-415.6.20 GD4000 Sigma Power Supply Step Down Transformer ................5-435.6.21 Dirty Air Duct..................................................................................5-445.6.22 Lower Guide Plate Assembly.........................................................5-445.5.23 Contactor DL110N (84041/512).....................................................5-455.5.24 Contactor DL165N (84041/712).....................................................5-45

APPENDIX A OTHER MODULE VERSIONSScope ............................................................................................. A-1Units Covered ................................................................................. A-1

A1 INTRODUCTION................................................................................... A-2A1.1 Rectifier Bridge Modules .............................................................. A-2A1.2 Transistor Bridge Modules ........................................................... A-5A2 SPECIFICATION................................................................................... A-7A2.1 Rectifier Bridge Modules .............................................................. A-7A2.1.1 Current Ratings............................................................................... A-7A2.1.2 Phase Rotation ............................................................................... A-8A2.1.3 Input Phase Voltage ....................................................................... A-8A2.1.4 Output DC Link Voltage .................................................................. A-8A2.1.5 Precharge ....................................................................................... A-9A2.1.6 Weight ............................................................................................ A-9A2.1.7 Environment.................................................................................... A-9A2.1.8 Terminations ................................................................................. A-10A2.1.9 Thermal Protection........................................................................ A-10


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A2.2 Transistor Modules .....................................................................A-10A2.2.1 AC Phase Current Ratings............................................................A-11A2.2.2 Phase Voltage...............................................................................A-11A2.2.3 DC Link Voltage ............................................................................A-11A2.2.4 Weight...........................................................................................A-11A2.2.5 Environment..................................................................................A-11A2.2.6 Terminations .................................................................................A-12A3 MECHANICAL INSTALLATION ..........................................................A-13A4 ELECTRICAL INSTALLATION ...........................................................A-14A4.1 Introduction .......................................................................................A-14A4.2 Rectifier Bridge Module Terminals ...................................................A-14A4.2.1 Control Terminals..........................................................................A-14A4.2.2 Power Terminals for GDR391 Rectifier Bridge Module .................A-15A4.2.3 Power Terminals for GDR633 Rectifier Bridge Module .................A-16A4.2.4 Power Terminals for GDR721 Rectifier Bridge Module .................A-17A4.2.5 Power Terminals for GDR872 Rectifier Bridge Module .................A-17A4.2.6 Power Terminals for GDR1168 Rectifier Bridge Module ...............A-18A4.3 Transistor Module Terminals ............................................................A-19A4.3.1 Control Terminals..........................................................................A-19A4.3.2 Power Terminals ...........................................................................A-19A4.3 Power Module Earthing Requirements ............................................A-20A5 OUTLINE DRAWINGS ........................................................................A-21A5.1 Rectifier Bridge Module GDR391 ..................................................A-21A5.2 Rectifier Bridge Module GDR633 ..................................................A-22A5.3 Rectifier Bridge Module GDR721

(with cubicle bus-bar assembly) ....................................................A-23A5.4 Rectifier Bridge Module GDR872


(without cubicle bus-bar assembly) ...............................................A-25A5.6 Rectifier Bridge Module GDR1168


(without cubicle bus-bar assembly) ...............................................A-27A5.8 DELTA Transistor Bridge ..............................................................A-28

APPENDIX B PRECHARGE COMPONENTS FOR 690V GD4000Scope....................................................................................................B-1

B1 Description...........................................................................................B-2B1.2 System Configurations....................................................................B-2B1.2 Common DC Link Schemes ............................................................B-2B2 Circuit Diagram....................................................................................B-3B3 Components ........................................................................................B-3B3.1 Precharge Resistors........................................................................B-3B3.2 Precharge Resistor Mounting Brackets...........................................B-4B3.3 Precharge Relay .............................................................................B-4B3.4 Precharge Relay Suppression ........................................................B-4B3.5 Precharge Contactor .......................................................................B-4B3.6 Precharge Contactor Coil Suppression ...........................................B-5B3.7 Recommended precharge Fuses....................................................B-5

APPENDIX C INTERCHANGING MODULES


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Scope ................................................................................................... C-1Units Covered...................................................................................... C-1

C1 Rectifier Bridge Modules .................................................................... C-2C2 Transistor Bridge Modules ................................................................. C-3C2.1 Single (and/or Output) Transistor Bridge Modules .......................... C-3C2.2 Parallel Transistor Bridges.............................................................. C-3C2.3 Setting Module Configuration Links ................................................ C-4C2.4 Transistor Bridge Modules - Mechanical Difference........................ C-5C2.5 Mounting of the Switch Mode Power Supply Module ...................... C-6C2.6 Alternative Build Versions ............................................................... C-6C2.6.1 Interchangeability of Complete DELTA Modules............................. C-6C2.6.2 Replacing Integrated Power Modules ............................................. C-6

APPENDIX D RECOMMENDED TIGHTENING TORQUE FIGURESScope ................................................................................................... D-1

D1.1 Electrical Connections .................................................................... D-2D1.2 Mechanical Connections................................................................. D-2

APPENDIX E GD2000E / GD3000 / GD3000E Connection DiagramsScope ................................................................................................... E-1Introduction ......................................................................................... E-1List of Circuit Element Diagrams ....................................................... E-3

Circuit A Input Bridge (Power) Connections ........................................................ E-5Circuit B Input Bridge (Control) Connections..................................................... E-16Circuit C Output Bridge (Power) Connections ................................................... E-21Circuit D Output Bridge (Control) Connections .................................................. E-25Circuit E User Termination Panels..................................................................... E-31Circuit F Cooling System................................................................................... E-32

ALSPA GD DELTA 1. Introduction

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,QWURGXFWLRQ1.1 General Description

The Alspa DELTA modular system covers the requirements of the AC variable speed drivemarket at high power levels. The range covers 150 kW - 1000 kW (200 - 1340 hp), 380 -690V ac input voltage. The Alspa DELTA system is a set of transistor and rectifier bridgesand their associated components. These are used as building blocks in constructing thepower circuit of AC drives.

The control systems for the complete AC drives are known as OMEGA for the GD2000Eand SIGMA for the GD4000. The Alspa GD2000E is a range of trip-resistant AC variablespeed drives for general purpose industrial applications. The Alspa GD3000 is a range offlux vector AC variable speed drives for high performance industrial applications. The AlspaGD4000 is a range of AC variable speed drives which offer high dynamic performance andthe ability to integrate into the most demanding multi-drive systems.

The power range is covered by the use of a single DELTA module, or by paralleling two orthree DELTA modules together.

Figure 1-1 Typical Large DELTA drive (GD4846 shown)

1. Introduction ALSPA GD DELTA

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DELTA modules are of a standard mechanical design, each being of a fixed height andmounted in the upper half of a cubicle to mate with a ducted cooling system on a"bookshelf" principle. All DELTA modules are withdrawable on a simple slide system forease of assembly and maintenance. The removal of the module from the cubicle requiressuitable lifting equipment.

The DELTA power system is totally flexible to meet the particular requirements of anyapplication, such as common DC link schemes, simple rectified 3 phase (6 pulse), or 6phase (12 pulse) (or sinusoidal for GD4000) input circuits.

1.1.1 About This Manual

This document describes the DELTA Bridge Modules and associated power equipmentused for the GD2000E, GD3000, GD4000 drives and common d.c. link drives over 150 kW. These components, as standard, are supplied loose as a kit of parts. This manual alsodescribes how these components may be assembled into a cubicle, to produce a completedrive. The commissioning and operation of the complete drive is detailed in the appropriateGD2000E, GD3000 or GD4000 manual.

1.2 Features

• Wide power range covered by common modules.• Parallel capability increases the power range.• Modular construction making maintenance and repair work simple.• Rapid module replacement.• Ease of handling - smaller, lighter modules are assembled in to large drives.• "Dirty air" capability (Separate unfiltered air path for main cooling).• Minimum spares holding.• Interfaces with OMEGA and SIGMA controllers.

1.3 DELTA System Description

Figure 1-2 Block Diagram for an AC Variable Speed Drive showing theFunctional Use of DELTA Modules.


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1.3.1 System Overview

As shown in Figure 1-2 the simple AC variable speed drive uses a control module to drivethe power assembly. The power assembly has two major blocks. An input bridge thatconverts the AC supply to DC, and an output bridge that chops up (inverts) this DC in to thevariable frequency, variable voltage output. These power blocks are constructed usingDELTA modules.

The input bridge may consist of an uncontrolled rectifier, a thyristor convertor, a sinusoidallycontrolled (GD4000) transistor bridge or any source of d.c. that is within the limits defined insection 2, Specification. The uncontrolled rectifier input bridge may be 6 pulse (3 phaseinput) or 12 pulse (6 phase input using a phase shifting transformer).

The output bridge for GD2000E, GD3000 and GD4000 is a controlled transistor bridge.

The control module defines the drive type and features - GD2000E, GD3000 or GD4000.

1.3.2 Basic System

This section shows the basic blocks used to construct an AC variable speed drive usingDELTA modules. All diagrams are introductions to the various configurations. Section 3gives guidance on the required components. Section 1.4 details the individual componentblocks.

1.3.3 Alspa GD2000E / GD3000 Standard 6 Pulse Input AC Drive

Figure 1-3 Block Diagram for Alspa GD2000E and Alspa GD3000 using DELTA Modules.


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Figure 1-4 Block Diagram for Sinusoidal Input GD4000 using DELTA Modules.

1.3.4 Alspa GD4000 Sinusoidal Input AC Drive


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Figure 1-5 Output Bridge using Parallel DELTA Transistor Modules.

1.3.5 Parallel Transistor Bridges

The current rating of an individual DELTA Transistor Bridge Module may be increased byparalleling it with another Transistor Bridge Module through a sharing reactor (the correctcontrol module must also be used).

When paralleling the Transistor Bridge Modules together as an input bridge, the standardsystem uses input fuses and line contactors in separate, parallel paths (the currents mustbe shared correctly for the transistor bridges to function correctly).

Figure 1.6 Sinusoidal Input Bridge Using Parallel DELTA Transistor Modules.


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1.3.6 12 Pulse Input Rectifier

Harmonic currents produced in the supply system by variable speed drives withuncontrolled rectifier inputs may be reduced by changing from 6 pulse (3 phase) to 12 pulse (6 phase) input.

A phase shifting transformer is used to produce the additional 3 phases which are phaseshifted by 30°. These two sets of three phase supplies are rectified by two rectifier bridges.Instantaneous voltage differences between the outputs of the two rectifiers are absorbed byan interbridge transformer connected between the two positive or negative outputs of therectifiers. The output to the d.c. link is taken from the centre-tap of the interbridgetransformer.

1.3.7 Parallel Rectifier Input

The Rectifiers Bridge Modules may be parallelled to give a higher current input bridge.Additional line reactors are fitted in the a.c. supply to force sharing between the individualrectifiers. As current sharing is dependant on the individual resistances of the parallelcircuits, care must be taken to have equal impedance between the parallel circuits, e.g.equal cable lengths. In practice, derating (usually 10% - see Rectifier Bridge ModuleSpecification 2.1) is still necessary to allow for differences in the rectifier impedances.

Figure 1-7 12 Pulse Input System

Figure 1-8 Parallel Rectifier Input System (6 Pulse)


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1.4 Mechanical Description

Cubicle installation of most DELTA components are directly from the DELTA mountingframe. This consists of a set of cross rails and cubicle side supports that form a "bookshelf"for the DELTA modules.

Figure 1-9 View of a Typical Assembly of a single DELTA module and the components thatMechanically Interact with it.


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The DELTA mounting frame consists of two sets of two cross rails. The lower pair supportthe weight of the DELTA modules and their sharing reactors, the upper cross rails supportthe top of the DELTA modules and the DELTA cooling system (fan box). The spacingbetween the upper and lower rails is fixed by the height of the DELTA module. The overallposition of the mounting frame being dependent on cubicle requirements.

The DELTA modules are mounted between the upper and lower cross rails by simpleguides, two located on the lower guide support plate and two on the fan box. The moduleslides between these guide rails and is then bolted to the cross rail. When extracting aDELTA module, the module slides as far as the stop pin and then has to be lifted over thispin before the it may be completely removed. The fan box and lower guide support plateare directly attached to the cross rails. The lower support plate and guide rails form part ofthe sharing reactor. When this reactor is not fitted the guide plate (and rails) are supplied asa separate item.

The installation of further DELTA modules is a step by 250 mm (9.84") and repeat of theassembly up to the width of the cross rails.

Figure 1-10 View of a Multiple DELTA Installation


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1.5 Cooling

The DELTA Cooling System is a fan assembly mounted above each DELTA module toprovide cooling for the power components and sharing reactors (when fitted). Module-typereactors also require a fan.

Air is drawn into the bottom of the Drive module through the sharing reactor A or B (or airduct). It is then expelled from the fan box in one or more directions (C, D or E) dependenton the positions of the outlet blanking plates.

In applications where the sharing reactor is not fitted then a dirty air inlet duct (optionalextra) may be used to pull air into the cubicle through the backsheet. Similarly, additionalducting may be fitted to the fan box to force the airflow out of the cubicle.

To avoid impairing cooling performance the airflow must not be impeded and extra fanassistance should be installed where significant impedance is introduced by filters orrestrictive ducting.

The power devicecooling system can use 'dirty' air providing it does not contain corrosive, conductive, or

Figure 1-11 Side View of Air Path through StandardDELTA Module System


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explosive dusts or gasses. It can be easily separated from the control cubicle internal air byducting the intake and output to the outside of the cubicle. As the cooling fans draw airthrough the power device cooling path a negative pressure is developed, so a small amountof clean air from the cubicle will constantly bleed into the dirty air duct and not vice versa.The air outlet must be carefully sealed as it is at a higher pressure than the internal cubicle"clean" air.

1.6 Reactors

General Description

A variety of reactors are available for use in conjunction with the DELTA power modules.The requirement for the optional reactors are detailed in the relevant GD2000E, GD3000,GD4000 manuals. The different functions these optional and the mandatory reactors maybe used for are briefly described below:

Input Line Reactor (sinusoidal input) used on GD4000

When using Transistor Bridge Modules in sinusoidal input applications they must be fed viaan input line reactor to achieve sinusoidal input characteristics, suitable reactors aresupplied when standard drive arrangements are ordered.

The reactors are large and heavy and are generally mounted in the base of, or near to, thedrive enclosure.

Sharing Reactors

To allow even load sharing between Transistor Bridge Modules which are connected inparallel (on both input and output applications) it is always necessary to fit additionalreactors in the three-phase connection of each parallel module.

Suitable sharing (or skew) reactors are provided with each applicable standard drivecombination ordered. These are supplied as full 3-phase units which are designed to fitdirectly below the module (to take advantage of the cooling air flow) to which they areconnected. They are supplied in two ratings to complement the two ratings of transistormodule. Note that the same reactor assembly may also be used as an input line reactor forsome GD2000E / GD3000s.

Output Line Reactors used on GD2000E, GD3000, GD3000E and GD4000

An output line reactor may be fitted at the drive output terminals where there is a highcapacitance coupling to ground caused by long cable runs or cable with highcapacitance/unit length, or when one drive unit is driving several motors. The reactor mayneed to be used in conjunction with a Line Output Module (LOM). See the GD2000E,GD3000, GD3000E and GD4000 manuals for further information.

The line reactor must be fitted close to the inverter output.

In the case of parallelled Transistor Bridge Modules, the sharing reactors also act as outputline reactors.

The single Transistor Bridge Modules are fitted with an output reactor to fully protect themodule against external faults.


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Input Line Reactor For Rectifier Bridge Modules

These reactors are used to provide impedance between the drive and the supply. Thisimpedance operates in conjunction with the suppression circuit on the rectifier modules toprevent supply transients from damaging the rectifier. It also limits the fault current and maybe used as part of the fuse protection.

It is recommended that input line reactors are fitted in the following circumstances:

- If there is primary switching of a transformer e.g. 13.8 kV circuit breakers, on lineprimary tap changing etc. and the transformer is large (i.e. greater than 17 MVA faultlevel).

- If there is power factor correction equipment on the same supply as the drive.

- If there is a high risk of a short circuit on the secondary of a transformer caused byother equipment with separate fuse protection.

- Where semi-conductor fuses will not protect the input rectifiers with out additional lineimpedance. See fuse information section 2.

Where a drive is supplied by an individual transformer of approximately the same rating asthe drive then input line reactors are not required.

The three-phase input line reactors for these applications are designed to fit in the standardmodule racks alongside or underneath the modules to which they are connected. These areenclosed and force cooled. Naturally ventilated, non-enclosed versions are available forsome duties, refer to supplier if required. Note that these naturally ventilated reactors arelarge and will require additional ventilation in the cubicle.

DC Link Inductor

When using the three phase (6 pulse) Rectifier Bridge Modules the mandatory d.c. linkinductor reduces the imposed supply harmonics. It also reduces the ripple current to thetransistor bridge.

These d.c. inductors are large and heavy. They are usually mounted on the base of thedrive enclosure.

Interbridge Transformer

When using the double Rectifier Bridge Modules for 12 pulse input, the mandatoryinterbridge transformer replaces the d.c. inductor. It forces sharing between the two rectifierbridges (one supply phase shifted by 30°).

The interbridge transformers are large and heavy. They are usually mounted in the base ofthe drive enclosure.


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1.7 Modules

1.7.1 Rectifier Bridge Modules

Introduction

The Rectifier Bridge Modules are used as input bridges only. They convert the AC supplyinto rectified, unsmoothed DC. These modules are used mainly on GD2000E and GD3000.

There are two types of DELTA Rectifier Bridge Modules; single rectifier modules and doublerectifier modules. Each type is available in a choice of power ratings. The largest rectifierpower ratings can be achieved by connecting modules in parallel.

The single Rectifier BridgeModule has one, three phase

Figure 1-12 Single Rectifier Module - GDR721


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rectifier bridge. The double Rectifier Bridge Module contains two, three phase rectifierbridges. This double rectifier has two sets of a.c. input terminals and two sets of d.c. outputterminals.

The double Rectifier Bridge Module may be operated as a 12-pulse input bridge. This isachieved by connecting the d.c. outputs together through an interbridge transformer, onea.c. input being phase-shifted in relation to the other by the external supply transformer. Alternatively the two bridges of the double Rectifier Bridge Module may be run as a highcurrent single rectifier bridge. The two bridges are connected in parallel using sharingreactors (Two single Rectifier Bridges Modules may also be paralleled and used as onebridge), see Specification.

Features

• The Rectifier Bridge Modules contain circuits capable of pre-charging the appropriateTransistor Bridge Modules. This circuit charges the d.c. link capacitors of thetransistor bridge via current limiting resistors in the rectifier modules.

• Modules fit in the standard rack system and are configured for "dirty air".

• Input filters are included to absorb surge energy from the mains. Supply impedance isnecessary for this to function correctly. See information on reactors section 1.6.

• Protection against d.c. link short circuits by the use of semiconductor fuses.

• Modules carry thermostat and thermistor protection so when they are connected tothe controller, the module is protected against overtemperature.

Variations

• Available in two versions single and double rectifier bridges.

• The single Rectifier Bridge Modules are available in three current ratings. The threeratings (d.c. output current) are 391A, 721A and 872A. The modules are thereforecalled GDR391, GDR721 and GDR872 respectively.

• Double Rectifier Bridge Modules are available in two current ratings. The two ratings(d.c. output current) are 633A and 1168A and are called GDR633 and GDR1168respectively.

• Higher current versions are possible by paralleling the modules through reactors togive higher currents. As the modules will not carry equal current, some derating of theoutput current is necessary.

• The Rectifier Bridge Modules are also available in two voltage versions 380 - 480Vand 525 - 690V ac.

Interface

• Signals between the controller and the rectifier bridge module are by discrete wires,which are between 'pluggable' terminal blocks.


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• The GDR391 and GDR633 power connections are designed for cable connection tostud terminals. The GDR721, GDR872 and GDR1168 are designed for cable orbusbar connection.

• Short busbars that connect to the ac rectifier terminals, enable the connection pointto be below the DELTA cross rails. These may be supplied in the kit of parts or as aseparate item.

External Requirements

• For parallel operation of these modules, external sharing reactors must be fitted.

Figure 1-13 Double Rectifier Module - GDR633


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• For 12 pulse operation the two supplies must be phase shifted by 30° to each otherand of balanced voltage. The output must be through an interbridge transformer,which replaces the d.c. link choke.

• Protection of the main input rectifier devices is by the addition of externalsemiconductor fuses. For recommended fuses see specification, section 2

• The ac terminals on the modules designed for busbar or cable connection are notsuitable to support the weight of any attached cables. These cables / busbars musthave additional mechanical support.

• The output from all of the Rectifier Bridge Modules must be through a d.c. linkinductor or an interbridge transformer.

• The high voltage versions of the Rectifier Bridge Module requires an additional 110Vac supply. On standard DELTA kits this will be available from the fan/contactor supplytransformer.

1.7.2 Cubicle busbars For Rectifier Bridge Modules

Introduction

The cubicle busbar assembly provides a simple way to interface to the rectifier modules. Itis an assembly of three a.c. phase (or six for the double bridges) connection busbars. Thea.c. phase busbars are assembled together and supported by a clamp attached to theDELTA cross-rails. This assists in supporting any attached cables.

Features

• Ease of cubicle assembly. The phase busbars are attached directly to pre-drilledfixings in the DELTA cross-rails. The busbar assembly allows the Rectifier BridgeModules to be withdrawn / inserted without removing the power cables, by removal ofthe busbar connection bolts.

• Connection point is more accessible having been moved to below the Rectifier BridgeModule and its supporting cross rails.

• The clamp on the a.c. phase busbars supports any cables attached to the busbars.This mechanical support is necessary for the Rectifier Bridge Modules designed forcable or busbar connection.

Variations

• There are three busbar assembly versions. These are suitable for the GDR721,GDR872 and GDR1168.


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Interface

• The a.c. busbar assembly connects directly behind the rectifier terminals and issupported from the DELTA mounting framework.


• The a.c. busbars attach to the right of the rectifier module, their position being fixedby the terminal positions. Ensure that there is sufficient creepage / clearance distancebetween any equipment mounted to the right of this rectifier and the busbarassembly.

Figure 1-14 Cubicle Busbar Assembly For GDR721


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1.7.3 Transistor Bridge Module

Introduction

In the standard GD2000E, GD3000, GD3000E and GD4000 applications DELTA TransistorBridge Modules are used in combination to provide:

• an output stage where the d.c. produced by the input bridge is converted into avariable frequency and variable voltage three phase output.

• an input stage for GD4000 where a normal three phase supply is rectified to d.c. Thetransistors being controlled to draw sinusoidal current from the mains.

Figure 1-15 Transistor Bridge Module


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Features

• DELTA Transistor Bridge Modules use the latest insulated-gate bipolar transistors(IGBT) fully integrated into Intelligent Power Modules (IPM) to provide low distortionoutput.

• DC smoothing capacitors that provide filtering for the drive DC link in addition to localenergy storage for output transistor switching.

• Output protection against earth faults and short circuits.

• Modules fit in standard DELTA rack system and are configured for "dirty air".

• Auxiliary DC link connection plug for connection to Switch Mode Power Supply(SMPS). The GD2000E, GD3000, and GD3000E SMPS may be directly mounted onthe Transistor Bridge Module.

• Each module carries thermistor protection. When connected to the GD2000E,GD3000, GD3000E and GD4000 controller the module is protected againstovertemperature.

Variations

• Available in three power ratings, having a nominal phase current of 282, 300 and 377A ac. They are called GDD282, GDD300 and GDD377. The GDD282 and GDD377are suitable for use on voltages up to 525 V ac. The GDD300 is suitable for use onvoltages up to 690 V ac. All three modules have the same dimensions; the differencein rating is due to the internal components used.

• The three versions are suitable for the output bridges on the GD2000E, GD3000 andGD3000E drives; the input and the output bridges on the GD4000 drives; and as theinput or output power bridges in common d.c. link applications.

Interface

• Signals between the controller and Transistor Bridge Module are by three 26 wayribbon cables per module. These cables also carry the supplies for the electronics onthe transistor bridge.

• Power connections are stud terminals for the ac, and inserts for the dc connections.


• The Transistor Bridge Modules contain smoothing capacitors which when used inboth input and output applications must be 'pre-charged'. These modules do not carrypre-charge circuits. The recommended pre-charge rate is specified in section 2 of thisdocument. For standard GD2000E, GD3000 and GD3000 drives the pre-chargecircuit is completely contained in the rectifier bridge module. In GD4000 applicationsa pre-charge panel is used in conjunction with a line contactor to provide thenecessary precharge action.

• The d.c. supply to the transistor module must be within appropriate voltage, currentand ripple limits and must be 'pre-charged'.


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• These modules must be forced ventilated to reach specified performance.

• When Transistor Bridge Modules are used as input bridges it is recommended thatsemiconductor fuses are fitted on the a.c. supply.

1.7.4 3-Phase AC Line Reactors 282A and 377A

Introduction

The 282A and 377A reactors are mainly used to assist the load sharing between transistormodules when they are used in parallel, so are referred to as sharing reactors. The twocurrent ratings match the ratings of the two Transistor Bridge Modules.

These reactors may also be used as input line reactors when rectifier modules are used forthe drive input. They may be used on drives up to the current ratings of the reactors e.g.GD2282, GD3282, GD2377 and GD3377.

Features

• The reactor may be used as a transistor bridge sharing or output reactor, or as aninput reactor for the rectifier bridge.

• The reactor attaches to DELTA cross rails, directly below the module to which it isconnected.

Figure 1-16 Line Reactor (sharing), 282A and 377A


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• The reactor is ventilated by the DELTA cooling system. It does not require anadditional fan.

• The power loss from this reactor is ducted out of the cubicle by the same air flow ductas the DELTA modules (the reactor box forms part of the duct).

• The air inlet to the reactor may be configured to be through the rear face or thebottom plate of the reactor box. The rear face may be sealed directly to a suitableopening in the cubicle back sheet and the bottom face blanked off to provide a dirtyair path.

WARNING

IF AIRFLOW IS THROUGH THE REAR OF THE REACTOR MODULE, CARE MUST BE TAKENTO ENSURE THAT THE REACTOR COILS ARE NOT ACCESSIBLE THROUGH THE REARCUBICLE CUT-OUT AS THEY EXPOSE HIGH VOLTAGES.

• For airflow entry to be through the bottom face of the reactor box, then the rear faceof the reactor may be sealed directly to the cubicle. No additional blanking plates arerequired as the rear face fits flush (using a sealing strip) to the cubicle back sheet.

• A version of the reactor box is also available that mounts semi-conductor fuses onthe front terminals. This version is used for fuse protecting the input rectifier bridgewhen the assembly is used as an input reactor.

Variations

• The two current ratings available are 282A and 377A. As standard these are notsupplied with semiconductor fuses. These fuses may be added using suitable pillarsto the front of the reactor box.

Interface

• This reactor bolts directly below the module to which it is connected. It is supportedby the DELTA crossrails from pre-drilled fixings.

• Electrical connections are by the two sets of terminals. The set of stud terminals arelocated on the front face of the reactor, the others are busbar connections locatedunderneath the reactor. The reactor will function correctly with either set of terminalsused as input/output.

• Air entry is through the back or underside of the reactor box.


• If airflow is required through the rear face of the modules only, then an additionalblanking plate is required to seal the bottom air inlet aperture.


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1.7.5 3-Phase AC Line Reactors 630A and 754A

The 630A and 754A reactors are used as input line reactors where rectifier modules areused on the drive input. They are enclosed to form an air duct and must be forceventilated. As these boxed reactors fit in to the standard module racks, they may bemounted alongside the rectifier modules to which they are connected.

Features

• The reactor fits directly into the DELTA module mounting system.

• Forced ventilation is through the DELTA cooling system. The same fan and air inlet /outlet positions (relative to the module) are used for both the reactor and the DELTAmodules.

• The reactor modules may be configured for Dirty air.

Figure 1-17 Line Reactor, 630A and 754A


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• Semiconductor fuses (to protect the input rectifier bridge) may be mounted on thefront of the module.

Variations

• The two reactors available are rated at 630A and 754A, both are suitable for frontmounting semiconductor fuses.

Interface

• The air flow inlet / outlet and cross-rail fixing positions are the same as a DELTAmodule.

• The electrical connections are on the front of the unit.

External

• To obtain the full current rating this unit requires force cooling. The DELTA coolingsystem is used.

• The reactor attaches to the standard DELTA cross rails. This requires an additional250mm (9.84") of cross rail per reactor and may increase the cubicle width.

• A fan supply transformer will be required to supply the additional DELTA fan box.This may require an increased rating fan transformer or an additional transformer.

• An additional set of air inlet / outlet ducts are required.


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1.7.6 DELTA Cooling System

Introduction

The DELTA cooling system (fan box) is located at the top of the DELTA module. It containsthe extractor fan that force cools the DELTA modules. It also contains the upper guide railsthat locate the DELTA module.

