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

GE AF-600 FP Design And Installation Manual

Fan & pump drive
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AF-600 FP
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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 WARNING HIGH VOLTAGE! DISCHARGE TIME! Adjustable frequency drives contain high voltage when Adjustable frequency drives contain DC link capacitors that connected to AC line power. Installation, start-up, and can remain charged even when AC line power is discon- maintenance should be performed by qualified personnel nected.
  • Page 3 Safety AF-600 FP Design and Installation Guide Symbols The following symbols are used in this manual. WARNING Indicates a potentially hazardous situation which, if not avoided, could result in death or serious injury. CAUTION Indicates a potentially hazardous situation which, if not avoided, may result in minor or moderate injury.

  • Page 4: Table Of Contents

    Contents AF-600 FP Design and Installation Guide Contents 1 Introduction 1.1 Purpose of the Manual 1.2 Additional Resources 1.3 Product Overview 1.4 Internal Adjustable Frequency Drive Controller Functions 2 Installation 2.1 Installation Site Checklist 2.2 Adjustable Frequency Drive and Motor Pre-installation Checklist 2.3 Mechanical Installation...
  • Page 5 Contents AF-600 FP Design and Installation Guide 2.5.8.3 Wiring to Control Terminals 3-14 2.5.8.4 Using Shielded Control Cables 3-15 2.5.8.5 Control Terminal Functions 3-15 2.5.8.6 Terminal 53 and 54 Switches 3-16 2.5.9 Serial Communication 3-16 3 Start Up and Functional Testing 3.1 Pre-start...
  • Page 6 Contents AF-600 FP Design and Installation Guide 6 Application Set-up Examples 6.1 Introduction 6.2 Application Examples 6.3 Advantages 6.3.9 Application Examples 7 Installation Consideration 7.1 General Aspects of EMC 7.2 Immunity Requirements 7.3 General Aspects of Harmonics Emission 7.4 Galvanic Isolation (PELV) 7.4.1 PELV - Protective Extra Low Voltage...
  • Page 7 Contents AF-600 FP Design and Installation Guide 12.3 Fuse Tables 13-16 12.3.2 Recommendations 13-16 12.3.3 CE Compliance 13-17 12.3.4 Fuse Specifications 13-17 12.3.5 NEC and UL Compliance 13-20 DET-768A...

  • Page 8: Introduction

    Introduction AF-600 FP Design and Installation Guide 1 Introduction Figure 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)
  • Page 9 Introduction AF-600 FP Design and Installation Guide Figure 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...
  • Page 10 Introduction AF-600 FP Design and Installation Guide Figure 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...
  • Page 11 Introduction AF-600 FP Design and Installation Guide Figure 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 12.3 Fuse Tables for part number) AUX Fan Line Fan Fuse (see 12.3 Fuse Tables for part number)
  • Page 12 Introduction AF-600 FP Design and Installation Guide Figure 1.5 Position of Ground Terminals IP21 (NEMA Type 1) and IP54 (NEMA Type 12) DET-768A...
  • Page 13 Introduction AF-600 FP Design and Installation Guide Figure 1.6 Rectifier Cabinet, unit sizes 61, 62, 63 and 64 24 V DC, 5 A Load sharing T1 Output Taps Temp Switch 104 105 Control Transformer Fuses (2 or 4 pieces). See 12.3 Fuse Tables for part numbers Manual Motor Starters SMPS Fuse.
  • Page 14 Introduction AF-600 FP Design and Installation Guide Figure 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 12.3 Fuse Tables for part numbers 101 102 103 SMPS Fuses.

  • Page 15: Purpose Of The Manual

    • Rectifier The rectifier bridge converts specific requirements. Contact the local GE the AC input to DC current to supplier or visit the GE website for downloads or supply inverter power additional information. • DC bus Intermediate DC bus circuit handles the DC current 1.3 Product Overview...
  • Page 16 Introduction AF-600 FP Design and Installation Guide Area Title Functions • Control circuitry Input power, internal processing, output, and motor current are monitored to provide efficient operation and control • User interface and external commands are monitored and performed •...
  • Page 17 Introduction AF-600 FP Design and Installation Guide 1-10 DET-768A...

