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GE AF-650 GP Series Operating Instructions Manual
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GE AF-650 GP Series Operating Instructions Manual

High power service manual
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GE Consumer & Industrial
Electrical Distribution
AF-650 GP & AF-600 FP
TM
High Power Service Manual
(460V/575V 150HP and above)
Operating Instructions

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Summary of Contents for GE AF-650 GP Series

  • Page 1 GE Consumer & Industrial Electrical Distribution AF-650 GP & AF-600 FP High Power Service Manual (460V/575V 150HP and above) Operating Instructions...
  • Page 2 HVAC market. AF-650 GP series frequency converters are fully programmable for either constant torque or variable torque industrial applications. They are full-featured frequency converters capable of operating a myriad of applications and incorporating a wide variety of control and communication options.
  • Page 3 AF-650 GP and AF-600 FP High Power Service Manual 1.5 Frame Size Definitions 380-480 VAC Power Model AF-600 FP kW @400 VAC HP @460 VAC Frame Size 41 / 43 41 / 43 42 / 44 42 / 44 42 / 44 51 / 52 51 / 52 51 / 52...
  • Page 4 AF-650 GP and AF-600 FP High Power Service Manual 1.6 Tools Required Operating Instructions for the Drives Series Frequency Converter Metric socket set 7–19 mm Socket extensions 100 mm–150 mm (4 in and 6 in) Torx driver set T10 - T50 Torque wrench 0.675–19 Nm (6–170 in-lbs) Needle nose pliers...
  • Page 5 AF-650 GP and AF-600 FP High Power Service Manual 1.8 Exploded Views Illustration 1.1: Exploded view D3 Frame size, D1 frame is similar. Control card PCA1 SCR/Diode module SCR 1, 2, 3 Control input terminals IGBT output bus bar Keypad Output motor terminals TB2 Control card C option Current sensor L2, L3, L4...
  • Page 6 AF-650 GP and AF-600 FP High Power Service Manual Illustration 1.2: Exploded view D4 frame size, D2 frame is similar. Control card PCA1 IGBT module IGBT1, 2 Control input terminals SCR/Diode module SCR1, 2, 3 Keypad IGBT output bus bar Control card C option Output motor terminals TB2 Mounting bracket...
  • Page 7 AF-650 GP and AF-600 FP High Power Service Manual Illustration 1.3: Exploded view E2 frame size, E1 frame is similar.
  • Page 8 AF-650 GP and AF-600 FP High Power Service Manual Control card PCA1 SCR and Diode SCR1, SCR2, SCR3 and D1, D2, D3 Control input terminals Fan inductor (not on all units) Keypad Soft charge resistor assy R1 Control card C option IGBT output bus bar Mounting bracket Fan assembly F1 + C1...
  • Page 9 AF-650 GP and AF-600 FP High Power Service Manual 1.9 Ratings Tables DC Voltage Levels 380–480 units 525-600 units and 525–690 units Inrush Circuit Enabled 370 VDC 548 VDC Inrush Circuit Disabled 395 VDC 600 VDC Inverter Undervoltage Disable 402 VDC 553 VDC Undervoltage Warning 423 VDC...
  • Page 10 AF-650 GP and AF-600 FP High Power Service Manual Mains supply 3 x 380–480 V Model number AF-600 FP AF-650 GP Light duty current ratings (110%): Output current Nominal [A] (380–440 V) MAX (60 sec) [A] (380–440 V) Nominal [A] (441–480 V) MAX (60 sec) [A] (441–480 V) Output Nominal [kVA] (400 V)
  • Page 11 AF-650 GP and AF-600 FP High Power Service Manual Mains supply 3 x 525–690 V Model number AF-600 FP AF-650 GP Light duty current ratings (110%): Output current Nominal [A] (525–550 V) MAX (60 sec) [A] (525–550 V) Nominal [A] (551–690 V) MAX (60 sec) [A] (551–690 V) Output Nominal [kVA] (550 V)
  • Page 12 AF-650 GP and AF-600 FP High Power Service Manual Mains supply 3 x 525–690 V Model number AF-600 FP AF-650 GP Light duty current ratings (110%): Output current Nominal [A] (525–550 V) MAX (60 sec) [A] (525–550 V) Nominal [A] (551–690 V) MAX (60 sec) [A] (551–690 V) Output Nominal [kVA] (550 V)
  • Page 13 AF-650 GP and AF-600 FP High Power Service Manual...
  • Page 14 AF-650 GP and AF-600 FP High Power Service Manual 2 Operator Interface and Frequency Converter Control 2.1 Introduction Frequency converters are designed with self-diagnostic circuitry to isolate fault conditions and activate display messages which greatly simplify troubleshooting and service. The operating status of the frequency converter is displayed in real-time. Virtually every command given to the frequency converter results in some indication on the Keypad display.
  • Page 15 AF-650 GP and AF-600 FP High Power Service Manual Display lines: Status line: Status messages displaying icons and graphics. Line 1-2: Operator data lines displaying data and variables defined or chosen by the user. By pressing the [Status] key, up to one extra line can be added.
  • Page 16 AF-650 GP and AF-600 FP High Power Service Manual Status display I: This readout state is standard after start-up or initialisation. Use [INFO] to obtain information about the value/measurement linked to the displayed operating variables (1.1, 1.2, 1.3, 2, and 3). See the operating variables shown in the display in this illustration.
  • Page 17 AF-650 GP and AF-600 FP High Power Service Manual Indicator lights (LEDs): If certain threshold values are exceeded, the alarm and/or warning LED lights up. A status and alarm text appears on the keypad. The On indicator lamp is activated when the frequency converter receives power from mains voltage, a DC bus terminal, or an external 24 V supply. At the same time, the back light is on.
  • Page 18 AF-650 GP and AF-600 FP High Power Service Manual [Main Menu] is used for programming all parameters. The Main Menu parameters can be accessed immediately unless a password has been created via par. K-60, K-61, K-65 and K-66. Parameter shortcut can be carried out by pressing down the [Main Menu] key for 3 seconds.
  • Page 19 AF-650 GP and AF-600 FP High Power Service Manual [Hand] Enables control of the frequency converter via the Keypad. [Hand] also starts the motor, and it is now possible to enter the motor speed data by means of the arrow keys. The key can be selected as Enable [1] or Disable [0] via par. K-40 [Hand] Button on Keypad. The following control signals will still be active when [Hand] is activated: •...
  • Page 20 AF-650 GP and AF-600 FP High Power Service Manual 2.3 Status Messages Status messages appear in the bottom of the display - see the example below. The left part of the status line indicates the active operation model of the frequency converter. The centre part of the status line indicates the references site.