Air is drawn into the fan box through the bottom mounting plate from the DELTA moduleheatsink. It is then expelled through three apertures in the box front, rear and top. Any twoout of the three outlets may be blanked off and the third ducted to allow dirty airconfiguration.

Features

• The same cooling system may be used for the transistor, rectifier and reactormodules.

• Supply to the standard cooling system fan is single phase, so it is phase rotationinsensitive.

• Air outlet may be in any of three directions - top, front or back. Two blanking platesare supplied to blank off the unused apertures.

• As the fan is an extractor, any leakage is into the dirty air path. Care must be takenwhen ducting the airflow out of the cubicle as this has positive pressure differential tothe remainder of the cubicle.

• The fan box may be sealed directly to a suitable opening in the cubicle roof plate. Noadditional ducting being required.

• The fan box attaches directly to the upper DELTA cross rails. Additional fixings areonly required to attach air outlet ducting.

Figure 1-18 DELTA Cooing Fan Box


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• The fan impeller may be removed / replaced from the front of the cubicle withoutremoving the DELTA module. Alternatively the whole assembly may be removed bypassing through the space of a removed DELTA module.

• The fan box also contains the rails used for guiding the DELTA modules during theirinstallation / removal.

• The fan is protected by internally mounted thermal cut-outs.

On the standard cooling system these are internally wired so as to stop the fan in theevent of the fan motor over-heating. Note this may lead to the drive tripping onheatsink overtemperature. Fan re-start is automatic when the fan temperature fallsbelow the reset temperature.

The High Performance Cooling System has the thermal cut-outs wired to the terminalblock. These must be wired to an external relay so as to isolate the fan, protecting itfrom single phasing, incorrect phase rotation or overheating. Note that stopping thefan may lead to the drive tripping on heatsink overtemperature. Thermal cut-out resetis automatic when the fan motor temperature falls below the reset temperature.

Variations

• The two versions are suitable for use with the transistor bridge, rectifier bridge andreactor modules. The standard Cooling System will normally be supplied, unless theHigh Performance version is specified at time of order.

Interface

• Air is drawn in through the bottom of the fan box directly from the DELTA modules airduct. It is expelled in one of three directions top, front or back; dependant on theposition of the supplied blanking plates.

• Electrical connections are to the terminal block located on the front of the fan box.

External requirements

• As the fan box contains moving parts the air outlet duct should prevent access to thefan box by the use of appropriate grills or the ducting itself.

• The fan requires a supply. This is usually from the fan supply transformer suppliedloose with GD2000E/3000/3000E. It is mounted on the pre-charge control panel forthe GD4000 up to 480V ac, but supplied loose for the higher voltages and non-standard drive configurations.

• The High Performance Cooling System has internal thermal contacts for fan motorover-temperature protection. These must be wired to an external protection relay toprevent damage from overheating - see section 4.


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1.7.7 Lower Guide Plate Sub-assembly

Introduction

The lower guide plate sub-assembly provides the bottom guide rails for the DELTA modulesand the interface between the cubicle cooling air duct and the dirty air inlet on the DELTAmodule.

Features

• Bolts to the DELTA support cross rails and contains the fixings for the dirty air inletduct.

Variations

• The sharing reactors (282A and 377A) have the DELTA guide rail as part of theirassembly. The lower guide rail sub-assembly is not required when the sharing reactoris used.

Interface

• The sub-assembly attaches directly to the DELTA cross rails. No other fixings arerequired.

External requirements

• 4 off fixing bolts (M5 Taptites).

Figure 1-19 Lower Guide Plate Sub-assembly


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1.7.8 DELTA Precharge Control Panel

Introduction

Where transistor modules are used as input bridges (i.e. in GD 4000 applications), or wherethere is no other means of pre-charging the d.c. link, the precharge control panel (orequivalent) must be installed. The panel is designed to limit the inrush current duringequipment power up. This is achieved by pre-charging the transistor power modulecapacitors and switching on the SMPS before closing a line contactor. Suitable contactorsare supplied with standard GD4000 drive kits.

For common d.c. link schemes, the modules will require custom designed pre-chargecircuits.

Features

• The panel contains the circuits capable of pre-charging the appropriate transistorbridge module(s), including the current limiting resistors, fuses and the control relay.

• The panel provides the supplies (via a transformer and fuses) for both the main linecontactor(s) and the Standard DELTA Cooling System fans.

• It also contains the supply fuses for the SMPS.Variations

Figure 1-20 DELTA Precharge Control Panel


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• There are four DELTA versions available. The panels are intended to drive two, four,six or twelve DELTA transistor modules when used for standard sinusoidal inputGD4000s. These panels are also capable of supplying up to six Standard DELTACooling System fans and the appropriate line contactor(s).

Interface

• The panel is intended to be attached to the backsheet of an appropriate cubicle byfour bolts.

• Electrical connections are to the two terminal blocks, one located at the top and oneat the bottom of the panel. Connections to the supply side of the line contactor are tothe lower terminal block. The upper terminal block connections are from the drive,and the drive side of the contactor. This keeps the wiring to the contactor short if thepre-charge control panel is mounted close to the line contactor.

External Construction

• The panels are of open construction fitted with a basic shroud. They must be installedin a suitable enclosure with restricted access.

1.7.9 Fan / Contactor Supply Transformer

Introduction

This transformer provides the supplies required for the DELTA Cooling System fans and forthe GD4000 pre-charge contactor coil.

Features

• The DELTA fan transformers are intended to drive two, four, or six Standard or HighPerformance DELTA Cooling System fans.

• When fitted in GD4000 applications they also supply one, two, or three input linecontactors.

Variations

• There are two product versions - Fan / Contactor Supply Transformer for StandardDELTA Cooling Systems, and the Fan / Contactor Supply Transformer for HighPerformance Cooling Systems.

• The single phase transformers for the Standard Cooling Systems are available in sixsizes. Three are for 380 - 500V supplies and the remainder for 525 - 690V supplies.

• The three phase transformers for the High Performance Cooling Systems are alsoavailable in six sizes. Three are for 380 - 500V supplies and the remainder for 525 -690V supplies.

• The 380V - 500V Standard Cooling System transformers have two outputs, autotransformer a.c. fan supply (non-isolated at 230V ac) and an isolated 110V accontactor supply.


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• The 525V - 690V Standard Cooling System transformers have two outputs, anisolated fan supply at 230V ac and an isolated 110V ac contactor supply.

• The 380V - 500V High Performance transformers have two outputs, auto transformera.c. fan supply (non-isolated at 400V ac) and an isolated contactor supply at 110Vac.

• The 525V - 690V High Performance transformers have two outputs, an autotransformer a.c. fan supply (non-isolated at 400V ac) and an isolated 110V accontactor supply.

Interface

• Connections to the transformer are to the terminal block mounted on top of the panel.

• The transformer is supplied as a loose item, and has four fixing holes for attaching toa cubicle backsheet.

• For GD4000 applications (standard DELTA cooling Systems up to 500V ac) thetransformer is supplied as part of the precharge control panel. The transformerconnections are wired to the panel terminals. Customer connections are to theprecharge panel terminals.


• The transformer is supplied as a loose item and will require fuse protection. It alsoexposes high voltage and should be suitably enclosed.

• When fitted on GD4000 precharge control panels the transformer is protected by thefuses internally mounted within the precharge control panel.

1.7.10 DELTA Mounting Kit

Introduction

The DELTA mounting kit is a framework of rails and brackets, which when installed in acubicle provide the support and fixings for the DELTA modules and the DELTA coolingsystem. It is suitable for installation into a standard CEGELEC Q80 cubicle.

Variations

• The standard kits are based on 600 (23.6") and 800mm (31.5") deep cubicles. Foreach of these depths of cubicle there are four cross rail widths available, 600 (23.6"),800 (31.5"), 1000 (39.4") and 1200mm (47.2"). The 800mm (31.5") wide kit is notfrequently used, as it will only hold two DELTA modules.

• The 600mm (23.6") and 800mm (31.5") wide rails will support up to two DELTAmodules.

• The 1000mm (39.4") wide rails will support up to three DELTA modules.


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• The 1200mm (47.2") wide rails will support up to four DELTA modules.

Interface and External Requirements

• The mounting frame bolts directly onto the Q80 cubicle

• Mounting frame kits are available for Rittal P4000 series cubicles in depths of 600and 800mm and widths of 600,800,1000 and 1200mm For details see section 2.11.1.For other types of enclosure see section 3.4

1.7.11 SIGMA Switch Mode Power Supply (SMPS) Step-Down Transformer (GD4000 only)

Introduction

This single phase transformer is used to supply the SIGMA Switched Mode Power SupplyUnit 31V1400/10. It is required when the GD4000 is connected to 600 - 690V supplies.

Features

• One isolated output at 400V ac for supplying the SIGMA SMPS.

Variations

• One version only, rated to supply one SIGMA SMPS.

Interface

• Connections to the transformer are to the terminal block mounted on top of the panel.

• The transformer is supplied as a loose item, and has four fixing holes for attaching toa cubicle backsheet.


• The transformer is supplied as a loose item and will require fuse protection. It alsoexposes high voltage and should be suitably enclosed.

1.7.12 GD2000E / GD3000 / GD3000E Switch Mode Power Supply

Introduction

The SMPS provides the electronic supplies for DELTA modules, and the GD2000E,GD3000 or GD3000E control module.


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Features

• One SMPS is connected directly to the DELTA Transistor Bridge Module.

• As the SMPS derives it's supply from the drive dc link, the electronics are suppliedduring temporary supply loss.

Variations

• There are three versions of SMPS. Each version is designed for a range of differentsupply voltages.

Interface

• These power supplies bolt directly to the front face of the DELTA Transistor BridgeModule using the fixings supplied.

• DC link input to the SMPS by flying lead plug and socket connection (supplied) toTransistor Bridge Module.

• Electronic outputs by ribbon cable connection.


• These SMPS are of open construction, fitted with a basic shroud. They must beinstalled in a suitable enclosure with restricted access.

ALSPA GD DELTA 2. Specification

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The specifications provided in this section are for the individual DELTA related powercomponents. Specifications for the standard Alspa GD2000E, GD3000, GD3000E andGD4000 drive systems using these modules are given in section 2 of the Alspa GD2000E,GD3000, GD3000E and GD4000 Technical Manuals.

2.1 ALSPA GD DELTA Components (General Environment)

All Alspa DELTA components are designed to comply with the following commonspecification unless otherwise detailed in the individual component specification.

2.1.1 Atmosphere (Operational)

Ambient Temperature

0 to 40°C

Humidity

0 to 95% non-condensing

Altitude

Normal operating altitude up to 1000m above sea level.Derate by 7.3% per 1000m (3300 ft) to a maximum of 2000m (6600 ft).

Cooling Air

DELTA modules must be mounted in clean, dust free air which is free from corrosivevapours. The power device cooling system can use 'dirty' air provided it does not containcorrosive, conductive or explosive gases.

Chemical (Maximum)

25 ppm SO2

25 ppm NO2

15 ppm H2S

2.1.2 Atmosphere (Storage, transport)

Temperature (storage)

-25 to +55°C

Temperature (transport)

-25 to +70°C

2. Specification ALSPA GD DELTA

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Humidity

0 to 95% non-condensing

Altitude (storage)

up to 3000 m above sea level

Altitude (transport)

Will withstand air transport

2.1.3 Mechanical

Enclosure :

IP00 (IEC529:1989 BSEN60529:1992) "Non-protected against ingress of solid foreignobjects and against ingress of water with harmful effects".

These modules must always be installed in an appropriate enclosure with restrictedaccess.

Vibration (Operational) :

IEC721-3-3 "Class 3M1" and prEN50178 "Vibration Level"Note: To achieve both standards, the products comply with the more severe requirementsfrom both standards this is given as the following composite curve :

Frequency IEC 721-3-3 Class 3M1 prEN 50178 Composite

2 Hz to 9 Hz 0.3 mm amplitude 0.3 mm amplitude

9 Hz to 28.13 Hz 1 m/s2 0.032 mm from 10 Hz 1 m/s2

28.13 Hz to 57 Hz 1 m/s2 0.032 mm amplitude 0.032 mm amplitude

57 Hz to 150 Hz 1 m/s2 5 m/s2 5 m/s2

150 Hz to 200 Hz 1 m/s2 1 m/s2

Vibration (Storage, Transport)

When equipment is packed for transport,Class 2M1 of IEC 721-3-2:

2 to 9 Hz 3.5 mm amplitude9 to 200 Hz 10 m/s2

200 to 500 Hz 15 m/s2


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Drop (Transport) :

When equipment is packed for transport,Class 2M1 of IEC 721-3-2:

mass < 20 kg 0.25 m20 kg ≤ mass < 100 kg 0.25 m100 kg ≤ mass 0.10 m

2.1.4 Miscellaneous Data

Pollution Degree 2

(according to IEC 664-1 and UL 508C).

Overvoltage Category

Alspa DELTA modules comply with the insulation co-ordination requirements ofIEC 664-1:1992 and UL 840:1993 when installed in an Overvoltage category III environment(Max. rated impulse Voltage 6000 V for equipment rated up to 600 V a.c., 8000 V forequipment rated up to 690 V a.c.)External means must be applied to control the Overvoltage within this limit unless thecharacteristics of the supply already do so. Any devices fitted for this purpose must meetthe requirements of UL 1449:1996, Standard for Transient Voltage Surge Suppressor.


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2.2 Rectifier Bridge Modules

Units covered: GDR391-4401, GDR391-4601, GDR633-4401, GDR633-4601,GDR721-4401, GDR721-4601, GDR872-4401, GDR872-4601, GDR1168-4401 &GDR1168-4601. GDR versions not listed above are covered in a separate manual.

2.2.1 Current Ratings

Table 2.2.1: Thermal Current Ratings of Rectifier Bridge Modules

Unit DC Current(With 1.5 xOverload)

AC Output CurrentCapability for a

Complete Alspa Drive(with 1.5 x Overload)

GDR391 391 332

GDR721 721 613

GDR872 872 741

GDR633 633 538

GDR1168 1168 993

Notes:All ratings above are for the maximum thermal rating of the Rectifier Bridge Modules at40°C ambient. To protect these modules from d.c. link side short circuits the fitting of a.c.supply semi-conductor fuses are recommended. The current ratings of the Rectifier BridgeModule with recommended fuses are given in Table 2.2.2.

Overloads are for 60 seconds, 6 times per hour equally spaced.

All ratings assume standard drive configurations using d.c. link reactors or interbridgetransformers.

The GDR633 and GDR1168 are double rectifier modules. To achieve the rating stated inTable 2.2.1 they must be supplied by a suitable 12 pulse supply feed transformer or sharingreactors in addition to the d.c. link reactors or interbridge transformers.

If two separate Rectifier Bridge Modules are paralleled (using sharing reactors) or used as12 pulse bridges the output current is derated by 10% to allow for current imbalancebetween the bridges.


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Table 2.2.2: Rectifier Bridge Module Current Rating when using Recommended Fuses

Module Voltage Fuse DC Cu rrent Rat ing

For 1.5Overload

For 1.1Overload

GDR391-4401 380 - 480V GSGB350 (3 qty) "P"GSGB400 (3 qty)GSGB450 (3 qty)

362 A391 A391 A

362 A458A493 A

GDR391-4601 500 - 690V A100P400 (3 qty) "P"A100P500 (3 qty)

391 A391 A

391 A493 A

GDR721-4401 380 - 480V GSGB580 (3 qty) "P"A366S800D1 (3 qty)A366S900D1 (3 qty)

633 A721 A721 A

633 A800 A876 A


721 A721 A

721 A876 A

GDR872-4401 380 - 480V A366S900D1 * (3 qty) "P"A366S1000 (3 qty)

872 A872 A

872 A1080 A

GDR872-4601 500 - 690V A100P800 * (3 qty) "P"A100P1000 (3 qty)

872 A872 A

872 A1080 A

GDR633-4401 380 - 480V GSGB350 (6 qty) "P"GSGB400 (6 qty)GSGB450 (6 qty)

586 A633 A633 A

600 A736 A800 A


633 A633 A

633 A800 A

GDR1168-4401 380 - 480V A366S800D1 (6 qty) "P"A366S900D1 (6 qty)

1168 A1168 A

1168 A1420 A


1168 A1168 A

1168 A1420 A

For other fuse types see also the appropriate drive technical manual.

Semi-conductor fuses of the correct rating must be fitted to each of the three phases of thea.c. supply input to ensure no catastrophic failure of the input rectifiers. They also offernormal cable protection. Devices marked "P" will also protect the input rectifier devicesagainst damage from over-current.

All ratings are calculated assuming a 31MVA supply (fault level), no added impedance. TheGDR872 (marked '*') requires an additional 33uH input reactor (or equivalent supply faultlevel) for fuse protection.

The ratings given above are for the recommended fuses from two suppliers. The GSGB arefrom the Alstom HRC fuse link range and the A366S from the Gould ShawmutSemiconductor fuse range Both ranges are rated up to 660V +10% (727V). The A100Prange are also Gould Shawmut and rated for 1000V operation. Note that the 900A Gouldfuse MUST be a size 3 fuse.

Codes for fuses may not be complete with mechanical details. These should be selected tosuit the user.


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2.2.2 Phase Rotation

The rectifier modules are not sensitive to phase rotation.

2.2.3 Input Phase Voltage

Table 2.2.3: AC Voltage Ratings (rms)

Module Nominal Input Voltage

GDR391-4401GDR633-4401GDR721-4401GDR872-4401GDR1168-4401

380 - 480V


500 - 690V

Nominal voltage is ac rms, 3 phase, 3-wire and ground.

The equipment will operate with a variation of ±10% of the nominal supply voltage. Forsupply voltages below the nominal, there will be a corresponding reduction in maximumoutput power. The equipment can operate up to a maximum of ±15% variation on thenominal supplies for a maximum of 30 cycles duration without the equipment trippingthough reduced performance may be observed. The equipment rated to 480V can beoperated on 500V ac supplies but with a +6% to -10% supply variation.

Supply frequency: 45Hz to 63Hz

2.2.4 Output DC Link Voltage

Table 2.2.4: DC Voltage Ratings (rms)

Module MaximumOutput

Maximum AllowedRegen. Voltage


780V dc 800V dc


1122V dc 1250V dc

Typical d.c. output: 1.35 x supply voltage (rms)


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2.2.5 Environment

Operating Ambient 0oC to 60oC Temp. outside dirty air path

Losses: The losses for this module may be calculatedapproximately using:

Total Losses = Power losses + Control losses.Power losses = 2.4 x Total dc output current.

Control losses : 35W for GDR391,45W for GDR721,70W for GDR633 and GDR872,90W for GDR1168.

2.2.6 Thermal Protection

GDR391 and GDR721: Thermistor

GDR633, GDR872 and GDR1168: Thermistor and Thermostat

Note: Thermistors are only to be used in conjunction with the Omega and Sigmacontrollers.

Thermostat Rating: 10A @ 250V a.c., 50/60Hz8.5A @ 24V d.c.7A @ 48V d.c.n/c contact opens at 90oC.

2.2.7 Precharge

Notes:

The precharge control signal switches in the main rectifiers when dc link has finishedprecharging. The drive control module (Sigma / Omega) determines when the chargingperiod is complete.

To prevent failure of the Rectifier Bridge Module precharge components, the rectifierprecharge acknowledge signal must be connected to the control module. If this signal is nothigh the control module must not allow the drive to run.

The auxiliary supply is required to energise the internal precharge contactor on the 500 -690V rectifiers. This supply may be obtained from the Fan / Contactor supply transformer.


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Table 2.2.5: Precharge Requirements

Module InternalPrechargeResistor

ControlSignalVoltage

ControlSignalLoad

Auxiliary S upplyRequired

GDR391-4401 15Ω 24 / 48V dc 36.4 mA Not Required



GDR872-4401 7.5Ω 24 / 48V dc 36.4 mA Not Required

GDR1168-4401 7.5Ω 24 / 48V dc 72.8 mA Not Required

GDR391-4601 30Ω 24 / 48V dc 42.0 mA 110V ac rms (Inrush/Hold65/9 VA)

GDR633-4601 37.5Ω 24 / 48V dc 42.0 mA 110V ac rms (Inrush/Hold65/9 VA)




2.2.8 Terminations

3 Phase Supply:

GDR391 3 terminals M10 stud for cable ring crimp.GDR633 6 terminals M10 stud for cable ring crimp.GDR721 3 terminals 50 x 6.3 (2 x ¼") busbar with 2 x 10.5mm holes.GDR872 3 terminals 63 x 6.3 (2½ x ¼") busbar with 2 x 10.5mm holes.GDR1168 6 terminals 50 x 6.3 (2 x ¼") busbar with 2 x 10.5mm holes.

DC Output:

GDR391 2 terminals M10 insert for cable ring crimp.GDR633 4 terminals M10 insert for cable ring crimp.GDR721 2 terminals 63 x 6.3 (2½ x ¼") busbar with 2 x M10 threaded inserts

/ studs for cable ring crimps.GDR872 2 terminals 80 x 6.3 (3 x ¼") busbar with 4 x M10 threaded inserts

for cable ring crimps.GDR1168 4 terminals 63 x 6.3 (2½ x ¼") busbar with 2 x M10 threaded inserts

/ studs for cable ring crimps.Control terminals accept up to 2.5mm2 (12 AWG) flexible cables.


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2.2.9 Weight

GDR391 30.5kg (67 lbs)

GDR633 48kg (105 lbs)

GDR721 37kg (82 lbs)

GDR872 51.5kg (114 lbs)

GDR1168 62kg (137 lbs)


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2.3 Transistor Bridge Modules

Units covered: GDD282-4501, GDD377-4501, GDD300-4601. GDD versions not listedabove are covered in a separate manual.

The values given in this section (2.3) are the Absolute Maximum Ratings for the TransistorBridge Modules. As external components (ie. controller) are required to form a completeinput / output circuit, then the ratings obtainable for the combined components should beused when sizing a drive. Refer to the GD2000E, GD3000 or GD4000 manual for theratings of the standard drives that use these modules.

2.3.1 AC Phase Current Ratings

Table 2.3.1: Absolute Maximum AC Phase Current Ratings (Input or Output Mode).

Conditions GDD282 GDD300 GDD377

Peak Instantaneous Current 600 Amps 636 Amps 800 Amps

Continuous ac rms Current allowingfor a 1.5 x Overload

282 Amps 300 Amps 377 Amps

Continuous ac rms Current allowingfor a 1.1 x Overload


Continuous ac rms Current with noallowance for Overloads


These current ratings are limited by the system design. The cooling system, number ofparalleled Transistor Bridge Modules, type and configuration of controller will limit thesystem rating. It is NOT possible to achieve these absolute ratings under all operatingconditions. Most combinations of ambient temperature, supply voltage, and switchingfrequencies will result in a reduced rating. Refer to the GD2000E, GD3000, or GD4000Technical Manual for the current ratings of the complete standard drive systems.

2.3.2 Phase Voltage

The maximum phase to phase rms voltage is Vdc/√2 for sinusoidal waveforms.

2.3.3 DC Link Voltage

Module Maximum ContinuousWorking Voltage

Maximum Voltage(Surge)

GDD282 875V 900V

GDD300 1160V 1200V

GDD377 875V 900V

2.3.4 Weight


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GDD282: 72.5kg

GDD300: 75kg

GDD377: 75kg

2.3.5 Environment

Operating Ambient Temperature : 0oC to 60oCOutside dirty air path

2.3.6 Terminations

Power: DC: M10 Nutsert and bolt for cable ring crimp.AC: M10 Stud for cable ring crimp.

Auxiliary DC: Amp Mate-and-Lock connector.

Control: 3 off 26-Way Ribbon Cable.

2.4 3 Phase Sharing Reactors

These forced ventilated reactors may also be used as input or output line reactors up totheir rated current in some applications.

Order No. Rating Weight Losses

31V5400/10 310A 16.1kg 3 x Iac² x 0.00132 Watts

31V5500/10 414A 39.5kg 3 x Iac² x 0.00078 Watts

Ratings given are for forced ventilation; the naturally ventilated ratings are 260A for the31V5400/10 and 340A for 31V5500/10.


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2.5 Sinusoidal Input Line Reactors

2.5.1 GD4000 Applications

Input line reactors are required in all sinusoidal input bridge Alspa GD4000 applications. The appropriate naturally ventilated reactors are supplied with standard GD4000 drive kitsas listed in table 2.5.1.

Table 2.5.1: GD4000 Input Line Reactors

Drive NominalSupplyVoltage

ReactorCurrentRating(RMS)

PhaseInductance

Weight Order No.

GD4282 380 - 480V 282A 0.9mH 250kg 50Z0015/01

GD4300 690V 335A 1.135mH 550kg 50Z0031/01

GD4377 380 - 480V 377A 0.675mH 500kg 33Z0314/10

GD4564 380 - 480V 564A 0.45mH 550kg 33Z0315/10

GD4600 690V 670A 0.565mH 800kg 50Z0032/01

GD4754 380 - 480V 754A 0.34mH 750kg 33Z0316/10

GD4846 380 - 480V 846A 0.3mH 750kg 33Z0317/10

GD4900 690V 1005A 0.375mH 1200kg 50Z0033/01

GD41131 380 - 480V 1131A 0.225mH 1050kg 33Z0361/10

GD41200 690 1500A 0.28mH 1300kg 50Z0061/01

GD41508 380-480 1508A 0.117mH N/A 50Z0102/01

GD41800 690 1800A 0.187mH N/A 50Z0104/01

GD42262 380-480 2262A 0.113mH 1650kg 50Z0103/01

Ratings given:40°C ambient temperature. Derate by 2.5% per °C above 40°C.Altitude up to 1000m. Derate by 0.73% per 100m up to a maximum altitude of 2000m.Allowed overload 1.5 x Rated Current for 1 minute.Temperature Rise: Class F to BS2757 (1986).

Each phase of the reactor is fitted with an isolated motor protection thermistor with a"switching" temperature of 140°C. These may be connected in series to a standardthermistor protection relay for overtemperature protection.

Thermistor Electrical Specification

Tr is the reference or "switching" temperature of the device.Maximum voltage for temperature sensing 2.5V dc.Isolation level 2.5kV ac rms 1 minute.


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Temperature Resistance Test Voltage DC

Tr 1000 ohms Typical 2.5V

Tr - 5°C 550 ohms Max. 2.5V

Tr + 5°C 1330 ohms Min. 2.5V

Tr + 15°C 4000 ohms Min. 7.5V

-20°C to Tr -20°C 250 ohms Max. 0.1V

2.5.2 Losses

Power loss = 3 x Iac² x Rreactor x 1.3 Watts

whereRreactor is in ohmsIac is in amperes.

Table 2.5.2. Reactor Resistance

Drive Reactor Order No. R reactor (ohms)

GD4282 50Z0015/01 1.59mΩ

GD4300 50Z0031/01 4.3mΩ

GD4377 33Z0314/10 1.19mΩ

GD4564 33Z0315/10 0.80mΩ

GD4600 50Z0032/01 1.6mΩ

GD4754 33Z0316/10 0.59mΩ

GD4846 33Z0317/10 0.53mΩ

GD4900 50Z0033/01 0.9mΩ

GD41131 33Z0361/10 0.39mΩ

GD41200 50Z0061/01 0.79mΩ

GD41508 50Z0102/01 0.29mΩ

GD41800 50Z1014/01 0.45 mΩ

GD52262 50Z0103/01 0.18mΩ

2.6 3 Phase Input Line Reactors

These optional force ventilated reactors are used for non-sinusoidal input circuits, i.e. whenusing the Input Rectifier Modules. This includes being used as sharing reactors for the inputrectifiers and they may also be used as output line reactors in some applications.

Order No. Rating Weight Losses

30V6500/10 630A 90kg 3 x Iac² x 0.00052


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30V6700/10 740A 75kg 3 x Iac² x 0.00266

Note: These reactors will NOT fit into a 600 mm deep cubicle without modification.


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2.7 DC Link Reactors

These naturally ventilated reactors are used with 6 pulse input rectifiers.

