GE AF-600 FP Series Guide

GE Consumer & Industrial

Electrical Distribution

AF-600 FPTM

Fan and Pump Drive

Design Guide

The instructions do not purport to cover all details or variations in equipment nor to provide for every possible

contingency to be met in connection with installation, operation or maintenance. Should further information be

desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes, the

matter should be referred to the GE company.

AF-600 FP is a trademark of the General Electric Company.

GE Consumer & Industrial

41 Woodford Avenue

Plainville, CT 06062

www.geelectrical.com/drives

130R0358 *MG11R102* DET-621

Contents

1 How to Read this Design Guide

Approvals 4

Symbols 4

Abbreviations 5

Definitions 5

2 Introduction to AF-600 FP

Safety 11

CE Labelling 13

Aggressive Environments 14

Vibration and Shock 15

Application Examples 22

Control Structures 28

General Aspects of EMC 35

Galvanic Isolation (PELV) 39

PELV - Protective Extra Low Voltage 39

Earth Leakage Current 40

Extreme Running Conditions 40

3 AF-600 FP Selection

Options and Accessories 45

4 How to Install

Mechanical Dimensions 59

Lifting 64

Electrical Installation 66

Electrical Installation and Control Cables 67

Final Set-Up and Test 82

Additional Connections 84

Motor Insulation 86

Motor Bearing Currents 87

Installation of Misc. Connections 88

Safety 90

EMC-correct Installation 90

Residual Current Device 93

5 Application Examples

Start/Stop 95

Pulse Start/Stop 95

Potentiometer Reference 96

AF-600 FP Design Guide

Auto Tune 96

Logic Controller 96

Logic Controller Programming 97

LC Application Example 97

BASIC Cascade Controller 99

Pump Staging with Lead Pump Alternation 100

System Status and Operation 100

Fixed Variable Speed Pump Wiring Diagram 101

Lead Pump Alternation Wiring Diagram 102

Cascade Controller Wiring Diagram 103

Start/Stop Conditions 103

6 RS-485 Installation and Set-up

105

RS-485 Installation and Set-up 105

Drive Protocol Overview 107

Network Configuration 109

Drive Protocol Message Framing Structure 109

Examples 114

Modbus RTU Overview 116

Modbus RTU Message Framing Structure 117

How to Access Parameters 121

Examples 122

GE Drive Control Profile 128

7 General Specifications and Troubleshooting

133

Mains Supply Tables 133

General Specifications 145

Efficiency 149

Acoustic Noise 150

Peak Voltage on Motor 150

Special Conditions 155

Troubleshooting 157

Alarms and Warnings 157

Alarm Words 161

Warning Words 162

Extended Status Words 163

Fault Messages 164

Index

169

AF-600 FP Design Guide

1 How to Read this Design Guide

AF-600 FP

Software version: 1.02

This guide can be used with all AF-600 FP frequency converters with

software version 1.02 or later.

The actual software version number can be read from

par. ID-43 Software Version.

1.1.1 Copyright, Limitation of Liability and Revision Rights

This publication contains information proprietary to GE. By accepting and using this manual the user agrees that the information contained herein will be used

solely for operating equipment from GE or equipment from other vendors provided that such equipment is intended for communication with GE equipment over

a serial communication link. This publication is protected under the Copyright laws of Denmark and most other countries.

GE does not warrant that a software program produced according to the guidelines provided in this manual will function properly in every physical, hardware or

software environment.

Although GE has tested and reviewed the documentation within this manual, GE makes no warranty or representation, neither expressed nor implied, with respect

to this documentation, including its quality, performance, or fitness for a particular purpose.

In no event shall GE be liable for direct, indirect, special, incidental, or consequential damages arising out of the use, or the inability to use information contained

in this manual, even if advised of the possibility of such damages. In particular, GE is not responsible for any costs, including but not limited to those incurred as

a result of lost profits or revenue, loss or damage of equipment, loss of computer programs, loss of data, the costs to substitute these, or any claims by third

parties.

