GE AF-600 FP Series Design And Installation Manual
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GE AF-600 FP Series Design And Installation Manual

Fan & pump drive
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Fan & Pump Drive
Design and Installation Guide
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  • Page 1 AF-600 FP Fan & Pump Drive Design and Installation Guide...
  • Page 2 Safety AF-600 FP Design and Installation Guide Safety WARNING Voltage Minimum Waiting Power Size Time [minutes] HIGH VOLTAGE 0.75-3.7 kW 1-5 HP 200-240 Frequency converters contain high voltage when 5.5-45 kW 7.5-60 HP connected to AC mains input power. Installation, start up, 0.75-7.5 kW 1-10 HP and maintenance should be performed by qualified 11-90 kW 15-125 HP...
  • Page 3 Safety AF-600 FP Design and Installation Guide DET-768b...

  • Page 4: Table Of Contents

    Contents AF-600 FP Design and Installation Guide Contents 1 Introduction 1.1 Exploded Views 1.2 Purpose of the Manual 1.3 Additional Resources 1.4 Product Overview 1.5 Internal Frequency Converter Controller Functions 2 Installation 2.1 Installation Site Check List 2.2 Frequency Converter and Motor Pre-installation Check List 2.3 Mechanical Installation 2.3.1 Cooling 2.3.2 Cooling and Airflow (125 HP and above)
  • Page 5 Contents AF-600 FP Design and Installation Guide 3.5 Check Motor Rotation 3.6 Local-control Test 3.7 System Start Up 4 User Interface 4.1 Keypad 4.1.1 Keypad Layout 4.1.2 Setting Keypad Display Values 4.1.3 Display Menu Keys 4.1.4 Navigation Keys 4.1.5 Operation Keys 4.2 Back Up and Copying Parameter Settings 4.2.1 Uploading Data to the Keypad 4.2.2 Downloading Data from the Keypad...
  • Page 6 Contents AF-600 FP Design and Installation Guide 7.7 Motor Bearing Currents 8 Status Messages 8.1 Status Display 8.2 Status Message Definitions 9 RS-485 Installation and Set-up 9.1 Installation and Set-up 9.1 Network Configuration 9.1.1 Frequency Converter with Modbus RTU 9.1.2 How to Access Parameters 9.1.2.1 Parameter Handling 9.1.2.2 Storage of Data 9.1.2.3 IND...
  • Page 7 Contents AF-600 FP Design and Installation Guide 13.3 Fuse Specifications 13.3.2 Recommendations 13.3.3 CE Compliance 13.3.4 Fuse Specifications 13.3.5 NEC and UL Compliance Index DET-768b...

  • Page 8: Introduction

    Introduction AF-600 FP Design and Installation Guide 1 Introduction 1.1 Exploded Views Illustration 1.1 Exploded View Unit Size 12 and 13 Keypad 10 Motor output terminals 96 (U), 97 (V), 98 (W) RS-485 serial bus connector (+68, -69) 11 Relay 1 (01, 02, 03) Analog I/O connector 12 Relay 2 (04, 05, 06) Keypad input plug...
  • Page 9 Introduction AF-600 FP Design and Installation Guide Illustration 1.2 Exploded View Unit Sizes 15, 21, 22, 31, and 32 Keypad Relay 2 (04, 05, 06) Cover Lifting ring RS-485 serial bus connector Mounting slot Digital I/O and 24 V power supply Grounding clamp (PE) Analog I/O connector Cable strain relief / PE ground...
  • Page 10 Introduction AF-600 FP Design and Installation Guide Illustration 1.3 Exploded View Unit Sizes 41h, 42h, 43h, 44h Local control panel mounting bracket Heatsink fan Control card and mounting plate Gate drive support bracket Power card and mounting plate Capacitor bank Inrush card Balance/High frequency card Inrush card mounting bracket...
  • Page 11 Introduction AF-600 FP Design and Installation Guide Illustration 1.4 Compact IP21 (NEMA 1) and IP54 (NEMA 12), Unit Sizes 41, 42, 43, 44, 51, 52 AUX Relay Temp Switch SMPS Fuse (see 13.3 Fuse Specifications for part number) AUX Fan Line Fan Fuse (see 13.3 Fuse Specifications for part number) Mains ground...
  • Page 12 Introduction AF-600 FP Design and Installation Guide Illustration 1.5 Position of Earth Terminals IP21 (NEMA Type 1) and IP54 (NEMA Type 12) Illustration 1.6 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).
  • Page 13 Introduction AF-600 FP Design and Installation Guide Illustration 1.7 Inverter Cabinet, Unit Sizes 62 and 64 (Unit Sizes 61 and 63 are similar with two inverter modules) External Temperature Monitoring Motor AUX Relay AUX Fan Fan Fuses. See 13.3 Fuse Specifications for part numbers 101 102 103 SMPS Fuses.

  • Page 14: Purpose Of The Manual

    • specific requirements. Contact the local GE Reduce RMS current DC reactors supplier or visit the GE website for downloads or • Raise the power factor additional information. reflected back to the line •...