Table 2.7.1. DC Link Reactors - Weight and Resistance

ReactorOrderNumber

Drive (1.5 xOverload)


NominalSupplyVoltage

Approx.Weight

Rreactor

33Z0327/10 GD2282GD3282

- 380 - 525V 70kg 0.7mΩ

50Z0038/01 GD2300GD3300

GD2300GD3300

690V 100kg 1.2mΩ

33Z0328/10 GD2377GD3377

GD2282GD3282

380 - 525V 60kg 0.8mΩ

33Z0329/10 GD2564GD3564

GD2377GD3377

380 - 525V 100kg 0.4mΩ

50Z0038/02 GD2600GD3600

GD2600GD3600

690V 160kg 0.6mΩ

33Z0330/10 GD2754GD3754

GD2564GD3564

380 - 525V 120kg 0.3mΩ

33Z0331/10 GD2846GD3846

GD2754GD3754

380 - 525V 120kg 0.3mΩ

50Z0038/03 GD2900GD3900

GD2900GD3900

690V 190kg 0.4mΩ

33Z0333/10 GD21131GD31131

GD2846GD3846

380 - 525V 160kg 0.2mΩ

50Z0019/01 - GD21131GD31131

380 - 525V 170kg 0.2mΩ

50Z0057/01 GD31200 GD31200 690V 210kg 0.6 mΩ

50Z0057/02 GD31500 GD31500 690V 260kg 0.5 mΩ

50Z0055/04 GD31508 GD31508 380 - 525V N/A 0.4mΩ

50Z0057/03 GD31800 GD31800 690V 325kg 0.4 mΩ

50Z0055/05 GD31885 GD31885 380 - 525V N/A 0.3mΩ

50Z0055/07 GD32262 GD32282 380 - 525V N/A 0.3 mΩ

2.7.1 Losses

Power loss = Idc² x Rreactor x 1.3 Watts

whereRreactor is in ohms and Idc is in amperes.


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2.8 Interbridge Transformers

These naturally ventilated transformers are used with 12 pulse input rectifiers

Table 2.8.1. Interbridge Transformers - Weight and Resistance

ReactorOrderNumber



NominalSupplyVoltage

Approx.Weight

Rreactor

33Z0350/10 GD2282GD3282

- 380 - 525V 31kg 3.0mΩ

50Z0043/01 GD2300GD3300

GD2300GD3300

690V 110kg 2.5mΩ

33Z0351/10 GD2377GD3377

GD2282GD3282

380 - 525V 39kg 2.0mΩ

33Z0352/10 GD2564GD3564

GD2377GD3377

380 - 525V 52kg 1.5mΩ

50Z0043/02 GD2600GD3600

GD2600GD3600

690V 160kg 1.0mΩ

33Z0353/10 GD2754GD3754

GD2564GD3564

380 - 525V 60kg 0.8mΩ

33Z0354/10 GD2846GD3846

GD2754GD3754

380 - 525V 65kg 0.6mΩ

50Z0043/03 GD2900GD3900

GD2900GD3900

690V 190kg 1.0mΩ

33Z0355/10 GD21131GD31131

GD2846GD3846

380 - 525V 110kg 0.4mΩ

50Z0021/10 - GD21131GD31131

380 - 525V 130kg 0.25mΩ

50Z0063/04 GD31200 690V N/A 0.8mΩ

50Z0063/01 GD31500 GD31200 690V 170kg 0.6 mΩ

50Z0062/01 GD31508 380 - 525V N/A 0.6mΩ

50Z0063/02 GD31800 GD31500 690V 215kg 0.5mΩ

50Z0063/03 - GD31800 690V N/A 0.4mΩ

50Z0062/02 GD31885 GD31508 380 - 525V N/A 0.5mΩ

50Z0062/03 GD32262 GD31885 380 - 525V N/A 0.4mΩ

50Z0062/04 - GD32262 380-525V N/A 0.3mΩ


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2.8.1 Losses

Power loss = Idc² x Rreactor x 0.325 Watts

whereRreactor is in ohmsIdc is in amperes.


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2.9 DELTA Cooling System

2.9.1 DELTA Cooling System - Standard Version (31V5200/10)

One cooling system (fan box) is fitted above each DELTA module. For each fan unit:

Supply Voltage 230V (single phase)Supply Frequency 50 / 60 HzInput Power 150 / 210WCurrent (Running) 0.65 / 0.81ACurrent (Starting) 2.0 / 2.5AStart-Up Time 2 secondsFan Speed 3100 rpm (60Hz)Noise Level 75 - 81dBA (dependent on ducting/enclosure)

2 off + 3dBA5 off + 7dBA6 off + 8dBA

Typical Airflow 370 CFM (630m3/h) at 1.1 in H2O (275 Pa)Total Weight 12.3 kg

Fan motor overtemperature protection - Internally connected thermal cut-outs.

2.9.2 DELTA Cooling System - High Performance Version (31V6900/10)

One cooling system (fan box) is fitted above each DELTA module. For each fan unit:

Supply Voltage 400V (3 phase)Supply Frequency 50 / 60 HzInput Power 0.75 / 1.25kWCurrent (Running) 1.35A / 1.9ACurrent (Starting) 5.4A / 7.6AStart-Up Time 2 secondsFan Speed 2880 / 3320 rpmNoise Level 80 - 88dBA (dependent on ducting/enclosure)

2 off + 3dBA5 off + 7dBA6 off + 8dBA

Typical Airflow 525 CFM (900m3/h) at 3.7 in H2O (900 Pa)Total Weight 25.4 kg

Fan motor overtemperature protection - Thermal contacts wired to customer terminal block.These contacts must be wired to an external relay so as to protect the fan from overheating.Thermal Contact Rating 250V

10A at 1.0 pf.6A at 0.6pf.


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2.10 Fan/Contactor Supply Transformer

2.10.1 Standard DELTA Cooling System

The transformer outputs are for the Standard DELTA Cooling System at 230V, single phaseac and the pre-charge contactor supply at an isolated 110V ac.

Supply Inputs 380 - 480V

The fan supply (DELTA Cooling System) is a non-isolated Autotransformer output.

On GD4000 this transformer is included on the pre-charge control panel.

Electrical Specification.

PartNumber

30Z4592/10 30Z4583/10 30Z4584/10

Used For GD2282 GD2377GD3282 GD3377GD4282 GD4377

GD2564 GD2754GD3564 GD3754GD4564 GD4754

GD2846 GD21131 GD3846GD31131 GD4846 GD41131

Max. No. of Fan Boxes

2 4 6

Fan Supply (230V ac)

1.7A continuous.4.4A start up.



Contactor Supply (110V ac)

245VA continuous.2150VA inrush.

390VAcontinuous.4200VA inrush.


PrimaryFuse Bin Ref.

7A Size 082030/110 (440V)4A NIT82120/202 (480V)

10A Size 082030/111 (440V)6A NIT82120/203 (480V)

10A Size 082030/111 (440V)10A NIT82120/204 (480V)

Secondary Fuse

5A Size 082030/109 (440V)

10A Size 082030/111 (440V)

15A Size 082030/112 (440V)

Transformer Inrush

25A 38A 60A

Weight 8.5kg 14.5kg 23.5kg

Losses * 9.5W 11W 18W

Supply Voltage 380/415/440/480V.(Selected by tap changes)Supply Tolerance ±10% from nominal, +15% for 30 cycles to IEC 204.Nominal Supply Frequency 50Hz/60Hz.Frequency Variations 45 - 63 Hz.Terminations Screw Terminal Block to accept 0.5 - 2.5mm² (20 - 24

AWG) cable.Max. Ambient Temp. 60°C.


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Altitude 0 - 2000 metres.Insulation Test Voltage 3.75kV between primary and 110V sec.(ac rms for 1 minute) 2.5kV between windings and case earth.Further insulation tests at these voltages may degrade the insulation barriers.Customers should NOT repeat this level of testing.

* Losses are given for 50 Hz at Nominal working current.


The fan supply (DELTA Cooling System) is an isolated output.


Part Number 50Z0036/01 50Z0036/02 50Z0036/02

Used For GD2300 GD3300GD4300

GD2600 GD3600GD4600

GD2900 GD3900GD4900


2 4 6

Fan Supply (230V ac, 50Hz)




Fan Supply (230V ac, 60Hz)








Primary Fuse 6A Type T 10A Type T 10A Type T

Secondary Fuse

5A Size 082030/109 (440V)

10A Size 082030/111 (440V)

15A Size 082030/112 (440V)

Transformer Inrush

50A 60A 70A

Weight 15kg 22kg 25kg

Losses * 60W 80W 100W

* Losses are given for 50 Hz at Nominal working current.

Supply Voltage 525/600/660/690V.(Selected by tap changes)Supply Tolerance ±10% from nominal, +15% for 30 cycles to IEC 204.Nominal Supply Frequency 50Hz/60Hz.Frequency variations 45 -63Hz.Terminations Screw Terminal Block to accept wire 0.5 - 2.5mm² (20 -

24 AWG) cable.Max. Ambient Temp. 60°C.Altitude 0 - 2000 metres.Insulation Test Voltage 3.0kV between windings, and between(ac rms for 1 minute) windings and case earth.


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Further insulation tests at these voltages may degrade the insulation barriers. Customersshould NOT repeat this level of testing.

2.10.2 For High Performance DELTA Cooling System

The transformer outputs are for the High Performance DELTA Cooling System at 400V ac(3 phase) and the pre-charge contactor supply at an isolated 110V ac. The fan supply(DELTA Cooling System) is a non-isolated Autotransformer output.



Part Number 50Z0018/01 50Z0018/02 50Z0018/03

Used For GD2282 GD2377GD3282 GD3377GD4282 GD4377

GD2564 GD2754GD3564 GD3754GD4564 GD4754

GD2846 GD21131GD3846 GD31131GD4846 GD41131


2 4 6

50Hz FanSupply (3ph 400V ac)

2.8 A continuous.10.8 A start up.

5.6A continuous21.5A start up




7.6A continuous29.2A start up.




390VA continuous4200VA inrush.


Primary Fuse * 16A Type T 16A Type T 20A Type T

Transformer Inrush (max.)

120A 180A 200A

Approx.Weight

19 kg 21.5 kg 40.0kg

Losses(50/60Hz) #

65/80W 80/100W 105/130W

Drives which use more than three Delta Transistor modules utilise a combination of Standard and highPerformance Fan units and so require combinations of Fan Transformer sizes and types which are detailed inthe price list.

* The primary fuses should be type "T" suitable for motor starting duty. These are rated for the transformerinrush current and also the motor starting characteristics for the fan and the contactor. Secondary fuses shouldbe selected to suit the fan and contactor requirements.

# Losses are given at Nominal working current.

Supply Voltage 380/415/440/480V/500V.


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(Selected by tap changes)Supply Tolerance ±10% from nominal, +15% for 30 cycles to IEC 204.Nominal Supply Frequency 50Hz/60Hz.Frequency Variations 45 - 63Hz.Terminations Screw Terminal Block to accept 0.5 - 2.5mm² (20 - 24

AWG) cable.Max. Ambient Temp. 50°C.Altitude 0 - 2000 metres.Insulation Test Voltage 3.75kV between primary and 110V sec.(ac rms for 1 minute) 2.5kV between windings and case earth.Further insulation tests at these voltages may degrade the insulation barriers. Customersshould NOT repeat this level of testing.



Part Number 50Z0037/01 50Z0037/02 50Z0037/03

Used For GD2300 GD3300GD4300

GD2600 GD3600GD4600

GD2900 GD3900GD4900


2 4 6



5.6A continuous21.5A start up




7.6A continuous29.2A start up.




390VA continuous4200VA inrush.


Primary Fuse * 10A Type T 16A Type T 20A Type T

Transformer Inrush (max.)

70A 120A 150A

Approx.Weight

24kg 35kg 60kg

Losses(50/60Hz) #

140W 200W 250W

Drives which use more than three Delta Transistor modules utilise a combination of Standard and highPerformance Fan units and so require combinations of Fan Transformer sizes and types which are detailed inthe price list.

* The primary fuses should be type "T" suitable for motor starting duty. These are rated for the transformerinrush current and also the motor starting characteristics for the fan and the contactor. Secondary fuses shouldbe selected to suit the fan and contactor requirements.



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Supply Voltage 525/600/660/690V.(Selected by tap changes)Supply Tolerance ±10% from nominal, +15% for 30 cycles to IEC 204.Nominal Supply Frequency 50Hz/60Hz.Frequency Variations 45 - 63Hz.Terminations Screw Terminal Block to accept 0.5 - 2.5mm² (20 - 24

AWG) cable.

Max. Ambient Temp. 50°C.Altitude 0 - 2000 metres.Insulation Test Voltage 3.0kV between windings, and between(ac rms for 1 minute) windings and case earth.Further insulation tests at these voltages may degrade the insulation barriers. Customersshould NOT repeat this level of testing.

2.11 Miscellaneous Mechanical Assemblies

2.11.1 DELTA Frames

The DELTA frames include the four side members and four cross rails complete with fixingscrews. Four frame widths are listed; the 800mm wide options are not supplied in standarddrive kits - supplied as a special.

Order Number Cubicle Width Cubicle Depth Frame WeightGDD000-4001 600mm 800mm 13.7kgGDD000-4002 800mm 800mm 16.1kgGDD000-4003 1000mm 800mm 18.2kgGDD000-4004 1200mm 800mm 20.5kgGDD000-4005 600mm 600mm 12 kgGDD000-4006 800mm 600mm 14.5kgGDD000-4007 1000mm 600mm 16.5kgGDD000-4008 1200mm 600mm 18.5kg

RITTAL PS4000 series cubicle mounting frames.

GDDRIT-46X6 600mm 600mm 12 kgGDDRIT-48X6 800mm 600mm 14.5kgGDDRIT-40X6 1000mm 600mm 16.5kgGDDRIT-42X6 1200mm 600mm 18.5kgGDDRIT-46X8 600mm 800mm 13.7kgGDDRIT-48X8 800mm 800mm 16.1kgGDDRIT-40X8 1000mm 800mm 18.2kgGDDRIT-42X8 1200mm 800mm 20.5kg

2.11.2 DELTA Module Lower Guide Support Plate (31V5800/10)

The module Lower Guide Support Plate listed below is the standard plate used without anunder-module reactor. Where a 282A or 377A 'under-module' reactor is employed this issupplied with its own module support plate and the weight is included in the total weight ofthe reactor assembly.


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Lower Guide Support Plate 1.2kg

2.11.3 Cubicle Busbars for Rectifier Bridge Modules

Order Number SuitableFor

Weight

41Y5810/10 GDR721 5 kg

41Y5356/10 GDR872 11 kg

41Y5810/20 GDR1168 15.5 kg

Note: For current rating see Rectifier Bridge Module specification.

2.12 Components For GD4000 Only

2.12.1 DELTA Precharge Panels (GD4000 only)

There are four DELTA precharge panels. The weight differences are accounted for by thesize of the fan supply transformer (larger drives with more modules require more fans andso a larger supply transformer).

Order Number Drive Application Weight

31V1900/20 GD4282 - GD4377 17kg31V1900/30 GD4564 - GD4754 23kg31V1900/40 GD4846 - GD41131 33kg31V1900/50 GD41508 - GD42262 4kg

2.12.2 Precharge Contactors (GD4000 only)

Two versions of precharge contactors are supplied with the standard ac input AlspaGD4000 drive kits. Products based on the 282A DELTA Transistor Bridge Module aresupplied with the DL110N, ie. GD4282-4001 (1 off), GD4564-4001 (2 off), GD4846-4001 (3off). Products based on the 377A DELTA Transistor Bridge Module are supplied with theDL165N ie. GD4377-4001 (1 off), GD4754-4001 (2 off), GD41131-4001 (3 off).

Contactor DL110N DL165N

Order No. 84041/512 84041/712Rated current (open/enclosed). 290/205A 380/295APower Dissipation per 37.9W 28.9Wpole at Rated current.Size of connecting bolts. M10 M12Maximum cable size. 185mm² 185mm²Mounting Position. Vertical Mounting Plane ±22.5°Weight. 9.0 Kg 18 Kg


Issue 05/99 $/63$*''(/7$7 Page 2-25

Caution: Always refer to the instructions supplied with the contactor beforeinstallation.

2.12.3 GD4000 Sigma Power Supply Step Down Transformer (50Z0042/01)

The transformer is intended to supply the GD4000 SIGMA SMPS unit 31V1400/10 whenused on high voltage (600 - 690V) supplies.


Supply Voltage 600/660/690V (single phase).(Selected by tap changes)Supply Tolerance ±10% from nominal, +15% for 30 cycles to IEC 204.Nominal Supply Frequency 50Hz/60Hz.Frequency Variations 45 - 63Hz.Output Voltage 400V ac rms (single phase).

Winding Configuration Double Wound.Terminations Screw Terminal Block to accept 0.5 - 2.5mm² (20 - 24

AWG).Max. Ambient Temp. 60°C.Humidity 5 - 95% non-condensing.Altitude 0 - 2000 metres.Insulation Test Voltage 3.0 kV between windings and between(ac rms for 1 minute) windings and case / earth.Further insulation tests at these voltages may degrade the insulation barriers. Customersshould NOT repeat this level of testing.Recommended Primary Fuse * 6 Amp type "T".Recommended Secondary Fuse 6 Amp type "T". CEGELEC Ref 82120/203.Transformer Inrush (max.) 50 AmpApprox. Weight 14kg.Losses# 60W* The primary fuses should be type "T" suitable for motor starting duty. These are rated for the transformerinrush current and also for the starting characteristics of the SMPS.



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2.13 Components For GD2000E / GD3000 and 3000E Only

2.13.1 GD2000 / GD3000 Switch Mode Power Supply (SMPS)

One SMPS unit must be fitted to each Transistor Bridge Module.

Order Number 30V7000/10 30V7100/10 30V7200/10

Nominal DriveSupply Voltage

380 - 480V 525V 690V

DC WithstandVoltage

800V 900V 1200V

Over-voltage Trip 790V 875V 1165V

Max. Ambient 50 °C 50 °C 50 °C

Weight 0.9 kg 1.5 kg 1.5 kg

ALSPA GD DELTA 3. Mechanical Installation

Issue 05/99 $/63$*''(/7$7 Page 3-1

0HFKDQLFDO,QVWDOODWLRQ

WARNING

zz THIS EQUIPMENT WEIGHS MORE THAN 20 kg.

IT SHOULD BE MOVED WITH LIFTING APPARATUS.

zz EXPOSED HIGH VOLTAGES

ALL EXPOSED HIGH VOLTAGES MUST BE ENCLOSED BEFORE THEEQUIPMENT IS ENERGISED.

zz EXPOSED ROTATING PARTS (FANS)

ACCESS TO ROTATING PARTS MUST BE PREVENTED.

zz IN THE EVENT OF FIRE TOXIC OR NOXIOUS FUMES CAN BE EMITTED.

CAUTION

Air used to cool the product is unfiltered.Air ejected from the product may contain particles of dirt.Air outlets should deflect the air away from eyes.

3.1 Introduction

Many components may be positioned within control enclosures at the installer's discretion. There are some assemblies however, which must interact mechanically and so must beinstalled following rules laid out in these instructions. There are also other considerations tobe taken into account on some mechanical arrangements. Included in the installationinstructions in this section therefore are the outline dimensions and installation requirementsof the various sub-assemblies and options available.

Before starting the assembly of the frames plan the installation thoroughly. You shouldknow before starting:

• the widths of frames to be assembled (2, 3 or 4 module).

• the module types to be fitted in each frame, and their positions.

• the modules that will require busbars to the phase terminals.

• the positions and types of reactors required.

Note References in this section to 'left' and 'right' should be taken to mean theviewer's left and right when facing the front of the equipment.

3.2 Receipt of Equipment

Before starting work the contents of the kit supplied should be carefully unpacked andinspected. Check the complete assignment against the delivery note for any shortages or

3. Mechanical Installation ALSPA GD DELTA

Page 3-2 $/63$*''(/7$7 Issue 05/99

loss in transit.

Damaged or missing parts must be reported immediately to the supplier, and the followingdetails quoted.

• List of damaged or missing items with names and part numbers.• Description of damage.• Delivery/Advice note numbers and dates, and order and item numbers.

If the equipment delivered to site is not to be installed immediately: - Re-pack it in its originalpackaging material. If this is not possible it should be enclosed in polythene sheet to protectit from the ingress of dust. - Store it in a clean dry atmosphere, preferably at roomtemperature (do not exceed the storage temperature limits given in the Section 2, ProductSpecification).

3.3 Cooling Requirements

To ensure cooling efficiency for the power devices in the power modules it is important thatthe fan boxes, modules and reactor boxes are always assembled together using theinterconnecting frame-work provided. Air paths must be free from obstruction whenentering the reactor boxes and exiting the fans. If the power device cooling system is using'dirty air' this must be separated from the internal cubicle air by ducting the input to thereactor boxes and the output from the fans (see section 3.6).

The general enclosure environment must dissipate the heat generated by the controlequipment and all ancillary devices. The maximum heat dissipation into the generalenclosure from the DELTA equipment is given in section 2 of this publication. Themaximum heat dissipation for the Alspa control equipment, and the complete drive aregiven in the relevant GD2000E, GD3000 and GD4000 Technical Manuals. The enclosureinternal temperature must always remain within the equipment operating limits as specifiedin section 2 of this technical manual. If fans are used to cool the general enclosureenvironment the air inlet should be filtered.

3.4 Frame Mounting Dimensions

The standard kit of parts includes a mounting frame for installing the equipment intostandard CEGELEC Q80 style cubicles, or Rittal PS4000 series cubicles (see section2.11.1) The kit however, does not include the cubicles. If another style of enclosure is tobe used it will be necessary to construct suitable brackets to mimic the Q80 mounting pointsto support the DELTA frame inside the selected cubicle.

Figure 3-1 shows the relative positions of the five brackets (and fixing hole centres) of theframe which must be interfaced with the enclosure. The mountings of the lower sidemembers and rear cross member must be strong enough to support the total weight of thepower modules, fans and load-sharing reactors (where fitted) with the frame andcabling/busbars. The weights of these components are listed in section 2.

The five brackets are secured to the cubicle with M6 Pozi-Pan Taptite screws (supplied). The screws are self-tapping, and should pass through holes in the cubicle into the pre-drilled brackets. The mounting holes on the cubicle should be drilled 7mm to clear thescrews.


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Dimension Key (mm):

A 900 E 35 I 742 (800 deep cubicle)B 44.4 F 504 (2 module) 542 (600 deep cubicle)C 100 G 904 (3 module) J ?? minimumD 30 H 1104 (4 module) K ?? minimum

Figure 3-1 Cubicle Dimensions for Mounting Frame


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3.5 Assembling Q80 Module Frames

3.5.1 General

The frames are available in two cubicle depths and four cubicle widths for mounting up totwo, three, or four modules side-by-side. The eight frames are all of identical constructionapart from the lengths of the cross members which determine the overall frame width andthe side supports which determine the cubicle depth. These instructions may be used forany frame.

Prepare suitable mounting arrangements for the frames as described in section 3.4. Allfixing holes for mounting the frames should be drilled 7mm (9/32) to clear the M6 Taptitescrews supplied. Taptites are self-tapping and may be driven in by hand using Posi-Drivescrewdrivers.

3.5.2 Side Supports

For 600mm (23.6") Deep Cubicles

There are four universal side supports that may be fitted to the left or right sides of thecubicle. The top of each of these supports may be identified by a hole in the long flangesee Figure 3-1. Note that front to back orientation is not important as all of the fixing holeshave been mirrored about the centre line.

Each side support has two fixing holes at each end which accept the M6 Taptite screwssupplied in the kit. Use four M6 x 10 mm (_") Taptite screws to mount each of the four sidesupports as shown in the figure 3-1.

For 800mm (31.5") Deep Cubicles

Identify the four main side supports; there are two left-handed and two right-handed. Thesemust be mounted the correct way round as shown in Figure 3-1. Note that in the top longflange of each side support there is a single hole. ( On later kits supports may beuniversal)

3.5.3 Cross Members

Installation of the four cross members is as follows:

(1) Identify the lower rear cross member. Use four M6 x 10 (_") Taptite screws to mountthe cross member to the cubicle steelwork (see Figure 3-1).

(2) Identify the upper rear cross member. Use four M6 Taptite screws to mount itbetween the two upper side-supports (see Figure 3-2). Check the turned flange is atthe bottom and facing backwards.

(3) Identify the lower front cross member. Use six M6 Taptite screws to mount it betweenthe two lower side-supports. The threaded inserts should be in the top and frontflanges (see Figure 3-2).

(4) Identify the upper front cross member. Use four M6 Taptite screws to mount itbetween the two upper side-supports. The threaded inserts should face forward (seeFigure 3-2).


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Figure 3-2 Fitting Cross Members


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3.5.4 Assembling Rittal PS4000 Module Frames

General

The frames are available in two cubicle depths and four cubicle widths for mounting up totwo, three, or four modules side-by-side. The eight frames are all of identical constructionapart from the lengths of the cross members which determine the overall frame width andthe side supports which determine the cubicle depth. These instructions may be used forany frame.

Prior to installing the side supports in the cubicle, insert the M6 spring captive nutsRIT/PS4614 (4 off per side support) into the framework at the desired distance L or M andside rail fixing centres B as shown on Fig 3.2.2.

3.5.5 Side Supports

For 600 or 800mm (23.6" or 31.5") Deep Cubicles

There are four universal side supports that may be fitted to the left or right sides of thecubicle. The top of each of these supports may be identified by either 1 hole (in 600 deepside support) or 2 holes (in 800 deep side support), in the long flange see Figure 3.2.2.Note that front to back orientation is not important as all of the fixing holes have beenmirrored about the centre line.

Each side support has two fixing holes at each end which accept the M6x12mm boltssupplied in the kit. Use four M6 x 12mm bolts to mount each of the four side supports asshown in the figure 3.2.2.

3.5.6 Cross Members

Installation of the four cross members is as follows:

(1) Identify the lower rear cross member. Use four M6 x 12mm bolts to mount the crossmember to the cubicle steelwork (see Figure 3.2.2)

(2) Identify the upper rear cross member. Use four M6 Taptite screws to mount itbetween the two upper side-supports (see Figure 3.2.2). Check the turned flange isat the bottom and facing backwards.

(3) Identify the lower front cross member. Use six M6 Taptite screws to mount it betweenthe two lower side-supports. The threaded inserts should be in the top and frontflanges (see Figure 3.2.2).

(4) Identify the upper front cross member. Use four M6 Taptite screws to mount itbetween the two upper side-supports. The threaded inserts should face forward (seeFigure 3.2.2).


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Fig 3.2.2 Rittal PS4000 series cubicle Mounting Frame details.

Dimension Key (mm)A. 900 E 535 (2 module 600 wide) J. 502 (600 deep cubicle)B. 75 F 735 (2 module 800 wide) K. 702 (800 deep cubicle)C. 125 G. 935 (3 module 1000 wide) L. ? minimumD. 49.5 H. 1135 (4 module 1200 wide) M. ? minimum

3.6 Fans


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One fan must be fitted above each module with four M6 x 15 mm (9/16") hex. head bolts withplain and spring washers. The fan mounting flange should sit flat against the underside ofthe two top cross members with the bolts screwing into the threaded inserts in the crossmembers. Partly screw in the bolts first and then slot the fan into place using the key-holesin the mounting flange as shown in Figure 3-3. Tighten the bolts fully.

Note as the fans are heavy and may be awkward to lift in to place, each fan may be splitinto two pieces. The fan duct fitted first, the main body of the fan then being added bypushing horizontally into the location tabs at the rear of the assembly and fixing by the twoM6 bolts at the front. Care must be taken to ensure that any wiring disconnected fromthe terminal block is correctly re-connected.

Each fan has a choice of three air outlets; front, top or rear. These are selected byremoving the appropriate cover and using this cover to block the unwanted outlet. To keeppersonnel from the main air and noise path it is recommended that the airflow outlet is through the top or rear of the drive enclosure.

These fans are normally fitted at the top of the enclosure, outside of the normal accidentalfinger access range. If they are installed in a position where the fan is accessible,mechanical protection must be provided .

The air outlet must not be obstructed and should preferably be ducted out of thecontrol enclosure . Figure 3-4 shows the six fixing centres on each of the fan outlets forconnecting a duct.

Figure 3-3 Installing Fan Box


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Description Order No. A B C D E F

Standard CoolingSystem

31V5200/10 200 90 10 90 100 5

High PerformanceCooling System

31V6900/10 298 144 5 102 112 5

Note: Standard pitch of 250 mm between duct outlets.

Figure 3-4 Fixing Centres on DELTA Cooling System for Ducting theOutlet


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Figure 3-4-1 Cubicle top cut out details for Rittal Cubicles and standard Top duct


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3.7 Lower Guide Support Plates

Each lower guide support plate supports a module and, (when fitted) the sharing reactors. If the sharing reactors are not to be installed use four M6 Taptites to screw the supportplates onto the top of the lower cross members at each position where a module is to befitted. The angle guide rails should be on top, with the raised tab to the front (see Figure 3-5).

If sharing reactors are to be installed, these are supplied as a complete assembly with alarger support plate fitted (see section 3.8)

3.8 Fitting Sharing ReactorsWARNING

IF AIRFLOW IS THROUGH THE REAR OF THE REACTOR MODULE, CARE MUST BETAKEN TO ENSURE THAT THE REACTOR COILS ARE NOT ACCESSIBLETHROUGH THE REAR CUBICLE CUT-OUT AS THEY EXPOSE HIGH VOLTAGES.