  • Page 21 AF-650 GP and AF-600 FP High Power Service Manual Reference Site [Remote] The Reference is given via internal preset references (absolute or relative) and/or external signals (analog or digital) and/or via serial communication. [Local] The drive uses the reference values set via the Keypad. For further information, please examine parameter F-02.
  • Page 22 AF-650 GP and AF-600 FP High Power Service Manual DC Voltage U0 In par. H-41 Motor Control Principle U/f and in par. H-80 Function at Stop DC Voltage U0 is selected. A Stop command (e.g. Stop (inverse)) is activated. The voltage selected according to the par.
  • Page 23 AF-650 GP and AF-600 FP High Power Service Manual Protection md The AF-650 GP/AF-600 FP has detected a critical status (e.g. an overcurrent, overvoltage). To avoid tripping the frequency converter (alarm), protection mode is activated, which includes reducing the switching frequency to 4 kHz. If possible, protection mode ends after approximately 10 s. Activation of protection mode can be restricted by adjusting the par.
  • Page 24 AF-650 GP and AF-600 FP High Power Service Manual A serious alarm occurred. It is possible, provided the cause of the alarm was cleared, to reset the alarm after the mains have been switched off and on again. This can be done via a reset signal ([Reset] on the Keypad, a control terminal or serial communication). Unit/Drive not ready PROFIDrive profile was selected in par.
  • Page 25 AF-650 GP and AF-600 FP High Power Service Manual 2.5 Frequency Converter Inputs and Outputs The frequency converter operates by receiving control input signals. The frequency converter can also output status data or control auxiliary devices. Control input is connected to the frequency converter in three possible ways. One way for frequency converter control is through the Keypad on the front of the frequency converter when operating in local (hand) mode.
  • Page 26 AF-650 GP and AF-600 FP High Power Service Manual 2.5.1 Input signals The frequency converter can receive two types of remote input signals: digital or analog. Digital inputs are wired to terminals 18, 19, 20 (common), 27, 29, 32, and 33.
  • Page 27 AF-650 GP and AF-600 FP High Power Service Manual 2.6 Control Terminals Control terminals must be programmed. Each terminal has specific functions it is capable of performing and a numbered parameter associated with it. See table below. The setting selected in the parameter enables the function of the terminal. It is important to confirm that the control terminal is programmed for the correct function.
  • Page 28 AF-650 GP and AF-600 FP High Power Service Manual 2.7 Control Terminal Functions The following describes the functions of the control terminals. Many of these terminals have multiple functions determined by parameter settings. Some options provide additional terminals. See Illustration 2-2. Terminal No.
  • Page 29 AF-650 GP and AF-600 FP High Power Service Manual Illustration 2.2: Control Terminals Electrical Diagram...
  • Page 30 AF-650 GP and AF-600 FP High Power Service Manual 2.8 Earthing Screened Cables It is recommended that screened control cables be connected with cable clamps at both ends to the metal cabinet of the frequency converter. Table 2-3 shows earth cabling for optimal results. Correct earthing Control cables and cables for serial communication must be fitted with cable clamps at both ends to ensure the best possible electrical connection.
  • Page 31 AF-650 GP and AF-600 FP High Power Service Manual...
  • Page 32 AF-650 GP and AF-600 FP High Power Service Manual 3 Internal Frequency Converter Operation 3.1 General This section is intended to provide an operational overview of the frequency converter’s main assemblies and circuitry. With this information, a repair technician should have a better understanding of the frequency converter's operation and aid in the troubleshooting process. 3.2 Description of Operation A frequency converter is an electronic controller that supplies a regulated amount of AC power to a three phase induction motor in order to control the speed of the motor.
  • Page 33 AF-650 GP and AF-600 FP High Power Service Manual 3.2.1 Logic Section The control card contains most of the logic section (see Illustration 3-2). The primary logic element of the control card is a microprocessor, which supervises and controls all functions of frequency converter operation. In addition, separate PROMs contain the parameters to provide the user with programmable options. These parameters are programmed to enable the frequency converter to meet specific application requirements.
  • Page 34 AF-650 GP and AF-600 FP High Power Service Manual Two relays for monitoring the status of the frequency converter are located on the power card. These are programmable through parameter group E-##. The relays are Form C, meaning it has one normally open contact and one normally closed contact on a single throw. The contacts of the relay are rated for a maximum load of 240 VAC at 2 Amps resistance.
  • Page 35 AF-650 GP and AF-600 FP High Power Service Manual 3.2.3 Power Section The high voltage power section consists of AC input terminals, AC and DC bus bars, fusing, harnessing, AC output, and optional components. The power section (see Illustration 3-3) also contains circuitry for the soft charge and SCR/diode modules in the rectifier; the DC bus filter circuitry containing the DC coils, often referred to as the intermediate or DC bus circuit;...
  • Page 36 AF-650 GP and AF-600 FP High Power Service Manual 3.3 Sequence of Operation 3.3.1 Rectifier Section When input power is first applied to the frequency converter, it enters through the input terminals (L1, L2, L3) and on to the disconnect or/and RFI option, depending on the unit's configuration (see Illustration 3-4).
  • Page 37 AF-650 GP and AF-600 FP High Power Service Manual HS FAN ASSEMBLY 175L9400 CBL8 190843 LEGEND: 27651 90kW = FC-302 P90K T5 FC-202 P100 T4 FC-102 P110 T4 (DISABLE MAINS RECTIFIER) EXTERNAL BRAKE TEMP SWITCH 190836 190836 110kW = FC-302 P110 T5 190835 AUX FAN HEATSINK...
  • Page 38 AF-650 GP and AF-600 FP High Power Service Manual 3.3.2 Intermediate Section Following the rectifier section, voltage passes to the intermediate section. (see Illustration 3-5). This rectified voltage is smoothed by an LC filter circuit consisting of the DC bus inductor and the DC bus capacitor bank. The DC bus inductor provides series impedance to changing current.
  • Page 39 AF-650 GP and AF-600 FP High Power Service Manual Illustration 3.5: Intermediate section...
  • Page 40 By employing a sophisticated control scheme, the frequency converter is capable of delivering a current waveform that nearly replicates a true AC sine wave. This waveform, as generated by the GE Advanced Vector Control PWM principle at the control card, provides optimal performance and minimal losses in the motor.
  • Page 41 AF-650 GP and AF-600 FP High Power Service Manual HS FAN ASSEMBLY 175L9400 CBL8 190843 LEGEND: 90kW = FC-302 P90K T5 27651 FC-202 P100 T4 FC-102 P110 T4 (DISABLE MAINS RECTIFIER) EXTERNAL BRAKE TEMP SWITCH 110kW = FC-302 P110 T5 190835 190836 190836...