  • Page 18: Installation

    Installation AF-600 FP Design and Installation Guide 2 Installation 2.1 Installation Site Checklist 2.3 Mechanical Installation • 2.3.1 Cooling The adjustable frequency drive relies on the ambient air for cooling. Observe the limitations on ambient air temperature for optimal operation •...

  • Page 19: Cooling And Airflow

    (i.e., Rittal Therm software). If the drive is the forced air cooling of the backchannel. Please consult GE only heat generating component in the enclosure, the for more details.

  • Page 20: Lifting

    Installation AF-600 FP Design and Installation 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 adjustable frequency drive according to the pressure drop.

  • Page 21: Ip21 Drip Shield Installation (Unit Sizes 41 And 42)

    Installation AF-600 FP Design and Installation Guide • 2.3.5 IP21 Drip Shield Installation (Unit Mount the unit to a solid flat surface or to the Sizes 41 and 42) optional backplate to provide cooling airflow (see Figure 2.7 and Figure 2.8).

  • Page 22: Installation Of Top And Bottom Covers

    Installation AF-600 FP Design and Installation Guide 2.4.2 Installation of Top and Bottom Covers Note: The current rating of 43 and 44 unit size drives are de-rated by 3% when installed in a NEMA- 3R enclosure. 52 unit size drives require no de-rating when installed in a Top and bottom covers can be installed on unit sizes 43, NEMA-3R enclosure.

  • Page 23: Installation Of Line Power Shield For Adjustable Frequency Drives

    Installation AF-600 FP Design and Installation Guide 2.4.7 Installation of Line Power Shield for Adjustable Frequency Drives This section is for the installation of a line power shield for the adjustable frequency drive series with Unit Sizes 41, 42 and 51. It is not possible to install in the IP00/ chassis drive types as these have included as standard a metal cover.

  • Page 24: Electrical Installation

    Installation AF-600 FP Design and Installation Guide • 2.5 Electrical Installation Connecting control and serial communication wiring This section contains detailed instructions for wiring the • After power has been applied, checking input adjustable frequency drive. The following tasks are and motor power;...

  • Page 25: Requirements

    Installation AF-600 FP Design and Installation Guide 2.5.1 Requirements Input fusing is required to provide this protection, see Figure 2.13. See maximum fuse ratings in 12.1 Power-dependent Specifications. WARNING EQUIPMENT HAZARD! Rotating shafts and electrical equipment can be hazardous. All electrical work must conform to national and local electrical codes.

  • Page 26: Leakage Current (>3.5 Ma)

    Installation AF-600 FP Design and Installation Guide • 2.5.2.2 Grounding Using Shielded Cable A dedicated ground wire is required for input power, motor power and control wiring Grounding clamps are provided for motor wiring (see • Do not ground one adjustable frequency drive to Figure 2.14).

  • Page 27: Ac Line Power Connection

    Installation AF-600 FP Design and Installation Guide NOTE! 2.5.5 Knock-outs (Unit Sizes 15, 21, 22, 31, and 32) UNIT SIZE 6X REQUIREMENTS An equal amount of wires to each inverter module is The legend for the figures: required. The cables must be of equal length within 10%...
  • Page 28 Installation AF-600 FP Design and Installation Guide NOTE! The connector plate must be fitted to the adjustable frequency drive to ensure the specified protection degree, as well as ensuring proper cooling of the unit. If the connector plate is not mounted, the adjustable frequency drive may trip on Alarm 69, Pwr.

  • Page 29: Control Wiring

    Installation AF-600 FP Design and Installation Guide Figure 2.25 Unit Size 64 Figure 2.22 Unit Size 61 2.5.8 Control Wiring • Isolate control wiring from high power components in the adjustable frequency drive. • If the adjustable frequency drive is connected to...