Sharing reactors are supplied with a module support plate (fitted with the lower guide rails).During installation of the reactor this plate may have to be removed. The reactor should befitted as one part, if it is of the new design* and the backsheet has not been fitted to thecubicle.

* The new design of the reactor is fitted with eight spacer columns between the modulesupport plate and the reactor; the previous design of reactor has one continuous insulatingsheet. Figure 3-6 shows the insulating sheet used in the previous design.

Figure 3-5 Fitting Lower Guide Support Plate


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If the support plate and spacer sheet (supplied fitted to the reactor) need to be temporarilyremoved prior to installation, remove the nine taptite screws and separate the support platefrom the reactor. Fit the plate in position between the lower cross rails and secure with fourM6 Taptites in the same manner as the normal support plate described in section 3.7.The reactor with spacer in position should now be lifted into position under the support plateusing suitable mechanical lifting gear with slings. The lifting points on the reactor are twofolded steel bars fitted just inside the upper air duct. With the reactor directly below thesupport plate pass the lifting sling through the support plate duct and lift the reactor intoposition to secure again with the nine screws. See Figure 3-6.

To fit the new design of reactor, use suitable mechanical lifting gear with slings. The liftingpoints on the reactor are the two folded steel bars just inside the upper air duct.

The reactor should first be placed in the bottom of the cubicle between the front and backcross rails. Pass the lifting sling between these two cross rails and lift the reactor so that therear edge of the module support plate (part of the reactor) rests on top of the lower rearcross-member, the remainder of the reactor hanging below the cross rails. Lift the front ofthe reactor box to just below the underside of the front guide rail, and pull the reactortowards the back of the cubicle. Lift the front of the reactor so that the support plate passes

Figure 3-6 Mounting Reactor and Support Plate


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between the lower cross-rails. When above the front cross member, gently slide the reactorforward until the module support plate rests on the front and the rear cross-rails. Line up thefour fixing holes and attach the reactor by the support plate in the same manner as thenormal support plate (described in section 3.7).

3.9 Dirty Air Intake Duct

If the power cooling path is separated from the control enclosure for 'dirty air' applicationsthe intake duct should be fitted. This is designed to draw air through a suitable aperture inthe enclosure rear sheet.

The intake duct screws directly to the underside of the standard module mounting plateusing four M4 and four M5 screws as shown in Figure 3-7.

Figure 3-7 Mounting the 'Dirty Air' Intake Duct


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3.10 Phase Busbars For Rectifier Modules

The three phase inputs to the GDR721, GDR872 and GDR1168 rectifiers are connected viashort busbars which enable access to the phase terminals from below. The busbars mustbe mounted on the frame before the module is put in place. Busbars are accommodated inthe space to the right of the module (they do not obstruct the fitting of a module in the nextposition to the right). Each of the three rectifiers has a different busbar arrangement and isdealt with separately in this section.

Note: If required, and if space permits, incoming cables or busbars may be terminateddirectly onto the module input. The extra busbars being omitted. The cables MUST haveadditional mechanical support to ensure that the device terminals are not stressed.

3.10.1 GDR721 Phase Busbars

Figure 3-8 Phase Busbar for GDR721


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The GDR721 requires three busbars. These are clamped onto the lower frame crossmembers between two paxolin strips as shown in Figure 3-8.

Assembly is as follows.

(1) Identify the longer of the two halves of the paxolin clamp. This bolts between thefront and rear frame cross members immediately to the right of the GDR721 modulesupport plate.

(2) There are two sets of mounting holes with threaded inserts in the cross members;use the holes which are further from the module and the inner two mounting holes inthe paxolin clamp. Bolt the clamp in position with the 5mm (_") spacers between theclamp and cross members using two M6 x 55 mm (25/32") bolts and plain and springwashers.

(3) The three busbars are fitted with the shortest in the front slot in the clamp, the middleone in the second slot, and the longest in the third slot.

(4) Fit the other half of the paxolin clamp bolting through in three places to the fixed halfwith M6 x 70 mm (2¾") bolts with nuts, and plain and spring washers. Do not tightenthese bolts until a module is fitted; the module will determine the positioning of thebars in the clamp.


The GDR872 requires three busbars. These are clamped onto the lower frame crossmembers between two paxolin strips and further supported by a steel bar at the rear asshown in Figure 3-9.


(1) Identify the longer of the two halves of the paxolin clamp. This bolts between thefront and rear frame cross members immediately to the right of the GDR872 modulesupport plate.

(2) There are two sets of mounting holes with threaded inserts in the cross members;use the holes which are closer to the module and the outer two mounting holes in thepaxolin clamp. Bolt the clamp in position with the 5mm (_") spacers between theclamp and cross member using two M6 x 55 mm (25/32") bolts and plain and springwashers.

(3) Fit the steel support bar next. This is held by the two M6 studs in the lower rear crossmember; use M6 nuts and plain and spring washers. Secure the top of the bar withan M6 Taptite screwed through into the pre-drilled hole in the top rear cross member.

(4) Fit two insulated stand-offs to the steel support bar using M6 x 12 (½") bolts with plainand spring washers. Fit the longest busbar to the stand-offs, again using M6 x 12(½") bolts with plain and spring washers. Note that the lower end of the busbarlocates in the rear slot of the paxolin clamp.


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Figure 3-9 Phase Busbars for GDR872


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(5) Pass an M6 x 16 mm (_") bolt with plain and spring washer through the remaininghole in the fitted busbar, from behind, and secure with a nut. Screw an insulatedstand-off to the exposed threads. Bolt the next longest busbar to the stand-off withan M6 x 12 mm (½") bolt with plain and spring washers. The lower end of the busbarshould locate in the second slot of the paxolin clamp.

(6) Pass an M6 x 16 mm (_") bolt with plain and spring washer through the hole in thesecond busbar from behind, and secure with a nut. Screw an insulated stand-offonto the exposed threads. Bolt the shortest busbar to the stand-off with an M6 x 12mm (½") bolt with plain and spring washers. The lower end of the busbar shouldlocate in the third slot of the paxolin clamp.

(7) Finally fit the other half of the paxolin clamp bolting through in three places to thefixed half with M6 x 70 mm (2¾") bolts with nuts, and plain and spring washers. Donot over-tighten these bolts; the busbars need only be lightly held.


The GDR1168 requires six busbars. These are clamped onto the lower frame crossmembers between two paxolin support strips with further paxolin supports fitted to the upperbars as shown in Figure 3-10.


(1) Identify the longer half of the larger paxolin clamp. This bolts between the front andrear frame cross members immediately to the right of the GDR1168 module supportplate.

(2) There are two sets of mounting holes with threaded inserts in the frame crossmembers; use the holes which are further from the module and the inner twomounting holes in the paxolin clamp. Bolt the clamp in position with the 5mm (_") spacers between the clamp and cross members using two M6 x 55 mm (25/32") boltsand plain and spring washers.

(3) The six busbars are fitted in order of size with the shortest in the front slot in theclamp and the longest in the rear slot.

(4) Fit the other half of the paxolin clamp bolting through in three places to the fixed halfwith M6 x 70 mm (2¾") bolts with nuts, and plain and spring washers. Do not tightenthese bolts until a module is fitted; the module will determine the vertical positioningof the bars in the clamp.

(5) Fit the small paxolin clamp to the upper half of the three longer bars using M6 x70 mm (2¾") bolts with nuts and plain and spring washers. Again, do not fullytighten the clamp until the module is in position to determine the height of the bars.


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Figure 3-10 Phase Busbars for GDR1168


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3.11 ModulesWARNING

zz THIS EQUIPMENT WEIGHS MORE THAN 20 kg (see section 2 for weight).

IT SHOULD BE MOVED WITH LIFTING APPARATUS.

CAUTION

The modules are delicate and vulnerable to damage. Only ever lift or move them bythe lifting bar and lay them down on the plain left-hand f ace when not fitted. Do notleave modules unsupported in the upright position.

Attach the module lifting bracket to the lifting equipmentshackle. The lifting bracket is located in the same place in each module (Figure 3-13 showsthe lifting bar on a rectifier module). It is a flat bar with a 16.5 mm (_") hole bolted betweenthe side sheets at the top of the module and is suitable for attaching to a shackle. Thebracket must be rotated out of its storage position inside the air duct (Figure 3-12).

Figure 3-11 Lifting Modules

Figure 3-12 Rotate theLifting Bracket tovertical


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When hung from the lifting bar the back of the module will be lower than the front. Modules shouldbe inserted into their slots in the frame at this angle, so that they clear the withdrawal stop built intothe bottom right-hand guide rail.

Figure 3-13 Module Lifting Bracket

Figure 3-14 Insert the Module between the Guide Rails


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When the rear of the module is located between the rails, lower and push back until it sitson the frame. Remove the lifting sling. Rotate the lifting bracket to its lower position andpush the module firmly back into position.

The topand bottom front flanges should lie against the front frame cross members and the fourfixing holes in the flanges should align with the holes in the cross members. Use four M6 x12 mm (½") bolts with plain and spring washers to secure the module in place.

Where phase busbars are fitted (GDR721, GDR872 and GDR1168) these should now beconnected. Use M10 x 20 mm (¾") bolts with plain and spring washers for the GDR721 andGDR1168 and use M12 x 20 mm (¾") bolts with plain and spring washers for the GDR872.

On the GDR721 tighten the busbar clamp once the terminals have been bolted together.

When all modules are fitted and connected up, fit shrouding over the exposed, high voltagecomponents.

Figure 3-15 Push the Module so that it clears the withdrawalStop Bracket


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3.11.1 DELTA Lifting Frame

The DELTA Lifting Frame has been designed specifically for the fitting and removal ofDELTA units. It has been specified to have a safe lifting capacity of 200 Kg (440 lb) whenused in accordance with the manufacturers user instructions.

The DELTA Lifting Frame is received by the user in a semi knock down form. Full assemblyinstructions are provided.

The unit is available directly from the following supplier:MegastrutUnit 7, Ward Road, Telephone: +44 (0)1299 878320Sandy Lane Industrial Estate,Stourport-On-Severn, Fax: +44 (0)1299 878322Worcestershire, DY13 9QB,England.

Always refer to the user instructions supplied with the Lifting Frame before use .

Figure 3-16 DELTA Lifting Frame Inserting / Withdrawing a Module


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3.12 Precharge Control Panel

The precharge panel has been designed to be positioned adjacent to the prechargecontactor/s to minimise the interconnections between these two components. It mayhowever, be fitted to any convenient vertical surface within the control enclosure using fourM6 (¼") bolts.

Fit the top two bolts in to the mounting surface, then mount the precharge panel on thesebolts using the two keyhole slots in the top flange. The lower two fixings may then be fitted.

Dimension A

31V1900/20 192 mm (7.6")31V1900/30 222 mm (8.7")31V1900/40 292 mm (11.5")31V1900/50 292 mm (11.5")

3.13 Precharge Control Contactor

Figure 3-17 Precharge Control Panel Mounting Dimensions


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Mount the contactor on a vertical surface, using four screws (M6 for DL110N and M8 orM10 for the DL165N). Refer to section 5 for mechanical outline.

Always refer to the installation instructions supplied with the contactor beforeinstallation.

3.14 GD2000E / GD3000E Switch Mode Power Supply (SMPS)

One SMPS fits directly on to the front of each Transistor Bridge Module.

The LV SMPS is attached using the upper two M5 screws of the Transistor Bridge Module.After installation, remove the blanking plug (if fitted) and then connect the SMPS supplycable to terminal block TB1 of the transistor module.

Installing the HV SMPS Versions (30V7100/10 & 30V7200/10)

The power cabling must be fitted before this SMPS is installed as the upper phase powerterminal (A) is obscured by this SMPS. Remove the blanking plug (if fitted) and thenconnect the SMPS supply cable to terminal block TB1 of the Transistor Bridge Module.Attach the SMPS using the upper and lower M5 screws on the front face of the TransistorBridge Module.

Figure 3-18 Installing the LV SMPS (30V7000/10)


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Figure 3-19 Installing the HV SMPS (30V7100/10 & 30V7200/10)


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ALSPA GD DELTA 4. Electrical Installation

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(OHFWULFDO,QVWDOODWLRQ

WARNING

zz EXPOSED HIGH VOLTAGES

ALL EXPOSED HIGH VOLTAGES MUST BE ENCLOSED BEFORE THEEQUIPMENT IS ENERGISED.

zz HIGH VOLTAGES AND HIGH STORED ENERGY LEVELS

THE INPUT SUPPLY MUST BE ISOLATED AND ALL MOTORS CONNECTEDTO THE EQUIPMENT MUST BE AT A STANDSTILL FOR A PERIOD OF5 MINUTES BEFORE ACCESS TO THE EQUIPMENT IS ALLOWED.

zz HIGH LEAKAGE CURRENT

EARTH (GROUND) CONNECTIONS TO THIS EQUIPMENT AND THEMOTOR(S) DRIVEN BY THE EQUIPMENT MUST BE CONNECTED AT ALLTIMES.

zz ALL EQUIPMENT PROVIDED MUST BE CONNECTED TO EARTH (GROUND)FROM THE EARTH TERMINAL PROVIDED.

THE MINIMUM SIZE OF THE PROTECTIVE CONDUCTOR MUST BE INACCORDANCE WITH LOCAL SAFETY REGULATIONS.

zz WHEN THE DRIVE IS CONFIGURED TO AUTO-RESTART, THE MOTOR CANSTART ROTATING WITH NO OPERATOR COMMAND.

UNDER THESE CONDITIONS, ALL NECESSARY PRECAUTIONS MUST BETAKEN TO PREVENT INJURY TO PERSONNEL.

zz RADIO TRANSMITTERS WITH A POWER GREATER THAN 2 W MUST NOT BEUSED IN THE VICINITY OF THE DRIVE.

RADIO TRANSMITTERS WITH A POWER LESS THAN 2 W MUST NOT BEUSED WITHIN 2 METRES (6 FEET) OF THE DRIVE.

zz THE COMBINED AUDIO NOISE EMITTED BY FANS IN AN INSTALLATION MAYBE GREATER THAN 70 dB(A) DEPENDENT ON THE AIR FLOW PATH.

THE AUDIO NOISE LEVEL IN AN INSTALLATION SHOULD BE MEASURED.

EAR DEFENDERS SHOULD BE USED WHEN THE AUDIO NOISE LEVELEXCEEDS 70 dB(A).

Note: some of the more complex items are supplied with shrouding. This is designed to protect against accidental contact with live parts for front access only. No shrouding is supplied for thelive right side or rear of the DELTA items.

4. Electrical Installation ALSPA GD DELTA

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CAUTION

zz This equipment contains semi-conductor devices and other similar components, e.g.integrated circuits, plastic film potentiometers, etc., which may be damaged by the use ofincorrect test equipment, e.g. high voltage insulation testers.

Insulation testing of cables must be carried out with the cables disconnected from theequipment.

zz All conductors connected to this product must be restrained.

zz On some items, nuts, bolts and washers to aid customer connection are supplied fittedinto the terminal busbar. These fasteners must be removed, and the customer'sconnecting crimp (or busbar) placed directly against the terminal busbar of the unit. Thetwo connecters are then clamped by the supplied fasteners. This is to prevent largecurrents flowing through the steel components and causing damage by overheatingthese and any adjacent components.

Definition

On Alspa GD DELTA and associated products the terminal intended for connection of a field-installed equipment grounding conductor shall be identified by the symbol shown in Figure 4-1.

Figure 4-1 Protective Earth (ground) symbol to IEC417.

Fastener Recommended Tightening Torque Figures

These are given in Appendix D of this manual.

4.1 Introduction

This section details the terminal arrangements for the various items of DELTA equipment. Wiring diagrams of specific modular drive arrangements for GD2000E, GD3000 and GD4000may be found in the GD2000E and GD3000 technical manual and the GD4000 technicalmanual supplement.

4.2 Rectifier Bridge Module Terminals(GDR391-4401, GDR391-4601, GDR633-4401, GDR633-4601, GDR721-4401,GDR721-4601, GDR872-4401, GDR872-4601, GDR1168-4401 & GDR1168-4601)

4.2.1 Control TerminalsThe rectifier control terminals are mounted at the top of the front face of the Rectifier BridgeModule. The terminals are the left half of a 10-pin plug and socket and may be unplugged forease of wiring. See Figures below for the terminal layouts for the different types of RectifierBridge Modules.


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Control Module connections are shown in System Design Section in Modular Drive Appendixfor GD2000E and GD3000E, or in the Modular Drive Supplement to Technical Manual ForGD4000.

Figure 4-2 Rectifier Bridge Module Control Terminals(GDR391-4401 & GDR721-4401)

Figure 4-3 Rectifier Bridge Module Control Terminals(GDR633-4401, GDR872-4401 & GDR1168-4401)


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Note: 1. Terminals will accept up to 2.5mm2 (12 AWG) flexible cables.2. The thermistors are intended to be used in conjunction with a Sigma or Omega

controller.3. To prevent failure of the Rectifier Bridge Module precharge components, the rectifier

precharge acknowledge signal (TB1/10) must be connected to the control module. Ifthis signal is not high the control module must not allow the drive to run. For standardcontrol module connection, see System Design Section in Modular Drive Appendix forGD2000 and GD3000, or in Modular Drive Supplement for GD4000.

4.2.2 Power Terminals for GDR391 Rectifier Bridge Module(GDR391-4401 & GDR391-4601)

All terminals appear at the front of the module and are suitable for cable ring-crimp connection.

Phase terminals (marked R, S and T) are M10 studs and the dc link connections (marked +and -) and the earth terminal are by M10 bolts into threaded inserts. Always use M10 plain andspring washers under nuts/bolts when connecting cables.

When tightening dc connections support the copper terminals to prevent twisting.

Figure 4-4 Rectifier Bridge Module Control Terminals(GDR391-4601 & GDR721-4601)

Figure 4-5 Rectifier Bridge Module Control Terminals(GDR633-4601, GDR872-4601 & GDR1168-4601)


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Figure 4-6 Terminals for GDR391 Rectifier Bridge Module


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All terminals appear at the front of the module and are suitable for cable ring-crimp connection.

The six phase terminals (marked R1, S1, T1 and R2, S2, T2) are M10 studs and the dc linkconnections (marked +1, -1 and +2, -2) and the earth terminal (marked Earth ) are by M10 boltsinto threaded inserts. Always use M10 plain and spring washers under nuts/bolts whenconnecting cables.

When tightening dc connections support the copper terminals to prevent twisting.



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Connections to the phase and dc link are may be made by copper busbars or cables. Whentightening connections support the terminals to prevent twisting.

Phase terminals (marked R, S and T) appear at the right-hand side of the module and matewith busbar risers fitted to the mounting steelwork. Once the module is in place use M10 boltswith plain and spring washers to bolt through the terminals to the threaded risers. The centreterminal may be rotated for cable connection see section 4.2.7.

DC link terminals (marked + and -) are at the front of the module. The dc positive terminalconnection has two M10 studs, the dc negative terminal has two M10 bolts into threadedinserts.

The earth terminal (M10 threaded insert) is located on the lower front face of the module.



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4.2.5 Power Terminals for GDR872 Rectifier Bridge Module (GDR872-4401 & GDR872-4601)

When tightening connections support the copper to prevent twisting. Phase terminals (markedR, S and T) appear at the right-hand side of the module and mate with busbar risers fitted tothe DELTA frame. Once the module is in place use M10 bolts with plain and spring washers tobolt through the terminals to the threaded risers. The centre terminal may be rotated for cableconnection see section 4.2.7.

DC link terminals (marked + and -) appear at the front of the module and are connected withfour M10 bolts in to the threaded inserts in the terminal.

The earth (ground) terminal (M10 threaded insert) is located on the lower front face of themodule. Protective earthing of the busbar support bracket (part of the cubicle busbarassembly) is by direct metal contact to the cubicle cross-rails. Ensure adequate earth continuityof this bracket to earth (ground).

4.2.6 Power Terminals for GDR1168 Rectifier Bridge Module



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(GDR1168-4401 & GDR1168-4601)

Connections to the phases and dc link may be made by copper busbars or cables. Whentightening connections support the terminals to prevent twisting.

Phase terminals (marked R1, S1, T1 and R2, S2, T2) appear at the right-hand side of themodule and mate with busbar risers fitted to the mounting steelwork. Once the module is inplace use M10 bolts with plain and spring washers to bolt through the six terminals to thethreaded risers. The centre terminal may be rotated for cable connection see section 4.2.7.

DC link terminals (marked + and -) appear at the front of the module and are connected withM10 bolts through the dc link busbars to the threaded terminals.

The earth terminal (M10 threaded insert) is located on the lower front of the module.

4.2.7 Cabling of Phase Power Terminals for GDR721, GDR872 & GDR1168(GDR721-4401, GDR721-4601, GDR872-4401, GDR872-4601, GDR1168-4401



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& GDR1168-4601)

When cabling to the phase terminals of these rectifiers the centre terminal may be rotatedthrough 180° to increase the clearance distance between the cable crimp and the adjacentterminal.

4.3 Transistor Bridge Module Terminals(GDD282-4501, GDD377-4501, GDD300-4601)

4.3.1 Control Terminals

The Transistor Bridge Modules are controlled via three 26-way ribbon cables which connect toeach of the three gate drive boards. In GD2000E, GD3000 and GD4000 applications theseare connected from the controller power interface boards.

There is also a two-pin terminal block (marked TB1) on each Transistor Bridge Module. This isconnected to the d.c. link and is used as the auxiliary d.c. link terminal. In GD4000applications this connects (on any one module only) to the Sigma control gates, and providesthe d.c. link feedback. In GD2000E and GD3000 application TB1 is connected to the SwitchedMode Power Supply mounted on each Transistor Bridge Module.

4.3.2 Gate Drive Links / Connectors

Temperature Feedback

Figure 4-11 Rotation of Centre Phase Terminal for Cable Connection


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The different controllers used with these versions of the Transistor Bridge Modules requiredifferent temperature feedback signals. This is configured on Transistor Bridge Module by alink (PL4) on the three gate drive pcbs 20X4284. On new installations these links should bepositioned to connect pin 2 to 3 (Front) on phase A and pin 1 to 2 (Back) on phase B andphase C gate drive pcbs. On replacement installations refer to Appendix C.

Overvoltage Input

The Transistor Bridge Module allows for an independent overvoltage trip input. This inhibits

Figure 4-12 Link Shown for Phase A.Figure 4-13 Position of Temperature Feedback Link

Figure 4-14 Position of Overvoltage trip Link


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the gate drive, turning off the transistor and so trips the drive on transistor fault. This feature isnot normally used. If required, the gate drive link PL6 should be replaced by the overvoltageinput.

4.3.3 Power Terminals

Connections to the phase and d.c. link terminals are intended to be made by cables.

Phase terminals (marked A, B and C) are M10 studs. DC link terminals (marked DC+ and DC-)are M10 inserts at the bottom of the module. The earth terminal (M10 Insert) is located on thelower front face of the module.

The shrouds for the power connections are attached by Snap Latch rivets as shown in thefigure below.

Figure 4-14 Transistor Bridge Module Power Terminals


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4.4 Power Module Earthing Requirements

The DELTA power modules are each provided with an earth terminal (M10 insert) at the bottomof the front face. It is not necessary to use this terminal if the mounting steelwork for themodules is adequately earthed (earth bonding test); it is provided as an additional terminal forcable connection.

4.5 DELTA Precharge Control Panel

There are two terminal blocks within the DELTA Precharge Panel, these are labelled TB1 andTB2. TB1 is at the bottom and the three phase input is connected here. TB2 at the top of thepanel connects the outputs from the panel.

When connecting the panel, position the supply voltage tap on the fan transformer (identifiedas T1) to the correct position for the cubicle supply.

Figure 4-15 Transistor Bridge Module Shrouding


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4.6. LineContactors and Relays

When installing line contactors and relays in close proximity to, or connected to, the DELTApower modules, the coils must be fitted with suppression devices.

Suppression will normally take the form of a suitably sized series connected capacitor andresistor connected across the contactor/relay coil. Suitable components are supplied withkitted drives or may be ordered.

4.7 Fans

4.7.1 Standard Cooling System

The single phase supply input to the fan is through the terminal block (TB1) located on thefront of the module - see Figure 4-18.

The fan motor is protected from overtemperature by an internal thermal cut-out. This cut-out iswired internally in series with the supply, so as to temporarily isolate and stop the fan. This maylead to the module being cooled by the fan to trip on overtemperature. Fan re-start is automaticwhen the fan motor temperature falls below the reset temperature.

For wiring protection the fan supply should be fused.

When commissioning the drive system ensure that the fan turns in a direction to extract airfrom the centre of the fan, ie that the fan turns so that the blades move in the direction

Figure 4-16 Precharge Control Panel Terminal Positions


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from the top to the bottom of the front outlet duct (see Figure 4-18).

4.7.2 High Performance Cooling System

The three phase supply input to the fan is through the terminal blocks located on the front ofthe module.

The fan motor is protected from overtemperature by two (series together) internal thermal cut-outs. These MUST be connected to an external protection relay to isolate and thus prevent

Figure 4-17 Direction of Rotation for Standard Cooling System.

Figure 4-18 Terminal Positions for High Performance Cooling System.


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damage from overheating. Thermal cut-out reset is automatic when the fan motor temperaturefalls below the reset temperature.

When commissioning the drive system ensure that the phase sequence to the fan is in theorder U, V, W and that the fan turns in the correct direction. The fan should turn in the directionto extract air from the centre of the fan, ie the fan turns so that the blades move in the directionfrom the top to the bottom of the front duct in the direction of the arrows attached to the fanmotor (see Figure 4-21).

4.8 Reactors

Figure 4-19 Example of Overtemperature Protection for High Performance Cooling System.

Figure 4-20 Direction of Rotation for High Performance Cooling system.


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The reactor terminal position and sizes are shown in the outline drawings in Section 5, CubiclePlanning.

Note: On the 282 / 377A Sharing Reactors (31V5400 & 31V5500) the terminals on the front ofthe reactor are M10 studs, and on the underside are busbars with ∅11 mm holes.

4.9 GD2000E / GD3000E Switch Mode Power Supply (SMPS)

The SMPS requires two connections.

The flying lead, supplied with the SMPS is connected to TB1 on the Transistor Bridge Module(see Mechanical Installation).

The 40 way ribbon socket PL212 is connected to the SMPS ribbon cable supplied in the drive'scable assembly kit. Further information is given in the Modular drive Appendix in the GD2000 /GD3000 Manual.

Protective earthing of the SMPS mounting bracket is by direct metal contact of the mountingtabs to the DELTA Transistor Bridge Module. Ensure adequate earth continuity betweenmounting bracket and Transistor Bridge Module.

4. Electrical Installation Alspa GD DELTA

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ALSPA GD DELTA 5. Cubicle Planning

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Cubicle Planning

This section gives guidance on planning and installing a DELTA based system. As eachapplication has different requirements, this section only give general rules and information.

Caution: Local safety regulations, in particular the regulations for equipment with highleakage current, must be observed.

5.1 Guidance Sequence

a) List the items to be installed, the next section gives two typical component lists. In themain GD2000E, GD3000, GD3000E and GD4000 manuals are examples of other drivesizes. Include any optional components and contract dependant components.

b) Locate these items together, typical mechanical layouts are shown in the next section.

c) Appreciate the approximate size and weight of the individual items. The outlinedimensions of the individual items that are common to GD2000E, GD3000, GD3000Eand GD4000 are shown at the end of this chapter. Items that are used uniquely on onedrive range are shown in the manual for that product.

d) Understand how the items are supported and mechanically interact. The MechanicalInstallation chapter details the assembly of these components and show their fixingpositions.

e) Ensure that the cooling requirement is adequate. This should include the clean airrequirement for the electronics, the main power cooling which may be configured for"dirty air" flow (see section 1.5) and their inlet/outlet positions. The airflow requirementsand losses for the modular components are detailed in the specification for eachmodule in section 2.

f) Ensure that the modules are able to be cabled together. Consideration should be givento the size and routing of the power cables that interconnect the modules. The positionsof main terminals and the control connections of the modules are shown in theElectrical Installation chapter (Those items unique to one drive range are shown in theindividual GD2000E, GD3000, GD3000E or GD4000 product manual).

g) Ensure that any additional contract dependant components have been included. Theoutlines of the optional components that may be used in a GD DELTA system areshown at the end of this chapter.

h) Detail the interfaces required for the operation of the drive. These should include anyadditional brackets required to interface the cubicle to the DELTA mounting frame, airinlet/outlet cut-outs and ducting, the mounting of the control module through a cut-out (ifmounted on the cubicle door) and the main cabling glanding/terminals in/out of thecubicle.

i) Care should be taken to ensure that the components are assembled in the sequencegiven in the mechanically assembly chapter and that sufficient clearance is allowed tofit those components. Any additional components should be fitted in positions that donot obstruct the removal and replacement of any modules.

j) Towards the end of this chapter is a list of comments that may be useful when installingthese products.