  • Page 15: Installation

    Installation AF-600 FP Design and Installation Guide 2 Installation 2.1 Installation Site Check List 2.2 Frequency Converter and Motor Pre- installation Check List • The frequency converter relies on the ambient air for cooling. Observe the limitations on ambient • Compare the model number of unit on the air temperature for optimal operation nameplate to what was ordered to verify the...
  • Page 16 Installation AF-600 FP Design and Installation Guide Illustration 2.1 Top and Bottom Cooling Clearance 32, 34, 41h, 42h, 43h, Size 12-15 21-24 31, 33 44h, 51, and 52 a/b [mm] Table 2.1 Minimum Airflow Clearance Requirements DET-768b...

  • Page 17: Cooling And Airflow (125 Hp And Above)

    Installation AF-600 FP Design and Installation Guide 2.3.2 Cooling and Airflow (125 HP and above) Cooling Cooling can be obtained in different ways, by using the cooling ducts in the bottom and the top of the unit, by taking air in and out the back of the unit or by combining the cooling possibilities.

  • Page 18: Mounting

    Installation AF-600 FP Design and Installation Guide 2.3.4 Mounting • Mount the unit vertically • The frequency converter allows side by side installation • Ensure that the strength of the mounting location will support the unit weight • Mount the unit to a solid flat surface or to the optional back plate to provide cooling airflow (see Illustration 2.3 and Illustration 2.4) •...

  • Page 19: Electrical Installation

    Installation AF-600 FP Design and Installation Guide 2.5 Electrical Installation This section contains detailed instructions for wiring the frequency converter. The following tasks are described. • Wiring the motor to the frequency converter output terminals • Wiring the AC mains to the frequency converter input terminals •...

  • Page 20: Requirements

    • GE recommends that all power connections be • Run motor cables from multiple frequency made with a minimum 75 °C rated copper wire. converters separately. Induced voltage from output motor cables run together can charge 2.5.2 Earth (Grounding) Requirements...

  • Page 21: Leakage Current (>3.5 Ma)

    Installation AF-600 FP Design and Installation Guide • 2.5.2.2 Grounding Using Shielded Cable Do not ground one frequency converter to another in a “daisy chain” fashion Earthing (grounding) clamps are provided for motor wiring • Using high-strand wire to reduce electrical noise (see Illustration 2.7).

  • Page 22: Ac Mains Connection

    Installation AF-600 FP Design and Installation Guide 2.5.4 AC Mains Connection 2.5.5 Knock-outs (Unit Sizes 15, 21, 22, 31, and 32) The legend for the illustrations: • Size wiring based upon the input current of the A: Line in frequency converter. B: Load sharing •...

  • Page 23: Control Wiring

    Installation AF-600 FP Design and Installation Guide 2.5.7 Gland/Conduit Entry (Unit Sizes 41h, 42h, and 51) 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 24: Control Terminal Types

    Installation AF-600 FP Design and Installation Guide DC terminal supply voltage, and a common for optional customer supplied 24 V DC voltage • Connector 2 terminals (+)68 and (-)69 are for an RS-485 serial communications connection • Connector 3 provides two analog inputs, one analog output, 10 V DC supply voltage, and commons for the inputs and output •...

  • Page 25: Wiring To Control Terminals

    Installation AF-600 FP Design and Installation Guide Terminal Description Open the contact by inserting a small screwdriver into the slot above or below the contact, as Digital Inputs/Outputs shown in Illustration 2.17. Default Terminal Parameter Setting Description Insert the bared control wire into the contact. +10 V DC 10 V DC analog Remove the screwdriver to fasten the control wire...

  • Page 26: Control Terminal Functions

    Installation AF-600 FP Design and Installation Guide 2.5.8.5 Control Terminal Functions 50/60 Hz ground loops With very long control cables, ground loops may occur. To eliminate ground loops, connect one end of the screen-to- Frequency converter functions are commanded by ground with a 100 nF capacitor (keeping leads short).

  • Page 27: Serial Communication

    Installation AF-600 FP Design and Installation Guide Cable Screened twisted pair (STP) 120 Ω Impedance Max. cable 1200 (including drop lines) length [m] 500 station-to-station Table 2.10 Cable Information 130BT310.10 Illustration 2.22 Location of Terminals 53 and 54 Switches 2.5.9 Serial Communication RS-485 is a two-wire bus interface compatible with multi- drop network topology, i.e.

  • Page 28: Start Up And Functional Testing

    Start Up and Functional Tes... AF-600 FP Design and Installation Guide 3 Start Up and Functional Testing 3.1 Pre-start 3.1.1 Safety Inspection WARNING HIGH VOLTAGE! If input and output connections have been connected improperly, there is potential for high voltage on these terminals. If power leads for multiple motors are improperly run in same conduit, there is potential for leakage current to charge capacitors within the frequency converter, even when disconnected from mains input.
  • Page 29 Start Up and Functional Tes... AF-600 FP Design and Installation Guide ☑ Inspect for Description • Environmental consider- See equipment label for the maximum ambient operating temperature limits ations • Humidity levels must be 5-95% non-condensing • Fusing and circuit Check for proper fusing or circuit breakers breakers •...

