Reliance Electric™ Drives
Reliance Electric™ Drives Service & Support
GV3000 Drives Ref: CPAG 2006-04-001
This PSA explains the potential safety issue, the steps required to verify the need for further action, and the steps required should a safety issue exist. ATTENTION: Only qualified electrical personnel familiar with the construction and operation of this equipment and the hazards involved should install, adjust, operate, or service this equipment. Read and understand the user manual D2-3360-5 and other applicable manuals in their entirety before proceeding. Failure to observe this precaution could result in severe bodily injury or death. ATTENTION: DC bus capacitors retain hazardous voltages after input power has been disconnected, wait five (5) minutes for the DC bus capacitors to discharge; and then check the voltage with a CAT III-1000V voltmeter to ensure the DC bus capacitors are fully discharged before touching any internal components. Failure to observe this precaution could result in severe bodily injury or death. ATTENTION: The drive contains ESD- (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing, or repairing the drive. Erratic machine operation and damage to, or destruction of, equipment can result if this procedure is not followed. Failure to observe this precaution can result in bodily injury - Issue Description - Safety Issue – Snubber capacitors may not discharge properly In the above referenced GV3000 drives, some may have phase module assemblies that do not discharge properly with the DC Bus after the drive has been powered down. In the affected drives, the snubber capacitors on the gate driver boards charge during the power up of the drive but fail to discharge properly when the drive is powered down. This is due to the location of the hardware on the phase module assembly. -Temporary Workarounds - - Product Identification -
The drive nameplate should be used to identify the model number of the affected GV3000 drive and is typically located on the door of the enclosure. The model numbers (M/N) relevant to this Product Safety Alert are “200V4160,” “200V4160DS,” “RX-200V4160,” or “RX-200V4160DS.” The horsepower rating, “200HP,” is identified to the right of the model number on the drive nameplate. The following image is an example of a nameplate for drive M/N 200V4160:
- How to Determine If Your Drive Is Affected by This PSA - Step 1: Turn off, lock out tag out the input power to the drive. Wait five minutes. Step 2: Open the outer cabinet door, leaving the inner cabinet door closed. Step 3: While standing on a non-conductive surface and wearing insulated gloves (1000V), verify that there is no voltage at the drive’s input power terminals using a CAT III-1000V voltmeter. Step 4: While standing on a non-conductive surface and wearing insulated gloves (1000V), measure the DC bus potential using a CAT III-1000V voltmeter. The DC bus potential is to be measured at the test points on the Power Module Interface board. See figure 9.5 in manual D2-3360-5 for the location. Wait until the bus voltage is zero. Step 5: Open the inner cabinet door and measure the DC bus potential on the DC bus bars. See figure 9.5 in manual D2-3360-5 for the location. Verify that the bus voltage on the DC bus bars is zero. Step 6: Do not touch any internal components. Locate the phase module assemblies. The following image shows the respective locations of the three (3) phase module assemblies:
Step 7: Do not touch the internal components. Using the below image as a guide, visually verify the correct placement of hardware in each of the phase module assemblies.
