GE AF-650 GP Design Manual
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GE AF-650 GP Design Manual

General purpose drive
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GE Consumer & Industrial
Electrical Distribution
AF-650 GP
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General Purpose Drive
Design Guide
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Summary of Contents for GE AF-650 GP

  • Page 1 GE Consumer & Industrial Electrical Distribution AF-650 GP General Purpose Drive Design Guide...

  • Page 2: Table Of Contents

    Symbols Abbreviations Definitions 2 Safety and Conformity Safety Precautions Aggressive Environments 3 Introduction to AF-650 GP Product Overview Control Principle AF-650 GP Controls Control Structure in Advanced Vector Control Control Structure in Flux Sensorless Control Structure in Flux with Motor Feedback...
  • Page 3 Control Cable Routing Control Terminals Switches S201, S202, and S801 Electrical Installation, Control Terminals Basic Wiring Example Electrical Installation, Control Cables Additional Connections How to Connect a PC to the Frequency Converter The AF-650 GP PC Software Residual Current Device...
  • Page 4 IP21/IP 4X/ TYPE 1 Unit Kit Sine-wave Filters 10 RS-485 Installation and Set-up RS-485 Installation and Set-up Network Configuration Drive Protocol Message Framing Structure - AF-650 GP Examples Modbus RTU Overview Modbus RTU Message Framing Structure How to Access Parameters...
  • Page 5 AF-650 GP Design Guide...

  • Page 6: How To Read This Design Guide

    The AF-650 GP Design Guide DET-619 entails all technical information about the drive and customer design and applications. The AF-650 GP Programming Guide DET-618 provides information on how to programme and includes complete parameter descriptions. The AF-650 GP Profibus Operating Instructions DET-629 provide the information required for controlling, monitoring and programming the drive via a Profibus network.

  • Page 7: Abbreviations

    AF-650 GP Design Guide 1.1.3 Abbreviations Alternating current American wire gauge Ampere/AMP Current limit Degrees Celsius °C Direct current Drive Control Tool PC Software DCT 10 Drive Dependent D-TYPE Electro Magnetic Compatibility Electronic Thermal Overload Elec. OL Gram Hertz Kilohertz...
  • Page 8 AF-650 GP Design Guide Motor frequency. Output from the frequency converter. Output frequency is related to the shaft speed on motor depending on number of poles and slip frequency. The maximum output frequency the frequency converter applies on its output. The maximum output frequency is set in limit par. F-16, F-17 and F-03.
  • Page 9 AF-650 GP Design Guide Stop command See Control commands. References: Advanced Vector Control If compared with standard voltage/frequency ratio control, Adv. Vector Control) improves the dynamics and the stability, both when the speed reference is changed and in relation to the load torque.
  • Page 10 AF-650 GP Design Guide Keypad The Keypad makes up a complete interface for control and programming of the frequency converter. The Keypad is detachable and can be installed up to 10ft/ 3M from the frequency converter, i.e. in a front panel with the optional Remote Keypad Mounting Kit (RMKYPDAC)..
  • Page 11 AF-650 GP Design Guide VT Characteristics Variable torque characteristics used for pumps and fans. 60° AVM Switching pattern called 60°Asynchronous Vector Modulation (par. F-37 Adv. Switching Pattern). x U x I ϕ Power Factor Power factor The power factor is the relation between I...

  • Page 12: Safety And Conformity

    AF-650 GP Design Guide 2 Safety and Conformity 2.1 Safety Precautions 2.1.1 Safety Precautions The voltage of the drive is dangerous whenever connected to mains. Incorrect installation of the motor, drive or network may cause damage to the equipment, serious personal injury or death. Consequently, the instructions in this manual, as well as national and local rules and safety regulations, must be complied with.
  • Page 13 Frequency converters must be CE labelled in accordance with the low-voltage directive of January 1, 1997. The directive applies to all electrical equipment and appliances used in the 50 - 1000 V AC and the 75 - 1500 V DC voltage ranges. GE CE-labels in accordance with the directive and issues a declaration of conformity upon request.
  • Page 14 It must be noted that the responsibility for the final EMC properties of the appliance, system or installation rests with the installer. As an aid to the installer, GE has prepared EMC installation guidelines for the Power Drive system. The standards and test levels stated for Power Drive systems are complied with, provided that the EMC-correct instructions for installation are followed, see the section EMC Immunity.

  • Page 15: Aggressive Environments

    Unit Sizes 4x and 5x have a stainless steel back-channel option to provide additional protection in aggressive environments. Proper ventilation is still required for the internal components of the drive. Contact GE for additional information. The frequency converter has been tested according to the procedure based on the shown standards: The frequency converter complies with requirements that exist for units mounted on the walls and floors of production premises, as well as in panels bolted to walls or floors.

  • Page 16: Introduction To Af-650 Gp

    AF-650 GP Design Guide 3 Introduction to AF-650 GP 3.1 Product Overview Frame size depends on Unit Size, power range and mains voltage Unit Size Unit Size 20/21 20/21 55/66 protection NEMA Chassis/ Type 1 Chassis/ Type 1 Type 12 Heavy duty (HD) rat- 0.25-3 kW (200–240 V)
  • Page 17 AF-650 GP Design Guide Unit Size Unit Size 21/54 21/54 protection NEMA Type 1/ Type 12 Type 1/ Type 12 Chassis Chassis Heavy duty (HD) rated 90-110 kW at 400 V 132-200 kW at 400 V 90-110 kW at 400 V...

  • Page 18: Control Principle

    AF-650 GP Design Guide 3.2.1 Control Principle A frequency converter rectifies AC voltage from mains into DC voltage, after which this DC voltage is converted into a AC current with a variable amplitude and frequency. The motor is supplied with variable voltage / current and frequency, which enables infinitely variable speed control of three-phased, standard AC motors and permanent magnet synchronous motors.

  • Page 19: Control Structure In Advanced Vector Control

    AF-650 GP Design Guide 3.2.3 Control Structure in Advanced Vector Control Control structure in Advanced Vector Control open loop and closed loop configurations: In the configuration shown in the illustration above, par. H-41 Motor Control Principle is set to “Advanced Vector Control [1]” and par. H-40 Configuration Mode is set to “Speed open loop [0]”.

  • Page 20: Control Structure In Flux Sensorless

    AF-650 GP Design Guide 3.2.4 Control Structure in Flux Sensorless Control structure in Flux sensorless open loop and closed loop configurations. In the shown configuration, par. H-41 Motor Control Principle is set to “Flux sensorless [2]” and par. H-40 Configuration Mode is set to “Speed open loop [0]”. The resulting reference from the reference handling system is fed through the ramp and speed limitations as determined by the parameter settings indicated.

  • Page 21: Control Structure In Flux With Motor Feedback

    3.2.5 Control Structure in Flux with Motor Feedback Control structure in Flux with motor feedback configuration (only available in AF-650 GP): In the shown configuration, par. H-41 Motor Control Principle is set to “Flux w motor feedb [3]” and par. H-40 Configuration Mode is set to “Speed closed loop [1]”.

  • Page 22: Local (Hand) And Remote (Auto) Control

    AF-650 GP Design Guide 3.2.7 Local (Hand) and Remote (Auto) Control The frequency converter can be operated manually via the local control panel (Keypad) or remotely via analog and digital inputs and serial bus. If allowed in par. K-40 [Hand] Button on Keypad, par. K-41 [Off] Button on Keypad, par. K-42 [Auto] Button on Keypad, and par. K-43 [Reset] Button on Keypad, it is possible to start and stop the frequency converter via the Keypad using the [Hand] and [Off] keys.
  • Page 23 AF-650 GP Design Guide 3.3 Reference Handling Local Reference The local reference is active when the drive is operated with ‘Hand On’ bottom active. Adjust the reference by up/down and left/right arrows respectively. Remote Reference The reference handling system for calculating the Remote reference is shown in the illustration below.

  • Page 24: Reference Limits

    AF-650 GP Design Guide 3.3.1 Reference Limits Par. F-50 Reference Range, par. F-52 Minimum Reference and par. F-53 Maximum Reference together define the allowed range of the sum of all references. The sum of all references are clamped when necessary. The relation between the resulting reference (after clamping) and the sum of all references is shown below.