  • Page 30: Control Terminal Types

    Installation AF-600 FP Design and Installation Guide Figure 2.27 Control Wiring Access for IP55/ Nema 12 and IP66/ Nema 4X Figure 2.29 Control Terminal Locations • Connector 1 provides four programmable digital inputs terminals, two additional digital terminals programmable as either input or output, a 24 V...

  • Page 31: Wiring To Control Terminals

    Installation AF-600 FP Design and Installation Guide Terminal Description Terminal Description Digital Inputs/Outputs Digital Inputs/Outputs Default Default Terminal Parameter Setting Description Terminal Parameter Setting Description 12, 13 +24 V DC 24 V DC supply 68 (+) O-3# RS-485 Interface. A control card switch is voltage.

  • Page 32: Using Shielded Control Cables

    Installation AF-600 FP Design and Installation Guide Avoid EMC noise on serial communication This terminal is grounded via an internal RC link. Use twisted-pair cables to reduce interference between conductors. The recommended method is shown below: Figure 2.34 Figure 2.31 Connecting Control Wiring Min.

  • Page 33: Terminal 53 And 54 Switches

    Installation AF-600 FP Design and Installation Guide 2.5.8.6 Terminal 53 and 54 Switches 2.5.9 Serial Communication • Analog input terminals 53 and 54 can select RS-485 is a two-wire bus interface compatible with multi- either voltage (0–10 V) or current (0/4–20 mA) drop network topology, i.e., nodes can be connected as a...

  • Page 34: 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.
  • Page 35 Start Up and Functional Tes... AF-600 FP Design and Installation Guide CAUTION Before applying power to the unit, inspect the entire installation as detailed in Table 3.1. Check mark those items when completed. ☑ Inspect for Description • Auxiliary equipment Look for auxiliary equipment, switches, disconnects, or input fuses/circuit breakers that may reside on the input power side of the adjustable frequency drive or output side to the motor.

  • Page 36: Applying Power To The Adjustable Frequency Drive

    Start Up and Functional Tes... AF-600 FP Design and Installation Guide 3.2 Applying Power to the Adjustable Frequency Drive WARNING 4 User Interface for detailed instructions on entering data through the keypad. HIGH VOLTAGE! Adjustable frequency drives contain high voltage when Enter data with power ON, but before operating the connected to AC line power.

  • Page 37: Auto Tune

    Start Up and Functional Tes... AF-600 FP Design and Installation Guide 3.4 Auto Tune 3.6 Local Control Test CAUTION Auto tune is a test procedure that measures the electrical characteristics of the motor to optimize compatibility MOTOR START! between the adjustable frequency drive and the motor.

  • Page 38: System Start-Up

    Start Up and Functional Tes... AF-600 FP Design and Installation Guide NOTE! 3.1 Pre-start through 3.6 Local Control Test in this chapter concludes the procedures for applying power to the adjustable frequency drive, basic programming, set-up, and functional testing. 3.7 System Start-up The procedure in this section requires user-wiring and application programming to be completed.
  • Page 39 Start Up and Functional Tes... AF-600 FP Design and Installation Guide DET-768A...

  • Page 40: 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 adjustable frequency drive.

  • Page 41: Setting Keypad Display Values

    User Interface AF-600 FP Design and Installation Guide 4.1.3 Display local operation. Also included are the status indicator lights. Menu keys are used for menu access for parameter set-up, Operational mode keys and reset. toggling through status display modes during normal operation, and viewing fault log data.

  • Page 42: 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 43: Uploading Data To The Keypad

    User Interface AF-600 FP Design and Installation Guide • Initialization of the adjustable frequency drive to Restoring the adjustable frequency drive parameter restore factory default settings does not change settings back to default values is done by initialization of data stored in the keypad memory the adjustable frequency drive.

