T1689-MV-DELTA-Air-Cooled-Technical Manual Rev-0007

GE
Power Conversion
T1689 Technical Manual Rev 0007

MV3000 Air Cooled DELTA
DEFINITIONS
PDS (Power Drive System)
CDM (Complete Drive Module)

Filters
Reactors
DELTA Power Modules
DELTA Control Components
Auxiliary Components
Machine
PDS (Power Drive System)
AEM Active Energy Management

CDC Common Drive Controller
CDM Complete Drive Module
DDM Drive Data ManagerTM
DELTA Generic term for the transistor module or rectifier unit in the DELTA modular drive
DFE Diode Front End
DIB DELTA Interface Board
Drive Cubiclised DELTA components (CDM)
DNV Det Norske Veritas
I/O Input/Output
IEC International Electro-technical Committee
IGBT Insulated Gate Bipolar Transistor
Machine Bridge The machine bridge controls the bi-directional power flow between the d.c. link and
the motor or generator
MVM Mains Voltage Monitor
Network Bridge The network bridge controls the power flow from the mains supply into the d.c. link.
In the case of an AEM system, bi-directional power flow between the supply and the
d.c. link is controlled.
PDS Power Drive System
PWM Pulse Width Modulation
SFE Sinusoidal Front End
SMPS Switch Mode Power Supply
System General term for the PDS
©COPYRIGHT 2016 GENERAL ELECTRIC COMPANY AND/OR ITS AFFILIATES. All rights reserved. This document and the
information it contains is the property of the General Electric Company and/or its affiliates. It has been provided solely
for private use. Copying, reproducing, selling, importing, exporting, displaying, transmitting or distributing this
document and any of the information it contains is strictly prohibited except as expressly authorized in writing by the
General Electric Company and/or its affiliates.
Page 2
SAFETY INSTRUCTIONS
Care has been taken with the design of this product to ensure that it is safe. However, in common with all
products of this type, misuse can result in injury or death. Therefore, it is very important that the
instructions in this manual and on the product are observed during transportation, commissioning,
operation, maintenance and disposal.
This technical manual must be regarded as part of the product. It should be stored with the product and
must be passed on to any subsequent owner or user.
Local safety laws and regulations must always be observed.
Persons working on the product must be suitably skilled and should have been trained in that work for
these products.
The product is a component designed for incorporation in installations, apparatus and machines.
The product must not be used as a single item safety system. In applications where maloperation of the
product could cause danger, additional means must be used to prevent danger to persons.
Product approvals and certifications will be invalidated if the product is transported, used or stored outside
its ratings or if the instructions in this manual are not observed.
Third party approvals to safety standards UL508C and CSA C22.2 No 14 are marked on the product.
In The European Union:
 Products within the scope of the Low Voltage Directive, 2014/35/EU are CE marked.
 The product complies with the essential requirements of the EMC directive 2014/30/EU, when
installed and used as described in this manual. The requirements of the EMC Directive should
be established before any installation, apparatus or machine which incorporates the product
is taken into service.
 A machine must not be taken into service until the machine has been declared in conformity
with the provisions of the Machinery Directive, 2006/42/EC.
WARNINGS, CAUTIONS & NOTES
WARNING
 “An instruction that draws attention to the risk of injury or death”.
CAUTION
 “An instruction that draws attention to the risk of damage to the product, process or surroundings”.
NOTES: Notes separate important information from the text and give additional information.
Page 3
UNITS COVERED
DELTA POWER MODULES
MVD300-3702 Transistor Module 300 A, 690 V a.c. 1200 V d. c.
MVD300-4602 Transistor Module 300 A, 690 V a.c. 1200 V d. c.
MVD500-4501 Transistor Module 500 A, 480 V a.c. 900 V d.c.
MVD500-4701 Transistor Module 500 A, 690 V a.c. 1200 V d.c.
GDR391-4401 DELTA Rectifier Bridge Module 391 A, 480 V a.c.

GDR391-4601 DELTA Rectifier Bridge Module 391A, 690 V a.c.
MVR1600-4601 DELTA Rectifier Bridge Module 1600A, 690 V a.c.
CUBICLE BUSBARS FOR RECTIFIER BRIDGE MODULES

41Y5810/10 Cubicle Busbars for GDR721
DFE NETWORK BRIDGE SHARING REACTORS

30V6500/10
30V6700/10
DFE DC Link Choke

33Z0329/10
33Z0331/10
50Z0019/01
50Z0055/04
50Z0055/05
50Z0050/07
50Z0038/01
50Z0038/02
50Z0038/03
50Z0057/01
50Z0057/02
50Z0057/03
Page 4
DFE INTERBRIDGE TRANSFORMERS FOR 12-PULSE SYSTEMS

33Z0352/10
33Z0354/10
50Z0021/10
50Z0043/01
50Z0043/02
50Z0043/03
50Z0063/04
50Z0063/01
50Z0063/02
50Z0063/03
AEM AND MACHINE BRIDGE SHARING REACTORS

31V5400/10
31V5500/10
50Z0126/01
DELTA CONTROL COMPONENTS

MVC3001-400x MV3000e Controller
MVC3002-4001 User I/O Termination Panel
MVC3003-40xx Switched Mode Power Supply
MVC3006-4003 Mains Voltage Monitor
MVS3000-4001 Drive Data ManagerTM (Keypad)
MVS3001-4001 Drive Data Manager TM (Keypad) Mounting Kit
FAN TRANSFORMERS
MV3 FTX 1306 A4 380V – 480V, 1 Fan
MV3 FTX 1865 A4 380V – 480V, 2 Fans
MV3 FTX 1306 A6 525V – 690V, 1 Fan
MV3 FTX 1865 A6 525V – 690V, 2 Fans
Page 5
DELTA RIBBON CABLES & ACCESSORIES

MVS3017-4001 16way Ribbon Cable Earthing Clamp
MVS3018-400x 40way Ribbon Cable Earthing Clamp
MVS3019-4001 50way Ribbon Cable Earthing Clamp
MVS3020-40xx 40way Screened Ribbon Cable
DELTA MOUNTING FRAMES FOR RITTAL TS8 ENCLOSURE

MVD-TS-4011 DELTA Mounting Kit 800D x 600W
LOWER GUIDE PLATE ASSEMBLY

31V5800/10 Lower Guide Plate assembly
HIGH PERFORMANCE FAN ASSEMBLY

MVC3014-4001 High Performance Fan
DIRTY AIR DUCTING

20T1671/01 Dirty Air Duct
Page 6
CONTENTS
DEFINITIONS............................................................................................................................................................ 2
SAFETY INSTRUCTIONS .......................................................................................................................................... 3
WARNINGS, CAUTIONS & NOTES ......................................................................................................................... 3
UNITS COVERED ...................................................................................................................................................... 4
CONTENTS ............................................................................................................................................................... 7
1. INTRODUCTION ............................................................................................................................................ 13
1.1 GENERAL DESCRIPTION .............................................................................................................................................. 13
1.1.1 Advantages Of The Modular System .......................................................................................................... 13
1.1.2 DELTA Product Range......................................................................................................................................... 13
1.2 ASSOCIATED MANUALS .............................................................................................................................................. 14
1.3 ABOUT THIS MANUAL.................................................................................................................................................. 15
1.4 DRIVE CONFIGURATIONS........................................................................................................................................... 16
1.4.1 DFE Network Bridge ............................................................................................................................................ 17
1.4.2 Sinusoidal Front End (AEM Network Bridge) ............................................................................................ 17
1.4.3 Machine Bridge...................................................................................................................................................... 17
1.5 TYPICAL LAYOUT OF KEY DELTA COMPONENTS ............................................................................................. 18
2. SPECIFICATION ............................................................................................................................................. 21
2.1 INTRODUCTION .............................................................................................................................................................. 21
2.2 DELTA COMPONENTS (GENERAL ENVIRONMENT).......................................................................................... 21
2.2.1 Electrical Supply .................................................................................................................................................... 21
2.2.2 Switching Frequency .......................................................................................................................................... 22
2.2.3 Temperature & Humidity .................................................................................................................................. 22
2.2.4 Ingress Protection ................................................................................................................................................ 23
2.2.5 Vibration.................................................................................................................................................................... 23
2.2.6 Inclination................................................................................................................................................................. 24
2.3 DRIVE PERFORMANCE WITH MV3000E CONTROLLER ................................................................................. 24
2.4 MV3000E CONTROLLER.............................................................................................................................................. 25
2.4.1 Electrical Connections ........................................................................................................................................ 26
2.4.2 Weight........................................................................................................................................................................ 27
2.4.3 Optional Modules.................................................................................................................................................. 27
2.5 USER I/O TERMINATION PANEL .............................................................................................................................. 27
2.5.2 Weight........................................................................................................................................................................ 29
2.6 MAINS VOLTAGE MONITOR (MVM) ......................................................................................................................... 30
2.6.2 Weight........................................................................................................................................................................ 30
2.7 SWITCHED MODE POWER SUPPLIES (SMPS)..................................................................................................... 31
2.8 MV3000E DRIVE DATA MANAGERTM (KEYPAD) .................................................................................................. 32
2.9 DELTA RECTIFIER MODULE ....................................................................................................................................... 33
2.9.1 DELTA Rectifier Type MVR................................................................................................................................. 34
2.9.2 DELTA Rectifier Type GDR ................................................................................................................................. 40
2.10 DELTA TRANSISTOR MODULE .................................................................................................................................. 54
2.10.1 Features .................................................................................................................................................................... 55
2.10.2 Interfaces ................................................................................................................................................................. 55
2.10.3 External Requirements ...................................................................................................................................... 55
2.10.4 A.C. Phase Current Ratings .............................................................................................................................. 55
2.10.5 Phase Voltage ........................................................................................................................................................ 56
2.10.6 D.C. Link Voltage ................................................................................................................................................... 56
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2.10.7 D.C. Link Capacitors ............................................................................................................................................. 56

2.10.8 Thermal Protection ............................................................................................................................................... 57
2.10.10 Heat Dissipation .................................................................................................................................................... 58
2.10.11 Weight ........................................................................................................................................................................ 58
2.10.12 Acoustic Noise ........................................................................................................................................................ 58
2.11 MV DELTA COOLING SYSTEM: HIGH PERFORMANCE VERSION (MVC3014-4001) ............................ 59
2.12 DELTA POWER MODULES – DIRTY AIR DUCTING 20T1671/01 ................................................................. 61
2.12.1 Introduction ............................................................................................................................................................. 61
2.12.2 Features ..................................................................................................................................................................... 61
2.12.3 Interface .................................................................................................................................................................... 61
2.13 REACTORS, INDUCTORS & TRANSFORMERS...................................................................................................... 62
2.13.1 General Description ............................................................................................................................................. 62
2.13.2 Input Reactor For DFE Drives .......................................................................................................................... 62
2.13.3 D.C. Link Inductor for DFE Drives ................................................................................................................... 63
2.13.4 Losses ......................................................................................................................................................................... 64
2.13.5 Interbridge Transformer For DFE Drives .................................................................................................... 65
2.13.6 Losses ......................................................................................................................................................................... 65
2.13.7 Input Reactor For AEM Drives ......................................................................................................................... 66
2.13.8 Shunt PWM Filter For AEM Drives .................................................................................................................. 66
2.13.9 AEM & Machine Bridge Sharing Reactors ................................................................................................. 66
2.14 FAN/CONTACTOR SUPPLY TRANSFORMER ........................................................................................................ 68
2.14.1 Standard MV DELTA Cooling System ........................................................................................................... 68
2.15 INSTALLATION ACCESSORIES (ELECTRICAL) ...................................................................................................... 69
2.15.1 Screened Ribbon Cables .................................................................................................................................... 69
2.15.2 Ribbon Cable Clamps .......................................................................................................................................... 69
2.15.3 Keypad Mounting Kit ........................................................................................................................................... 70
2.16 INSTALLATION ACCESSORIES (MECHANICAL) ................................................................................................... 70
2.16.1 DELTA Module Mounting Frames .................................................................................................................. 70
2.16.2 Variations .................................................................................................................................................................. 70
2.16.3 DELTA Power Modules – Lower Guide Plate Sub Assembly 31V5800/10 .................................. 71
2.17 STANDARDS ...................................................................................................................................................................... 72
2.17.1 Safety .......................................................................................................................................................................... 72
2.17.2 Electromagnetic Compatibility (EMC) .......................................................................................................... 72
2.17.3 Ratings/Performance .......................................................................................................................................... 72
3. DRIVE (CDM) DESIGN ................................................................................................................................... 73
3.1 INTRODUCTION ............................................................................................................................................................... 73
3.1.1 How To Use This Section ................................................................................................................................... 74
3.2 INITIAL DELTA KIT LIST ................................................................................................................................................. 75
3.3 ELECTRICAL DESIGN PRINCIPLES ........................................................................................................................... 75
3.3.1 Electrical Safety ..................................................................................................................................................... 75
3.3.2 Electrical Design For Reliability....................................................................................................................... 77
3.4 OVERVIEW OF COMPONENTS REQUIRED ........................................................................................................... 78
3.4.1 DELTA Modules & Associated Components (DELTA Kit List) ............................................................. 78
3.4.2 Items To Be Supplied By The CDM Designer / Builder ......................................................................... 79
3.4.3 Items To Be Supplied By The PDS Designer / Builder........................................................................... 80
3.5 MECHANICAL DESIGN PRINCIPLES ........................................................................................................................ 80
3.5.1 The Equipment Must Be Enclosed................................................................................................................. 80
3.5.2 Impact of Electrical Safety On Mechanical Design ............................................................................... 81
3.5.3 Electrical Bonding ................................................................................................................................................. 82
3.5.4 Routing & Segregation Of Cables .................................................................................................................. 83
3.6 INITIAL CDM ARRANGEMENT.................................................................................................................................... 85
3.6.1 General Design Considerations...................................................................................................................... 85
3.6.2 Enclosure Size ......................................................................................................................................................... 86
3.6.3 CDM Installation In Multiple Enclosures ..................................................................................................... 86
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3.6.4 Position Of DELTA Rectifier Modules ........................................................................................................... 87

3.6.5 Position Of DELTA Transistor Modules........................................................................................................ 87
3.6.6 Position Of Reactors & Filtering Components ........................................................................................ 87
3.6.7 Position Of Switched Mode Power Supply (SMPS)................................................................................. 87
3.6.8 Position Of Control Components................................................................................................................... 88
3.6.9 Typical CDM Arrangement ............................................................................................................................... 89
3.7 COMPONENT SELECTION – COOLING SYSTEM DESIGN .............................................................................. 90
3.7.1 Introduction To Cooling System .................................................................................................................... 90
3.7.2 Primary Air Cooling .............................................................................................................................................. 90
3.7.3 Secondary Air Cooling ........................................................................................................................................ 91
3.8 COMPONENT SELECTION – ELECTRICAL............................................................................................................. 92
3.8.1 DELTA Power & Control Modules .................................................................................................................. 92
3.8.2 Control Circuit – Auxiliary Components ..................................................................................................... 94
3.8.3 Filters .......................................................................................................................................................................... 95
3.8.4 Power Cabling & Terminals.............................................................................................................................. 95
3.8.5 Fuse Selection & Mounting .............................................................................................................................. 97
3.8.6 Pre-Charge Requirements ............................................................................................................................... 97
3.8.7 Dynamic Braking (DB) Units ............................................................................................................................. 98
3.9 COMPONENT SELECTION - MECHANICAL .......................................................................................................... 99
3.9.1 Enclosure (/s) ........................................................................................................................................................... 99
3.9.2 DELTA Mounting Frames................................................................................................................................. 101
4. PDS DESIGN ................................................................................................................................................ 103
4.1 SUITABILITY OF MOTORS ......................................................................................................................................... 103
4.2 SUITABILITY OF MOTOR CABLES........................................................................................................................... 103
4.3 ENCODERS & ENCODER CABLES .......................................................................................................................... 104
4.3.1 Encoder Selection ............................................................................................................................................... 104
4.3.2 Encoder Resolution ............................................................................................................................................ 104
4.3.3 Encoder Mounting .............................................................................................................................................. 105
4.3.4 Encoder Cable Screening ............................................................................................................................... 105
4.4 MAINS SUPPLY CABLES ............................................................................................................................................ 105
4.5 SPECIAL REQUIREMENTS FOR “IT” NETWORKS ............................................................................................. 106
4.5.1 Protection Against Transients ...................................................................................................................... 106
4.5.2 Earth Fault Monitoring ..................................................................................................................................... 106
4.6 PROTECTION OF CABLES ROUTED OUTSIDE THE ENCLOSURE .............................................................. 107
5. CDM ASSEMBLY .......................................................................................................................................... 109
5.1 INTRODUCTION ............................................................................................................................................................ 109
5.1.1 Recommended Order of Assembly ............................................................................................................ 110
5.2 RECEIPT & STORAGE OF EQUIPMENT ................................................................................................................. 111
5.2.1 For immediate installation ............................................................................................................................. 111
5.2.2 For long term storage ...................................................................................................................................... 111
5.2.3 Electrolytic Capacitor Shelf Life ................................................................................................................... 111
5.2.4 Procedures after Removing DELTA Transistor Bridge Modules from Long Periods of Storage
..................................................................................................................................................................................... 112
5.3 FITTING FLOOR MOUNTED REACTORS .............................................................................................................. 113
5.4 ASSEMBLING THE MOUNTING FRAME FOR DELTA POWER MODULES .............................................. 114
5.4.1 General .................................................................................................................................................................... 114
5.4.2 Side Support Rails............................................................................................................................................... 114
5.4.3 Lower Cross-members .................................................................................................................................... 115
5.4.4 Guide Plates .......................................................................................................................................................... 115
5.4.5 Upper Cross-Members ..................................................................................................................................... 115
5.5 FANS .................................................................................................................................................................................. 115
5.5.1 Fan installation .................................................................................................................................................... 115
5.5.2 Fan air outlet......................................................................................................................................................... 116
5.5.3 Fan Support Bracket ......................................................................................................................................... 117
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5.6 FITTING A.C. SHARING REACTORS ....................................................................................................................... 117

5.7 FITTING DELTA POWER MODULES ...................................................................................................................... 117
5.7.1 Guidance for Handling .................................................................................................................................... 117
5.7.2 Transistor Module Identity ............................................................................................................................. 117
5.7.3 DELTA Rectifier Module Position ................................................................................................................. 118
5.7.4 DELTA Power Module Lifting & Fitting Procedure ............................................................................... 118
5.8 MV3000E CONTROLLER ........................................................................................................................................... 119
5.9 USER I/O TERMINATION PANEL ............................................................................................................................ 119
5.10 MAINS VOLTAGE MONITOR .................................................................................................................................... 119
5.11 DRIVE DATA MANAGER (KEYPAD) .................................................................................................................... 119
5.12 DELTA RECTIFIER MODULE POWER CONNECTIONS ................................................................................... 119
5.12.1 General .................................................................................................................................................................... 119
5.12.2 A.C. Terminals....................................................................................................................................................... 119
5.12.3 D.C. Terminals ...................................................................................................................................................... 121
5.12.4 Earth Connection ............................................................................................................................................... 122
5.12.5 Fitting Shrouds .................................................................................................................................................... 122
5.13 DELTA TRANSISTOR MODULE POWER CONNECTIONS.............................................................................. 123
5.13.1 General .................................................................................................................................................................... 123
5.13.2 A.C. Connections ................................................................................................................................................. 123
5.13.3 D.C. Connections ................................................................................................................................................ 123
5.13.4 Earth Connection ............................................................................................................................................... 123
5.13.5 Fitting Shrouds .................................................................................................................................................... 123
5.14 FITTING EARTH BONDING PLATES ...................................................................................................................... 124
5.15 CONNECTIONS TO THE A.C. SHARING REACTORS ....................................................................................... 125
5.16 CONNECTIONS TO FLOOR MOUNTED REACTORS........................................................................................ 125
5.17 SWITCH MODE POWER SUPPLY ........................................................................................................................... 125
5.18 CONTROL CONNECTIONS - RIBBON CABLES ................................................................................................. 126
5.18.1 Fitting Screened Ribbon Cables .................................................................................................................. 126
5.18.2 DELTA Transistor Modules ............................................................................................................................. 126
5.18.3 User I/O Termination Panel ........................................................................................................................... 127
5.18.4 Mains Voltage Monitor .................................................................................................................................... 127
5.19 CONTROL CONNECTIONS – DISCRETE WIRING ............................................................................................ 127
5.19.1 General .................................................................................................................................................................... 127
5.19.2 Connecting Cable Screens To Earth.......................................................................................................... 127
5.19.3 Rectifier ................................................................................................................................................................... 127
5.19.4 Controller ............................................................................................................................................................... 127
5.19.5 User I/O Panel ...................................................................................................................................................... 127
5.19.6 MVM .......................................................................................................................................................................... 128
5.20 FITTING ENCLOSURE SHROUDS ........................................................................................................................... 128
6. CDM COMMISSIONING GUIDANCE ..........................................................................................................129
6.1 INTRODUCTION ............................................................................................................................................................ 129
6.2 VISUAL INSPECTION................................................................................................................................................... 130
6.3 ELECTRICAL SAFETY TESTS ..................................................................................................................................... 130
6.3.1 Introduction .......................................................................................................................................................... 130
6.3.2 Earth Continuity .................................................................................................................................................. 130
6.3.3 Voltage Groups For Insulation Tests ......................................................................................................... 131
6.3.4 Insulation Resistance Test ............................................................................................................................. 132
6.3.5 High Voltage Insulation Test ......................................................................................................................... 132
6.4 FUNCTIONAL TESTS ................................................................................................................................................... 133
6.4.1 Software ................................................................................................................................................................. 133
6.4.2 Fans .......................................................................................................................................................................... 133
6.4.3 Communication Links ...................................................................................................................................... 133
6.4.4 Plant I/O .................................................................................................................................................................. 133
6.4.5 Power Circuit ........................................................................................................................................................ 133
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7. PDS COMMISSIONING GUIDANCE ........................................................................................................... 135

7.1 INTRODUCTION ............................................................................................................................................................ 135
7.2 VISUAL INSPECTION ................................................................................................................................................... 136
7.2.1 Delivery Checks ................................................................................................................................................... 136
7.2.2 Enclosure Installation ....................................................................................................................................... 136
7.3 DRY-OUT / WARM-UP PROCEDURE .................................................................................................................... 136
7.4 SYSTEM CONFIGURATION WHEN NON-OPERATIONAL ............................................................................. 137
7.5 FUNCTIONAL TESTS .................................................................................................................................................... 137
7.5.1 Software.................................................................................................................................................................. 137
7.5.2 Fans........................................................................................................................................................................... 137
7.5.3 Communication Links ....................................................................................................................................... 137
7.5.4 Plant I/O .................................................................................................................................................................. 137
7.5.5 Power Circuit......................................................................................................................................................... 137
8. MAINTENANCE ........................................................................................................................................... 139
8.1 INTRODUCTION ............................................................................................................................................................ 139
8.1.1 Restarting The System Following Maintenance .................................................................................. 139
8.2 SPECIAL TOOLS, EQUIPMENT & MATERIALS .................................................................................................... 139
8.3 PREVENTATIVE MAINTENANCE ............................................................................................................................. 140
8.3.1 Bi-Annual Maintenance Routine ................................................................................................................. 140
8.4 REMOVAL OF MODULES FOR SERVICE OR REPAIR....................................................................................... 141
8.4.1 Preliminary Checks ............................................................................................................................................ 141
8.4.2 Removal Of The Controller ............................................................................................................................. 141
8.4.3 Removal Of The I/O Termination Panel.................................................................................................... 142
8.4.4 Removal Of The MVM Module ...................................................................................................................... 142
8.4.5 Removal Of An SMPS Module ....................................................................................................................... 142
8.4.6 Removal Of A DELTA Rectifier Module ...................................................................................................... 143
8.4.7 Removal Of DELTA Transistor Module ...................................................................................................... 144
8.5 REPLACEMENT OF MODULES FOLLOWING SERVICE OR REPAIR........................................................... 145
8.5.1 Replacement Of Control Components ..................................................................................................... 145
8.5.2 Replacement Of DELTA Transistor & Rectifier Modules ................................................................... 145
8.5.3 Re-Commissioning The System ................................................................................................................... 146
8.6 DELTA MODULE PACKAGING & TRANSPORTATION ..................................................................................... 146
8.6.1 DELTA Module ...................................................................................................................................................... 146
8.7 SYSTEM DIAGNOSTICS .............................................................................................................................................. 148
8.7.1 Controller Diagnostics ...................................................................................................................................... 148
8.7.2 DELTA Transistor Module Diagnostics ...................................................................................................... 148
8.8 SPARES & SERVICING................................................................................................................................................. 149
8.8.1 Spares ...................................................................................................................................................................... 149
8.8.2 Servicing ................................................................................................................................................................. 149
8.8.3 Pre-Charge Fuses ............................................................................................................................................... 149
8.9 CAPACITOR REFORMING .......................................................................................................................................... 149
9. DISPOSAL..................................................................................................................................................... 151
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10. APPENDIX A: DIMENSIONED MECHANICAL DRAWINGS ......................................................................153

10.1 SCOPE............................................................................................................................................................................... 153
10.2 CONTROL ARRANGEMENT ...................................................................................................................................... 153
10.3 MV RECTIFIER BRIDGE MODULE: MVR1600-4601 ....................................................................................... 154
10.4 GDR RECTIFIER MODULES....................................................................................................................................... 155
10.4.1 GDR391 ................................................................................................................................................................... 155
10.4.2 GDR633 ................................................................................................................................................................... 156
10.4.3 GDR721 With Busbar Assembly (41Y5810/10)..................................................................................... 157
10.4.4 GDR872 ................................................................................................................................................................... 158
10.4.5 GDR872 With Busbar Assembly (41Y5356/10)..................................................................................... 159
10.4.6 GDR1168 ................................................................................................................................................................ 160
10.4.7 GDR1168 With Busbar Assembly (41Y5810/20 ................................................................................... 161
10.5 MV TRANSISTOR MODULES .................................................................................................................................... 162
10.5.1 MVD300 .................................................................................................................................................................. 162
10.5.2 MVD500 .................................................................................................................................................................. 163
10.6 REACTORS, INDUCTORS & TRANSFORMERS................................................................................................... 165
10.6.1 Input Line Reactors For DFE Drives ........................................................................................................... 165
10.6.2 DC Link Inductors ............................................................................................................................................... 167
10.6.3 Interbridge Transformers ............................................................................................................................... 168
10.6.4 Interbridge Transformers (cont’d) .............................................................................................................. 169
10.6.5 Sharing Reactors ................................................................................................................................................ 170
10.6.6 Dirty Air Ducting.................................................................................................................................................. 172
10.6.7 Lower Guide Plate: 31V5800/10 ................................................................................................................. 172
11. APPENDIX B: ELECTRICAL CONNECTION DIAGRAMS ...........................................................................173
11.1 SCOPE............................................................................................................................................................................... 173
11.2 RECTIFIER BRIDGE – CONTROL CONNECTIONS ............................................................................................ 173
11.2.1 MVR1600 Rectifier Bridge .............................................................................................................................. 173
11.2.2 GDR391 & GDR721 Rectifier Bridge .......................................................................................................... 174
11.2.3 GDR633, GDR872 & GDR1168 Rectifier Bridge .................................................................................... 175
11.3 MACHINE BRIDGE: CONTROL CONNECTIONS................................................................................................ 176
11.4 RECTIFIER NETWORK BRIDGE – POWER CONNECTIONS .......................................................................... 177
11.4.1 MVR1600 Rectifier Module ............................................................................................................................ 177
11.4.2 GDR391 & GDR721 Rectifier Modules ...................................................................................................... 177
11.4.3 GDR633, GDR872 & GDR1168 Rectifier Modules ................................................................................ 178
11.5 AEM NETWORK BRIDGE: POWER CONNECTIONS ........................................................................................ 180
11.6 MACHINE BRIDGE: POWER CONNECTIONS .................................................................................................... 181
12. APPENDIX C: RECOMMENDED TORQUE SETTINGS ...............................................................................183
12.1 SCOPE............................................................................................................................................................................... 183
12.2 TORQUE SETTINGS FOR ELECTRICAL CONNECTIONS ................................................................................ 183
12.3 TORQUE SETTINGS FOR BUSBAR JOINTS ........................................................................................................ 183
12.4 TORQUE SETTINGS FOR MECHANICAL CONNECTIONS ............................................................................. 183
13. APPENDIX D: MV3000E DRIVE SELECTION CHARTS ..............................................................................185
13.1 RATINGS MV3000E DELTA DRIVE SELECTION TABLES ............................................................................... 185
CONTACT DETAILS FOR SALES, SERVICE & SUPPORT ...................................................................................188
Page 12
T1689 Technical Manual Rev 0007 Introduction
MV3000 Air Cooled DELTA General Description
1. INTRODUCTION
1.1 GENERAL DESCRIPTION
An MV3000e DELTA a.c. drive is used to control a motor, generator, or power conditioning application.
It uses a modular approach which allows the use of a small number of common components to create a
large number of system variants.
1.1.1 Advantages Of The Modular System

 The DELTA transistor and rectifier modules are of a standard mechanical design, using the
same mounting method and dimensions;
 DELTA rectifier and transistor modules can be connected in parallel to provide a wide range of
power levels;
 Modular construction makes maintenance and repair work simple, and enables rapid module
replacement;
 DELTA transistor and rectifier modules can be withdrawn on a simple slide system for ease of
assembly and maintenance.
 Ease of handling – smaller, lighter modules are assembled to form large drives.
1.1.2 DELTA Product Range

 Rectifier module(s);
 Transistor module(s);
 MV3000e Controller
 SMPS (Switch Mode Power Supply) unit(s);
 User I/O termination panel;
 MVM (Mains Voltage Monitor);
 DDM (Drive Data ManagerTM)– Keypad;
 Reactors and transformers;
 Installation accessories (mounting kits and control cables).
Page 13
Introduction T1689 Technical Manual Rev 0007
Associated Manuals MV3000 Air Cooled DELTA
1.2 ASSOCIATED MANUALS

 T1676 MV3000e Getting Started Manual (for rectifier fed systems);
 T1679 MV3000e Software Manual (and Firmware Supplement T2154);
 T2002 MV3000e Getting Started Manual (for AEM systems).
The T1676 and T2002 manuals include commissioning and operating details for the complete MV3000e
DELTA drive.
The T1676, T1679 and T2002 manuals should be regarded as part of the DELTA product. Individual DELTA
component instructions sheets that may also be required are shown below:
 T1692EN MVS3004-4001 - User’s Guide – Drive Coach;

 T1694 MVS3007-4002 - Profibus Field Coupler 12 Mb/s;
 T1915 MVS3000-4001 – Drive Data Manager TM (keypad);
 T1916 MVS3001-4001 - Keypad mounting kit;
 T1930 MVC3006-4003 – Mains Voltage Monitor (MVM);
 T1968 MVS3011-4001 – MV3000e 2nd CAN Port, CAN Port & DeviceNet;
 T1973 MVC3003-40xx – Switch Mode Power Supply (SMPS) Module;
 T1975 Instruction Sheet – Firmware Update Package (FUP32);
 T2013EN MV3000e CANopen Fieldbus Facility;
 T2017EN MV3000e DeviceNet Fieldbus Facility Technical Manual;
 T2034EN MVS3012-400x – MV3000e Ethernet interface;
 T2111EN MVR1600-4601 – Air Cooled Rectifier Technical Data Sheet;
 T2112 Instruction Sheet - MVC3001-400x – DELTA Controller;
 T2159EN MVD500-4x01 – Air Cooled DELTA Technical Data Sheet;
 T2165 Instruction Sheet – Firmware Update Procedure, Ethernet Module
MVS3012-4001/2;
 T2196EN MVC3014-4001 - MV & PECe High Performance Fan.
These documents should be retained for the life of the product and passed on to any subsequent owner.
Page 14
MV3000 Air Cooled DELTA About this Manual
1.3 ABOUT THIS MANUAL

Section 1 – Introduction
 Overview of the main concepts used in DELTA drives;
Section 2 – Specifications
 Common environmental data for the DELTA product range;

 Gives individual DELTA component data.
Section 3 – Complete Drive Module (CDM) Design
 Guidance for component selection;

 Enclosure design;
 Cooling system design;
Section 4 – Power Drive System (PDS) Design
 Motor requirements;
 Motor and supply cable selection;
 Encoder details.
Section 5 – Complete Drive Module (CDM) Assembly
 Guidance for assembly of DELTA components into an enclosure.
Section 6 – CDM Commissioning
 Guidance for commissioning the CDM, including electrical safety checks and functional
testing.
Section 7 – PDS Commissioning
 Guidance for commissioning the CDM in the final location.
Section 8 – Maintenance
 Diagnostic information;
 Preventative maintenance;
 Module replacement.
Section 9 – Disposal
Appendices
 Mechanical drawings of DELTA components;

 Electrical connection diagrams
 Torque values.
Page 15
Drive Configurations MV3000 Air Cooled DELTA
1.4 DRIVE CONFIGURATIONS