  • Page 25: Scaling Of Analog And Pulse References And Feedback

    AF-650 GP Design Guide 3.3.3 Scaling of Analog and Pulse References and Feedback References and feedback are scaled from analog and pulse inputs in the same way. The only difference is that a reference above or below the specified minimum and maximum “endpoints”...
  • Page 26 AF-650 GP Design Guide The size of the Dead Band is defined by either P1 or P2 as shown in the graph below. Thus a reference endpoint of P1 = (0 V, 0 RPM) will not result in any dead band, but a reference endpoint of e.g. P1 = (1V, 0 RPM) will result in a -1V to +1V dead band in this case provided that the end point P2 is placed in either Quadrant 1 or Quadrant 4.
  • Page 27 AF-650 GP Design Guide Case 2: Positive Reference with Dead band, Digital input to trigger reverse. Clamping rules. This Case shows how Reference input with limits outside -Max – +Max limits clamps to the inputs low and high limits before addition to External reference. And...

  • Page 28: Speed Pid Control

    AF-650 GP Design Guide Case 3: Negative to positive reference with dead band, Sign determines the direction, -Max – +Max 3.4 PID Control 3.4.1 Speed PID Control The table shows the control configurations where the Speed Control is active. Par. H-40 Configuration Mode Par. H-41 Motor Control Principle Motor Control Principle...
  • Page 29 AF-650 GP Design Guide The following parameters are relevant for the Speed Control: Parameter Description of function Par. PI-00 Speed PID Feedback Source Select from which input the Speed PID should get its feedback. Par. PI-02 Speed PID Proportional Gain The higher the value - the quicker the control. However, too high value may lead to oscillations.
  • Page 30 AF-650 GP Design Guide In the parameter list below it is assumed that all other parameters and switches remain at their default setting. The following must be programmed in order shown - see explanation of settings in the Programming Guide.

  • Page 31: Process Pid Control

    AF-650 GP Design Guide A good start value for par. PI-06 Speed PID Lowpass Filter Time is 5 ms (lower encoder resolution calls for a higher filter value). Typically a Max Torque Ripple of 3 % is acceptable. For incremental encoders the Encoder Resolution is found in either par. E-80 Term 32/33 Pulses Per Revolution (24V HTL on standard drive) or par.
  • Page 32 AF-650 GP Design Guide The following parameters are relevant for the Process Control Parameter Description of function Par. PI-20 Process CL Feedback 1 Resource Select from which Source (i.e. analog or pulse input) the Process PID should get its feedback Par.
  • Page 33 AF-650 GP Design Guide 3.4.4 Example of Process PID Control The following is an example of a Process PID Control used in a ventilation system: In a ventilation system, the temperature is to be settable from - 5 - 35°C with a potentiometer of 0-10 Volt.
  • Page 34 AF-650 GP Design Guide Example of Process PID Control set-up Function Par. no. Setting Initialize the frequency converter H-03 [2] Initialization - make a power cycling - press reset 1) Set motor parameters: Set the motor parameters according to name plate data P-02 to...

  • Page 35: Ziegler Nichols Tuning Method

    AF-650 GP Design Guide 3.4.5 Ziegler Nichols Tuning Method In order to tune the PID controls of the frequency converter, several tuning methods can be used. One approach is to use a technique which was developed in the 1950s but which has stood the test of time and is still used today. This method is known as the Ziegler Nichols tuning method.
  • Page 36 AF-650 GP Design Guide 3.5 General Aspects of EMC 3.5.1 General Aspects of EMC Emissions Electrical interference is usually conducted at frequences in the range 150 kHz to 30 MHz. Airborne interference from the drive system in the range 30 MHz to 1 GHz is generated from the inverter, motor cable, and the motor.

  • Page 37: Emc Test Results

    AF-650 GP Design Guide 3.5.2 EMC Test Results The following test results have been obtained using a system with a frequency converter (with options if relevant), a screened control cable, a control box with potentiometer, as well as a motor and motor screened cable.
  • Page 38 The immunity requirements for frequency converters depend on the environment where they are installed. The requirements for the industrial environment are higher than the requirements for the home and office environment. All GE frequency converters comply with the requirements for the industrial environment and consequently comply also with the lower requirements for home and office environment with a large safety margin.

  • Page 39: Pelv - Protective Extra Low Voltage

    AF-650 GP Design Guide EMC immunity form Voltage range: 200-240 V, 380-480 V Basic standard Burst Surge Radiated electromagnetic field RF common IEC 61000-4-4 IEC 61000-4-5 IEC 61000-4-2 IEC 61000-4-3 mode voltage IEC 61000-4-6 Acceptance criterion Line 2 kV/2 Ω DM 4 kV CM —...
  • Page 40 Installation at high altitude: 380 - 480 V, unit size 1x, 2x and 3x: At altitudes above 2 km, please contact GE regarding PELV. 380 - 480V, unit size 4x, 5x and 6x: At altitudes above 3 km, please contact GE regarding PELV.

  • Page 41: Brake Functions In Af-650 Gp

    AF-650 GP Design Guide 3.8 Brake Functions in AF-650 GP Braking function is applied for braking the load on the motor shaft, either as dynamic braking or static braking. 3.8.1 Mechanical Holding Brake A mechanical holding brake mounted directly on the motor shaft normally performs static braking. In some applications the static holding torque is working as static holding of the motor shaft (usually synchronous permanent motors).
  • Page 42 560 kW at 115% braking torque GE offers brake resistors with duty cycle of 5%, 10% and 40%. If a 10% duty cycle is applied, the brake resistors are able to absorb brake power for 10% of the cycle time. The remaining 90% of the cycle time will be used on dissipating excess heat.
  • Page 43 1130 V * Power size dependent Check that the brake resistor can cope with a voltage of 410 V, 850 V, 975 V or 1130 V - unless GE brake resistors are used. GE recommends the brake resistance R , i.e. one that guarantees that the...

  • Page 44: Mechanical Brake Control

    AF-650 GP Design Guide 3.8.4 Control with Brake Function The brake is protected against short-circuiting of the brake resistor, and the brake transistor is monitored to ensure that short-circuiting of the transistor is detected. A relay/digital output can be used for protecting the brake resistor against overloading in connection with a fault in the frequency converter.

  • Page 45: Hoist Mechanical Brake

    3.9.2 Hoist Mechanical Brake The AF-650 GP features a mechanical brake control specifically designed for hoisting applications. The hoist mechanical brake is activated by choice [6] in par. F-25 Start Function. The main difference comed to the regular mechanical brake control, where a relay function monitoring the output current is used, is that the hoist mechanical brake function has direct control over the brake relay.
  • Page 46 For enhanced EMC performance a metal screen can be used. 3.10 Logic Controller - AF-650 GP The Logic Controller (LC) is essentially a sequence of user defined actions (see par. LC-52 Logic Controller Action) executed by the LC when the associated user defined event (see par.
  • Page 47 AF-650 GP Design Guide 3.11 Extreme Running Conditions Short Circuit (Motor Phase – Phase) The frequency converter is protected against short circuits by means of current measurement in each of the three motor phases or in the DC link. A short circuit between two output phases will cause an overcurrent in the inverter.
  • Page 48 The Electronic Thermal Overload feature is calculating the motor temperature based on actual current and speed. The calculated temperature is visible as a read out parameter in par. DR-18 Motor Thermal in the AF-650 GP.

  • Page 49: Safe Stop Of Af-650 Gp

    3.12 Safe Stop of AF-650 GP The AF-650 GP can perform the safety function Safe Torque Off (As defined by IEC 61800-5-2) or Stop Category 0 (as defined in EN 60204-1). It is designed and approved suitable for the requirements of : Safety Category 3 in EN 954-1 (and ISO EN 13849-1) Performance Level "d"...
  • Page 50 The Safe Stop function is activated by removing the voltage at Terminal 37 of the Safe Inverter. By connecting the Safe Inverter to external safety devices providing a safe relay, an installation for a safe Stop Category 1 can be obtained. The Safe Stop function of AF-650 GP can be used for asynchronous and synchronous motors.
  • Page 51 After activation of Safe Stop (i.e. after the response time), the frequency converter coasts (stops creating a rotational field in the motor). The response time is shorter than 10 ms for the complete performance range of AF-650 GP. For AF-650 GP up to 7.5 kW it is even shorter than 5 ms.
  • Page 52 Case 1: restart prevention for Safe Stop is required (i.e. Safe Stop only where par. E-07 Terminal 37 Safe Stop is set to default value [1]: Remove the 24 V DC voltage supply to terminal 37 by the interrupt device while the motor is driven by the AF-650 GP (i.e. mains supply is not interrupted).
  • Page 53 AF-650 GP Design Guide...