  • Page 30: Applying Power

    Start Up and Functional Tes... AF-600 FP Design and Installation Guide 3.2 Applying Power WARNING Press [Quick Menu] on the keypad. Use the navigation keys to scroll to Quick Start HIGH VOLTAGE! and press [OK]. Frequency converters contain high voltage when Select language and press [OK].

  • Page 31: Check Motor Rotation

    Start Up and Functional Tes... AF-600 FP Design and Installation Guide NOTE motor characteristics with the data entered in P-02, P-03, P-06, P-07, F-04 and F-05. The [hand] key provides a local start command to the • frequency converter. The [Off] key provides the stop The motor shaft does not turn and no harm is function.

  • Page 32: System Start Up

    Start Up and Functional Tes... AF-600 FP Design and Installation Guide 3.7 System Start Up The procedure in this section requires user-wiring and application programming to be completed. is intended to help with this task. Other aids to application set-up are listed in 1.3 Additional Resources.

  • Page 33: User Interface

    User Interface AF-600 FP Design and Installation Guide 4 User Interface 4.1 Keypad 4.1.1 Keypad Layout The keypad is the combined display and keys on the front of the unit. The keypad is the user interface to the frequency converter. The keypad is divided into 4 functional groups (see Illustration 4.1).

  • Page 34: Setting Keypad Display Values

    User Interface AF-600 FP Design and Installation Guide 4.1.2 Setting Keypad Display Values 4.1.3 Display Menu Keys The display area is activated when the frequency converter receives power from mains voltage, a DC bus terminal, or Menu keys are used for menu access for parameter set-up, an external 24 V DC supply.

  • Page 35: Navigation Keys

    User Interface AF-600 FP Design and Installation Guide 4.1.4 Navigation Keys 4.1.5 Operation Keys Navigation keys are used for programming functions and Operation keys are found at the bottom of the keypad. moving the display cursor. The navigation keys also provide speed control in local (hand) operation.

  • Page 36: Uploading Data To The Keypad

    User Interface AF-600 FP Design and Installation Guide WARNING selections, personal menu settings, fault log, alarm log, and other monitoring functions UNINTENDED START! • Using H-03 Restore Factory Settings is generally When the frequency converter is connected to AC mains, recommended the motor may start at any time.

  • Page 37: About Programming

    About Programming AF-600 FP Design and Installation Guide 5 About Programming 5.1 Introduction The frequency converter is programmed for its application functions using parameters. Parameters are accessed by pressing either [Quick Menu] or [Main Menu] on the keypad. (See 4 User Interface for details on using the keypad function keys.) Parameters may also be accessed through a PC using the DCT-10.
  • Page 38 About Programming AF-600 FP Design and Installation Guide AN-10 Terminal 53 Low Voltage. Set minimum AN-15 Terminal 53 High Ref./Feedb. Value. Set external voltage reference on Terminal 53 at 0 V. maximum speed reference on Terminal 53 at 50 (This sets the minimum input signal at 0 V.) Hz.

  • Page 39: Control Terminal Programming Examples

    About Programming AF-600 FP Design and Installation Guide 5.3 Control Terminal Programming Examples Control terminals can be programmed. • Each terminal has specified functions it is capable of performing • Parameters associated with the terminal enable the function See Table 2.6 for control terminal parameter number and default setting.

  • Page 40: Parameter Menu Structure

    About Programming AF-600 FP Design and Installation Guide Parameter International North American default parameter default parameter 5.5 Parameter Menu Structure value value AN-50 Terminal 42 Speed 0-HighLim Speed 4-20 mA Establishing the correct programming for applications Output often requires setting functions in several related H-04 Auto-Reset Manual reset Infinite auto reset...

  • Page 41: Main Menu Structure

    About Programming AF-600 FP Design and Installation Guide DET-768b...
  • Page 42 About Programming AF-600 FP Design and Installation Guide DET-768b...
  • Page 43 About Programming AF-600 FP Design and Installation Guide DET-768b...
  • Page 44 About Programming AF-600 FP Design and Installation Guide DET-768b...

  • Page 45: Remote Programming With Dct-10

    AF-600 FP Design and Installation Guide 5.6 Remote Programming with DCT-10 GE has a software program available for developing, storing, and transferring frequency converter programming. The DCT-10 allows the user to connect a PC to the frequency converter and perform live programming rather than using the keypad.