A DELTA drive consists of two ‘bridges’ – the network bridge and the machine bridge.
Two generic configurations are available, each with a different network topology:
 Diode Front End (DFE) – power transfer from the network to the load only;
 Active Energy Management (AEM) – power transfer to and from the network.
Both the DFE and AEM drives share the same machine bridge topology.
Figure 1–1 is a simplified schematic diagram of a DFE system. Figure 1–2 is a simplified schematic diagram
of an AEM system.
Circuit diagrams for the various drive configurations are included in:
Appendix B: Electrical Connection Diagrams.
POWER FLOW
Interbridge
Network Bridge Transformer Machine Bridge
+
-
MOTOR
User I/O Controller
Figure 1–1. – Schematic Diagram of a DFE DELTA System
Figure 1–2. – Schematic Diagram of an AEM DELTA System
Page 16
MV3000 Air Cooled DELTA Drive Configurations
1.4.1 DFE Network Bridge

A DFE network bridge comprises of one or more diode rectifier modules, plus ancillary components, which
could include:
 Line reactor;
 Fusing;
 Pre-charge circuit;
 Interbridge transformer;
 D.C. Link inductor.
The network bridge converts the a.c. supply to an unsmoothed d.c. voltage. Power flow is from the network
supply only.
Harmonic currents produced in the supply system by variable speed drives with uncontrolled rectifier inputs
may be reduced by changing from 6 pulse to 12 pulse (6 phase) input.
In the case of a 12 pulse input:
 A phase shifting transformer is used to produce the additional 3 phases which are phase
shifted by 30° as shown in Figure 1–1. 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 by
an interbridge transformer connected between the two positive outputs of the rectifiers. The
output to the d.c. link is taken from the centre-tap of the interbridge transformer.
1.4.2 Sinusoidal Front End (AEM Network Bridge)

The network bridge of an AEM drive comprises of one to six DELTA transistor modules. The network bridge
is combined with the following ancillary components to form a Sinusoidal Front End (SFE):
 Line reactor;
 Fusing;
 PWM filter;
 MVM unit;
 Sharing reactors;
 MV3000e Controller.
The SFE bridge can be used to convert the a.c. supply to a d.c. voltage, but also has the capability to allow
regeneration of energy back into the network, and as such is required for power generation applications
(e.g. wind turbines).
The AEM network bridge provides a very clean waveform, but the harmonic content will require filtering.
1.4.3 Machine Bridge

The machine bridge converts between a d.c. and an a.c. voltage of variable frequency and amplitude.
Generally in a DFE system, the power flows from the d.c. link, out into the a.c. load. In an AEM system, power
flow is bi-directional.
The machine bridge comprises of one to six DELTA transistor modules and the following ancillary
components:
 Sharing reactors;
 Fusing;
 MV3000e Controller.
Page 17
Typical Layout OF KEY DELTA COMPONENTS MV3000 Air Cooled DELTA
1.5 TYPICAL LAYOUT OF KEY DELTA COMPONENTS

A typical layout showing the key DELTA components that may be combined to build a CDM (Complete Drive
Module) is shown in Figure 1–3.
MVC3006-4003 Mains SMPS Module 50Z0126/xx

Voltage Monitor MVC3003-40xx Sharing Reactor
DELTA Rectifier Module

MVRL1600
Drive Data Manager TM
MVS3000-4001
MV3000e Controller
MVC3001-400x
DELTA Transistor Module

User I/O Termination Panel Line reactor / Interbridge transformer, d.c. link reactor MVD500
MVC3002-4001
Figure 1–3. – Typical layout of CDM
Page 18
MV3000 Air Cooled DELTA Typical Layout OF KEY DELTA COMPONENTS
Figure 1–4. – Interconnections between Controller and DELTA
Page 19
Typical Layout OF KEY DELTA COMPONENTS MV3000 Air Cooled DELTA
Page Intentionally Blank
Page 20
T1689 Technical Manual Rev 0007 Specification
MV3000 Air Cooled DELTA Introduction
2. SPECIFICATION
2.1 INTRODUCTION
The specifications provided in this section are for the individual DELTA components. These components are
the transistor and rectifier modules, the MV3000e Controller, the Switched Mode Power Supply (SMPS), the
User I/O Termination Panel, the Mains Voltage Monitor (MVM) – if required, associated reactors and
transformers and the installation accessories (for use in enclosures). Consideration should be given to the
rating of individual components when they are included in a CDM as derating for parallel applications may
apply.
2.2 DELTA COMPONENTS (GENERAL ENVIRONMENT)

All DELTA components are designed to comply with the common specifications in Table 2–1 to Table 2–7
unless otherwise detailed in the individual component specification. Drive performance data for an
MV3000e based DELTA drive is included in Table 2–9.
2.2.1 Electrical Supply

DELTA modules are intended to be used in a drive connected to an electrical supply with the following
characteristics:
FUNCTION SPECIFICATION
Electrical Supply
TN or TT (i.e. earthed/grounded neutral).
Can also be connected to IT network (i.e. isolated or high impedance neutral) if IT network
Network Type
separated from public mains supply by an isolating transformer.
See Section 4.5.1: Protection Against Transients.
Product dependant.
Refer to module details, see below:
MVR Phase Voltage Section 2.9.1.6.
Voltage Range
GDR Phase Voltage Section 2.9.2.6.
MVD Phase Voltage Section 2.10.5.
MVD D.C. Link Voltages Section 2.10.6.
Voltage Variation
10% long term, 15% for 0.5 to 30 cycles with loss of performance but no trip
(on voltage range)
Voltage Unbalance Negative sequence voltage not to exceed 3%
Frequency (optimised) 50 Hz, 60 Hz
Operational Frequency 45 Hz to 63 Hz. With frequencies outside the optimised values, extra d.c. link ripple may
Range be apparent and may impair motor control performance.
Insulation Coordination
EN 50178, IEC 61800-5-1, UL 840, CSA C22.2 No. 0.2
TN or TT network : Overvoltage Category III
Overvoltage Category IT network : Overvoltage Category II
(line to earth) For full compliance with UL 508C, transient suppressers complying with UL 1449 must be
fitted between line and earth. These must be fitted as close as possible to the point
where the electrical supply enters the drive enclosure.
Table 2–1. – Electrical Specification
Page 21
Specification T1689 Technical Manual Rev 0007
DELTA Components (General Environment) MV3000 Air Cooled DELTA
2.2.2 Switching Frequency

The switching frequency is set by parameter P35.00 in the MV3000e controller (see MV3000e Software
Manual T1679). The range of possible switching frequencies is given in Table 2–2.
Default Alternatives Available
Network Bridge (AEM only) 2.5 kHz 5 kHz
Machine Bridge 1.25 kHz 2.5 kHz, 5 kHz
Notes:
1. If one of the alternative switching frequencies is selected, it may be necessary to reduce the power rating
of the drive, particularly at higher ambient temperatures.
2. If the switching frequency of the network bridge is altered, the effects on the PWM filter must be
assessed. The change of PWM frequency will affect the power dissipation in the filter and will also affect
the emissions onto the electricity supply.
Table 2–2. – Switching Frequency
2.2.3 Temperature & Humidity

DELTA modules and associated components (including the controller) are intended to be installed in a local
ambient (inside the enclosure) with the following characteristics:
FUNCTION SPECIFICATION
Environmental
Operating
Ambient air temperature range 0 to 40°C derate to 50°C (32 to 104°F derate to 122°F)
Note: If clean/dirty air is segregated, the control electronics can withstand 60°C
(140°F).
Relative humidity 5 to 95% (non-condensing)
Normal operating altitude up to 1000m above sea level.
Altitude From 1000 m (3280 ft.) to a maximum of 2000 m (6551 ft.) derate by 7.3% per
1000 m (3280 ft.).
Pollution Degree 2 (IEC 60664-1, UL 840 and CSA C22.2 No. 0.2-93) i.e. clean, free
from dust, condensation and conductive or corrosive gases. If conductive pollution
Cooling air or condensation are expected (Pollution Degree 3), the drive must be placed in an
enclosure which achieves Pollution Degree 2 by:
- excluding the conductive pollution e.g. by the use of filtered air;
- preventing condensation e.g. by use of anti-condensation heaters.
In extreme environments dual circuit heat exchangers are recommended.
The dirty air path can be exposed to unfiltered air that does not contain corrosive,
conductive or explosive dust or gases.
See Section 3.9.1. for requirements for the drive enclosure.
Atmospheric chemicals (max) 15 ppm H2S 25 ppm NO2 25 ppm SO2
Storage
Temperature range -25°C to +55°C (-13°F to 131°F)
Relative humidity 5 to 95% non-condensing
Altitude Up to 3000 m (9842 ft.) above sea level
Transport
Temperature range -25°C to +70°C (-13°F to +158°F) – without coolant
Relative humidity  95% (non-condensing)
Altitude Will withstand air transport
Table 2–3. – Temperature & Humidity
Page 22
MV3000 Air Cooled DELTA DELTA Components (General Environment)
2.2.4 Ingress Protection

According to IEC 60529, EN 60529:
IP00 (not protected).
The DELTA modules and associated components must always be installed in an appropriate enclosure with
restricted access.
2.2.5 Vibration
2.2.5.1 Operational
The products comply with the vibration requirements in the following tables. This meets or exceeds the
requirements of the standards indicated:
For MVD500 & MVR1600 product
 EN 50178;
 IEC 61800-2 (this standard uses class 3M1 of IEC 60721-3-3);
 IEC 61800-5-1;
 DNV Rules for Ships, Pt. 4 Ch.8 Sec. 3.
Frequency Vibration Level

2 Hz to 5 Hz 0.3 mm displacement
5 Hz to 42.4 Hz 20 mm/s velocity
42.4 Hz to 57 Hz 0.075 mm displacement
57 Hz to 150 Hz 10 m/s2 acceleration
Table 2–4. – Vibration Withstand Levels: MVD500 & MVR1600
For MVD300 & all GDR product
 EN 50178;
 IEC 61800-2 (this standard uses class 3M1 of IEC 60721-3-3);
 IEC 61800-5-1;

9 Hz to 28.13 Hz 1 m/s2 acceleration
28.13 Hz to 57 Hz 0.032 mm displacement
Table 2–5. – Vibration Withstand Levels: MVD300 & all GDR Products
The above vibration levels are used as an accelerated life test. For reliable operation, it is recommended
that the vibration levels in operation do not exceed the levels of class 3M1 according to IEC 60721-3-3.
These are given in Table 2–6 below:

Table 2–6. – Recommended Maximum Operational Vibration Levels
Page 23
DRIVE PERFORMANCE WITH MV3000e CONTROLLER MV3000 Air Cooled DELTA
2.2.5.2 Transport & Storage

The levels in Table 2–7 are permitted only when the modules are packed for transport.
To IEC 61800-2 which specifies Class 2M1 of IEC 60721-3-2 when equipment
is packed for transport:
Vibration - 2 to 9 Hz 3.5mm amplitude
Storage and
transport 9 to 200 Hz 10m/s2 acceleration
200 to 500 Hz 15m/s2 acceleration
To IEC 61800-2 which specifies Class 2M1 of IEC 60721-3-2 when equipment
Drop -
is packed for transport:
Transport
mass < 100kg 0.25m; 100kg  mass 0.10m
Table 2–7. – Transportation & Storage Vibration Levels
2.2.6 Inclination
Inclination levels for the DELTA power modules are defined below.
Condition Severity
Static List 15°, trim 5°
9 Hz to 200 Hz ±22.5°, pitch ±7.5° (may occur simultaneously)
Table 2–8. – Recommended Maximum Operational Vibration Levels
2.3 DRIVE PERFORMANCE WITH MV3000E CONTROLLER

Table 2–9 includes the drive performance data.
FREQUENCY
Resolution 0.01% Control Accuracy 0.1%
SPEED
Resolution 0.01% Accuracy (absolute) 0.01%
SPEED CONTROL
FREQUENCY ENCODERLESS FLUX FLUX VECTOR WITH
CONTROL (VVVF) VECTOR ENCODER
Range 50 : 1 50 : 1 >1000 : 1
Bandwidth N/A 20 rad/s 100 rad/s
Accuracy  1%  0.5%  0.02%
TORQUE CONTROL
Bandwidth < 1 rad/s > 500 rad/s > 500 rad/s
Accuracy  10%  10%  5%
Table 2–9. – Drive Performance Data
Page 24
MV3000 Air Cooled DELTA MV3000e Controller
2.4 MV3000E CONTROLLER

Units covered: MVC3001-400x.
The MV3000e controller, shown in Figure 2–1, provides all control and monitoring functions for the
transistor and rectifier bridges in a DELTA drive (to a maximum of 6 transistor modules and 2 rectifier
modules).
The controller is supplied in a ‘stand-alone’ chassis for mounting within an enclosure.
The controller derives an electrical supply from the SMPS of an associated DELTA transistor module. The
controller includes facilities for communication with both the transistor and rectifier bridge modules, and
external equipment.
The controller can be mounted at various locations in an enclosure. Section 3 Drive (CDM) Design includes
the requirements for determining the position of a controller in an enclosure.
PL20 – 50 way ribbon cable M5 earth terminal

connector for user I/O
termination panel
Optional communication
module slot
LED status indication

See Figure 8–1
SK5 – Drive Data Manager
TB7 – CANopen
communications
PL12 – rectifier control

wiring
PL10 – 16 way ribbon cable

connector for MVM
PL2 to PL7 – 40 way ribbon

cable connectors for DELTA
modules
M5 earth terminal
Figure 2–1. – MVC3001-400x Controller Electrical Connections
Page 25
MV3000e Controller MV3000 Air Cooled DELTA
2.4.1 Electrical Connections

The connections from the MV3000e controller to other equipment in a DELTA drive are as follows:
 Six 40 way ribbon cable connectors for transistor modules, see Table 2–10;
 One 50 Way ribbon cable connector for a user I/O termination panel;
 One 16 way ribbon cable connector for an Mains Voltage Monitor unit;
 One D-type connector for a Drive Data Manager keypad;
 One 9 way connector for wiring to the rectifier module, see Table 2–11;
 One 5 way connector for wiring CANopen communications, see Table 2–12.
PL2 to PL7 carry the control signals to and from the DELTA transistor modules. Each DELTA transistor
module is identified by the connector position it occupies, as shown in Table 2–10:
Controller DELTA Designation
Connector
PL2 DELTA 1, PL1
PL3 DELTA 2, PL1
PL4 DELTA 3, PL1
PL5 DELTA 4, PL1
PL6 DELTA 5, PL1
PL7 DELTA 6, PL1
Table 2–10. – DELTA Ribbon Connector Identities
The connection arrangement for the modules at the controller is shown in the connection diagrams in
Appendix B: Electrical Connection Diagrams.
The rectifier module control connections are made to PL12, as listed in Table 2–11. Rectifier control wiring
should have a cross sectional area between limits of:
Minimum 0.5 mm2 or 20 AWG (use a consolidating crimp)
Maximum 2.5 mm2 or 14 AWG
Terminal Function
Number
1 NTC Temperature Monitor - Thermistor
2 NTC Temperature Monitor - Thermistor
3 Thermostat (+24 V = HEALTHY)
4 +24 V
5 +24 V
6 0V
7 +24 V
8 Pre-charge Relay +24 V
9 Pre-charge Acknowledge (+24 V = HEALTHY)
Table 2–11. – PL12 Connection Functions For Rectifier Modules
CAN communications are made available on TB7. The pin assignments are shown in Table 2–12. The CAN
port connector wiring should have a cross sectional area between limits of:
TB7 Pin Function
Number
1 Comms GND
2 CAN_LO
3 Screen
4 CAN_HI
5 N/C
Table 2–12. – TB7 Connection Functions For The CANport
Page 26
MV3000 Air Cooled DELTA User I/O Termination Panel
2.4.2 Weight
The MV3000e controller weighs approximately 4 kg (8.8 lb.).
2.4.3 Optional Modules

Several optional communication modules are available for retrofit to the standard MV3000e controller:
 MVC3007-4002 Profibus field coupler 12 Mb/s;

 MVS3011-4001 2nd CAN port communications module;
 MVS3012-4001 Ethernet interface, single channel;
 MVS3012-4002 Ethernet interface, dual channel.
Installation and operation instructions are supplied with each module, see Section 1 - Introduction.
2.5 USER I/O TERMINATION PANEL

Unit covered: MVC3002-4001
The user termination panel, shown in Figure 2–2, provides connection facilities for I/O signals to and from
the MV3000e drive.
TB1 to TB6 user I/O

terminals

connector to controller
Figure 2–2. – User I/O Termination Panel
Except for connections to TB1, TB2, and TB3, multicore-screened cables should always be used. For each
screened cable, crimp the braid to an M4 (No. 8 or 3/16 in) ring crimp and secure it to the panel with the M4
screws provided.
The user connectors on the user I/O termination panel are suitable for 0.5 mm2 - 2.5mm2 (20 to 14 AWG)
single core or flexible cable. A consolidating crimp should be used for the minimum size. Refer to table
below for a specification of each terminal function.
Refer to the Commissioning section of T1676 or T2002 MV3000 Getting Started Manuals for basic I/O
configuration.
Plant I/O is configured by Menu 7 of the MV3000 firmware. Refer to T1679 MV3000 Software Manual for
details of Menu 7.
There are two DIP switches on the module (see Figure 2–3) that configure the analogue I/O for current or
voltage operation. Further parameterisation is done through Menu 7 of the MV3000 firmware.
NOTE: TB4 and TB6 are each 9 way terminal blocks of the same connector pitch and so it is important that
wiring for these blocks is connected to the correct terminal block. TB1 is also a 9 way terminal block
but this has a different connector pitch to TB4 and TB6.
Page 27
User I/O Termination Panel MV3000 Air Cooled DELTA

The connections from the I/O panel to other equipment in the DELTA drive are as follows:
 One 50 way ribbon cable (925 mm [36.4 in] long), supplied with the I/O termination panel,
connects to the controller.
The user connections made available by the I/O panel are:
 TB1 - Digital outputs (three);

 TB2 - 24 V d.c. auxiliary input;
 TB3 - Digital inputs (six), interlock, 24 V peripheral supply;
 TB4 - Communications (RS485, HSIO);
 TB5 - Encoder / PTC (Thermistor, positive temperature coefficient);
 TB6 - Analogue I/O (2 inputs, 2 outputs).
Figure 2–3. – Wiring Diagram For User I/O Termination Panel
Page 28
MV3000 Air Cooled DELTA User I/O Termination Panel
TB6 Analogue Inputs/Outputs (Menu 7) Specifications

Pin Signal
1/2 AN O/P 1 and 2 Analogue outputs 1 and 2 V or I: (11 bit + sign), 5% full scale accuracy,
Voltage (V) or Current (I) as selected by SW1 update time 5 ms
V: –10 V to +10 V,  5 mA load
I: –20 mA to +20 mA,  500  load
3 AN GND Analogue earth / ground for i/p and o/p Connected to earth/ground internally
4/9 –10.5 V/+10.5V Reference supplies for analogue inputs Maximum Load: 5 mA, current limited
5/6 AN I/P 2 –/2 + Differential analogue input 2 V or I: (11 bit + sign), 5% full scale accuracy:
7/8 AN I/P 1 –/1 + Differential analogue input 1 V: –10 V to +10 V, 100 k load input Z
Voltage (V) or Current (I) as selected by SW1 I: –20 mA to +20 mA, 235  load input Z
Common mode volts = 2.5 V maximum
TB5 Encoder/PTC (Menu 13) Specifications
1 M_PTC Input from motor PTC Resistive: Trip: P2.13 (0  to 7 k)
Reset: P2.13 – 0.1 k
2/5 FB –/FB+ Encoder power supply feedback for accurate
setting
4/6 +5 V/+24 V Power supply outputs for the encoder +5 V: Adjustable, 350 mA maximum
4.5 - 6.5 V,
+24 V : Fixed, 350 mA maximum
3 0V Common return line for encoder power supply Connected to earth/ground internally
and the PTC
7/8 Z–/Z+ Marker signal from encoder EIA RS422A, Max edge frequency 1.5 MHz
9 - 12 B–/B+, A–/A+ Encoder position signals EIA RS422A, Max edge frequency 1.5 MHz
TB4 Communications Specifications
1/2 RS485 Tx +/Tx– Differential link for improved noise immunity 0 - 2 km range. Update time 10 ms.
3/4 RS485 Rx +/Rx– (Menu 32)
5 GND Common ground for communications links Connected to earth / ground internally
6/7 No function No connection -
8/9 HSIO +/– High speed digital link (Menu 20) RS422 protocol,  signal differential wrt GND pin.
Common mode volts  15 V
TB3 Digital Inputs (Menu 7) Specifications
1 0 V (digital) 0 V reference of digital inputs Connected to earth / ground internally
2 & 10 +24 V O/P User supply for peripheral equipment Volts range: +22.8 V to +25.3 V
Max load: 500 mA
3 to 8 DIGIN 1-6 For remote control of drive – default functions are Impedance: 15 k
shown in wiring diagram Active: +12 V to +50 V
Inactive: Open circuit or < 7 V
9 INTERLOCK Hardware interlock – must be made to enable Impedance: 15 k
drive Healthy: +12 V to +50 V
Unhealthy: Open circuit or < 7 V
TB2 Auxiliary Input Supply Specifications
1 0 V Aux Input Allows monitoring and programming with main Current, nominal (Keypad + CDC): 500 mA
2 +24 V Aux Input power switched off Current, max (all versions): 2.2 A
TB1 Digital Outputs Specifications
DIGOUT 1 to 3 Volt-free changeover relay outputs Max volts: 250 Vac, 30 V d.c.
Max current: 3 A (resistive load)
Table 2–13. – User I/O Termination Panel Connections

2.5.2 Weight
The user I/O termination panel weighs approximately 1 kg (2.2 lb.).
Page 29
MAINS VOLTAGE MONITOR (MVM) MV3000 Air Cooled DELTA
2.6 MAINS VOLTAGE MONITOR (MVM)

Unit covered: MVC3006-4003.
The Mains Voltage Monitor unit, shown in Figure 2–4, is used to precisely monitor the mains voltage and
phase angle, to allow an MV3000e to operate as an AEM drive. The full specification is given on the
datasheet provided with the unit.
PL28 – 3 way connector to

the a.c. supply
PL27 – 16 way ribbon cable M5 earth terminal

connector to controller
Figure 2–4. – Mains Voltage Monitor Unit (MVM)

The terminations from the MVM module to other equipment in the DELTA drive are as follows:
 One 16 way ribbon cable (360 mm [14.2 in] long) supplied with the MVM unit, connects to the
controller;
 One 3 pin connector to a.c. input.
Wiring to PL28 should have a cross sectional area between limits of:
2.6.2 Weight
The MVM module weighs approximately 1.75 kg (3.85 lb.).
Page 30
MV3000 Air Cooled DELTA Switched Mode Power Supplies (SMPS)
2.7 SWITCHED MODE POWER SUPPLIES (SMPS)

Units covered: See Table 2–14.
The DELTA SMPS, shown in Figure 2–5, is mounted on the front of each transistor module. It provides power
to the control electronics of the transistor module and for the MV3000e controller. The SMPS derives a
supply from the drive d.c. link, via a connector on the associated transistor module.
There are several versions, offering different operating voltages, or enhanced d.c. link monitoring.
Power to the control electronics is maintained during a temporary loss of supply.
Connection to the DC link
40 way ribbon cable

connector to the DELTA
transistor module
Figure 2–5. – MVC3003 SMPS Module
SMPS Type
Parameter MVC3003- MVC3003- MVC3003- MVC3003- MVC3003- MVC3003-
4001 4002 4003 4020 4025 4030
Nominal drive 380 – 440 V a.c. 460 – 525 V a.c. 575 - 690 V a.c.
supply voltage (400 V nominal) (480 V nominal) (600 V nominal)
SMPS supply Fed from d.c. link of DELTA transistor module
Start up
450 V d.c. 550 V d.c.
voltage
Instantaneous
Overvoltage 784 V d.c. 882 V d.c. 1172 V d.c. 1188 V d.c. 1290 V .d.c. 1262 V d.c.
Trip
Timed
Overvoltage Not available 1188 V d.c. Not available 1188 V d.c.
Trip
Undervoltage
400 V d.c. 450 V d.c. 560 V d.c.
Trip
Output power 110 W
Maximum
50°C
ambient
Weight 1.5 (3.3 lbs.) 1.8 (4 lbs.) 1.5 (3.3 lbs.) 1.8 (4 lbs.)
Table 2–14. - SMPS Specifications
NOTE: See Section 3: Drive (CDM) Design for SMPS selection guidance.
Page 31
MV3000e Drive Data ManagerTM (Keypad) MV3000 Air Cooled DELTA

The connections from the SMPS unit to other equipment in the DELTA drive are as follows:
 One 40 way ribbon cable, supplied as part of the DELTA transistor module;
 A two pin connector plugs into the d.c. link of the associated DELTA transistor module.
2.8 MV3000E DRIVE DATA MANAGERTM (KEYPAD)

Units covered: MVS3000-4001 (DDM)
MVS3001-4001 (Installation kit)
The Drive Data ManagerTM, shown in Figure 2–6, is an ergonomically designed keypad which provides the
functionality to configure a drive system. It also provides motor control and diagnostic functions.
The Drive Data ManagerTM derives its power supply from the MV3000e Controller.
Figure 2–6. – Drive Data ManagerTM (Keypad)
An installation kit containing a waterproof gasket and a lead is available separately. The lead for
connection from the Keypad to the MV3000e controller has a maximum length of 3 m (9.8 ft.). This lead
length determines the relative positions of the Drive Data ManagerTM and the controller. When supplied
with a waterproof gasket, it can be mounted on an enclosure door to meet IP 65 enclosure protection.
The specification for the Drive Data ManagerTM and its electrical connections, are included in the T1915
Instruction Sheet which is supplied with the Drive Data ManagerTM.
Page 32
MV3000 Air Cooled DELTA DELTA Rectifier Module
2.9 DELTA RECTIFIER MODULE

Unit covered: MVR1600-4601
GDR391-4401 & -4601
GDR633-4401 & -4601
GDR721-4401 & -4601
GDR872-4401 & -4601
GDR1168-4401 & -4601
In a DELTA drive system, rectifier modules are used in network bridges to convert an a.c. supply into a
rectified, unsmoothed d.c. supply. See Figure 2–7.
The rectifier module is available either as a single bridge or as a double bridge, each in several ratings.
Larger rectifier power ratings can be achieved by connecting the modules in parallel (derating will be
necessary). See Section 2.9.1.4: Current Ratings and Recommended Fuses.
Each module has either:
 A three-phase, six pulse rectifier, with individual a.c. input terminals and two d.c. terminals (d.c.
positive and d.c. negative)
 A pair of three-phase, six pulse rectifiers, with two sets of individual a.c. input terminals and
four d.c. terminals (d.c. positive and d.c. negative for each six pulse rectifier bridge). The d.c.
connections must be connected by the end user with appropriate interbridge components.
The rectifier module may be operated as a 12-pulse network bridge. This configuration is achieved by
connecting the d.c. positive outputs together through an interbridge transformer and one a.c. input being
phase-shifted in relation to the other by an external supply transformer.
Two types are available and are detailed separately.
Page 33
DELTA Rectifier Module MV3000 Air Cooled DELTA
2.9.1 DELTA Rectifier Type MVR
Lifting point 20 mm (0.75”)

diameter
TB1 – Control connections
R – a.c. phase connection
S – a.c. phase connection
T – a.c. phase connection
RECT + : d.c. positive

connection
RECT - : d.c. negative

connection
Earth terminal
Figure 2–7. – DELTA Rectifier Module (MVR1600-4601)
2.9.1.1 Features
 The rectifier module includes a circuit, which is capable of pre-charging the transistor
modules. This circuit charges the d.c. link capacitors of the transistor modules via current
limiting resistors in the rectifier module;
 Modules fit in the standard DELTA mounting frames; and are configured for ‘dirty air’
applications.
 Metal oxide varistors are included to absorb surge energy from the mains. Supply impedance
is necessary for this to function correctly;
 Protection against d.c. link short circuits is by the use of recommended semi-conductor fuses;
 Modules carry thermostat and thermistor temperature sensing devices, which are monitored
by the MV3000e controller to provide over-temperature protection.
2.9.1.2 Interfaces
 Signals between the controller and rectifier module are by individual wires;
 The a.c. and d.c. power connections have stud connections and are designed for cable
connection, however maximum sizes for busbar connections to d.c. terminals are provided in
this manual.
Page 34
2.9.1.3 External Requirements

 For parallel operation of rectifier modules, external sharing reactors must be fitted;
 For 12-pulse operation, the two supplies must be phase shifted by 30° to each other, and be of
balanced voltage. The d.c. output must be through an interbridge transformer;
 Protection of the main input rectifier devices is by the addition of external semi-conductor
fuses.
For recommended fuses, see Section 2.9.1.4 - Current Ratings and Recommended Fuses;
 The a.c. and d.c. terminals on the modules are not suitable to support the weight of any
attached cables. These cables must have additional mechanical support;
 These modules must be cooled by an external MVC3014-4001 fan assembly located above the
unit.
2.9.1.4 Current Ratings and Recommended Fuses

Overloads are for 60 seconds, 6 times per hour equally spaced.
All ratings assume standard drive configurations using the recommended interbridge transformers.
Parallel Ratings
Output current should be de-rated by 10% in the following circumstances:
 Two separate rectifier modules connected in parallel;

 Two halves of the same rectifier connected in parallel (6 pulse).
In systems with parallel rectifiers, a.c. line reactors will be required.
Fusing
To protect a DELTA rectifier module from d.c. link side short circuits it is recommended that semi-conductor
fuses be fitted in the a.c. supply. The current rating of the rectifier module with the recommended fuses is
given in Table 2–15. Other manufacturers’ fuses may be used but they should be equivalent to the types
specified in this manual. Appendix B: Electrical Connection Diagrams includes details of the input power
circuits and the fusing arrangements.
Module Voltage (V) Fuse DC Current Rating (A)

For 1.5 For 1.1
Overload Overload
MVR1600-4601 500 - 690 Cooper Bussmann, 170M6718 (3 1600
qty)
Ferraz, 8.5 URD 73 TTF 1400, Ref
No. : S 300 718 (3 qty)
MVR1600-4601 500 - 690 Cooper Bussmann, KTU-1500 (3 qty) 1300
Ferraz, 6.6 URD 33 TTF 1400.
Ref no. C 300 085 (3 qty)
Table 2–15. – Recommended Fuses For Rectifier Module Input Protection
NOTES: Semi-conductor fuses of the correct rating must be fitted to each of the three phases of the a.c. supply
input to protect against catastrophic failure of the input rectifiers.
The fuses should be fitted remotely from the rectifier;
All ratings are calculated assuming a 31 MVA supply (fault level), no added impedance.
The codes for fuses may not specify the mechanical details. These should be selected to suit user
requirements.
All incoming mains cables should be protected with fuses according to local wiring regulations, for
example, in Europe (or any other countries that use IEC standards) using fuses type gG and in USA and
Canada using Class L fuses.
Page 35
2.9.1.5 Phase Rotation

Rectifier modules are not sensitive to phase rotation.
2.9.1.6 Phase Voltage

The Input Phase Voltage is detailed in Table 2–16.
Nominal voltage is a.c. r.m.s, 3 phase, 3-wire and earth/ground.
The equipment will operate with a variation of ±10% of the nominal supply voltage. For supply voltages
below the nominal, there will be a corresponding reduction in maximum output power. The equipment can
operate up to a maximum of +15% variation on the nominal supplies for a maximum of 30 cycles duration
without the equipment tripping though reduced performance may be observed.
Supply frequency : 45 Hz to 63 Hz.
Input AC Voltage Output DC Link Voltage

Module Nominal AC Input Maximum Maximum Allowed
Voltage (V r.m.s.) Output Regenerative
(V d.c.) Voltage (V d.c.)
MVRL2100-4601/2 575 - 690 1122 1250
Table 2–16. – Input a.c. Voltage & Output d.c. Link Voltage Ratings
Page 36
2.9.1.7 A.C. Voltage Frequency

2.9.1.8 D.C. Link Voltage

The Output d.c. Link Voltage is detailed in Table 2–16.
Typical d.c. output: 1.35 x supply voltage (r.m.s).
2.9.1.9 Pre-Charge
Pre-charge requirements are listed in Table 2–17. The pre-charge control signal switches in the main
rectifiers when the d.c. link has finished pre-charging. The drive controller determines when the charging
period is complete. The MVRL2100-4601/2 DELTA rectifier module is capable of pre-charging:
 Up to four MVD300 or MVD500 DELTA transistor modules;
The rectifier pre-charge acknowledge signal must be connected to the MV3000e controller at PL12, to allow
drive operation. See Table 2–11.
Internal Control Signal Control Signal

Module Pre-charge Voltage Load
Resistor (Ohm) (V d.c.) (mA)
MVRL2100-4601/2 72 24 V 10 mA
Table 2–17. – Pre-Charge Requirements
Fusing
Pre-charge fuses are listed in Table 2–18.
GE Part Order Number Description