  • Page 54: Gp Selection

    AF-650 GP Design Guide 4 AF-650 GP Selection 4.2 Electrical Data - 200-240 V Mains Supply 3 x 200 - 240 VAC AF-650 GP Typical Shaft Output [kW] 0.25 0.37 0.75 Typical Shaft Output [HP] at 208 V Unit Size IP 20...
  • Page 55 AF-650 GP Design Guide Mains Supply 3 x 200- 240 VAC AF-650 GP 20 HP 25 HP 30 HP 40 HP 50 HP High/ Normal Load* Typical Shaft Output [kW] 18.5 18.5 Typical Shaft Output [HP] at 208 V Unit Size IP20...

  • Page 56: Electrical Data - 380-480

    AF-650 GP Design Guide 4.3 Electrical Data - 380-480 V Mains Supply 3 x 380 - 480 VAC AF-650 GP 0.37 0.75 Typical Shaft Output [kW] Typical Shaft Output [HP] at 460V Unit Size IP20/IP21 Unit Size IP55, 66 Output current...
  • Page 57 AF-650 GP Design Guide Mains Supply 3 x 380 - 480 VAC AF-650 GP 15 HP 20 HP 25 HP 30 HP High/ Normal Load* Typical Shaft output [kW] 18.5 18.5 22.0 22.0 30.0 Typical Shaft Output [HP] at 460 V...
  • Page 58 AF-650 GP Design Guide Mains Supply 3 x 380 - 480 VAC AF-650 GP 40 HP 50 HP 60 HP 75 HP 100 HP High/ Normal Load* Typical Shaft output [kW] Typical Shaft Output [HP] at 460V Unit Size IP20...
  • Page 59 AF-650 GP Design Guide Mains Supply 3 x 380 - 480 VAC AF-650 GP 125 HP 150 HP 200 HP 250 HP 300 HP Heavy Duty/Light Duty* Typical Shaft output at 400 V [kW] Typical Shaft output at 460 V [HP]...
  • Page 60 AF-650 GP Design Guide Mains Supply 3 x 380 - 480 VAC AF-650 GP 350 HP 450 HP 500 HP 550 HP Heavy Duty/Light Duty* Typical Shaft output at 400 V [kW] Typical Shaft output at 460 V [HP] Typical Shaft output at 480 V...
  • Page 61 AF-650 GP Design Guide Mains Supply 3 x 380 - 480 VAC AF-650 GP 600 HP 650 HP 750 HP 900 HP 1000 HP 1200 HP Heavy Duty/Light Duty* Typical Shaft output at 1000 400 V [kW] Typical Shaft output at...

  • Page 62: Electrical Data - 525-600

    AF-650 GP Design Guide 4.4 Electrical Data - 525-600 V Mains Supply 3 x 525 - 600 VAC AF-650 GP Typical Shaft Output [kW] 0.75 Typical Shaft Output [HP] at 575V Unit Size IP20 Unit Size IP55 Output current Continuous 11.5...
  • Page 63 AF-650 GP Design Guide Mains Supply 3 x 525 - 600 VAC AF-650 GP 15 HP 20 HP 25 HP 30 HP 40 HP High/ Normal Load* Typical Shaft Output [kW] 18.5 18.5 Typical Shaft Output [HP] at 575V Unit Size IP 55, 66...
  • Page 64 AF-650 GP Design Guide Mains Supply 3 x 525 - 600 VAC AF-650 GP 50 HP 60 HP 75 HP 100 HP High/ Normal Load* Typical Shaft Output [kW] Typical Shaft Output [HP] at 575V Unit Size IP 55, 66...

  • Page 65: Electrical Data - 525-690

    AF-650 GP Design Guide 4.5 Electrical Data - 525-690 V Mains Supply 3 x 525- 690 VAC AF-650 GP 15 HP 20 HP 25 HP 30 HP Heavy Duty/Light Duty* Typical Shaft output at 550 V 18.5 18.5 [kW] Typical Shaft output at 575 V...
  • Page 66 AF-650 GP Design Guide Mains Supply 3 x 525- 690 VAC AF-650 GP 40 HP 50 HP 60 HP 75 HP 100 HP Heavy Duty/Light Duty* Typical Shaft output at 550 V [kW] Typical Shaft output at 575 V [HP]...
  • Page 67 AF-650 GP Design Guide Mains Supply 3 x 525- 690 VAC AF-650 GP 125 HP 150 HP 200 HP 250 HP 300 HP Heavy Duty/Light Duty* Typical Shaft output at 550 V [kW] Typical Shaft output at 575 V [HP]...
  • Page 68 AF-650 GP Design Guide Mains Supply 3 x 525- 690 VAC AF-650 GP 350 HP 400 HP 500 HP Heavy Duty/Light Duty* Typical Shaft output at 550 V [kW] Typical Shaft output at 575 V [HP] Typical Shaft output at 690 V [kW]...
  • Page 69 AF-650 GP Design Guide Mains Supply 3 x 525- 690 VAC AF-650 GP 550 HP 650 HP 750 HP Heavy Duty/Light Duty* Typical Shaft output at 550 V [kW] Typical Shaft output at 575 V [HP] Typical Shaft output at 690 V [kW]...
  • Page 70 AF-650 GP Design Guide Mains Supply 3 x 525- 690 VAC AF-650 GP 900 HP 1000 HP 1200 HP Heavy Duty/Light Duty* Typical Shaft output at 550 V [kW] Typical Shaft output at 575 V [HP] 1050 Typical Shaft output at 690 V [kW]...
  • Page 71 AF-650 GP Design Guide Mains Supply 3 x 525- 690 VAC AF-650 GP 1250 HP 1350 HP Heavy Duty/Light Duty* Typical Shaft output at 550 V [kW] 1000 Typical Shaft output at 575 V [HP] 1050 1150 1150 1350 Typical Shaft output at 690 V [kW]...

  • Page 72: General Specifications

    Mains voltage low / mains drop-out: During low mains voltage or a mains drop-out, the AF-650 GP continues until the intermediate circuit voltage drops below the minimum stop level, which corresponds typically to 15% below the frequency converter's lowest rated supply voltage. Power-up and full torque cannot be expected at mains voltage lower than 10% below the frequency converter's lowest rated supply voltage.
  • Page 73 1) Terminals 27 and 29 can also be programmed as output. 2) Terminal 37 is only available in AF-650 GP. It can only be used as safe stop input. Terminal 37 is suitable for category 3 installations according to EN 954-1 (safe stop according to category 0 EN 60204-1) as required by the EU Machinery Directive 98/37/EC.
  • Page 74 AF-650 GP Design Guide Analog inputs: Number of analog inputs Terminal number 53, 54 Modes Voltage or current Mode select Switch S201 and switch S202 Voltage mode Switch S201/switch S202 = OFF (U) Voltage level -10 to +10 V (scaleable) Input resistance, R approx.
  • Page 75 AF-650 GP Design Guide Digital output: Programmable digital/pulse outputs Terminal number 27, 29 Voltage level at digital/frequency output 0 - 24 V Max. output current (sink or source) 40 mA Max. load at frequency output 1 kΩ Max. capacitive load at frequency output...
  • Page 76 AF-650 GP Design Guide Control card performance: Scan interval AF-650 GP: 1 ms Surroundings: Unit Size 12, 13 and 15 (see 3.1 Product Overview for power ratings) IP 20, IP 55, IP 66 Unit Size 21, 22, 31 and 32...
  • Page 77 AF-650 GP Design Guide 4.7.1 Efficiency Efficiency of the frequency converter (η DRIVE The load on the frequency converter has little effect on its efficiency. In general, the efficiency is the same at the rated motor frequency f , even if the motor supplies 100% of the rated shaft torque or only 75%, i.e.