  • Page 46: Application Set-Up Examples

    Application Set-Up Examples AF-600 FP Design and Installation Guide 6 Application Set-Up Examples 6.1 Introduction The examples in this section are intended as a quick Parameters reference for common applications. Function Setting • Parameter settings are the regional default values AN-12 Terminal 4mA* unless otherwise indicated (selected in...
  • Page 47 Application Set-Up Examples AF-600 FP Design and Installation Guide Parameters Parameters Function Setting Function Setting E-01 Terminal 18 [9] Latched E-01 Terminal 18 [8] Start Digital Input Start Digital Input E-03 Terminal 27 [6] Stop E-02 Terminal 19 [10] Digital Input Inverse Digital Input Reversing*...
  • Page 48 Application Set-Up Examples AF-600 FP Design and Installation Guide Parameters Function Setting S p e e d AN-10 Terminal R e f e r e n c e 53 Low Voltage 0.07V* AN-11 Terminal 10V* 53 High Voltage S t a r t ( 1 8 ) AN-14 Terminal 0RPM 53 Low Ref./...
  • Page 49 Application Set-Up Examples AF-600 FP Design and Installation Guide Hand Off Auto (HOA), without the use of the Drive keypad CAUTION To have a HOA system with an external 0-10 V potenti- Thermistors must use reinforced or double insulation to ometer for the hand reference and a 4-20 mA signal for meet PELV insulation requirements.

  • Page 50: Advantages

    * = Default Value control system for controlling fan and pump systems. Notes/comments: GE 30mm HOA Cat# (1) 104PSG34B & (3) CR104PXC1 Illustration 6.4 The Graph is showing Fan Curves (A, B and C) for Reduced Fan Volumes Table 6.10 HOA...
  • Page 51 Application Set-Up Examples AF-600 FP Design and Installation Guide 6.3.3 Example of Energy Savings 6.3.4 Better Control As can be seen from the figure (Illustration 6.6), the flow is If a frequency converter is used for controlling the flow or controlled by changing the RPM.
  • Page 52 Application Set-Up Examples AF-600 FP Design and Installation Guide 6.3.7 Without a Frequency Converter Illustration 6.7 shows a fan system made in the traditional way. Illustration 6.7 Traditional Fan System D.D.C.=Direct Digital Control V.A.V.=Variable Air Volume Sensor P=Pressure E.M.S.=Energy Management system Sensor T=Temperature DET-768b...

  • Page 53: Application Examples

    Application Set-Up Examples AF-600 FP Design and Installation Guide 6.3.8 With a Frequency Converter Illustration 6.8 shows a fan system controlled by frequency converters Illustration 6.8 Frequency Converter Controlled Fan System 6.3.9 Application Examples The next few pages give typical examples of applications within HVAC. DET-768b...
  • Page 54 Application Set-Up Examples AF-600 FP Design and Installation Guide 6.3.10 Variable Air Volume VAV or Variable Air Volume systems, are used to control both the ventilation and temperature to satisfy the requirements of a building. Central VAV systems are considered to be the most energy efficient method to air condition buildings. By designing central systems instead of distributed systems, a greater efficiency can be obtained.
  • Page 55 Several features of the GE dedicated frequency converter can be utilized to improve the performance of your CAV system. One concern of controlling a ventilation system is poor air quality. The programmable minimum frequency can be set to maintain a minimum amount of supply air regardless of the feedback or reference signal.
  • Page 56 The frequency converters can also be used to turn the fan on and off as needed. Several features of the GE dedicated frequency converter, the HVAC frequency converter can be utilized to improve the performance of your cooling tower fans application. As the cooling tower fans drop below a certain speed, the effect the fan has on cooling the water becomes small.
  • Page 57 Application Set-Up Examples AF-600 FP Design and Installation Guide 6.3.16 Condenser Pumps Condenser Water pumps are primarily used to circulate water through the condenser section of water cooled chillers and their associated cooling tower. The condenser water absorbs the heat from the chiller's condenser section and releases it into the atmosphere in the cooling tower.
  • Page 58 Application Set-Up Examples AF-600 FP Design and Installation Guide 6.3.18 Primary Pumps Primary pumps in a primary/secondary pumping system can be used to maintain a constant flow through devices that encounter operation or control difficulties when exposed to variable flow. The primary/ secondary pumping technique decouples the “primary”...
  • Page 59 Application Set-Up Examples AF-600 FP Design and Installation Guide 6.3.20 Secondary Pumps Secondary pumps in a primary/secondary chilled water pumping system are used to distribute the chilled water to the loads from the primary production loop. The primary/secondary pumping system is used to hydronically de-couple one piping loop from another.

  • Page 60: Installation Consideration

    Installation Consideration AF-600 FP Design and Installation Guide 7 Installation Consideration 7.1 General Aspects of EMC 7.1.1 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 61 Installation Consideration AF-600 FP Design and Installation Guide When unscreened cables are used, some emission requirements are not complied with, although the immunity requirements are observed. In order to reduce the interference level from the entire system (unit + installation), make motor and brake cables as short as possible.

  • Page 62: Immunity Requirements

    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 63: General Aspects Of Harmonics Emission

    Installation Consideration AF-600 FP Design and Installation Guide Voltage range: 200-240 V, 380-480 V Basic standard Burst Surge Radiated electromagnetic RF common IEC 61000-4-4 IEC 61000-4-5 field mode voltage 61000-4-2 IEC 61000-4-3 IEC 61000-4-6 Acceptance criterion 2 kV/2 Ω DM Line 4 kV CM —...