5. Cubicle Planning ALSPA GD DELTA

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5.1.2 Additional requirements for Electro-Magnetic Compatibility (EMC)

a) The drive must be installed in a steel (conductive) enclosure to reduce radiatedemissions from the drive and to protect the drive from radiating sources ( they must alsobe enclosed for electrical safety. The enclosure doors must be closed and allunnecessary apertures should be avoided.

b) Clean air cooling apertures in to the enclosure should be fitted with EMC screen filters.

c) The gland plate for input / output cables must be bolted directly to the enclosure walls,or to metal framework to which the outer walls are electrically bonded. Gland plate notto be spaced off, even on metal pillars or bars.

d) DELTA mounting rails are to be secured to the metal frame of the enclosure, to achievehigh mechanical strength and good earth bonding for electrical safety and EMC.

e) If more than one enclosure is used for the DELTA system, bond these securelytogether making a "continuous enclosure". This bonding should be by direct metal-to-metal contact, not by braids or cables. If it is not practical to have these enclosuresadjacent, use armoured cable or conduit glanded to each enclosure.

f) Reactors (even iron-cored) emit magnetic fields. Air-cored reactors must have aminimum segregation of 300 mm (12"). Refer to the GD2000E, GD3000, GD3000E orGD4000 Technical Manuals for additional information.

g) Iron-cored reactors (DC link reactor, interbridge transformer, GD4000 input line reactor)must be installed in a steel enclosure to prevent radiation (for electrical safety, theymust also be enclosed).

These will usually be on the floor of the enclosure as they are large and heavy.

h) If an EMC filter is fitted, it must be mounted onto a metal panel which is directly boltedto the metal framework of the cubicle.

On GD4000’s the filter must be on the mains side of the input reactor. If this filter is in adifferent cubicle to the rest of the drive, the wiring between them should be steel wirearmoured or run in metal conduit. The armour or conduit should be bonded to bothcubicles.

On GD2000E , GD3000 and GD3000E the filter may be on either side of the inputreactor

I) Wiring between the mains input and the RFI filter to be segregated by a minimum of300 mm (12’’) from all other drive and output components , i.e. DELTA modules,inductors, motor cable.

j) Ribbon cables supplied with DELTA kits to be run along earthed metalwork and notthrough mid air. Use the ribbons supplied, do not extend these ribbons. If the ribbonsare too long, fold the excess length backward and forward (do not roll) to make a non-inductive bundle.

k) The GD2000E, GD3000, GD3000E or GD4000 controller should be in the same cubicleor suite of cubicles as the DELTA modules. If the controller is fitted to a hinged gate thisshould be mounted directly to the metal frame of the enclosure. There are lengthrestrictions from the controller to the furthest DELTA module, due to the ribbon cablelengths.


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l) I/O (Termination ) panels should be mounted in the same cubicle as the control module.

Ribbons from I/O board to controller should run along earthed metalwork and notthrough mid-air. Again, there are distance restrictions, check that the ribbon cables willreach. These ribbons should be segregated (approximately 300 mm) from powercables and from external plant wiring.

In the case of the GD2000E, GD3000, and GD3000E, the termination panels aresupplied with a long earth lead. This lead must not be extended, and if possible, itshould be shortened ( unlike the ribbon cables, preferably to less than 100 mm. Itshould be connected to the metal of the enclosure local to the panel, not to the cubicleearth bar.

The I/O panel on the GD4000 should be mounted so that there is good metal-metalcontact between it and the frame of the cubicle.

m) Outside the cubicle, plant wiring (screening, segregation, termination etc.) should be asdetailed in the product manuals.

.


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5.2 Example 1 - GD2282 6 Pulse Input Drive

5.2.1 Component List

The list of components required for the drive will have been discussed at the time of ordering.Listed below are the typical list of components required for a standard GD2000E drive.

Required Components QtyGDD282 transistor bridge module 1GDR391 rectifier bridge module 1GD2282 control assembly 1GD2000E termination panel 1Switch Mode Power Supply 1DC Inductor 1DELTA Cooling System 2Fan Transformer (or supply) 1Ribbon Cable Kit 1DELTA mounting frame kit 1Lower guide support plate 1*

* This item may be replaced by an item from the optional component list.

Optional Components

Input line reactor*

Input fusesDirty air intake duct

Customer Supplied Components

Power CablesControl wiring (other than ribbons)Enclosure (cubicle)

5.2.2 GD2282 Cubicle Layout

The drive components listed above are shown in a "typical" cubicle layout. The majorcomponents - fan boxes, transistor modules, rectifier modules, sharing/input/output reactors,cross rails, and side supports are all attached together and so form a sub-assembly (thedimensions of these are shown in Figure 5-3. The horizontal position of this assembly isdetermined by the cross rails used and so are fixed for a width of cubicle. The vertical positionis determined by the cubicle planner and is dependant on the outlet ducting and thecomponents to be fitted underneath the DELTA modules.

The enclosure shown in Figures 5-1 and 5-2 represents a GD2282 installed in a 2200mm high,600mm wide, 800mm deep cubicle. In addition to the mandatory components listed in section5.2.1 the optional input line reactor is also shown attached to the cross rails. Note that the fantransformer and customer termination panel are mounted independently on the cubiclebacksheet. The d.c. link choke is mounted on the cubicle floor as it is large and heavy.

The control module is attached directly to a cut-out in the front door of the cubicle. If requiredan optional hinged gate is available to mount the control panel inside the cubicle.


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Figure 5-1 Typical Front View of a GD2282/2377 Cubicle - Showing Drive Components Supplied as 'Kit of Parts' (Control Module Mounted on Cubicle Door, Not Shown for Clarity).


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Figure 5-2 Typical Side View of GD2282/2377 Cubicle Showing Drive Components Supplied as Kit of Parts.


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Figure 5-3 Dimensions of the Component Assembly for a GD2282.


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5.3 Example 2 - GD4754 Sinusoidal Input

5.3.1 Component List Qty

Required Components

GDD377 transistor bridge module 4Sigma Control Assembly for GD4754 1GD4000 Customer I/O Assembly 1Switch Mode Power Supply 1A.C. Input Reactor 1DELTA Cooling System 4Precharge Control Panel 1Output/Sharing Reactor 4Ribbon Cable Kit 1DELTA Mounting Kit (1200mm wide) 1Sigma Stop Bracket (1200mm wide) 2Line Contactor (110V coil) 2

Optional Components

Input fuses,(one set of semi-conductor fuses per input transistor bridge).Dirty air intake duct,(Not required in this case as air inlet is through the sharing reactors).Front door ventilation duct

Customer Supplied Components

Power CablesControl wiring (other than ribbons and fixed assemblies)Enclosure (cubicle)

5.3.2 GD4754 Cubicle Layout

The drive components listed above are shown in a "typical" cubicle layout. The majorcomponents - fan boxes, transistor modules, rectifier modules, sharing/input/output reactors,cross rails, and side supports are all attached together and so form a sub-assembly (thedimensions of these are shown in Figure 5-6. The horizontal position of this assembly isdetermined by the cross rails used and so are fixed for a width of cubicle. The vertical positionis determined by the cubicle planner and is dependant on the outlet ducting and thecomponents to be fitted underneath the DELTA modules.

The enclosure shown in Figures 5-4 and 5-5 represents a GD4754 installed in a 2200mm high,1200mm wide, 800mm deep cubicle. The components shown are those that are mandatory forthis size of drive. The input line reactor outline is also shown. This is large and heavy and isusually mounted externally to the main drive cubicle. As the reactor exposes high voltage itmust be fitted into a protective enclosure.


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Figure 5-4 Front view of a typical GD4754 installation. The control assembly and stop brackets are not shown for clarity.

Figure 5-5 Side view of a typical GD4754 installation.


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Figure 5- 6 Dimensions of Component Assembly for a GD4754


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5.4 600mm (23.6") Deep Enclosures

DELTA components* listed in the main sections of this manual (not Appendix A) may bemounted in 600mm (23.6") deep enclosures. This requires careful enclosure planning as theindividual components utilise the full enclosure depth. (see Figure 5-7).

* The 3 Phase Input Line Reactors 30V6500/10 & /20 and 30V6700/10 & /20 will not fit asstandard into a 600mm deep enclosure.

5.4.1 Position of GD2000E (OMEGA) / GD3000, GD3000E Control Module

If the controller is mounted on the enclosure door, in front of a Transistor Bridge Module, then itmust be vertically positioned between the shroud for the d.c. busbars and the SMPS. Do notplace the controller in front of a Rectifier Bridge Module as this space is generally used forbusbar / shrouding.

Figure 5-7 Position of Control Module


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Adequate clearance (38mm (1.5") min.) must be allowed between the top of the controller andthe LV SMPS (30V7000/10) for cooling air flow. The lower face of HV SMPS (30V7100/10 &30V7200/10) is open so this clearance may be reduced if the 40 way SMPS ribbon is routed toavoid the controller fan outlet.

5.4.2 Position of GD4000 Controller (SIGMA)

There is insufficient space in a 600mm deep enclosure to mount the GD4000 controller in frontof the DELTA Transistor Bridge Modules. Only the keypad may be mounted on the enclosuredoor in front of the Transistor Bridge Module/s. It must be positioned so that the connectinglead from the back of the keypad (this projects approximately 50mm (2")) is not in front of theshrouding around the modules d.c. power terminals.

5.4.3 Position of GD2000E, GD3000, GD3000E SMPS

The normal mounting position for the SMPS is on the upper front face of each TransistorBridge Module. If the SMPS is mounted in any other position, then it is critical that the d.c. linkconnections are kept short (if both leads are twisted tightly together then the absolutemaximum length is 500mm (20")). The d.c. supply to the SMPS may be taken from any of theTransistor Bridge Modules, either from TB1 or the d.c. power terminals.

5.4.4 Double Door Flanges

WARNING

Ensure sufficient Insulation / Clearance between module live parts and enclosure doors.

IEC 664 and UL508 requires an absolute minimum of 12.7mm (1.0") for the HV Versions.

The Transistor and Rectifier Bridge Modules utilise the full nominal 600mm (23.6") enclosuredepth. If double enclosure doors are fitted they must be selected so that the vertical doorflanges avoid the space occupied by the Transistor, Rectifier and the GD2000E, GD3000,GD3000E SMPS Modules (if fitted) - see below.

If it is not possible to avoid the position of the Transistor or Rectifier Bridge Modules, then thedoor flange must be positioned to avoid their power terminals, see Figure 5-8 and 5-9. Theshrouds supplied with these modules will then require modification or replacement.Interconnecting busbars or cables will also need to be routed to avoid these flanges.

1000mm (39.4") Wide Enclosure With Double Doors - Example of GD2000E, GD3000

The normal size of double doors for a 1000 wide enclosure are two 500 (19.7") wide or one400 (15.7") and one 600 (23.6") wide doors. The position of these flanges are shown inFigure 5-8.

Two Doors, both 500mm (19.7") Wide.

The centre flange is located at the d.c. power terminals of the Transistor Bridge Module. Thereis not sufficient clearance, so this solution should not be used. Change the door sizes to 400 /600 wide or re-drill the cross-rails to reposition the DELTA modules.


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Two Doors, one 400mm (15.7") and the Other 600mm (23.6") Wide

With the 400 wide door fitted to the left side of the enclosure, the centre door flange is locatedin front of the Transistor Bridge Module. This area is normally used for the d.c. terminal shroudand for mounting the GD2000E, GD3000, GD3000E SMPS (if fitted). To use this flangeposition the shroud requires modification / replacement, the SMPS moved to a differentlocation (see 5.4.3) and the d.c. power connections routed away from the flange.

With the 600 wide door fitted to the left side of the enclosure, the centre door flange is locatedat the boundary between the Transistor and Rectifier Bridge Modules. This area is normallyused for the d.c. terminal shrouds. To use this flange position the shrouds require modification/ replacement and the d.c. power connections routed away from the flange.

1200mm (47.2") Wide Enclosure With Double Doors - Example of GD2000E, GD3000

The normal size of double doors for a 1200 wide enclosure are two 600 (23.6") wide, or one500 (19.7") and one 700 (27.6") wide, or one 400 (15.7") and one 800 (31.5") wide doors. Theposition of these flanges are shown in Figure 5-9.

Figure 5-8 Normal Position of Door Flanges for 1000mm (39.4") Enclosure


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Two Doors, both 600mm (23.6") Wide

The centre door flange is located in front of the Transistor Bridge Module. This area is normallyused for the d.c. terminal shroud and for mounting the GD2000E, GD3000, GD3000E SMPS (iffitted). To use this flange position the shroud requires modification / replacement, the SMPSmoved to a different location (see 5.4.3) and the d.c. power connections routed away from theflange.

Two Doors, One 500mm (19.7") and the Other 700mm (27.6") Wide

With the 500 wide door fitted to the left hand side of the enclosure, the centre door flange islocated adjacent to the d.c. power terminals. There is insufficient clearance, so this solutionshould not be used. Change the door sizes or re-drill the cross-rails to re-position the DELTAmodules.

With the 700 wide door fitted to the left hand side of the enclosure, the centre door flange islocated at the d.c. power terminals of the Transistor Bridge Module. There is not sufficientclearance, so this solution should not be used. Change the door sizes or re-drill the cross-railsto reposition the DELTA modules.

Two Doors, One 400mm (15.7") and the Other 800mm (31.5") Wide

With the 400 wide door fitted to the left hand side of the enclosure, the centre door flange islocated close to the d.c. power terminals. There maybe sufficient clearance dependant on theexact size of the door flange. This area is also normally used for the d.c. terminal shroud andfor mounting the GD2000E, GD3000, GD3000E SMPS (if fitted). To use this flange position the

Figure 5-9 Normal Door Positions of Door Flanges for 1200mm (47.2") Wide Enclosure


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shroud requires modification / replacement, the SMPS moved to a different location (see 5.4.3)and the d.c. power connections routed away from the flange.

With the 800 wide door fitted to the left side of the enclosure, the centre door flange is locatedat the boundary between the Transistor and Rectifier Bridge Modules. This area is normallyused for the d.c. terminal shrouds. To use this flange position the shrouds require modification/ replacement and the d.c. power connections routed away from the flange.

5.5 Additional Information

1. The input bridge is usually mounted to the right of the output bridge. This is due to mostcubicle doors being hinged on the left, so door interlocked isolators are mounted on theright of the cubicle. To keep cabling short and simple the input bridge is above theisolator, to the right of the cubicle.

2. The horizontal position of the DELTA modules mounting position is offset 20mm furtherto the left on the 600mm cross rails than on the longer versions.


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5.6 Module Outlines

5.6.1 Rectifier Bridge Module - GDR391 (GDR391-4401 & GDR391-4601)

Figure 5-10 Outline of Rectifier Bridge Module - GDR391


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5.6.2 Rectifier Bridge Module - GDR633 (GDR633-4401 & GDR633-4601)

Figure 5-11 Outline of Rectifier Bridge Module GDR633


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5.6.3 Rectifier Bridge Module - GDR721 with Cubicle Bus-bar Assembly(GDR721-4401 & GDR721-4601 fitted with 41Y5810/10)

Figure 5-12 Outline of Rectifier Bridge Module - GDR721 with Busbar Assembly


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5.6.4 Rectifier Bridge Module - GDR721 without Cubicle Bus-bar Assembly (GDR721-4401 &GDR721-4601)

Figure 5-13 Outline of Rectifier Bridge Module GDR721 Without Busbar Assembly


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5.6.5 Rectifier Bridge Module - GDR872 with Cubicle Bus-bar Assembly (GDR872-4401 &GDR872-4601 with 41Y5356/10)

Figure 5-14 Outline of Rectifier Bridge Module - GDR872 with Busbar Assembly


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5.6.6 Rectifier Bridge Module - GDR872 without Cubicle Bus-bar Assembly (GDR872-4401 &GDR872-4601)

Figure 5-15 Outline of Rectifier Bridge Module - GDR872 (Without busbar kit)


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5.6.7 Rectifier Bridge Module GDR1168 with Cubicle Bus-bar Assembly (GDR1168-4401 &GDR1168-4601 with 41Y5810/20)

Figure 5-16 Outline of Rectifier Bridge Module GDR1168 (with cubicle bus-bar assembly)


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5.6.8 Rectifier Bridge Module GDR1168 without Cubicle Bus-bar Assembly (GDR1168-4401 &GDR1168-4601)

Figure 5-17 Outline of Rectifier Bridge Module GDR1168 Without Busbar Assembly


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5.6.9 DELTA Transistor Bridge Module (GD2000E, GD3000, GD3000E SMPS not fitted)(GDD282-4501, GDD300-4601 & GDD377-4501)

For Transistor Bridge Modules fitted with a GD2000E, GD3000, GD3000E SMPS see nextfigure.

Figure 5-18 Outline and Fixing Dimensions for DELTA Transistor Bridge Module


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DELTA Transistor Bridge Modules (Fitted with GD2000E, GD3000, GD3000E SMPS)(GDD282-4501, GDD300-4601 & GDD377-4501)

Figure 5-19 Outline and Fixing Dimensions for DELTA Transistor Bridge Module fitted with SMPS


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Figure 5-20 Outline and Fixings for 282/377 Amp Reactor Box.

5.6.10 282A / 377 Amp Reactor Box (31V5400/10 & 31V5500/10)


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5.6.11 Sinusoidal Input Line Reactor (used on GD4000 only)

Drive Order No A B C D E F G H I J Tml K

GD4282 50Z0015/01 360 542 530 108 296 180 175 290 340 13 Fig A 11

GD4300 50Z0031/01 640 935 700 220 300 620 195 350 400 17 Fig A 11

GD4377 33Z0314/10 400 600 900 200 480 200 175 310 360 17 Fig A 11

GD4564 33Z0315/10 640 950 700 220 300 310 195 350 400 17 Fig A 13

GD4600 50Z0032/01 See Figure 5-23

GD4754 33Z0316/10 700 1050 800 270 370 340 220 400 450 17 Fig B 14

GD4846 33Z0317/10 700 1050 800 270 370 340 220 400 450 17 Fig B 14

GD4900 50Z0033/01 See figure 5-24

GD41131 33Z0361/10 760 1150 850 305 360 370 250 420 470 17 Fig C 12

GD41200 50Z0061/01 See Figure 5-25

GD41508 50Z0102/01 Details not available

GD41800 50Z0104/01 Details not available

GD42262 50Z0103/01 See figure 5-26

Figure 5-20 Sinusoidal Input Line Reactors (For GD4000)


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Sinusoidal Input Line Reactor (GD4000 only) - 50Z0032/01.

Figure 5-21-1 Terminal Connections for Input Line Reactors

Figure 5-22 Outline and Fixing Dimensions for Sinusoidal Input Line Reactor (GD4000 only)


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Sinusoidal Input Line Reactor (GD4000 only) - 50Z0061/01



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5.6.12 564 Amp Input Line Reactor (GD2000E, GD3000 & GD3000E only) - 30V6500/20

Note: 30V6500/10 has the same outline as 30V6500/20 but does not include the optionalfuses. Customer connection for 30V6500/10 is to A1, A2 & A3 not A, B, & C as shown for30V6500/20.

Figure 5-26 Outline and Fixings for 564 Amp Reactor


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5.6.13 741 Amp Input Line Reactor (GD2000E & GD3000 only) - 30V6700/10

Note: 30V6700/10 has the same outline as 30V6700/20 but does not include the optionalfuses. Customer connection for 30V6700/10 is to A1, A2 & A3 not A, B, & C as shown for30V6700/20.

Figure 5-27 Outline and Fixings for 741 Amp Reactor


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5.6.14 DC Link Reactor

Drive Order No A B C D E F G H J K L M

GD2282 33Z0327/10 165 60 286 184 260 310 38 13 24 285 242 270

For other d.c. reactor outlines see next page.

Figure 5-28 Outline and Fixings for GD2282 DC Link Reactor


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Figure 5-29 Outline and Fixings for DC Link Reactors

For Dimensions see page 5-32.


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Drive Order No A B C D E F DetailA

G H J

GD3300 50Z0038/01 325 465 245 160 280 335 Fig 1 11 N/A 11

GD3377 33Z0328/10 260 420 310 130 210 260 Fig 1 13 N/A 11

GD3564 33Z0329/10 320 500 350 160 280 330 Fig 2 12 25 11

GD3600 50Z0038/01 325 470 395 160 320 375 Fig 2 14 33 11

GD3754 33Z0330/10 320 500 390 160 300 350 Fig 2 14 33 11

GD3846 33Z0331/10 325 465 390 160 300 355 Fig 3 12 40 11

GD3900 50Z0038/03 365 610 385 180 300 355 Fig 3 14 50 11

GD31131 33Z0333/10 325 470 398 160 320 375 Fig 3 14 50 14

- 50Z0019/01 365 610 365 180 280 335 Fig 3 14 50 11

GD31200 50Z0057/01 400 700 300 200 290 340 Fig 4 12 40 13

GD31500 50Z0057/02 400 700 330 200 330 385 Fig 4 14 37.5 13

GD31508 50Z0055/04 Details on request

GD31800 5070057/03 430 725 433 220 330 385 Fig 4 14 37.5 13


GD32262 50Z0055/07 440 440 460 220 350 400 Fig4 14 37.5 13


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5.6.15 Interbridge Transformer

Drive Order No A B C D E F G H I J K L M

GD2282 33Z0350/10 162 235 30 120 235 195 80 120 215 135 11 10 18

GD2377 33Z0351/10 162 235 30 145 280 195 80 120 215 148 11 10 18

GD2564 33Z0352/10 165 290 30 135 250 245 90 125 240 160 11 13 24

Figure 5-30 Outline and Fixings for GD2282 Interbridge Transformer


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Drive Reactor OrderNo

A B C D E F I DetailA1 & A3

G H DetailA2

G H

GD3300 50Z0043/01 325 465 345 160 280 335 11 Fig 1 11 - Fig 1 13 -

GD3600 50Z0043/02 325 470 385 160 320 375 11 Fig 1 13 - Fig 3 12 40

GD3754 33Z0353/10 265 395 308 130 210 265 Fig 1 13 - Fig 2 14 33

GD3846 33Z0354/10 265 395 308 130 210 265 Fig 1 13 - Fig 2 14 33

GD3900 50Z0043/03 365 610 385 180 300 355 11 Fig 2 12 33 Fig 3 14 50

GD31131 33Z0355/10 325 465 348 160 280 335 Fig 2 12 25 Fig 3 14 50

- 50Z0021/01 325 465 420 160 280 335 11 Fig 3 12 40 Fig 3 14 50

GD31200 50Z0063/01 365 665 358 180 270 325 Fig 2 12 40 Fig4 12 30

Figure 5-31 Outline and Fixings for Interbridge Transformer


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- 50Z0063/04 Details on request

GD31500 50Z0063/02 365 665 337 180 300 355 Fig 3 12 40 Fig 4 12 30


- 50Z0062/02 Details on request




5.6.16 DELTA Cooling System - Standard Version (31V5200/10)

)LJXUHOutline and fixings for DELTA Cooling System - Standard Version


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5.6.17 DELTA Cooling System - High Performance Version (31V6900/10)

Figure 5-33 Outline and Fixings for DELTA Cooling System - High Performance Version.


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5.6.18 Single Phase Fan/Contactor Supply Transformer for Standard Cooling System

Supply Inputs 380 - 500V ac.

This transformer is included on the pre-charge panel for some applications.

Part No. No. of FanBoxes

A B C D E F G H J

30Z4592/10 2 89 114 12.5 24 163 89 130 6 11

30Z4583/10 4 89 140 26 39 193 108 155 7 13

30Z4584/10 6 114 195 41 60 260 95 160 9 19

Figure 5-34 Outline and Fixings For Fan/Contactor Supply Transformer


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Part No. No. of FanBoxes

A B C D E F G H J K

50Z0036/01 2 89 119 167 22.5 140 113 129 190 105 7

50Z0036/02 4 114 - 216 33 180 100 127 180 100 9.5

50Z0036/03 6 114 - 216 33 180 125 153 210 110 9.5

Figure 5-35 Outline and Fixings For Fan/Contactor Supply Transformer


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5.6.19 3 Phase Fan/Contactor Supply Transformer for High Performance Cooling System


Part No. Supply For x HighPerformance Fans

A B C D E F G

50Z0018/01 2 85 270 40 80 115 200 245

50Z0018/02 4 90 270 50 100 135 200 245

50Z0018/03 6 95 320 55 110 145 204 305

Figure 5-36 Outline and Fixings for 3 Phase Fan/Contactor Transformer


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Part No. Supply For x HighPerformance Fans

A B C D E F G

50Z0037/01 2 90 270 50 100 135 200 245

50Z0037/02 4 105 310 55 110 140 250 300

50Z0037/03 6 115 310 65 130 160 250 300

Figure 5-37 Outline and Fixings for 3 Phase Fan/Contactor Transformer


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5.6.20 GD4000 Sigma Power Supply Step Down Transformer (50Z0042/01)

Figure 5-38 Outline and Fixing Dimensions for Sigma Power Supply Step Down Transformer


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5.6.21 Dirty Air Duct (20T1671/01)

5.6.22 Lower Guide Plate Assembly (31V5800/10)

Figure 5-39 Outline of Dirty Air Duct attached to the Lower Guide Support Plate.

Figure 5-40 Outline of the Lower Guide Plate Assembly


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5.6.23 Contactor DL110N (84041/512)

5.6.24 Contactor DL165N (84041/712)

Figure 5-41 Outline and Fixings for 282 Amp Contactor

Figure 5-42 Outline and Fixings for 377 Amp Contactor

5. Cubicle Planning Alspa GD DELTA

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Blank

ALSPA GD DELTA Appendix A - Alternative Module Versions

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Scope

Appendix A should be read in conjunction with the Warnings and Cautions at the front ofthis manual and sections 1 - 5.

This appendix provides an introduction, specification, electrical installation and outlinedrawings for DELTA modules not detailed in the main manual. The mechanical installationof these modules is covered in Section 3.

Units Covered

GDR391-4001 DELTA Rectifier Bridge Module 391A, 380-480V, Single Bridge.GDR633-4001 DELTA Rectifier Bridge Module 633A, 380-480V, Double Bridge.GDR721-4001 DELTA Rectifier Bridge Module 721A, 380-480V, Single Bridge.GDR872-4001 DELTA Rectifier Bridge Module 872A, 380-480V, Single Bridge.GDR1168-4001 DELTA Rectifier Bridge Module 1168A, 380-480V, Double Bridge.GDD282-4001 DELTA Transistor Bridge Module 282A, 380-480V.GDD282-4002 DELTA Transistor Bridge Module 282A, 380-480V.GDD282-4004 DELTA Transistor Bridge Module 282A, 380-480V.GDD377-4001 DELTA Transistor Bridge Module 377A, 380-480V.GDD377-4002 DELTA Transistor Bridge Module 377A, 380-480V.GDD377-4004 DELTA Transistor Bridge Module 377A, 380-480V.

Appendix A - Alternative Module Versions ALSPA GD DELTA

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A1 Introduction

A1.1 Rectifier Bridge Modules

The Rectifier Bridge Modules are used as input bridges only. They convert the AC supplyinto rectified, unsmoothed DC. These modules are used mainly on GD2000E and GD3000.

There are two types of DELTA Rectifier Bridge Modules; single rectifier modules and doublerectifier modules. Each type is available in a choice of power ratings. The largest rectifierpower ratings can be achieved by connecting modules in parallel.

The single Rectifier Bridge Module has one, three phase rectifier bridge. The doubleRectifier Bridge Module contains two, three phase rectifier bridges. This double rectifier hastwo sets of a.c. input terminals and two sets of d.c. output terminals.

Figure A1 Single Rectifier Module - GDR872


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The double Rectifier Bridge Module may be operated as a 12-pulse input bridge. This isachieved by connecting the d.c. outputs together through an interbridge transformer, onea.c. input being phase-shifted in relation to the other by the external supply transformer.

lternatively the two bridges of the double Rectifier Bridge Module may be run as a highcurrent single rectifier bridge. The two bridges are connected in parallel using sharingreactors (Two single Rectifier Bridges Modules may also be paralleled and used as onebridge), see Specification.

Features

• The Rectifier Bridge Modules contain circuits capable of pre-charging the appropriateTransistor Bridge Modules. This circuit charges the d.c. link capacitors of thetransistor bridge via current limiting resistors in the rectifier modules.

• Modules fit in the standard rack system and are configured for "dirty air".

• Input filters are included to absorb surge energy from the mains. Supply impedance isnecessary for this to function correctly. See information on reactors section 1.6.

Figure A2 Double Rectifier Module - GDR633


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• Protection against d.c. link short circuits by the use of semiconductor fuses.

• Modules carry thermostat and thermistor protection so when they are connected tothe controller, the module is protected against overtemperature.

Variations

• Available in two versions single and double rectifier bridges.

• The single Rectifier Bridge Modules are available in three power ratings.The threeratings (d.c. output current) are 391A, 721A and 872A. The modules are thereforecalled GDR391, GDR721 and GDR872 respectively.