  • Page 78: Acoustic Noise

    If the motor cable is long (100 m), the rise time and peak voltage are higher. Peak voltage on the motor terminals is caused by the switching of the IGBTs. The AF-650 GP complies with the demands of IEC 60034-25 regarding motors designed to be controlled by frequency converters.
  • Page 79 AF-650 GP Design Guide AF-650 GP 230V 15 HP Rise time du/dt Cable Mains Upeak length [m] voltage [V] [μsec] [kV] [kV/μsec] 0.556 0.650 0.935 0.592 0.594 0.802 0.708 0.587 0.663 AF-650 GP 230V 20 HP Cable Mains Rise time...
  • Page 80 AF-650 GP Design Guide AF-650 GP 460V 10 HP Rise time du/dt Cable Mains Upeak length [m] voltage [V] [μsec] [kV] [kV/μsec] 0.04755 0.739 8.035 0.207 4.548 0.6742 1.030 2.828 AF-650 GP 460V 15 HP Cable Mains Rise time Upeak...
  • Page 81 AF-650 GP Design Guide AF-650 GP 460V 60 HP Rise time du/dt Cable Mains Upeak length [m] voltage [V] [μsec] [kV] [kV/μsec] 0.256 1.230 3.847 0.328 1.200 2.957 0.456 1.200 2.127 0.960 1.150 1.052 AF-650 GP 460V 75 HP Rise time...

  • Page 82: Special Conditions

    AF-650 GP Design Guide 4.10 Special Conditions 4.10.1 Purpose of Derating Derating must be taken into account when using the frequency converter at low air pressure (heights), at low speeds, with long motor cables, cables with a large cross section or at high ambient temperature. The required action is described in this section.
  • Page 83 AF-650 GP Design Guide Unit Sizes 2x For the Unit Sizes 2x and 3x the derating also depends on the overload mode selected in par. H-44 Constant or Variable Torque OL SFAVM - Stator Frequency Asyncron Vector Modulation 60º AVM - Pulse Width Modulation Illustration 4.7: Derating of I...
  • Page 84 AF-650 GP Design Guide Unit Sizes 3x SFAVM - Stator Frequency Asyncron Vector Modulation 60º AVM - Pulse Width Modulation Illustration 4.13: Derating of I for different T for Unit AMB, MAX Illustration 4.12: Derating of I for different T...
  • Page 85 AF-650 GP Design Guide Unit Sizes 4x SFAVM - Stator Frequency Asyncron Vector Modulation, 380 - 480 V 60º AVM - Pulse Width Modulation, 380 - 480 V Illustration 4.18: Derating of I for different T for Unit Illustration 4.19: Derating of I...
  • Page 86 AF-650 GP Design Guide Illustration 4.25: Derating of I for different T for Unit Illustration 4.24: Derating of I for different T for Unit AMB, MAX AMB, MAX Size 4x at 690 V, using SFAVM in Normal torque mode (110% Size 4x at 690 V, using 60º...
  • Page 87 AF-650 GP Design Guide Unit Sizes 5x and 6x SFAVM - Stator Frequency Asyncron Vector Modulation, 380 - 480 V 60º AVM - Pulse Width Modulation, 380 - 480 V Illustration 4.30: Derating of I for different T for Unit Illustration 4.31: Derating of I...
  • Page 88 ) should be derated in accordance with the shown diagram. Illustration 4.38: Derating of output current versus altitude at T for unit sizes 1x, 2x and 3x. At altitudes above 2 km, please contact GE regarding AMB, MAX PELV. An alternative is to lower the ambient temperature at high altitudes and thereby ensure 100% output current at high altitudes. As an example of how to read the graph, the situation at 2 km is elaborated.

  • Page 89: Automatic Tuning To Ensure Performance

    AF-650 GP Design Guide 4.10.4 Derating for Running at Low Speed When a motor is connected to a frequency converter, it is necessary to check that the cooling of the motor is adequate. The level of heating depends on the load on the motor, as well as the operating speed and time.

  • Page 90: Mechanical Installation - Unit Sizes 1, 2 And

    AF-650 GP Design Guide 5 Mechanical Installation - Unit Sizes 1, 2 and 3 5.1.1 Safety Requirements of Mechanical Installation Pay attention to the requirements that apply to integration and field mounting kit. Observe the information in the list to avoid serious injury or equipment damage, especially when installing large units.
  • Page 91 AF-650 GP Design Guide...
  • Page 92 AF-650 GP Design Guide...
  • Page 93 AF-650 GP Design Guide 5.1.2 Mechanical Mounting All Open Chassis, Nema 12, and Nema 4 drives can be mounted side-by-side.. If the IP21/Nema 1 field installed option kits are installed, there must be a clearance of a minimum of 50mm or 2 inches between drives.

  • Page 94: Mechanical Installation - Unit Size 4, 5 And

    AF-650 GP Design Guide 6 Mechanical Installation - Unit Size 4, 5 and 6 6.1 Pre-installation 6.1.1 Planning the Installation Site Before performing the installation it is important to plan the installation of the frequency converter. Neglecting this may result in extra work during and after installation.

  • Page 95: Lifting

    AF-650 GP Design Guide Illustration 6.1: Mounting Template for Unit Size 4X drives (460V, 125 to 300 HP, 575/600V, 125 to 400 HP) 6.1.4 Lifting Always lift the frequency converter in the dedicated lifting eyes. For all 4X unit size and 52 unit size (IP00) Units, use a bar to avoid bending the lifting holes of the frequency converter.
  • Page 96 AF-650 GP Design Guide Illustration 6.3: Recommended lifting method, Unit Size 61 Illustration 6.5: Recommended lifting method, Unit Size 63 (460V, 600 to 900 HP, 575/600V, 900 to 1150 HP). (460V, 600 to 900 HP, 575/600V, 900 to 1150 HP).

  • Page 97: Mechanical Dimensions

    AF-650 GP Design Guide...
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  • Page 103 AF-650 GP Design Guide Mechanical dimensions , Unit Sizes 4 Unit size 90 - 110 kW 132 - 200 kW 90 - 110 kW 132 - 200 kW (380 - 480 V) (380 - 480 V) (380 - 480 V)

  • Page 104: Mechanical Installation

    AF-650 GP Design Guide 6.2 Mechanical Installation Preparation of the mechanical installation of the frequency converter must be done carefully to ensure a proper result and to avoid additional work during installation. Start taking a close look at the mechanical drawings at the end of this instruction to become familiar with the space demands.
  • Page 105 AF-650 GP Design Guide Illustration 6.10: Space in front of IP21/Nema 1 and IP54/Nema drive types for unit size 63 Illustration 6.9: Space in front of IP21/Nema 1 and IP54/Nema drive types for unit size 61 Illustration 6.12: Space in front of IP21/Nema 1 and IP54/Nema drive types for unit size 64 Illustration 6.11: Space in front of IP21/Nema 1 and IP54/Nema...

  • Page 106: Terminal Locations - Unit Size 4X

    AF-650 GP Design Guide 6.2.3 Terminal Locations - Unit Size 4X Take the following position of the terminals into consideration when you design for cables access. Illustration 6.13: Position of power connections, 43/44 Unit Sizes Be aware that the power cables are heavy and hard to bend. Consider the optimum position of the frequency converter for ensuring easy installation of the cables.

  • Page 107: Terminal Locations - Unit Size 5X

    AF-650 GP Design Guide 6.2.4 Terminal Locations - Unit Size 5X Terminal Locations - Unit Size 51 Take the following position of the terminals into consideration when designing the cable access. Illustration 6.14: IP21 (NEMA Type 1) and IP54 (NEMA Type 12) drive type power connection positions...
  • Page 108 AF-650 GP Design Guide Terminal locations - Unit Size 52 Take the following position of the terminals into consideration when designing the cable access. Illustration 6.16: IP00 Open Chassis drive type power connection positions Illustration 6.17: IP00 Open Chassis drive type power connection positions Note that the power cables are heavy and difficult to bend.