  • Page 64: Galvanic Isolation (Pelv)

    Installation Consideration AF-600 FP Design and Installation Guide 7.3.1 Harmonics Emission Requirements made as described in local/national regulations on PELV supplies. Equipment connected to the public supply network: All control terminals and relay terminals 01-03/04-06 Options Definition comply with PELV (Protective Extra Low Voltage) (Does not IEC/EN 61000-3-2 Class A for 3-phase balanced apply to grounded Delta leg above 400 V).

  • Page 65: Derating

    GE regarding PELV. 380 - 480V, unit size 4x, 5x and 6x: At altitudes above 3 km, please contact GE regarding PELV. 525 - 690 V: At altitudes above 2 km, please contact GE regarding PELV. 7.5 Derating Illustration 7.4 Derating of output current versus altitude at T...

  • Page 66: Motor Insulation

    Installation Consideration AF-600 FP Design and Installation Guide 7.5.5 Derating for Running at Low Speed Nominal Mains Voltage Motor Insulation ≤ 420 V Standard U = 1300 V When a motor is connected to a frequency converter, it is 420 V < U ≤...

  • Page 67: Status Messages

    Status Messages AF-600 FP Design and Installation Guide 8 Status Messages Remote The speed reference is given from external signals, serial communication, or internal 8.1 Status Display preset references. Local The frequency converter uses [Hand] control When the frequency converter is in status mode, status or reference values from the keypad.
  • Page 68 Status Messages AF-600 FP Design and Installation Guide Feedback high The sum of all active feedbacks is above the Protection md Protection mode is active. The unit has feedback limit set in H-77 Warning Feedback detected a critical status (an overcurrent or High.
  • Page 69 Status Messages AF-600 FP Design and Installation Guide Start fwd/rev Start forward and start reverse were selected as functions for two different digital inputs. The motor will start in forward or reverse depending on which corresponding terminal is activated. Stop The frequency converter has received a stop command from the keypad, digital input or serial communication.

  • Page 70: Installation And Set-Up

    RS-485 Installation and Set... AF-600 FP Design and Installation Guide 9 RS-485 Installation and Set-up Letter Number 9.1 Installation and Set-up 9.1 Network Configuration 9.1.1 Frequency Converter with Modbus To enable Modbus RTU on the frequency converter, set the following parameters Parameter Setting O-30 Protocol...

  • Page 71: Parameter Values

    RS-485 Installation and Set... AF-600 FP Design and Installation Guide Conversion index Conversion factor Bit value = 0 Bit value = 1 1/60 (time) Reference value external selection lsb 1000000 Reference value external selection msb 100000 DC brake Ramp 10000 Coasting No coasting 1000...
  • Page 72 RS-485 Installation and Set... AF-600 FP Design and Installation Guide Bit 04, Quick stop Bit 12, Relay 04 Bit 04 = ’0’: Makes the motor speed decel to stop (set in Bit 12 = "0": Relay 04 is not activated. Bit 12 = "1": Relay 04 C-23 Quick Stop Decel Time).
  • Page 73 RS-485 Installation and Set... AF-600 FP Design and Installation Guide 9.2.2 Status Word According to Drive Bit 04, No error/error (no trip) Profile (STW) (O-10 Control Word Bit 04 = ’0’: The frequency converter is not in fault mode. Profile = Drive profile) Bit 04 = “1”: The frequency converter shows an error but does not trip.

  • Page 74: Bus Speed Reference Value

    RS-485 Installation and Set... AF-600 FP Design and Installation Guide Bit 14, Torque OK/limit exceeded Bit 14 = ’0’: The motor current is lower than the torque limit selected in F-43 Current Limit. Bit 14 = ’1’: The torque limit in F-43 Current Limit is exceeded. Bit 15, Timer OK/limit exceeded Bit 15 = ’0’: The timers for motor thermal protection and thermal protection are not exceeded 100%.

  • Page 75: Warnings And Alarms

    Warnings and Alarms AF-600 FP Design and Installation Guide 10 Warnings and Alarms 10.1 System Monitoring 10.3 Warning and Alarm Displays The frequency converter monitors the condition of its input power, output, and motor factors as well as other system performance indicators. A warning or alarm may not necessarily indicate a problem internal to the frequency converter itself.

