GE AF-600 FP User Manual
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GE AF-600 FP User Manual

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Section
1
Thanks - DEH40607
2
Installation and Start-up Instructions for AF-600 Bypass, NON Bypass & Disconnect Drive Panels -
DEH40600
3
Operating And Troubleshooting Instructions for AF-600 FP Bypass Panels - DEH40602
4
Operating and Troubleshooting Instructions for AF-600 FP NON Bypass & Disconnect Drive Panels -
DEH40608
5
AF-600 FP User's Guide (DET – 609 or DET – 610) – DEH40605
6
Appendix A – Current Ratings and Fuse Sizes - DEH40604
7
In-Warranty Information Form – DEH40606
8
Appendix B – Wire Sizes, Torque and Estimated Watt loss Details – DEH40603
9
Product Drawings – Electrical and Mechanical (To be inserted)
DEH40601 – Page 1

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AN 12-1007 Rev 05, 04/04/2012
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Summary of Contents for GE AF-600 FP

  • Page 1 DEH40600 Operating and Troubleshooting Instructions for AF-600 FP Bypass Panels - DEH40602 Operating and Troubleshooting Instructions for AF-600 FP NON Bypass & Disconnect Drive Panels - DEH40608 AF-600 FP User’s Guide (DET – 609 or DET – 610) – DEH40605 Appendix A –...
  • Page 2 GE Drives wishes to thank you for choosing our adjustable frequency controller product. We are committed to being the world’s leading supplier of AC adjustable speed drives by providing the highest quality products as well as the best documentation and product support available in the industry.
  • Page 3 The AF-600 FP Drive User’s Guide (DET - 609 or DET - 610) and the AF-600 FP Panel Operating Instructions contained in this notebook have additional information and will be referenced through out this document.
  • Page 4 All wall-mounted enclosures must be mounted on a non-flammable or heat resistant surface. Some enclosure configurations of AF-600 FP Panels require ventilation to keep the components and inverter within their thermal recommendations. The enclosure door and sides contains grilles at the bottom and top to allow for air to circulate through the enclosure.
  • Page 5 CAUTION: Failure to cover components from metal shavings may result in damage to equipment. Use 3/8-16 Hardware’s for all slim line wall mount enclosures and 1/2-13 Hardware’s for all Standard Wall mount and Floor mount enclosures mounting to fulfill Seismic Requirements For NEMA 12 enclosure types, liquid tight conduit and fittings shall be installed to maintain the enclosure integrity.
  • Page 6 If signal wire is UL recognized shielded cable, separation can be minimized to a one (1) inch separation. AF-600 FP Bypass Panels require no additional control wiring to operate properly. Additional control interfacing to your control panel can be accomplished through the panel mounted customer terminal board “CTB”.
  • Page 7 “CTB”. Please reference the appropriate wiring diagram. Torque values for connecting to “CTB” are located in the Appendices. If your application requires wiring to the AF-600 FP inverter I/O control terminal board, Use 20 to 28 AWG wire.
  • Page 8 AF 600 FP BYPASS PANELS Your AF 600 FP Bypass Panel comes with an AF 600 FP Adjustable Frequency Drive from GE Drives mounted on or in an enclosure which contains the following equipment to manually or automatically allow motor operation across-the-line in addition to motor operation from the drive.
  • Page 9 Table of Contents Operator Devices page 3 Customer Terminal Board page 8 AF 600 FP Drive Terminal Board I/O page 11 Adjustments page 12 AF 600 FP Drive Function Code Changes page 16 Troubleshooting page 19 NOTE: The terms drive and inverter is used interchangeably in this document.
  • Page 10 1. Operator Devices Your Bypass panel is equipped with several panel door mounted operator devices which may include the following: one (1) through-the-door, lockable, input device disconnect handle; three (3) operator selector switches; six (6) indicator lights; and one (1) speed potentiometer. The operation of these devices is explained in this section.
  • Page 11 In the “Test” position AC input power to the drive will be applied and the inverter will run at the speed dictated by the speed pot with the Hand/Off/Auto (H-O-A) switch in the “Hand” position. If the H-O-A switch is in the “Auto” position the inverter will run at the speed dictated by the remote customer supplied reference signal (0-10 VDC or 4-20 mA).
  • Page 12 0-10 VDC or 4-20 mA signal. Hand - Off - Auto on Drive Keypad All AF-600 FP Drive Panels include a keypad for programming and operation of the drive and includes Hand, Off, and Auto operation keys / buttons. When shipped from the factory, the Hand, Off and Auto buttons are enabled .