  • Page 109: Terminal Locations - Unit Sizes 6X

    AF-650 GP Design Guide Illustration 6.18: Terminal in details Power connections can be made to positions A or B 6.2.5 Terminal Locations - Unit Sizes 6X Terminal locations - Unit Sizes 61 and 63 Illustration 6.19: Terminal locations - Inverter Cabinet - 61 and 63 (front, left and right side view). The gland plate is 42 mm below .0 level.
  • Page 110 AF-650 GP Design Guide Terminal locations - Unit Sizes 62/64 Illustration 6.20: Terminal locations - Inverter Cabinet - 62 and 64 (front, left and right side view). The gland plate is 42 mm below .0 level. 1) Ground bar Terminal locations - Rectifier (Unit Sizes 61, 62, 63 and 64)
  • Page 111 AF-650 GP Design Guide Terminal locations - Options Cabinet (Unit Sizes 63 and 64) Illustration 6.22: Terminal locations - Options Cabinet (Left side, front and right side view). The gland plate is 42 mm below .0 level. 1) Ground bar Terminal locations - Options Cabinet with circuit breaker/ molded case switch (Unit Sizes 63 and 64) Illustration 6.23: Terminal locations - Options Cabinet with circuit breaker/ molded case switch (Left side, front and right side view).

  • Page 112: Cooling And Airflow

    A dedicated option has been developed to optimize installation of IP00/chassis drive types in Rittal TS8 Units utilizing the fan of the frequency converter for forced air cooling of the backchannel. Please consult GE for more details. The air out the top of the Unit could but ducted outside a facility so the heat loses from the backchannel are not dissipated within the control room reducing air- conditioning requirements of the facility.
  • Page 113 AF-650 GP Design Guide External ducts If additional duct work is added externally to the Rittal cabinet the pressure drop in the ducting must be calculated. Use the charts below to derate the frequency converter according to the pressure drop.
  • Page 114 AF-650 GP Design Guide 6.2.7 Installation on the Wall - IP21 (NEMA 1) and IP54 (NEMA 12) Units This only applies to 41 and 42 Unit Sizes (460V, 125 - 300 HP, 575/600V, 125 - 400 HP). It must be considered where to install the unit.
  • Page 115 AF-650 GP Design Guide 6.2.8 Gland/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA12) Cables are connected through the gland plate from the bottom. Remove the plate and plan where to place the entry for the glands or conduits. Prepare holes in the marked area on the drawing.
  • Page 116 AF-650 GP Design Guide Unit Size 61 Unit Size 62 Unit Size 63 Unit Size 64 Unit Size 61 to 64: Cable entries viewed from the bottom of the frequency converter - 1) Place conduits in marked areas...
  • Page 117 AF-650 GP Design Guide Illustration 6.30: Mounting of bottom plate,51Unit Size . The bottom plate of the 51 Unit Size can be mounted from either in- or outside of the Unit Size, allowing flexibility in the installation process, i.e. if mounted from the bottom the glands and cables can be mounted before the frequency converter is placed on the pedestal.

  • Page 118: Electrical Installation

    AF-650 GP Design Guide 7 Electrical Installation 7.1 Connections- Unit Sizes 1x, 2x and 3x Cables General All cabling must comply with national and local regulations on cable cross-sections and ambient temperature. Copper (75°C) conductors are recommended. Aluminium Conductors Terminals can accept aluminium conductors but the conductor surface has to be clean and the oxidation must be removed and sealed by neutral acid-free Vaseline grease before the conductor is connected.

  • Page 119: Connection To Mains And Earthing

    AF-650 GP Design Guide 7.1.2 Connection to Mains and Earthing The plug connector for power is plugable on frequency converters up to 7.5 kW. Fit the two screws in the de-coupling plate, slide it into place and tighten the screws.
  • Page 120 AF-650 GP Design Guide Mains connection for Unit Sizes 12 and 13 IP20 Open Chassis drive types (230V to 5HP, 460V/575V to 10HP): Mains connector (IP 55/66)Unit Size 15 Nema 12 or Nema 4 drive types (230V to 5HP, 460V/575V to 10HP)
  • Page 121 AF-650 GP Design Guide Illustration 7.1: Mains connection for unit sizes 21 and 22 Nema 12 or Nema 4 drive types (230V, 7.5 to 15HP, 460V/575V, 15 to 30HP). Illustration 7.2: Mains connection for unit size 23 IP20 Open Chassis drive type (230V, 7.5 to 10HP, 460V/575V, 15 to 25HP).

  • Page 122: Motor Connection

    AF-650 GP Design Guide 7.1.3 Motor Connection Use a screened/armoured motor cable to comply with EMC emission specifications. For more information, see EMC Test Results. See section General Specifications for correct dimensioning of motor cable cross-section and length. Screening of cables: Avoid installation with twisted screen ends (pigtails). If it is necessary to break the screen to install a motor isolator or motor contactor, the screen must be continued at the lowest possible HF impedance.
  • Page 123 AF-650 GP Design Guide Illustration 7.9: Motor connection for unit sizes 21 and 22 Nema 12 or Nema 4 drive types (230V, 7.5 to 15HP, 460V/575V, 15 to 30HP) Illustration 7.10: Motor connection for for unit size 23 IP20 Open Chassis drive type (230V, 7.5 to 10HP, 460V/575V, 15 to 25HP).
  • Page 124 AF-650 GP Design Guide Illustration 7.16: Cable entry holes for unit size 31. The sugges- Illustration 7.14: Cable entry holes for unit size 21. The sugges- ted use of the holes are purely recommendations and other ted use of the holes are purely recommendations and other solutions are possible.

  • Page 125: Relay Connection

    AF-650 GP Design Guide 7.1.4 Relay Connection To set relay output, see par. group E-2# Relays. 01 - 02 make (normally open) 01 - 03 break (normally closed) 04 - 05 make (normally open) 04 - 06 break (normally closed)

  • Page 126: Connections - Unit Sizes 4, 5 And

    AF-650 GP Design Guide 7.2 Connections - Unit Sizes 4, 5 and 6 7.2.1 Torque When tightening all electrical connections it is very important to tighten with the correct torque. Too low or too high torque results in a bad electrical con- nection.
  • Page 127 AF-650 GP Design Guide Use a screened/armoured motor cable to comply with EMC emission specifications. For more information, see EMC specifications in the AF-600 FP/AF-650 GPDesign Guide. See section General Specifications for correct dimensioning of motor cable cross-section and length.
  • Page 128 AF-650 GP Design Guide Illustration 7.19: Compact IP 21 (NEMA 1) and IP 54 (NEMA 12), Unit Size 41 Illustration 7.20: Compact IP 21 (NEMA 1) and IP 54 (NEMA 12) Unit Size 42 AUX Relay Brake Temp Switch SMPS Fuse (see fuse tables for part number)
  • Page 129 AF-650 GP Design Guide Illustration 7.21: Compact IP 00 (Chassis), Unit Size 43 Illustration 7.22: Position of earth terminals IP00 (Chassis), 4X unit sizes Illustration 7.23: Position of earth terminals IP21 (NEMA type 1) and IP54 (NEMA type 12)Unit Size 42...
  • Page 130 AF-650 GP Design Guide Illustration 7.24: Compact IP 21 (NEMA 1) and IP 54 (NEMA 12) Unit Size 51 Illustration 7.25: Position of earth terminals IP00 (Chassis), Unit Size 52...
  • Page 131 AF-650 GP Design Guide Illustration 7.26: Rectifier Cabinet, unit sizes 61, 62, 63 and 64. 24 V DC, 5 A Loadsharing T1 Output Taps Temp Switch 104 105 Control Transformer Fuses (2 or 4 pieces). See fuse tables for part numbers Manual Motor Starters SMPS Fuse.
  • Page 132 AF-650 GP Design Guide Illustration 7.27: Inverter Cabinet, unit sizes 61 and 63. External Temperature Monitoring Motor AUX Relay NAMUR NAMUR Fuse. See fuse tables for part numbers AUX Fan Fan Fuses. See fuse tables for part numbers 101 102 103 SMPS Fuses.
  • Page 133 AF-650 GP Design Guide Illustration 7.28: Inverter Cabinet, unit sizes 62 and 64 External Temperature Monitoring Motor AUX Relay NAMUR NAMUR Fuse. See fuse tables for part numbers AUX Fan Fan Fuses. See fuse tables for part numbers 101 102 103 SMPS Fuses.