• Double Rectifier Bridge Modules are available in two power ratings. These are (d.c.output current) 633A and 1168A, called GDR633 and GDR1168 respectively.

• Higher current versions are possible by paralleling the modules through reactors togive higher currents. As the modules will not carry equal current, some derating of theoutput current is necessary.

Interface

• Signals between the controller and the rectifier bridge module are by discrete wires,which are between 'pluggable' terminal blocks.

• The GDR391 and GDR633 power connections are designed for cable connection tostud terminals. The GDR721, GDR872 and GDR1168 are designed for busbarconnection.

• Short busbars that connect to the rectifier terminals enable the connection point to bebelow the DELTA cross rails. These may be supplied in the kit of parts or as aseparate item.


• For parallel operation of these modules, external sharing reactors must be fitted.

• For 12 pulse operation the two supplies must be phase shifted by 30° to each otherand of balanced voltage. The output must be through an interbridge transformer,which replaces the d.c. link choke.

• Protection of the main input rectifier devices is by the addition of externalsemiconductor fuses. For recommended fuses see specification, section 2

• The modules designed for busbar connection are not suitable to support the weight ofany attached cables. These cables must have an additional mechanical support.

• The output from all of the Rectifier Bridge Modules must be through a d.c. linkinductor or an interbridge transformer.

A1.2 Transistor Bridge Module


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In the standard GD2000E, GD3000 and GD4000 applications DELTA Transistor BridgeModules are used in combination to provide:

• an output stage where the d.c. produced by the input bridge is converted into avariable frequency and variable voltage three phase output.

• an input stage for GD4000 where a normal three phase supply is rectified to d.c. Thetransistors being controlled to draw sinusoidal current from the mains.

Features

• DELTA Transistor Bridge Modules use insulated-gate bipolar transistors (IGBT)providing low distortion output.

• DC smoothing capacitors that provide filtering for the drive DC link in addition to localenergy storage for output transistor switching.

• Output protection against earth faults and short circuits.

• Modules fit in standard DELTA rack system and are configured for "dirty air".

• Auxiliary DC link connection plug for connection to Switch Mode Power Supply(SMPS). The GD2000E, GD3000 SMPS may be directly mounted on the TransistorBridge Module.

• Each module carries thermostat and thermistor protection so when connected to theGD2000E, GD3000 and GD4000 controller the module is protected againstovertemperature.

Variations

• Available in two nominal power ratings (a.c. phase current) of 282A and 377A. Theyare called GDD282 and GDD377. Both modules have the same dimensions; thedifference in rating is due to the internal components used.

• The two versions are suitable for the output bridges on the GD2000E and GD3000drives; the input and the output bridges on the GD4000 drives; and as the input oroutput power bridges in common d.c. link applications.

Interface

• Signals between the controller and transistor module are by three 26 way ribboncables per module. These cables also carry the supplies for the electronics on thetransistor bridge.

• Power connections are stud terminals for the DC, and busbars (suitable for cabletermination) for the AC connections. The AC connections may be rotated / offset toallow cable / busbar connection.


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• The Transistor Bridge Modules contain smoothing capacitors which when used inboth input and output applications must be 'pre-charged'. These modules do notcarry pre-charge circuits. The recommended pre-charge rate is specified in section 2of this document. For standard GD2000E and GD3000 drives the pre-charge circuitis completely contained in the rectifier bridge module. In GD4000 applications a pre-charge panel is supplied for use in conjunction with a line contactor and provides thenecessary precharge action.

• The d.c. supply to the transistor module must be within appropriate voltage, currentand ripple limits and must be 'pre-charged'.

• These modules must be forced ventilated to reach specified performance.

• When Transistor Bridge Modules are used as input bridges it is recommended thatsemiconductor fuses are fitted on the a.c. supply.

Figure A3 Transistor Bridge Module


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A2 Specification

This section provides the specifications for the DELTA power components listed. Forspecifications of complete standard Alspa GD2000E, GD3000 and GD4000 drives seesection 2 of the Alspa GD2000E, GD3000 and GD4000 Technical Manuals.

A2.1 Rectifier Bridge Modules

Units covered: GDR391-4001, GDR633-4001, GDR721-4001, GDR872-4001,GDR1168-4001.

A2.1.1 Current Ratings

Table A2.1.1: Thermal Current Ratings of Rectifier Bridge Modules

Unit DC Current(With 1.5 xOverload)

AC Output CurrentCapability for a

Complete Alspa Drive(with 1.5 x Overload)

GDR391 391 332

GDR721 721 613

GDR872 872 741

GDR633 633 538

GDR1168 1168 993

Notes:

All ratings above are for the maximum thermal rating of the Rectifier Bridge Modules at40°C ambient. To protect these modules from d.c. link side short circuits the fitting of a.c.supply semi-conductor fuses are recommended. The current ratings of the Rectifier BridgeModule with recommended fuses are given in Table A2.1.2.

Overloads are for 60 seconds, 6 times per hour equally spaced.

All ratings assume standard drive configurations using d.c. link reactors or interbridgetransformers.

The GDR633 and GDR1168 are double rectifier modules. To achieve the rating stated inTable A2.1.1 they must be supplied by a 12 pulse supply feed transformer or sharingreactors in addition to the d.c. link reactors or interbridge transformers.

If two separate Rectifier Bridge Modules are paralleled (using sharing reactors) or used as12 pulse bridges the output current is derated by 10% to allow for current imbalancebetween the bridges.

Table A2.1.2: Rectifier Bridge Module Current Rating when using Recommended Fuses

Module Fuse DC Current (with DC Current (with


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no Overload) 1.5 x Overload)

GDR391 GSGB350 (3 off) 384 362

GDR721 GSGB580 (3 off) 671 633

A366S800D1 (3 off) 817 721

GDR872 A366S900D1 * (3 off) 926 872

GDR633 GSGB350 (6 off) 622 586

GDR1168 A366S800D1 (6 off) 1323 1168

All ratings are calculated assuming a 31MVA supply, no added impedance. The GDR872(marked '*') requires an additional 33uH input reactor (or equivalent supply fault level) forfuse protection.

Ambient temperature is 40°C.

The ratings given above are for the recommended fuses from two suppliers. The GSGB arefrom the GEC Alstom HRC fuse link range and the A366S from the Gould ShawmutSemiconductor fuse range (the 900A fuse MUST be a size 3 fuse).

A2.1.2 Phase Rotation

The rectifier modules are not sensitive to phase rotation.

A2.1.3 Input Phase Voltage

380V to 480V a.c. rms (nominal). 3 phase, 3-wire and ground.

Note: The above supply limits refer to the nominal supply voltages. The equipment willoperate with a variation of ±10% of the nominal supply voltage. For supplyvoltages below the nominal, there will be a corresponding reduction inmaximum output power. The equipment can operate up to a maximum of±15% variation on the nominal supplies for a maximum of 30 cycles durationwithout the equipment tripping though reduced performance may beobserved. The equipment can be operated on 500V ac supplies but with a+6% to -10% supply variation.

Supply frequency: 45Hz to 63Hz

A2.1.4 Output DC Link Voltage

Maximum d.c. output: 780V d.c.

Typical d.c. output: 1.35 x supply voltage (rms)

Maximum d.c. link: 800V d.c.(regenerating)

A2.1.5 Precharge


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Precharge resistors: GDR391, GDR721, GDR633, GDR1168- 15 ohms.GDR872 - 7.5 ohms.

Precharge control signal: requires 24V or 48V d.c. input signal when d.c.link is charged.

Precharge control signal load: 36.4mA (660 ohms at 24V dc)

A2.1.6 Weight

GDR391 30.5kg

GDR633 48kg

GDR721 39kg

GDR872 65kg

GDR1168 62kg

A2.1.7 Environment

Operating Ambient 0oC to 40oC into power cooling pathTemp.

0oC to 60oC (all other components)

Storage Temperature: -25oC to +70oC

Relative Humidity: 5% to 95% non-condensing

Altitude: Normal operating altitude up to 1000m above sea level.Derate by 7.3% per 1000m (3300 ft) to a maximum of2000m (6600 ft).

Enclosure: IP00 (these modules must always be installed in anappropriate enclosure with restricted access)

Mounting: Fits standard slot on DELTA mounting frame.

Losses: The losses for this module may be calculatedapproximately using:

Total Losses = Power losses + Control losses.Power losses = 2.4 x Total dc output current.

Control losses : 35W for GDR391,45W for GDR721,70W for GDR633 and GDR872,90W for GDR1168.

A2.1.8 Terminations


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3 Phase Supply:

GDR391 3 terminals M10 stud for cable ring crimp.GDR633 6 terminals M10 stud for cable ring crimp.GDR721 3 terminals 50 x 6.3 busbar with 2 x 10mm holesGDR872 3 terminals 63 x 6.3 busbar with 2 x 12mm holesGDR1168 6 terminals 50 x 6.3 busbar with 2 x 10mm holes

DC Output:

GDR391 2 terminals M10 stud for cable ring crimp.GDR633 4 terminals M10 stud for cable ring crimp.GDR721 2 terminals 63 x 6.3 busbar with 2 x M12 threaded insertsGDR872 2 terminals 63 x 6.3 busbar with 2 x M12 threaded insertsGDR1168 4 terminals 50 x 6.3 busbar with 2 x M10 threaded inserts

Control terminals accept up to 2.5mm2 flexible cables.

A2.1.9 Thermal Protection

GDR391 and GDR721: Thermistor

GDR633, GDR872 and GDR1168: Thermistor and Thermostat

Thermostat Rating: 10A @ 250V a.c., 50/60Hz8.5A @ 24V d.c.7A @ 48V d.c.n/c contact opens at 90oC.

Note: Thermistors are only to be used in conjunction with the Omega and Sigmacontrollers.

A2.2 Transistor Bridge Modules

Units covered: GDD282-4001, GDD282-4002, GDD282-4004, GDD377-4001,GDD377-4002, GDD377-4004.

The values given in this section (A2.2) are the Absolute Maximum Ratings for the TransistorBridge Modules. As external components (ie. controller) are required to form a completeinput / output circuit, then the ratings obtainable for the combined components should beused when sizing a drive. Refer to the GD2000E, GD3000 or GD4000 manual for theratings of the standard drives that use these modules.


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A2.2.1 AC Phase Current Ratings

Table A2.2.1: Absolute Maximum AC Phase Current Ratings (Input or Output Mode).

Conditions GDD282 GDD377

Peak Instantaneous Current 600 Amps 800 Amps

Continuous ac rms Current allowing for a 1.5 xOverload

282 Amps 377 Amps

Continuous ac rms Current allowing for a 1.1 xOverload

384 Amps 514 Amps

Continuous ac rms Current with no allowancefor Overloads

423 Amps 565 Amps

These current ratings are limited by the system design. The cooling system, number ofparalleled Transistor Bridge Modules, type and configuration of controller will limit thesystem rating. It is NOT possible to achieve these absolute ratings under all operatingconditions. Most combinations of ambient temperature, supply voltage, and switchingfrequencies will result in a reduced rating. Refer to the GD2000E, GD3000, or GD4000Technical Manual for the current ratings of the complete standard drive systems.

A2.2.2 Phase Voltage

The maximum phase to phase rms voltage is Vdc/√2 for sinusoidal waveforms.

A2.2.3 DC Link Voltage

430V - 750V dc (continuous working voltage)up to 800V dc (surge)

A2.2.4 Weight

GDD282: 78kg

GDD377: 78kg

A2.2.5 Environment

Operating Ambient Temperature: 0oC to 40oC (into power cooling path)

0oC to 60oC (all other components)Storage Temperature: -25oC to 70oC

Relative Humidity: 5% to 95% non-condensing

Altitude: Rated operating altitude up to 1000m above sea level.

Enclosure: IP00 (these modules must always be installed in anappropriate enclosure with restricted access)

A2.2.6 Terminations


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Power: DC: M10 Stud for cable ring crimpAC: Busbar with 10mm hole

Auxiliary DC: Amp Mate-and-Lock

Control: 3 off 26-Way Ribbon Cable


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A3 Mechanical Installation

Refer to section 3 of the main manual for mechanical installation of these modules.


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A4 Electrical Installation

WARNING

THESE PRODUCTS EXPOSE VOLTAGES UP TO 795V AC and 1200V DC

These items are intended to be mounted in enclosures and it is the responsib ility of theinstaller to ensure that the risk of electrocution is minimised.

In order to assist with this, the complex items are supplied with shrouding.

The shrouding is designed to protect against accidental contact with live parts for frontaccess only. No shrouding is supplied for the live right side or rear of the DELTA items.

Caution

On some items, nuts, bolts and washers to aid customer connection are supplied fitted intothe terminal busbar. These fasteners must be removed, and the customer's connectingcrimp (or busbar) placed against the terminal busbar of the unit. The two connecters arethen clamped by the supplied fasteners. This is to prevent large currents flowing throughthe steel components and causing damage by overheating these and any adjacentcomponents.

Definition

On Alspa GD DELTA and associated products the terminal intended for connection of afield-installed equipment grounding conductor shall be identified by the symbol shown inFigure A4.

Figure A4 Protective Earth (ground) symbol to IEC417.

A4.1 Introduction

This section details the terminal arrangements for the various items of DELTA equipment. Wiring diagrams of specific modular drive arrangements for GD2000E, GD3000 andGD4000 may be found in the GD2000E and GD3000 technical manual and the GD4000technical manual supplement.

A4.2 Rectifier Bridge Module Terminals

A4.2.1 Control Terminals

The rectifier control terminals are mounted at the top of the front flange of the RectifierBridge Module. The terminals are the upper half of a 10-pin plug and socket and may beunplugged for ease of wiring. See Figures A5 & A6 for the terminal layouts for the twotypes of Rectifier Bridge Modules.


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Terminals will accept up to 2.5mm2 flexible cables.

note: The thermistors are intended to be used in conjunction with a Sigma orOmega controller.

A4.2.2 Power Terminals for GDR391 Rectifier Bridge Module

All terminals appear at the front of the module and are suitable for cable ring-crimpconnection.

Phase terminals (marked R, S and T) and the earth terminal (marked Earth ) are M10 studsand the d.c. link connections (marked + and -) are by M10 bolts into threaded inserts. Always use M10 plain and spring washers under nuts/bolts when connecting cables.

When tightening d.c. connections support the copper terminals to prevent twisting.

Figure A5 Rectifier Bridge Module Control Terminals (GDR391 & GDR721)

Figure A6 Rectifier Bridge Module Control Terminals (GDR633, GDR872 & GDR1168)


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All terminals appear at the front of the module and are suitable for cable ring-crimpconnection.

The six phase terminals (marked R1, S1, T1 and R2, S2, T2) and the earth terminal(marked Earth ) are M10 studs and the d.c. link connections (marked +1, -1 and +2, -2) areby M10 bolts into threaded inserts. Use either or both of the two studs of the phaseterminals. Always use M10 plain and spring washers under nuts/bolts when connectingcables.

Figure A7 Terminals for GDR391 Rectifier Bridge Module



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When tightening d.c. connections support the copper terminals to prevent twisting.


Connections to the phases and d.c. link are intended to be made by copper busbars.

Phase terminals (marked R, S and T) appear at the right-hand side of the module and matewith busbar risers fitted to the mounting steelwork. Once the module is in place use M10bolts with plain and spring washers to bolt through the terminals to the threaded risers.

DC link terminals (marked + and -) appear at the front of the module and are connected withtwo M12 bolts through the d.c. link busbars to the threaded terminals.

When tightening connections support the terminals to prevent twisting.

The earth terminal (marked Earth ) appears at the bottom front of the module and is an M10stud.



Phase terminals (marked R, S and T) appear at the right-hand side of the module and matewith busbar risers fitted to the DELTA frame. Once the module is in place use M12 boltswith plain and spring washers to bolt through the terminals to the threaded risers.

DC link terminals (marked + and -) appear at the front of the module and are connected withtwo M12 bolts through the d.c. link busbars to the threaded terminals.



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When tightening connections support the copper to prevent twisting.




Phase terminals (marked R1, S1, T1 and R2, S2, T2) appear at the right-hand side of themodule and mate with busbar risers fitted to the mounting steelwork. Once the module is inplace use M10 bolts with plain and spring washers to bolt through the six terminals to thethreaded risers.

DC link terminals (marked + and -) appear at the front of the module and are connected withM10 bolts through the d.c. link busbars to the threaded terminals.

When tightening connections support the terminals to prevent twisting.




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A4.3 Transistor Bridge Module Terminals

A4.3.1 Control Terminals

The Transistor Bridge Modules are controlled via three 26-way ribbon cables which connectto each of the three gate drive boards. In GD2000E, GD3000 and GD4000 applicationsthese are connected from the controller power interface boards.

There is also a two-pin terminal block (marked TB1) on each Transistor Bridge Module. Thisis connected to the d.c. link and is used as the auxiliary d.c. link terminal. In GD4000applications this connects (on any one module only) to the Sigma control gates, andprovides the d.c. link feedback. In GD2000E and GD3000 application TB1 is connected tothe Switched Mode Power Supply mounted on each Transistor Bridge Module.

A4.3.2 Power Terminals

Connections to the phase and d.c. link terminals are intended to be made by cables.

Phase terminals (marked A, B and C) are M10 studs. There are two studs at each terminalposition, the right-hand one has the phase connection, the left-hand one may be used toanchor one end of a terminal bar to if required.

DC link terminals (marked DC+ and DC-) are M10 studs at the bottom front face of thedrive.



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A4.3 Power Module Earthing Requirements

The DELTA power modules are each provided with an earth terminal at the bottom of thefront face. It is not necessary to use this terminal if the mounting steelwork for the modulesis adequately earthed; it is provided as an additional terminal for cable connection.

Figure A12 Transistor Bridge Module Power Terminals


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A5 Module Outlines

A5.1 Rectifier Bridge Module - GDR391 (GDR391-4001)

Figure A13 Outline of Rectifier Bridge Module - GDR391


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A5.2 Rectifier Bridge Module - GDR633 (GDR633-4001)

Figure A14 Outline of Rectifier Bridge Module GDR633


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A5.3 Rectifier Bridge Module - GDR721 with Cubicle Bus-bar Assembly (GDR721-4001 with41Y5810/10)

Figure A15 Outline of Rectifier Bridge Module - GDR721 with Busbar Assembly


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A5.4 Rectifier Bridge Module - GDR872 with Cubicle Bus-bar Assembly (GDR872-4001 with41Y5356/10)

Figure A16 Outline of Rectifier Bridge Module - GDR872 with Busbar Assembly


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A5.5 Rectifier Bridge Module - GDR872 without Cubicle Bus-bar Assembly (GDR872-4001)

Figure A17 Outline of Rectifier Bridge Module - GDR872 (Without busbar kit)


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A5.6 Rectifier Bridge Module GDR1168 with Cubicle Bus-bar Assembly (GDR1168-4001 with41Y5810/20)

Figure A18 Outline of Rectifier Bridge Module GDR1168 (with cubicle bus-bar assembly)


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A5.7 Rectifier Bridge Module GDR1168 without Cubicle Bus-bar Assembly (GDR1168-4001)

Figure A19 Outline of Rectifier Bridge Module GDR1168 Without Busbar Assembly


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Figure A20 Outline and Fixing Dimensions for DELTA Transistor Bridge GDD282/377.

A5.8 DELTA Transistor Bridge GDD282 / GDD377 (GDD282-4001, GDD282-4002,GDD377-4001 & GDD377-4002)

ALSPA GD DELTA Appendix B - Precharge components for 690V GD4000

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Scope

This Appendix lists the components required to precharge the DC link capacitor bankcontained inside the DELTA Transistor Bridge Modules used in the 690V ac Alspa GD4000.The drives covered are the GD4300, GD4600 and GD4900. The circuit connections for theprecharge components are also shown.

The GD4000 may be used on a variety of international supplies. The components are listedagainst those supplies and the international standards that the components meet (aspublished by the various suppliers of those components).

The components listed will be supplied (when ordered) as loose items to the systemintegrator to build into the drive enclosure. Shrouding of those items which are connected tohigh voltage remains the responsibility of the system integrator.

Appendix B - Precharge Components for 690V GD4000 ALSPA GD DELTA

Page B-2 $/63$*''(/7$7 Issue 05/99

B1 Description

The 'systems' specified below list only those modules containing capacitors that requireprecharging. To construct a complete drive system other components are required, iecontrol module, SMPSs, line reactors... These components do not require precharging, sothey are NOT listed as parts of the system configuration.

The GDB400-4601* is the 400 Amp, 690V Dynamic Braking Unit. This module is notrequired as part of most GD4000s. When fitted it does require to be precharged by thecomponents detailed below. So the maximum number of Dynamic Braking units that may befitted in each system has also been listed.* Not yet available.

B1.1 System Configurations:

For the GD4300 (2 x GDD300-4601 DELTAs + 1 GDB400-4601*)(Maximum Total Nominal Capacitance for system = 17 233uF).

For the GD4600 (4 x GDD300-4601 DELTAs + 2 x GDB400-4601*)(Maximum Total Nominal Capacitance for system = 34 466uF).

For the GD4900 (6 x GDD300-4601 DELTAs + 3 x GDB400-4601*)(Maximum Total Nominal Capacitance for system = 51 700uF).

Note that all of the above items contain capacitors manufacturer to a possible +30%tolerance. So the total maximum capacitance in each system = the Nominal x 1.3.

B1.2 Common DC Link Schemes

Larger common dc link schemes which contain capacitance in excess of the Maximum TotalNominal Capacitance given in section B1.1 may be 'soft started' by using parallel prechargecircuits. The increase is proportional to the number of parallel paths, ie 3 x the GD4900precharge circuit will precharge 3 x 51 700uF (= 155 100uF).


Issue 05/99 $/63$*''(/7$7 Page B-3

B2 Circuit Diagram

For full drive wiring diagram refer to GD4000 Technical Manual.

B3 Components

B3.1 Precharge Resistors (R1 - R9)

Specifications Designed to comply with EN60146, prEN 50178,UL508C, CSA C22.2 No. 14 :690V ac (For drive product using this component).


Page B-4 $/63$*''(/7$7 Issue 05/99

GD4300 (2 x GDD300-4601): 6 qty of 7.5 ohm, 140W, UC417 CEGELECup to 690V ac. order No 62767/843 fitted R1 - 6. Note R7 - 9 not

fitted.

GD4600 (4 x GDD300-4601): 6 qty of 7.5 ohm, 140W, UC417 CEGELECup to 690V ac. order No 62767/843 fitted R1 - 6. Note R7 - 9 not

fitted.

GD4900 (6 x GDD300-4601): 9 qty of 7.5 ohm, 140W, UC417 CEGELECup to 690V ac. order No 62767/843 fitted R1 - 9.

B3.2 Precharge Resistor Mounting Brackets (For R1-9)

Specifications Designed to comply with EN60146, prEN 50178,UL508C, CSA C22.2 No. 14 : 690V ac (For driveproduct using this component).

2 qty required per precharge resistor. CEGELEC order No 79320/103.

B3.3 Precharge Relay (RL1)

Specifications IEC 337-1, IEC 947 : 750V ac.CSA/UL : 600V ac.

GD4300 (2 x GDD300-4601): 1 qty of HLg4K-31 control relay, 48V dc coil CEGELECorder No 86407/994.



B3.4 Precharge Relay Suppression D1


GD4300 (2 x GDD300-4601): 1 qty of 1N4007 diode, CEGELEC order No 71545/450.



B3.5 Precharge Contactor (CN1-3)

Specifications IEC 947-1, BS 5424 : 750V ac.CSA 22.2-Nr. 14, UL 508 : 600V ac.

GD4300 (2 x GDD300-4601): 1 qty of DL132N contactor, 110V ac coil CEGELECorder No 84041/612 fitted CN1.


Issue 05/99 $/63$*''(/7$7 Page B-5

GD4600 (4 x GDD300-4601): 2 qty of DL132N contactor, 110V ac coil CEGELECorder No 84041/612 fitted CN1-2.

GD4900 (6 x GDD300-4601): 3 qty of DL132N contactor, 110V ac coil CEGELECorder No 84041/612 fitted CN1-3.

B3.6 Precharge Contactor Coil Suppression (C1-3 & R10-11)


GD4300 (2 x GDD300-4601): 1 qty of DL132N, 110V ac coil suppression CEGELECorder No 41Y5829/10, fitted C1 & R10.

GD4600 (4 x GDD300-4601): 2 qty of DL132N, 110V ac coil suppression CEGELECorder No 41Y5829/10, fitted C1-2 & R10-11.

GD4900 (6 x GDD300-4601): 3 qty of DL132N, 110V ac coil suppression CEGELECorder No 41Y5829/10, fitted C1-3 & R10-12.

B3.7 Recommended Precharge Fuses (FS1-3)

Specification (1) BS88-2, IEC 947-4, : 660V acNote these fuses have been tested to 10% overvoltage(726V ac)

GD4300 (2 x GDD300-4601): 3 qty of TIA 16 HRC fuses CEGELEC order No82130/105.



Fuse Holders for TIA HRC fuse range

Specification (1) BS88-2, IEC 947-4, : 660V ac

1 qty RS 32H per fuse. CEGELEC order No. 82931/101 or RS 63H CEGELEC order No.82932/101.

Specification (2) BS 2692 : 1200V ac.ie these fuses will comply with the specification of 690V+10% (pr EN 50178, IEC 38), and +15% for 30 cycles(EN 60146-1).

GD4300 (2 x GDD300-4601): 3 qty of TAC 16 HRC fuses CEGELEC order No (Notcoded)

GD4600 (4 x GDD300-4601): 3 qty of TAC 16 HRC fuses CEGELEC order No (Notcoded).


Page B-6 $/63$*''(/7$7 Issue 05/99

GD4900 (6 x GDD300-4601): 3 qty of TAC 10 HRC fuses CEGELEC order No82141/104.

Fuse Holders for TIA HRC fuse range

1 qty per fuse. RSL 63H CEGELEC order No. 82945/102.

Specification (3) UL Recognized : 700V ac

GD4300 (2 x GDD300-4601): 3 qty of Gould A70P16, 16A semiconductor fusesCEGELEC order No (Not coded).



Fuse Holders for A70P fuse range (1-30A)

1 qty per fuse. Gould Catalog No. 20306. CEGELEC order No. (Not coded)

Specification (4) IEC 269-1, EN 60269-1 : 660/690V ac

GD4300 (2 x GDD300-4601): 3 qty of 10A HRC fuses SIBA NH00 range or ABBOFAA range - CEGELEC order No (Not coded).



ALSPA GD DELTA Appendix C - Interchanging Modules

Issue 05/99 ALSPA GD DELTA (T1641)ALSPA GD DELTA (T1641) Page C-1

Scope

This document must be read in conjunction with the following sections from the DELTAmanual T1641:

WARNINGS AND CAUTIONSSection 5.6.9 Outline of DELTA Transistor Bridge Module

(GDD282-4501, GDD300-4601 & GDD377-4501)Section A5.8 Outline of DELTA Transistor Bridge Module

(GDD282-4001, GDD282-4002, GDD282-4004, GDD377-4001,GDD377-4002& GDD377-4004).

Section 3.14 Mechanical Installation of GD2000E/GD3000 Switch Mode Power Supply.

These documents describe which versions of DELTA modules may be interchanged whenused on GD2000, GD2000E, GD3000 and GD4000. It covers only the GD2000, GD2000Eand GD3000 drives up to 480V supply voltage. For GD4000 the supply voltage covered isdependent on the application (typically limited to 440/460V). Check the control moduleversion as detailed for each module.

Units Covered:

GDR391-4001 DELTA Rectifier Bridge Module 391A, 380-480V, Single Bridge.GDR391-4401 DELTA Rectifier Bridge Module 391A, 380-480V, Single Bridge.GDR633-4001 DELTA Rectifier Bridge Module 633A, 380-480V, Double Bridge.GDR633-4401 DELTA Rectifier Bridge Module 633A, 380-480V, Double Bridge.GDR721-4001 DELTA Rectifier Bridge Module 721A, 380-480V, Single Bridge.GDR721-4401 DELTA Rectifier Bridge Module 721A, 380-480V, Single Bridge.GDR872-4001 DELTA Rectifier Bridge Module 872A, 380-480V, Single Bridge.GDR872-4401 DELTA Rectifier Bridge Module 872A, 380-480V, Single Bridge.GDR1168-4001 DELTA Rectifier Bridge Module 1168A, 380-480V, Double Bridge.GDR1168-4401 DELTA Rectifier Bridge Module 1168A, 380-480V, Double Bridge.

GDD282-4001 DELTA Transistor Bridge Module 282A.GDD282-4002 DELTA Transistor Bridge Module 282A.GDD282-4004 DELTA Transistor Bridge Module 282A.GDD282-4501 DELTA Transistor Bridge Module 282A.GDD377-4001 DELTA Transistor Bridge Module 377A.GDD377-4002 DELTA Transistor Bridge Module 377A.GDD377-4004 DELTA Transistor Bridge Module 377A.GDD377-4501 DELTA Transistor Bridge Module 377A.