  • Page 13 Actuation of the OL relay will automatically cause power to be removed from the motor regardless of the positions of the H-O-A and Drive/Off/Bypass selectors. The GE C-2000 relay in your panel can be set for either manual or automatic reset. It is shipped...
  • Page 14 Without the drive reporting a fault condition. Note that this light only means that the drive output contactor is energized and the panel is operating in “Drive” mode. If the motor’s shaft is not rotating then it may be due to 1) no run command provided to the drive (i.e.
  • Page 15 2. Customer Terminal Board – “CTB” Inside the panel enclosure there is terminal board for convenient connection of customer control wiring. The customer interface drawing provides a visual reference of the terminal board positions with the detailed descriptions as follows: CTB1-1 through CTB1-3 Customer safety interlocks.
  • Page 16 CAUTION: Jumpering CTB1-35 and CTB1-36 together will not allow for motor flux to decay prior to applying AC line power to the motor in the event of a drive fault. The absence of the 10-second time delay can result in a devastating torque pulse which can damage your motor, driven load and/or installation.
  • Page 17 With Smoke purge option, After C20 Procedure follow below instruction Main menu Parameter data set…with down arrow E - ## Digital In/Out E-0 # Digital Inputs Down arrow – 5 times SET TO [14] Jog DEH40602 – Page 10 AN 11-2021 Rev 05, 12/15/2011...
  • Page 18 3. AF 600 FP Drive Terminal Board I/O Any of the AF 600 FP terminal board I/O points which are not already in use for proper operation of the bypass panel are available for customer use. The meanings and connection diagrams for these I/O points are well described and illustrated in the AF 600 FP User’s Guide (DET609 –...
  • Page 19 4. Adjustments The AF 600 FP & Bypass panel has several user settable adjustments, which allow it to be tailored specifically for your 3-phase induction motor. Setting these adjustments appropriately is an important factor in ensuring that applicable safety codes are met and that your bypass panel, wiring, and motor are adequately protected. The following list comprises all of the user adjustable devices/components inside the AF 600 FP &...
  • Page 20 The overload relay in your AF 600 FP & Bypass panel is the C-2000 Class 20 or Class 30 fixed heater type from GE which is panel mounted. Class 30 overload relays are utilized for panels rated 60Hp and above at 208 VAC plus 150Hp and above at 460 VAC.
  • Page 21 According to GE ED&C publication DET-034B entitled C-2000 Contactors & Starters Technical Information, the trip level dial on the contactors should be set as follows.  Motors with Service Factor of 1.15 or Greater - adjust OL relay dial to the motor nameplate FLA.
  • Page 22 3. Reduce the load on the motor during acceleration. Total motor load during this period is the sum of the accelerating torque plus load torque. Once motor is up to speed the load can be reapplied. WARNING: The overload relay should not be turned to a higher setting than allowed by the rules above to allow starting the motor across the line without tripping.
  • Page 23 5. AF 600 FP Drive Function Code Changes The AF 600 FP Adjustable Frequency Drive has programmable function. A complete description of these function codes can be found in DET – 609 or DET – 610. The purpose of this section is to identify those function codes which changed from the factory defaults for bypass panel installation.
  • Page 24 AN – 0 # AN – 00 TIME [Loss of ref time] 10 Sec – Default AN – 01 – TIME OUT FUNCTION [3] Jogging Jog frequency setup Main Menu Parameter data set Down arrow C - ## C – 0 # Down arrow C –...
  • Page 25 E-0 # Digital Inputs 5 Times downward arrow SET TO [14] JOG Auto-Tune In the event that it is desired to “auto-tune” the drive to the connected motor, reference the following instructions along with the AF 600 FP User’s Guide (DET – 609 or DET - 610): With power applied to the panel –...
  • Page 26 6. Troubleshooting If careful attention to phase rotation is not made during connection of the panel to the three-phase power supply and motor, then there is only a one chance in four that the motor will rotate correctly in both drive and bypass modes.

  • Page 27: Operating And Troubleshooting Instructions For Af-600 Fp Non Bypass & Disconnect Drive Panels

    AF-600 FP NON BYPASS & DISCONNECT DRIVE PANELS Your AF-600 FP NON Bypass & Disconnect Drive Panels comes with an AF-600 FP Adjustable Frequency Drive from GE Drives mounted on or in an enclosure, which contains the following equipment to control motor operation from the drive.

  • Page 28: Operator Devices

    Table of Contents Operator Devices page 3 Customer Terminal Board page 5 AF-600 FP Drive Terminal Board I/O page 7 Adjustments page 8 AF-600 FP Drive Function Code Changes page 10 Troubleshooting page 13 NOTE: The terms drive and inverter is used interchangeably in this document.