  • Page 134: Fuses

    Short-circuit protection: The frequency converter must be protected against short-circuit to avoid electrical or fire hazard. GE recommends using the fuses mentioned below to protect service personnel and equipment in case of an internal failure in the drive. The frequency converter provides full short-circuit protection in case of a short-circuit on the motor output.
  • Page 135 AF-650 GP Design Guide Non UL compliance If UL/cUL is not to be complied with, we recommend using the following fuses, which will ensure compliance with EN50178: In case of malfunction, not following the recommendation may result in unnecessary damage to the frequency converter.
  • Page 136 AF-650 GP Design Guide UL Compliance - max. fuse size The fuses below are suitable for use on a circuit capable of delivering 100,000 Arms (symmetrical), 240V, or 480V, or 600V depending on the drive voltage rating. With the proper fusing the drive Short Circuit Current Rating (SCCR) is 100,000 Arms.
  • Page 137 AF-650 GP Design Guide Ferraz- Ferraz- SIBA Littel fuse Shawmut Shawmut Type RK1 Type RK1 Type CC Type RK1 0.5-1 5017906-006 KLS-R6 ATM-R6 A6K-6R 5017906-010 KLS-R10 ATM-R10 A6K-10R 5017906-020 KLS-R20 ATM-R20 A6K-20R 5017906-025 KLS-R25 ATM-R25 A6K-25R 5012406-032 KLS-R30 ATM-R30 A6K-30R...
  • Page 138 AF-650 GP Design Guide Ferraz- Bussmann Bussmann SIBA LittelFuse Bussmann Bussmann Internal AF-650 Shawmut E1958 E4273 E180276 E71611 E4274 E125085 Option E76491 JFHR2** T/JDDZ** JFHR2 JFHR2** H/JDDZ** JFHR2* Bussmann JFHR2 125 HP FWH- JJS- 2061032. L50S-300 6.6URD30D08A NOS- 170M3017 170M3018...
  • Page 139 AF-650 GP Design Guide AF-650 GP Bussmann PN* Rating Siba Internal Bussmann Option 900 HP 170M7081 1600 A, 700 V 20 695 32.1600 170M7082 1000 HP 170M7081 1600 A, 700 V 20 695 32.1600 170M7082 1200 HP 170M7081 1600 A, 700 V 20 695 32.1600...
  • Page 140 AF-650 GP Design Guide Supplementary fuses Unit Sizes Bussmann PN* Rating 4X, 5X and 6X KTK-4 4 A, 600 V Table 7.10: SMPS Fuse Size/Type Bussmann PN* LittelFuse Rating 125HP-350HP, 380-480 V KTK-4 4 A, 600 V 125HP-550HP, 525-690 V...

  • Page 141: Disconnectors, Circuit Breakers And Contactors

    AF-650 GP Design Guide 7.4 Disconnectors, Circuit Breakers and Contactors 7.5 Additional Motor Information 7.5.1 Motor Cable The motor must be connected to terminals U/T1/96, V/T2/97, W/T3/98. Earth to terminal 99. All types of three-phase asynchronous standard motors can be used with a frequency converter unit.

  • Page 142: Motor Bearing Currents

    7.5.3 Motor Bearing Currents All motors installed with AF-650 GP 90 kW or higher power drives should have NDE (Non-Drive End) insulated bearings installed to eliminate circulating bearing currents. To minimize DE (Drive End) bearing and shaft currents proper grounding of the drive, motor, driven machine, and motor to the driven machine is required.

  • Page 143: Control Cable Routing

    AF-650 GP Design Guide 7.6.2 Control Cable Routing Tie down all control wires to the designated control cable routing as shown in the picture. Remember to connect the shields in a proper way to ensure optimum electrical immunity. Field Installed Network Module options connection Connections are made to the network options on the control card.

  • Page 144: Control Terminals

    AF-650 GP Design Guide Installation of field installed 24 Volt external DC Supply option module (OPC24VPS) Torque: 0.5 - 0.6 Nm (5 in-lbs) Screw size: M3 Function 35 (-), 36 (+) 24 V external DC supply 24 VDC external supply can be used as low-voltage supply to the control card and any I/O or network option cards installed. This enables full operation of the Keypad (including parameter setting) without connection to mains.

  • Page 145: Switches S201, S202, And S801

    AF-650 GP Design Guide 7.6.4 Switches S201, S202, and S801 Switches S201 (A53) and S202 (A54) are used to select a current (0-20 mA) or a voltage (-10 to 10 V) configuration of the analog input terminals 53 and 54 respectively.

  • Page 146: Electrical Installation, Control Terminals

    AF-650 GP Design Guide 7.6.5 Electrical Installation, Control Terminals To mount the cable to the terminal: Strip insulation of 9-10 mm Insert a screwdriver in the square hole. Insert the cable in the adjacent circular hole. Remove the screw driver. The cable is now mounted to the terminal.

  • Page 147: Basic Wiring Example

    AF-650 GP Design Guide 7.6.6 Basic Wiring Example Mount terminals from the accessory bag to the front of the fre- quency converter. Connect terminals 18, 27 and 37 to +24 V (terminal 12/13) Default settings: 18 = Start, par. E-01 Terminal 18 Digital Input [9] 27 = Stop inverse, par.

  • Page 148: Electrical Installation, Control Cables

    Illustration 7.34: Diagram showing all electrical terminals without options. A = analog, D = digital Terminal 37 is used for Safe Stop. For instructions on Safe Stop installation please refer to the section Safe Stop Installation of the AF-650 GP Design Guide.
  • Page 149 AF-650 GP Design Guide Input polarity of control terminals Control cables must be screened/armoured. See section entitled Earthing of Screened/Armoured Control Cables for the 130BA681.10 correct termination of control cables. 130BA681.10...

  • Page 150: Additional Connections

    Please note that voltages up to 1099 VDC may occur on the terminals. Load Sharing calls for extra equipment and safety considerations. For further information, please contact GE. Please note that mains disconnect may not isolate the frequency converter due to DC link connection...
  • Page 151 AF-650 GP Design Guide 7.7.3 Installation of Brake Cable The connection cable to the brake resistor must be screened and the max. length from the frequency converter to the DC bar is limited to 25 metres (82 feet). Connect the screen by means of cable clamps to the conductive...

  • Page 152: How To Connect A Pc To The Frequency Converter

    Use only isolated laptop as PC connection to the USB connector on the frequency converter. Illustration 7.35: USB connection. 7.7.6 The AF-650 GP PC Software Data storage in PC via DCT 10 Set-Up Software: Data transfer from PC to drive via DCT 10 Set-Up Software:...
  • Page 153 AF-650 GP Design Guide 7.8.2 Earthing The following basic issues need to be considered when installing a frequency converter, so as to obtain electromagnetic compatibility (EMC). • Safety earthing: Please note that the frequency converter has a high leakage current and must be earthed appropriately for safety reasons. Apply local safety regulations.
  • Page 154 AF-650 GP Design Guide Illustration 7.36: EMC-correct electrical installation of a frequency converter in cabinet. Illustration 7.37: Electrical connection diagram.
  • Page 155 7.9.2 Use of EMC-Correct Cables GE recommends braided screened/armoured cables to optimise EMC immunity of the control cables and the EMC emission from the motor cables. The ability of a cable to reduce the in- and outgoing radiation of electric noise depends on the transfer impedance (Z ).
  • Page 156 AF-650 GP Design Guide 7.9.3 Earthing of Screened/Armoured Control Cables Generally speaking, control cables must be braided screened/armoured and the screen must be connected by means of a cable clamp at both ends to the metal cabinet of the unit.

  • Page 157: Residual Current Device

    AF-650 GP Design Guide 7.10.1 Mains Supply Interference/Harmonics A frequency converter takes up a non-sinusoidal current from mains, which Harmonic currents increases the input current I . A non-sinusoidal current is transformed by 50 Hz 250 Hz 350 Hz means of a Fourier analysis and split up into sine-wave currents with different frequencies, i.e.