  • Page 44: About Programming

    About Programming AF-600 FP Design and Installation Guide 5 About Programming 5.1 Introduction The adjustable frequency drive is programmed for its F-01 Frequency Setting 1 application functions using parameters. Parameters are accessed by pressing either [Quick Menu] or [Main Menu] on the keypad.
  • Page 45 About Programming AF-600 FP Design and Installation Guide F-53 Maximum Reference. Set maximum internal AN-11 Terminal 53 High Voltage. Set maximum adjustable frequency drive reference to 50 Hz. external voltage reference on Terminal 53 at 10 V. (This sets the maximum adjustable frequency (This sets the maximum input signal at 10 V.)

  • Page 46: Control Terminal Programming Examples

    About Programming AF-600 FP Design and Installation Guide AN-15 Terminal 53 High Ref./Feedb. Value. Set 5.3 Control Terminal Programming maximum speed reference on Terminal 53 at 50 Examples Hz. (This tells the adjustable frequency drive that the maximum voltage received on Terminal 53 Control terminals can be programmed.

  • Page 47: International/North American Default Parameter Settings

    About Programming AF-600 FP Design and Installation Guide Scroll to parameter group E-0# Digital Inputs and Parameter International North American press [OK] default parameter default parameter value value Scroll to E-01 Terminal 18 Digital Input. Press [OK] F-03 Max Output...

  • Page 48: Parameter Menu Structure

    About Programming AF-600 FP Design and Installation Guide 5.4.1 Parameter Data Check 5.5.1 Quick Menu Structure Press [Quick Menu]. Quick Start K-01 Language Scroll to Parameter Data Check and press [OK]. K-02 Motor Speed Unit P-02 Motor Power [HP] P-07...

  • Page 49: Main Menu Structure

    About Programming AF-600 FP Design and Installation Guide 5.5.2 Main Menu Structure DET-768A...
  • Page 50 About Programming AF-600 FP Design and Installation Guide DET-768A...
  • Page 51 About Programming AF-600 FP Design and Installation Guide DET-768A...
  • Page 52 About Programming AF-600 FP Design and Installation Guide DET-768A...
  • Page 53 About Programming AF-600 FP Design and Installation Guide 5-10 DET-768A...
  • Page 54 About Programming AF-600 FP Design and Installation Guide DET-768A 5-11...
  • Page 55 About Programming AF-600 FP Design and Installation Guide 5-12 DET-768A...

  • Page 56: Remote Programming With Dct-10

    About Programming 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 adjustable frequency driveprogramming. The DCT-10 allows the user to connect a PC to the adjustable frequency drive and perform live programming rather than using the keypad.
  • Page 57 About Programming AF-600 FP Design and Installation Guide 5-14 DET-768A...

  • Page 58: 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...
  • Page 59 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...
  • Page 60 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 0.07 V* AN-11 Terminal 10 V* 53 High Voltage...
  • Page 61 Application Set-up Examples AF-600 FP Design and Installation Guide Parameters CAUTION Function Setting Thermistors must use reinforced or double insulation to meet PELV insulation requirements. H-20 Motor Feedback Loss Function [1] Warning H-21 Motor 100 RPM Feedback Speed Error H-22 Motor...

  • Page 62: Advantages

    Application Set-up Examples AF-600 FP Design and Installation Guide Hand Off Auto (HOA), without the use of the drive keypad them. You just have to make sure you edit the To have a HOA system with an external 0–10 V potenti- correct set-up.
  • Page 63 Application Set-up Examples AF-600 FP Design and Installation Guide proportional to the RPM. The consumption of electricity, however, is reduced by 50%. If the system in question only needs to be able to supply a flow corresponding to 100% a few days each year, while...
  • Page 64 PID control. 6.3.5 Cos φ Compensation Generally speaking, the AF-600 FP has a cos φ of 1 and provides power factor correction for the cos φ of the motor, which means that there is no need to make allowance for the cos φ...
  • Page 65 Application Set-up Examples AF-600 FP Design and Installation Guide 6.3.7 Without an Adjustable Frequency Drive Figure 6.7 shows a fan system made in the traditional way. Figure 6.7 D.D.C.=Direct Digital Control V.A.V.=Variable Air Volume Sensor P=Pressure E.M.S.=Energy Management System Sensor T=Temperature...