S82028/310 8A 600V a.c. Cartridge Fuse (10x38mm)
Table 2–18. – Pre-Charge Fusing
2.9.1.10 Thermal Protection

Thermal protection is provided on each rectifier module by a thermistor and a thermostat located on each
heatplate. Connection details are given in Table 2–11. The thermostat contact is a normally closed contact
and opens at at 90°C ±3°C (194°F ±5°F).
Page 37
2.9.1.11 Electrical Connections

Control Connections
The rectifier control terminals are mounted at the top of the front face of the Rectifier module.
See Figure 2–7. The customer terminals are the left half of a 10-pin plug and socket, referenced TB1, and
may be unplugged for ease of wiring. See Figure 2–8 for the terminal layouts and functions.
Thermistor
10 9 8 7 6 5 4 3 2 1
1 2 3 4 5 6 7 8 9 10
Thermistor
Thermostat
Thermostat (+24 V)
No Connection
0V
+24 V
Pre-charge
Pre-charge Acknowledge
No Connection
Figure 2–8. – Rectifier Module Control Terminals At TB1
Terminals will accept up to 2.5 mm2 (12 AWG) flexible cables. To prevent failure of the Rectifier module pre-
charge components, the rectifier pre-charge acknowledge signal (TB1/9) must be connected to the control
module. If this signal is not healthy the control module will not allow the drive to run.
Power Connections
Terminations for the 3-phase supply, the d.c. output and earth/ground are detailed in Table 2–19.
Termination Stud Size Crimp Size
a.c. terminals 3 x M10 stud connections per phase. M10 (or 3/8 in) ring crimps
3 x M10 stud connections per d.c.
d.c. terminals M10 (or 3/8 in) ring crimps
connection
Earth Terminal 1 x M10 bolt M10 (or 3/8 in) ring crimps
Table 2–19. – Terminations For 3-Phase a.c. Supply, d.c. Output & Earth
The a.c. terminals are suitable for a maximum of 3 x 120 mm2 cables (2 x 250 MCM in North America).
The d.c. terminals are suitable for a maximum of 3 x 185 mm2 cables (3 x 350 MCM in North America).
To achieve the full current rating of the product, it may be necessary to use high temperature cable. See
Section 3: Drive (CDM) Design.
NOTE: Do not allow the temperature of the cable to exceed 125°C (257°F).
The d.c. positive terminals are suitable for a maximum size of busbar at 76 mm x 6.3 mm wide (= 3 in x ¼ in).
The d.c. negative terminals are suitable for a maximum size of busbar at 140 mm x 6.3 mm wide ( 5.1/2 in
x 1/4 in).
Ratings and sizes of busbars are application dependent.
Page 38
2.9.1.12 Heat Dissipation

The heat dissipation for a DELTA rectifier module will vary depending upon the drive in which it is used.
Losses
The losses for this module may be calculated approximately using:
‘Dirty air’ losses = 2.4 x Total d.c. output current.
‘Clean air’ losses = 90 W maximum.
2.9.1.13 Weight
The weight of the MVR1600 DELTA rectifier module is 79.5 kg (175 lb).
2.9.1.14 Acoustic Noise

The acoustic noise generated by the DELTA rectifier module itself is negligible. The acoustic noise
generated will be from the fan module MVC3014-4001 and will be specific to each application due to
location, air routing, and the use of any grills or baffles.
Page 39
2.9.2 DELTA Rectifier Type GDR

TB1 – Control connections diameter
R – a.c. phase connection
S – a.c. phase connection
T – a.c. phase connection
RECT + : d.c. positive

connection RECT - : d.c. negative
connection
Earth terminal
Figure 2–9. – DELTA Rectifier Module (GDR872-4601)
2.9.2.1 Features
 The rectifier module includes a circuit, which is capable of pre-charging the transistor
modules. This circuit charges the d.c. link capacitors of the transistor modules via current
limiting resistors in the rectifier module;
 Modules fit in the standard DELTA mounting frames and are configured for ‘dirty air’
applications;
 RC network included to absorb surge energy from the mains. Supply impedance is necessary
for this to function correctly;
 Protection against d.c. link short circuits is by the use of recommended semi-conductor fuses;
 Modules carry thermostat and thermistor temperature sensing devices, which are monitored
by the MV3000e controller to provide over-temperature protection.
2.9.2.2 Interfaces
 Signals between the controller and rectifier module are by individual wires;
 The a.c. and d.c. power connections have stud or insert connections (type dependant) and are
designed for cable connection, however maximum sizes for busbar connections to d.c.
terminals are provided in this manual.
NOTE: Short busbars are available that connect to the a.c. rectifier terminals which enable the connection
point to be below the DELTA cross rails. These may be supplied in either a kit of parts or as a separate
item. See Section 2.9.2.15 – Cubicle busbars for Rectifier Modules.
Page 40

 The output from all rectifier modules must be through a d.c. link inductor or an Interbridge
transformer
 The high voltage versions of the rectifier module require a 110V a.c. supply for the pre-charge
circuitry.
 For parallel operation of rectifier modules, external sharing reactors must be fitted;
 Similarly, for parallel operation of the two six-pulse rectifiers within a GDR633-4x01 and
GDR1168-4x01 modules, external sharing reactors must be fitted;
 For 12-pulse operation, the two supplies must be phase shifted by 30° to each other, and be of
balanced voltage. The d.c. output must be through an Interbridge transformer;
 Protection of the main input rectifier devices is by the addition of external semi-conductor
fuses. For recommended fuses, see Section 2.9.1.4: Current Ratings and Recommended Fuses;
 These modules must be cooled by an MVC3014-4001 fan assembly located above the unit.
2.9.2.4 Current Ratings and Recommended Fuses

Overloads are for 60 seconds, 6 times per hour equally spaced.
All ratings assume standard drive configurations using the recommended Interbridge transformers.
Parallel Ratings
Output current should be de-rated by 10% in the following circumstances:
 Two separate rectifier modules connected in parallel;

 Two halves of the same rectifier connected in parallel (6 pulse).
In systems with parallel rectifiers, a.c. line reactors will be required.
Page 41
Fusing
To protect a DELTA rectifier module from d.c. link side short circuits it is recommended that semi-conductor
fuses be fitted in the a.c. supply. The current rating of the rectifier module with the recommended fuses is
given in Table 2–20. Other manufacturers’ fuses may be used but they should be equivalent to the types
specified in this manual. Table 2–21 includes details of the input power circuits and the fusing
arrangements.
Module Voltage (V) Fuse DC Current Rating (A)
For 1.5 For 1.1
Overload Overload
GDR391-4401 380 – 480 GSGB350 (3 qty) P 362 362
GSGB400 (3 qty) 391 391
GSGB450 (3 qty) 391 493
GDR391-4601 500 – 690 A100P400 (3 qty) P 391 391
A100P500 (3 qty) 391 493
GDR721-4401 380 – 480 GSGB580 (3 qty) P 633 633
A366S800D1 (3 qty) 721 800
A366S900D1 (3 qty) 721 876
GDR721-4601 500 – 690 A100P700 (3 qty) P 721 721
A100P1000 (3 qty) 721 876
GDR872-4401 380 – 480 A366S900D1 * (3 qty) P 872 872
A366S1000 (3 qty) 872 1080
GDR872-4601 500 – 690 A100P800 * (3 qty) P 872 872
A100P1000 (3 qty) 872 1080
GDR633-4401 380 – 480 GSGB350 (6 qty) P 586 600
GSGB400 (6 qty) 633 633
GSGB450 (6 qty) 633 800
GDR633-4601 500 – 690 A100P400 (6 qty) P 633 633
A100P500 (6 qty) 633 800
GDR1168-4401 380 – 480 A366S800D1 (6 qty) P 1168 1168
A366S900D1 (6 qty) 1168 1420
GDR1168-4601 500 – 690 A100P700 (6 qty) P 1168 1168
A100P1000 (6 qty) 1168 1420
Table 2–20. – Recommended Fuses For Rectifier Module Input Protection
NOTES: Semi-conductor fuses of the correct rating must be fitted to each of the three phases of the a.c. supply
input to protect against catastrophic failure of the input rectifiers.
Devices marked ‘P’ will also protect the input rectifier devices against damage from overcurrent.
However, it may result in a lower effective rectifier rating. The GDR872 (marked ‘*’) requires an
additional 31 µH input reactor (or equivalent supply fault level) and the appropriately rated fuse for
fuse protection.
The fuses should be fitted remotely from the rectifier;
All ratings are calculated assuming a 31 MVA supply (fault level), no added impedance.
The ratings given at Table 2-3 are for the recommended semiconductor fuses from two suppliers. The
GSGB are from the GE Power Controls HRC fuse link range rated up to 660 V +10% (727 V) and the
A366S from the Gould Shawmut Semiconductor fuse range rated up to 660 V +10% (727 V).
The codes for fuses may not specify the mechanical details. These should be selected to suit user
requirements.
All incoming mains cables should be protected with fuses according to local wiring regulations, for
example, in Europe (or any other countries that use IEC standards) using fuses type gG and in USA and
Canada using Class L fuses.
Page 42
2.9.2.5 Phase Rotation

Rectifier modules are not sensitive to phase rotation.
2.9.2.6 Phase Voltage

The Input Phase Voltage is detailed in Table 2–16.
Nominal voltage is a.c. r.m.s, 3 phase, 3-wire and earth/ground.
The equipment will operate with a variation of ±10% of the nominal supply voltage. For supply voltages
below the nominal, there will be a corresponding reduction in maximum output power. The equipment can
operate up to a maximum of +15% variation on the nominal supplies for a maximum of 30 cycles duration
without the equipment tripping though reduced performance may be observed.
Input AC Voltage Output DC Link Voltage

Module Nominal AC Input Maximum Maximum Allowed
Voltage (V r.m.s.) Output Regenerative
(V d.c.) Voltage (V d.c.)
GDR391-4401
GDR633-4401
GDR721-4401 380 - 480 780 800
GDR872-4401
GDR1168-4401
GDR391-4601
GDR633-4601
GDR721-4601 500 - 690 1122 1250
GDR872-4601
GDR1168-4601
Table 2–21. – Input a.c. Voltage & Output d.c. Link Voltage Ratings
2.9.2.7 A.C. Voltage Frequency

2.9.2.8 D.C. Link Voltage

The Output d.c. Link Voltage is detailed in Table 2–16.
Typical d.c. output: 1.35 x supply voltage (r.m.s).
Page 43
2.9.2.9 Pre-Charge
Pre-charge requirements are listed in Table 2–22. The pre-charge control signal switches in the main
rectifiers when the d.c. link has finished pre-charging. The drive controller determines when the charging
period is complete.
The rectifier pre-charge acknowledge signal must be connected to the MV3000e controller at PL12, to allow
drive operation. See Table 2–11.
An external 110 Va.c. auxiliary supply is required to energise the internal pre-charge contactor on the 500 -
690 V GDR rectifiers.
Module Internal Control Signal Control Signal Auxiliary Supply
Pre-charge Voltage Load Required
Resistor (Ohm) ( Vd.c.) (mA)
GDR391-4401 15 24 / 48 36.4 Not Required
GDR633-4401 15 24 / 48 72.8 Not Required
GDR721-4401 15 24 / 48 36.4 Not Required
GDR872-4401 7.5 24 / 48 36.4 Not Required
GDR1168-4401 30 24 / 48 72.8 Not Required
GDR391-4601 37.5 24 / 48 42.0 110 Va.c. rms *
GDR633-4601 37.5 24 / 48 42.0 110 Va.c. rms *
GDR721-4601 37.5 24 / 48 42.0 110 Va.c. rms *
GDR872-4601 37.5 24 / 48 42.0 110 Va.c. rms *
GDR1168-4601 15 24 / 48 42.0 110 Va.c. rms *
Table 2–22. – Pre-Charge Requirements
NOTE: * Requires an Inrush/Hold of 65/9 VA.
2.9.2.10 Thermal Protection

Thermal protection is provided on each rectifier module by a thermistor on the upper heatplate and a
thermostat located on the lower heatplate (if fitted). Connection details are given in Table 2–11. The
thermostat contact is a normally closed contact and opens at 90°C ±3°C (194°F ±5°F).
2.9.2.11 Electrical Connections

Control Connections
The rectifier control terminals are mounted at the top of the front face of the rectifier module.
See Figure 2–9.
The customer terminals are the left half of a 10-pin plug and socket, referenced TB1, and may be unplugged
for ease of wiring. See Figure 2–10 to Figure 2–13 for the terminal layouts and functions.
Figure 2–10. – Rectifier Bridge Module Terminals (GDR391-4401 & GDR721-4401))
Page 44
Figure 2–11. – Rectifier Bridge Module Terminals (GDR633-4401, GDR872-4401 & GDR1168-4401))
Figure 2–12. – Rectifier Bridge Module Terminals (GDR391-4601 & GDR721-4601))
Figure 2–13. – Rectifier Bridge Module Terminals (GDR633-4601, GDR872-4601 & GDR1168-4601))
NOTES
Terminals will accept up to 2.5 mm2 (12 AWG) flexible cables.
To prevent failure of the Rectifier Bridge Module pre-charge components, the rectifier pre-charge
acknowledge signal (TB1/10) must be connected to the control module. If this signal is not high, the control
module must not allow the drive to run.
Power Connections
Terminations for the 3-phase supply, the d.c. output and earth/ground are detailed in Table 2–23.
Page 45
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.
See Figure 2–14.
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 and spring washers under
nuts/bolts when connecting cables.
When tightening dc connections support the copper terminals to prevent twisting.
Figure 2–14. – Terminals for GDR391 Rectifier Bridge Module
Page 46

(GDR633-4401 & GDR633-4601)
All terminals appear at the front of the module and are suitable for cable ring-crimp connection.
See Figure 2–15.
The six phase terminals (marked R1, S1, T1 and R2, S2, T2) are M10 studs and the d.c. link connections
(marked +1, -1 and +2, -2) and the earth terminal (marked Earth) 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.
Page 47

(GDR721-4401 & GDR721-4601)
Connections to the phase and d.c. link are may be made by copper busbars or cables.
See Figure 2–16.
When tightening connections support the terminals to prevent twisting.
Phase terminals (marked R, S and T) appear at the right-hand side of the module and mate with busbar
risers fitted to the mounting steelwork. Once the module is in place use M10 bolts with plain and spring
washers to bolt through the terminals to the threaded risers. The centre terminal may be rotated for cable
connection – see Section 5.2.7.
DC link terminals (marked + and -) are at the front of the module. The d.c. positive terminal connection has
two M10 studs, the d.c. negative terminal has two M10 bolts into threaded inserts.
The earth terminal (M10 threaded insert) is located on the lower front face of the module.
Page 48

(GDR872-4401 & GDR872-4601)
When tightening connections support the copper to prevent twisting. Phase terminals (marked R, S and T)
appear at the right-hand side of the module and mate with busbar risers fitted to the DELTA frame.
See Figure 2–17.
Once the module is in place use M10 bolts with plain and spring washers to bolt through the terminals to
the threaded risers. The centre terminal may be rotated for cable connection – see Figure 2–19.
DC link terminals (marked + and -) appear at the front of the module and are connected with four 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 the module.
Protective earthing of the busbar support bracket (part of the cubicle busbar assembly) is by direct metal
contact to the cubicle cross-rails. Ensure adequate earth continuity of this bracket to earth (ground).
Page 49

(GDR1168-4401 & GDR1168-4601)
Connections to the phase and d.c. link are may be made by copper busbars or cables.
See Figure 2–18.
When tightening connections support the terminals to prevent twisting.
Phase terminals (marked R1, S1, T1 and R2, S2, T2) appear at the right-hand side of the module and mate
with busbar risers fitted to the mounting steelwork. Once the module is in place use M10 bolts with plain
and spring washers to bolt through the six terminals to the threaded risers. The centre terminal may be
rotated for cable connection – see Figure 2–19.
DC link terminals (marked + and -) appear at the front of the module and are connected with M10 bolts
through the d.c. link busbars to the threaded terminals.
The earth terminal (M10 threaded insert) is located on the lower front of the module.
Page 50
Cabling of phase power terminals for GDR721, 872 & 1168

When cabling to the phase terminals of these rectifiers the centre terminal may be rotated through 180° to
increase the clearance distance between the cable crimp and the adjacent terminal.
Figure 2–19. – Rotation of Centre Phase Terminal for Cable Connection
Terminations
Module Type Number of Description of termination

Terminals
3-phase Supply
GDR391 3 M10 stud for cable ring crimp (use M10 or 3/8 in crimp)
GDR633 6 M10 stud for cable ring crimp (use M10 or 3/8 in crimp)
GDR721 3 50 x 6.3 (2 x ¼ in) busbar with 2 x 10.5 mm holes
GDR872 3 63 x 6.3 (2½ x ¼ in) busbar with 2 x 10.5 mm holes
GDR1168 6 50 x 6.3 (2 x ¼ in) busbar with 2 x 10.5 mm holes
D.C. Output
GDR391 2 M10 insert for cable ring crimp (use M10 or 3/8 in crimp)
GDR633 4 M10 insert for cable ring crimp (use M10 or 3/8 in crimp)
GDR721 2 63 x 6.3 (2½ x ¼ in) busbar with 2 x M10 threaded inserts / studs
for cable ring crimps (use M10 or 3/8 in crimp)
GDR872 2 80 x 6.3 (3 x ¼ in) busbar with 4 x M10 threaded inserts for cable
ring crimps (use M10 or 3/8 in crimp)
GDR1168 4 63 x 6.3 (2½ x ¼ in) busbar with 2 x M10 threaded inserts / studs
for cable ring crimps (use M10 or 3/8 in crimp)
Table 2–23. – Terminations for 3-Phase Supply & DC Output
The a.c. terminals are suitable for a maximum of 2 x 150 mm2 cables (2 x 300 MCM in North America).
To achieve the full current rating of the product, it may be necessary to use high temperature cable.
See Section 3 – Drive (CDM) Design
NOTE: Do not allow the temperature of the cable to exceed 125°C (257°F).
The d.c. positive terminals are suitable for a maximum size of busbar at 76 mm x 6.3 mm wide (= 3 in x ¼ in).
The d.c. negative terminals are suitable for a maximum size of busbar at 140 mm x 6.3 mm wide ( 5½ in x
¼ in). Ratings and sizes of busbars are application dependent.
Page 51
2.9.2.12 Heat Dissipation

The heat dissipation for a DELTA rectifier module will vary depending upon the drive in which it is used.
Losses
The losses for this module may be calculated approximately using:
‘Dirty air’ losses = 2.4 x Total d.c. output current.
‘Clean air’ losses = 90 W maximum.
2.9.2.13 Weight
The weight of each Rectifier Module is listed in Table 2–24.
Weight
Module type
kg lb
GDR391 30.5 67
GDR633 48 105
GDR721 37.0 82
GDR872 51.5 114
GDR1168 62.0 137
Table 2–24. – Rectifier Module Weights
2.9.2.14 Acoustic Noise

location, air routing and the use of any grills or baffles. See Section 2.11.1.4
Page 52
MV3000 Air Cooled DELTA DELTA Transistor Module
2.9.2.15 Cubicle busbars for Rectifier Modules
Introduction
The cubicle busbar assembly provides a simple way to interface to the rectifier modules, it’s an assembly of
either three or six connection busbars (type dependant). The busbars are assembled together and
supported by a clamp attached to the DELTA cross rails, this assists in supporting any attached cables.
Features
 Busbar assembly allows the rectifier modules to be withdrawn or inserted without removing
the power cables through removal of the busbar connection bolts.
 Connection points are more accessible through being moved to below the rectifier module
and its cross rails.
 The clamp on the a.c. phase busbars supports any cables attached to the busbars. This
support is necessary for the rectifier modules designed for cable or busbar connection.
Variations
Three versions of the busbars are available which are suitable for the GDR721, GDR872 and GDR1168.
Part number Suitable for Weight

kg lb
41Y5810/10 GDR721 5.0 11
41Y5356/10 GDR872 11.0 24
41Y5810/20 GDR1168 15.5 35
Interface
The a.c. busbar assembly connects directly behind the rectifier terminals and is supported from the DELTA
mounting framework.
External requirements
The a.c. busbars attach to the right of the rectifier module, their position dictated by the terminal positions.
Ensure there is sufficient creepage and clearance distances between any equipment mounted to the right
of the rectifier and the busbar assembly.
Page 53
DELTA Transistor Module MV3000 Air Cooled DELTA
2.10 DELTA TRANSISTOR MODULE

Units covered: MVD300-3702
MVD300-4602
MVD500-4501
MVD500-4701
In a DELTA drive, transistor modules shown in Figure 2–20, are used in both machine bridges and AEM
network bridges, to convert between variable frequency a.c. and d.c. voltages.
Transistor modules are available in two current ratings. Larger power ratings can be achieved by
connecting modules of the same rating in parallel (derating will be necessary).
When operated in parallel, sharing reactance will be required.
Each module has three-a.c. phase, one d.c. negative, and one d.c. positive terminal.

diameter
TB1 – SMPS d.c. connector
SMPS mounting location
40 way ribbon cable - SMPS

A phase (behind shroud) control connection

connector
B phase (behind shroud)
C phase (behind plastic

shroud)
Stop screw (behind busbar)
Earth terminal (behind DC Connections behind

plastic shroud) plastic shroud
Figure 2–20. – DELTA Transistor Module type MVD500-4701
The values given in this section are the absolute maximum ratings for the DELTA transistor modules. As
other components (i.e. controller) are required to form a complete drive circuit, then the ratings arising from
the combined components should be used when sizing a drive.
Page 54
2.10.1 Features
 DELTA transistor modules use insulated-gate, bipolar transistors (IGBTs) to provide low
distortion output;
 Wide range of optional features can be configured;
 Modules fit in the standard DELTA mounting frames and are configured for dirty air
applications;
 Smoothing capacitors provide filtering for the drive d.c. link, in addition to local energy storage
for IGBT switching;
 Output protection against short circuits;
 Auxiliary d.c. link connection plug for connection to the SMPS. The SMPS unit is mounted on
the transistor module;
 Each module includes thermistor protection. When connected to the MV3000e controller the
module is protected against excessive temperature;
2.10.2 Interfaces
 Signals between the controller and transistor module are by a single 40 way, ribbon cable per
module. This cable also carries the supplies for the electronics in the controller;
 An SMPS unit is connected to the transistor module with a 40 way, ribbon cable and a 2 pin,
d.c. connection;
 The a.c. and d.c. power connections have stud terminals and are designed for cable
connection, however maximum sizes for busbar connections to d.c. terminals are provided in
this manual.
2.10.3 External Requirements

 Transistor modules contain smoothing capacitors, which when used in both network and
machine bridge applications, must be ‘pre-charged’. These modules do not have inbuilt pre-
charge circuits. Pre-charge is either via a DELTA rectifier module or external circuitry. Refer to
Section 3: Drive (CDM) Design for external pre-charge guidance;
 The d.c. supply to the transistor module must be within appropriate voltage, current and ripple
limits, and must be ‘pre-charged’;
 When transistor modules are used as network bridges, it is recommended that semi-
conductor fuses are fitted on the a.c. supply on a per module basis.
 These modules must be force ventilated to achieve the specified performance levels.
2.10.4 A.C. Phase Current Ratings

The a.c. phase current ratings, detailed in Table 2–25are limited by the system design. The cooling system,
number of parallel DELTA transistor modules, plus type and configuration of controller, will limit the system
rating. It is NOT possible to achieve these absolute ratings under all operating conditions. Most
combinations of ambient temperature, supply voltage, and switching frequencies will result in a reduced
rating. Refer to GE Power Conversion for specific ratings for different configurations.
Conditions Peak instantaneous Continuous a.c. Continuous a.c.
current rms current rms current
allowing for a allowing for a
1.5 x overload 1.1 x overload
MVD300-3702 636 A 300 A 400 A
MVD300-4602 636 A 300 A 400 A
MVD500-4501 778 A 367 A 500 A
MVD500-4701 778 A 367 A 500 A
Table 2–25. – Absolute Maximum a.c. Phase Current Ratings (network or machine mode)
Page 55
2.10.5 Phase Voltage

The modules are designed for operation on a nominal a.c. supply voltage of:
MVD500-4501: 380 - 525 V
MVD300-3702, MVD300-4602, MVD500-4701: 575 - 690 V
The maximum output phase to phase r.m.s voltage is V d.c./2 for sinusoidal waveforms.
2.10.6 D.C. Link Voltage

DELTA transistor module d.c. voltage ratings are given in Table 2–26. For instance, when a motor is braked
power is returned to the drive and the d.c. link voltage rises. To protect the DELTA transistor modules the
drive is programmed to trip if the d.c. link voltage rises to an excessive level. The overvoltage trip level is
determined by the type of SMPS units fitted. See Table 2–14.
Module Maximum Maximum Voltage Maximum Silicon Overvoltage Trip

Continuous Working (Surge) * Voltage Level for 600 V & 690
Voltage for d.c. link (VCES) V Nominal Supply
Voltage
MVD300-3702 1200 V 1200 V
MVD300-4602 1160 V 1200 V
1700 V See note**
MVD500-4501 875 V 900 V
MVD500-4701 1170 V 1275 V
Table 2–26. – DC Link Voltage & Overvoltage Trip Level
NOTES: * : the maximum surge level is the lesser of the d.c. link capacitor rating and the short circuit test rating
for the IGBT (Insulated-gate Bipolar Transistor).
** : overvoltage trip level is determined by the type of SMPS unit fitted. See Section 3 – Drive (CDM)
Design
2.10.7 D.C. Link Capacitors

Table 2–27 gives the capacitance values for single DELTA transistor modules.
Product Type Voltage Value of Number in Total Total Discharge Time
rating of Capacitor Series Quantity Capacitance (F) (< 50 V d.c.)*
each (F)
capacitor
(V d.c.)
MVD300-3702 450 3
15 7,833
(5 parallel
MVD300-4602 400 paths)
2
MVD500-4501 4700 (8 parallel 16 18,800 5 minutes
paths)
450
3
MVD500-4701 (5 parallel 15 7,833
paths)
* The quoted d.c. link discharge times assume maximum d.c. link operating voltage.
Table 2–27. – DC Link Capacitors For A Single DELTA Transistor Module
Page 56
2.10.8 Thermal Protection

Thermal protection is provided on DELTA transistor modules by a thermistor embedded within each IGBT
module, which is monitored by the MV3000e controller via the DIB.

2.10.9.1 Control Connections
The control terminations for the DELTA transistor module are detailed in Table 2–28. The connectors are
supplied with the product.
Termination Connection Type Description

Connector ‘TB1’ for SMPS & Voltage monitoring
SMPS supply / d.c. feedback 3-way Amp ‘Mat-n-lok’
(Pin 1 = DC+, 2=n/c, 3=DC-)
PCB connector PL3 (from the MV3000 SMPS)
Control signals 2x 40-way Ribbon Connector
PCB connector PL1 (to/from MV3000e Controller)
Table 2–28. – Terminations For Control Circuits On DELTA Transistor Modules
2.10.9.2 Power Connections

Terminations for 3-phase, d.c. outputs and earth/ground are detailed in Table 2–29.
Terminations Connector Maximum cable Size Crimp Size
a.c. terminals 1 x M10 stud per phase 120mm2 (250 MCM) per phase
1 x M10 stud per 150mm2 (300 MCM) per M10 (or 3/8 in) ring
d.c. terminals
connection connection crimps
Earth terminal 1 x M10 bolt

Table 2–29. – Terminations For 3-Phase & d.c.
To achieve the full current rating of the product, it may be necessary to use high temperature cable, see
Section 3: Drive (CDM) Design.
NOTE: The AC and DC Power connections (above) are intended for inter-connection within the enclosure (not
field wiring terminals). Sizes are based on High Temperature Cable up to a maximum allowed
conductor temperature of 125°C (257F).
Examples of high temperature cable are: silicon rubber (e.g. or Nexans type SIWO-KUL) or polyolefin
(e.g. Huber and Schüner type Radox 125).
The recommended grounding for the DELTA is by direct connection.
The d.c. terminals are suitable for a maximum size of busbar at 6.3 mm x 70 mm wide ( 1/4 in x 2. 3/4 in).
Ratings and sizes of busbars are application dependent.
Page 57
2.10.10 Heat Dissipation

The heat dissipation for a DELTA transistor module will vary depending upon the drive system in which it is
used. Refer to the ratings table in Appendix D: MV3000e Drive Selection Charts.
2.10.11 Weight
The weight of each Transistor Module is listed in Table 2–30.
Weight
DELTA Transistor Module
kg lb
MVD300-xxxx 74 163
MVD500-xxxx 71 156
Table 2–30. – Transistor Module Weights
2.10.12 Acoustic Noise

location, air routing and the use of any grills or baffles. See Section 2.11.1.4.
Page 58
MV3000 Air Cooled DELTA MV DELTA Cooling System: High Performance Version (MVC3014-4001)
2.11 MV DELTA COOLING SYSTEM: HIGH PERFORMANCE VERSION (MVC3014-4001)
Figure 2–21. – MVC3014-4001 DELTA High Performance Cooling System
2.11.1.1 Introduction
Each DELTA rectifier and transistor module is principally cooled by a fan located above the module itself.
The fan force cools the DELTA modules by drawing air in through the bottom mounting plate from the
DELTA module heat sink, which is then expelled through a chosen aperture (front, rear or top) to allow a
dirty air configuration.
2.11.1.2 Features
 Common design for use in transistor, rectifier, and reactor modules.
 Single-phase a.c. supply
 Air outlet may be in any of three directions, top front, or back. Two blanking plates are
supplied to blank off the unused apertures.
 The fan assembly may be sealed directly to a suitable opening in the cubicle roof plate
meaning no additional ducting is required.
 Attaches directly to the DELTA upper cross rails, additional fixings only being required to
attach air outlet ducting (application dependant).
 Fan assembly steelwork contains upper guide rails for DELTA module installation.
 Fan impeller may be removed from the front of the cubicle without removing the DELTA
module.
 Motor current & output limit protection.
 Soft start.
 Over temperature protection wired through internal monitoring relay with auto restart
(temperature dependant).
 Line under voltage / phase failure detection.
NOTE: As the fan is an extractor, any leakage is into the ‘dirty air’ path. Care must be taken when ducting the
airflow out of the cubicle as this has a positive pressure differential to the remainder of the cubicle.
Page 59
MV DELTA Cooling System: High Performance Version (MVC3014-4001) MV3000 Air Cooled DELTA
2.11.1.3 External requirements

 One fan support bracket (50Y9743/01) must be used per assembly to provide mechanical
stability to the unit.
NOTE: Failure to fit this bracket may result in mechanical damage.
 As the fan assembly contains moving parts, the air outlet ducting (application dependant)
should prevent access to the unit by using appropriate grills or the ducting itself.
 The fan requires a 230V a.c. supply, which must be suitably protected with appropriate fusing.
rated to the voltage and current potential of the fan.
2.11.1.4 Electrical Characteristics

One cooling system (fan box) is fitted above each DELTA module. For each fan unit:
Supply Voltage : 230 V (single phase)
Supply Frequency : 50 Hz – 60 Hz
Input Power : 500 W
Current (Running) : 2.2 A
Current (Starting) : < 2.2 A
Start-up Time : 6 seconds
Fan Speed : 3740 rpm
Noise Level : 84 - 90 dBA (dependent on ducting/enclosure)
2 Fan Boxes : + 3 dBA
Typical Airflow : 1355 m3/hour (797 cf/min) at 733 Pa (2.9 in H2O)
Weight : 15.0 kg (33.0 lb)
Fan motor over-temperature 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: 250 V a.c.
: 2 A (AC1)
Page 60
MV3000 Air Cooled DELTA DELTA POWER Modules – Dirty Air Ducting 20T1671/01
2.12 DELTA POWER MODULES – DIRTY AIR DUCTING 20T1671/01

2.12.1 Introduction
When the power cooling path is separated from the control enclosure for ‘dirty air’ applications an intake
duct, 20T1671/01, should be fitted. This duct enables air to be drawn through a suitable aperture in the
enclosure rear sheet.
Figure 2–22. – Mounting the ‘Dirty Air’ Intake Duct
2.12.2 Features
 Allows segregation of the cooling path from the control enclosure.
 Enables air to be drawn through a suitable aperture in the enclosure rear sheet.
2.12.3 Interface
The ‘dirty air’ intake duct fixes directly to the underside of the standard module mounting plate using four
M4 screws.
Page 61
Reactors, Inductors & Transformers MV3000 Air Cooled DELTA
2.13 REACTORS, INDUCTORS & TRANSFORMERS

2.13.1 General Description
A variety of reactors, inductors and transformers are available for use in conjunction with DELTA drives.
Further information is given in Section £ - Drive CDM Design. With the exception of the DELTA transistor
module sharing reactors, these components are application specific.
2.13.2 Input Reactor For DFE Drives

The input reactor provides impedance between the a.c. supply and the rectifier module(s). This helps to
reduce the input current ripple, peak currents, harmonics, aids transient voltage protection and fuse
protection.
NOTE: If the system is supplied by an individual transformer of approximately the same rating as the drive
then input line reactors are not required.
Figure 2–23. – DFE Input Line Reactor

2.13.2.1 Features
 The reactor fits directly into the DELTA mounting framework and may be mounted alongside
or underneath rectifier module(s).
 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 DELTA modules.
 The reactor modules may be configured for ‘dirty air’.
 Semiconductor fuses may be mounted on the front of the module
NOTE: The use of semiconductor fuses are strongly recommended in order to protect the input rectifier
bridge module(s)
2.13.2.2 Variations
 Two current ratings are available, 630 and 754A.
 Supplied as an enclosed product, to be used for force cooling
Reactor Part Nominal Current Phase Rreactor Weight

Number Supply Voltage Rating Inductance (mΩ)
kg lb
(V a.c.) (A r.m.s) (µH)
30V6500/10 0 – 690 630 20 0.52 86 189
30V6700/10 0 - 690 740 31 2.66 82 180
Table 2–31. – 3-Phase Input Line Reactors
Page 62
MV3000 Air Cooled DELTA Reactors, Inductors & Transformers
2.13.2.3 Interface
 The airflow path is the same as DELTA modules.
 Cross-rail fixing positions are the same as DELTA modules.
 Phase connections are made by busbar or cable between the rectifier module and reactor.
 The module earth connection is made via M10 stud connection.