  • Page 158: Final Setup And Test

    AF-650 GP Design Guide 7.12 Final Setup and Test To test the set-up and ensure that the frequency converter is running, follow these steps. Step 1. Locate the motor name plate The motor is either star- (Y) or delta- connected (∆). This information is located on the motor name plate data.
  • Page 159 "Report Value” in the [Alarm Log] shows the last measuring sequence carried out by the Auto Tune, before the frequency converter entered alarm mode. This number along with the description of the alarm will assist you in troubleshooting. If you contact GE for service, make sure to mention number and alarm description.

  • Page 160: Application Examples

    AF-650 GP Design Guide 8 Application Examples 8.1.1 Start/Stop Terminal 18 = par. E-01 Terminal 18 Digital Input [8] Start par. F -16 par. F -15 par. F -03 par. CL-14 8.1.2 Pulse Start/Stop Terminal 18 = par. E-01 Terminal 18 Digital InputLatched start, [9]...

  • Page 161: Encoder Connection

    AF-650 GP Design Guide 8.1.3 Potentiometer Reference Voltage reference via a potentiometer: Reference Source 1 = [1] Analog input 53 (default) Terminal 53, Low Voltage = 0 Volt Terminal 53, High Voltage = 10 Volt Terminal 53, Low Ref./Feedback = 0 RPM Terminal 53, High Ref./Feedback = 1500 RPM...

  • Page 162: Closed Loop Drive System

    Motor • (Gearbox) (Mechanical Brake) • AF-650 GP • Encoder as feed-back system Illustration 8.1: Basic Set-up for AF-650 GP Closed Loop Speed • Brake resistor for dynamic braking Control • Transmission • Load Applications demanding mechanical brake control will usually need a brake resistor.

  • Page 163: Advanced Mechanical Brake Control For Hoisting Applications

    AF-650 GP Design Guide 8.1.8 Advanced Mechanical Brake Control for Hoisting Applications 1. The vertical movement In the vertical movement, the key point is that the load must be held, stopped, controlled (raised, lowered) in a perfectly safe mode during the entire operation.

  • Page 164: Auto Tune

    AF-650 GP Design Guide Par. B-24 Stop Delay. Allows successive starting without applying the mechanical brake. (e.g. reversing) Par. B-25 Brake Release Time. The time needed by the brake to be open/closed. In closed loop structure, the parameter dependency is: Par.

  • Page 165: Lc Application Example

    AF-650 GP Design Guide 8.1.11 LC Application Example One sequence 1: Start – accel – run at reference speed 2 sec – decel and hold shaft until stop. Set the accel/decel times in par. F-07 Accel Time 1 and par. F-08 Decel Time 1 to the wanted times −...

  • Page 166: Torque Control Open Loop

    AF-650 GP Design Guide Set the Logic Controller in par. LC-00 Logic Controller Mode to ON. Start / stop command is applied on terminal 18. If stop signal is applied the frequency converter will decel and go into free mode.
  • Page 167 AF-650 GP Design Guide Parameter set-up Torque open loop in Advanced Vector Control mode Function Parameter Setting Data Value Basic Settings Configuration Mode H-40 Torque Open Loop Motor Control Principle H-41 Advanced Vector Torque PI control settings Torque PI Proportional Gain...

  • Page 168: Options And Accessories

    AF-650 GP Design Guide 9 Options and Accessories GE offers a wide range of options and accessories for AF-650 GP. 9.1.1 Mounting of Option Modules in Slot A Slot A position is dedicated to Network options. For further information, see separate operating instructions.

  • Page 169: General Purpose Input Output Module Opcgpio

    AF-650 GP Design Guide 9.2 General Purpose Input Output Module OPCGPIO OPCGPIO General Purpose I/O Option Module is used for extension of digital and analog inputs and outputs of AF-650 GP. Contents: OPCGPIO must be fitted into slot B in the AF-650 GP.
  • Page 170 AF-650 GP Design Guide 9.2.1 Galvanic Isolation in the OPCGPIO Digital/analog inputs are galvanically isolated from other inputs/outputs on the OPCGPIO and in the control card of the frequency converter. Digital/analog outputs in the OPCGPIO are galvanically isolated from other inputs/outputs on the OPCGPIO, but not from these on the control card of the drive.
  • Page 171 Resolution for analog inputs 10 bit (+ sign) Accuracy of analog inputs Max. error 0.5% of full scale Bandwidth AF-650 GP: 20 Hz/ AF-650 GP: 100 Hz 9.2.4 Digital Outputs - Terminal X30/6, 7: Digital output: Number of digital outputs Terminal number X30.6, X30.7...

  • Page 172: Opcenc Encoder Option Module

    AF-650 GP Design Guide 9.3 OPCENC Encoder Option Module The encoder module can be used as feedback source for closed loop Flux control (par. H-42 Flux Motor Feedback Source) as well as closed loop speed control (par. PI-00 Speed PID Feedback Source). Configure encoder option in parameter group EC-## Used for: •...
  • Page 173 AF-650 GP Design Guide Max. cable length 150 m.

  • Page 174: Opcres Resolver Option Module

    AF-650 GP Design Guide 9.4 OPCRES Resolver Option Module OPCRES is used for interfacing resolver motor feedback to AF-650 GP. Re- solvers are used basically as motor feedback device for Permanent Magnet brushless synchronous motors. The Resolver option kit includes: •...

  • Page 175: Opcrly Relay Option Module

    AF-650 GP Design Guide Set-up example In this example a Permanent Magnet (PM) Motor is used with resolver as speed feedback. A PM motor must usually operate in flux mode. Wiring: The max cable length is 150 m when a twisted pair type of cable is used.
  • Page 176 AF-650 GP Design Guide 12, 13, 23 15, 21, 22, 24, 31, 32, 33, 34 IMPORTANT ! The label MUST be placed on the Keypad frame as shown (UL approved). Warning Dual supply How to add the OPCRLY Relay Option Module: •...

  • Page 177: Opc24Vps 24V Dc External Supply Module

    External 24 V DC supply specification: 24 V DC ±15 % (max. 37 V in 10 s) Input voltage range Max. input current 2.2 A Average input current for AF-650 GP 0.9 A Max cable length 75 m Input capacitance load <...

  • Page 178: Brake Resistors

    Brake resistors are used to dissipate the excess energy resulting from the regenerative braking. The resistor is selected in respect to its ohmic value, its power dissipation rate and its physical size. GE offers a wide variety of different resistors that are specially designed to our frequency converters.
  • Page 179 AF-650 GP Design Guide...

  • Page 180: Ip21/Ip 4X/ Type 1 Unit Kit

    AF-650 GP Design Guide 9.12 IP21/IP 4X/ TYPE 1 Unit Kit IP 20/IP 4X top/ TYPE 1 is an optional unit element available for IP 20 Compact units. If the unit kit is used, an IP 20 unit is upgraded to comply with unit IP 21/ 4X top/TYPE 1.

  • Page 181: Sine-Wave Filters

    AF-650 GP Design Guide 9.14 Sine-wave Filters When a motor is controlled by a frequency converter, resonance noise will be heard from the motor. This noise, which is the result of the design of the motor, arises every time an inverter switch in the frequency converter is activated. The frequency of the resonance noise thus corresponds to the switching frequency of the frequency converter.

  • Page 182: Rs-485 Installation And Set-Up

    AF-650 GP Design Guide 10 RS-485 Installation and Set-up 10.1 RS-485 Installation and Set-up 10.1.1 Overview RS-485 is a two-wire bus interface compatible with multi-drop network topology, i.e. nodes can be connected as a bus, or via drop cables from a common trunk line.
  • Page 183 When crossing is unavoidable, the RS-485 cable must cross motor and brake resistor cables at an angle of 90 degrees. The Drive protocol, also referred to as Drive bus or Standard bus, is the GE standard network. It defines an access technique according to the master-slave principle for communications via a serial bus.