  • Page 76: Warnings/Alarm Messages

    Warnings and Alarms AF-600 FP Design and Installation Guide If an alarm cannot be reset, the reason may be that its Warning LED Alarm LED cause has not been rectified, or the alarm is trip-locked Warning (see also Table 10.2). Alarm On (Flashing) Trip-Lock...
  • Page 77 Warnings and Alarms AF-600 FP Design and Installation Guide Description Warning Alarm/Trip Alarm/Trip Lock Parameter Reference Control word time-out O-04 Control Word Timeout Function Temp. Input Error Param Error Internal Fans External Fans Brake resistor short-circuited Brake resistor power limit B-13 Braking Thermal Overload Brake chopper short-circuited...
  • Page 78 Warnings and Alarms AF-600 FP Design and Installation Guide Description Warning Alarm/Trip Alarm/Trip Lock Parameter Reference Heat sink Temperature Low Option Module Configuration has Changed Pwr. Card Temp Illegal Drive configuration Illegal Profile Sel. Power Unit Setup Reduced power mode SP-59 Actual Number of Inverter Units Tracking Error...
  • Page 79 Warnings and Alarms AF-600 FP Design and Installation Guide Alarm Word Alarm Word 2 Warning Word Warning Extended Word 2 Status Word 00000100 Motor Electronic reserved Motor Electronic OL reserved Output Current Low OL Over (A10) Over (W10) 00000200 Drive Overld. (A9) reserved Drive Overld (W9) reserved Output Freq High...

  • Page 80: Warning And Alarm Definitions

    Warnings and Alarms AF-600 FP Design and Installation Guide 10.4 Warning and Alarm Definitions The warning/alarm information below defines each WARNING 6, DC link voltage low warning/alarm condition, provides the probable cause for The intermediate circuit voltage (DC) is lower than the low- the condition, and details a remedy or troubleshooting voltage warning limit.
  • Page 81 Record the value of the following parameters and contact either terminal 18 or 19 (digital input PNP only) your GE supplier: and terminal 50. Check F-12 Motor Thermistor Input selects terminal 18 or 19.
  • Page 82 Warnings and Alarms AF-600 FP Design and Installation Guide WARNING/ALARM 17, Control word timeout Current. The warning is active when the dissipated braking There is no communication to the frequency converter. is higher than 90% of the brake resistance power. If [2] Trip The warning is only active when O-04 Control Word is selected in B-13 Braking Thermal Overload, the frequency Timeout Function is NOT set to [0] Off.
  • Page 83 Check for loose or missing wiring the short-circuit connection. Check E-57 Term X30/7 Digi Out (OPCGPIO). It may be necessary to contact your GE supplier or service department. Note the code number for further trouble- ALARM 45, Earth fault 2 shooting directions.
  • Page 84 • Check the control card ALARM 50, Auto tune calibration failed Contact your GE supplier or GE Service Department. WARNING 66, Heatsink temperature low The frequency converter is too cold to operate. This warning is based on the temperature sensor in the IGBT...
  • Page 85 Warnings and Alarms AF-600 FP Design and Installation Guide ALARM 95, Broken belt Torque is below the torque level set for no load, indicating a broken belt. AP-60 Broken Belt Function is set for alarm. Troubleshoot the system and reset the frequency converter after the fault has been cleared.

  • Page 86: Basic Troubleshooting

    Basic Troubleshooting AF-600 FP Design and Installation Guide 11 Basic Troubleshooting 11.1 Start Up and Operation Symptom Possible cause Test Solution Missing input power See Table 3.1 Check the input power source Missing or open fuses or circuit See open fuses and tripped circuit Follow the recommendations breaker tripped breaker in this table for possible...
  • Page 87 Basic Troubleshooting AF-600 FP Design and Installation Guide Symptom Possible cause Test Solution Motor rotation limit Check that H-08 Reverse Lock is Program correct settings programmed correctly. Active reversing signal Check if a reversing command is Deactivate reversing signal Motor running in wrong programmed for the terminal in direction parameter group E-0# Digital...
  • Page 88 Basic Troubleshooting AF-600 FP Design and Installation Guide Symptom Possible cause Test Solution Bypass critical frequencies by using parameters in parameter group C-0# Acoustic noise or vibration Turn off over-modulation in Check if noise and/or vibration (e.g. a fan blade is making Resonances, e.g.

  • Page 89: Terminal And Applicable Wire

    Terminal and Applicable Wir... AF-600 FP Design and Installation Guide 12 Terminal and Applicable Wire 12.1 Cables DET-768b...

  • Page 90: Specifications

    Specifications AF-600 FP Design and Installation Guide 13 Specifications 13.1 Power-dependent Specifications 13.1.1 Power, Currents and Enclosures 200-240 V Input Efficiency IP20/Chassis IP55/Type 12 IP66/Type 4X 0.75 0.96 0.96 10.6 0.96 Unit size 12 Unit size 15 Unit size 15 16.7 0.96 24.2...
  • Page 91 Specifications AF-600 FP Design and Installation Guide 380-480 V Input Efficiency IP00/ IP20/Chassis IP21/Type 1 IP54/IP55/Type 12 IP66/Type 4X ≤ 440 V >440 V Chassis 0.98 Unit size 42h Unit size 42h 0.98 Unit size 52 0.98 Unit size 51 Unit size 51 0.98 0.98...

  • Page 92: Dimensions, Unit Size 1X

    Specifications AF-600 FP Design and Installation Guide 525-690 V Input Efficiency IP00/Chassis IP20/Chassis IP21/Type 1 IP54/IP55/Type 12 ≤ 550 V >690 V 0.98 0.98 Unit size 44h Unit size 42h Unit size 42h 0.98 0.98 0.98 0.98 Unit size 52 Unit size 51 Unit size 51 0.98...
  • Page 93 Specifications AF-600 FP Design and Installation Guide Illustration 13.2 Unit Size 13 Illustration 13.3 Unit Size 15 DET-768b...