  • Page 66: Application Examples

    Application Set-up Examples AF-600 FP Design and Installation Guide 6.3.8 With an Adjustable Frequency Drive Figure 6.8 shows a fan system controlled by adjustable frequency drives Figure 6.8 6.3.9 Application Examples The next few pages give typical examples of applications within HVAC.
  • Page 67 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 complexity of the installation. Instead of creating an both the ventilation and temperature to satisfy the artificial pressure drop or causing a decrease in fan requirements of a building.
  • Page 68 Units (AHUs) with a heating coil, and many are also used Several features of the GE dedicated adjustable frequency to air condition buildings and have a cooling coil. Fan coil drive can be utilized to improve the performance of your units are frequently used to assist in the heating and CAV system.
  • Page 69 Cooling tower fans are used to cool condenser water in water-cooled chiller systems. Water-cooled chillers provide Several features of the GE dedicated adjustable frequency the most efficient means of creating chilled water. They drive can be utilized to improve the performance of your are as much as 20% more efficient than air-cooled chillers.
  • Page 70 Application Set-up Examples AF-600 FP Design and Installation Guide 6.3.16 Condenser Pumps Using an adjustable frequency drive instead of a throttling valve simply saves the energy that would have been absorbed by the valve. This can amount to savings of 15–...
  • Page 71 Application Set-up Examples AF-600 FP Design and Installation Guide 6.3.18 Primary Pumps The first method uses a flow meter. Because the desired flow rate is known and constant, a flow meter installed at the discharge of each chiller can be used to control the Primary pumps in a primary/secondary pumping system pump directly.
  • Page 72 Application Set-up Examples AF-600 FP Design and Installation Guide 6.3.20 Secondary Pumps With the proper sensor location, the addition of adjustable frequency drives allows the pumps to vary their speed to follow the system curve instead of the pump curve.
  • Page 73 Application Set-up Examples AF-600 FP Design and Installation Guide 6-16 DET-768A...

  • Page 74: Installation Consideration

    Installation Consideration AF-600 FP Design and Installation Guide 7 Installation Consideration ), there will in principle only be a small electro-magnetic field (I ) from the shielded motor cable according to the 7.1 General Aspects of EMC below figure. 7.1.1 General Aspects of EMC Emissions The shield reduces the radiated interference but increases the low-frequency interference on line power.
  • Page 75 Installation Consideration AF-600 FP Design and Installation Guide 7.1.2 Emission Requirements adjustable frequency drive. Four categories are defined in the EMC product standard. The definitions of the four categories together with the requirements for line power According to the EMC product standard for adjustable...

  • Page 76: Immunity Requirements

    Installation Consideration AF-600 FP Design and Installation Guide 7.1.3 EMC Test Results (Emission) relevant), a shielded control cable, a control box with potentiometer, as well as a motor and motor-shielded cable. The following test results were obtained using a system...
  • Page 77 Installation Consideration AF-600 FP Design and Installation Guide • EN 61000-4-5 (IEC 61000-4-5): Surge transients: See Table 7.4. Simulation of transients brought about, e.g., by lightning that strikes near installations. • EN 61000-4-6 (IEC 61000-4-6): RF Common mode: Simulation of the effect from radio-transmission equipment joined by connection cables.

  • Page 78: General Aspects Of Harmonics Emission

    Installation Consideration AF-600 FP Design and Installation Guide • EN 61000-4-5 (IEC 61000-4-5): Surge transients: See Table 7.4. Simulation of transients brought about, e.g., by lightning that strikes near installations. • EN 61000-4-6 (IEC 61000-4-6): RF Common mode: Simulation of the effect from radio-transmission equipment joined by connection cables.

  • Page 79: Galvanic Isolation (Pelv)

    Installation Consideration AF-600 FP Design and Installation Guide NOTE! It is the responsibility of the installer or user of the equipment to ensure, by consultation with the distribution Some of the harmonic currents might disturb communi- network operator if necessary, that the equipment is...