  • Page 184: Network Configuration

    Par. O-33 Drive port parity Even parity, 1 stop bit (default) 10.4 Drive Protocol Message Framing Structure - AF-650 GP 10.4.1 Content of a Character (byte) Each character transferred begins with a start bit. Then 8 data bits are transferred, corresponding to a byte. Each character is secured via a parity bit, which is set at "1"...
  • Page 185 AF-650 GP Design Guide 10.4.4 Frequency Converter Address (ADR) Two different address formats are used. The address range of the frequency converter is either 1-31 or 1-126. 1. Address format 1-31: Bit 7 = 0 (address format 1-31 active) Bit 6 is not used...
  • Page 186 AF-650 GP Design Guide Text block: The text block is used to read or write texts via the data block. 10.4.7 The PKE Field The PKE field contains two sub-fields: Parameter command and response AK, and Parameter number PNU: Bits no. 12-15 transfer parameter commands from master to slave and return processed slave responses to the master.
  • Page 187 AF-650 GP Design Guide If the command cannot be performed, the slave sends this response: 0111 Command cannot be performed - and issues the following fault report in the parameter value (PWE): PWE low (Hex) Fault Report The parameter number used does not exit...
  • Page 188 AF-650 GP Design Guide 10.4.11 Data Types Supported by AF-650 GP Unsigned means that there is no operational sign in the telegram. Data types Description Integer 16 Integer 32 Unsigned 8 Unsigned 16 Unsigned 32 Text string Byte string Time difference...

  • Page 189: Examples

    AF-650 GP Design Guide 10.5 Examples All parameters in the AF-650 GP are named with one or two letters, a "-" and Letter Number a number e.g. F-07. To access parameters the following table has to be used because letters cannot be addressed.
  • Page 190 AF-650 GP Design Guide Note: par. F-15 Motor Speed High Limit [Hz] is a single word, and the parameter command for write in EEPROM is “E”. Parameter number F-15 is 00F in hex- adecimal. The response from the slave to the master will be: 10.5.2 Reading a Parameter Value...

  • Page 191: Modbus Rtu Overview

    AF-650 GP Design Guide 10.6 Modbus RTU Overview 10.6.1 Assumptions These operating instructions assume that the installed controller supports the interfaces in this document and that all the requirements stipulated in the controller, as well as the frequency converter, are strictly observed, along with all limitations therein.

  • Page 192: Modbus Rtu Message Framing Structure

    AF-650 GP Design Guide 10.7 Network Configuration To enable Modbus RTU on the frequency converter, set the following parameters: Parameter Number Parameter name Setting O-30 Protocol Modbus RTU O-31 Address 1 - 247 O-32 Baud Rate 2400 - 115200 O-33...
  • Page 193 AF-650 GP Design Guide 10.8.3 Start / Stop Field Messages start with a silent period of at least 3.5 character intervals. This is implemented as a multiple of character intervals at the selected network baud rate (shown as Start T1-T2-T3-T4). The first field to be transmitted is the device address. Following the last transmitted character, a similar period of at least 3.5 character intervals marks the end of the message.
  • Page 194 AF-650 GP Design Guide Coil Number Description Signal Direction 1-16 Frequency converter control word (see table below) Master to slave 17-32 Frequency converter speed or set-point reference Range 0x0 – 0xFFFF (-200% ... ~200%) Master to slave 33-48 Frequency converter status word (see table below)
  • Page 195 AF-650 GP Design Guide 10.8.9 How to Control the Frequency Converter This section describes codes which can be used in the function and data fields of a Modbus RTU message. For a complete description of all the message fields please refer to the section Modbus RTU Message Framing Structure.

  • Page 196: How To Access Parameters

    AF-650 GP Design Guide 10.9 How to Access Parameters 10.9.1 Parameter Handling The PNU (Parameter Number) is translated from the register address contained in the Modbus read or write message. The parameter number is translated to Modbus as (10 x parameter number) DECIMAL.

  • Page 197: Ge Drive Control Profile

    AF-650 GP Design Guide 10.10 GE Drive Control Profile 10.10.1 Control Word According to Drive Profile (par. O-10 Control Word Profile = Drive profile) Bit value = 0 Bit value = 1 Reference value external selection lsb Reference value external selection msb...
  • Page 198 AF-650 GP Design Guide Bit 03, Coasting: Bit 03 = ’0’: The frequency converter immediately "lets go" of the motor, (the output transistors are "shut off") and it coasts to a standstill. Bit 03 = ’1’: The frequency converter starts the motor if the other starting conditions are met.
  • Page 199 AF-650 GP Design Guide Bit 13/14, Selection of set-up: Set-up Bit 14 Bit 13 Use bits 13 and 14 to choose from the four menu set-ups according to the shown table: . The function is only possible when Multi Set-Ups is selected in par. K-10 Active Set-up.
  • Page 200 AF-650 GP Design Guide Bit 04, No error/error (no trip): Bit 04 = ’0’: The frequency converter is not in fault mode. Bit 04 = “1”: The frequency converter shows an error but does not trip. Bit 05, Not used: Bit 05 is not used in the status word.
  • Page 201 AF-650 GP Design Guide 10.10.3 Bus Speed Reference Value Speed reference value is transmitted to the frequency converter in a relative value in %. The value is transmitted in the form of a 16-bit word; in integers (0-32767) the value 16384 (4000 Hex) corresponds to 100%. Negative figures are formatted by means of 2’s complement.
  • Page 202 AF-650 GP Design Guide 10.10.5 Control Word according to PROFIdrive Profile (CTW) The Control word is used to send commands from a master (e.g. a PC) to a Bit = 0 Bit = 1 slave. OFF 1 ON 1 OFF 2...
  • Page 203 AF-650 GP Design Guide Bit 05, Hold frequency output/Use Accel/Decel When bit 05 = "0", the current output frequency is being maintained even if the reference value is modified. When bit 05 = "1", the frequency converter can perform its regulating function again; operation occurs according to the respective reference value.
  • Page 204 AF-650 GP Design Guide Bits 13/14, Set-up selection Set-up Bit 13 Bit 14 Bits 13 and 14 are used to choose between the four parameter set-ups ac- cording to the following table: The function is only possible if Multi Set-up has been chosen in par. K-10 Active Set-up.
  • Page 205 AF-650 GP Design Guide Bit 02, Coasting/Enable When bit 02 = "0", bit 00, 01 or 02 of the Control word is "0" (OFF 1, OFF 2 or OFF 3 or coasting) - or the frequency converter is switched off (trip).
  • Page 206 AF-650 GP Design Guide Bit 15, Timer OK/Timer exceeded When bit 15 = "0", the timers for the thermal motor protection and electronic overload protection have not exceeded 100%. When bit 15 = "1", one of the timers has exceeded 100%.

  • Page 207: Index

    AF-650 GP Design Guide Index Abbreviations Access To Control Terminals Acoustic Noise Advanced Vector Control Aggressive Environments Air Humidity Airflow Analog Inputs Analog Inputs - Terminal X30/11, 12 Analog Output Analog Output - Terminal X30/8 Auto Tune Auto Tune 157, 163...
  • Page 208 AF-650 GP Design Guide Definitions Derating For Ambient Temperature And Igbt Switching Frequency Derating For Low Air Pressure Derating For Running At Low Speed Devicenet Digital Inputs - Terminal X30/1-4 Digital Inputs: Digital Output Digital Outputs - Terminal X30/6, 7...
  • Page 209 AF-650 GP Design Guide It Mains Leakage Current Lifting Load Sharing Local (hand) And Remote (auto) Control Logic Controller Mains Drop-out Mains Supply Mains Supply 53, 61, 62, 63 Mains Supply (l1, L2, L3) Mains Supply Interference Mechanical Brake Mechanical Dimensions...
  • Page 210 AF-650 GP Design Guide Pulse/encoder Inputs Radiated Emission Rated Motor Speed 9, 39 Receiving The Frequency Converter Reference Limits Relay Connection Relay Outputs Removal Of Knockouts For Extra Cables Residual Current Device 39, 156 Rise Time Rs 485 Bus Connection...
  • Page 211 AF-650 GP Design Guide Voltage Reference Via A Potentiometer What Is Ce Conformity And Labelling? What Is Covered Wire Access...
  • Page 212 GE company. AF-650 GP is a trademark of the General Electric Company. GE Consumer & Industrial 41 Woodford Avenue Plainville, CT 06062 www.geelectrical.com/drives...

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