 This module must be used with the DELTA Cooling System to obtain the full current rating.
 The reactor requires an additional 250mm (9.84”) of cross rail to attach to the standard DELTA
cross rails – this may increase overall cubicle width.
 An external 230V a.c. supply is required to power the DELTA Cooling System.
 An additional set of air inlet / outlet ducts are required to properly channel the cooling path
using these modules.
NOTE: These reactors will not fit into a 600mm deep cubicle without modification.
2.13.3 D.C. Link Inductor for DFE Drives

This inductor is used in conjunction with the DFE input reactor, to provide a more continuous current into
the machine bridge and reduce the harmonics that the drive imposes on the supply. This item is mandatory
when using three-phase, 6 pulse, rectifier modules.
NOTE: When using twelve pulse rectifier modules the use of an Interbridge transformer replaces the
mandatory requirement for the d.c. link inductor.
Figure 2–24. – DC Link Inductor
These naturally ventilated inductors are used with 6 pulse input rectifiers - see Table 2–32.
Page 63
Current Nominal Approx.

Reactor Order Drive (1.1 x Drive (1.5 x Weight Rreactor
Rating Supply
Number Overload) Overload) (m)
(A r.m.s) Voltage (V) kg lb
33Z0329/10 670 1 x MVD500 380-525 60 132 0.8
33Z0331/10 1004 2 x MVD500 380-525 120 264 0.3
50Z0019/01 1860 3 x MVD500 380-525 170 374 0.2
50Z0055/04 2295 4 x MVD500 380-525 TBA 0.4
50Z0055/05 2850 5 x MVD500 380-525 310 682 0.3
50Z0050/07 3405 6 x MVD500 380-525 TBA
50Z0038/01 423 1x MVD300 1 x MVD300 690 100 220 1.2

2 x MVD300
50Z0038/02 846 2 x MVD300 690 160 352 0.6
1 x MVD500
3 x MVD300
50Z0038/03 1270 3 x MVD300 690 190 419 0.4
2 x MVD500
4 x MVD300
50Z0057/01 1660 4 x MVD300 690 210 462 0.6
3 x MVD500
5 x MVD300
50Z0057/02 2075 5 x MVD300 690 260 572 0.5
4 x MVD500
6 x MVD300 0.4
50Z0057/03 2485 6 x MVD300 690 325 715
5 x MVD500
Table 2–32. – DC Link Inductors – Weight & Resistance
2.13.4 Losses
Power loss = Idc² x Rreactor x 1.3 Watts
Where Rreactor is in ohms

Idc is in amperes.
Page 64
2.13.5 Interbridge Transformer For DFE Drives

When using DELTA rectifier modules in a 12-pulse DFE drive, it is mandatory that an interbridge transformer
replaces the d.c. link inductor. In addition to performing the same functions as a d.c. link inductor, the
interbridge transformer forces sharing between the two rectifier bridges (one supply phase-shifted by 30°).
These naturally ventilated transformers are used with 12 pulse input rectifier systems - see Table 2-14.
Reactor Drive (1.5 x Drive (1.1 x Nominal Approx. Weight Rreactor

Order Overload) Overload) Supply (m)
Number Voltage (V) kg lb
33Z0352/10 1 x MVD500 380 - 525 52 114.6 1.5

33Z0354/10 2 x MVD500 380 - 525 65 143 0.6
50Z0021/10 3 x MVD500 380 - 525 130 286 0.25
50Z0043/01 1 x MVD300 1 x MVD300 690 110 242 2.5

50Z0043/02 2 x MVD300 2 x MVD300 690 160 352 1.0
1 x MVD500
50Z0043/03 3 x MVD300 3 x MVD300 690 190 419 1.0
2 x MVD500
50Z0063/04 4 x MVD300 690 NA 0.8
50Z0063/01 5 x MVD300 4 x MVD300 690 170 374 0.6
3 x MVD500
50Z0063/02 6 x MVD300 5 x MVD300 690 215 473 0.5
4 x MVD500
50Z0063/03 6 x MVD300 690 NA 0.4
Table 2–33. – Interbridge Transformers – Weight & Resistance
2.13.6 Losses
Power loss = Idc² x Rreactor x 0.325 Watts
Idc is in amperes.
Page 65
2.13.7 Input Reactor For AEM Drives

The input reactor provides the impedance between the a.c. supply and the PWM generated voltage of the
network bridge. This impedance is required to allow the network bridge to provide the correct voltage
vector output that will generate a sinusoidal current with a very low harmonic content to the supply
voltage.
2.13.8 Shunt PWM Filter For AEM Drives

The PWM filter provides the correct shunt path to attenuate the PWM harmonics generated by the
transistor bridge. These filters are tuned to the switching frequency of the network bridge, with a
combination of resistance, capacitance and inductance.
2.13.9 AEM & Machine Bridge Sharing Reactors

To allow equal load sharing between DELTA transistor modules which are connected in parallel, it is always
necessary to fit additional reactance in the three-phase connection of each parallel module. Two variants
are available, a low power type for use with the MVD300 products and a high power type for use with the
MVD500. Dimensioned drawings of these reactors are included in
Figure 2–25. – Low power sharing reactor 31V5500/10 Figure 2–26. – High power sharing rector 50Z0126/01
for fitting under MVD300 DELTA in air cooling path for stand alone placement
2.13.9.1 31V5500/10 Sharing Reactor Features

 Designed to fit directly below a DELTA module and is ventilated by the DELTA cooling system
 Allows airflow to be in one of two directions (underside or rear), a blanking plate is provided to
cover the unused aperture.
 Able to be used as a transistor bridge sharing or output reactor, or as an input reactor for the
rectifier bridge (application and power rating dependant).
 Attaches to the standard DELTA cross rails, directly below the module to which it is connected.
 Suitable for ‘dirty air’ applications through sealing the rear face to a suitable opening in the
cubicle rear sheet and blanking off the underside face.
 Units available to complement both voltage ratings of DELTA modules, 380-525V and 575-
690V a.c.
2.13.9.2 31V5500/10 Interface

 Bolts directly below the module to which it is connected, and is supported by the DELTA cross
rails from pre-drilled fixings.
 Electrical connections are by two sets of terminals, one through stud terminals located on the
front face of the module and the other by busbar connection on the underside of the reactor.
 The electrical connections are not polarity sensitive, meaning either set of terminals may be
used as input or output connections.
 Air entry is through either the back or underside of the module.
Page 66
2.13.9.3 31V5500/10 External Requirements

 If airflow is through the rear of the reactor module, care must be taken to ensure that the
reactor coils are not accessible through the rear of the cubicle as they expose high voltages.
An additional blanking plate is required in this instance to seal the underside air inlet aperture.
2.13.9.4 50Z0126/01 Sharing Reactor Features

 Designed for installation within the cubicle adjacent to the DELTA module..
 Able to be used as a transistor bridge sharing or output reactor, or as an input reactor for the
rectifier bridge (application and power rating dependant).
2.13.9.5 50Z0126/01 Interface

 Item width allows adjacent fitting at a pitch similar to the DELTA module.
 Electrical connections are by two sets of terminals, located at the front of the module
 The electrical connections are not polarity sensitive, meaning either set of terminals may be
used as input or output connections.
Reactor Order Design Current Reactance Weight Rreactor

Number Rating (A) (µH) kg lb (m)
31V5500/10 Air-cored 414 20/phase 39.5 (87) 0.78
50Z0126/01 Iron-cored 643 10/phase 30 (66) 0.26
Table 2–34. – Sharing Reactor Details
2.13.9.6 Losses
Power loss = 3 x Iac² x Rreactor Watts
Iac is in amperes.
Page 67
Fan/Contactor Supply Transformer MV3000 Air Cooled DELTA
2.14 FAN/CONTACTOR SUPPLY TRANSFORMER

2.14.1 Standard MV DELTA Cooling System
The transformer outputs are for the MV DELTA Cooling System at 230 V, single phase a.c. and the pre-
charge contactor supply at 110 Va.c.
2.14.1.1 Transformer Details

The fan and contactor supplies (MV DELTA Cooling System) are isolated from the primary of the transformer.
Part Number MV3FTX1306A4 MV3FTX1865A4 MV3FTX1306A6 MV3FTX1865A6

Supply Voltage 380V – 480V 380V – 480V 525V – 690V 525V – 690V
Maximum Number 1 2 1 2
of Fan Boxes
a) Primary Fuse 10A 16A 10A 10A
(IEC) Type gG
b) Primary Fuse 10A 12A 8A 10A
(UL/CSA) Type J
Fan Supply Rating 4A 6A 4A 6A
(@230 Va.c. 50Hz)
Fan Secondary 7A 10A 7A 10A
Fuse
Contactor Supply 386VA 485VA 386VA 485VA
(@110 Va.c.)
Weight in kg (lb) 23 kg (50.6 lb) 27 kg (59.5 lb) 23 kg (50.6 lb) 27 kg (59.5 lb)
Table 2-35. – Electrical Specification for Supply Inputs & Outputs
NOTES:
Supply Voltage (MV3FTXxxxxA4) : 380/415/440/480 V (Selected by tap changes)

(MV3FTXxxxxA6) : 500/525/600/660/690 V (Selected by tap changes)
Supply Tolerance : ±10% from nominal, +15% for 0.5 to 30 cycles to

IEC 60146-1-1
Nominal Supply Frequency : 50 Hz/60 Hz

Frequency Variations : 45 - 63 Hz
Terminations : Screw Terminal Block to accept 0.5 - 2.5 mm²

(20 - 14 AWG) cable
NOTE: Use a consolidated crimp for smaller sized
wires.
Insulation Test Voltage : 3.0 kV between primary and secondary

(a.c. rms for 1 minute) : 3.0 kV between windings and case earth/ground
Further insulation tests at these voltages may degrade the insulation barriers. Customers should NOT
repeat this level of testing.
Page 68
MV3000 Air Cooled DELTA INSTALLATION ACCESSORIES (ELECTRICAL)
2.15 INSTALLATION ACCESSORIES (ELECTRICAL)

2.15.1 Screened Ribbon Cables
Units covered: MVS3020-40xx.
Most control connections in the DELTA drive are made with screened ribbon cables. The 16 way and
50 way ribbon cables for connecting the mains Voltage Monitor and I/O termination panel respectively are
supplied with those units.
The length of the 40 way ribbon cables to connect the DELTA transistor modules to the controller are
application specific, and should be determined during the enclosure design stage. See Section 3 - Drive
(CDM) Design.
NOTE: Only ribbon cables supplied by GE Power Conversion must be used. This is to ensure that the screen is
of a suitable construction and performance, enabling the clamps described in See Section 2.15.2 –
Ribbon Cable Clamps.
These cables are available pre-terminated in a range of lengths - from 0.7 m to 3.0 m, (27.5 in to 118.1 in) in
increments of 0.1 m (4 in).
Part Number Length Part Number Length
MVS3020-4007 0.7 m (27.5 in) MVS3020-4019 1.9 m (74.8 in)
MVS3020-4008 0.8 m (31.5 in) MVS3020-4020 2.0 m (78.7 in)
MVS3020-4009 0.9 m (35.5 in) MVS3020-4021 2.1 m (82.7 in)
MVS3020-4010 1.0 m (39.4 in) MVS3020-4022 2.2 m (86.6 in)
MVS3020-4011 1.1 m (43.3 in) MVS3020-4023 2.3 m (90.6 in)
MVS3020-4012 1.2 m (47.3 in) MVS3020-4024 2.4 m (94.5 in)
MVS3020-4013 1.3 m (51.2 in) MVS3020-4025 2.5 m (98.4 in)
MVS3020-4014 1.4 m (55.2 in) MVS3020-4026 2.6 m (102.4 in)
MVS3020-4015 1.5 m (59.0 in) MVS3020-4027 2.7 m (106.3 in)
MVS3020-4016 1.6 m (63.0 in) MVS3020-4028 2.8 m (110.2 in)
MVS3020-4017 1.7 m (66.9 in) MVS3020-4029 2.9 m (114.2 in)
MVS3020-4018 1.8 m (70.9 in) MVS3020-4030 3.0 m (118.1 in)
Table 2–36. – 40-Way Screened Ribbon Cable Range
2.15.2 Ribbon Cable Clamps

Units covered: MVS3017-4001
MVS3018-400x
MVS3019-4001
To ensure good signal integrity, the screen of each ribbon cable should be clamped at both ends to the
component / drive chassis or enclosure steelwork. 16 way and 50 way ribbon cable clamps are only
available to clamp single ribbon cables. 40 way ribbon cable clamps are available to clamp up to six ribbon
cables.
Part Number Description
MVS3017-4001 16 way ribbon cable clamp, one cable
MVS3018-4002 40 way ribbon cable clamp, two cables
MVS3018-4003 40 way ribbon cable clamp, three cables
MVS3018-4004 40 way ribbon cable clamp, four cables
MVS3018-4005 40 way ribbon cable clamp, five cables
MVS3018-4006 40 way ribbon cable clamp, six cables
Table 2–37. – Ribbon Clamp Range
Page 69
INSTALLATION ACCESSORIES (MECHANICAL) MV3000 Air Cooled DELTA
2.15.3 Keypad Mounting Kit

Unit covered: MVS3001-4001
This kit allows the Drive Data Manager TM to be mounted to the vertical face of the drive enclosure.
Information is provided with the kit, detailing its specification and fitting instructions.
2.16 INSTALLATION ACCESSORIES (MECHANICAL)

2.16.1 DELTA Module Mounting Frames
The DELTA module mounting kit is a framework of cross members and brackets, which when installed in an
enclosure, provide support and fixing points for the modules. It is suitable for installation into standard
Rittal TS8 series enclosures.
The DELTA module mounting frames include four side supports and three cross members, complete with
fixing screws. Four frame widths are listed. The frames are supplied in a kit form. Lower guide plates are
also included with the kits.
2.16.2 Variations
The mounting kits are based on 600 mm (23.6 in) and 800 mm (31.5 in) deep enclosures. For each of these
depths there are four widths available:
 600 mm (23.6 in) - to support up to two DELTA modules;

 800 mm (31.5 in) - to support up to two DELTA modules;
 1000 mm (39.4 in) - to support up to three DELTA modules.
 1200 mm (47.2 in) – to support up to four DELTA modules.
The detailed part references for the DELTA module mounting frames for installation in Rittal TS8 enclosures
are listed in Table 2–38.
Part Number Number Enclosure Enclosure Frame Weight

of DELTA Width Depth kg (lb)
Modules (mm) (mm)
MVD-TS-4011 2 600 800 13.7 (30.2)
MVD-TS-4012 2 800 800 16.1 (35.5)
MVD-TS-4013 3 1000 800 18.2 (40.7)
MVD-TS-4014 4 1200 800 20.5 (45.2)
MVD-TS-4015 2 600 600 12 (26.4)
MVD-TS-4016 2 800 600 14.5 (32)
MVD-TS-4017 3 1000 600 16.5 (36.3)
MVD-TS-4018 4 1200 600 18.5 (40.7 )
Table 2–38. – DELTA Module Mounting Frame Specifications
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MV3000 Air Cooled DELTA INSTALLATION ACCESSORIES (MECHANICAL)
2.16.3 DELTA Power Modules – Lower Guide Plate Sub Assembly 31V5800/10
2.16.3.1 Introduction
 The lower guide plate provides the bottom guide rails for the DELTA modules and the interface
between the cubicle cooling air duct and the ‘dirty air’ inlet on the DELTA module.
 Supplied with all DELTA Mounting Kits, MVD-TS-401x.
Refer to T1641 – Figure 1-19.
Figure 2–27. – Lower Guide Support Plate
2.16.3.2 Interface
 Attaches directly to the DELTA cross rails using four M5 taptites - no other fixings are required.
2.16.3.3 Compatibility with sharing reactors

Where sharing reactors are fitted, the lower guide plate is not required as the sharing reactor has the plate
as part of its design.
Weight
Part Number Suitable for
kg lb
31V5800/10 All modules 1.2 2.6
Table 2–39. – Lower Guide Support Plate
2.16.3.4 Cubicle Busbars for Rectifier Bridge Modules

Cubicle busbars for Rectifier Bridge Modules are listed in Table 2-20.
Weight
Part Number Suitable for
kg lb
41Y5810/10 GDR721 5 11
41Y5356/10 GDR872 11 24.2
41Y5810/20 GDR1168 15.5 34.2
Table 2–40. – Cubicle Busbars for Rectifier Bridge Modules
NOTE: For current rating see Rectifier Bridge Module specification.
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Standards MV3000 Air Cooled DELTA
2.17 STANDARDS
When installed in a CDM, in accordance with this manual, the DELTA components are designed to comply
with the standards listed below.
2.17.1 Safety
EN 50178 Electronic equipment for use in power installations.
EN 61800-5-1 Adjustable speed electrical power drive systems:
(IEC 61800-5-1) Part 5-1-Safety requirements – Electrical, thermal and energy.
ANSI / UL508C Power conversion equipment.
CAN / CSA C22.2-14 Industrial control equipment, industrial products.
2.17.2 Electromagnetic Compatibility (EMC)

EN 61800-3 Adjustable speed electrical power drive systems:
(IEC 61800-3) Part 3 – EMC product standard including specific test methods.
In particular, this includes the following immunity requirements:

IEC 61000-4-2 Electrostatic discharge 6 kV contact discharge
8 kV air discharge
IEC 61000-4-3 Electromagnetic field 80 MHz – 2 GHz, 10 V/m

2 GHz – 2.7 GHz, 1 V/m
IEC 61000-4-4 Electrical fast 2 kV

transient/burst
IEC 61000-4-5 Surge 1 kV line-line

2 kV line-earth
IEC 61000-4-6 Conducted radio-frequency 150 kHz – 80 MHz, 10 V
2.17.3 Ratings/Performance
EN 61800-2 Adjustable speed electrical power drive
(IEC 61800-2) systems:
Part 2 – General requirements - Rating specifications for low voltage
adjustable frequency power drive systems.
EN 60146-1-1 Semiconductor converters. General requirements
(IEC 60146-1-1) and line commutated converters.
Page 72
T1689 Technical Manual Rev 0007 Drive (CDM) Design
3. DRIVE (CDM) DESIGN
WARNING
 Ensure that access to rotating arts of fans is prevented.
 Air used to cool the product is unfiltered. Air ejected from the product may contain foreign particles. Air
outlets should be arranged to deflect the air away from the eyes.
 The combined audible noise emitted by fans in an installation can be greater than 70 dB(A), dependent on
the air flow path.
Measure the audible noise in the installation.
When the audible noise level exceeds 70 dB(A), appropriate warning notices should be displayed.
3.1 INTRODUCTION
This section is aimed primarily at the designer of the ‘Complete Drive Module’ (CDM). The design requires
detailed Engineering knowledge and circuit design experience. The data given here cannot replace that
knowledge, but is intended to give additional information for particular requirements for the MV3000 DELTA
products.
Design data for other parts of the Power drive system can be found in Section 4: PDS Design.
If the drive (CDM) has been supplied as a complete item of cubicalised equipment, then this chapter can be
ignored.
Page 73
Drive (CDM) Design T1689 Technical Manual Rev 0007
Introduction MV3000 Air Cooled DELTA
3.1.1 How To Use This Section
Figure 3–1. – Organisation Of Drive (CDM) Design Section

The sequence for this section is based on the recommended work flow shown in Figure 3–1.
Page 74
MV3000 Air Cooled DELTA initial DELTA Kit list
3.2 INITIAL DELTA KIT LIST

The customer’s requirements and initial discussions with the local supplier’s Sales Office should have
established:
 The overall configuration of the drive;

 The ratings;
 An initial list of the DELTA modules and associated components;
 This initial list may need to be modified during the design of the drive,
 Additional components will have to be specified and purchased to complete the CDM.
3.3 ELECTRICAL DESIGN PRINCIPLES

Using the DELTA modular components allows many different configurations. Some typical circuit diagrams
are shown in Appendix B: Electrical Connection Diagrams for both power and control connections.
In addition to following good electrical design practice, the following sections give details on specific
requirements for the DELTA power and control modules.
See Figure 3–1 for the location of detailed design information and recommended work flow.
3.3.1 Electrical Safety

3.3.1.1 CDM Over-Current Protection
The CDM will be connected to hazardous voltages and high energy supplies. In common with all high power
electrical installations, the available short circuit power of the final installation must be considered when
designing the CDM.
The breaking capacity of over-current protective devices (e.g. fuses and breakers), the short-circuit current
rating of cables and components, and the layout and strength of the enclosure must be co-ordinated and
be capable of protecting personnel under normal and fault conditions.
The CDM must be protected against over-current from all energy sources. These sources are usually:
 The main supply (network);

 Machines (e.g. generators or motors regenerating energy);
 Auxiliary power supplies;
 Control power supplies;
 I/O signals.
Over-Current Protection Of DELTA Modules

DELTA modules use solid state (semi-conductor) transistors to regulate the a.c. current. In common with all
products using semiconductor devices, it is possible for two series transistors to fail and create a short-
circuit. This short-circuit will be fed from both the supply and the CDM’s d.c. link capacitors. To limit
consequential damage to other parts of the DELTA module and CDM, external protection is required. This
protective device will be unable to prevent the failure of the short circuit device.
The DELTA modules have been assessed against “breakdown of components” to IEC61800-5-1 and UL508C
when used with high speed fuses (also called semiconductor fuses). These recommended fuses are given in
the specification section for each module.
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Electrical design principles MV3000 Air Cooled DELTA
3.3.1.2 Segregation Of Persons From Hazardous Voltages

The CDM must be designed in such a manner that persons are not exposed to hazardous voltages during
normal or fault conditions.
The control connections in the DELTA modules and the controller are designed with “protective separation”
from hazardous voltages. The construction of the CDM must be done in such a manner that this protective
separation is not invalidated.
Therefore:
 Separate extra low voltage wiring and components from:

 high voltage components and cabling;
 high power components and cabling (separation still required during arc-faults);
 Design the CDM so that items that need to be monitored or adjusted while the equipment is
live can be accessed without risk.
 To ensure safe access during commissioning, maintenance and fault finding:

 The points of electrical isolation/disconnection of all sources of supply must be clearly
identified;
 Ensure segregation of wiring on the live side of such points from all other items in the
CDM;
 Cover (to the required IP rating) and label all circuits that are permanently live;
 Where it is necessary to measure hazardous voltages during commissioning or fault
finding, ensure that this can be done without risk;
 When the CDM is isolated (electrically safe work condition) from the electrical supplies,
ensure there is access to points that require measurement to prove the absence of
voltage. In addition to supply connections, this must include the d.c. link connections to
the transistor modules as these contain a stored electrical charge.
3.3.1.3 Protection Against Arcing Faults (arc-flash)

Catastrophic failure of equipment fed from high power supplies may cause arcs. This arcing can result in
the ejection of air and particles at high pressure and high temperature. Therefore, arc containment should
be taken into account in the design of the enclosure. Refer to the relevant national or international
standards for further data.
3.3.1.4 Electrical Interference / Electromagnetic Compatibility (EMC)

The CDM has high power, high speed switching devices and sensitive electronic controllers in close
proximity. Care must be taken to avoid these interfering with each other, adjacent equipment or
installations.
The adjacent equipment or installations must also be prevented from interfering with the CDM or DELTA
modules.
Immunity Level Of The DELTA Modules & The CDM

The individual DELTA modules and MV3000 control components comply with the immunity requirements for
an industrial environment (‘also known as ‘second environment’) according to IEC 61800-3 or IEC 61000-6-2.
When all of the equipment used in the CDM also meets this immunity requirement (see also Section 2.17.2:
Electromagnetic Compatibility (EMC)) and after a relevant assessment of the complete CDM, this should also
comply with the requirements for the industrial environment.
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MV3000 Air Cooled DELTA Electrical design principles
Emission Levels From The CDM

DELTA modules are open frame units that contain electrically noisy waveforms. The actual emission levels
from the CDM will be heavily dependent on the selection and layout of all the components in the CDM.
Some general guidance is given here:
If no special measures are taken, the drive may have to be classified as Category C4 according to
IEC 61800-3.
Compliance with IEC 61800-3 will require radio-frequency filtering on the main supply of AEM drives and
may be required on the DFE drives. If an auxiliary supply is used, it is likely to require some filtering because
this emission category has a lower emission limit for ports with rated current below 100 A. Some care with
shielding and segregation will also be required. An “EMC style” enclosure may be required.
The “industrial” limit of IEC 61000-6-4 / EN 61000-6-4 is identical to IEC 61800-3 Category C2. This will
require filters with high attenuation on both main power and auxiliary connections. It will also require
significant care with shielding and segregation within the enclosure, which is beyond the scope of this
manual.
Due to the very high power rating, it is extremely unlikely that the CDM would be used in an environment
that requires compliance with the residential emission limits of IEC 61000-6-3 / EN 61000-6-3 or IEC
61800-3 Category C1. Compliance with such a limit is very difficult to achieve on equipment with such high
power rating.
3.3.1.5 Designing The CDM To Comply With International Standards

The DELTA modules have been designed and evaluated against the international standards shown in the
specification section. The designer of the CDM is responsible to ensure that the design, assembly and
testing of the CDM complies with the relevant standards.
The following data has been provided where the individual module depends on particular features of the
CDM for compliance against the named standard.
System Design Requirements To Satisfy UL 508C

UL 508C has a number of requirements that must be satisfied when designing the CDM. The following have
been highlighted as they may be missed when designing the CDM to comply with UL508C:
 Motor over-temperature monitoring is required. See the data on the User I/O panel for
available inputs for the CDM;
 Semiconductor fuses should be located within the same enclosure as the DELTA module;
 The integral short circuit protection provided by the DELTA module does not provide branch
circuit protection. Branch circuit protection must be provided in accordance with the National
Electric Code and any additional local codes.
3.3.2 Electrical Design For Reliability

3.3.2.1 Bonding
In additional to electrical safety bonding, functional bonding of the enclosure/s and components is
mandatory.
Page 77
Overview of Components Required MV3000 Air Cooled DELTA
3.4 OVERVIEW OF COMPONENTS REQUIRED

The DELTA product range is a modular component sub-system that requires installation into an enclosure
with additional components to form a Complete Drive System (CDM). These additional components are
specified and purchased by the CDM designer / builder in addition to the parts supplied by GE Power
Conversion.
3.4.1 DELTA Modules & Associated Components (DELTA Kit List)

A typical list will include:
Item Drive Type Component Description Notes

Air cooled transistor modules Required
All versions
Dynamic Braking Units (DBs) Optional
Power modules
Rectifier fed
Air cooled rectifier modules Required
(DFE)
Required for
Transistor module current sharing reactor parallel
All versions modules
Filter reactors (see Filters) Required
d.c. link reactor Optional
Wound components Required for

Rectifier inter-bridge reactor parallel
Rectifier fed
rectifiers
(DFE)
Required for
Rectifier current sharing reactor parallel
modules
All versions Input line reactor Required
MV3000e Controller
MV3000e User I/O Termination Panel Required
All versions
MV3000e Switch Mode Power Supply(s) (SMPS)
Control components Drive Data Manager (Keypad) Optional
Rectifier fed
Optional
(DFE) Mains Voltage Monitor (MVM)
AEM Required
Ribbon cables
Accessories All versions Required
Ribbon cable clamps
DELTA power module mounting frame Required
Module Cooling Fans Required
Mechanical All versions ‘Dirty Air’ Intake Duct Optional

Required for
EMC Module to Module Link Plate parallel
modules
All versions Machine protection DV/DT Filter Optional
Filters AEM PWM Filter Required
AEM
Common mode filter Optional
Page 78
MV3000 Air Cooled DELTA Overview of Components Required
3.4.2 Items To Be Supplied By The CDM Designer / Builder

The following parts are also typically necessary to assemble the CDM:
To include gland plates, baying brackets, panel earth continuity,

Enclosure(s) All versions apertures for cables/vents etc.
(Rittal TS8 enclosures are recommended)
For mounting:
 control components;
Internal Panels and  auxiliary components.
All versions
Brackets
Mounting frame interface brackets (if Rittal TS8 enclosure is not used).
Additional panels for earthed ribbon cable highway.
Cables
Bus ways (busbars)
Power Connections All versions
Customer terminals
Gland plates
Auxiliary supplies
Internal discrete wiring
Control All versions
Control supplies (In addition to SMPS if required)
Terminal blocks (In addition to I/O panel if required)
Options include:
Filters All versions  PWM filter;
 DV/DT filter.
Air cooling system, see Section 3.7.8
Cooling system All versions
(including enclosure ventilation fans etc.)
Options include:
Wound Components
 AFE main reactor;
(other than sharing All versions
 Filter reactors;
reactors)
 Control supply transformers.
All cables and wiring other than the ribbon cables supplied with the
Control cables All versions
DELTA components, or separately supplied by GE Power Conversion.
To provide protection for:
Fuses / circuit breakers /  AC power;
All versions
isolators  DC power;
 Auxiliary supplies.
For DC Fed
DC link Pre-charge circuit Required for drives that do not use DELTA Rectifier modules.
& AEM
DB resistors All versions
To include, for example:
 All screws, bolts and washers that are not provided with the
Fixings / labels / crimps All versions DELTA products;
 User connection identification;
 All crimps for power and control wiring.
To maintain communication with the controller in the absence of the
24 V d.c. power supply All versions
main power supply. (optional)
Enclosure Heaters All versions To protect against low temperature and/or condensation.
Transient protection All versions To protect the equipment against transient conditions
Earth Fault monitoring AEM
To include:
Temperature monitoring /
All versions  Enclosure ambient;
protection
 Cooling system.
Test equipment All versions To test and commission the CDM
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Mechanical Design principles MV3000 Air Cooled DELTA
3.4.3 Items To Be Supplied By The PDS Designer / Builder

To complete the power drive system, examples of these are:
Machine (motor or For all versions To include machine monitoring, such as an encoder
generator) or
controlled
load/source
Interconnection / For all versions
supply cables
Transient / over- For all versions
voltage protection
Earth fault protection For AEM
Supply over-current For all versions
protection, etc.
Where there is a specific requirement for any of these items to be used with DELTA modules, some
guidance on the design of these components is given in Section 4: PDS Design. The design and specification
of these components is the responsibility of the PDS designer.
3.5 MECHANICAL DESIGN PRINCIPLES

After the selection of the electrical components the mechanical arrangement into an enclosure is required.
3.5.1 The Equipment Must Be Enclosed

The DELTA modules and associated components are usually ‘open type’ products (IP00) for installation into
an enclosure.
 The front of the DELTA power module is supplied with terminal shrouds. These provide limited
protection for personnel against accidental direct electrical contact;
 The transistor power modules contain a d.c. link capacitor bank. This capacitor has resistors
fitted to discharge it to below 50V in less than 5 minutes (see specification for the times for
individual modules) after the isolation of the supply;
 The electrical components on rear and side of the power modules are not shrouded. They will
need to be enclosed to prevent accidental contact.
All wound components (e.g. d.c. link reactor, inter-bridge transformer, input line reactors) must be installed
in a steel enclosure to prevent:
 Contact of persons against hazardous voltages and temperatures. These are usually supplied
as IP00 (open components);
 Emission of magnetic and electrical noise.
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MV3000 Air Cooled DELTA Mechanical Design principles
3.5.1.1 Essential Requirements For The Enclosure
 Protection of personnel against direct contact of hazardous parts:
 Electrical – all hazardous live parts, e.g. the DELTA module power terminals;
 Thermal - hot parts - on the DELTA module, the heatsink and busbars. For the system these
plus high temperature cables, reactors etc.;
 Moving parts – in the DELTA none; in the CDM the impellers of the cooling fans;
 Energy hazards – Electrical (including the stored energy in the dc capacitor bank, which takes
up to five minutes to discharge), the rotational mechanical energy in the fans (this stops within
20-30 seconds) and the energy that could be supplied into the enclosure during catastrophic
failure of any part of the system ‘arc-containment’.
 The enclosure strength, over-current protection, and supply fault levels must be co-ordinated and
sufficiently robust to contain the arc-fault energy. The enclosure must be of sufficient strength to
support the combined weight of items inside and also contain faults and provide protection.
 Protection of the enclosed equipment against the environmental conditions:
 Mechanical impact against the enclosure;

 Shock and vibration;
 Environmental control against the ingress of water, dust and solid objects;
 Condensation and pollution control to meet the requirements of Pollution Degree 2 (see
Section 2: Specification);
 Sufficient strength of supports and enclosure (and lifting arrangement) for environment of the
final installation and transport.
 Reduction of electrical radiated emissions from the drive and protection of the drive from radiating
sources (see Section 3.3.1.4: Electrical Interference / Electromagnetic Compatibility (EMC))
 Allow access in a safe way for operation, adjustment and maintenance:
 This must also allow access to prove ‘absence of voltage’ (proving dead) after safe isolation
(e.g. Lock-out, Tag-out).
3.5.2 Impact of Electrical Safety On Mechanical Design

The mechanical design must not be detrimental to the electrical safety or electrical function of the CDM.
Follow the instructions on electrical design given in Sections 3.3.1: Electrical Safety to 3.3.2: Electrical Design
For Reliability and 3.5.3: Electrical Bonding to 3.5.4: Routing & Segregation Of Cables.
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Mechanical Design principles MV3000 Air Cooled DELTA
3.5.3 Electrical Bonding

In additional to electrical safety bonding, functional bonding of the enclosure/s and the components
located in these is mandatory to ensure that the CDM performs correctly.
This bonding is especially important between the control components and the DELTA power modules.
 A continuous bond of earthed metal is required from all the DELTA transistor modules to the
controller:
 This is usually achieved by a wide steel plate that provides a low inductance path between
modules and to the controller. The high frequency currents creating a small voltage
difference across this bond.
 Also bond the DELTA power modules together using the bonding plate supplied with the
DELTA modules to form a single metal highway across the front of the DELTAs. This
arrangement forms a ground plane (low resistive and low inductive path) against which the
control ribbon cables must be run (see Section 5.14: Fitting Earth Bonding Plates).
 It is unnecessary to extend this bonding highway to the rectifier modules.
 Additional low inductance paths are beneficial.
 The DELTA mounting frames when directly fastened (metal-to-metal) to the unpainted
enclosure frame also aid this bonding.
 Screened control cables also provide a low inductance path, but without adequate parallel
metal-to-metal component bonding, the signals carried will be disrupted by noise currents.
 The installer of the modules must complete the bonding path (and cable routing) to the
controller. These parts are not supplied with the modules as the exact position of the
controller is not fixed.
 The control enclosure must also be bonded to the power modules enclosure:
 Use high frequency techniques.