  • Page 42 AF-650 GP and AF-600 FP High Power Service Manual 3.3.4 Brake Option For frequency converters equipped with the dynamic brake option, a brake IGBT along with terminals 81(R-) and 82(R+) is included for connecting an external brake resistor. The function of the brake IGBT (see Illustration 3-8) is to limit the voltage in the intermediate circuit, whenever the maximum voltage limit is exceeded. It does this by switching the externally mounted resistor across the DC bus to remove excess DC voltage present on the bus capacitors.
  • Page 43 AF-650 GP and AF-600 FP High Power Service Manual 3.3.5 Cooling Fans All frequency converters in this size range are equipped with cooling fans to provide airflow along the heatsink. Units in NEMA 1 (IP21) and NEMA 12 (IP54) enclosures have a fan mounted in the enclosure door to provide additional airflow to the unit.
  • Page 44 DC bus at power up is required. Last, a mains voltage source is required to power the fans within the frequency converter. Again such a configuration should not be attempted without first consulting GE Application Engineering.
  • Page 45 AF-650 GP and AF-600 FP High Power Service Manual...
  • Page 46 AF-650 GP and AF-600 FP High Power Service Manual 4 Troubleshooting 4.1 Troubleshooting Tips Before attempting to repair a frequency converter, here are some tips to follow to make the job easier and possibly prevent unnecessary damage to functional components. Note all warnings concerning voltages present in the frequency converter.
  • Page 47 AF-650 GP and AF-600 FP High Power Service Manual 4.4 Visual Inspection The table below lists a variety of conditions that require visual inspection as part of any initial troubleshooting procedure. 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 frequency converter or the output side to motor.
  • Page 48 AF-650 GP and AF-600 FP High Power Service Manual 4.5 Fault Symptoms 4.5.1 No Display The Keypad display provides two display indications. One by means of the backlit LCD alphanumeric display. The other is three LED indicators lights near the bottom of the Keypad. If the green power-on LED is illuminated but the backlit display is dark, this indicates that the Keypad itself is defective and must be replaced.
  • Page 49 AF-650 GP and AF-600 FP High Power Service Manual 4.5.3 Motor Will not Run In the event that this symptom is detected, first verify that the unit is properly powered up (display is lit) and that there are no warning or alarm messages displayed. The most common cause of this is either incorrect control logic or an incorrectly programmed frequency converter.
  • Page 50 AF-650 GP and AF-600 FP High Power Service Manual 4.5.4 Incorrect Motor Operation Occasionally, a fault can occur where the motor will continue to run, but not in the correct manner. The symptoms and causes may vary considerably. Many of the possible problems are listed below by symptom along with recommended procedures for determining their causes.
  • Page 51 AF-650 GP and AF-600 FP High Power Service Manual 4.6 Warning/Alarm Messages 4.6.1 Warning/Alarm Code List A warning or an alarm is signalled by the LEDs on the front of the frequency converter and by a code on the display. A warning indicates a condition that may require attention or a trend that may eventually require attention.
  • Page 52 AF-650 GP and AF-600 FP High Power Service Manual Description Warning Alarm/Trip Alarm/Trip Lock Brake resistor power limit Brake chopper fault Brake check failed Heatsink temp Motor phase U missing Motor phase V missing Motor phase W missing Inrush fault Network communication fault Line failure Internal fault...
  • Page 53 AF-650 GP and AF-600 FP High Power Service Manual LED indication Warning yellow Alarm flashing red Trip locked yellow and red WARNING 1, 10 volts low The control card voltage is below 10 V from terminal 50. Remove some of the load from terminal 50, as the 10 V supply is overloaded. Max. 15 mA or minimum 590 Ω. This condition can be caused by a short in a connected potentiometer or improper wiring of the potentiometer.
  • Page 54 See section 5.2 for more details. ALARM 15, Hardware mismatch A fitted option is not operational with the present control board hardware or software. Record the value of the following parameters and contact your GE supplier: par. ID-40 Drive Type par. ID-41 Power Section par.
  • Page 55 AF-650 GP and AF-600 FP High Power Service Manual par. ID-49 SW ID Control Card par. ID-50 SW ID Power Card par. ID-60 Option Mounted par. ID-61 Option SW Version (for each option slot) ALARM 16, Short circuit There is short-circuiting in the motor or on the motor terminals. Turn off the frequency converter and remove the short-circuit.
  • Page 56 This warning/alarm is only active if the supply voltage to the frequency converter is lost and par. SP-10 Line failure is NOT set to OFF. Check the fuses to the frequency converter ALARM 38, Internal fault It may be necessary to contact your GE supplier. Some typical alarm messages:...
  • Page 57 WARNING 47, 24 V supply low The 24 VDC is measured on the control card. The external 24 VDC backup power supply may be overloaded, otherwise contact your GE supplier. WARNING 48, 1.8 V supply low The 1.8 Volt DC supply used on the control card is outside of allowable limits.
  • Page 58 Rs and Rr are increased. In most cases, however, this is not critical. ALARM 58, Auto tune internal fault Contact your GE supplier. WARNING 59, Current limit The current is higher than the value in par. F-43 Current Limit.
  • Page 59 AF-650 GP and AF-600 FP High Power Service Manual ALARM 70, Illegal Drive Configuration The current control board and power board combination is illegal. Warning 73, Safe stop auto restart Safe stopped. Note that with automatic restart enabled, the motor may start when the fault is cleared. ALARM 79, Illegal power section configuration The scaling card is the incorrect part number or not installed.
  • Page 60 AF-650 GP and AF-600 FP High Power Service Manual ALARM 245, Heatsink sensor This alarm is only for 6x Frame frequency converters. It is equivalent to Alarm 39. The report value in the alarm log indicates which power module generated the alarm: 1 = left most inverter module.
  • Page 61 AF-650 GP and AF-600 FP High Power Service Manual 4.7 After Repair Tests Following any repair to a frequency converter or testing of a frequency converter suspected of being faulty, the following procedure must be followed to ensure that all circuitry in the frequency converter is functioning properly before putting the unit into operation. Perform visual inspection procedures as described in Table 3-1.
  • Page 62 F-41 Torque Limiter (Braking) sets the limit for frequency converter torque. The factory setting is 160% for AF-650 GP series and 110% for AF-600 FP series and will vary with motor power setting. For example, a frequency converter programmed to operate a smaller rated motor will yield a higher torque limit value than the same frequency converter programmed to operate a larger size motor.
  • Page 63 AF-650 GP and AF-600 FP High Power Service Manual motor. At this point the motor becomes a generator and starts returning energy to the frequency converter. This is called regenerative energy. Regeneration occurs when the speed of the load is greater than the commanded speed. This return voltage is rectified by the diodes in the IGBT modules and raises the DC bus. If the amount of returned voltage is too high, the frequency converter will trip.