  • Page 80: Derating

    [2 km], please contact GE regarding PELV. 380–480 V, unit size 4x, 5x and 6x: At altitudes above 10,000 ft [3 km], please contact GE regarding PELV. 525–690 V: At altitudes above 6,600 ft [2 km], please contact GE regarding PELV.

  • Page 81: Motor Insulation

    Installation Consideration AF-600 FP Design and Installation Guide Figure 7.7 Maximum load for a standard motor at 104° F [40°C] driven by an AF-600 FP drive Figure 7.5 ─ ─ ─ ─ Typical torque at VT load ─•─•─•─ Max torque with forced cooling ‒‒‒‒‒...

  • Page 82: Motor Bearing Currents

    Installation Consideration AF-600 FP Design and Installation Guide 7.7 Motor Bearing Currents All motors installed with 150 hp 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 83 Installation Consideration AF-600 FP Design and Installation Guide 7-10 DET-768A...

  • Page 84: Status Messages

    Status Messages AF-600 FP Design and Installation Guide 8 Status Messages 8.1 Status Display 8.2 Status Message Definitions Table When the adjustable frequency drive is in status mode, The next three tables define the meaning of the status status messages are generated automatically from within message display words.
  • Page 85 Status Messages AF-600 FP Design and Installation Guide Operation Status Operation Status Ctrl. Ramp-down Control Ramp-down was selected in SP-10 Line Freeze ref. Freeze Reference was chosen as a function for failure. a digital input. The corresponding terminal is •...
  • Page 86 Status Messages AF-600 FP Design and Installation Guide Operation Status Operation Status Ramping The motor is accelerating/decelerating using Trip lock An alarm occurred and the motor is stopped. the active ramp-up/down. The reference, a Once the cause of the alarm is cleared, power limit value or a standstill is not yet reached.
  • Page 87 Status Messages AF-600 FP Design and Installation Guide DET-768A...

  • Page 88: Warnings And Alarms

    Warnings and Alarms AF-600 FP Design and Installation Guide 9 Warnings and Alarms 9.1 System Monitoring 9.3 Warning and Alarm Displays The adjustable frequency drive monitors the condition of its input power, output, and motor factors as well as other system performance indicators.

  • Page 89: Warning And Alarm Definitions

    Warnings and Alarms AF-600 FP Design and Installation Guide Warn. LED Alarm LED Warning Alarm On (Flashing) Trip Lock On (Flashing) Table 9.1 Figure 9.3 9.4 Warning and Alarm Definitions Table 9.2 defines whether a warning is issued before an alarm, and whether the alarm trips the unit or trip locks the unit.
  • Page 90 Warnings and Alarms AF-600 FP Design and Installation Guide Description Warning Alarm/Trip Alarm/Trip Lock Parameter Reference Motor phase V missing H-78 Missing Motor Phase Function Motor phase W missing H-78 Missing Motor Phase Function Inrush fault Fieldbus communication fault Option Fault...
  • Page 91 Warnings and Alarms AF-600 FP Design and Installation Guide Description Warning Alarm/Trip Alarm/Trip Lock Parameter Reference Clock Fault K-7# Fire M was Active Fire M Limits Exceeded Missing Motor Locked Rotor Brake IGBT Heatsink temp Heatsink sensor Pwr.card supply Pwr.card temp...
  • Page 92 Warnings and Alarms AF-600 FP Design and Installation Guide WARNING/ALARM 8, DC undervoltage Running Auto tune in P-04 Auto Tune tunes the If the intermediate circuit voltage (DC link) drops below adjustable frequency drive to the motor more the under voltage limit, the adjustable frequency drive accurately and reduces thermal loading.
  • Page 93 Warnings and Alarms AF-600 FP Design and Installation Guide Troubleshooting Troubleshooting: Check connections on the serial communication cable. Remove power and check if the motor shaft can be turned. Increase O-03 Control Word Timeout Time Make sure that the motor size matches the Check the operation of the communication adjustable frequency drive.
  • Page 94 Check the load connected to terminal 29 or remove short- Check for loose or missing wiring circuit connection. Check E-00 Digital I/O Mode and It may be necessary to contact your GE supplier or service E-52 Terminal 29 Mode. department. Note the code number for further trouble- WARNING 42, Overload of digital output on X30/6 or shooting directions.
  • Page 95 Check for clogged filters. adjustable frequency drive will trip. • Check fan operation. ALARM 50, Auto tune calibration failed Contact your GE supplier or GE Service Department. • Check the control card. ALARM 51, Auto tune check U and I...
  • Page 96 Warnings and Alarms AF-600 FP Design and Installation Guide ALARM 69, Power card temperature The temperature sensor on the power card is either too hot or too cold. Troubleshooting Check that the ambient operating temperature is within limits. Check for clogged filters.
  • Page 97 Warnings and Alarms AF-600 FP Design and Installation Guide 9-10 DET-768A...