 Use multiple paths.
 Bond all of the enclosures together.
 Converters contain high leakage current equipment so currents will flow between adjacent
enclosures.
 To minimise the voltage created by these currents, a low impedance, low inductance
path (some of these currents are at high frequency) must be provided. This is usually in
addition to any safety bonding.
 This bonding must be by direct metal-to-metal contact, not by braids or cables to make
a ‘continuous enclosure’.
 Bond all of the enclosure’s panels together.
 This bonding must be by direct metal-to-metal contact, not by braids or cables to make a
‘continuous enclosure’.
 Bond all the cable gland plates to the enclosure.
 To continue the screening effectiveness of screened or armoured cables, you must bond to
the ground plate by a 360° degree connection.
 The gland plate must then be connected directly to the enclosure walls, or to metal framework
to which the outer walls are electrically bonded.
 Gland plates must not be spaced off, even on metal pillars or bars.
 Direct metal-to-metal contact across a large surface area must be achieved for low
inductance continuity.
 This bonding is required in addition to any electrical safety bonding.
 Both control and power cabling gland plates must be directly bonded.
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MV3000 Air Cooled DELTA Mechanical Design principles
 Provide a return path for noisy electrical components.
 EMC filters (if fitted) shunt the noise current from the power connection to the local ground. A
low inductance path to the noise source e.g. DELTA transistor module must be provided. So
should be mounted to a metal panel, which is bonded to the metal framework of the DELTA
power modules.
 Bond control components together.
 For best EMC practice the MV3000e controller, I/O panel and MVM unit (if fitted) must be fitted
to the same unpainted, conductive panel.
 A low inductance, direct electrical bond is required and so an unpainted panel (e.g. plated or
galvanised,) must be used.
 See Section 3.6.8: Position Of Control Components for the recommended layout.
3.5.3.1 DELTA Module Earthing/Grounding Requirements

The steel mounting frame into which DELTA Rectifier or Transistor modules are mounted can be used as the
earthing method provided that:
 The earth continuity is checked between the module earth terminal and the main enclosure earth
point.
 The earth continuity must be equal to or less than 0.02 Ω (as stated by IEC 61800-5-1 clause
4.3.5.3), with at least 10 A supplied from a source of not more than 24 V, measured between
the M10 earth terminal and the enclosure earth stud.
 If this value is not achieved then the module must be separately earthed via the M10 earth
terminal at the lower front face of the modules. The M10 earth terminal is identified on the
module by the symbol shown in Figure 3–2.
Figure 3–2. – Protective Earth (ground) Symbol to IEC 60417 (Symbol 5019)
3.5.4 Routing & Segregation Of Cables
3.5.4.1 Segregation Of High Current Or Electrically Noisy Cables To Other Circuits
 Screen the control ribbon cables;
 Bond the screen at both ends;

 See Section 2.15.1 – Screened Ribbon Cables for ribbon cables;
 The ribbon cable bonding clamp at the DELTA transistor module end is provided with
the transistor module;
 The ribbon clamp for the controller end must be separately ordered. See Section 2:
Specification.
 All Analogue I/O and communications cables must use screened cable. The screen must be
connected to earthed metalwork using an uninsulated, metal ‘p-clip’;
 Keep apart sensitive control wiring and power cables;
 Maximise the distance between control and power cables;

 Do not run the control wiring in parallel with power cables;
 a.c. power cables between DELTA transistor modules and filters are especially noisy.
Page 83
InItial CDM ARRANGEMENT MV3000 Air Cooled DELTA
3.5.4.2 Routing Of Control Cables

Ribbon cables between control components and between control components and the DELTA modules
must be:
 Run along earthed metal, not through ‘mid-air’.

 Select the cable lengths to allow this routing, refer to Section 2: Specification for
available lengths.
 Segregated from power cables and from external plant wiring.
 Not extended. If the ribbons are too long, fold the excess length backward and forward (do
not roll) to make a low-inductance bundle.
3.5.4.3 Routing Of Power Cables

Minimise large current loops e.g. High current components close together, cables should be arranged in tri-
foil, and DC+ run immediately against DC-.
Figure 3–3 Trefoil Cable

Avoid eddy currents in metal work by passing the current flow and return conductors through the same
hole e.g. DC+ with DC-, or R and S with T for 3phase cabling.
Position high power components together to minimise interconnection cable lengths to reduce cable power
loss, radiated (RF) noise and cable costs.
Ensure that the power cabling to high frequency (hf) shunt filters (e.g. PWM filter) does not cause the hf
current to bypass that component:
 Run the series current path through the filter, see Figure 3–4. Any parallel connections must
use low inductance techniques such as flat and wide busbars, short trefoil cables or parallel
cables.
50/60Hz HF HF 50/60Hz
(SERIES
CONNECTED)
HF
(PARALLEL
CONNECTED)
FILTER
Poor filtering as HF Current bypasses filter.
50/60Hz HF
HF 50/60Hz
(SERIES
CONNECTED)
(PARALLEL
CONNECTED)
HF
FILTER
Good filter performance
Figure 3–4 Cable Routing Effect On Filter Performance
Page 84
MV3000 Air Cooled DELTA InItial CDM ARRANGEMENT
3.6 INITIAL CDM ARRANGEMENT

This section provides guidance for:
 Enclosure sizing;
 Positioning of DELTA components within the enclosure.
Specifications of individual DELTA components can be found in Section 2: Specification.

Further details relating to the assembly processes can be found in Section 5: CDM Assembly.
3.6.1 General Design Considerations

The CDM layout should include sufficient clearance to fit each component. Consideration should be given
to servicing access.
Ensure positions allow removal and replacement of all required modules/components.
 Do not obstruct the DELTA power modules or control components by installing other
equipment in front of them.
When a 600 mm (23.6 in) deep enclosure is used, careful planning is required as there is limited space in
front of the modules for interconnections, door flanges and ventilation.
3.6.1.1 Component Weight

The weight of components must be considered in the CDM design. Most heavy components would be best
located at the base of the cabinet.
3.6.1.2 Thermal Considerations

Position the components with the lowest temperature rating and those dissipating small air losses in the
lowest temperature airflow, e.g.:
 adjacent to the air inlet of the enclosure in an IP21 application;

 adjacent to the air outlet from an air-to-liquid heat exchanger for an IP54 enclosure.
Allow space throughout the enclosure for adequate airflow.
3.6.1.3 Cable Routing

Consider the power cable entry and exit points as this will determine the enclosure’s internal arrangement.
Mechanical support will be required for all cables. Ensure that features are designed into the enclosure to
support cables.
The bend radii of all cables must be respected. Space must be allowed in the design for cables to change
direction.
Access is required to main and control connections of the modules.
For cable segregation, see Section 3.5.4: Routing & Segregation Of Cables.
Page 85
3.6.1.4 Cooling System

Each DELTA module must be cooled by an MVC3014-4001 fan assembly.
This fan assembly is an integral part of the frame system and locates above the DELTA module. Details for
the installation of this fan assembly are in Section 5.5.
Only one fan may be mounted above each DELTA Power Module. Fan support brackets must be fitted to aid
in the load bearing of the unit.
Consider the cooling path within the cubicle, DELTA power modules are designed to be force ventilated from
an air intake at the bottom of the cubicle and vented at the top of the cubicle. Also consider the type of
cooling air required, for instances where ‘dirty air’ is permitted through the DELTA module, a ‘dirty air’ duct is
available.
The fan assembly itself has the ability to channel air out from the front, top or rear; it is recommended that
the airflow outlet be through the top or rear of the drive enclosure.
Adequate clearance for the fan assembly and any required ducting must be considered for installation and
maintenance.
3.6.2 Enclosure Size

See Section 3.9.1: Enclosure (/s) for other enclosure requirements.
3.6.2.1 Depth
DELTA drives require a minimum enclosure depth of 600 mm. Standard DELTA mounting frames are
available for use in 600 mm and 800 mm (23.6 or 31.5 in) deep Rittal TS8 style enclosures.
See Section 2: Specification.
The mounting frames position the DELTA power modules close to the rear of the enclosure. This maximises
the space at the front of the DELTA power modules for interconnections and for mounting SMPS modules
and CDM shrouding.
3.6.2.2 Height
It is usual for DELTA drives to be installed into 1600 mm to 2400 mm tall enclosures. The enclosure height is
application specific and depends on the other equipment fitted around the DELTA modules and the final
installation space requirement. The DELTA module mounting frame may be fitted at any height within the
enclosure, but the height is determined by the following constraints:
 Position of cooling system;

 Location and type of reactors;
 Cable entry;
 Position of auxiliary equipment.
3.6.2.3 Width
The width of the enclosure is predominantly determined by the number of DELTA power modules used in
each bridge (up to a maximum of three per bridge).
DELTA power modules are mounted side by side, on a pitch of 250 mm. If the control components are
mounted into the same enclosure, ensure there is sufficient width for these, to the side of the power
modules.
The horizontal position of the DELTA power modules is determined by the mounting frame.
3.6.3 CDM Installation In Multiple Enclosures

If a CDM is to be installed into multiple enclosures, these must be electrical bonded as detailed in Section
3.3.2.1: Bonding.
Page 86
3.6.4 Position Of DELTA Rectifier Modules

It is recommended that the DELTA rectifier module(s) is mounted on the right hand side of the enclosure
(front view), with enough space to the right of the module for the following:
 Access to a.c. connections (on some variants);

 Access for tidy routing of cables from the a.c. connections;
 Most enclosure doors are hinged on the left, so door interlocked isolators are mounted on the
right of the enclosure.
3.6.5 Position Of DELTA Transistor Modules

DELTA transistor modules are identified by the 40 way connector position they occupy on the controller.
Table 2–10 gives the DELTA designations. For ease of identification, it is recommended that the DELTA
transistor modules are fitted in the same sequence into the enclosure.
3.6.6 Position Of Reactors & Filtering Components

Reactors and other iron-cored components emit strong magnetic fields. When installing these components
ensure that:
 Air-cored reactors have a minimum segregation of 300 mm (12 in) from sensitive components
and control electronics;
 All wound components have an air gap to adjacent steel components to prevent eddy
currents. The minimum recommended gap is 100mm (4”) but smaller distances may be
acceptable if evaluated by the CDM designer.
Iron-cored components (for example an inter-bridge transformer), will usually be mounted on the floor of
the enclosure due to their size and weight.
Sharing reactors are usually fitted adjacent to the DELTA transistor module (typically below) dependant on
cable entry requirements.
Filters are designed to absorb high frequency currents. They must be positioned to have low inductance
connections to the source of the noise and to ensure that the hf current does not bypass the filter. The
effect of cable routing is shown in Figure 3–4.
3.6.7 Position Of Switched Mode Power Supply (SMPS)

An SMPS module is required for each DELTA transistor module.
The SMPS is mounted on the upper front face of the DELTA transistor module, from which it derives a d.c.
power supply.
Page 87
3.6.8 Position Of Control Components

The control assembly must comply with the requirements for electrical bonding given in Section 3.3.2.1:
Bonding. It is also recommended that the components are arranged as shown in Figure 3–5. This will give
good electrical noise immunity and ensure that the ribbon interconnection cables supplied will be of
sufficient length. A dimensioned version of this drawing is included in in Appendix A: Dimensioned
Mechanical Drawings.
The controller should be positioned towards the front of the enclosure to aid access.
Figure 3–5. – Control Component Arrangement
The following should be observed when locating the control components:
 Allow 50 mm (2 in) ventilation space above and below the controller;

 The status LEDs on the controller and I/O panel should be visible;
 Allow access to the plugs, sockets and terminals on the control components;
 Allow sufficient space around the components for the routing and retention of all associated
cables;
 The interconnection ribbon cables available with these units have limited lengths – see Section
3.6.8.1: Control Cabling Requirements.
Page 88
3.6.8.1 Control Cabling Requirements

There are limits to the cable lengths allowed in a DELTA drive. When calculating the lengths of cable routes,
remember the requirements for routing given in Section 3.5.4: Routing & Segregation Of Cables.
To ensure that the maximum cable lengths are not exceeded:
 Ensure that the cable routing distances for the 40 way ribbon cables from the controller to the
DELTA transistor modules do not exceed 3 m (9.8 ft.). Available ribbon cable lengths are given
in Section 2: Specification;
 When used, an optional Drive Data Manager (Keypad) will have to be mounted in a position
which is within the 3 metre (9.8 ft.) cable length of the cable provided. This dimension will
influence controller and DDM position;
 Ensure that the cable routing distance of the wiring from PL12 to the DELTA rectifier module
(or modules) does not exceed 25 m (82 ft.);
 Ensure that the cable routing distance for the 50 way ribbon cable from PL20 on the
controller, to the user I/O termination panel does not exceed 2 m (6.5 ft.). The ribbon cable
provided with the I/O panel is 925 mm (36.4 in) long;
 The ribbon cable provided with the MVM unit is 360 mm (14.2 in) long.
3.6.9 Typical CDM Arrangement
Figure 3–6. – Typical Layout Of CDM (DFE Drive)
Page 89
Component Selection – Cooling System Design MV3000 Air Cooled DELTA
3.7 COMPONENT SELECTION – COOLING SYSTEM DESIGN

3.7.1 Introduction To Cooling System
3.7.1.1 DELTA Power Modules:
 Have the power losses removed by the fan located above the module.
 Requires some forced air flow to provide ventilation for components that are not in the main
air path of the primary cooling fan.
3.7.1.2 DELTA Control Components

 Air cooled, with low power losses.
3.7.1.3 DELTA Wound Components

 Cooling depends on the individual component (see specification chapter).
 Some components e.g. sharing reactors are usually air-cooled.
 Wound components usually have high temperature rating (class H is up to 180°C).
3.7.2 Primary Air Cooling

The main cooling process for the DELTA modules is the MVC3014-4001 High Performance fan that is
located above each of the DELTA modules. The cooling air is drawn in at the base of the DELTA modules, is
drawn over the heatsink(s) within the module, through a fan chamber above the DELTA modules and out
through the fan housing.
Air into the DELTA module can be drawn in directly into the unit or (preferably) routed via ducting from
outside of the enclosure.
The direction of the air out of the fan housing is defined by blanking off the appropriate opening with the
blanking plates provided. The air out can be forwards, upwards or rearwards. Ducting should then be used
to route this out of the enclosure.
To avoid impairing cooling performance the airflow must not be impeded and extra fan assistance should
be installed where significant impedance is introduced by filters or restrictive ducting.
The primary cooling system can use 'dirty' air providing it does not contain corrosive, conductive, or
explosive dusts or gasses, See Table 2–3. – Temperature & Humidity. It can be easily separated from the
control cubicle internal air by ducting the intake and output to the outside of the cubicle. As the cooling fans
draw air through the power device cooling path a negative pressure is developed, so a small amount of
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.
Page 90
MV3000 Air Cooled DELTA Component Selection – Cooling System Design
Figure 3-7. – Side View of Air Path through the Standard DELTA Module System
3.7.3 Secondary Air Cooling

The DELTA modules have a proportion of losses that are removed by the local airflow within the enclosure.
The proportion of losses depends on the ratio of temperatures (module surface temperature-to-air), surface
area and the velocity of air flow. In addition to these stray losses, there is also the power loss from any
component that is not directly by the main cooling fans. These losses and any localised hotspots need to be
removed by the air cooling.
Typical losses for individual DELTA assemblies are given in the Appendix D: MV3000e Drive Selection Charts.
These are for indication only as the exact losses depend on the environmental conditions.
The cooling air temperature and quality should also ensure operation within the environmental conditions
given in Section 2: Specification.
This cooling may be by ventilation through the enclosure or by recirculating the air through a heat-
exchanger.
Page 91
Component Selection – Electrical MV3000 Air Cooled DELTA
3.8 COMPONENT SELECTION – ELECTRICAL

3.8.1 DELTA Power & Control Modules
These are selected as part of the initial kit list (Section 3.2: initial DELTA Kit list), with the description and
specification for these units shown in Section 2: Specification. Some units have a small amount of
additional selection information shown below.
3.8.1.1 Switch Mode Power Supply (SMPS)

Several variants are available as shown in Table 2–14. These variants allow for different voltage supplies
and different voltage transients on these supplies. Higher voltage transient SMPS must only be used with
higher transient capable DELTA power modules as the SMPS provides the under- and over-voltage
protection for that power module.
Standard Tolerance a.c. Supplies

Table 3–1 shows compatible DELTA SMPS units for the standard a.c. supply voltage (as shown in Table 2–1)
of the CDM. This SMPS supply voltage rating must also match the DELTA Transistor module.
SMPS Version AC Supply Voltage Compatible DELTA module

MVC3003-4001 380 – 440 V a.c. (400 V nominal) MVD5xx-x5xx
MVC3003-4002 460 – 525 V a.c. (480 V nominal) MVD5xx-x5xx
MVC3003-4003 575 - 690 V a.c. (600 / 690 V nominal) MVD3xx-x7xx, MVD5xx-x7xx
Table 3–1: SMPS Units For Standard Supplies
Poor Tolerance a.c. Supplies

The following variants have been designed specifically for use in systems with poor supply regulation.
These units are more complex and are only to be fitted to DELTA modules with higher withstand voltage.
The sequence of SMPS connections to the controller is important:
MVC3003-4020
This SMPS is designed to maximise the achievable system voltage by fitting a high tolerance over-voltage
feedback circuit. The other (if fitted) parallel DELTA transistor module(s) must then fitted with an SMPS
(MVC3003-4025) where the over-voltage trip is set above this trip level.
The MVC3003-4020 must be connected to the controller PL2 (DELTA 1 position) only. The -4025 version is
fitted in DELTA 2 – 6 positions (PL3 – 7 on the controller).
Page 92
MV3000 Air Cooled DELTA Component Selection – Electrical
MVC3003-4030
This SMPS is designed to maximise the achievable system voltage by allowing a time delay on the over-
voltage trip. The Timed Overvoltage is user configurable for up to 7.5s.
The unit is fitted with another higher voltage trip circuit. If this voltage threshold is reached the drive is
tripped instantly.
If other parallel DELTA transistor modules are fitted then these require an SMPS (MVC3003-4025) where the
over-voltage trip is set above these levels.
MVC3003-4030 must be installed in DELTA position 1 only. The -4025 version is fitted in DELTA 2 – 6
positions.
MVC3003-4025
These units are to be installed in DELTA positions 2 to 6 in multi bridge DELTA systems. Their overvoltage
trip level is set to 1290V nominal, and is intended to be a back-up for the master trip circuitry in MVC3003-
4020 and MVC3003-4030. The analogue volts feedback is disabled in this variant.
If the MVC3003-4025 is fitted in the controller PL2 (DELTA 1 position) the system will trip on DC Link Under-
voltage.
Configuring The Timed Overvoltage Trip Duration

MVC3003-4020 and MVC3003-4030 are both fitted with 20X4344 daughter boards. This board contains the
configuration links for the Timed Overvoltage trip duration. The table below shows the link settings and
their corresponding duration.
20X4344 Configuration Links Duration

TP10 TP11 TP12 TP14 (seconds)
0 0 0 0 0.0
0 0 0 1 0.5
0 0 1 0 1.0
0 0 1 1 1.5
0 1 0 0 2.0
0 1 0 1 2.5
0 1 1 0 3.0
0 1 1 1 3.5
1 0 0 0 4.0
1 0 0 1 4.5
1 0 1 0 5.0
1 0 1 1 5.5
1 1 - - 6.0
1 1 0 1 6.5
1 1 1 0 7.0
1 1 1 1 7.5
Table 3–2. – Link Settings & Durations
Page 93
DC Overvoltage – Origin Discrimination

By monitoring the AC supply and the DC Link voltage it is possible to discriminate between a supply induced
overvoltage and a motor/load derived overvoltage (for example regeneration of power through the output
bridge beyond the braking capacity connected to the DC Link).
For this discrimination a MVC3006-4001 Mains Voltage Monitor unit and the appropriate firmware are
required.
With this hardware and software arrangement, the following actions will occur:
Mains Induced Overvoltage

In this case both the mains voltage and the DC Link will have reached predefined threshold levels. The PWM
will be inhibited until the DC Link falls below 1188V (1%) when the software will perform an auto restart
operation and flycatch the load.
Motor/Load Induced Overvoltage

A DC Link transient without an accompanying AC supply transient will be treated in the normal way and the
drive will trip.
3.8.2 Control Circuit – Auxiliary Components

Additional components to those shown in the typical circuit diagrams will be required. Typically these are:
 Pre-charge circuits for AEM / DC feeder schemes. See Section 3.8.6 – Pre-Charge Requirements.
 Cooling fan supplies and controls.
 Primary cooling fans

 Enclosure fans
 Temperature monitoring and protection of component and enclosure.
 Check in specification chapter which items already have internal monitoring and
protection.
 For those not monitored, decide on protection strategy and add monitoring as
appropriate.
 Auxiliary control supplies.
 The power supplies for the MV3000e controller are supplied by the SMPS unit.
 A 24V d.c. auxiliary input connection on TB2 (pin 2 =24V, Pin 1 = 0V) is also available for
monitoring and programming the controller when the main supply is switched off.
 24V d.c. output is available for digital inputs.
See Table 2–13. – User I/O Termination Panel Connections.
 Customer interfaces may use other supplies these must be protected against over-current
and voltage transients.
 Additional devices added to the CDM e.g. contactors or heaters may require 110V a.c. supplies.
3.8.2.1 Line Contactors & Relays

When installing line contactors and relays in close proximity to, or connected to, the DELTA modules the
coils must be fitted with suppression devices.
Suppression will normally take the form of a suitably sized series connected capacitor and resistor
connected across the contactor/relay coil.
Page 94
3.8.3 Filters
3.8.3.1 PWM Filter
This must be fitted to an AEM drive to filter the PWM harmonics.
 Sized for the application, depends on:

 PWM frequency;
 Supply reactance;
 Impedance of the input reactor;
 Drive rating;
 Attenuation required (acceptable level of harmonics).
Due to the large variation of applications, standard versions are unavailable.

Electrical location shown in Section 11.5 - AEM Network Bridge: Power Connections.
3.8.3.2 EMC Filters

Used as part of the measures to attenuate the high frequency (radio frequency) emissions from the CDM.
 Fitted to the a.c. supply connections to the CDM.

 Most effective when used at an EMC shielding boundary.
 Cables and components (e.g. isolator) on the mains side of the filter must be screened
from the rest of the DELTA circuit.
 Sized for the application.

 Type and attenuation depend on the emission level required for application (see Section
3.3.1.4: Electrical Interference / Electromagnetic Compatibility (EMC)).
 AEM style drives require more attenuation DFE drives.
 Current rating based on the power rating of the CDM for the main supply connections,
and the power rating of auxiliary components for control supplies.
NOTE: Auxiliary supplies may have lower emissions limits (see Section 3.3.1.4: Electrical Interference /
Electromagnetic Compatibility (EMC)).
 EMC filters may only be used if the supply neutral is connected to earth/ground at the source
of the supply (also known as TN or TT network). They must not be used on networks with
ungrounded neutral (also known as IT network).
 If EMC filters are to be used and there are also thyristor converters (e.g. d.c. drives) on the
same supply, there will be restrictions on the allowed commutation notch depth.
 When used on AEM drives, filters must be rated for the voltage-to-ground.
3.8.4 Power Cabling & Terminals

Voltage Rating
The insulation between live conductors and between live conductors and ground (earth) must be suitable
for the voltages applied. In some locations there will be additional voltages due to PWM switching edges.
These edges may be amplified by ‘ringing’ caused by reflections or resonant circuits. Every layout will have
different stray inductive/capacitive circuits so the actual value must be measured.
Cable insulation must be selected to include a margin for these repetitive voltages.
Nominal (continuous) voltage ratings:

AEM drives, d.c. link voltage is usually 1.6x a.c. r.m.s. voltage.
DFE drive d.c. link voltage is 1.35x a.c. r.m.s. voltage.
Page 95
Current Rating Of Connections

Simple formulae are provided to allow the quick selection of power cable current rating (ampacity) between
power modules. Leave a margin in the sizing based on these simple formulae or use a detailed circuit
analysis for accurate size calculations:
For drives supply power to motors:

√3 . .
. .
√3 .
Where:

. . 1.6 . .
. . 1.35 . .

1.05, 1.1
Also:
. . .
. . (i.e. 4% sharing allowance)

. . .

. . .

NOTE: The rectifier part number gives the d.c. current in Amps, i.e. MVRL1600 = 1600 A d.c. and is designed for
cable connection only.
Temperature Rating
 There is limited space for power cabling to the a.c. connections on the DELTA power modules
and so the connections are intended for use with high temperature cables.
 The a.c. and d.c. terminal insulation in the DELTA power module limit the maximum allowed
conductor temperature of the interconnection cable. This is usually 125°C (257F), but refer to
the individual component specifications for actual component values.
 Beware that non-DELTA parts may have lower temperature limits, for example cable supports,
cable ties, terminals and adjacent insulation.
 To minimise inductance the cables are normally arranged in trefoil, so the cable
rating / temperature rise requires the appropriate bunching factor.
Examples of high temperature 125°C (257F) or above cables are:

 Silicon rubber, e.g. or Nexans type SIWO-KUL (www.nexans.com ) or
 Polyolefin, e.g. Huber and Suhner type Radox 125 (www.hubersuhner.com).
These cables are intended for inter-connection within the enclosure (not field wiring terminals).
Page 96
3.8.5 Fuse Selection & Mounting

Fuses from other manufacturers may be used in place of those specified in Table 2–15 and Table 2–18, for
use with the Rectifier and Transistor Modules if they give equivalent performance.
 Semiconductor fuses usually require a minimum sized busbar connection and have limits on
local ambient temperature – refer to the manufacturer’s data.
3.8.5.1 Fuse Micro-Switch Attachment

For fuse indication a micro-switch attachment should be fitted to each fuse. The micro-switch should be
connected as shown in the circuit diagrams in Appendix B: Electrical Connection Diagrams.
3.8.6 Pre-Charge Requirements

MV3000e drive systems require a pre-charge routine to be in place to establish the d.c. link operating
voltage of the system.
3.8.6.1 Pre-charge for DFE systems

For DFE systems, the pre-charge circuitry is integrated into the MVR and GDR modules.
Upon the connection of the external a.c. supply, a controlled charging of the internal capacitor bank will be
carried out. Once the internal d.c. is established, the SMPS modules power up the controller. This will
interrogate the d.c. voltage and if the correct conditions are present, will initiate a “pre-charge complete”
signal and allow the drive system to become operational.
3.8.6.2 Pre-charge for AEM systems

For AEM systems, this is achieved by a pre-charge resistor and contactor in parallel with the main supply
(network) contactor. The pre-charge sequence is initiated manually or automatically and is controlled by
the MV3000e Common Drive Controller (CDC). Completion of the pre-charge event is indicated by the CDC,
which then allows full power operation to begin.
A Pre-Charge representation for an AEM system configuration is shown in Figure 3–8.
Main Supply
Contactor
Control
Supply
Reactor
Network Bridge
Main a.c.
Supply
Pre-Charge Pre-Charge
Fuses Resistors
Control
Pre-Charge
Contactor
Figure 3–8. – AEM Pre-Charge Arrangement
Page 97
3.8.6.3 Pre-Charge System Components

NOTE: All components are system dependant and must be specified and sourced per application.
 Pre-charge resistors (multiple components in series/parallel to provide the correct rating per
phase) and mounting kits.
 Pre-charge contactor and suppression components.
 Pre-charge fuses and mounting kits.
 Power connections between supply, fuses, pre-charge resistors, pre-charge contactor and
main supply reactor.
 Control electrical connections to the controller for the pre-charge contactor and main supply
contactor.
3.8.6.4 Pre-Charge System Electrical Details

See Figure 3–8.
 Pre-charge current is typically 30 to 50% of drive rating. DELTA module capacitor bank details
are given in the individual component specification.
 Pre-charging energy levels need to be considered due to the impulse nature of the pre-
charging event.
 When sizing pre-charge components, consider all items to be pre-charged (DELTA modules,
DB units, SMPS’s).
 In multiple parallel network DELTA systems, pre-charging can be done through one DELTA
module only.
 The control connections are as follows:
 The “pre-charge complete” signal is generated by the controller and must be used to
close the main supply contactor.
 The “pre-charge acknowledge” signal from the main contactor back to the controller
confirms correct operation and interlocks the sequence to prevent the drive from
starting if not complete.
 The pre-charge circuit must be opened at the end of the pre-charging period to prevent
circulating currents.
 Controller connections are detailed in Section 2: Specification.
3.8.7 Dynamic Braking (DB) Units

The DB Unit is used in conjunction with an externally mounted braking resistor, to dissipate kinetic energy
stored in a motor and its load or to assist in limiting transient voltages. The kinetic energy is regenerated
into the drive during deceleration or when the load is overhauling. The DB monitors the DC link voltage and
switches the braking resistor into circuit when the voltage exceeds a pre-set level.
Figure 3–9. – DB System Arrangement
Page 98
MV3000 Air Cooled DELTA Component Selection - Mechanical
3.8.7.1 DB System Components

 DB Unit (e.g. GDB400).
 Braking Resistor, specified and sourced per application.
 An integral thermal protection device must be used.
 Power connections between the CDM DC Link, DB Unit and brake resistor.
 The unit is designed for cable connection only.
 These cables must be rated for high voltage d.c. plus switching transients. See
recommended cable types in Section 3.8.4.
 Control connections to the controller (indicates DB status).

 d.c. link fuse protection (as defined by the application and unit specification).
3.8.7.2 DB System Location

The DB unit must be located close to the DC Link of the PDS to minimize the cable loop inductance.
The DB unit must be located within the same enclosure as the DELTA power modules.
When the DB resistor is located outside of the enclosure, the losses are dissipated to the external ambient
without heating the enclosure.
The resistor’s local enclosure must meet the Essential Requirements For The Enclosure as given in
Section 3.5.1.1.
 For EMC compliance, the power cables must be screened, e.g. run inside metal conduit.
 Ventilation will be dependent upon resistor style and duty cycle but space must be left around
the resistor for ventilation and also for segregation as this will be a hot component.
 Some duty cycles may produce high acoustic noise levels in the resistor.
3.9 COMPONENT SELECTION - MECHANICAL