  • Page 64 AF-650 GP and AF-600 FP High Power Service Manual If the signal is present at the terminal, the control card is defective and must be replaced. If the signal is not present, the problem is external to the frequency converter. The circuitry providing the signal along with its associated wiring must then be checked. 5.1.4 Programming Problems Difficulty with frequency converter operation can be a result of improper programming of the frequency converter parameters.
  • Page 65 AF-650 GP and AF-600 FP High Power Service Manual 5.2.2 Current Sensor Faults When a current sensor fails, it is indicated sometimes by an overcurrent alarm that cannot be reset, even with the motor leads disconnected. Most often, however, the frequency converter will experience frequent false earth fault trips. This is due to the DC offset failure mode of the sensors. To explain this it is necessary to investigate the internal makeup of a Hall effect type current sensor.
  • Page 66 AF-650 GP and AF-600 FP High Power Service Manual 5.2.5 Sources of EMI Modern frequency converters (see Illustration 5-1) utilise Insulated-Gate Bipolar Transistors (IGBTs) to provide an efficient and cost effective means to create the Pulse Width Modulated (PWM) output waveform necessary for accurate motor control. These devices rapidly switch the fixed DC bus voltage creating a variable frequency, variable voltage PWM waveform.
  • Page 67 AF-650 GP and AF-600 FP High Power Service Manual Frequency Converter Motor Stray capacitance Signal wiring to BMS Illustration 5.3: Signal Conductor Currents Unprotected or poorly routed signal conductors located close to or in parallel to motor and mains conductors are susceptible to EMI. Signal conductors are especially vulnerable when they are run parallel to the power conductors for any distance.
  • Page 68 AF-650 GP and AF-600 FP High Power Service Manual 5.2.7 Preventive Measures EMI related problems are more effectively alleviated during the design and installation phases rather than after the system is in service. Many of the steps listed here can be implemented at a relatively low cost when compared to the cost for identifying and fixing the problem later in the field. Earthing The frequency converter and motor should be solidly earthed to the equipment frame.
  • Page 69 AF-650 GP and AF-600 FP High Power Service Manual 5.2.8 Proper EMC Installation Shown in the illustration below is a correct installation with EMC considerations in mind. Although most installations will not follow all the recommended practices the closer an installation resembles this example the better immunity the network will have against EMI. Should EMI problems arise in an installation, refer to this example.
  • Page 70 AF-650 GP and AF-600 FP High Power Service Manual 6 Test Procedures 6.1 Introduction Touching electrical parts of frequency converter may be fatal even after equipment has been disconnected from AC power. Wait 20 minutes for 4x-frame sizes or 40 minutes for 5x-frame sizes after power has been removed before touching any internal components to ensure that capacitors have fully discharged.
  • Page 71 AF-650 GP and AF-600 FP High Power Service Manual 6.1.1 Tools Required for Testing Digital volt/ohm meter capable of reading real RMS Analog volt meter Oscilloscope Clamp-on style ammeter Signal test board p/n 6KAF6H8437 Test cable p/n 6KAF6H8439 6.1.2 Signal Test Board The signal test board can be used to test circuitry within the frequency converter and provides easy access to test points.
  • Page 72 AF-650 GP and AF-600 FP High Power Service Manual 6.1.3 Test Cables The test cables bypass the main DC bus capacitors and supply DC voltage to the power card from the soft charge card. This provides voltage for testing the power card without the frequency converter circuitry being powered.
  • Page 73 AF-650 GP and AF-600 FP High Power Service Manual 6.2 Static Test Procedures All tests should be made with a meter capable of testing diodes. Use a digital volt/ohmmeter (VOM) set on the diode scale or an analog ohmmeter set on Rx100 scale.
  • Page 74 AF-650 GP and AF-600 FP High Power Service Manual 6.2.1 Soft Charge and Rectifier Circuits Test: 4x-frame size Both the rectifier and soft charge circuits are tested simultaneously. The soft charge circuit is made up of the soft charge rectifier, fuses and the soft charge resistor.
  • Page 75 AF-650 GP and AF-600 FP High Power Service Manual Main rectifier circuit test part I Connect the positive (+) meter lead to the positive (+) DC bus connector MK105 (A) on the power card. Connect the negative (–) meter lead to terminals L1, L2, and L3 in sequence. Each reading should show infinity.
  • Page 76 AF-650 GP and AF-600 FP High Power Service Manual 2. Disconnect the DC cable at the connector MK3. Since the rectifier test requires the soft charge resistor to be in the circuit, verify the resistor is good before proceeding. 3. Measure the resistance between pins A and B of connector MK4 on the soft charge card. It should read 27 ohms (±10%) for 380–480V frequency converters and 68 ohms (±10%) for 525–690V.
  • Page 77 AF-650 GP and AF-600 FP High Power Service Manual 6.2.3 Soft Charge and Rectifier Circuits Test: 5x-frame sizes For 5x-frame size frequency converters, the rectifier and soft charge circuits are tested separately. The soft charge circuit is made up of the soft charge rectifier, fuses and the soft charge resistor.
  • Page 78 AF-650 GP and AF-600 FP High Power Service Manual Main rectifier circuit test 5x-frames part I Connect the positive (+) meter lead to the positive (+) DC bus connector MK105 (A) on the power card. Connect the negative (–) meter lead to terminals L1, L2, and L3 in sequence. If a disconnect option is used, measure on top side of fuses. Each reading should show infinity.
  • Page 79 AF-650 GP and AF-600 FP High Power Service Manual 6.2.4 Soft Charge Rectifier Test: 5x-frame size The DC cable at connector MK3 remains disconnected for this procedure. Since the rectifier test requires the soft charge resistor to be in the circuit, verify the resistor is good before proceeding. 1.
  • Page 80 AF-650 GP and AF-600 FP High Power Service Manual Disconnect motor leads when testing inverter section. With leads connected, a short circuit in one phase will read in all phases, making isolation difficult. Before starting tests, ensure that meter is set to diode scale. If removed previously, reinstall the soft charge card and power cards. Do not disconnect the cable to connector MK105 on the power card since the path for continuity would be broken.
  • Page 81 AF-650 GP and AF-600 FP High Power Service Manual 6.2.6 Brake IGBT Test This test can only be carried out on units equipped with a dynamic brake option. If a brake resistor is connected to terminals 81 and 82, disconnect it before proceeding.