  • Page 29: Customer Terminal Board

    The purpose of the panel mounted input disconnect with through-the-door handle is to provide a local, lockable method of removing all AC input power from the panel and AF-600 FP drive. WARNING: Although input power is removed from the drive in the “Off”...
  • Page 30 Hand - Off - Auto on Drive Keypad All AF-600 FP Drive Panels include a keypad for programming and operation of the drive and includes Hand, Off, and Auto operation keys / buttons. When shipped from the factory, the Hand, Off and Auto buttons are enabled. Pressing the Off button while the drive is running will cause the drive to decelerate and shut off regardless of the positions of the panel’s selector switches.
  • Page 31 2. Customer Terminal Board – “CTB” The following section does not apply to the Disconnect Drive Panels. All customer terminations for control wiring are made on the drive’s connections. Refer to product user guide for details. Inside the panel enclosure there is a terminal board for convenient connection of customer control wiring. The customer interface drawing provides a visual reference of the terminal board positions with the detailed descriptions as follows: CTB1-1 through CBT1-3...
  • Page 32 CTB1-27 through CTB1-28 Analog Output 0/4-20 mA. NOTE: 4-20 mA output signal will be available from the drive at terminal 39 and 42, which is wired for customer to terminal board CTB1-27 and CTB1-28. CTB1-20 through CTB1-22 Connect customer supplied 0-10 VDC or 4-20 mA “Auto” speed reference signal. This signal functions as the drive’s speed reference when the H-O-A switch is in the “Auto”...
  • Page 33 3. AF-600 FP Drive Terminal Board I/O CTB-Customer Terminal Boards are not available in Disconnect Drive panels Any of the AF 600 FP terminal board I/O points which are not already in use for proper operation of the Non bypass panel are available for customer use. The meanings and connection diagrams for these I/O points are well described and illustrated in the AF 600 FP User’s Guide (DET609 –...

  • Page 34: Adjustments

    4. Adjustments The AF-600 FP panel has several user settable adjustments which allow it to be tailored specifically for your 3- phase induction motor. Setting these adjustments appropriately is an important factor in ensuring that applicable safety codes are met and that your panel, wiring, and motor are adequately protected. The following list comprises all of the user adjustable devices/components inside the AF-600 FP, Bypass &...
  • Page 35 However, the rating plugs for the circuit breakers in the AF-600 FP panels have been chosen to allow trip level settings up to 13 times the current ratings of the panel. If the...

  • Page 36: Af 600 Fp Drive Function Code Changes

    5. AF 600 FP Drive Function Code Changes The following section does not apply to the Disconnect Drive Panels. All programmable functions are at the drive’s factory defaults. The AF 600 FP Adjustable Frequency Drive has programmable function. A complete description of these function codes can be found in DET –...
  • Page 37 AN – 0 # AN – 00 TIME [Loss of ref time] 10 Sec – Default AN – 01 – TIME OUT FUNCTION [3] Jogging Jog frequency setup Main Menu Parameter data set Down arrow C - ## C – 0 # Down arrow C –...
  • Page 38 E-0 # Digital Inputs 5 Times downward arrow SET TO [14] JOG DEH40608 – Page 12 AN 11-2021 Rev 05, 12/15/2011...