3.9.1 Enclosure (/s)
3.9.1.1 Selection Of Enclosure/s
The power rating and complexity of the CDM will define how many separate enclosures (these must be
bonded together as described in Section 3.3.2.1: Bonding) are required.
For a simple, low power system one enclosure may be used but care must be taken to ensure adequate
separation of the LV control circuits to the hazardous voltage, high power circuits, see Section 3.5.4.
3.9.1.2 Performance
The enclosure must meet the Essential Requirements For The Enclosure as given in Section 3.5.1.1.
3.9.1.3 Enclosure Size

This will have been established from the initial mechanical layout.
Page 99
Component Selection - Mechanical MV3000 Air Cooled DELTA
3.9.1.4 Enclosure Type
Panels
Material Steel To provide a conductive and magnetic screen in addition to
safety segregation.
This minimises electrical radiated emissions from the drive
and helps protect the drive from radiating sources
Finish External Painted Good environmental protection
Internal plated or galvanised (e.g. Zintec) For good electrical bonding
Frame
Material Steel Strength and cost
Finish Plated or galvanised This gives good low inductance connections for electrical
bonding
Recommended
Rittal TS range:
 with galvanized frame and

 painted steel cladding
 without the rear mounting panel
or the EMV version for higher emission shielding.
3.9.1.5 Enclosure Further Requirements

Earthing / Bonding
The enclosure bonding must comply with instructions given in Section 3.5.3: Electrical Bonding.
Openings
Avoid all unnecessary apertures. All doors and covers to hazardous parts to be closed when the equipment
is energized.
Cable Glanding
The cables entering the enclosure must be correctly bonded through the gland plates. See Section 3.5.3:
Electrical Bonding.
Page 100
MV3000 Air Cooled DELTA Component Selection - Mechanical
3.9.2 DELTA Mounting Frames

DELTA power modules are only designed to fit into the DELTA guide plate and support frames. The
assembly of these ‘frames’ is shown in Section 5: CDM Assembly.
These frames are designed to fit Rittal TS8 enclosures. See Section 3.9.1.4: Enclosure Type for
recommended types.
 Ensure that the enclosure attachment point is sufficiently strong for the weight of components
attached to the frame, for lifting and for the final installations environment (e.g. vibration).
 See Section 2: Specification for available frame sizes.
 These are limited to a maximum of four DELTAs per frame due to the combined weight
of these modules.
 It is recommended that a standard mounting frame is used regardless of the enclosure

selection. If an alternative enclosure style is utilised, interface brackets will be required to
allow the mounting frame to be used.
 If a standard mounting frame is not to be used, the CDM builder will need to design and
manufacture their own, following the guidance below:
 A maximum of four DELTA power modules per enclosure (due to the combined module
weight over a wide span);
 It must be possible to secure the DELTA power modules with their designed fixing
points. DELTA power module dimensions are shown in Appendix A: Dimensioned
Mechanical Drawings;
 Access to all fixing points and coolant connections must not be affected;
 Air flow through the d.c. link capacitors of DELTA transistor modules must not be
affected;
 Clearance to the enclosure frame is required when fitting and removing modules;
 The live right side of the module requires clearance to the enclosure’s earthed metal
during operation.
Page 101
Component Selection - Mechanical MV3000 Air Cooled DELTA
Page 102
T1689 Technical Manual Rev 0007 PDS Design
MV3000 Air Cooled DELTA Suitability of Motors
4. PDS DESIGN
4.1 SUITABILITY OF MOTORS
Motors with Insulation Peak Voltage Withstand ratings of 1200 V (400 V motors), 1500 V (500 V motors) and
2250 V (690 V motors) can be operated with rectifier-fed drives without risk to the motor winding insulation,
for cable lengths up to 500 m (1640 ft.). Such motors are available from reputable manufacturers, as
standard motors up to 500 V and with an enhanced insulation system for voltages greater than 500 V up to
690 V. For lower quality motors, a dv/dt filter will be required.
The DC link voltage in an AEM drive is higher than the DC link voltage in a diode rectifier-fed drive. For the
default DC link voltage, motors with Insulation Peak Voltage Withstand ratings of 1420 V (400 V motors),
1560 V (480 V motors), 2000 V (600 V motors) and 2250 V (690 V motors) can be operated with AEM drives
without risk to the motor winding insulation, for cable lengths up to 500 m (1640 ft.). Such motors are
available from reputable manufacturers, as standard motors up to 415 V and with an enhanced insulation
system for voltages greater than 415 V up to 690 V. For lower quality motors a dv/dt filter will be required.
The maximum dV/dt at the DELTA power module terminals can be 20kV/μs. The use of output sharing
reactors or the use of dV/dt filters will result in the dV/dt at the output terminals of the converter being
lower than this. The distributed inductance and capacitance of the motor cables will further reduce this
dV/dt see at the motor terminals, dependent upon the installation.
In applications where the rated voltage of the motor is lower than the supply voltage, the motor insulation
must comply with the requirements for the supply voltage. For example, a 600 V motor used on a drive fed
from 690 V must comply with the insulation requirements for a 690V motor.
NOTE: If a high control bandwidth (Vector control) is required from the MV3000e drive, dv/dt filters cannot be
used. Cable the motor directly to the drive.
4.2 SUITABILITY OF MOTOR CABLES

To avoid EMC problems, the motor cable should be screened (e.g. NYCWY according to VDE 0276 or steel
wire armoured) or fully enclosed in metallic trunking. The screen or metallic trunking must be continuous
throughout its length and be connected directly to both the drive enclosure and the motor.
Where the current rating of the drive is beyond the capability of an overall screened or armoured 3-core
cable, several 3-core cables should be connected in parallel, as shown in Figure 4–1. It is important that the
phase currents are evenly distributed across the cables - it is not permissible to run the whole of each
phase current down one cable. The screen or armour of each cable must be bonded to both the drive
enclosure and the motor.
DC+ U
U
V V M
W
DC- W
Figure 4–1. – Parallel Cables For High Current Ratings

If unscreened cables are run within metallic trunking, the following points need to be taken into account:
 The cables should be run in trefoils, each trefoil carrying one cable of each phase. This is to
avoid unequal sharing of current between cables.
 Where the trunking is not large enough to take all the cables, each trunking should carry an
equal number of trefoils.
 The metal trunking must be bonded to the drive enclosure and to the motor.
Page 103
PDS Design T1689 Technical Manual Rev 0007
Encoders & Encoder Cables MV3000 Air Cooled DELTA
Outside the drive enclosure, the motor cable must be segregated from other cables by at least 300 mm (12
in).
In the case of some types of screened/armoured cable, the cable screen/armour is not acceptable as a
protective earth conductor. This is usually when the screen/armour has a low cross-sectional area. In such
cases, the following points must be noted:
 If the cable has only four internal cores, do not use the fourth core as a protective earthing
conductor. The unequal magnetic coupling from this core to the other three cores would
result in a voltage being induced into the protective earthing conductor. This voltage will then
cause nuisance currents to circulate in the cable screen/armour or in the external installation.
If this type of cable is used, use a protective earth conductor external to the
screened/armoured cable.
 If the protective earth conductor is run inside the cable, a symmetrical cable must be used.
This is a cable which contains three protective earth conductors equally distributed inside the
cable. Such cables are marketed as “VFD cables”. The purpose of this is to ensure that
magnetic fields inside the cable do not induce unwanted currents into the protective earthing
system of the installation. All three protective earthing conductors must be bonded to both
the drive cubicle and the motor.
 If the screen/armour of a cable with internal protective earthing conductors is bonded at both
ends, the screen/armour terminations must be capable of handling any residual circulating
currents that are induced by the internal protective earth conductors.
 If the screen/armour of a cable with internal protective earthing conductors is bonded at one
end only, the shielding effectiveness of the cable at radio-frequencies will be reduced. This
could cause problems in installations with low radio-frequency emission limits.
4.3 ENCODERS & ENCODER CABLES

4.3.1 Encoder Selection
Only encoders having RS422A output (A/B/Z) can be used (a marker pulse is only required when using the
drive's position controller).
The MV3000e is equipped with two power supplies to power various encoders, which may be used. There
are two acceptable types of encoder:
 Encoders requiring +5 V supply and producing RS422A output.

For these encoders use TB5/4 (+5 V) to supply them and in cases where long cable runs cause
a supply volts drop to the encoder, parameter P13.06 will allow this supply voltage to be
adjusted between +4.5 V to +6.5 V. Refer to the guided commissioning charts in the
Commissioning section of the appropriate Getting Started Manual for details. If the sense
wires are connected (FB+ and FB–) at the encoder end of the cable, the MV3000e will
automatically adjust the encoder supply accordingly.
 Encoders requiring +24 V supply and producing RS422A output. For these encoders use TB5/6
(+24 V).
Encoders requiring +24 V supply and producing 24 V differential outputs are NOT compatible with the
MV3000e controller, the pulse train must be RS422A.
4.3.2 Encoder Resolution

For accurate speed control, especially at low speeds, a resolution ("line count") of no less than 1024 pulses
per revolution is suggested.
There are two limits on the maximum line count for the chosen encoder. The line count must comply with
both of the following conditions:
 The line count must be less than or equal to 64 000 pulses per revolution (due to the drive
software).
 The time delay between an edge on encoder channel A and an edge on channel B must be
greater than 333 ns at the required top speed of the motor.
Page 104
MV3000 Air Cooled DELTA Mains Supply Cables
Due to imperfections in encoder manufacture, the edges are not equally spaced. Some encoder
manufacturers quote the minimum edge separation in electrical degrees. This is 90° for a perfect encoder
but can be as low as 40°.
For a given required top speed and encoder minimum edge separation, the line count must not exceed:
500  10 3  (Min _ Edge _ Separation )
Max _ Line _ Count 
Required _ Top _ Speed
Where :
Min_Edge_Separation is in electrical degrees
Required_Top_Speed is in rev/min.
If the encoder manufacturer quotes a “scribing error” in electrical degrees, then

Min_Edge_Separation = 90 - Scribing_Error.
If the encoder manufacturer quotes a symmetry of 180  x and a quadrature phase shift of 90  y, then
Min_Edge_Separation = 90 - x - y.
4.3.3 Encoder Mounting

For vector control mode, the mechanical coupling between motor and encoder is critical and any
eccentricity in the mechanical coupling will impair performance. The best solution is a motor built with an
integral shaft encoder, otherwise accurate alignment of encoder with motor shaft is very important.
An encoder may be used to perform position control. For position control in frequency control or
encoderless vector control modes, an encoder or linear scale may be mounted on the controlled plant.
To prevent electrical noise being coupled from the motor into the electrical signals from the encoder:
 The encoder shaft must be electrically insulated from the motor shaft and motor frame;
 The encoder body must be electrically insulated from the motor frame.
4.3.4 Encoder Cable Screening

The encoder wires, including the encoder power supply wires, must be contained in a screened cable and
the screen must be connected to the M4 screw adjacent connector TB5 on the User I/O Termination Panel.
The screen must be continuous throughout its length. In addition to the connection to the M4 screw on the
User I/O Termination Panel, the screen should be connected by a 360° bond to the drive enclosure and to
the encoder body.
4.4 MAINS SUPPLY CABLES

Where the mains supply cable to the drive is a screened or armoured cable, the screen must be bonded to
the drive enclosure. The screen or armour should also be bonded to safety earth at the source of the
supply.
Where the drive is fed from an isolating transformer, the supply cable to the drive must be screened or
armoured or placed in a metallic trunking. The screen or armour or metallic trunking must be bonded to the
drive enclosure and to safety earth at the supply transformer. This bonding is most effective when it is done
via 360 cable glands.
Page 105
Special Requirements for “IT” Networks MV3000 Air Cooled DELTA
4.5 SPECIAL REQUIREMENTS FOR “IT” NETWORKS

An IT network is a network in which the neutral of the supply is not earthed.
This leads to two requirements:
 Protection against transients coupled from the primary of the supply transformer;
 Earth fault monitoring.
4.5.1 Protection Against Transients

In IT networks, the power circuit is effectively floating. A capacitive potential divider can exist between the
supply transformer primary, the motor and the system earth, with the power electronics of the DC link,
being the centre node. If switching transients are capacitively coupled from the primary of the transformer,
the DC link could move to a very high voltage with respect to earth. This could exceed the voltage rating of
the insulation between the power circuit and the control electronics on the DELTA modules.
To prevent this, the supply transformer must contain an earthed screen.
4.5.2 Earth Fault Monitoring

Local safety regulations may dictate the form of earth fault monitoring. Where these regulations conflict
with the information here, the safety regulations take precedence.
NOTE: Only a single Earth Fault Monitoring system should be incorporated into a drive system, using multiple
systems on the same drive may cause nuisance alarms and trips.
The enclosure designer should clarify whether earth fault monitoring is to be performed within the drive
enclosure or whether it is being performed elsewhere in the supply system.
Proprietary insulation monitoring devices operate by using an internal voltage source to inject a signal with
respect to earth and thereby to measure the insulation resistance of the system. Such insulation
monitoring devices should comply with an appropriate safety standard, such as IEC 61557-8, Insulation
monitoring devices for IT systems up to 1000V AC and 1500V DC. If such a device is used, this should be
fitted between the supply transformer and the drive.
Alternatively, one point in the supply system may be connected to earth via a high resistance. A current
sensor measuring any current to earth is then used to drive an earth fault alarm. If such a system is used,
the following points should be observed:
 If the neutral of the supply system is available, the resistor should be connected between the
supply neutral and earth. The voltage and power rating of the resistor must be able to
withstand the full line-to-line voltage in case of an earth fault on the output to the motor.
 If the neutral of the supply system is not available, two resistors may be connected in series
across the DC link. The midpoint is then connected to earth. This method is only possible
when there is only one drive connected to the supply transformer. Each resistor must have a
voltage and power rating sufficient to withstand the full DC link voltage in case of an earth
fault on the DC link.
Page 106
MV3000 Air Cooled DELTA Protection of Cables Routed Outside the Enclosure
Figure 4–2. – DC Link Earth Referencing
 The resistance value should be chosen to suitably limit the current to earth during fault
conditions. A value of 1 k per resistor is commonly used.
 A current sensor placed around the wire between the resistor and earth will detect an earth
fault anywhere in the system.
 Only the live conductors should pass through the current sensor. Earth wires, cable screens,
and armours should not be passed through the sensor.
 The current sensor must be capable of detecting DC as well as AC.
If earth fault monitoring is to be used, only one system should be installed. Multiple earth fault monitoring
systems can interfere with each other.
4.6 PROTECTION OF CABLES ROUTED OUTSIDE THE ENCLOSURE

All cables which are routed outside the drive enclosure - e.g. plant wiring where there is a requirement for
screening, segregation, terminations etc. - require protection which would normally be determined by the
application but generally follow the rules already described in this section.
Page 107
Protection of Cables Routed Outside the Enclosure MV3000 Air Cooled DELTA
Page 108
T1689 Technical Manual Rev 0007 CDM Assembly
5. CDM ASSEMBLY
WARNING
 Connect this equipment to earth (ground) using the earth terminal provided.
The minimum size of the protective conductor must be in accordance with local safety regulations.
 High Leakage Current
This equipment and the driven motor(s) must be earthed (grounded).
 High Voltages
Replace all shrouds and close all doors before energising the equipment.
 This equipment may be connected to more than one live circuit.
Disconnect all supplies before working on the equipment.
 Wait at least eight minutes after isolating supplies and check that the voltage between DC+ and DC- has
reduced to a safe level before working on this equipment.
 Surfaces on the following items can reach high temperatures and remain hot for some time after power
has been removed:
- Reactors and transformers
- Cables
- Coolant pipes and couplings
 Ensure that access to rotating arts of fans is prevented.
 Air used to cool the product is unfiltered. Air ejected from the product may contain foreign particles. Air
outlets should be arranged to deflect the air away from the eyes.
 Items marked with weights greater than 20kg (44 lb.) should only be moved with lifting apparatus.
CAUTION
 This equipment contains solid state devices which may be affected by electrostatic discharge.
Observe static handling precautions.
 Ensure that all conductors connected to this product are mechanically restrained.
 Where nuts, bolts and washers are supplied fitted to the terminal busbar, remove these fasteners, place
the user’s crimp (or busbar) directly against the terminal busbar of the unit and refit the fasteners. This is
to prevent large currents flowing through steel fasteners and causing overheating.
 When drilling a panel or door to fit components do not allow any swarf from the drilling operation to enter
the enclosure – it may cause component malfunction.
NOTES: Some components of the DELTA range are supplied with shrouds to partially protect against accidental
contact with live parts – from front access only.
DELTA transistor modules are not supplied with shrouds for the live right side or rear surface.
For certain applications, the shrouding supplied with these products may not provide the required
protection. Additional shrouding must be fitted in these instances.
5.1 INTRODUCTION
This section of the manual describes the generic assembly processes for installing DELTA components into
the enclosure. Other application specific tasks (such as mounting circuit breakers or fuses) should be
performed when appropriate, and have not been included in these assembly instructions. Reference should
be made to the specific assembly instructions and drawings produced by the drive designer.
Recommended torque settings are given in Appendix C: Recommended Torque Settings.
Guidance for Electromagnetic Compatibility is in Section 3: Drive (CDM) Design.
Page 109
CDM Assembly T1689 Technical Manual Rev 0007
Introduction MV3000 Air Cooled DELTA
5.1.1 Recommended Order of Assembly

It is recommended that the drive assembly order shown below is followed:
a) Fit floor mounted reactors (interbridge transformer / d.c. link reactor, line reactor).
b) Fit DELTA mounting rails and other internal metalwork.
c) Fit a.c. sharing reactors.
d) Install Fan assembly.
e) Install DELTA power modules.
f) Install control components.
g) Connect high power cables or busbars.
h) Fit DELTA power module shrouds and earth bonding plates.
i) Fit SMPS modules.
j) Connect control cabling.
k) Fit overall enclosure shrouds
NOTE: Some of the steps listed above may not be required, depending upon individual system configuration.
Before starting any assembly work, reference should be made to Sections 2, and 3 of this manual.
Section 2: Specification gives details of individual components of the DELTA product range.
Section 3: Drive (CDM) Design includes details about preparation and planning for assembly, and guidance
for design of the cooling circuit.
NOTE: References in this section to 'left' and 'right' should be taken to mean the viewer's left and right when
facing the front of a module.
Page 110
MV3000 Air Cooled DELTA Receipt & Storage of Equipment
5.2 RECEIPT & STORAGE OF EQUIPMENT

5.2.1 For immediate installation
If the product is to be built immediately into equipment, before starting work the contents of the equipment
supplied should be carefully unpacked and inspected.
Check the complete consignment against the delivery note for any shortages or loss in transit.
Damaged or missing parts must be reported immediately to the supplier and the following details quoted:
 List of damaged or missing items with names and part numbers;

 Description of damage;
 Delivery/advice note numbers; dates; order numbers; item numbers.
If the equipment delivered to site is not to be installed immediately:
 Re-pack it in its original packaging material - if this is not possible it should be enclosed in
polythene sheet to protect it from the ingress of dust;
 Store it in a clean dry atmosphere, preferably at room temperature - DO NOT EXCEED the
storage temperature limits referred to in Table 2–3;
 Ensure that, if the equipment is stored for a long period of time, usually greater than two
years, the equipment supplier is contacted for advice about reforming the d.c. link capacitors
before the equipment is put into service;
 If the equipment is unpacked in a warm environment condensation may occur - if
condensation is seen do not use the equipment until its temperature has stabilised to that of
the working environment;
NOTE: Whenever possible retain and store the original packing materials for use if a product has to be
returned for repair. See Section 13: Contact Details for Sales, Service & Support.
5.2.2 For long term storage

If the product is to be installed at a later date or is being kept for spares:
 Retain the product within the packaging supplied – only remove when required.
 The modules are fragile and vulnerable to damage – handle and store carefully.
 Handling of the packed modules must be with appropriate pallet trucks or fork-lift trucks.
 Store in a dry area and protect from external water ingress.
 Maintain environmental levels within those defined in Table 2–3.
 If the packaging that the module is supplied in is considered inappropriate for the location
where they are to be stored, do not remove the existing packaging but locate within an
additional protective packaging.
5.2.3 Electrolytic Capacitor Shelf Life

The storage life of a variable speed drive is determined by the shelf life of the electrolyte capacitors used in
the product.
In the case of AC Drives these are:
 The main DC Link Capacitors;

 The small capacitors on the electronic control boards.
After long periods of storage, these capacitors will eventually ‘de-polarise’ and become ineffective. The
effects of this are difficult to predict as too many variables are involved. The symptoms could include
random or spurious trips, power supply failures, or extreme levels of ripple on the DC bus. Excessive
capacitor leakage could also lead to overheating of pre-charge resistors.
The shelf life of the electrolyte capacitors varies with storage temperature. The higher the temperature –
the shorter the shelf life.
Page 111
Receipt & Storage of Equipment MV3000 Air Cooled DELTA
DC Link Capacitors
 For a 35°C storage temperature, the shelf life is approximately 40,000 hours or 4.5 years.*
 For a 25°C storage temperature, the shelf life is approximately 80,000 hours or 9 years.*
* Data based on BHC Aluminium Electrolyte Capacitors – Long Life type.

Taking into account other components inside the drive we can approximate a guide shown below.
Approximate shelf life of an

inverter
The boundaries depend on storage
temperature.
5.2.4 Procedures after Removing DELTA Transistor Bridge Modules from Long Periods of
Storage
5.2.4.1 For DELTA Transistor Bridge Modules Stored for up to Three Years
The DELTA Power Module can be powered up and used without further consideration for capacitor
reforming. Refer to the additional replacement instructions in Section 9.5.
5.2.4.2 For DELTA Transistor Bridge Modules Stored from Three to Five Years
Power up the DELTA Power Module and leave with the power applied for a period of 4 hours before
attempting to use. Refer to the additional replacement instructions in Section 9.5.
5.2.4.3 For DELTA Transistor Bridge Modules Stored in High Ambient Temperatures for Four Years or
more
It is possible that the main DC Link Capacitors need to be reformed. This is a specialist task: return the
DELTA Power Module to the factory.
If this is not practicable:
a) Apply a current limited, variable voltage power supply to the DC Link (with the DELTA Power Module
isolated from the normal mains supply) and slowly raise the value from zero to the normal working
voltage of the DC Link.
During this period, limit the current to 5mA per capacitor (around 60mA for a parallel bank of 12).
This procedure involves the use of high voltages and should only be attempted by qualified and
experienced engineering personnel. This procedure can also result in damage to one or more of the DC Link
Capacitors.
Page 112
MV3000 Air Cooled DELTA fitting FLOOR MOUNTED REACTORS
5.3 FITTING FLOOR MOUNTED REACTORS

Depending upon the system configuration, a number of wound components will require floor mounting.
Figure 5–1 shows a typical interbridge transformer. Other reactors (line, sharing and d.c. link) will be
similarly constructed.
The reactor should be lifted into position, by its lifting eye bolts, with suitable lifting equipment. It should be
secured through the fixing holes to the base of the enclosure.
Lifting eyebolts Terminal block for

thermistor
connections
A1 terminal
A3 terminal
A2 terminal
Earth terminal
4 fixing holes 4 fixing holes
Figure 5–1. – Typical Interbridge Transformer
Page 113
assembling the Mounting Frame for delta POWER Modules MV3000 Air Cooled DELTA
5.4 ASSEMBLING THE MOUNTING FRAME FOR DELTA POWER MODULES

5.4.1 General
Figure 5–2 shows the construction of the MVD-TS-40xx mounting frame in a Rittal TS8 enclosure. The
diagram and following instructions can be used for all versions of the mounting frame. If an enclosure
other than a Rittal TS8 is used, interface parts must be fitted to the enclosure prior to fitting the frame.
Instructions for fitting interface parts should be provided by the enclosure designer.
A E
B
The side support rails should
be fixed with a spacing of
850 mm (measured from the
same point on the upper and
lower side support rails).
C
A
Figure 5–2. – Assembly Of MVD-TS-400x
5.4.2 Side Support Rails

Each mounting frame kit contains four identical side support rails (either 600 mm [23.6 in] or 800 mm [31.5
in] long) that may be fitted to the left or right sides of the enclosure. The correct orientation of these
supports can be identified by the holes in the upper flange - see Figure 5–2, item A.
NOTE: Front to back orientation is not important as all of the fixing holes have been mirrored about the centre
line.
Each side support rail has two fixing holes at each end which accept the M5 hexagon head screws supplied
in the kit. Use four M5 x 10 mm hexagon head earthed-nib screws to mount each of the four side supports
as shown in Figure 5–2.
NOTE: For reasons of safety and correct routing of noise currents, there must be good low-inductance
electrical continuity between the DELTA module mounting frame and the enclosure. For this reason,
the mounting points for the side support rails must be of unpainted metal.
Page 114
MV3000 Air Cooled DELTA Fans
5.4.3 Lower Cross-members

5.4.3.1 Rear
Fit the lower rear cross-member (Item B in Figure 5–2). The cross-member is secured to the side rails with
two M6 x 12 mm hexagon head self-tapping screws, and to the enclosure pillars with four M5 x 10 mm
hexagon head screws.
5.4.3.2 Front
All six fixing holes for mounting the lower front cross member are pre-drilled to suit the M6 self-tapping
screws supplied. The self-tapping screws may be driven in by hand using a pozi-drive screwdriver.
The exact position of the lower front cross-member (Item C) is shown in Figure 5–2.
Secure using six M6 x 12 mm hexagon head self-tapping screws between the two lower side-supports.
Ensure that the threaded inserts are in the top and front faces.
5.4.4 Guide Plates

Two guide plates are shown in Figure 5–2 (Item D). A guide plate is required for each DELTA power module.
Guide plates are secured to the lower cross-members with four M5 x 10 mm self-tapping screws. The
support plates locate onto the top of the lower cross members at each position where a module is to be
fitted. The angle guide rails should be on top, with the raised tab to the front.
5.4.5 Upper Cross-Members

5.4.5.1 Rear
Fit the upper rear cross-member (Item E in Figure 5–2). The cross-member is secured to the side rails with
four M6 x 12 mm hexagon head self-tapping screws. Ensure that the turned flange is at the bottom and
facing backwards.
5.4.5.2 Front
Fit the upper front cross-member (Item F in Figure 5–2). The cross-member is secured to the side rails with
four M6 x 12 mm hexagon head self-tapping screws. The threaded inserts must face forward and
downwards.
5.5 FANS
One fan must be fitted above each module.
5.5.1 Fan installation

The fan assembly is installed to the underside of the top cross members. Partly screw in the four M6 x 15
mm (9/16 in) hexagon headed bolts with plain and spring washers and then slot the fan into place using the
key-holes in the mounting flange as shown in Figure 4-4. The fan mounting flange should sit flat against
the underside of the two top cross members.
The fans are heavy and may be awkward to lift into place, each fan may be split into two pieces to simplify
installation. The fan duct fitted first, the main body of the fan then being added by pushing horizontally into
the location tabs at the rear of the assembly and fixing by the two M6 bolts at the front. Care must be taken
to ensure that any wiring disconnected from the terminal block is correctly re-connected.
Page 115
Fans MV3000 Air Cooled DELTA
5.5.2 Fan air outlet

Each fan has a choice of three air outlets; front, top or rear. These are selected by removing the appropriate
cover and using this cover to block the unwanted outlet.
The air outlet must not be obstructed and should preferably be ducted out of the control enclosure. Figure
4-5 shows the six fixing centres on each of the fan outlets for connecting a duct.
To keep personnel 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 accidental finger access
range. If they are installed in a position where the fan is accessible, mechanical protection must be
provided.
Figure 5-3. – Installing a Fan Box
Figure 5-4. – Fixing Centres on DELTA Cooling System for Ducting the Outlet
Description Part No. Units A B C D E F

High Performance MVC3014- mm 298 144 5 68 78 5
Cooling System 4001 in 11.73 5.66 0.2 2.68 3.07 0.20
Table 5-1. –Dimensions for Figure 4-5
NOTE: Standard pitch of 250 mm between duct outlets.
Page 116
MV3000 Air Cooled DELTA Fitting a.c. Sharing Reactors
5.5.3 Fan Support Bracket
NOTE: The bracket (50Y9743/01) must be fitted to the cubicle to provide support for the high performance fan.
Failure to fit this bracket may cause mechanical damage.
Each bracket should be secured to the Upper Rear Cross Member with an M5 x 10 mm pozi-headed Taptite
screw.
Figure 5-5 shows the recommended fitting for the support bracket.
Figure 5-5. – Fitting of Fan Support Bracket (50Y9743/01)
5.6 FITTING A.C. SHARING REACTORS

The a.c. sharing reactors are usually mounted above or below the DELTA power modules. The mounting
frames for DELTA modules do not provide features for mounting the sharing reactors. Such mounting
features have to be provided by the CDM designer. Refer to Section 2: Specification for technical details,
including weight, and Appendix A: Dimensioned Mechanical Drawingsfor dimensional details.
5.7 FITTING DELTA POWER MODULES
CAUTION
 The modules are delicate and vulnerable to damage – handle carefully.
Only lift or move them by use of the lifting point.
Lay them down on the plain left-hand face when not fitted in a frame.
Do not leave modules unsupported in the upright position.
5.7.1 Guidance for Handling

The DELTA power modules require particular care and attention during handling to ensure that personnel
are not injured, or the modules damaged. The lifting arrangement is the same for each type of module.
They should only be lifted with a crane rated for the module weights, as detailed in Section 2: Specification,
and suitable for enclosure access. The modules should be handled without any cables or busbars attached.
All preparatory work should be done in the enclosure prior to any module being lifted.
5.7.2 Transistor Module Identity

DELTA transistor modules in the drive are numbered from 1 to 6. This identity is determined by the
connections that are made to the controller, see Appendix B: Electrical Connection Diagrams. It is
recommended that DELTA transistor module number 1 is located either at the left-hand or right-hand end
of the group of DELTA transistor modules in the cabinet. The remaining DELTA transistor modules should be
connected sequentially.
Page 117
Fitting DELTA Power Modules MV3000 Air Cooled DELTA
5.7.3 DELTA Rectifier Module Position

If a DELTA rectifier module is fitted, it is recommended that it be located in the right hand side of the cabinet
to give the best access for cabling.
5.7.4 DELTA Power Module Lifting & Fitting Procedure
a) Rotate the module lifting bracket ((16.5mm (5/8 in)

diameter), at the top of the module - into a vertical
position and attach it to the lifting equipment shackle.
See Figure 5–7,
Figure 5–6. – Preparing to Lift A DELTA Power Module
b) Lift the module to the appropriate height and move it

into position to insert into the frame.
See Figure 5–7 and Figure 5–8.
Figure 5–7. – Lifting A DELTA Power Module
c) Tilt the module as it is moved into its slot so that it

clears the withdrawal ‘stop screw’ which is built into
the bottom right-hand guide.
See Section 2 Figure 2–7, Figure 2–20 and Figure 5–8.
d) When the rear of the module is located between the

guide rails, it can be slowly lowered and pushed into
the frame until the stop screw is reached.
Figure 5–8. – Positioning A Power Module Between The
Guide Rails
e) Remove the lifting shackle and push the module

firmly into position, lifting over the stop screw. The
upper and lower flanges of the power module will be
in contact with the front face of the cross-members.
The four fixing holes will align with the holes in the
cross-members.
f) Use four M6 x 12 mm pozi-head screws with plain

and spring washers, supplied as part of the mounting
frame kit, to secure the power module in place, see
Figure 5–9. Figure 5–9. – Positioning & Securing Power Module
Beyond The Stop Screw
Page 118
MV3000 Air Cooled DELTA MV3000e Controller
5.8 MV3000E CONTROLLER

Mount the controller with four M5 self-tapping screws to the fixing dimensions in Appendix A: Dimensioned
Mechanical Drawings and torque setting as detailed in Appendix C: Recommended Torque Settings The
orientation of the controller will depend upon the application.
5.9 USER I/O TERMINATION PANEL

Mount the I/O panel with two M5 self-tapping screws to the fixing dimensions in Appendix A: Dimensioned
Mechanical Drawings, and torque setting as detailed in Appendix C: Recommended Torque Settings The
orientation of the I/O panel will depend upon the application; however it must be mounted adjacent to the
controller due to the length of the supplied ribbon cable.
5.10 MAINS VOLTAGE MONITOR

Mount the MVM unit with four M5 self-tapping screws to the fixing dimensions in Appendix A: Dimensioned
Mechanical Drawings, and torque setting as detailed in Appendix C: Recommended Torque Settings. The
orientation of the MVM unit will depend upon the application; however it must be mounted adjacent to the
controller due to the length of the supplied ribbon cable.
5.11 DRIVE DATA MANAGER (KEYPAD)

The Keypad can be mounted in a separate location from the controller within the enclosure. It should be
retained by the six M4 x 8 mm fixing screws and washers supplied.
Refer to the Instruction Sheets T1915 (Drive Data Manager Installation) and T1916 (Mounting Kit
Instructions) for details of the keypad and mounting.
5.12 DELTA RECTIFIER MODULE POWER CONNECTIONS

5.12.1 General
The a.c. and d.c. terminals on the modules are not suitable to support the weight of any attached cables.
These cables must have additional mechanical support;
The bending radii limits of all cables must be respected.
Refer to Appendix C: Recommended Torque Settings.
5.12.2 A.C. Terminals
NOTE: When tightening connections support the terminals to prevent twisting.
5.12.2.1 For GDR391 Rectifier Models

All a.c. power terminals are located on the front of the module (see Figure 2–14), and are marked R, S and T.
Each terminal provides an M10 stud, suitable for ring-crimp connection. Refer to Appendix C:
Recommended Torque Settings for torque settings.