  • Page 82 AF-650 GP and AF-600 FP High Power Service Manual 6.2.8 Heatsink Temperature Sensor Test The temperature sensor is an NTC (negative temperature coefficient) device. As a result, high resistance means low temperature. As temperature decreases, resistance increases. Each IGBT module has a temperature sensor mounted internally. The sensor is wired from the IGBT module to the gate drive card connector MK100.
  • Page 83 AF-650 GP and AF-600 FP High Power Service Manual Ohm test of fans Measure between terminals 11 and 13 of power card connector MK107. A reading of 20 ohms should be indicated. On IP21 and IP 54 units: Disconnect the spade connectors from the door fan and repeat the measurement. A reading of 21 ohms should be indicated. On IP21 and IP 54 units: Read the door fan terminals with the wires disconnected.
  • Page 84 AF-650 GP and AF-600 FP High Power Service Manual 6.2.10 Fan Continuity Tests: 5x-frame size Make all continuity checks using an ohmmeter set to Rx1 scale. A digital or analog ohmmeter can be used. Some instability may result when measuring resistance of a transformer with a multimeter.
  • Page 85 AF-650 GP and AF-600 FP High Power Service Manual Ohm test of fans Measure between terminals 3 and 5 of power card connector MK107. It should read approximately value D in Table 6-1. Incorrect reading For fans without an inductor, replace the fan. For frequency converters with a fan and inductor, isolate the fault between the fan and the inductor as follows.
  • Page 86 AF-650 GP and AF-600 FP High Power Service Manual 6.3 Dynamic Test Procedures Refer to the terminal locations in Illustration 6-10 for performing dynamic test procedures. Test procedures in this section are numbered for reference only. Tests do not need to be performed in this order. Perform tests only as necessary. Never disconnect the input cabling to the frequency converter with power applied due to danger of severe injury or death.
  • Page 87 In addition to the actual voltage reading, the balance of the voltage between the phases is also important. The frequency converter can operate within specifications as long as the imbalance of supply voltage is not more than 3%. GE calculates mains imbalance per an IEC specification. Imbalance = 0.67 X (Vmax – Vmin)/Vavg For example, if three phase readings were taken and the results were 500 VAC, 478.5 VAC, and 478.5 VAC;...
  • Page 88 AF-650 GP and AF-600 FP High Power Service Manual Incorrect reading Open (blown) input fuses or tripped circuit breakers usually indicate a more serious problem. Prior to replacing fuses or resetting breakers, perform static tests described in section 6.2. An incorrect reading here requires that the main supply be investigated further. Typical items to check would be: Open (blown) input fuses or tripped circuit breakers Open disconnects or line side contactors Problems with the power distribution system...
  • Page 89 AF-650 GP and AF-600 FP High Power Service Manual The lack of any one of these power supplies indicates the low voltage supplies on the power card are defective. This assumes of course that the proper DC bus voltage was read at power card connector MK105 (A) and (B). Replace the power card in accordance with the disassembly procedures in Section 7 or 8. 6.3.5 Zero DC Bus Voltage Test If no voltage is present at power card connector MK105 (A) and (B), check the condition of the DC power supply fuse.
  • Page 90 AF-650 GP and AF-600 FP High Power Service Manual One way to determine if the mains supply is at fault is to swap two of the incoming phases. This assumes that two phases read one current while the third deviates by more than 5%. If all three phases are different from one another, swap the phase with the highest current with the phase with the lowest current.
  • Page 91 AF-650 GP and AF-600 FP High Power Service Manual 6.3.8 Input Waveform Test Testing the current waveform on the input of the frequency converter can assist in troubleshooting mains phase loss conditions or suspected problems with the SCR/diode modules. Phase loss caused by the mains supply can be easily detected. In addition, the rectifier section is controlled by SCR/diode modules. Should one of the SCR/diode modules become defective or the gate signal to the SCR lost, the frequency converter will respond the same as loss of one of the phases.
  • Page 92 AF-650 GP and AF-600 FP High Power Service Manual With a phase loss, the current waveform of the remaining phases would take on the appearance shown in Illustration 6-15. Illustration 6.15: Input Current Waveform with Phase Loss. Always verify the condition of the input voltage waveform before forming a conclusion. The current waveform will follow the voltage waveform. If the voltage waveform is incorrect proceed to investigate the reason for the AC supply problem.
  • Page 93 AF-650 GP and AF-600 FP High Power Service Manual If the control card is suspect, replace it in accordance with the disassembly procedures in Section 7 or 8. Should the above tests check correctly, proceed to testing the SCR gate signals. To view the gate signals, an oscilloscope and a current probe are required.
  • Page 94 AF-650 GP and AF-600 FP High Power Service Manual The initial test can be made with the motor connected and running its load. If suspect readings are recorded then the motor leads may have to be disconnected to further isolate the problem. Using a voltmeter, measure AC output voltage at frequency converter motor terminals 96 (U), 97 (V), and 98 (W).
  • Page 95 AF-650 GP and AF-600 FP High Power Service Manual Measure pins 1 and 2 of each test connector. Each reading should be approximately -9 VDC, indicating all IGBTs are turned off. Apply the run command to the frequency converter and 30 Hz reference. If using a DVM, measure pins 1 and 2 of each connector.
  • Page 96 AF-650 GP and AF-600 FP High Power Service Manual Insert the signal test board into power card connector MK104. With scope probe earth connected to terminal 4 (common) of signal board, measure six gate signals at signal board terminals 25 through 30. Place the frequency converter in run at 30 Hz.
  • Page 97 AF-650 GP and AF-600 FP High Power Service Manual In sequence, connect the positive (+) meter lead to the frequency converter output terminals U, V, and W. The meter should indicate a diode drop. Leave the negative meter lead connected to cable MK105, and run the frequency converter at 30 Hz. In sequence, again connect the positive (+) meter lead to the frequency converter output terminals U, V, and W.
  • Page 98 AF-650 GP and AF-600 FP High Power Service Manual If an incorrect reading was obtained from the above tests, further tests of the current feedback signals are required using the signal test board. Testing current feedback with the signal test board. 8.
  • Page 99 AF-650 GP and AF-600 FP High Power Service Manual Supply voltage Supply voltage for the fans is from the soft charge card to power card connector MK106. First, verify the supply voltage is present as follows. Use a voltmeter to measure the AC phase to phase voltage at R, S, and T of power card connector MK106. It should equal main supply voltage applied to frequency converter.
  • Page 100 AF-650 GP and AF-600 FP High Power Service Manual 6.3.16 Input Terminal Signal Tests The presence of signals on either the digital or analog input terminals of the frequency converter can be verified on the frequency converter display. Digital or analog input status can be selected or read in parameters DR-60 through DR-64.