  • Page 94: Dimensions, Unit Size 2X

    Specifications AF-600 FP Design and Installation Guide 13.1.3 Dimensions, Unit Size 2x Illustration 13.4 Unit Size 21 Illustration 13.5 Unit Size 22 DET-768b...
  • Page 95 Specifications AF-600 FP Design and Installation Guide Illustration 13.6 Unit Size 23 Illustration 13.7 Unit Size 24 DET-768b...

  • Page 96: Dimensions, Unit Size 3X

    Specifications AF-600 FP Design and Installation Guide 13.1.4 Dimensions, Unit Size 3x Illustration 13.8 Unit Size 31 Illustration 13.9 Unit Size 32 DET-768b...
  • Page 97 Specifications AF-600 FP Design and Installation Guide Illustration 13.10 Unit Size 33 Illustration 13.11 Unit Size 34 DET-768b...

  • Page 98: Dimensions, Unit Size 4Xh

    Specifications AF-600 FP Design and Installation Guide 13.1.5 Dimensions, Unit Size 4xh Illustration 13.12 Unit Size 41h Illustration 13.13 Unit Size 42h DET-768b...
  • Page 99 Specifications AF-600 FP Design and Installation Guide Illustration 13.14 Unit Size 43h Illustration 13.15 Unit Size 44h DET-768b...

  • Page 100: Dimensions, Unit Size 5X

    Specifications AF-600 FP Design and Installation Guide 13.1.6 Dimensions, Unit Size 5x Illustration 13.16 Unit Size 51 (Floor Mount) Illustration 13.17 Unit Size 52 (Cabinet Mount) DET-768b...

  • Page 101: Dimensions, Unit Size 6X

    Specifications AF-600 FP Design and Installation Guide 13.1.7 Dimensions, Unit Size 6x Illustration 13.18 Unit Size 61 (Floor Mount) (23.9) 1804 (71.0) IP 21/NEMA 1 2100 m (1236 CFM) IP 54/NEMA 12 1575 m (927 CFM) 2280 (89.8) 2205 (86.8) 1497 (58.9) 3941 m...
  • Page 102 Specifications AF-600 FP Design and Installation Guide (23.9) 1997 (78.6) IP 21/NEMA 1 1444 m (100 CFM) IP 54/NEMA 12 2100 m (1236 CFM) 2280 (89.3) 2205 (86.8) 1497 (58.9) 2956 m (1740 CFM) Illustration 13.20 Unit Size 63 (Floor Mount) (23.9) 2401 (94.5)

  • Page 103: General Technical Data

    Specifications AF-600 FP Design and Installation Guide 13.2 General Technical Data Mains supply (L1, L2, L3) 380-480 V ±10% Supply voltage 525-600 V ±10% Supply voltage Mains voltage low / mains drop-out: During low mains voltage or a mains drop-out, the drive continues until the intermediate circuit voltage drops below the minimum stop level, which corresponds typically to 15% below the drive's lowest rated supply voltage.
  • Page 104 Specifications AF-600 FP Design and Installation 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 0 to +10 V (scaleable) Input resistance, R approx.
  • Page 105 Specifications AF-600 FP Design and Installation 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 10 nF Minimum output frequency at frequency output 0 Hz...
  • Page 106 Specifications AF-600 FP Design and Installation Guide Surroundings Enclosure, frame size 4X and 5X IP00, IP21, IP54 Enclosure, frame size 6X IP21, IP54 Vibration test 0.7 g Relative humidity 5% - 95%(IEC 721-3-3; Class 3K3 (non-condensing) during operation Aggressive environment (IEC 60068-2-43) H S test class kD Test method according to IEC 60068-2-43 H...

  • Page 107: Fuse Specifications

    Fuses or Circuit Breakers are mandatory to comply with IEC frequency converter. 60364. GE recommend using a selection of the following. Over current protection: The fuses below are suitable for use on a circuit capable of...

  • Page 108: Fuse Specifications

    Specifications AF-600 FP Design and Installation Guide 13.3.4 Fuse Specifications AF-600 3- Recommended fuse Recommended max AF-600 3- Recommended fuse Recommended max phase size fuse phase size fuse [kW]/[HP] [kW]/[HP] 0.75/1 0.75/1 1.5/2 gG-16 gG-25 1.5/2 gG-16 gG-25 2.2/3 2.2/3 3.7/5 gG-20 gG-32...
  • Page 109 Specifications AF-600 FP Design and Installation Guide AF-600 3- Recommended fuse Recommended max AF-600 3- Recommended fuse Recommended max phase size fuse phase size fuse [kW]/[HP] [kW]/[HP] 0.75/1 gG-20 gG-32 0.75/1 1.5/2 1.5/2 gG-10 gG-25 2.2/3 2.2/3 3.7/5 3.7/5 5.5/7.5 5.5/7.5 gG-16 gG-32...
  • Page 110 Specifications AF-600 FP Design and Installation Guide AF-600 3- Recommended fuse Recommended max phase size fuse [kW]/[HP] 11/15 gG-25 15/20 gG-32 gG-63 18.5/25 22/30 gG-40 30/40 gG-63 gG-80 37/50 gG-100 45/60 gG-80 gG-125 55/75 gG-100 gG-160 75/100 gG-125 90/125 110/150 aR-250 aR-250 132/200...