  • Page 98: Basic Troubleshooting

    Basic Troubleshooting AF-600 FP Design and Installation Guide 10 Basic Troubleshooting 10.1 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...
  • Page 99 Basic Troubleshooting AF-600 FP Design and Installation Guide Symptom Possible Cause Test Solution Service switch open or missing Check if the motor is connected Connect the motor and check the motor connection and the connection is not service switch. interrupted (by a service switch or other device).
  • Page 100 Basic Troubleshooting AF-600 FP Design and Installation Guide Symptom Possible Cause Test Solution Phase to phase short Motor or panel has a short phase Eliminate any shorts detected. to phase. Check motor and panel phase for shorts. Motor overload Motor is overloaded for the Perform start-up test and verify application.
  • Page 101 Basic Troubleshooting AF-600 FP Design and Installation Guide 10-4 DET-768A...

  • Page 102: Terminal And Applicable Wire

    Terminal and Applicable Wir... AF-600 FP Design and Installation Guide 11 Terminal and Applicable Wire 11.1 Cables DET-768A 11-1...
  • Page 103 Terminal and Applicable Wir... AF-600 FP Design and Installation Guide 11-2 DET-768A...

  • Page 104: Specifications

    Specifications AF-600 FP Design and Installation Guide 12 Specifications 12.1 Power-dependent Specifications 12.1.1 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 16.7 0.96 24.2 0.96 30.8 0.96 46.2 0.96 59.4 0.96...
  • Page 105 Specifications AF-600 FP Design and Installation Guide 380–480 V Input Efficiency IP00/Chassis IP20/Chassis IP 21/Type 1 IP54/IP55/Type 12 IP66/Type 4X ≤ 440 V >440 V 0.98 42h/51 42h/51 0.98 0.98 0.98 0.98 0.98 61/63 61/63 1120 1050 1090 0.98 1000 710...

  • Page 106: Dimensions, Unit Size 1X

    Specifications AF-600 FP Design and Installation Guide 525–690 V Input Efficiency IP00/Chassis IP20/Chassis IP 21/Type 1 IP54/IP55/Type 12 ≤ 550 V >690 V 0.98 0.98 41h/41 41h/41 0.98 0.98 0.98 42h/42 42h/42 0.98 0.98 0.98 0.98 0.98 0.98 1000 710 0.98...
  • Page 107 Specifications AF-600 FP Design and Installation Guide Figure 12.2 Unit Size 13 Figure 12.3 Unit Size 15 12-4 DET-768A...

  • Page 108: Dimensions, Unit Size 2X

    Specifications AF-600 FP Design and Installation Guide 12.1.3 Dimensions, Unit Size 2x Figure 12.4 Unit Size 21 Figure 12.5 Unit Size 22 DET-768A 12-5...
  • Page 109 Specifications AF-600 FP Design and Installation Guide Figure 12.6 Unit Size 23 Figure 12.7 Unit Size 24 12-6 DET-768A...