  • Page 101 AF-650 GP and AF-600 FP High Power Service Manual If the 10 volts is present proceed with checking the individual inputs as follows. Connect the (-) negative meter lead to reference terminal 55. Connect the (+) positive meter lead to desired terminal 53 or 54. For analog input terminals 53 and 54, a DC voltage between 0 and +10 VDC should be read to match the analog signal being sent to the frequency converter.
  • Page 102 AF-650 GP and AF-600 FP High Power Service Manual 7 4x-Frame Sizes Disassembly and Assembly Instructions 7.1 Electrostatic Discharge (ESD) Frequency converters contain dangerous voltages when connected to mains voltage. No disassembly should be attempted with power applied. Remove power to the frequency converter and wait at least 20 minutes to let the frequency converter capacitors fully discharge. Only a competent technician should carry out service.
  • Page 103 AF-650 GP and AF-600 FP High Power Service Manual Illustration 7.1: Control Card Access 380–480V: Yellow tape on the main SMPS transformer in the upper right corner. 525–690V: White tape on the main SMPS transformer in the upper right corner. Keypad (Step 2) Power card PCA3 Keypad cradle (Step 3)
  • Page 104 AF-650 GP and AF-600 FP High Power Service Manual 7.2.3 Power Card Remove the control assembly support bracket in accordance with procedure. Unplug power card connectors MK100, MK102, MK105, MK106, MK107 and MK109. If customer connections are present, unplug connectors FK102, FK103, and MK112. Remove the 7 mounting screws (T25 Torx) from the power card.
  • Page 105 AF-650 GP and AF-600 FP High Power Service Manual 7.2.4 Power Card Mounting Plate Reinstall in reverse order of this procedure. The ring lug for the wire assembly that connects to power card connector MK102 attaches to the right mounting stud on the top of the power card mounting plate.
  • Page 106 AF-650 GP and AF-600 FP High Power Service Manual 7.2.6 Gate Drive Card Disconnect the cables from the connectors on gate drive card MK100, MK102, MK103, MK104, MK106, and, if the unit has a brake option, MK105, and, for 380-480 V units with an RFI filter, MK101. Remove the gate drive card by removing the 6 mounting screws (T25 Torx) from the standoffs.
  • Page 107 AF-650 GP and AF-600 FP High Power Service Manual 7.2.7 Capacitor Bank(s) Some 42/44 size units have 2 capacitor bank assemblies mounted one above the other. Separate disassembly instructions are given for upper and lower capacitor banks. For units with one capacitor bank assembly only, disassemble in accordance with instructions for Single capacitor bank 41/43 units.
  • Page 108 AF-650 GP and AF-600 FP High Power Service Manual Remove the 4 retaining nuts (10 mm) from the cap bank cover plate, and remove the plate. Note that the weight of the cap bank is approximately 9 kg (20 lbs). Remove the cap bank by pulling it free from the mounting studs. Reinstall in reverse order of this procedure.
  • Page 109 AF-650 GP and AF-600 FP High Power Service Manual 7.2.8 Soft Charge (SC) Resistors 42/44 Units Remove the upper capacitor bank assembly in accordance with procedure. On 42/44 units, only the upper cap bank assembly is removed. The MK4 connector on the soft charge card must be disconnected. Disengage the soft charge card far enough to access the MK4 (see Illustration 7-3) in accordance with steps 1-3 in the soft charge card disassembly procedure.
  • Page 110 AF-650 GP and AF-600 FP High Power Service Manual 7.2.9 Soft Charge (SC) Resistors 41/43 Units Remove the capacitor bank per instructions. Remove the input terminal mounting plate per instructions. Note the colour coding for each of three wires attached to terminal 1 for each SCR/diode module. Ensure that the correct wire is attached to the applicable stud during reassembly.
  • Page 111 AF-650 GP and AF-600 FP High Power Service Manual Remove the six retaining screws (T25) from the SCR/diode modules, terminals 2 and 3 in each module. Remove the 4 (10 mm) retaining nuts from the DC inductor input bus bars and the 4 retaining nuts (not shown) from the side mounted bus bars. (Side mounted bus bars are only present on units with load sharing.) Remove the DC input bus assembly.
  • Page 112 AF-650 GP and AF-600 FP High Power Service Manual Remove the soft charge resistor by removing the two mounting screws. Illustration 7.1: 41/43 Soft Charge Resistor (3 of 3) 380–480V: Clear wire leads. 525–690V: Black wire leads. Soft charge resistor Mounting screws (Step 6) Reassembly Clean the heatsink surface with a mild solvent or alcohol solution.
  • Page 113 AF-650 GP and AF-600 FP High Power Service Manual 7.2.10 Input Terminal Mounting Plate Assembly Disconnect the input power wiring from L1, L2, L3, and earth connection. Remove the upper most bus bar retaining nuts (13 mm) from the AC power input bus bars L1, L2, and L3. Disconnect the fan autotransformer cable at the in-line connector.
  • Page 114 AF-650 GP and AF-600 FP High Power Service Manual 7.2.11 SCR/Diode Module 42/44 Units Remove the lower DC capacitor bank per instructions. Remove the input terminal plate per instructions. Remove the retaining nuts (8 mm) from the SCR input bus bars, one for each input phase. Note the colour coding for each of the three wires attached to the retaining studs.
  • Page 115 AF-650 GP and AF-600 FP High Power Service Manual Remove twelve (T30) screws from the output (lower) side of the IGBT modules. Remove the retaining nut (8 mm) from each intermediate IGBT output bus bar. Remove the intermediate IGBT bus bars. Remove 4 nuts (10 mm), two on either side, connecting the rectifier DC bus bars to the main DC bus bars.
  • Page 116 AF-650 GP and AF-600 FP High Power Service Manual Note which gate leads are attached to which module to ensure that the leads are reconnected to the correct modules upon reassembly. Remove the rectifier DC bus bars by removing the 3 screws (T25) connecting each rectifier DC bus bar to standoffs on the SCR/diode modules. Bus bar BB27 Bus bar BB28 Retaining screws (Step 10)
  • Page 117 AF-650 GP and AF-600 FP High Power Service Manual Remove the SCR gate lead connectors from the modules. Remove the SCR/diode module retaining screws on each module (T30) and remove the SCR/diode modules. Illustration 7.1: 42/44 SCR/Diode Module (4 of 4) SCR/diode module (Step 12) SCR gate lead connectors (Step 11) SCR/diode module mounting screws (Step 12)
  • Page 118 AF-650 GP and AF-600 FP High Power Service Manual 7.2.12 SCR/Diode Module 41/43 Units Remove the capacitor bank per instructions. Remove the input terminal mounting plate per instructions. Remove the retaining screw (T25) from terminal 1 of each SCR/diode module. Remove the 8 mm retaining nut from the bus bar holding bracket and remove the bus bar, one for each input phase.