GE reserves the right to revise this publication at any time and to make changes to its contents without prior notice or any obligation to notify former or present

users of such revisions or changes.

AF-600 FP Design Guide

1.1.2 Available Literature for AF-600 FP

-Operating Instructions provide the necessary information for getting the drive up and running.

-Design Guide entails all technical information about the drive and customer design and applications.

-Programming Guide provides information on how to program and includes complete parameter descriptions.

GE technical literature is available in print from your local GE Sales Office or online at: www.geelectrical.com/drives

- AF-600 FP Built-in network manuals are available separately.

1.1.3 Approvals

1.1.4 Symbols

Symbols used in this guide.

NB!

Indicates something to be noted by the reader.

Indicates a general warning.

Indicates a high-voltage warning.

*Indicates default setting

AF-600 FP Design Guide

1.1.5 Abbreviations

Alternating current AC

American wire gauge AWG

Ampere/AMP A

Current limit ILIM

Degrees Celsius °C

Direct current DC

Drive Control Tool PC Software DCT 10

Drive Dependent D-TYPE

Electro Magnetic Compatibility EMC

Electronic Thermal Overload Elec. OL

Gram g

Hertz Hz

Kilohertz kHz

Meter m

Millihenry Inductance mH

Milliampere mA

Millisecond ms

Minute min

Nanofarad nF

Newton Meters Nm

Nominal motor current IM,N

Nominal motor frequency fM,N

Nominal motor power PM,N

Nominal motor voltage UM,N

Parameter par.

Protective Extra Low Voltage PELV

Printed Circuit Board PCB

Rated Inverter Output Current IINV

Revolutions Per Minute RPM

Regenerative terminals Regen

Second s

Synchronous Motor Speed ns

Torque limit TLIM

Volts V

1.1.6 Definitions

Drive:

IDRIVE,MAX

The maximum output current.

IDRIVE,N

The rated output current supplied by the frequency converter.

UDRIVE, MAX

The maximum output voltage.

Input:

Control command

You can start and stop the connected motor by means of keypad and the

digital inputs.

Functions are divided into two groups.

Functions in group 1 have higher priority than functions in group 2.

Group 1 Reset, Coasting stop, Reset and Coasting stop, Quick-stop, DC brak-

ing, Stop and the "Off" key.

Group 2 Start, Pulse start, Reversing, Start reversing, Jog and Freeze output

AF-600 FP Design Guide

Motor:

fJOG

The motor frequency when the jog function is activated (via digital terminals).

The motor frequency.

fMAX

The maximum motor frequency.

fMIN

The minimum motor frequency.

fM,N

The rated motor frequency (nameplate data).

The motor current.

IM,N

The rated motor current (nameplate data).

nM,N

The rated motor speed (nameplate data).

PM,N

The rated motor power (nameplate data).

TM,N

The rated torque (motor).

The instantaneous motor voltage.

UM,N

The rated motor voltage (nameplate data).

Break-away torque

DRIVE

The efficiency of the frequency converter is defined as the ratio between the power output and the power input.

AF-600 FP Design Guide

Start-disable command

A stop command belonging to the group 1 control commands - see this group.

Stop command

See Control commands.

References:

Analog Reference

A signal transmitted to the analog inputs 53 or 54, can be voltage or current.

Bus Reference

A signal transmitted to the serial communication port (drive port).

Preset Reference

A defined preset reference to be set from -100% to +100% of the reference range. Selection of eight preset references via the digital terminals.

Pulse Reference

A pulse frequency signal transmitted to the digital inputs (terminal 29 or 33).

RefMAX

Determines the relationship between the reference input at 100% full scale value (typically 10 V, 20mA) and the resulting reference. The maximum reference value

set in par. F-53 Maximum Reference.