Step 8: If all three of the phase module assemblies have the correct hardware placement, close the inner cabinet door, close and latch the outer cabinet door, and put the drive back in service. The drive is not affected by this PSA. If any of the phase module assemblies have the incorrect hardware placement, proceed to the next sections (Issue Correction, Phase Module Assembly Rework Instructions and Detailed Rework Instructions). - Issue Correction -
- Phase Module Assembly Rework Instructions -
Refer to the following pages for detailed instructions for each of these three tasks: - Detailed Rework Instructions - The following steps outline the procedure required to correct the location of the phase module assembly hardware: Step 1: Turn off, lock out tag out the input power to the drive. Wait five minutes. Step 2: Open the outer cabinet door, leaving the inner cabinet door closed. Step 3: While standing on a non-conductive surface and wearing insulated gloves (1000V), verify there is no voltage at the drive’s input power terminals using a CAT III-1000V voltmeter. Step 4: While standing on a non-conductive surface and wearing insulated gloves (1000V), measure the DC bus potential using a CAT III-1000V voltmeter. The DC bus potential is to be measured at the test points on the Power Module Interface board. See figure 9.5 in manual D2-3360-5 for the location. Wait until the bus voltage is zero. Open the inner cabinet door and measure the DC bus potential on the DC bus bars. See figure 9.5 in manual D2-3360-5 for the location. Verify that the bus voltage on the DC bus bars is zero. Step 5: Wear an approved ESD wrist strap and attach the strap to the drive enclosure or other earth ground potential. Do not come in contact with the nearby inner cabinet door and the cabinet surfaces while performing this step because these surfaces are at earth ground potential. While standing on a non-conductive surface and wearing insulated gloves (1000V), connect the test leads from a CAT III-1000V voltmeter across the snubber capacitors at the points indicated in following image for the first phase module assembly:
Step 6: Leave the voltmeter connected to these points until the reading is zero volts. Step 7: Repeat steps 5 and 6 for the two remaining phase module assemblies. Step 8: Verify that the voltage across each snubber capacitor (quantity of 24) is zero volts before proceeding. Step 9: Place a piece of paper at the bottom of the enclosure just below the lowest phase module assembly. This will prevent screws or other hardware from falling deeper into the drive if they are dropped during this procedure. Step 10: For the affected phase module assembly, unplug all four (4) harness connectors. One connector is located near the upper left edge of the gate driver board, one at the lower left edge, and two at the upper right edge. Step 11: Use a #2 Phillips screwdriver to remove all six (6) gate driver board mounting screws. Step 12: Use a 7mm socket wrench to remove all four (4) gate driver board mounting nuts. Step 13: Retain the 6 screws and 4 nuts in a plastic bag or other container to avoid loosing any of the components since they will be reused later in this procedure. Step 14: Use both hands to gently remove the gate driver board and the insulating sheet (located behind the board) away from the phase module assembly. Step 15: Place the insulating sheet and board out of the way on a static dissipating surface.
Step 16: Determine if hardware is correctly placed by referring to step 7 of the “How to Determine If Your Drive Is Affected by This PSA” section. Use a 13mm socket wrench to hold the threaded standoff attached to the busbar for any incorrectly placed hardware. Step 17: Use a 13mm open end wrench to loosen the nut on the back side of the standoff. Step 18: Use your gloved fingers to completely remove the nut and the back washer. Step 19: Remove the standoff and front washer and reinstall them into the correct busbar location. Refer to step 7 of the “How to Determine If Your Drive Is Affected by This Product Safety Alert” section for the proper hardware location. Step 20: While holding the standoff in the center of the busbar hole to aid in the alignment of the gate driver board, reapply the back washer and glove hand tighten the nut until snug. Step 21: Repeat steps 16 through 20 for all incorrectly placed hardware for the affected phase module assembly. Step 22: Temporarily install the insulating sheet and the gate driver board to ensure that all ten (10) holes on the circuit board align properly. Remove the gate driver board and insulating sheet and place them out of the way on a static dissipating surface. Make any necessary adjustments to the posts to ensure alignment. Step 23: Maintaining the alignment established in step 22, use the 13mm socket wrench to hold the post and the 13mm open end wrench to carefully tighten the nut moved in steps 19 and 20. Specified torque is 80-100 in-lbs or 6.7-8.3 ft-lbs. Do not over tighten.
Step 24: Replace the insulating sheet and the gate driver board over the four (4) threaded mounting posts. Step 25: Gloved hand start all four (4) gate driver board mounting nuts and all six (6) mounting screws. Step 26: Using the 7mm socket, tighten all four (4) mounting nuts. Specified torque is 11-15 in-lbs. or 0.9-1.3 ft-lb. Do not over tighten. Note that the orange torque seal does not need to be reapplied. Step 27: Using the #2 Phillips screwdriver, tighten all six (6) mounting screws. Specified torque is 11-15 in-lbs. or 0.9-1.3 ft-lb. Do not over tighten. Note that the orange torque seal does not need to be reapplied. Step 28: Reconnect all four (4) harness connectors to the gate driver board. Step 29: Repeat steps 10 through 28 for all affected phase module assemblies. Step 30: Using the image below as an example, visually verify the correct placement of hardware in each of the three (3) phase module assemblies.
- Requested Customer Action - Each notified customer should take the following actions:
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