  • Page 119 AF-650 GP and AF-600 FP High Power Service Manual Remove the six retaining screws (T25) from the SCR/diode modules, terminals 2 and 3 in each module. Remove the 4 (10 mm) retaining nuts from the DC inductor input bus bars and the 4 retaining nuts (not shown) from the side mounted bus bars. (Side mounted bus bars are only present on units with load sharing.) Remove the DC input bus assembly.
  • Page 120 AF-650 GP and AF-600 FP High Power Service Manual Note which gate leads attach to which module for reassembly. Remove the SCR/diode gate lead connectors from the modules (not shown). If the unit is equipped with a brake option, remove the two bus bars attaching the brake IGBT module to the IGBT bus assy. Remove the SCR/diode mounting screws.
  • Page 121 AF-650 GP and AF-600 FP High Power Service Manual 7.2.13 Current Sensor Remove the motor cabling, as required. Remove the input terminal mounting plate assembly per instructions. Remove terminals U, V, and W by removing the 3 mounting screws. The terminal slides out from under the current sensor. Disconnect the current sensor cable from the current sensor.
  • Page 122 AF-650 GP and AF-600 FP High Power Service Manual 7.2.14 Heatsink Fan Assembly Remove the input terminal mounting plate assembly per instructions. Remove the 3 IGBT output bus bars (see Illustration 7-19) by removing the 6 retaining nuts (8 mm), one from each end, of the IGBT output bus bars. Remove the bus bars.
  • Page 123 AF-650 GP and AF-600 FP High Power Service Manual 5. Disconnect the in-line Molex connector. 6. Remove the fan assy by removing the 6 (8 mm) retaining nuts from the stud. Note that the fan assembly weighs approximately 8 kg (18 lbs). Reinstall in reverse order of this procedure.
  • Page 124 AF-650 GP and AF-600 FP High Power Service Manual 7.2.15 AC Input Terminals Remove the AC input power cabling, as required. Remove the R/L1, S/L2, T/L3 terminals by removing the 3 retaining screws. Reinstall in reverse order of this procedure. Tighten the mounting nuts per specifications in the unit's instruction manual. Illustration 7.1: AC Input Terminals (no options shown) 380–480/500V: White label on fan transformer.
  • Page 125 AF-650 GP and AF-600 FP High Power Service Manual 7.2.16 IGBT Modules 42/44 Units Remove the capacitor banks per instructions. Note the IGBT gate signal cables connected between gate drive card connectors MK100 (temperature sensor), MK102 (U), MK103 (V), and MK104 (W) and IGBTs.
  • Page 126 AF-650 GP and AF-600 FP High Power Service Manual Remove the 4 (10 mm) retaining nuts at the top of the IGBT bus bar assy. Remove the 12 retaining screws (6 on each module) on the upper portion of the IGBT modules. These screws also attach the snubber capacitors to the IGBT modules (see Illustration 7-22, item 5 for snubber capacitor location).
  • Page 127 AF-650 GP and AF-600 FP High Power Service Manual Remove the 2 IGBT modules by removing the 16 retaining screws (8 per module) and sliding the modules free from under the bus bars. Clean the heatsink surface with a mild solvent or alcohol solution. Illustration 7.1: 42/44 IGBT Modules (3 of 3) IGBT module Retaining screw (Step 13)
  • Page 128 AF-650 GP and AF-600 FP High Power Service Manual 7.2.17 IGBT Modules 41/43 Units Remove the control card cassette per instructions. Remove the input terminal mounting plate per instructions. Note the IGBT gate signal cables connected between the gate drive card connectors MK100 (temperature sensor), MK102 (U), MK103 (V), and MK104 (W) and the IGBT module connectors.
  • Page 129 AF-650 GP and AF-600 FP High Power Service Manual 8. Remove the 4 (10 mm) retaining nuts at the top of the IGBT bus bar assy. 9. Remove the 6 retaining screws on the upper portion of the IGBT modules. These screws also attach the snubber capacitors to the IGBT modules. Remove the 3 snubber capacitors.
  • Page 130 AF-650 GP and AF-600 FP High Power Service Manual 8 5x-Frame Sizes Disassembly and Assembly Instructions 8.1 Electrostatic Discharge (ESD) Frequency converters contain dangerous voltages when connected to mains voltage. No disassembly should be attempted with power applied. Remove power to the frequency converter and wait at least 40 minutes to let the frequency converter capacitors fully discharge. Only a competent technician should carry out service.
  • Page 131 AF-650 GP and AF-600 FP High Power Service Manual Illustration 8.1: Control Card Access 380–480V: Yellow tape on the main SMPS transformer in the upper right cor- 525–690V: White tape on the main SMPS transformer in the upper right cor- ner.
  • Page 132 AF-650 GP and AF-600 FP High Power Service Manual 8.2.3 Power Card Remove the control assembly support bracket in accordance with procedure. Unplug power card connectors MK100, MK102, MK105, MK106, MK107 and MK109. If customer connections are present, unplug connectors FK102, FK103, and MK112. Remove the 7 mounting screws (T25 Torx) from the power card.
  • Page 133 AF-650 GP and AF-600 FP High Power Service Manual 8.2.4 Soft Charge Card Disconnect MK1, MK2, MK3, and MK4. Remove the 4 mounting screws (T25) from the standoffs. Remove the soft charge card. Note the insulation sheet below the soft charge card. Remove and keep the insulation with the card for reinstallation. Reinstall by mounting the insulation onto the standoffs.
  • Page 134 AF-650 GP and AF-600 FP High Power Service Manual 8.2.5 Gate Drive Card Disconnect the cables from connectors on the gate drive card MK100, MK102, MK103, MK104, MK106, and, if unit has a brake option, MK105, and, for 380–480 V units with an RFI filter, MK101. Remove the gate drive card by removing the 6 mounting screws (T25 Torx) from the standoffs.
  • Page 135 AF-650 GP and AF-600 FP High Power Service Manual 8.2.6 Capacitor Banks Upper Capacitor Banks Remove the control assembly support bracket and the gate drive card in accordance with the instructions. The capacitor bank connection to the DC bus bars can be seen recessed in the gap between the upper and the lower capacitor banks. A minimum extension of 6 inches (150 mm) is required.
  • Page 136 AF-650 GP and AF-600 FP High Power Service Manual Illustration 8.1: Upper and Lower Capacitor Bank Assemblies Upper capacitor bank assy Lower capacitor bank assy Upper cap bank assy electrical connection nuts (Step 2) Gate drive card Lower cap bank assy electrical connection nuts (Step 2) Upper cap bank assy retaining nut (Step 4) Lower cap bank assy retaining nut (Step 3) Soft charge card...