RefMIN

Determines the relationship between the reference input at 0% value (typically 0V, 0mA, 4mA) and the resulting reference. The minimum reference value set in

par. F-52 Minimum Reference

Miscellaneous:

Advanced Vecter Control

If compared with standard voltage/frequency ratio control, Advanced Vecter Control improves the dynamics and the stability, both when the speed reference is

changed and in relation to the load torque.

Analog Inputs

The analog inputs are used for controlling various functions of the frequency converter.

There are two types of analog inputs:

Current input, 0-20 mA and 4-20 mA

Voltage input, 0-10 V DC.

Analog Outputs

The analog outputs can supply a signal of 0-20 mA, 4-20 mA, or a digital signal.

Auto Tune

Auto Tune algorithm determines the electrical parameters for the connected motor at standstill.

CT Characteristics

Constant torque characteristics used for screw and scroll refrigeration compressors.

Digital Inputs

The digital inputs can be used for controlling various functions of the frequency converter.

Digital Outputs

The frequency converter features two Solid State outputs that can supply a 24 V DC (max. 40 mA) signal.

AF-600 FP Design Guide

DSP

Digital Signal Processor.

Relay Outputs:

The frequency converter features two programmable Relay Outputs.

Electronic Thermal Overload

Electronic Thermal Overload is a thermal load calculation based on present load and time. Its purpose is to estimate the motor temperature.

Initialising

If initialising is carried out (par. H-03 Restore Factory Settings), the programmable parameters of the frequency converter return to their default settings.

Intermittent Duty Cycle

An intermittent duty rating refers to a sequence of duty cycles. Each cycle consists of an on-load and an off-load period. The operation can be either periodic duty

or none-periodic duty.

keypad

The keypad makes up a complete interface for control and programming of the frequency converter. The is detachable and can be installed up to 3 metres from

the frequency converter, i.e. in a front panel by means of the installation kit option.

lsb

Least significant bit.

MCM

Short for Mille Circular Mil, an American measuring unit for cable cross-section. 1 MCM ≡0.5067 mm2.

msb

Most significant bit.

On-line/Off-line Parameters

Changes to on-line parameters are activated immediately after the data value is changed. Changes to off-line parameters are not activated until you enter [OK]

on the keypad.

PID Controller

The PID controller maintains the desired speed, pressure, temperature, etc. by adjusting the output frequency to match the varying load.

RCD

Residual Current Device.

Set-up

You can save parameter settings in four Set-ups. Change between the four parameter Set-ups and edit one Set-up, while another Set-up is active.

SFAVM

Switching pattern called Stator Flux oriented Asynchronous V ector M odulation (par. F-37 Adv. Switching Pattern).

Slip Compensation

The frequency converter compensates for the motor slip by giving the frequency a supplement that follows the measured motor load keeping the motor speed

almost constant.

Logic Controller (LC)

The LC is a sequence of user defined actions executed when the associated user defined events are evaluated as true by the LC.

Thermistor:

A temperature-dependent resistor placed where the temperature is to be monitored (frequency converter or motor).

AF-600 FP Design Guide

Trip

A state entered in fault situations, e.g. if the frequency converter is subject to an over-temperature or when the frequency converter is protecting the motor,

process or mechanism. Restart is prevented until the cause of the fault has disappeared and the trip state is cancelled by activating reset or, in some cases, by

being programmed to reset automatically. Trip may not be used for personal safety.

Trip Locked

A state entered in fault situations when the frequency converter is protecting itself and requiring physical intervention, e.g. if the frequency converter is subject

to a short circuit on the output. A locked trip can only be cancelled by cutting off mains, removing the cause of the fault, and reconnecting the frequency converter.

Restart is prevented until the trip state is cancelled by activating reset or, in some cases, by being programmed to reset automatically. Trip locked may not be

used for personal safety.

VT Characteristics

Variable torque characteristics used for pumps and fans.

60° AVM