All a.c. power terminals are located on the front of the module (see Figure 2–15), and are marked R1, S1, T1
and R2, S2, T2.
Each terminal provides two M10 studs, suitable for ring-crimp connection. Refer to Appendix C:
Recommended Torque Settings for torque settings.
Page 119
DELTA RECTIFIER MODULE Power CONNECTIONS MV3000 Air Cooled DELTA

All a.c. power terminals are located on the right hand side of the module and mate with the busbar risers
fitted to the mounting steelwork, the terminals are marked R, S and T (See Figure 2–16).
Each terminal requires an M10 bolt with plain and spring washers to bolt through the terminals to the
threaded risers. The centre terminal may be rotated for cable connection. See Figure 2–19.

fitted to the mounting steelwork, the terminals are marked R, S and T (See Figure 2–17).

fitted to the mounting steelwork, the terminals are marked R1, S1, T1 and R2, S2, T2 (See Figure 2–18).
5.12.2.6 For MVR1600 Rectifier Models

All a.c. power terminals are located on the front of the module (see Figure 2–7), and are marked R, S, & T.
Each terminal provides three M10 studs, suitable for three 120mm2 cables with ring-crimp connection per
phase.
Page 120
MV3000 Air Cooled DELTA DELTA RECTIFIER MODULE Power CONNECTIONS
5.12.3 D.C. Terminals
NOTE: When tightening connections support the terminals to prevent twisting.

The d.c. terminals are located on the front of the module (see Figure 2–14).
Each d.c. connection, marked + & - requires connection by M10 bolt with plain and spring washers into
threaded inserts. All terminals are suitable for ring-crimp connection.

Each d.c. connection, marked +1, -1 & +2, -2 requires connection by M10 bolt with plain and spring washers
into the threaded inserts. All terminals are suitable for ring-crimp connection.

The d.c. positive connection, marked +, has an M10 stud, suitable for ring-crimp connection.
The d.c. negative connection, marked – requires connection by M10 bolt with plain and spring washers into
threaded inserts. All terminals are suitable for ring-crimp connection.
5.12.3.4 For GD872 Rectifier Models

Each d.c. connection, +1, -1 & +2, -2 requires connection by M10 bolt with plain and spring washers into the
threaded inserts.

Each d.c. connection, marked other than RECT+ requires connection by M10 bolt with plain and spring
washers into the threaded inserts.
NOTE: The lower RECT+ terminals are suitable for ring crimp connection.
5.12.3.6 For MVR1600 Rectifier Models

The d.c. positive connection, marked +, has three M10 studs.
The d.c. negative connection, marked -, has three M10 studs.
All terminals are suitable for ring-crimp connection.
Page 121
DELTA RECTIFIER MODULE Power CONNECTIONS MV3000 Air Cooled DELTA
5.12.4 Earth Connection

The earth terminal is a single M10 threaded insert, located on the lower front of any DELTA Rectifier module
and identified as shown in Figure 5–10.
Figure 5–10. - Protective Earth (ground) Symbol
5.12.5 Fitting Shrouds
Figure 5–11. – Shroud Assembly
Shrouds used on the DELTA rectifier module are shown in Figure 5–11. One shroud covers all of the a.c.
phase terminals R1, S1 T1 and R2, S2, T2. It is secured with M5 pozi-head screws into spacers which in turn
screw into the front of the module.
NOTE: These shrouds are supplied loose and must be fitted after the connections have been made.
Page 122
MV3000 Air Cooled DELTA DELTA TRANSISTOR MODULE POWER CONNECTIONS
5.13 DELTA TRANSISTOR MODULE POWER CONNECTIONS

5.13.1 General
 The bending radii limits of all cables must be respected.
Refer to Appendix C: Recommended Torque Settings for torque settings.
5.13.2 A.C. Connections

The a.c. power terminals are located on the front of the module (see Figure 2–7), and are marked A, B and C.
To gain access, the three shrouds must be removed. The A and B phase shrouds are secured with two
“snap” type rivets. The C phase shroud also covers the d.c. connections and is secured with four ‘snap’ type
rivets.
Each terminal provides one M10 stud, which is suitable for ring-crimp connection.
5.13.3 D.C. Connections

The d.c. link terminals are located in the lower front of the module (see Figure 2–7), and are marked DC+ and
DC-.
The d.c. shroud also covers the C phase a.c. connection and is secured with four ‘snap’ type rivets.
Each terminal provides one M10 insert, which requires an M10 bolt with plain and spring washers for
connection.
To avoid stressing the d.c. terminals when connecting these together with a single busbar, ensure that
DELTA transistor modules are fully inserted and are correctly aligned.
5.13.4 Earth Connection

The earth terminal is a single M10 threaded insert, located on the lower front of the module and identified
Figure 5–12. - Protective Earth (ground) symbol
5.13.5 Fitting Shrouds

The shrouds for the A and B phase terminals are secured with ‘snap’ type rivets as shown in Figure 5–12.
The shroud for the C phase d.c. power connection are secured with ‘snap’ type rivets
All shrouds must be fitted after the connections have been made.
Page 123
Fitting Earth Bonding Plates MV3000 Air Cooled DELTA
B Phase stud type

connection
C Phase stud type

connection
DC+ insertion type

connection
Earth insertion type

connection
DC+ insert type

connection
Figure 5–13. – MV DELTA Transistor Bridge Power Connections & Shrouding Details
5.14 FITTING EARTH BONDING PLATES

Each DELTA transistor module is supplied with a bonding plate. These plates must be fitted between
adjacent DELTA transistor modules as shown in Figure 5–14. The bonding plates are secured to the
transistor module chassis with four M5 x 10 SEM Torx screws which are supplied with the DELTA transistor
modules.
Figure 5–14. – DELTA transistor bonding plate fitment

A similar bonding plate system should be incorporated to link the DELTA transistor modules to the controller
and enclosure frame. Since controller location may vary from installation to installation, this is the
responsibility of the drive designer.
Where multiple sections of plate are used, they must be in direct metal-to-metal contact with each other,
without intervening paint or wires.
Page 124
MV3000 Air Cooled DELTA CONNECTIONS TO THE a.c. SHARING REACTORS
5.15 CONNECTIONS TO THE A.C. SHARING REACTORS

Dependent upon the variant, connections to the a.c. terminals should be made with M10 or M12 bolts. The
a.c terminals are identified as:
 U, V & W or
 A, B, & C
For a given phase, the cable lengths from the DELTA transistor module to sharing reactor must be the same
on each DELTA module.
5.16 CONNECTIONS TO FLOOR MOUNTED REACTORS

Connections to floor mounted reactors will vary dependent upon the application. Refer to the circuit
diagrams provided by the drive designer, and Appendix C: Recommended Torque Settings.
The chassis of the reactor must be connected to earth
5.17 SWITCH MODE POWER SUPPLY

Each DELTA transistor module requires an SMPS module to be fitted.
NOTE: If an MVC3003-4020 or MVC3003-4030 SMPS unit is to be used, it MUST be fitted to DELTA 1.

See Section 2: Specification for DELTA identity information.
See Section 3.8.1.1 for Over-voltage Trip link settings.
The SMPS unit is mounted on to three M5 studs as shown in Figure 5–15.

a) Loosen the ‘Nyloc’ nuts and locate the SMPS on to the studs.
b) Retighten the three M5 nuts.
The cable supplied as part of the SMPS, should be connected to TB1 on the DELTA transistor module. A 40
way ribbon cable, supplied as part of the DELTA transistor module, should be connected to PL22 (or PL2 on
MVC3003-4020 and MVC3003-4030) on the SMPS.
TB1 d.c. connection
M5 studs
40 way ribbon cable

connects to PL22
Figure 5–15. – Fitting The SMPS
Page 125
CONTROL CONNECTIONS - RIBBON CABLES MV3000 Air Cooled DELTA
5.18 CONTROL CONNECTIONS - RIBBON CABLES

5.18.1 Fitting Screened Ribbon Cables
The ribbon cables used in the DELTA drive are screened to prevent the electrical noise generated by the
drive from interfering with control signals. It is therefore very important that these cables are fitted
correctly.
The screen is exposed at each end of the ribbon cable, and this exposed area should be located in the two-
piece clamps provided with the products (or available separately), and the clamps tightened.
NOTE: The correct clamp should be chosen for securing the 40-way DELTA ribbon cables at the controller.
Clamp sets are available to secure from one to six ribbon cables.
Only ribbon cables supplied by GE Power Conversion must be used. This is to ensure that the screen is
of a suitable construction and performance, enabling the clamps described in Section 2.15.2 – Ribbon
Cable Clamps to correctly secure the ribbon cables.
Ribbon cables should be routed flat to earthed steelwork where possible and secured at regular intervals
with cable ties or similar mechanical restraints. Typical ribbon cable installations are shown in Figure 5–16
to Figure 5–19.
NOTE: Ribbon cables must not be run in front of the ribbon header of another DELTA module.
Figure 5–16. – Ribbon Cable Clamp At The DELTA Figure 5–17. – Ribbon Cable Clamp At The DELTA
Transistor Module Controller
Figure 5–18. – Typical Ribbon Cable Routing Across The Figure 5–19. – Typical Ribbon Cable Routing Between
DELTA Transistor Modules Enclosures
5.18.2 DELTA Transistor Modules

DELTA transistor modules are connected to the controller with a 40 way screened ribbon cable. PL1 of
DELTA 1 should always be connected to PL2 on the controller. PL1 on the remaining DELTA transistor
modules should be connected in ascending order as shown in Appendix B: Electrical Connection Diagrams.
Page 126
MV3000 Air Cooled DELTA CONTROL CONNECTIONS – DISCRETE WIRING
5.18.3 User I/O Termination Panel

The user I/O termination panel is connected to PL20 of the MV3000e controller with a 50 way screened
ribbon cable. The ribbon cable is supplied with the Termination Panel.
5.18.4 Mains Voltage Monitor

The MVM unit is connected to PL10 of the MV3000e controller with a 16 way screened ribbon cable. The
ribbon cable is supplied with the MVM unit.
5.19 CONTROL CONNECTIONS – DISCRETE WIRING

5.19.1 General
 The terminals on the modules are not suitable to support the weight of any attached cables.
These cables must have additional mechanical support;
 The bending radii limits of all cables must be respected.
 Refer to Section 3 – Drive (CDM) Design for cable routing guidance.
5.19.2 Connecting Cable Screens To Earth

All cable screens must be connected to earthed metalwork. These connections must be via an uninsulated
metal ‘p-clip’.
5.19.3 Rectifier
The rectifier control terminals are located on the front face of the module and identified as TB1. The
connections shown in Appendix B: Electrical Connection Diagrams should be made to PL12 on the
controller. Maximum wire sizes are given in Section 2: Specification.
5.19.4 Controller
The Drive Data Manager TM cable plugs directly into SK5. The cable connector screw locks should be
tightened to secure the cable. Details for connecting the cable at the keypad are provided in T1916.
CAN communications are made available on TB7. For connectivity see Section 2: Specification and circuit
diagrams provided by the CDM designer. For wire size information, see Section 2: Specification.
NOTE: Optional communication modules such as a 2nd CAN port or Ethernet are available. Installation and
operation instructions are provided with those modules and are therefore not covered by this manual.
5.19.5 User I/O Panel

User connections to the I/O termination panel are dependent upon the particular application. Section
Section 2: Specification provides details of the connector functions and wiring sizes. Reference should be
made to the assembly documentation and circuit diagrams provided by the CDM designer.
All wiring must be mechanically supported.
NOTE: TB4 and TB6 are both 9 way terminal blocks of the same connector pitch and so it is important that
wiring for these blocks is connected to the correct terminal block. TB1 is also a 9 way terminal block
but this has a different connector pitch to TB4 and TB6.
Page 127
Fitting enclosure Shrouds MV3000 Air Cooled DELTA
5.19.6 MVM
Connections to the incoming a.c. supply are made to PL28, as shown in Figure 5–20. For further installation
instructions, see T1930.
Pin 3 – T phase
Pin 1 – R phase
Pin 2 – S phase
Figure 5–20. - PL28 a.c. connections
5.20 FITTING ENCLOSURE SHROUDS

Overall enclosure shrouds should be fitted after all assembly and wiring have been completed. These will
be application specific, and must be fitted in accordance with the CDM designer’s instructions.
Page 128
T1689 Technical Manual Rev 0007 CDM Commissioning Guidance
6. CDM COMMISSIONING GUIDANCE
WARNING
 Do not use mobile phones or radio communication equipment within 2 metres (6 feet) of the enclosure.
The minimum size of the protective conductor must be in accordance with local safety regulations.
This equipment and the driven motor(s) must be earthed (grounded).
Disconnect all supplies before working on the equipment.
 High Voltages
has been removed:
- reactors & transformers
- cables
the air flow path.
- Measure the audible noise in the installation.
- When the audible noise level exceeds 70 dB(A), appropriate warning notices should be displayed.
CAUTION
6.1 INTRODUCTION
The detailed commissioning procedure for an Air Cooled DELTA Drive System will vary for each application;
such details are not included in this manual. However, reference should be made to the MV3000e Getting
Started Manual T1676 (or T2002 for AEM drives) which does include general guidance for commissioning.
The procedures in this manual are split into two discrete sections. This section describes the commissioning
procedures for the Complete Drive Module that should be undertaken by the enclosure manufacturer.
Section 7: PDS Commissioning Guidance describes the procedures for integrating the CDM into the end
user’s application.
Each section gives guidance on visual inspection, coolant system pressure tests and electrical safety tests.
When the equipment has been designed and built for a particular application by an enclosure
manufacturer then it is important, for the safety of personnel and equipment, that all commissioning
instructions prepared by the manufacturer include the following details:
 Warnings and cautions as necessary;

 Visual / mechanical checks;
 Electrical safety checks;
 Cooling system checks - internal and external to the enclosure;
 Functional tests.
Page 129
CDM Commissioning Guidance T1689 Technical Manual Rev 0007
Visual Inspection MV3000 Air Cooled DELTA
6.2 VISUAL INSPECTION

The pre-commissioning visual checks now outlined apply to DELTA equipment housed in an enclosure and
where appropriate, to DELTA modules supplied loose. The checks outlined include those for the cooling
system within the enclosure. Check that:
 If multiple modules are required, ensure they are of the same type and voltage grade;
 Check that the Timed Overvoltage links (if fitted) on the DELTA 1 SMPS module are correct;
 The modules have been correctly assembled in the appropriate mounting frames in
accordance with the instructions in Section 5; CDM Assembly.
 There is adequate clearance around the control components within the enclosure for
ventilation;
 There is adequate clearance around the enclosure for ventilation, and that the ventilation
louvres are not covered or blocked;
6.3 ELECTRICAL SAFETY TESTS

6.3.1 Introduction
When the visual inspection has been completed, it is recommended that earth continuity and insulation
tests be carried out, prior to the equipment being commissioned. This is to check that cables have not been
damaged during installation and that the equipment is correctly bonded for earthing purposes. These tests
will vary in detail for each application, and therefore only general guidance is included.
6.3.2 Earth Continuity

All external metal parts (such as doors, side and rear panels, roof plate) and internal panels, support rails
and other metal hardware must be tested to ensure that they are effectively connected to the main
incoming enclosure earth connection. The test is performed by injecting a current of at least 25A between
the earth connection and each panel in turn.
The measured resistance MUST be less than 0.1.
Page 130
MV3000 Air Cooled DELTA Electrical Safety Tests
6.3.3 Voltage Groups For Insulation Tests

For the insulation tests, drive systems can be considered to consist of several different voltage groups, see
the typical system example in Figure 6–1 and Table 6–1.
MVC3001-400x MVC3002-4001 110 V ac / 230 V ac

KEYPAD CONTROLLER I/O PANEL C PLANTSIDE I/O
<30 V ac / < 50 V dc
PLANTSIDE I/O
MVC3003-40xx D
SMPS
PL2 DC +/-
DELTA
TB1
RECTIFIER MODULE
PL3 DIB
TB1
PL1
SHARING
REACTOR
PL2
Interlock
R
RECT + DC+ U U
S
V V
T RECT - DC- W W
MAIN AC
CIRCUIT
BREAKER A
415 Vac Auxiliary 110 / 230 Vac Auxiliary

Components Components
Fans
Contactors Contactors
E
R S T
B C
Figure 6–1. – Voltage Grouping For Insulation Tests
Group Nominal Circuit Detail

Operating Voltage
690 V a.c. The main power circuit – includes main fuses, main isolator, DELTA module power
A Or connections, input, d.c. link and output reactors
480Vac
B 400 – 480 V a.c. Auxiliary circuits - may include coolant circuit pumps, fans and contactors
C 110 / 230 V a.c. Auxiliary circuits - may include coolant circuit pumps, fans, contactors and plant I/O
D <30 V a.c. / < 50 V Extra Low Voltage (ELV), such as plant I/O circuits
d.c.
E Earth Main enclosure earth point, enclosure structure, other earthed metalwork etc.
Table 6–1. – Voltage Grouping For Insulation Tests
Page 131
Electrical Safety Tests MV3000 Air Cooled DELTA
6.3.4 Insulation Resistance Test

The insulation resistance should be measured and recorded before and after the High Voltage Insulation
test. The connections of each voltage group will be bonded together, and then connected to earth. Each
group is tested individually by removing its bond to earth (the other circuits remain connected to earth).
After each group is tested, the earth bond must be reconnected.
NOTE: Lightning surge arrestors should be disconnected for the tests.
Test voltage = 1000 V

The resistance value is expected to be >500M.
6.3.5 High Voltage Insulation Test

The connections of each voltage group will be bonded together, and then connected to earth. Each group
is tested individually – see Table 6–2 - by removing its bond to earth (the other circuits remain connected to
earth). After each group is tested, the earth bond must be reconnected.
NOTE 1: Use test voltages and periods that are required by the standards the drive system must adhere to. The
test voltages and periods quoted in Table 6–2 are MAXIMUM values and must not be exceeded.
NOTE 2: All high voltage insulation tests must be conducted using a test set that indicates the current, and
whose output is limited with a trip circuit to reduce the consequential damage should an insulation
failure occur.
NOTE 3: Lightning surge arrestors should be disconnected for the tests.
Maximum Maximum
Test Group Procedure
Test Voltage Duration
 Connect groups B, C and D to group E (earth);
 Close or short circuit the main breaker;
A
 Remove control connections to the DELTA transistor and 3.1 kV dc
≥690 V a.c.
rectifier modules;
 Disconnect the SMPS units; or 60 s
or
 Disconnect the MVM module (if fitted);
 Disconnect the earth connection to the DVDT filter (if fitted); 2.8 kV dc
480 V a.c.
 Connect the insulation test set output to group A;
 Connect the insulation test set output to group E.
 Connect groups A, C and D to group E (earth);
 Close or short circuit any breakers necessary to make
B
these connections; 2.8 kV dc 60 s
400 – 480 V a.c.
 Connect the insulation test set output to group B;
 Connect groups A, B and D to group E (earth);
 Close or short circuit any breakers necessary to make
C these connections;
2.5 kV dc 60 s
110 / 230 V a.c.  Remove any transformer Centre Tap Earth connections;
 Connect the insulation test set output to group C;
D  Connect groups A, B and C to group E (earth)
<30 V a.c. /  Connect the insulation test set output to group D; 140 V d.c. 60 s
< 50 V d.c.  Connect the insulation test set output to group E.
Table 6–2. – Insulation Test Guidance
Page 132
MV3000 Air Cooled DELTA Functional Tests
6.4 FUNCTIONAL TESTS

The following information is generic explanation of commissioning for many variants of the MV3000e DELTA
drives. The commissioning procedure should be in accordance with instructions in the MV3000e Getting
Started Manual T1676 (or T2002 for AEM drives) and, when applicable, additional instructions prepared by
the enclosure manufacturer.
6.4.1 Software
Drive software will already have been installed in the controller at its manufacture. This will need to be
checked to ensure it is the latest version. If not, the latest version must be installed.
The drive controller will need to be loaded with the relevant application code. A PC with Drive CoachTM
software will be required for this.
For information on how to perform software updates / installation, see T1676 (or T2002), T1679 and the
specific application notes prepared for the drive.
6.4.2 Fans
Ensure that all fans operate as they should, fans could include:
 Enclosure fans;
 Capacitor fans;
 Controller fan.
6.4.3 Communication Links

Ensure that the communication links to the drive are operational. These should be initialised by following
the guidance provided by the relevant Instruction Sheet. The communication links could include CANopen,
Ethernet and Serial Links.
6.4.4 Plant I/O

Check all feedback signals into the I/O circuits are functioning. This could include cooling system feedbacks,
and “User Daisy Chain” healthy signals. The operation of these circuits will be detailed in the circuit
diagrams and the Test Specification produced by the enclosure manufacturer.
6.4.5 Power Circuit

The method of testing the power circuit will depend upon the facilities available at the enclosure
manufacturer, and the requirements of the final customer. Ideally, the drive should be run at its rated
current and voltage for an extended period to prove that all system functions are operating correctly.
Page 133
Functional Tests MV3000 Air Cooled DELTA
Page 134
T1689 Technical Manual Rev 0007 PDS Commissioning Guidance
7. PDS COMMISSIONING GUIDANCE
WARNING
 Do not use mobile phones or radio communication equipment within 2 metres (6 feet) of the enclosure.
- The minimum size of the protective conductor must be in accordance with local safety regulations.
- This equipment and the driven motor(s) must be earthed (grounded).
- Disconnect all supplies before working on the equipment.
 High Voltages
- Replace all shrouds and close all doors before energising the equipment.
has been removed:
- reactors & transformers
- cables
the air flow path.
- Measure the audible noise in the installation.
- When the audible noise level exceeds 70 dB(A), appropriate warning notices should be displayed.
CAUTION
7.1 INTRODUCTION
The detailed commissioning procedure for an Air Cooled DELTA Drive System will vary for each application;
such details are not included in this manual. However, reference should be made to the MV3000e Getting
Started Manual T1676 (or T2002 for AEM drives) which does include general guidance for commissioning.
The procedures in this manual are split into two discrete sections. Section 6.0 – Commissioning Guidance
describes the commissioning procedures for the Complete Drive Module that should be undertaken by the
enclosure manufacturer.
This section describes the commissioning procedures for integrating the Complete Drive Module into the
Power Drive System on the end user’s site.
Each section gives guidance on visual inspection, coolant system pressure tests and electrical safety tests.
When the equipment has been designed and built for a particular application by an enclosure
manufacturer then it is important, for the safety of personnel and equipment, that all commissioning
instructions prepared by the manufacturer include the following details:
 Warnings and cautions as necessary;

 Visual / mechanical checks;
 Dry out / warm-up procedure;
 Electrical safety checks;
 Cooling system checks - internal and external to the enclosure;
 Functional tests.
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PDS Commissioning Guidance T1689 Technical Manual Rev 0007
Visual Inspection MV3000 Air Cooled DELTA
7.2 VISUAL INSPECTION

7.2.1 Delivery Checks
It is possible that the enclosure could have sustained damaged during transport and installation. Inspect
the enclosures for any damage that may have been caused.
This could include:
 Broken or cracked shrouds;

 Wiring insulation damage;
 Panel damage including paint chips or dents;
 Loose or broken connections;
 Debris or foreign objects in the enclosures.
7.2.2 Enclosure Installation

Once the enclosures have been installed into their final location, the following checks should be made:
 Ensure that the enclosure is connected to the local earth circuit;

 Ensure that all wiring to the system is in accordance with the installation drawings. This could
include supply, communications and I/O connections;
 Ensure that the enclosure is supported using the correct mounting points;
 Check that, all gland plates are present and secured in place with appropriate glands fitted;
7.3 DRY-OUT / WARM-UP PROCEDURE

Before applying power to the converter for the first time, or after an extended period of no power applied to
the converter, it is necessary to go through a heat/dry cycle.
This is dependent on many factors, including the following:
 Where the converter was manufactured;

 When the converter was manufactured;
 The converter’s final installation location;
 The environmental conditions at the time of final installation and commissioning.
The dry-out process must be implemented by one or more of the following:
 All doors and panels closed;

 Operating the internal heater systems (e.g. anti-condensation heaters);
 Applying an external heat source;
The duration of the dry-out period is dependent on the initial condition of the equipment and the following
time durations are recommended:
Initial condition of equipment Recommended dry-out period

Commissioning of equipment in humid conditions 48 hours
Commissioning of equipment in dry conditions 24 hours
Re-starting of equipment following a period of isolation in excess of 48 hours 24 hours
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T1689 Technical Manual Rev 0007 PDS Commissioning Guidance
MV3000 Air Cooled DELTA System Configuration When Non-operational
7.4 SYSTEM CONFIGURATION WHEN NON-OPERATIONAL

The installation, configuration and modes of operation of this equipment may require internal heating
during periods when the main drive is not powered to prevent condensation forming.
The implementation of this type of heating is dependent on the following:
 External environmental conditions;

 Required internal environmental limits;
 External power sources;
 Safety implications of powered heater elements.
7.5 FUNCTIONAL TESTS

7.5.1 Software
Drive software will already be installed in the controller. This will need to be checked to ensure it is the
latest version. If not, the latest version must be installed.
The drive controller will need to be loaded with the relevant application code. A PC with Drive Coach TM
software will be required for this.
For information on how to perform software updates / installation, see T1676 (or T2002 for AEM drives),
T1679 and the specific application notes prepared for the system.
7.5.2 Fans
Ensure that all fans operate as they should, fans could include:
 DELTA cooling fans;

 Enclosure fans;
 Controller fan.
7.5.3 Communication Links

Ensure that the communication links to the drive are operational. These should be initialised by following
the guidance provided by the relevant Instruction Sheet. The communication links could include CANopen,
Ethernet and Serial Links.
7.5.4 Plant I/O

Check all feedback signals into the I/O circuits are functioning. This could include cooling system feedbacks,
and “User Daisy Chain” healthy signals. The operation of these circuits will be detailed in the circuit
diagrams and the Test Specification produced by the enclosure manufacturer.
7.5.5 Power Circuit

The commissioning procedure for the power circuit should be determined by the final customer. Reference
should be made to the Getting Started Manual T1676 (or T2002 for AEM drives) and the enclosure
manufacturer installation instructions.
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PDS Commissioning Guidance T1689 Technical Manual Rev 0007
Functional Tests MV3000 Air Cooled DELTA
Page 138
T1689 Technical Manual Rev 0007 Maintenance
8. MAINTENANCE
WARNING
 Disconnect ALL supplies before working on the equipment.
 Ensure system is isolated using appropriate lock out – tag out (LOTO) procedures.
 Wait at least 5 minutes after isolating supplies and check that voltage between DC+ and DC- has reduced
to a safe level before working on this equipment.
 Do not use mobile phones or radio communication equipment within 2 metres (6 feet) of the equipment.
 High Voltages
 Ensure appropriate PPE is worn at all times.
 Items marked with weights greater than 20kg (44lb) should only be moved with lifting apparatus.
CAUTION
 These items should only be fitted by a skilled person who has been trained by GE Power Conversion or an
authorised training centre.
8.1 INTRODUCTION
This section describes maintenance for the DELTA modules and the controller in an air-cooled DELTA
System.
No component maintenance is described for the module or the controller. If either product requires
component maintenance, a request for assistance should be made to a GE Power Conversion via the
appropriate national address at the back of this manual.
Some users may have the facilities, skilled personnel and the appropriate lifting equipment to enable a
replacement DELTA module to be fitted should this become necessary. This section of the manual therefore
includes sufficient detail to enable such users to remove and refit a module.
Due to the technology used in the DELTA modules there is a requirement for periodic maintenance to be
carried out and this is also detailed in this section of the manual.
NOTE: Throughout this section of the manual reference to a DELTA module should be read as applying to
either a rectifier or transistor module unless a type of module is specifically stated.
8.1.1 Restarting The System Following Maintenance

Following any maintenance procedure, the system should be restarted following the instructions provided
in Section 6: CDM Commissioning Guidance.
8.2 SPECIAL TOOLS, EQUIPMENT & MATERIALS

In addition to commonly available hand tools such as spanners, and screwdrivers, certain specific tools are
required to perform maintenance tasks on a DELTA drive system:
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Maintenance T1689 Technical Manual Rev 0007
Preventative Maintenance MV3000 Air Cooled DELTA
8.3 PREVENTATIVE MAINTENANCE

There are several preventive maintenance routines which should be performed to ensure optimum
operating efficiency of the system is maintained. GE Power Conversion recommends that these are
performed bi-annually, but individual applications may require a different maintenance schedule.
NOTE: All supplies must be isolated before preventative maintenance tasks are performed.
8.3.1 Bi-Annual Maintenance Routine

The following checks should be carried out every six months:
a) Ensure that all ventilation louvres to the cubicle are unobstructed;
b) Ensure the airflow through the cooling ducts is unobstructed.
c) Examine all power terminations for any signs of overheating;
d) Check that all electrical connections are secure. Torque settings are given in Appendix C:
Recommended Torque Settings;
e) Remove any accumulated dust from the system, using a vacuum cleaner with a non-conducting
nozzle.
Page 140
MV3000 Air Cooled DELTA Removal of Modules for service or repair
8.4 REMOVAL OF MODULES FOR SERVICE OR REPAIR
WARNING
 High Voltages
- Replace all shrouds and close all doors before energising the equipment.
- Disconnect all supplies before working on the equipment.
 Wait at least 8 minutes after isolating supplies and check that the voltage between DC+ and DC- has
has been removed:
- Reactors and transformers
- Cables
 Items marked with weights greater than 20kg (44 lb.) should only be moved with lifting apparatus.
CAUTION
- Observe static handling precautions.
8.4.1 Preliminary Checks

Before commencing any maintenance or servicing tasks on a DELTA system check that:
 The warnings and cautions given above have been understood and followed;
 If a DELTA module is to be replaced, ensure that:
 All supplies have been isolated;
 A suitably rated crane is available;
8.4.2 Removal Of The Controller

Removal of the controller does not require any special equipment. The controller should be removed from
the enclosure by following the steps below. Refer to Section 5: CDM Assembly, for further information:
a) Remove the ribbon cable clamps (secured with M5 nuts) as required. Carefully cut and remove any
cable ties securing the wiring. Disconnect the ribbon cables, first noting their routing and positions;
b) Disconnect all remaining wiring from the controller by unplugging the connectors. It is not required
to remove individual wires from the terminals. Ensure that wiring is labelled to allow correct
connections to be made to the replacement controller;
c) Loosen (removal is not necessary) the four M5 fixing screws and remove the controller by lifting it
free of the screws.
8.4.2.2 Removal Of Optional Modules

If the controller has an optional communications module fitted, it should be removed at this stage. Refer to
the relevant instruction sheet for details.
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Removal of Modules for service or repair MV3000 Air Cooled DELTA
8.4.3 Removal Of The I/O Termination Panel

Removal of the I/O termination panel does not require any special equipment. The I/O panel should be
removed from the enclosure by following the steps below. Refer to Section 5: CDM Assembly, for further
information:
a) Disconnect all wiring from the panel by unplugging the ribbon cable and terminal blocks. It is not
required to remove individual wires from the terminals. Ensure that each terminal block is labelled to
allow correct connections are made to the replacement unit;
b) Loosen (removal is not necessary) the two M5 fixing screws and remove the I/O panel by lifting it free
of the screws;
c) Note the position of the DIP switches on the I/O panel so that the replacement can be correctly
configured.
8.4.4 Removal Of The MVM Module

Removal of the MVM module does not require any special equipment. The MVM module should be removed
from the enclosure by following the steps below. Refer to Section 5: CDM Assembly, for further information:
a) Carefully cut and remove any cable ties that secure the ribbon to the MVM module.
b) Disconnect the three pin connector and the ribbon cable;
c) Loosen (removal is not necessary) the four M5 fixing screws and remove the MVM module by lifting it
free of the screws.
8.4.5 Removal Of An SMPS Module