  • Page 111: Nec And Ul Compliance

    Specifications AF-600 FP Design and Installation Guide 13.3.5 NEC and UL Compliance Fuses or Circuit Breakers are mandatory to comply with NEC 2009. We recommend using a selection of the following The fuses below are suitable for use on a circuit capable of delivering 100,000 Arms (symmetrical), 240 V, or 480 V, or 600 V depending on the drive voltage rating.
  • Page 112 Specifications AF-600 FP Design and Installation Guide Recommended max. fuse AF-600 1- AF-600 3- Ferraz- Ferraz- Bussmann Littel fuse phase phase Shawmut Shawmut [kW]/[HP] [kW]/[HP] Type JFHR2 Type J Type JFHR2 Type JFHR2 0.75/1 FWX-10 HSJ-10 1.5/2 FWX-15 HSJ-15 1.5/2 2.2/3 FWX-20 HSJ-20...
  • Page 113 Specifications AF-600 FP Design and Installation Guide Recommended max. fuse Ferraz- Ferraz- AF-600 1-phase AF-600 3-phase SIBA Littel fuse Shawmut Shawmut [kW]/[HP] [kW]/[HP] Type RK1 Type RK1 Type CC Type RK1 0.75/1 5017906-006 KLS-R-6 ATM-R-6 A6K-10-6 1.5-2.2/2-3 5017906-010 KLS-R-10 ATM-R-10 A6K-10-R 3.7/5 5017906-020...
  • Page 114 Specifications AF-600 FP Design and Installation Guide Recommended max. fuse AF-600 Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann [kW]/[HP] Type RK1 Type J Type T Type CC Type CC Type CC 0.75/1 KTS-R-5 JKS-5 JJS-6 FNQ-R-5 KTK-R-5 LP-CC-5 1.5-2.2/2-3 KTS-R-10 JKS-10 JJS-10 FNQ-R-10 KTK-R-10...
  • Page 115 Specifications AF-600 FP Design and Installation Guide AF-600 3-phase Bussmann Bussmann Bussmann SIBA Littel fuse Ferraz-Shawmut Ferraz-Shawmut [kW]/[HP] Type RK1 Type J Type T Type RK1 Type RK1 Type RK1 Type J 11/15 KTS-R-30 JKS-30 JJS-30 5017906-030 KLS-R-030 A6K-30R HST-30 15/20 KTS-R-35 JKS-35...
  • Page 116 Specifications AF-600 FP Design and Installation Guide AF-600 Bussmann PN Rating Alternate Siba PN [kW]/[HP] 500/650 170M8611 1100A, 1000V 20 781 32.1000 560/750 170M8611 1100A, 1000V 20 781 32.1000 630/900 170M6467 1400A, 700V 20 681 32.1400 710/1000 170M6467 1400A, 700V 20 681 32.1400 800/1200 170M8611...

  • Page 117: Index

    Index AF-600 FP Design and Installation Guide Conducted Emission................59 Index Conduit....................17, 25 Constant Air Volume..................52 A53......................23 Torque Applications (CT Mode)..........63 A54......................23 Control Cables....................23 Input....................11, 19 Card....................... 77 Mains..................11, 16, 19 Card Performance................. 103 Waveform...................
  • Page 118 Index AF-600 FP Design and Installation Guide Harmonics Harmonics................... 11 Emission Requirements..............61 Earth Test Results (Emission)..............61 Connections..................25 Hold Output Frequency..............69 Wire....................... 25 Earthing Earthing....................25 (Grounding)..................26 IEC 61800-3..................... 19 Electrical Noise..................18 IGVs......................51 Immunity Requirements..............59 EMC.......................
  • Page 119 Index AF-600 FP Design and Installation Guide Motor Protection Cables................12, 17, 18, 28 Protection................... 61 Current................11, 28, 81, 31 And Features................... 103 Data..................28, 78, 81 Public Supply Network............... 61 Frequency................... 31 Pulse Inputs..................101 Output....................100 Power................16, 17, 81, 31 Pump Impeller..................
  • Page 120 Index AF-600 FP Design and Installation Guide Supply Voltage..............20, 21, 25, 80 Surroundings..................103 Switching Frequency................65 Symbols....................... i System Feedback..................... 11 Monitoring..................72 Start Up....................29 Temperature Limits................25 Terminal 53..................... 23, 34, 35 54......................23 Programming..................23 Programming Examples..............
  • Page 121 Should further information be desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes, the matter should be referred to the GE company. AF-600 FP is a trademark of the General Electric Company.

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