  • Page 137 AF-650 GP and AF-600 FP High Power Service Manual 8.2.7 Input Terminal Mounting Plate Assy Option The frequency converter has component options that can be mounted on the input mounting plate. This results in differing unit configurations. These options include input terminal blocks, input disconnect, RFI filter, input fuses, and an additional cooling fan. These options may need to be removed from the mounting plate assembly to reduce the weight of the assembly for ease of removal.
  • Page 138 AF-650 GP and AF-600 FP High Power Service Manual 8.2.8 Soft Charge Resistor Remove the input terminal plate assembly in accordance with procedure. Disconnect the MK4 connector on the soft charge card. Loosen top retaining nut (8 mm) on soft charge resistor. Remove bottom retaining nut (8 mm) on the soft charge resistor.
  • Page 139 AF-650 GP and AF-600 FP High Power Service Manual 8.2.9 SCR and Diode Modules Remove the lower DC capacitor bank in accordance with procedure. Remove the input terminal plate in accordance with procedure. Remove the wire retaining nut (10 mm) from each of the 3 SCR input bus bars (BB41). Note colour coding for each of the 3 wires attached to the retaining studs.
  • Page 140 AF-650 GP and AF-600 FP High Power Service Manual If the unit is not equipped with the load sharing option, proceed to step 9. If the unit is equipped with load sharing, the load share minus (-) bus bar must be removed as follows.
  • Page 141 AF-650 GP and AF-600 FP High Power Service Manual 11. Note which gate lead connects to which SCR module. Ensure that the correct wire is attached to the applicable SCR upon reassembly. Remove the wiring from each SCR module. The connector is keyed for proper reinstallation. DO NOT force the connection. 12.
  • Page 142 AF-650 GP and AF-600 FP High Power Service Manual 8.2.10 Current Sensor Remove the input terminal plate in accordance with procedure. Remove the retaining nut (17 mm) connecting the current sensor bus bar to the motor terminal bus bar. Remove the retaining nut (17 mm) or T50 screw, depending on unit type, connecting the current sensor bus bar to the IGBT via the fan bus bar. Note which cable is attached to the current sensor.
  • Page 143 AF-650 GP and AF-600 FP High Power Service Manual 8.2.11 Heatsink Fan Assembly Remove the input terminal plate in accordance with procedure. Remove the retaining nut (17 mm) or T50 Torx screw, depending on the unit type, connecting each of the 3 IGBT over-fan bus bars to the 3 current sensor bus bars.
  • Page 144 AF-650 GP and AF-600 FP High Power Service Manual 8.2.12 AC Input, Motor, Load Sharing or Regen Terminals Remove the external wiring from the terminals as required. Remove the retaining nut (17 mm) connecting the terminal bus bar to other bus bar assemblies. Remove the 2 retaining nuts (13 mm) attaching the terminal bus bar to the terminal block insulation.
  • Page 145 AF-650 GP and AF-600 FP High Power Service Manual 8.2.13 IGBT Modules Remove both DC capacitor banks in accordance with the procedure. Remove the Input Terminal Plate in accordance with procedure. Remove the wire retaining nut (10 mm) from each of the 3 SCR input bus bars. Note colour coding for each of the 3 wires attached to the retaining studs.
  • Page 146 AF-650 GP and AF-600 FP High Power Service Manual If the unit is not equipped with the load sharing option, proceed to step 9. If the unit is equipped with load sharing, the load share minus (-) bus bar must be removed as follows.
  • Page 147 AF-650 GP and AF-600 FP High Power Service Manual Remove the 6 retaining screws (T30) connecting each IGBT module output to the IGBT output bus bars. Remove the retaining nut (17 mm) connecting the IGBT output bus bar to IGBT over-fan bus bar. Note that there is one for each of three phases. Remove the retaining nut (17 mm) or T50 Torx screw, depending on the unit type, connecting to IGBT over-fan bus bar to current sensor bus bar.
  • Page 148 AF-650 GP and AF-600 FP High Power Service Manual Remove the 18 retaining screws (T30) on the IGBT input terminals. Note snubber capacitors come off when screws are removed. There are 6 screws for each IGBT module. Remove the 2 retaining nuts (8 mm) connecting each IGBT-cap bus bar assembly to the IGBT-Ind bus bar assembly and remove the IGBT-cap bus bar assembly.
  • Page 149 AF-650 GP and AF-600 FP High Power Service Manual Attaching Hardware Tightening Torque 8 mm/T25 2.3 Nm (20 in-lbs) 10 mm/T30 4 Nm (35 in-lbs) 13 mm 9.5 Nm (85 in-lbs) 17 mm/T50 19 Nm (170 in-lbs)
  • Page 150 Test equipment described in this section is available from GE. Using the test cable allows powering the frequency converter without having to charge DC bus capacitors. Main input power is required and all devices and power supplies connected to mains are energised at rated voltage.
  • Page 151 AF-650 GP and AF-600 FP High Power Service Manual To install the cable, first make sure the frequency converter is powered down and the DC bus is fully discharged. For 4x-frame size units, follow the procedure in Section 7 for soft charge card removal and disengage the soft charge card far enough to disconnect the cable plugged into the MK3.
  • Page 152 AF-650 GP and AF-600 FP High Power Service Manual Current sensed, .937 VACpeak @ 165% of CT current rating. AC V phase, not conditioned waveform @ output frequency of the frequency converter. Approx 400 mv RMS @100% load Current sensed, .937 VACpeak @ 165% of CT current rating.
  • Page 153 AF-650 GP and AF-600 FP High Power Service Manual Pin No. Schematic Function Description Reading Using a Digital Voltmeter Acronym HI_LOW Control signal from Signal to switch fan speeds between high and low +5VDC = fans on high, Power Card Otherwise, 0VDC.
  • Page 154 AF-650 GP and AF-600 FP High Power Service Manual 10 Replacement Parts 10.1.1 General Notes General Notes: All replacement parts are suitable for conformal coated frequency converters and can be used in either coated or non-conformal coated frequency converters. Bus bars used in some units are aluminum. Replacement part bus bars are always plated copper. Plated copper bus bars are useable for all units. For the latest replacement parts list, visit the www.geelectrical.com/drives...
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  • Page 176 AF-650 GP and AF-600 FP High Power Service Manual 11 Block Diagrams 11.1 Block Diagrams for 4x-Frames 11.1.1 41/43 380–480 VAC...
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  • Page 183 AF-650 GP and AF-600 FP High Power Service Manual 11.2 Block Diagrams for 5x-Frames 11.2.1 51/52 380–480 VAC...
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  • Page 185 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-650 GP and AF-600 FP are trademarks of the General Electric Company.

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