Removal of an SMPS module does not require any special equipment. An SMPS module should be removed
from the enclosure by following the steps below. Refer to Section 5: CDM Assembly, for further information:
a) Disconnect the two pin connector and the ribbon cable;
b) Loosen the three M5 nuts that secure the SMPS to the DELTA module;
c) Remove the SMPS module by lifting clear of the fixing screws.
d) If the SMPS is a -4020 or -4030 variant (identified on the rating label on the rear of the module), note
the position of the DIP switches so that the replacement can be correctly configured
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MV3000 Air Cooled DELTA Removal of Modules for service or repair
8.4.6 Removal Of A DELTA Rectifier Module
CAUTION
- Only lift or move them by use of the lifting point.
- Lay them down on the plain left-hand face when not fitted in a frame.
- Do not leave modules unsupported in the upright position.
A DELTA rectifier module should be removed from the enclosure by following the steps below. Refer to
Section 5: CDM Assembly, for further information:
8.4.6.1 Removal Of Electrical Connections

a) Remove the terminal shrouds;
b) Disconnect the control connections by unplugging the connector;
c) Disconnect the a.c. phase cables or busbars, first noting their positions;
d) Disconnect the d.c. cables or busbars;
e) Disconnect the earth cable (if fitted).
8.4.6.2 Removal Of The Module

a) Remove four M6 fixing screws (two from the top of the module and two from the bottom);
b) Slide the module forwards until the stop pin is reached;
c) Connect a suitable crane shackle to the lifting hole in the top of the module;
d) Take up the weight of the module, lift it over the stop pin and withdraw from the enclosure;
e) Move the module into a safe position with its left hand side (when viewed from the front) laid on a flat
surface.
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Removal of Modules for service or repair MV3000 Air Cooled DELTA
8.4.7 Removal Of DELTA Transistor Module
CAUTION
- Only lift or move them by use of the lifting point.
- Lay them down on the plain left-hand face when not fitted in a frame.
- Do not leave modules unsupported in the upright position.
A DELTA transistor module should be removed from the enclosure by following the steps below. Refer to
Section 5: CDM Assembly, for further information:
8.4.7.1 Removal Of Electrical Connections

a) Remove the SMPS module by following the instructions in Section 8.4.5: Removal Of An SMPS Module;
b) Disconnect the control ribbon cable by unplugging the connector;
c) Carefully cut and remove any cable ties securing the control ribbon cable to the SMPS plate. It may
be necessary to release control ribbon cables to other DELTA modules if they run across the module
to be removed;
d) Remove the SMPS mounting plate by loosening the M5 fixings and lifting clear;
e) Remove the terminal shrouds;
f) Disconnect the a.c. phase cables or busbars, first noting their positions;
g) Disconnect the d.c. cables or busbars;
8.4.7.2 Removal Of The Module

a) Remove four M6 fixing screws (two from the top of the module and two from the bottom);
b) Slide the module forwards until the stop pin is reached;
c) Connect a suitable crane shackle to the lifting hole in the top of the module;
d) Take up the weight of the module, lift it over the stop pin and withdraw from the enclosure;
e) Move the module into a safe position with its left hand side (when viewed from the front) laid on a flat
surface.
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MV3000 Air Cooled DELTA Replacement of Modules FOLLOWING SERVICE OR REPAIR
8.5 REPLACEMENT OF MODULES FOLLOWING SERVICE OR REPAIR
WARNING
 All items exposing high voltage must be placed in a suitable enclosure with restricted access.
- This equipment and the driven motor(s) must be earthed (grounded).
Refer to Section 5: CDM Assembly, for fitting instructions of replacement modules.
8.5.1 Replacement Of Control Components

Ensure that the following are observed when replacing control components:
 Ensure that the part number of the replacement item matches exactly with the original
module;
 Refit any optional communications module to the replacement controller before installing it in
the enclosure;
 Set DIP switches on replacement I/O panel and SMPS (if fitted) to match the original unit
configuration.
NOTE: Fitting a replacement module with a different part number to the original item, or failure to set the DIP
switches correctly may result in maloperation of the system.
8.5.2 Replacement Of DELTA Transistor & Rectifier Modules

Ensure that the following are observed when replacing control components:
 Ensure that the part number of the replacement item matches exactly with the original
module;
 Refer to Appendix C: Recommended Torque Settings for the correct torque settings of the
electrical connections;
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DELTA MODULE PACKAGING & TRANSPORTATION MV3000 Air Cooled DELTA
8.5.3 Re-Commissioning The System

The equipment should be re-commissioned in accordance with the instructions for the particular
application. See Section 6: CDM Commissioning Guidance for further details.
Depending on the replacement module source and the replacement duration, it may be necessary to dry
out the equipment before powering it up.
The dry-out process must implement the following (as appropriate):
 All doors and panels closed;

 Operating the internal heater systems (e.g. anti-condensation heaters);
The duration of the dry-out period will be dependent upon the initial condition of the equipment and the
following time durations are recommended:
Storage conditions for DELTA Initial condition of equipment Recommended

module acclimatisation and
dry-out period
DELTA module kept in remote Installing new replacement DELTA module (sealed prior 2 hours acclimatisation
storage area with to installation). +
environmental controls 4 hours dry-out
DELTA module kept in remote Installing new replacement DELTA module (sealed prior 2 hours acclimatisation
storage area without to installation). +
DELTA module kept in remote Installing a replacement DELTA module that is either 2 hours acclimatisation
storage area without not new or not inside sealed packaging. +
Unknown storage conditions DELTA module unsealed and covered in dust or Do not use the
showing signs of surface moisture/condensation or replacement DELTA
showing signs of previous exposure to moisture (e.g. module.
watermarks, rusting metalwork)
Table 8–1. – Acclimatisation & Dry Out Periods for DELTA Modules Installed from Storage
8.6 DELTA MODULE PACKAGING & TRANSPORTATION

Appropriate tools, equipment and materials are required for the handling and packaging of a DELTA
module, MV3000e Controller, SMPS, I/O panel or MVM unit for transportation.
 Where possible return a module in its original packaging material, or in the replacement
module packaging;
 If new packaging is used, label the box with all the warnings for transit including weight,
orientation, protect against water, stacking limitations and temperature limitations.
8.6.1 DELTA Module

A suitable crane for moving the DELTA module will be required. The packaging process is detailed below:
a) Wrap the module in a protective layer of paper packing/wrapping.
b) Seal the module and desiccant in an anti-static bag.
c) Evacuate the air from the bag prior to final sealing.
d) Seal and label the packing crate.
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MV3000 Air Cooled DELTA DELTA MODULE PACKAGING & TRANSPORTATION
8.6.1.2 Packing Materials For A DELTA Module

 a waterproof anti-static bag size 1030 mm long x 730 mm wide x 840 mm high
(≈ 41 in x 29 in x 33 in);
 300 g ( 11 oz) of desiccant for moisture protection inside the bag;
 a supply of paper packing/wrapping or polystyrene suitable for the protection of a module
within the packing case during transit;
 a tri-wall packing case, with wooden pallet, of internal dimensions 965 mm wide x 710 mm
deep x 300 mm high (≈ 38 in x 28 in x 12 in) which is capable of withstanding the conditions of
transportation.
8.6.1.3 Control Components

The packaging process is detailed below:
a) Seal the module and desiccant in an anti-static bag.
b) Evacuate the air from the bag prior to final sealing.
c) Seal and label the packing box.
8.6.1.4 Packing Materials For A Control Component

 a gusseted waterproof anti-static bag size 508 mm long x 610 mm wide (≈ 20in x 24in) for the
controller;
 10 gm of desiccant for moisture protection inside the bag;
 suitable polystyrene materials for retaining the controller in position in a packing box;
 a suitable packing box of internal dimensions 604 mm wide x 318 mm deep x 168 mm high
(≈ 24 in x 13 in x 7 in) which is capable of withstanding the conditions of transportation.
Page 147
SYSTEM DIAGNOSTICS MV3000 Air Cooled DELTA
8.7 SYSTEM DIAGNOSTICS

8.7.1 Controller Diagnostics
The MV3000e Controller provides diagnostic information which can be accessed by use of the optional
Drive Data Manager (Keypad). The drive conditions for which diagnostic information is available are:
 drive status;
 warning of a problem;
 fault condition;
 trips.
The controller includes a group of LEDs (Light Emitting Diodes) shown in Figure 8–1 to provide an indication
of the four statuses listed above. All of the diagnostic information, and some of the helpful hints for fault
diagnosis, are detailed in the MV3000e Getting Started Manuals T1676 or T2002 (for AEM systems).
Tripped D5
RS485
D79
Transmit
Warning D18
Running D39
RS485
D80
Receive
Ready D54
Figure 8–1. – MV3000e Controller LED Functions
All diagnostic information is detailed within the following documents:

a) MV3000e Software Technical Manual T1679;
b) T1676 Getting Started Manual for MV3000e AC-Fed Drives;
c) T2002 Getting Started Manual for MV3000e Active Energy Management Drives
8.7.2 DELTA Transistor Module Diagnostics

The PCB on the DELTA transistor module includes a group of six LEDs that display the operational status of
the module. The LED functions are shown in Figure 8–2.
+ 5 V OK + 15 V OK
Running Healthy
Fan 1 OK Fan 2 OK
DELTA Interface PCB

20X4381 / 20X4384
Figure 8–2. – DELTA Transistor Module LED Functions
Page 148
MV3000 Air Cooled DELTA Spares & Servicing
8.8 SPARES & SERVICING

8.8.1 Spares
There are no recommended spares for the DELTA modules or the control components except for the pre-
charge protection fuses for the MVR1600 rectifier module (see Section 8.8.3: Pre-Charge Fuses).
If either a DELTA module or a control component is suspected of being faulty it should be returned to GE
Power Conversion for servicing.
8.8.2 Servicing
Before removing a module for return to GE Power Conversion for servicing the user should ensure that the
facilities, skilled personnel and the appropriate lifting equipment are available to replace the module.
Detailed instructions are included earlier in Section 1: Introduction.
When any equipment is being returned for servicing it is important that all the details available about the
conditions under which the equipment failed are conveyed, preferably in writing, with the returned
equipment.
When referring to GE Power Conversion about any modules the serial number for the suspect item must
always be quoted. Any references to replacement ribbon cables should quote the part number from the
original ribbon/connector.
8.8.3 Pre-Charge Fuses

The recommended pre-charge protection fuse for the MVRL1600-4601 rectifier module is:
GE Power Conversion reference S82028/310.
Bussmann type KTK-8. Rated at 8 A, 600 V a.c.
Cartridge size 10 x 38 mm
NOTE: Replacing these fuses with another rating or type will invalidate safety approvals.
Three pre-charge fuses are located on the upper printed circuit board which is located at the rear of the
rectifier module.
8.9 CAPACITOR REFORMING

If this equipment is kept in store for long periods of time, usually greater than two years, it may be
necessary to reform capacitors before putting the equipment of which they are a part into service. This
requirement applies to the d.c. link capacitors on the DELTA transistor module. Refer to Section 5.2.2 / 5.2.3.
for further information on Electrolytic Capacitor Shelf Life and Procedures after Removing DELTA Transistor
Bridge Modules from Long Periods of Storage.
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Capacitor Reforming MV3000 Air Cooled DELTA
Page 150
T1689 Technical Manual Rev 0007 Disposal
9. DISPOSAL
This equipment or any part of the equipment should be disposed of in accordance with the laws of the
country of use.
Modern high technology materials have been used in the manufacture of the equipment to ensure
optimum performance. Care has been taken with the selection of these materials to minimise risks to
health and safety. However, some materials require special consideration during disposal.
In common with all products of this type, the high voltage electrolytic capacitors contain an electrolyte,
which must be disposed of as hazardous waste. The electrolytes are solutions of organic and/or boric acid.
The major solvents in the capacitors are butyrolactone and monoethylene glycol. The electrolyte is non-
carcinogenic, but may cause irritation to the skin if contact is prolonged.
Page 151
Page 152
T1689 Technical Manual Rev 0007 Appendix A: Dimensioned Mechanical Drawings
MV3000 Air Cooled DELTA Scope
10. APPENDIX A: DIMENSIONED MECHANICAL DRAWINGS

10.1 SCOPE
This section gives dimensioned drawings of some DELTA components, to allow the design and fabrication of
application specific mounting arrangements.
The mechanical and electrical installation of the DELTA modules and the related control components are
shown in Section 5: CDM Assembly of this manual.
10.2 CONTROL ARRANGEMENT
Page 153
Appendix A: Dimensioned Mechanical Drawings T1689 Technical Manual Rev 0007
MV RECTIFIER Bridge MODULE: MVR1600-4601 MV3000 Air Cooled DELTA
10.3 MV RECTIFIER BRIDGE MODULE: MVR1600-4601
Page 154
MV3000 Air Cooled DELTA GDR Rectifier Modules
10.4 GDR RECTIFIER MODULES

10.4.1 GDR391
Page 155
GDR Rectifier Modules MV3000 Air Cooled DELTA
10.4.2 GDR633
Page 156
10.4.3 GDR721 With Busbar Assembly (41Y5810/10)
Page 157
10.4.4 GDR872
Page 158
10.4.5 GDR872 With Busbar Assembly (41Y5356/10)
Page 159
10.4.6 GDR1168
Page 160
10.4.7 GDR1168 With Busbar Assembly (41Y5810/20
Page 161
MV TRANSISTOR MODULEs MV3000 Air Cooled DELTA
10.5 MV TRANSISTOR MODULES

10.5.1 MVD300
Page 162
MV3000 Air Cooled DELTA MV TRANSISTOR MODULEs
10.5.2 MVD500
10.5.2.1 Module Without Shrouding
Page 163
MV TRANSISTOR MODULEs MV3000 Air Cooled DELTA
10.5.2.2 Module With Shrouding
Page 164
10.6 REACTORS, INDUCTORS & TRANSFORMERS

10.6.1 Input Line Reactors For DFE Drives
10.6.1.1 30V6500, 630A a.c.
NOTE: 30V6500/10 has the same outline as 30V6500/20 but does not include the optional fuses.
Customer connection for 30V6500/10 is to A1, A2 & A3 not A, B & C as shown for 30V6500/20
Page 165
10.6.1.2 30V6500 630A a.c.
NOTE: 30V6700/10 has the same outline as 30V6700/20 but does not include the optional fuses.
Customer connection for 30V6700/10 is to A1, A2 & A3 not A, B & C as shown for 30V6700/20
Page 166
10.6.2 DC Link Inductors
Order No. A B C D E F Detail A G H J

33Z0329/10 320 500 350 160 280 330 Fig 2 12 25 11
33Z0331/10 325 465 390 160 300 355 Fig 3 12 40 11
50Z0019/01 365 610 365 180 280 335 Fig 3 14 50 11
50Z0055/04 Details Upon Request
50Z0055/05 Details Upon Request
50Z0050/07 X
50Z0038/01 325 465 245 160 280 335 Fig 1 11 N/A 11
50Z0038/02 325 470 395 160 320 375 Fig 2 14 33 11
50Z0038/03 365 610 385 180 300 355 Fig 3 14 50 11
50Z0057/01 400 700 300 200 290 340 Fig 4 12 40 13
50Z0057/02 400 700 330 200 330 385 Fig 4 14 37.5 13
50Z0057/03 430 725 433 220 330 385 Fig 4 14 37.5 13
Page 167
10.6.3 Interbridge Transformers
Order No. A B C D E F G H I J K L M
33Z0352/10 165 290 30 135 250 245 90 125 240 160 11 13 24
Page 168
10.6.4 Interbridge Transformers (cont’d)
Order No. A B C D E F I Detail A1 & A3 G H Detail A2 G H

33Z0354/10 265 395 308 130 210 265 Fig 1 13 - Fig 2 14 33
50Z0021/10 325 465 420 160 280 335 11 Fig 3 12 40 Fig 3 14 50
50Z0043/01 325 465 345 160 280 335 11 Fig 1 11 - Fig 1 13 -
50Z0043/02 325 470 385 160 320 375 11 Fig 1 13 - Fig 3 12 40
50Z0043/03 365 610 385 180 300 355 11 Fig 2 12 33 Fig 3 14 50
50Z0063/01 365 665 358 180 270 325 Fig 2 12 40 Fig 4 12 30
50Z0063/02 365 665 337 180 300 355 Fig 3 12 40 Fig 4 12 30
50Z0063/03 Details Upon request
50Z0063/04 Details Upon request
Page 169
10.6.5 Sharing Reactors

10.6.5.1 31V5500/10, 377A a.c.
Page 170
10.6.5.2 50Z0126/01, 643A a.c.
Page 171
10.6.6 Dirty Air Ducting
10.6.7 Lower Guide Plate: 31V5800/10
Page 172
T1689 Technical Manual Rev 0007 Appendix B: Electrical Connection Diagrams
11. APPENDIX B: ELECTRICAL CONNECTION DIAGRAMS

11.1 SCOPE
This appendix shows the standard connections for: a.c. input DELTA modular drive systems. The diagrams
can be used for drive systems constructed from a single module, to multiple modules connected in parallel.
It shows the control connections required for two rectifier modules. If a single rectifier module is required,
explicit connection changes are detailed.
It also details the full complement of two rectifier or six transistor modules and the required connections.
These diagrams can still be used for smaller systems by omitting the modules that are not required.
The mechanical and electrical installation of the DELTA modules and the related control components are
shown in Section 5: CDM Assembly of this manual.
11.2 RECTIFIER BRIDGE – CONTROL CONNECTIONS

11.2.1 MVR1600 Rectifier Bridge
Machine Bridge
Control Connections
MVC3001-400x
MVR1600-4601
Controller
Rectifier Module #1
PL12 TB1
Thermistor 1 1 Thermistor
Thermistor 2 2 Thermistor
Thermostat 3 3 Thermostat
Thermostat 4 4 Thermostat
Not connected 5 5 Not connected
0V 6 6 0V
24V 7 7 +24V
Precharge Complete 24V 8 8 Precharge Complete
Precharge Acknowledge 9 9 Precharge Acknowledge
10 Not connected
Drive Data
Manager™
(Keypad) MVR1600-4601
Mains Voltage Rectifier Module #2
Monitor
TB1
(Optional) Thermistor
1
2 Thermistor
Optional 3 Thermostat
Communications 4 Thermostat
Modules 5 Not connected
6 0V
7 +24V
User I/O
8 Precharge Complete
Termination Panel
9 Precharge Acknowledge
10 Not connected
Connections to user’s “system

healthy” daisy chain circuit
Page 173
Appendix B: Electrical Connection Diagrams T1689 Technical Manual Rev 0007
RECTIFIER Bridge – CONTROL CONNECTIONS MV3000 Air Cooled DELTA
11.2.2 GDR391 & GDR721 Rectifier Bridge
Page 174
MV3000 Air Cooled DELTA RECTIFIER Bridge – CONTROL CONNECTIONS
11.2.3 GDR633, GDR872 & GDR1168 Rectifier Bridge
Page 175
Machine Bridge: Control Connections MV3000 Air Cooled DELTA
11.3 MACHINE BRIDGE: CONTROL CONNECTIONS

PL7
PL6
PL5
PL4
PL3
PL2
TB1
TB1
DELTA 6
DELTA 1
PL1
PL1
PL12
PL2
PL2
SK5
PL10
PL20
TB1
TB2
TB1
TB1
TB3
PL1
PL1
TB4
PL2
PL2
TB5
PL1
TB6
PL27
PL28
TB1
TB1
PL1
PL1
PL2
PL2
Page 176
MV3000 Air Cooled DELTA RECTIFIER Network Bridge – POWER CONNECTIONS
11.4 RECTIFIER NETWORK BRIDGE – POWER CONNECTIONS

11.4.1 MVR1600 Rectifier Module
11.4.1.1 12 Pulse Supply, Dual Rectifier Modules
11.4.2 GDR391 & GDR721 Rectifier Modules

11.4.2.1 6 Pulse Supply, Single Rectifier Modules*
* This configuration also applies to the MVR1600 Rectifier Module when a single unit is used.
Page 177
RECTIFIER Network Bridge – POWER CONNECTIONS MV3000 Air Cooled DELTA
11.4.3 GDR633, GDR872 & GDR1168 Rectifier Modules

11.4.3.1 12 Pulse Supply, Dual Rectifier Modules with Phase Shifted Supply
Page 178
MV3000 Air Cooled DELTA RECTIFIER Network Bridge – POWER CONNECTIONS
11.4.3.2 12 Pulse Supply, Dual Rectifier Modules with Standard Supply
Connections to user’s
“system healthy” SHARING
daisy chain circuit REACTOR
A1 A2 R1 TB1
B1 B2 S1 RECT 1+
C1 C2 T1
GDR633, 872 or 1168

RECTIFIER MODULE
SHARING
REACTOR
A1 A2 R2
B1 B2 S2 RECT 2+
DC LINK
C1 C2 T2 RECT 1 / 2- REACTOR
DC+
3 PHASE
SUPPLY
DC-
SHARING
REACTOR
A1 A2 R1 TB1
B1 B2 S1 RECT 1+
C1 C2 T1
GDR633, 872 or 1168

RECTIFIER MODULE
SHARING
REACTOR
A1 A2 R2
B1 B2 S2 RECT 2+
C1 C2 T2 RECT 1 / 2-
Page 179
AEM Network Bridge: Power Connections MV3000 Air Cooled DELTA
11.5 AEM NETWORK BRIDGE: POWER CONNECTIONS

MVC3003-40xx
SMPS
PL2 DC +/-
MVD DELTA
TB1
MODULE 1
PL3 DIB
PL1
SHARING
REACTOR
PL2
Interlock
A DC+
B
C DC-
MVC3003-40xx
SMPS
PL2 DC +/-
MVD DELTA
TB1
MODULE 2
PL3 DIB
PL1
SHARING
REACTOR
PL2
Interlock
A DC+
B
C DC-
MVC3003-40xx
SMPS
PL2 DC +/-
MVD DELTA
TB1
MODULE 3
PL3 DIB
PL1
SHARING
REACTOR
PL2 Interlock
A DC+
B
PRECHARGE C DC-
CIRCUIT INPUT LINE MVC3003-40xx
REACTOR SMPS
DC+
PL2 DC +/-
MVD DELTA
3 PHASE
TB1
MODULE 4
SUPPLY
PL3 DIB
PL1
SHARING DC-
REACTOR
PL2
Interlock
PWM FILTER
A DC+
B
C DC-
MVC3003-40xx
SMPS
PL2 DC +/-
Mains Voltage Monitor MVD DELTA

TB1
(Optional) MODULE 5
PL3 DIB
PL1
TB28
SHARING
REACTOR
PL2
Interlock
PL27
A DC+
B
C DC-
MVC3003-40xx
SMPS
PL2 DC +/-
MVD DELTA
TB1
MODULE 6
PL3 DIB
PL1
SHARING
REACTOR
PL2
Interlock
A DC+
B
C DC-
Connections to user’s
“system healthy”
daisy chain circuit
Page 180
MV3000 Air Cooled DELTA Machine Bridge: Power Connections
11.6 MACHINE BRIDGE: POWER CONNECTIONS
Page 181
Machine Bridge: Power Connections MV3000 Air Cooled DELTA
Page 182
T1689 Technical Manual Rev 0007 Appendix C: Recommended Torque Settings
12. APPENDIX C: RECOMMENDED TORQUE SETTINGS

12.1 SCOPE
This document details the recommended tightening torque settings for electrical and mechanical
connections to DELTA modules.
The recommended torque settings are applicable to high-tensile steel (Grade 8.8) fasteners fitted 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:
fasteners with any other material (e.g. brass);
fasteners with any other finish (e.g. raw steel, cadmium plated, lubrication of any sort);
slotted holes in either steel or copper.
12.2 TORQUE SETTINGS FOR ELECTRICAL CONNECTIONS

The figures included in Table 12–1 are for electrical connections of copper conductor crimps to device
terminals and to all copperwork except busbars, for which figures are included in Table 12–2.
Fastener Size Torque Setting
Carbon Steel (8.8)
Nm lbf. in lbf. ft.
M5 3.5 - 5.5 30 - 48 2.5 - 4
M6 7 - 10 60 - 90 5 - 7.5
M8 10.5 - 16 96 - 144 8 - 12
M10 27 - 40 240 - 360 20 - 30
M12 40 - 60 360 - 576 30 - 48
M16 90 - 135 780 - 1200 65 - 100
Table 12–1. – Torque Settings for Electrical Connections
12.3 TORQUE SETTINGS FOR BUSBAR JOINTS

The figures in Table 12–2 are for all busbar joints on copperwork.
Carbon Steel (8.8)
Nm lbf. in lbf. ft.
M8 20 180 15
M10 40 360 30
M12 64 576 48
Table 12–2. – Torque Settings for Busbar Joints
12.4 TORQUE SETTINGS FOR MECHANICAL CONNECTIONS

The figures in Table 12–3 are for the assembly and mounting of steel parts where specific electrical
connection, other than continuity, is not involved.
Carbon Steel (8.8)
Nm lbf. in lbf. 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 - 47 300 - 420 25 - 35
M12 54 - 82 480 - 720 40 - 60
M16 135 - 200 1200 - 1800 100 - 150
Table 12–3. – Torque Settings for Mechanical Connections
Page 183
Page 184
T1689 Technical Manual Rev 0007 Appendix D: MV3000e Drive Selection Charts
MV3000 Air Cooled DELTA Ratings MV3000e DELTA Drive Selection Tables
13. APPENDIX D: MV3000E DRIVE SELECTION CHARTS

13.1 RATINGS MV3000E DELTA DRIVE SELECTION TABLES
Assumed Efficiency = 0.95 Ambient = 40C Altitude = 1000 metres 575 V - 690 V DELTA DRIVES
Assumed Cos = 0.9 PWM Frequency = 1.25 kHz Voltage = nominal 150%/110% OVERLOAD
380-525 V a.c. Units: 110% & 150% Overload

400V 480V 525V
Drive Unit Motor Motor Motor

Losses Losses Losses
Amps Power Amps Power Amps Power
(kW) (kW) (kW)
(kW) (kW) (kW)
MVD500-4501 (110% O/L) 500 296 3.80 500 355 4.02 500 389 4.13
MVD500-4501 (150% O/L) 367 218 2.44 367 261 2.60 367 285 2.67
Table 13–1. – MVD500-4501 Ratings in 1.1 & 1.5 Overload
575 – 690 V a.c. Units: 110% & 150% Overload

575V 600V 690V
Drive Unit Motor Motor Motor

(kW) (kW) (kW)
(kW) (kW) (kW)
MVD500-4701 (110% O/L) 500 427 4.31 495 440 4.32 475 485 4.34
MVD500-4701 (150% O/L) 367 313 2.78 367 326 2.83 367 375 3.03
Table 13–2. – MVD500-4701 Ratings in 1.1 & 1.5 Overload
575 – 690 V a.c. Units: 110% Overload

Drive Units 600V 660V 690V
Motor Motor Motor
(kW) (kW) (kW)
(kW) (kW) (kW)
MV3300 (1 DELTA) 367 326 5.03 360 352 5.06 356 364 5.07
MV3600 (2 DELTA) 705 627 9.67 691 676 9.71 684 699 9.73
MV3900 (3 DELTA) 1058 940 14.50 1037 1013 14.57 1026 1049 14.60
MV31200 (4 DELTA) 1410 1253 19.33 1382 1351 19.42 1368 1398 19.47
MV31500 (5 DELTA) 1763 1566 24.16 1728 1689 24.28 1710 1748 24.34
MV31800 (6 DELTA) 2115 1880 29.00 2074 2027 29.13 2052 2097 29.20
Table 13–3. – MVD300 Ratings in 1.1 Overload
Page 185
Appendix D: MV3000e Drive Selection Charts T1689 Technical Manual Rev 0007
575 – 690 V a.c. Units: 150% Overload

Drive Units 600V 660V 690V
Motor Motor Motor
(kW) (kW) (kW)
(kW) (kW) (kW)
MV3300 (1 DELTA) 291 259 3.47 285 279 3.51 282 289 3.53
MV3600 (2 DELTA) 559 497 6.66 548 535 6.74 542 554 6.78
MV3900 (3 DELTA) 838 745 9.99 822 803 10.11 813 831 10.17
MV31200 (4 DELTA) 1118 933 13.33 1096 1071 13.49 1084 1108 13.57
MV31500 (5 DELTA) 1397 1241 16.66 1370 1339 16.86 1355 1385 16.96
MV31800 (6 DELTA) 1677 1490 19.99 1643 1606 20.23 1627 1662 20.35
Table 13–4. – MVD300 Ratings in 1.5 Overload
Ratings are based on:
 Rectifier fed (Diode Front End) drive with a d.c. link voltage = 1.35xVac,
 No sharing reactor in DELTA air stream (e.g. 31V5500/10 not fitted)
 Typical device characteristics
 50 000 hours continuous use for d.c. capacitor bank
 Overloads are for 60s every 10minutes. The current must be reduced between overloads so
that the rms current does not exceed the rated current shown.
 A.C. output current shown in Amps (rms)
 Ratings assume the use of the High Performance Cooling System.
NOTE: Full kit lists are available from GE Power Conversion.
Page 186
T1689 Technical Manual Rev 0007 Appendix D: MV3000e Drive Selection Charts
MV3000 Air Cooled DELTA Ratings MV3000e DELTA Drive Selection Tables
Page 187
CONTACT DETAILS FOR SALES, SERVICE & SUPPORT

www.ge.com
Please refer to your local technical support centre if you have any queries about this product.
Technical Support Centre
UK For all parts enquiries:

GE Power Conversion Email: [email protected]
West Avenue,
Kidsgrove For all repairs enquiries:
Stoke-on-Trent, Staffordshire ST7 1TW Email: [email protected]
Tel: +44(0)1782 781000
Fax: +44(0)1782 781001 For all new orders:
Email: [email protected]
For Marine specific applications:

Email: [email protected]
Other Offices
Brasil India
GE Power Conversion GE Power Conversion
Av. Álvares Cabral, 1345 Unit No 1003, Tower B, 10th Floor
Bairro Lourdes, Belo Horizonte Millennium Plaza, sector 27
Minas Gerais, 30170-001 Gurgaon, 122 002 Haryana
Tel: +55 31 3330 5800 Tel: +91 124 4200190
China Russia
29F, Building A, Lane 58, Majorov pereulok, 14 Bldg.7
East Xinjian Road, Minhang District 105023 Moscow
201100 Shanghai Tel: +7 495 225-19-16
Tel: +86 21 641 46080
France UK
1, Square John H. Patterson Boughton Road
91345 Massy Cedex Rugby, Warwickshire CV21 1BU
Tel: +33 (0) 1 77 31 20 00 Tel: +44 (0) 1788 563 563
Germany USA
Culemeyerstraße 1 610 Epsilon Drive
12277 Berlin Pittsburgh, PA 15238
Tel: +49 (0) 30 7622 – 0 Tel: +1 412 967 0765
Page 188

T1689-MV-DELTA-Air-Cooled-Technical Manual Rev-0007

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What are the different drive configurations described in the document?

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What are the environmental specifications for Delta components described in the document?

GE

T1689 Technical Manual Rev 0007

PDS (Power Drive System)

CDM (Complete Drive Module)

DELTA Power Modules

DELTA Control Components

PDS (Power Drive System)

AEM Active Energy Management

In The European Union:

WARNINGS, CAUTIONS & NOTES

GDR391-4401 DELTA Rectifier Bridge Module 391 A, 480 V a.c.

MVR1600-4601 DELTA Rectifier Bridge Module 1600A, 690 V a.c.

CUBICLE BUSBARS FOR RECTIFIER BRIDGE MODULES

DFE NETWORK BRIDGE SHARING REACTORS

DFE DC Link Choke

DFE INTERBRIDGE TRANSFORMERS FOR 12-PULSE SYSTEMS

AEM AND MACHINE BRIDGE SHARING REACTORS

DELTA CONTROL COMPONENTS

DELTA RIBBON CABLES & ACCESSORIES

DELTA MOUNTING FRAMES FOR RITTAL TS8 ENCLOSURE

LOWER GUIDE PLATE ASSEMBLY

HIGH PERFORMANCE FAN ASSEMBLY

DIRTY AIR DUCTING

2.10.7 D.C. Link Capacitors ............................................................................................................................................. 56

3.6.4 Position Of DELTA Rectifier Modules ........................................................................................................... 87

5.6 FITTING A.C. SHARING REACTORS ....................................................................................................................... 117

7. PDS COMMISSIONING GUIDANCE ........................................................................................................... 135

10. APPENDIX A: DIMENSIONED MECHANICAL DRAWINGS ......................................................................153

1.1.1 Advantages Of The Modular System

1.1.2 DELTA Product Range

1.2 ASSOCIATED MANUALS

 T1692EN MVS3004-4001 - User’s Guide – Drive Coach;

1.3 ABOUT THIS MANUAL

 Overview of the main concepts used in DELTA drives;

 Common environmental data for the DELTA product range;

Section 3 – Complete Drive Module (CDM) Design

 Guidance for component selection;

Section 4 – Power Drive System (PDS) Design

Section 5 – Complete Drive Module (CDM) Assembly

 Guidance for assembly of DELTA components into an enclosure.

Section 6 – CDM Commissioning

Section 7 – PDS Commissioning

 Guidance for commissioning the CDM in the final location.

 Mechanical drawings of DELTA components;

1.4 DRIVE CONFIGURATIONS

User I/O Controller

Figure 1–1. – Schematic Diagram of a DFE DELTA System

Figure 1–2. – Schematic Diagram of an AEM DELTA System

1.4.1 DFE Network Bridge

1.4.2 Sinusoidal Front End (AEM Network Bridge)

1.4.3 Machine Bridge

1.5 TYPICAL LAYOUT OF KEY DELTA COMPONENTS

MVC3006-4003 Mains SMPS Module 50Z0126/xx

DELTA Rectifier Module

DELTA Transistor Module

Figure 1–3. – Typical layout of CDM