  • Page 39: Troubleshooting

    In the event that it is desired to “auto-tune” the drive to the connected motor, reference the following instructions along with the AF-600 FP User’s Guide (DET – 609 or DET - 610): With power applied to the panel –...
  • Page 40 AF-600 FP User’s Guide DET -609 AF 600 FP User’s Guide for up to 60HP @ 208V & up to 125HP @460/575 DET - 610 AF 600 FP User’s Guide for 150HP and above @ 460/575V to be inserted here along with any other GEI for any options which may be included.
  • Page 41 Appendix A – Current Ratings and Fuse Sizes Table A 208 VAC Panel Current Ratings and Maximum Allowable Fuse Sizes Table B 460 VAC Panel Current Ratings and Maximum Allowable Fuse Sizes Table C 575 VAC Panel Current Ratings and Maximum Allowable Fuse Sizes In-Warranty Information Form DEH40604 –...
  • Page 42 Table A AF 600 FP Panels – 208 VAC Current Ratings and Maximum Fuse Sizes VAC Panel VAC Panel Max Allowable Hp Rating Current Rating Fuse Size 10.33 13.13 10.6 18.55 16.7 29.23 24.2 42.35 30.8 53.90 46.2 80.85 59.4 103.95 74.8 130.90...
  • Page 43 Table B AF 600 FP Panels – 460 VAC Current Ratings and Maximum Fuse Sizes VAC Panel VAC Panel Max Allowable Hp Rating Current Rating Fuse Size 3.68 5.95 8.40 13.30 19.25 14.5 24.50 36.75 47.25 59.50 70.00 91.00 113.75 134.75 168.00 217.00...
  • Page 44 Table C AF 600 FP Panels – 575 VAC Current Ratings and Maximum Fuse Sizes VAC Panel VAC Panel Max Allowable Hp Rating Current Rating Fuse Size 4.20 4.73 7.18 10.68 15.75 19.25 30.10 38.50 47.25 57.23 71.75 91.00 108.50 138.08 173.25 218.75...
  • Page 45 In-Warranty Information Form The purpose of this form is to provide specific information to GE Drives to aid in expediting part replacement and/or troubleshooting assistance for AF-600 FP Bypass OR NON Bypass OR Disconnect Drive panels. The following information is required prior to any assistance being provided.
  • Page 46 VI. To aid in part replacement please fill complete the following: To: ______________________ From: _____________________ Fax: _____________________ Fax: ______________________ Phone: ____________________ Phone: ____________________ The following is the ship to address for all warranty replacement items: Company Name ________________________________________________________________ ________________________________________________________________ Street Address ________________________________________________________________ ________________________________________________________________ City...
  • Page 47 Appendix B – and Estimated Watt loss Wire Sizes, Torque Details Table 1 Wire Sizes and Torque Requirements for 208 VAC Panels Table 2 Wire Sizes and Torque Requirements for 460 VAC Panels Table 3 Wire Sizes and Torque Requirements for 575 VAC Panels Table A 6KFP Series Bypass Configuration - Electrical Channel Table B...
  • Page 48 Table – 1 (208V) Device AF - 600 HP Rating(s) Minimum Wire Size Maximum Wire Size Required Torque NON FUSED DISCONNECTOR AND FUSE BLOCK 2-5Hp # 14 AWG # 4 AWG Note 1 7.5-10HP # 14 AWG # 4 AWG Note 1 15-20 # 8 AWG...
  • Page 49 Table – 2 (460V) AF - 600 HP Device Minimum Wire Size Maximum Wire Size Required Torque Rating(s) NON FUSED DISCONNECTOR AND FUSE BLOCK 1 through 10Hp # 14 AWG # 4 AWG Note 1 15 through 30Hp # 14 AWG # 4 AWG Note 1 40 through 50Hp...
  • Page 50 Table – 2 (460V) AF - 600 HP Required Device Minimum Wire Size Maximum Wire Size Rating(s) Torque Load Reactor (6KFP 1 through 5 # 22 AWG # 10 AWG 4.5 lb. in. Series) 7.5 through 15 # 14 AWG # 6 AWG 16 lb.
  • Page 51 Table – 3 (575V) Device AF - 600 HP Rating(s) Minimum Wire Size Maximum Wire Size Required Torque NON FUSED DISCONNECTOR AND 1 through 10Hp # 14 AWG # 4 AWG Note 1 FUSE BLOCK 15 through 40Hp # 14 AWG # 4 AWG Note 1 50 through 60Hp...
  • Page 52 Table – 3 (575V) Device AF - 600 HP Rating(s) Minimum Wire Size Maximum Wire Size Required Torque Load Reactor (6KFP Series) 1 through 5 # 22 AWG # 10 AWG 4.5 lb. in. 7.5 through 20 # 14 AWG # 6 AWG 16 lb.
  • Page 53 UL508 Table 54.1 , Tightening torque for screws Tightening torque (lb in.) Hexagonal head - external drive socket Slotted head no 10 and large Test wire size installed wrench in connector (AWG) Slot width - 0.047 inch Slot width - 0.047 or less and slot length inch or slot length - Split bolt connectors...
  • Page 54 Table 54.3 , Tightening torque for socket head screws Socket size across flat in inches Tightening torque in lb.in 5/32 3/16 7/32 5/16 9/16 DEH40603 – Page 8 AN 12-1007 Rev 05, 04/04/2012...
  • Page 55 Table A 6KFP Series Bypass Configuration -Electrical Channel Estimated Watt Loss (Watts) at HP Ratings 208V 460V 575V DEH40603 – Page 9 AN 12-1007 Rev 05, 04/04/2012...
  • Page 56 Table B 6KFP Series Non-Bypass Configuration -Electrical Channel Estimated Watt Loss (Watts) at HP Ratings 208V 460V 575V 1133 1261 1863 1090 2034 1208 1147 2422 1336 1331 1719 1696 2101 2074 2256 2228 4283 4083 4977 5902 6770 DEH40603 – Page 10 AN 12-1007 Rev 05, 04/04/2012...
  • Page 57 Table C 6KFP*L Series Non-Bypass Configuration - Electrical Channel Estimated Watt Loss (Watts) at HP Ratings 208V 460V 575V 4014 3902 4644 4430 5372 5332 6369 6247 7182 7141 7682 9623 8106 9701 9140 10997 11601 10852 10852 DEH40603 – Page 11 AN 12-1007 Rev 05, 04/04/2012...

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