Appendix C - Interchanging Modules ALSPA GD DELTA

Page C-2 ALSPA GD DELTA (T1641)ALSPA GD DELTA (T1641) Issue 05/99

Contents

Scope...........................................................................................................C-1Units Covered..............................................................................................C-1Contents ......................................................................................................C-1

C1 Rectifier Bridge Modules ............................................................................C-2C2 Transistor Bridge Modules.........................................................................C-3C2.1 Single (and/or Output) Transistor Bridge Modules ............................C-3C2.2 Parallel Transistor Bridges ................................................................C-3C2.3 Setting Module Configuration Links ..................................................C-4C2.4 Transistor Bridge Modules - Mechanical Difference..........................C-5C2.5 Mounting of the Switch Mode Power Supply Module ........................C-6

IMPORTANT:

Where module order codes are shown as "***", the replacement module must have thesame current rating.

C1 Rectifier Bridge Modules

Replacing Versions GDR***-4001

These may be replaced by version GDR***-4401.Notes:1. There are minor differences in the positions of the d.c. power terminals between the

two versions.2. The front shroud (and its fixings) are different between the two versions.3. Version "-4001" does not have a "precharge acknowledge signal" (pin 10 on TB1).

Replacing modules by "-4401", this pin is not connected.4. Version "-4001" is deeper (front-to-back) than "-4401".



C2 Transistor Bridge Modules

Versions GDD***-4001, GDD***-4002 and GDD***-4004 are mechanically identical.Although version GDD***-4501 is mechanically different (details in section C2.4), it will fitthe same mounting rail position as "-4001", "-4002" or "-4004".

When used in parallel all modules must be the same version, or have an "Active Sharing"controller fitted (see section C2.2).

C2.1 Single Output (and/or Input) Transistor Bridge Modules

Replacing Versions GDD***-4001, GDD***-4002 or GDD***-4004

These may be replaced by versions "-4001", "-4002", "-4004" or "-4501".Note that version "-4501" is mechanically different and requires links to be adjusted (sectionC2.3 & C2.4).

Replacing Versions GDD***-4501

Replace module by the same version as the original.

C2.2 Parallel Transistor Bridges

The modules that may be interchanged are dependent on the controller. Those controlmodules that use "active sharing" may have a mixture of module versions - seeconfigurations below. The controllers without active sharing (identified by the PowerInterface Board (PIB) number on GD2000, GD2000E & GD3000) must have the sameversion of Transistor Bridge Module.

GD2000, GD2000E & GD3000 Transistor Bridge Module Replacement

Fitted with 20X4262/60 - 90 PIB.

All Transistor Bridge Modules must be of the same version. Replacement of a singlemodule must be by the same version. Alternatively replace all parallel modules by anew version (480V max nominal supply voltage); or replace the controller by an activesharing version (20X4282/60 - 90).

Fitted with 20X4282/60 - 90 or 20X4262/260 - 290 (Active sharing PIB).

Modules may be replaced individually by versions "-4001", "-4002", "-4004" or"-4501". Version "-4501" is mechanically different and requires links to be adjusted(section C2.3 & C2.4).

Fitted with 20X4282/310 - 320 (Active sharing PIB).

Modules must be version "-4501".



GD4000 Transistor Bridge Module Replacement.

Control Modules 31V5300/10 - /70

All Transistor Bridge Modules must be the same version. Replace a single module bythe same version. Alternatively replace all of the parallel modules by a new version,or replace the controller# by an active sharing version (31V7100/10 - /50). #Replacingthe control module is not simple. In addition to mechanical changes,the softwaredatabase modules (firmware) also require modification.

Control Modules 31V7100/10, /20, & /50 (Active sharing version).

GDD***-4001, GDD***-4002 or GDD***-4004 may be replaced by versions "-4001", "-4002", "-4004" or "-4501". Note version "-4501" is mechanically different and requireslinks to be adjusted (see section C2.3 & C2.5).

Version "-4501" must be replaced by "-4501".

Control Modules 31V7100/30, /40, /60 & /70

This controller is only used for higher voltage supplies than those covered in thisdocument. Replace module by the same version as the original.

C2.3 Setting Module Configuration Links

When the Transistor Bridge Module version "-4501" is used to replace versions "-4001", "-4002" or "-4004" then the temperature feedback needs to be configured for the controller.The link PL4 on each of the three phase gate drive PCBs must be positioned to link pins 1and 2. Note PL4 on phase B and C gate drives should already be linking pin 1 and 2.

C2.4 Transistor Bridge Module - Mechanical Differences

Figure C1 Position of Temperature Feedback Link Figure C2 Link Pin 1 to 2 on PL4



The depth of version "-4501" is less than that for "-4001", "-4002" & "-4004" (see outlinedrawings in sections 5.6.9 & A5.8).

Power Connections

The power connections for version "-4501" are in a different position compared to "-4001" -"4004". Changing versions may require new cables, dependent on cable routing. If the d.c.connections are via busbars these will have to be altered.

Control Connections

On versions "4001" - "4004" the ribbon cable connections are towards the left side of theTransistor Bridge Module. On version "-4501" these connections are further to the right by200mm (8"), see Figure C3. The ribbon cables may fit the different versions if there is sparelength left in the routing of the cables. Care must be taken to avoid damaging these cableswhen moved, ie avoid sharp edges.Auxiliary DC Connection - TB1

Figure C3 Gate Drive Ribbon Cable Positions



This connector is in a similar position on "-4501" compared to "-4001" - "-4004" (Figure C3).Changing versions may require new cables dependent on cable routing.

C2.5 Mounting of the Switch Mode Power Supply (SMPS) module

GD4000 drives are not affected as the SMPS is not mounted directly on to the TransistorBridge Module.

GD2000, GD2000E & GD3000 drives require a SMPS for each Transistor Bridge Module.This SMPS (Printed Circuit Board) is mounted on top of the 'A' Phase Gate Drive Board,inside the Transistor Bridge Module shroud on versions "-4001" - "-4004". Version "-4501"uses the same SMPS PCB, but it is mounted on a steel panel and inside a separate shroud.This assembly is then attached to the front of the Transistor Bridge Module.

There are three versions of SMPS PCB for a.c. supplies up to 480V, 525V & 690V. ThisAppendix covers GD2000, GD2000E & GD3000 product on supplies up to 480V. Only theSMPS PCB 20X4275/10 used in the assemblies 30V6600/10 or 30V7000/10 may be usedfor this supply voltage.

Replacing versions "-4001", "-4002" or "-4004" with "-4501"

The SMPS PCB must be replaced by the assembly 30V7000/10. This comescomplete with mounting panel and shroud - see Mechanical Installation section 3.14.

C2.6 Alternative Build Versions

There are two versions of the GDDxxx-4501 and GDDxxx-4601 DELTA Modules. They aredifferentiated by the build version and also by the type of interface printed circuit boardfitted. The build version can be found on the white label mounted on the front of the unit.The build version is a number in the form 31V7x00/nn for the original versions of theDELTA and 31V7x00/2nn for the later versions.

C2.6.1 Interchangeability of Complete DELTA Modules

All complete DELTA modules of the same type number are completely interchangeable ascomplete modules so that any GDDxxx-4501 will replace any other provided that the xxxnumber is the same. Any GDD300-4601 will replace any other GDD300-4601.

C2.6.2 Replacing Integrated Power Modules

If a DELTA module of the older version has a failed Integrated Power (SKIIP) Module and isto be repaired then the complete phase module must be changed including the InterfacePrinted Circuit Board. A new type SKIIP module must not be fitted into an old versionDELTA without changing the interface board.

The tables below show the replacement part numbers for each type of module and for eachphase.Note...

A complete DELTA module can have a mixture of the Phase Modules provided thatthey are all the correct size and in the case of GDD282 or GDD377 appropriate to theparticular phase.



GDD282 - 4501

Build Version Interface Board A Phase ModuleOriginal

A Phase ModuleReplacement

B & C PhaseModule Original

B & C PhaseModuleReplacement

31V7400/10 20X4284/20A 41Y7161/20 S41Y7161/220 41Y7161/50 S41Y7161/25031V7400/30 20X4246/20A 41Y7160/220 S41Y7161/220 41Y7161/250 S41Y7161/250

GDD377 - 4501






GDD300 - 4601






ALSPA GD DELTA Appendix D - Recommended Tightening Torque Figures

Issue 05/99 *''(/7$7 Page D-1

Scope

This document details the recommended tightening torques for the connectors used on theDELTA based modules.

The recommended torque settings are applicable to high-tensile steel (8.8 Grade) fastenersfitted with a single turn spring washer under the nut, and with the threads being zinc plated,passivated and unlubricated over the normal operating temperature of these components.

Specifically excluded are :

i) Fasteners with any other material (e.g. brass)ii) Fasteners with any other finish (e.g raw steel, cadmium plated, lubrication of any

sort).iii) Slotted holes in either steel or copper.

Appendix D - Recommended Tightening Torque Figures ALSPA GD DELTA

Page D-2 $/63$*''(/7$7 Issue 05/99

D1.1 Torque Tightening Figures for Electrical Connections

(These include busbar to busbar joints)

Fastener SizeSteel (8.8)

Torque Setting

Nm lb in. lb ft.

M5 3.5 - 5.5 30 - 48 2.5 - 4

M6 7 - 10 60 - 90 5 - 7.5

M8 10.5 - 20 96 - 180 8 - 15

M10 27 - 40 240 - 360 20 - 30

M12 40 - 60 360 - 576 30 - 48

M16 90 - 135 780 - 1200 65 - 100

D1.2 Torque Tightening Figures for Mechanical Connections

These figures are for the assembly and mounting of steel parts, where specific electricalconnection, other than continuity, is not involved.

Fastener SizeSteel (8.8)

Torque Setting

Nm lb in. lb ft.

M5 4 - 6 36 - 54 3.0 - 4.5

M6 7 - 10 60 - 90 5 - 7.5

M8 16 - 25 144 - 216 12 - 18

M10 34 - 47 240 - 420 25 - 35

M12 54 - 82 480 - 720 40 - 60

M16 135 - 200 1200 - 1800 100 - 150

ALSPA GD DELTA Appendix E - GD2000E/GD3000/GD3000E Connection Diagrams

Issue 05/99 ALSPA GD DELTA (T1641) Page E-1

Scope

This document shows the standard connections for ac input Alspa GD2000E / GD3000/GD3000E modular drives (current ratings of 282A and larger). These modular drivesare constructed using DELTA modules and range from the connection of a singleDELTA Transistor Bridge Module and a Rectifier Bridge Module, to multiple DELTAmodules connected in parallel.

Introduction

Each drive circuit diagram is built from a series of circuit elements. This documentcontains a variety of these circuit elements for a range of different driveconfigurations. (Using circuit elements allows the large number of standard, differentdrive configurations to be shown in one document).

These configurations allow different :• Main supply Inputs, including

• Type of supply• 6 Pulse supply• 12 Pulse supply (for harmonic reduction) including

• Isolated secondary supply transformer• Polygonal (non-isolated) supply transformer

• Supply voltages• 380 - 480V• 525V• 525 - 690V

• Drive current ratings• 282A and above• 1.1 x and 1.5 x overload current ratings• 1 - 6 Output Transistor Bridge Modules• 1 - 4 Input Rectifier Bridge Modules• Standard and High Performance Cooling Systems

• Types of drive• GD2000E• GD3000• GD3000E

The complete drive circuit diagram is a set of 6 separate circuit elements. Theseelements are in the form of a letter followed by a number. The letter defines thecircuit element type, e.g.

“A_” shows “Input Bridge (Power)”“B_” shows “Input Bridge (Control)”“C_” shows “Output Bridge (Power)”“D_” shows “Output Bridge (Control)”“E_” shows “User Termination Panel Connections”“F_” shows “Cooling Circuit”

The number shows that circuit elements configuration, e.g.““A1” shows “Input bridge (Power),”6 Pulse supply input, 1 (single) rectifier”

Appendix E - GD2000/GD3000/GD3000E Connection Diagrams ALSPA GD DELTA

Page E-2 ALSPA GD DELTA (T1641) Issue 05/99

A full list of the circuit elements has been included after this introduction section. One circuitelement out of each of all 6 sections must be used to generate the complete drive.The outline of a complete drive diagram is shown in Figure 1.

INPUT BRIDGE (CONTROL) OUTPUT BRIDGE(CONTROL)

USER I/O

F A N F A N F A N

INPUT BRIDGE(POWER)

C O N T R O L L E R

COOLING CIRCUIT

3 PHASE SUPPLY M O T O R

(B)

(A)

(D) (E)

(F)

D C +

D C -

OUTPUT BRIDGE(POWER)

(C)

Figure 1 Drive Circuit Diagram

The selection of the particular circuit elements depends on the drive configuration.This information may be supplied with the parts list for the drive, or may be derivedfrom the information supplied with each section of this document.



WARNING

•• ALL EQUIPMENT PROVIDED MUST BE CONNECTED TO EARTH (GROUND) FROM THEEARTH TERMINAL PROVIDED

THE MINIMUM SIZE OF THE PROTECTIVE CONDUCTOR MUST BE IN ACCORDANCEWITH LOCAL SAFETY REGULATIONS.

Caution

This document is based on the installer having the complete parts and circuit element lists forthe drive to be installed. Ensure that ALL parts required are listed before start of installation.

The mechanical and electrical installation of DELTA modules are shown in the DELTA manual.Controller Installation is shown in the GD2000E/ GD3000 / GD3000E manual, as appropriate.

Definition

P.I.B. Power Interface Board (used in the control module).

List of Circuit Element Diagrams

CIRCUIT A INPUT BRIDGE (POWER) CONNECTIONS..........................................................................5Circuit A1: Input Bridge (Power), 6 Pulse Supply Input, 1 (Single) Rectifier ............................................ 6Circuit A2: Input Bridge (Power), 6 Pulse Supply Input, 2 (Single) Rectifiers ............................................ 6Circuit A3: Input Bridge (Power), 6 Pulse Supply Input, 3 (Single) Rectifiers ........................................... 6Circuit A4: Input Bridge (Power), 6 Pulse Supply Input, 4 (Single) Rectifiers ............................................ 7Circuit A5: Input Bridge (Power), 6 Pulse Supply Input, 1 (Double) Rectifier ........................................... 7Circuit A6: Input Bridge (Power), 6 Pulse Supply Input, 2 (Double) Rectifiers.......................................... 8Circuit A7: Input Bridge (Power), 6 Pulse Supply Input, 3 (Double) Rectifiers.......................................... 8Circuit A8: Input Bridge (Power), 6 Pulse Supply Input, 1 (Single) and 1 Double Rectifier ..................... 9Circuit A9: Input Bridge (Power), 6 Pulse Supply Input, 1 (Single) and 2 (Double) Rectifiers ................. 9Circuit A10: Input Bridge (Power), 6 Pulse Supply Input, 1 (Single) and 3 (Double) Rectifiers ..............10Circuit A11: Input Bridge (Power), 12 Pulse (Isolated) Supply Input, 2 (Single) Rectifiers.......................11Circuit A12: Input Bridge (Power), 12 Pulse (Isolated) Supply Input, 4 (Single) Rectifiers.......................11Circuit A13: Input Bridge (Power), 12 Pulse (Polygonal) Supply Input, 2 (Single) Rectifiers ...................12Circuit A14: Input Bridge (Power), 12 Pulse (Polygonal) Supply Input, 4 (Single) Rectifiers ...................12Circuit A15: Input Bridge (Power), 12 Pulse (Isolated) Supply Input, 1 (Double) Rectifier .....................13Circuit A16: Input Bridge (Power), 12 Pulse (Isolated) Supply Input, 2 (Double) Rectifiers ....................13Circuit A17: Input Bridge (Power), 12 Pulse (Isolated) Supply Input, 3 (Double) Rectifiers ....................14Circuit A18: Input Bridge (Power), 12 Pulse (Polygonal) Supply Input, 1 (Double) Rectifier..................14Circuit A19: Input Bridge (Power), 12 Pulse (Polygonal) Supply Input, 2 (Double) Rectifiers ................15Circuit A20: Input Bridge (Power), 12 Pulse (Polygonal) Supply Input, 3 (Double) Rectifiers ................15

CIRCUIT B INPUT BRIDGE (CONTROL)...........................................................................................16Circuit B1: Input Bridge (Control), 1 Input Rectifier Bridge Module (Single), 1 P.I.B. Controller............17Circuit B2: Input Bridge (Control), 1 Input Rectifier Bridge Module (Double), 1 P.I.B. Controller .........17Circuit B3: Input Bridge (Control), 2 Input Rectifier Bridge Modules, 1 P.I.B. Controller........................18Circuit B4: Input Bridge (Control), 2 Input Rectifier Bridge Modules (Single), 2 P.I.B. Controller ..........18Circuit B5: Input Bridge (Control), 1 Input Rectifier Bridge Module (Double), 2 P.I.B. Controller .........19Circuit B6: Input Bridge (Control), 2 Input Rectifier Bridge Modules (Double), 2 P.I.B. Controller........19



Circuit B7: Input Bridge (Control), 3 Input Rectifier Bridge Modules, 2 P.I.B. Controller ....................... 20Circuit B8: Input Bridge (Control), 4 Input Rectifier Bridge Modules, 2 P.I.B. Controller ....................... 20

CIRCUIT C OUTPUT BRIDGE (POWER) .......................................................................................... 21Circuit C1: Output Bridge (Power), 1 Transistor Bridge Module, ........................................................... 21Circuit C2: Output Bridge (Power), 2 Transistor Bridge Modules ............................................................ 21Circuit C3: Output Bridge (Power), 3 Transistor Bridge Modules ............................................................ 21Circuit C4: Output Bridge (Power), 4 Transistor Bridge Modules ........................................................... 22Circuit C5: Output Bridge (Power), 5 Transistor Bridge Modules ........................................................... 23Circuit C6: Output Bridge (Power), 6 Transistor Bridge Modules ........................................................... 24

CIRCUIT D OUTPUT BRIDGE (CONTROL)....................................................................................... 25Circuit D1: Output Bridge (Control), 1 Transistor Bridge Module........................................................... 26Circuit D2: Output Bridge (Control), 2 Transistor Bridge Modules .......................................................... 26Circuit D3: Output Bridge (Control), 3 Transistor Bridge Modules .......................................................... 27Circuit D4: Output Bridge (Control), 4 Transistor Bridge Modules ......................................................... 28Circuit D5: Output Bridge (Control), 5 Transistor Bridge Modules ......................................................... 29Circuit D6: Output Bridge (Control), 6 Transistor Bridge Modules ......................................................... 30

CIRCUIT E USER TERMINATION PANELS ......................................................................................... 31Circuit E1: GD2000E User Termination (Control) ..................................................................................... 31Circuit E2: GD3000 (1 P.I.B. Controller only) User Termination (Control) ............................................... 31Circuit E3: GD3000 (2 P.I.B. Controller only) and GD3000E User Termination (Control)....................... 31

CIRCUIT F COOLING SYSTEM ..................................................................................................... 32Circuit F1: Standard Cooling System Multiple Fans, 1 Fan transformer ................................................ 33Circuit F2: Standard Cooling System, Multiple Fans, 2 Fan transformers .............................................. 33Circuit F3: Standard Cooling System, Multiple Fans, 3 Fan transformers .............................................. 34Circuit F4: High Performance Fans, 1 Fan transformer........................................................................... 34Circuit F5: High Performance Fans, 2 Fan transformers ......................................................................... 35Circuit F6: High Performance Fans, 3 Fan transformers ......................................................................... 35



Circuit A Input Bridge (Power) ConnectionsThis section is based on:1. Type of Supply

• 6 Pulse (3 phase supply)• 12 Pulse (two 30° phase shifted, 3 phase supplies) generated from :

• Transformer with Isolated secondaries• Polygonal Transformer (non-isolated)

2. Type of DELTA Rectifier Bridge module Rectifier Bridge (Single) Modules.

Examples are :• GDR391-4401• GDR391-4601• GDR721-4401• GDR721-4601• GDR872-4401• GDR872-4601

Rectifier Bridge (Double) Modules Examples are :

• GDR633-4401• GDR633-4601• GDR1168-4401• GDR1168-4601

3. Number of DELTA Rectifier Bridge Modules.• As required for current rating.

Note : Optional input line reactors or filters are not shown. Refer to drive Technical manual for

further information on these items.



Circuit A1: Input Bridge (Power), 6 Pulse Supply Input, 1 (Single) Rectifier

FUSES

3 PHASE SUPPLY

FAN CIRCUIT

S1

T1 RECT1-

RECTIFIERBRIDGEMODULE TB1

R1 RECT1+

DC-

DC LINK REACTOR

DC+

Circuit A2: Input Bridge (Power), 6 Pulse Supply Input, 2 (Single) Rectifiers

3 PHASE SUPPLY

DC LINK REACTOR

RECTIFIERBRIDGEMODULE

FAN CIRCUIT

SHARINGREACTOR

C2

B2

A2

C1

B1

A1

TB1

R1

S1

T1

RECT1+

RECT1-

FUSESSHARINGREACTOR

C2

B2

C1

B1

A2A1

S1

T1 RECT1-


R1 RECT1+

DC-

DC+


DC LINK REACTOR

3 PHASE SUPPLY


FAN CIRCUIT

SHARINGREACTOR

C2

B2

A2

C1

B1

A1

TB1

R1

S1

T1

RECT1+

RECT1-

SHARINGREACTOR

C2

B2

C1

B1

A2A1

FUSESSHARINGREACTOR

C2

B2

A2

C1

B1

A1

S1

T1 RECT1-


R1 RECT1+


R1

S1

T1

RECT1+

RECT1-

DC-

DC+




3 PHASE SUPPLY

DC LINK REACTOR


B2B1

FAN CIRCUIT

C2C1

SHARINGREACTOR A2A1

SHARINGREACTOR

C2

B2

A2

C1

B1

A1

S1

T1 RECT1-


R1 RECT1+

TB1

R1

S1

T1

RECT1+

RECT1-

SHARINGREACTOR

C2

B2

C1

B1

A2A1

FUSESSHARINGREACTOR

C2

B2

A2

C1

B1

A1

S1

T1 RECT1-


R1 RECT1+


R1

S1

T1

RECT1+

RECT1-

DC-

DC+

Circuit A5: Input Bridge (Power), 6 Pulse Supply Input, 1 (Double) Rectifier

3 PHASE SUPPLY

DC-

DC LINK REACTOR

SHARINGREACTOR

SHARINGREACTOR

FAN CIRCUIT

B1

C1

B1

A1

C1

FUSESA1

B2

C2 T1

S1

RECT1-

B2

A2

C2

A2

S2

R1

T2

RECT1+

RECT2-


R2 RECT2+

TB1



Circuit A6: Input Bridge (Power), 6 Pulse Supply Input, 2 (Double) Rectifiers

T1

S1

RECT1-



3 PHASE SUPPLY

R1

T2

R2

S2

SHARINGREACTOR

B1

C1

A1

T1

S1

R1A2

B2

C2

FUSESSHARINGREACTOR

C1

A1

B1

T2C2

R2

S2

A2

B2

RECT1+

RECT2-

RECT2+

RECT1-

RECT1+

TB1DC-

DC+

RECT2-

RECT2+

TB1

DC LINK REACTOR

FAN CIRCUIT

SHARINGREACTOR

B1

C1

A1

B2

C2

A2

SHARINGREACTORA1

C1

B1

A2

C2

B2

Circuit A7: Input Bridge (Power), 6 Pulse Supply Input, 3 (Double) Rectifiers

3 PHASE SUPPLY

FAN CIRCUIT

C1

B1

C1

A1

B1

A1

B1

C1

A1

SHARINGREACTOR

T1

S1

C2

B2

R1

T2

S2

C2

A2

B2

RECT1-

RECT1+

RECT2-


R2SHARINGREACTOR A2

T1

S1

R1SHARINGREACTOR

B2

C2

A2

RECT2+

TB1

RECT1-

RECT1+

A1

A1

C1

B1

B1

C1

A1

C1

B1

FUSES

SHARINGREACTOR R1A2 RECT1+


T2

R2

S2

SHARINGREACTOR A2

C2

B2

T1

S1B2

C2

RECT2-

RECT2+

TB1

RECT1-


SHARINGREACTOR R2A2

T2C2

S2B2

RECT2+

RECT2-

TB1

DC+

DC-

DC LINK REACTOR



Circuit A8: Input Bridge (Power), 6 Pulse Supply Input, 1 (Single) and 1 DoubleRectifier

C1

B1

A1SHARINGREACTOR

T1

S1

C2

B2

R1A2

RECT1-

RECT1+

TB1RECTIFIERBRIDGEMODULE(SINGLE)

FAN CIRCUIT

DC-

3 PHASE SUPPLY

DC LINK REACTOR


SHARINGREACTOR

SHARINGREACTOR

C1

B1

A1

C1

B1

A1

T1

S1

C2

B2

R1A2

RECT1-

RECT1+

T2C2

S2B2

R2A2

RECT2-

RECT2+FUSES

TB1

Circuit A9: Input Bridge (Power), 6 Pulse Supply Input, 1 (Single) and 2 (Double)Rectifiers

DC LINK REACTOR

FAN CIRCUIT

SHARINGREACTOR

C1

B1

A1

C1

3 PHASE SUPPLY

B1

A1SHARINGREACTOR

C1

B1

SHARINGREACTORA1

C1

T1

S1

C2

B2

R1A2

RECT1-

RECT1+

T B 1RECTIFIERBRIDGEMODULE(SINGLE)

T1C2 RECT1-

S1B2

R1A2 RECT1+

T2C2

S2B2

RECT2-


R2A2 RECT2+

T1C2 RECT1-

T B 1

C1

B1

A1SHARINGREACTOR

B1

A1SHARINGREACTOR

FUSES

T2

S2

C2

B2

RECT2-

R1A2

S1B2

RECT1+


R2A2 RECT2+

T B 1

DC+

DC-



Circuit A10: Input Bridge (Power), 6 Pulse Supply Input, 1 (Single) and 3 (Double)Rectifiers

C1

B1

A1SHARINGREACTOR

T1

S1

C2

B2

R1A2

RECT1-

RECT1+

TB1RECTIFIERBRIDGEMODULE(SINGLE)

FAN CIRCUIT

3 PHASE SUPPLY

A1

A1

C1

B1

B1

C1

A1

C1

B1

FUSES

SHARINGREACTOR R1A2 RECT1+


T2

R2

S2

SHARINGREACTOR A2

C2

B2

T1

S1B2

C2

RECT2-

RECT2+

TB1

RECT1-


SHARINGREACTOR R2A2

T2C2

S2B2

RECT2+

RECT2-

TB1

DC+

DC-

DC LINK REACTOR


SHARINGREACTOR

C1

B1

A1SHARINGREACTOR

C1

B1

A1

T1

S1

C2

B2

R1A2

RECT1-

RECT1+

T2C2

S2B2

R2A2

RECT2-

RECT2+

C1

A1SHARINGREACTOR

B1

T1C2 RECT1-

TB1

R1A2

S1B2

RECT1+



Circuit A11: Input Bridge (Power), 12 Pulse (Isolated) Supply Input, 2 (Single) Rectifiers



FUSESISOLATED TRANSFORMER

3 PHASESUPPLY

OR AND

FAN CIRCUIT

T1

R1

S1

T1

S1

R1

INTER-BRIDGE TRANSFORMER

TB1

RECT1-

RECT1+

RECT1-

RECT1+

DC-

DC+

TB1

Circuit A12: Input Bridge (Power), 12 Pulse (Isolated) Supply Input, 4 (Single) Rectifiers


DC-

DC+3 PHASESUPPLY

FAN CIRCUIT


C2C1 T1

B2B1

SHARINGREACTOR A2A1

S1

R1

RECT1-

TB1

RECT1+

OR AND

ISOLATED TRANSFORMER

FUSES



SHARINGREACTOR

C2

B2

A2

C1

B1

A1 R1

S1

T1

SHARINGREACTOR

C2

B2

C1

B1

A2A1

S1

T1

R1

TB1

RECT1+

RECT1-

RECT1-

TB1

RECT1+


SHARINGREACTOR

C2

B2

A2

C1

B1

A1 R1

S1

T1

TB1

RECT1+

RECT1-

A1

A3

A2

A1

A2A3



Circuit A13: Input Bridge (Power), 12 Pulse (Polygonal) Supply Input, 2 (Single)Rectifiers

DC-

DC+



S1

T1

R1

RECT1-

TB1

RECT1+

INTER-BRIDGE TRANSFORMERS

3 PHASESUPPLY

POLYGONAL TRANSFORMER

FAN CIRCUIT

T1 RECT1-

R1 RECT1+

S1

TB1

Circuit A14: Input Bridge (Power), 12 Pulse (Polygonal) Supply Input, 4 (Single)Rectifiers