  • Page 110: Dimensions, Unit Size 3X

    Specifications AF-600 FP Design and Installation Guide 12.1.4 Dimensions, Unit Size 3x Figure 12.8 Unit Size 31 Figure 12.9 Unit Size 32 DET-768A 12-7...
  • Page 111 Specifications AF-600 FP Design and Installation Guide Figure 12.10 Unit Size 33 Figure 12.11 Unit Size 34 12-8 DET-768A...

  • Page 112: Dimensions, Unit Size 4X

    Specifications AF-600 FP Design and Installation Guide 12.1.5 Dimensions, Unit Size 4x Figure 12.12 Unit Size 41 (Floor or Cabinet Mount) DET-768A 12-9...
  • Page 113 Specifications AF-600 FP Design and Installation Guide Figure 12.13 Unit Size 42 (Floor or Cabinet Mount) 12-10 DET-768A...
  • Page 114 Specifications AF-600 FP Design and Installation Guide Figure 12.14 Unit Size 43 (Cabinet Mount) 765 m 255 m 1327 1280 1099 Drives shown with optional disconnect switch Figure 12.15 Unit Size 44 (Cabinet Mount) DET-768A 12-11...

  • Page 115: General Technical Data

    Starting torque maximum 135% up to 0.5 s Overload torque (Constant torque) maximum 110% for 1 min. *Percentage relates to AF-600 FP Drive's nominal torque. Cable lengths and cross-sections for control cables Max. motor cable length, shielded 500 ft [150 m] Max.
  • Page 116 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 117 Specifications AF-600 FP Design and Installation Guide Control card, RS-485 serial communication Terminal number 68 (P,TX+, RX+), 69 (N,TX-, RX-) Terminal number 61 Common for terminals 68 and 69 The RS-485 serial communication circuit is functionally seated from other central circuits and galvanically isolated from the supply voltage (PELV).
  • Page 118 122° F [50°C] - at full continuous drive output current max. 113° F [45°C] For more information on derating see the AF-600 FP, section on Special Conditions. Minimum ambient temperature during full-scale operation 32° F [0°C] Minimum ambient temperature at reduced performance 14°...

  • Page 119: Fuse Tables

    Specifications AF-600 FP Design and Installation Guide Protection and Features • Electronic thermal motor protection against overload. • Temperature monitoring of the heatsink ensures that the adjustable frequency drive trips if the temperature reaches a predefined level. An overload temperature cannot be reset until the temperature of the heatsink is below the values stated in the tables on the following pages (guideline - these temperatures may vary for different power sizes, unit sizes, enclosure ratings, etc.).

  • Page 120: Ce Compliance

    100,000 Arms. will mainly be limited to damage inside the unit. 12.3.3 CE Compliance Fuses or circuit breakers are mandatory to comply with IEC 60364. GE recommend using a selection of the following. 12.3.4 Fuse Specifications AF-600 3- Recommended fuse...
  • Page 121 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...
  • Page 122 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...

  • Page 123: Nec And Ul Compliance

    Specifications AF-600 FP Design and Installation Guide 12.3.5 NEC and UL Compliance Fuses or Circuit Breakers must comply with NEC 2009. We 600 V depending on the drive voltage rating. With the recommend using a selection of the following. proper fusing, the drive Short Circuit Current Rating (SCCR) is 100,000 Arms.
  • Page 124 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...
  • Page 125 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...
  • Page 126 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...
  • Page 127 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...
  • Page 128 Specifications AF-600 FP Design and Installation Guide AF-600 Bussmann PN Rating Alternate Siba PN [kW]/[HP] 500/650 170M8611 1100 A, 1000 V 20 781 32.1000 560/750 170M8611 1100 A, 1000 V 20 781 32.1000 630/900 170M6467 1400 A, 700 V 20 681 32.1400...
  • Page 129 GE company. AF-600 FP is a trademark of the General Electric Company. 41 Woodford Avenue Plainville, CT 06062 www.geelectrical.com/drives...

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