DC-

DC+

FUSES



SHARINGREACTOR

C2

B2

C1

B1

A2A1

S1

T1

R1

RECT1-

TB1

RECT1+


SHARINGREACTOR

C2

B2

A2

C1

B1

A1 R1

S1

T1

TB1

RECT1+

RECT1-



3 PHASESUPPLY

SHARINGREACTOR

FAN CIRCUIT

R1

C2C1 T1

B2B1

A2A1

S1

RECT1-

RECT1+

C2C1 T1 RECT1-


R1SHARINGREACTOR A2A1

B2B1 S1

RECT1+

TB1

A1

A2

A2

A3

A3

A1

A1

A2A3

A1

A2

A3



Circuit A15: Input Bridge (Power), 12 Pulse (Isolated) Supply Input, 1 (Double)Rectifier

Circuit A16: Input Bridge (Power), 12 Pulse (Isolated) Supply Input, 2 (Double)Rectifiers

C1

B1

C1

B1

B1

C1

B1

C1

3 PHASESUPPLY

OR AND

FAN CIRCUIT

A1

A1


A1

A1

FUSES

C2

SHARINGREACTOR

B2

A2

T1 RECT1-

S1

R1 RECT1+

SHARINGREACTOR A2

C2

B2

R2 RECT2+

T2

S2

RECT2-


DC-

DC+

C2 T2 RECT2-

SHARINGREACTOR A2

B2

C2

R1 RECT1+

T1

S1

RECT1-

SHARINGREACTOR A2

B2

TB1

R2

S2

RECT2+



A1

A2A3



Circuit A17: Input Bridge (Power), 12 Pulse (Isolated) Supply Input, 3 (Double)Rectifiers

3 PHASESUPPLY

FAN CIRCUIT

OR AND

R2SHARINGREACTORA1 A2

SHARINGREACTORA1

B1

C1

C1

B1

A2 R1

B2

C2 T1

S1

T2

S2

C2

B2

SHARINGREACTOR

C1

B1

A1

T1C2


S1

R1

B2

A2


SHARINGREACTOR

SHARINGREACTOR

C1

A1

B1

B1

C1

A1


T2

R2

S2

C2

A2

B2

B2

C2 T1

S1

A2 R1

SHARINGREACTORA1

B1

C1

FUSESA2 R2

B2

C2

S2

T2


DC+

RECT2+

RECT1+

RECT1-

RECT2-

RECT1-

TB1

RECT1+

DC-


TB1

RECT2-

RECT2+

RECT1-

RECT1+

RECT2+

RECT2-

TB1

Circuit A18: Input Bridge (Power), 12 Pulse (Polygonal) Supply Input, 1 (Double)Rectifier

FAN CIRCUIT

3 PHASESUPPLY



SHARINGREACTORA1

B1

C1

C1

B1

A2 R1

B2

C2 T1

S1

T2

S2

C2

B2

FUSES


RECT2+

RECT1+

RECT1-

RECT2-

DC-

DC+


TB1

A1

A2

A3

A12A2

A3A1

A2

A3



Circuit A19: Input Bridge (Power), 12 Pulse (Polygonal) Supply Input, 2 (Double)Rectifiers

FAN CIRCUIT

3 PHASESUPPLY


SHARINGREACTORA1

B1

C1

C1

B1

A2 R1

B2

C2 T1

S1

T2

S2

C2

B2

SHARINGREACTOR

C1

B1

A1

T1C2


S1

R1

B2

A2

POLYGONAL TRANSFORMERSHARINGREACTOR

C1

A1

B1

FUSES


T2

R2

S2

C2

A2

B2

RECT2+

RECT1+

RECT1-

RECT2- DC-

RECT1-

TB1

RECT1+


DC+

TB1

RECT2-

RECT2+

Circuit A20: Input Bridge (Power), 12 Pulse (Polygonal) Supply Input, 3 (Double)Rectifiers

FAN CIRCUIT


SHARINGREACTORA1

B1

C1

C1

B1

A2 R1

B2

C2 T1

S1

T2

S2

C2

B2

SHARINGREACTOR

C1

B1

A1

T1C2


S1

R1

B2

A2


SHARINGREACTOR

SHARINGREACTOR

C1

A1

B1

B1

C1

A1


T2

R2

S2

C2

A2

B2

B2

C2 T1

S1

A2 R1

SHARINGREACTORA1

B1

C1

FUSES

A2 R2

B2

C2

S2

T2


DC+

RECT2+

RECT1+

RECT1-

RECT2-

RECT1-

TB1

RECT1+

DC-

TB1

RECT2-

RECT2+

RECT1-

RECT1+


RECT2+

RECT2-

TB1

3 PHASESUPPLY

A1

A2A3A1

A3A2

A3A1

A1

A2

A2A3



Circuit B Input Bridge (Control)This section is based on :1. Type of controller

• 1 P.I.B. (Power Interface Board) Controller Examples are :

• 30V4800/300 (GD2000E)• 30V4800/310 (GD2000E)• 30V4800/320 (GD2000E)• 30V4800/330 (GD3000)• 30V4800/340 (GD3000)• 30V4800/350 (GD3000)• 30V4800/390 (GD3000E)• 30V4800/400 (GD3000E)• 30V4800/410 (GD3000E)

• 2 P.I.B. Controller Examples are :


2. Type of DELTA Rectifier Bridge module Rectifier Bridge (Single) Modules.

Examples are :• GDR391-4401• GDR391-4601• GDR721-4401• GDR721-4601• GDR872-4401• GDR872-4601

Rectifier Bridge (Double) Modules Examples are :

• GDR633-4401• GDR633-4601• GDR1168-4401• GDR1168-4601

3. Number of DELTA Rectifier Bridge Modules.• As required for current rating.



Circuit B1: Input Bridge (Control), 1 Input Rectifier Bridge Module (Single), 1 P.I.B.Controller

CONTROL MODULE

BRIDGE 1

1 1 0 V F R O MC O O L I N G C I R C U I T(FOR RECTIF IER VERSION " -4601"O N L Y )

PL

19

8P.I.B.

PL

19

7

C O N T R O L C O N N E C T I O N S


O U T P U T B R I D G E

PL

19

4

PL

19

9

PL

19

6

PL

19

5

PL

15

2

PL

15

1

PL

15

3

P L 2 0 9

8110V INPUT

PREC ACKN110V INPUT 9

1 0TB1

48V

24V

THERMOSTATTHERMOSTATTHERMISTORTHERMISTOR

0V 2

4567

3

1

U S E R T E R M I N A T I O N

8(24V)PREC ACKN

PL210

P A N E L

91 0

THERMOSTATTHERMOSTAT

(0V)

THERMISTORTHERMISTOR

34567

12

Circuit B2: Input Bridge (Control), 1 Input Rectifier Bridge Module (Double), 1 P.I.B.Controller

BRIDGE 1

1 1 0 V F R O MCOOLING C IRCUIT(FOR RECTIF IER VERSION " -4601"O N L Y )

T H E R M O S T A TT H E R M O S T A TT H E R M I S T O RT H E R M I S T O R

CONTROL MODULE

P.I.B.

PL

19

8

T H E R M O S T A TT H E R M O S T A T

T H E R M I S T O RT H E R M I S T O R

PL

19

7

C O N T R O L C O N N E C T I O N S


O U T P U T B R I D G E

PL

19

4

PL

19

9

PL

19

6

PL

19

5

PL

15

2

PL

15

1

PL

15

3

P L209

7110V INPUT

P R E C A C K N110V INPUT

89

10TB1

4 8 V0 V

2 4 V2

456

3

1

USER TERMINAT ION

8

PL210

(24V)

P A N E L

P R E C A C K N 910

(0V)

2

4567

3

1



Circuit B3: Input Bridge (Control), 2 Input Rectifier Bridge Modules, 1 P.I.B. Controller

BRIDGE

BRIDGE A2

BRIDGE A1

BRIDGEM O D U L E

RECTIFIER

M O D U L E

OUTPUT BRIDGECONTROL CONNECTIONS

CONTROL MODULE

110V FROMCOOLING CIRCUIT(FOR RECTIFIER VERSION "-4601"ONLY)

P.I.B.

PL

19

7

PL

19

4

PL

19

9

PL

19

8

RECTIFIER

PL

15

1

PL

19

5

PL

19

6

PL209

PL

15

3

PL

15

2

5T H E R M I S T O R

5T H E R M I S T O RT H E R M O S T A T

PREC ACKN110V INPUT110V INPUT

T H E R M O S T A T89

10

67

T B 1

48V0V

24V

T H E R M I S T O R

110V INPUTT H E R M O S T A T

PREC ACKN110V INPUT

T H E R M O S T A T

4

123

89

10

67

T B 1

PL210

48V0V

24V

T H E R M I S T O R

USER TERMINATIONPANEL

4

123

PREC ACKN(24V)

T H E R M I S T O R

T H E R M O S T A TT H E R M O S T A T

(0V)

T H E R M I S T O R

4

89

10

567

123

Circuit B4: Input Bridge (Control), 2 Input Rectifier Bridge Modules (Single), 2P.I.B. Controller

PREC ACKN110V INPUT

RECTIF IERB R I D G EM O D U L E

BRIDGE B1

OUTPUT BRIDGE CONTROL CONNECTIONS

48V0V

24V

89

10

4567

123

89

10

4567

123

110V INPUTTHERMOSTATTHERMOSTAT

PREC ACKN110V INPUT



PREC ACKN

(0V)

(24V)

PL210

BRIDGE A1

P.I.B. (A)

TB1


PL15

3

PL15

2

PL15

1

PL19

4

PL19

6

PL19

5

PL19

7

PL19

9

PL19

8



PL15

1

PL19

6

PL19

5

PL19

4

PL19

7

PL19

8

PL19

9

CONTROL MODULE

P.I.B. (B)



P_AKN


110V INPUTTHERMOSTATTHERMOSTATTHERMISTORTHERMISTOR

48V0V

24V



PL210

PREC ACKN89

10

4567

123

(24V)

(0V)PL209 PL209

PL15

2

PL15

3

89

10

4567

123

TB1

TO DCLINKFUSESWHENFITTED



Circuit B5: Input Bridge (Control), 1 Input Rectifier Bridge Module (Double), 2 P.I.B.Controller

48V0V

24V

89

10

4567

123

89

10

4567

123


PREC ACKN110V INPUT



PREC ACKN

(0V)

(24V)

PL210

BRIDGE A1

P.I.B. (A)

TB1


PL15

3

PL15

2

PL15

1

PL19

4

PL19

6

PL19

5

PL19

7

PL19

9

PL19

8



PL209

OUTPUT BRIDGE CONTROL CONNECTIONSUSER TERMINATIONPANEL


P_AKN

PL15

2

PL15

1

PL19

6

PL19

5

PL19

4

PL19

7

PL19

8

PL19

9


CONTROL MODULE

P.I.B. (B)PL209

89

10

4567

123THERMOSTAT

THERMOSTAT

(0V)


5K6 (1/4 W)

PL15

3

PL210

PREC ACKN(24V)

Circuit B6: Input Bridge (Control), 2 Input Rectifier Bridge Modules (Double), 2 P.I.B.Controller

PREC ACKN110V INPUT


BRIDGE B1

48V0V

24V

89

10

4567

123

89

10

4567

123


PREC ACKN110V INPUT



PREC ACKN

(0V)

(24V)

BRIDGE A1

P.I.B. (A)

TB1


PL15

3

PL15

2

PL15

1

PL19

4

PL19

6

PL19

5

PL19

7

PL19

9

PL19

8



PL15

1

PL19

6

PL19

5

PL19

4

PL19

7

PL19

8

PL19

9

CONTROL MODULE

P.I.B. (B)

OUTPUT BRIDGE CONTROL CONNECTIONS OUTPUT BRIDGE CONTROL CONNECTIONSUSER TERMINATIONPANEL

PL209PL209

PL210

P_AKN


110V INPUTTHERMOSTATTHERMOSTATTHERMISTORTHERMISTOR

48V0V

24V



PREC ACKN

PL210

89

10

4567

123

(24V)

(0V)

PL15

3

PL15

2

89

10

4567

123

TB1






BRIDGE A1

BRIDGE A2

P.I.B. (A)



BRIDGE B1RECTIFIERBRIDGEMODULE

89

10

4567

123

TB1


PL

19

5

PL

19

4

PL

19

7

PL

19

8

PL

19

9

PL

19

6CONTROL MODULE

P.I.B. (B)89

10

4567

123

PL

19

7

PL

19

9

PL

19

8


89

10

4567

123

TB1


89

10

4567

123

TB1


P_AKN


89

10

4567

123

PL

15

3

PL

15

2

PL

15

1

PL

19

4

PL

19

6

PL

19

5

PL210

PL209

PL

15

3

PL209

PL

15

2

PL

15

1

PL210


BRIDGE A1

BRIDGE A2

P.I.B. (A)





89

10

4567

123

TB1

89

10

4567

123

TB1


PL

19

4

PL

19

7

PL

19

8

PL

19

9

PL

19

5

PL

15

2

PL

15

1

PL

19

6

CONTROL MODULE

P.I.B. (B)89

10

4567

123

PL

19

7

PL

19

9

PL

19

8


89

10

4567

123

TB1


89

10

4567

123

TB1


P_AKN


89

10

4567

123

PL

15

3

PL

15

2

PL

15

1

PL

19

4

PL

19

6

PL

19

5

PL210

PL209PL209

PL

15

3

PL210





Circuit C Output Bridge (Power) Note : Optional output reactors or filters are not shown. Refer to drive Technical manual for

further information on these items.

Circuit C1: 1 Output Bridge (Power), 1 Transistor Bridge Module,

TRANSISTORBRIDGEMODULE

DC-

DC+MOTOR

+

-

P L 1

P L 1

P L 1

A

C

B

Circuit C2: Output Bridge (Power), 2 Transistor Bridge Module

DC-

DC+

MOTOR

TRANSISTORBRIDGE

MODULE

-

+

C

PL1

PL1

A

B

TRANSISTORBRIDGE

MODULE

-

+

PL1

C

A

B

PL1

PL1

PL1

SHARINGREACTOR

C1

B1

A1

C2

B2

A2

SHARINGREACTOR

C1

B1

A1

C2

B2

A2

Circuit C3: Output Bridge (Power), 3 Transistor Bridge Modules

DC-

DC+MOTOR

B

+ ABRIDGEMODULE

-

B

C

TRANSISTOR

PL1

PL1

PL1

- C

C-

TRANSISTORBRIDGE

MODULE+

PL1

PL1

PL1

A

TRANSISTORBRIDGE

MODULE+

PL1

PL1

PL1

B

A

B1 B2

SHARINGREACTORA1

B1

C1

C1

A2

B2

C2

C2

SHARINGREACTOR

SHARINGREACTOR

C1

A1

B1

A1

C2

A2

B2

A2




- C C1 C2

TRANSISTORBRIDGE

MODULE

TRANSISTORBRIDGE

MODULE

P L 1

P L 1

P L 1

+

-

P L 1

P L 1

P L 1

+

B B1 B2

SHARINGREACTOR

B B1

A A1

BRIDGE B2

C C1

B2

A2

C2

SHARINGREACTORA A1 A2

DC-

DC+

INPUT BRIDGE(CONTROL)

P_AKN

SHARINGREACTOR

SHARINGREACTOR

P L 1

P L 1

P L 1

TRANSISTORBRIDGE

MODULE

TRANSISTORBRIDGE

MODULE

P L 1

P L 1

P L 1 BRIDGE A1

MOTOR

B2

C2

A2

B2

C2

A2

-

+

-

+

BRIDGE B1

B

C

A

B1

C1

A1

BRIDGE A2

B

C

A

B1

C1

A1




MOTORINPUT BRIDGE(CONTROL)

TRANSISTORBRIDGE

MODULE

SHARINGREACTOR

BRIDGE B1

BRIDGE B2

TRANSISTORBRIDGE

MODULE

PL1

PL1

PL1

-

B

C

TRANSISTORBRIDGE

MODULE+ A

-

B

C

DC-

DC+

P_AKN

PL1

PL1

PL1

+ A

- C

B1

C1

B2

C2

SHARINGREACTORA1 A2

B1

C1

B2

C2

SHARINGREACTORA1 A2

B2

C1 C2

A2

BRIDGE A1

PL1

PL1

PL1

PL1

PL1

PL1

TRANSISTORBRIDGE

MODULE

PL1

PL1

PL1

TRANSISTORBRIDGE

MODULE+ A

-

B

C

C2

SHARINGREACTOR

B2

A2

SHARINGREACTOR A2A1

B2

C2

B1

C1

-

+

+

C C1

BRIDGE A3

A

B

A1

B1

BRIDGE A2

A

B

A1

B1




SHARINGREACTOR

SHARINGREACTOR

SHARINGREACTOR

PL1

PL1

PL1

PL1

PL1

PL1

-

B B1

C C1

TRANSISTORBRIDGE

MODULE+ A A1

BRIDGE B3

TRANSISTORBRIDGE

MODULE

-

+

B B1

C C1

A A1

DC-

DC+

TRANSISTORBRIDGE

MODULE+ A A1

-

B B1

C C1

BRIDGE B2

PL1

PL1

PL1 BRIDGE B1

B2

C2

A2

B2

C2

A2

MOTOR

A2

B2

C2

SHARINGREACTOR

SHARINGREACTOR

SHARINGREACTOR

PL1

PL1

PL1

INPUT BRIDGE(CONTROL)

P_AKN

PL1

PL1

PL1

TRANSISTORBRIDGE

MODULE

- C C1

TRANSISTORBRIDGE

MODULE

TRANSISTORBRIDGE

MODULE+ A A1

-

B

C

B1

C1

PL1

PL1

PL1BRIDGE A1

B2

C2

A2

B2

C2

A2

A2

B2

C2

-

+

+

C C1

A

B

A1

B1

BRIDGE A3

A

B

A1

B1

BRIDGE A2



Circuit D Output Bridge (Control)This section is based on :1. Type of controller

• 1 P.I.B. (Power Interface Board) Controller Examples are :


• 2 P.I.B. Controller Examples are :


2. Number of Transistor Bridge Modules• Dependent on drive current rating



Circuit D1: Output Bridge (Control), 1 Transistor Bridge Module


PL1PHASE A

PL1PHASE C

PL1PHASE B

SMPSTB1

+

-

CONTROL MODULE

C

B

A

PL15

3

PL15

2

PL15

1

PL210PL209

PL19

7

PL19

9

PL19

8

PL19

6

PL19

5

PL19

4

Circuit D2: Output Bridge (Control), 2 Transistor Bridge Modules


PL1PHASE A

PL1PHASE C

PL1PHASE B

SMPSTB1


PL1PHASE A

PL1PHASE C

PL1PHASE B

SMPSTB1

+

-

+

-

CONTROL MODULE

A

C

B

C

B

A


INPUT BRIDGECONTROL CONNECTIONS

PL19

7

PL15

3

PL15

2

PL15

1

PL210PL209

PL19

9

PL19

8

PL19

6

PL19

5

PL19

4




PL210


PL1PHASE A

PL1PHASE C

PL1PHASE B

SMPSTB1


PL1PHASE A

PL1PHASE C

PL1PHASE B

SMPSTB1


PL1PHASE A

PL1PHASE C

PL1PHASE B

SMPSTB1

+

- C

B

A

+

-

+

-

PL19

6

CONTROL MODULE

PL15

3PL

152

PL15

1

PL209

A

C

B

C

B

A

PL19

8PL

197

PL19

9

PL19

4PL

195





PL1PHASE A

PL1PHASE C

PL1PHASE B

SMPSTB1


PL1PHASE A

PL1PHASE C

PL1PHASE B

SMPSTB1

PL210


PL1PHASE A

PL1PHASE C

PL1PHASE B

SMPSTB1


PL1PHASE A

PL1PHASE C

PL1PHASE B

SMPSTB1

+

-

+

-

PL15

3

PL15

2

PL15

1

PL209

A

C

B

C

B

A


INPUT BRIDGE CONTROL CONNECTIONS INPUT BRIDGE CONTROL CONNECTIONS

+

-

+

-

CONTROL MODULE

A

C

B

C

B

A

P.I.B. (A)

PL19

9

PL19

8

PL19

7

PL19

6

PL19

5

PL19

4

BRIDGE B1 BRIDGE A1

BRIDGE A2BRIDGE B2

PL19

8

P.I.B. (B)

PL15

3

PL15

2

PL15

1

PL210PL209

PL19

7

PL19

4

PL19

9

PL19

6

PL19

5





PL1PHASE A

PL1PHASE C

PL1PHASE B

SMPSTB1


PL1PHASE A

PL1PHASE C

PL1PHASE B

SMPSTB1

PL210


PL1PHASE A

PL1PHASE C

PL1PHASE B

SMPSTB1


PL1PHASE A

PL1PHASE C

PL1PHASE B

SMPSTB1


PL1PHASE A

PL1PHASE C

PL1PHASE B

SMPSTB1

+

- C

B

A

+

-

+

-

PL15

3

PL15

2

PL15

1

PL209

A

C

B

C

B

A



+

-

+

-

A

C

B

C

B

A

P.I.B. (A)

PL19

9

PL19

8

PL19

7

PL19

6

PL19

5

PL19

4

BRIDGE A3

BRIDGE A2

BRIDGE A1

BRIDGE B2

BRIDGE B1

PL19

8

P.I.B. (B)

CONTROL MODULE

PL15

3

PL15

2

PL15

1

PL210PL209

PL19

7

PL19

4

PL19

9

PL19

6

PL19

5





PL1PHASE A

PL1PHASE C

PL1PHASE B

SMPSTB1


PL1PHASE A

PL1PHASE C

PL1PHASE B

SMPSTB1


PL1PHASE A

PL1PHASE C

PL1PHASE B

SMPSTB1

+

- C

B

A

PL210


PL1PHASE A

PL1PHASE C

PL1PHASE B

SMPSTB1


PL1PHASE A

PL1PHASE C

PL1PHASE B

SMPSTB1


PL1PHASE A

PL1PHASE C

PL1PHASE B

SMPSTB1

+

- C

B

A

+

-

+

-

PL15

3

PL15

2

PL15

1

PL209

A

C

B

C

B

A



+

-

+

-

A

C

B

C

B

A

P.I.B. (A)

PL19

9

PL19

8

PL19

7

PL19

6

PL19

5

PL19

4

BRIDGE A3

BRIDGE A1

BRIDGE A2

BRIDGE B1

BRIDGE B2

BRIDGE B3

CONTROL MODULEPL

196

PL15

3

PL15

2

PL15

1

PL210PL209

PL19

9

P.I.B. (B)

PL19

7

PL19

8

PL19

4

PL19

5



Circuit E User Termination Panels

Circuit E1: GD2000E User Termination (Control)


PL5 PL5

TB8

TB7

TB6

C O N T R O L M O D U L EUSER TERMINATIONP A N E L


PL15

3

PL19

6

PL15

1

PL15

2

PL210 PL209

PL19

7

PL19

8

PL19

4

PL19

9

PL19

5

Circuit E2: GD3000 (1 P.I.B. Controller only) User Termination (Control)For GD3000E and GD3000 (2 P.I.B. Controller) see next section


PL5 PL5

CONTROL MODULEUSER TERMINATIONPANEL

PL254PL236

T B 4

T B 3

T B 1

T B 2

T B 7

PL1

97


PL1

53

PL1

51

PL1

52

PL210 PL209

PL1

94

PL1

98

PL1

99

PL1

96

PL1

95

Circuit E3: GD3000 (2 P.I.B. Controller only) and GD3000E User Termination (Control)

PL5

CONTROL MODULE

TB4

TB3

TB2

S K 1

TB1

PL3A

PL5ATB7

TB6

TB5

PL3

INPUT BRIDGECONTROLCONNECTIONS


PL1

53

PL1

96

PL1

95

PL1

51

PL1

52

P L210PL209

STANDARD TERMINATIONPANEL

ENHANCED TERMINATIONPANEL (OPTIONAL)

PL1

97

PL1

99

PL1

98

PL1

94



Circuit F Cooling System

This section is based on :1. Type of cooling system

• Standard system (Single phase) Example of components used are :

• Cooling Fan 31V5200/10• Transformers 30Z4592/10 30Z4583/10 30Z4584/10 50Z0036/01 50Z0036/02 50Z0036/03

• High Performance System (Three phase) Example of components used are :

• Cooling Fan 31V6900/10• Transformers 50Z0018/01

50Z0018/0250Z0018/0350Z0037/0150Z0037/0250Z0037/03



Circuit F1: Standard Cooling System Multiple Fans, 1 Fan transformer

FS3 - 4

1 2

230V

F A N230V

F A N230V

F A N230V

F A N

0V

230V (FAN SUPPLY)

FS1 - 2

SUPPLYV O L T A G E

"FAN SUPPLY"FROM INPUT BRIDGE (POWER)

N C

FAN T R A N S F O R M E R

FS5110V

0V

n-1 n

Circuit F2: Standard Cooling System, Multiple Fans, 2 Fan transformers"FAN SUPPLY"FROM INPUT BRIDGE (POWER)

FS5 - 6

1 2 n-1

FAN

230V2 3

FAN

230V2 3

FAN

230V2

SUPPLYVOLTAGE

230V (FAN SUPPLY)

0V

FS1 - 2

N C

FS3 - 4

n

FAN

2

0V

110V TO INPUT BRIDGE (CONTROL)

FAN FAN FAN

230V2 3

FAN

230V2 3

n-1 n1

FAN TRANSFORMER

110V

0V

FS5 - 6

FS7

FS3 - 4

3

230V2 3

FAN TRANSFORMER

110V

0V

230V2 3

230V2 3

230V (FAN SUPPLY)

SUPPLYVOLTAGE



Circuit F3: Standard Cooling System, Multiple Fans, 3 Fan transformers

2

0V

230V (FAN SUPPLY)

SUPPLYVOLTAGE

FAN TRANSFORMER

110V

0V

FAN TRANSFORMER

FS3 - 4

FS5 - 6

FS7

FAN

230V2 3

FAN

230V2 3

FAN

230V2 3

n-1 n


FS5 - 6

1 2 n-1

FAN

230V2 3

FAN

230V2 3

FAN

230V2 3

SUPPLYVOLTAGE

230V (FAN SUPPLY)

0V

110V

0V

FS1 - 2

NC

FS3 - 4

21n

FAN

230V

FAN

230V2 3 2 3

FAN

230V2 3

1n-1 n

SUPPLYVOLTAGE

230V (FAN SUPPLY)

FAN TRANSFORMER

FS5 - 6

FAN

230V2 3

0V

110V

0V

FS3 - 4

FAN

230V2 3

FAN

2 3

230V

Circuit F4: High Performance Fans, 1 Fan transformer

T

WU WU U

2

FAN

1

FAN

T T T

. . . . n-1

T

FAN

T

V V VW WU

n

FAN

T T

V

RL1

FS1 - 3

400V FAN SUPPLY

SELECT SUPPLYVOLTAGE


CUSTOMER USEFOR FAN FAILURE INTERLOCK

FS4 - 6

0V

110VFS7

FAN TRANSFORMER




Circuit F5: High Performance Fans, 2 Fan transformers

T

WU WU U

2

FAN

1

FAN

T T T

. . . . n-1

T

FAN

T

V V VW WU

n

FAN

T T

V

R L 1

FS1 - 3

C U S T O M E R U S EFOR FAN FAILURE INTERLOCK

400V FAN SUPPLY



FS4 - 6

FS7 - 9

0V

FS10110V

F A N T R A N S F O R M E R

21 . . . . n-1 n

0V

FAN

VU W U

FAN

T T T

VW U W

T T

FAN

T

V

FS7 - 9

WU

T

FAN

T

V

R L 1

FS10

400V FAN SUPPLY

SELECT SUPPLYV O L T A G E

110V

FS4 - 6

F A N T R A N S F O R M E R

Circuit F6: High Performance Fans, 2 Fan transformers

T

WU WU U

2

F A N

1

F A N

T T T

. . . . n-1

T

F A N

T

V V VW WU

n

F A N

T T

V

RL1

FS1 - 3

CUSTOMER USEFOR FAN FAILURE INTERLOCK

T

WU WU U

2

F A N

1

F A N

T T T

. . . . n-1

T

F A N

T

V V VW WU

n

F A N

T T

V

RL1

400V FAN SUPPLY


400V FAN SUPPLY



T

WU WU U W U

21

T

F A NF A N

T T T

. . . . n-1

T

F A N

T

V V VW

n

F A N

T

V

RL1

FS4 - 6 FS4 - 6

400V FAN SUPPLY

FS7 - 9

0V

FS10110V

FAN TRANSFORMER


FS7 - 9

0V

FAN TRANSFORMER

FS10110V

FS4 - 6

FS7 - 9

0V

FAN TRANSFORMER

110VFS10




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