GE AV-300i User manual

GEH-6668A
Supersedes GEH-6668
GE Industrial Systems
AV-300i TM
575V
User’s Guide

© 2004 General Electric Company, USA.
All rights reserved.
This book is referred to SW version 1.X00
These instructions do not purport to cover all details or variations in equipment, nor to provide every possible contin-
gency to be met during installation, operation, and maintenance. If further information is desired or if particular problems
arise that are not covered sufficiently for the purchaser’s purpose, the matter should be referred to GE Industrial Systems,
Salem, Virginia, USA.
This document contains proprietary information of General Electric Company, USA and is furnished to its customer
solely to assist that customer in the installation, testing, operation, and/or maintenance of the equipment described. This
document shall not be reproduced in whole or in part nor shall its contents be disclosed to any third party without the
written approval of GE Industrial Systems.
AV300i is a trademark of General Electric Company. USA.
Klixon is a trademark of Texas Instruments, Inc.
National Electric code and NEC are registered trademarks of the National Fire Protection Association.

3
GEH-6688 AV300i User’s Guide
Safety Symbol Legend / Légende des Signes de Sécurité
WARNING!Commands attention to an operating procedure, practice, condition, or statement which, if
not strictly observed, could result in personal injury or death.
Attire l’attention sur les modes d’utilisation et les procédés et conditions d’exploitation qui,
en cas d’inobservation, pourraient entraîner des blessures corporelles ou la mort.
CAUTION!Commands attention to an operating procedure, practice, condition, or statement which, if
not strictly observed, could result in damage or destruction of equipment.
The seriousness of the injuries and of the damages which could be caused by the non- obser-
vance of such indications, depends on the different conditions. Anyway, the instructions
given below should always be followed with the highest attention.
Attire l’attention sur les modes d’utilization et les procédés et conditions d’exploitation qui,
en cas d’inobservation, pourraient entraîner la détérioration ou la destruction des appareils.
La gravité des blessures et des dommages matériels possibles dépendent de différent facteurs.
Toutefois, les instructions mentionées ci-dessous devraient être toujours suivies avec la plus
grande attention.
NOTE!Commands attention to an operating procedure, practice, condition, or statement that must
be highlighted.
Attire l’attention sur les modes d’utilization et les procédés et conditions d’exploitation qui
présentent un intéret particulier.

4 • Table of Contents GEH-6668A AV300i User’s Guide
Table of Contents
Safety Symbol Legend / Légende des Signes de Sécurité ............................................. 3
Chapter 0 - Safety Precautions / Precautions de Securité .......................................... 13
Chapter 1 - Function and Features (Overview) ............................................................ 17
Chapter 2 - Inspection Procedure, Component Identification and Standard
Specification .............................................................................................................. 19
2.1. Upon Delivery Inspection Procedures.............................................................................................19
2.1.1. General ..................................................................................................................................19
2.1.2.Inverter TypeDesignation .......................................................................................................19
Figure 2.1.2.1: Inverter type designation ............................................................................................19
2.1.3. Nameplate .............................................................................................................................20
Figure 2.1.3.1: Identification nameplate ..........................................................................................20
Figure 2.1.3.2: Firmware & Card revision level nameplate..................................................................20
Figure 2.1.3.3: Nameplates position ...................................................................................................20
2.2. Component Identification ...............................................................................................................21
Figure 2.2.1: Basic Setup of Frequency Inverter.................................................................................21
Figure 2.2.2: Drive view & components ..............................................................................................22
2.3. Standard Specifications .................................................................................................................23
2.3.1.PermissibleEnvironmentalConditions.....................................................................................23
Table 2.3.1.1: Environmental specification..........................................................................................23
Disposal of the Device.........................................................................................................................24
2.3.2.ACInput/OutputConnection....................................................................................................24
Table 2.3.2.1: AC Input/Output specifications.....................................................................................25
2.3.3. AC Input Current ....................................................................................................................26
2.3.4. AC Output ..............................................................................................................................26
Tables 2.3.4.1: Nominal Drive Current ................................................................................................27
2.3.5.Open-Loop andClosed-LoopControlSection...........................................................................28
2.3.6. Accuracy................................................................................................................................29
Chapter 3 - Installation Guidelines ................................................................................ 31
3.1.MechanicalSpecification................................................................................................................31
Figure 3.1.1: Drive dimensions (sizes 3002 up to 3020)......................................................................31
Figure 3.1.2: Mounting methods (sizes 3002 up to 3020)...................................................................31
Table 3.1.1: Drive dimensions and weights (sizes 3002 up to 3020) ..................................................31
Figure 3.1.3: Drive dimensions (sizes 3025 up to 3075) ....................................................................32
Figure 3.1.4: Mounting methods (sizes 3025 up to 3075)...................................................................32
Table 3.1.2: Drive dimensions and weights (sizes 3025 up to 3075).................................................32
Figure 3.1.5: Keypad positioning.........................................................................................................33
3.2. Watts Loss, Heat Dissipation, Internal Fans and Minimum Cabinet Opening Suggested for the
Cooling .............................................................................................................................................33
Table 3.2.1: Heat dissipation and required air flow ............................................................................33
Table 3.2.2: Minimum cabinet opening suggested for the cooling .....................................................33
3.2.1CoolingFansPower Supply .....................................................................................................34
Figure 3.2.1: UL type fans connections on 3125 to3200...................................................................34
Figure 3.2.2: UL type fans connections on 3100 ...............................................................................34
Figure 3.2.3: Example for external connection....................................................................................34
3.3. Installation Mounting Clearance .....................................................................................................35

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GEH-6668A AV300i User’s Guide
Figure 3.3.1: Max. angle of inclination ...............................................................................................35
Figure 3.3.2: Mounting clearance.......................................................................................................35
3.4. Motors and Encoders.....................................................................................................................36
3.4.1. Motors...................................................................................................................................36
3.4.2. Encoders................................................................................................................................37
Table 3.4.2.1: Recommended cable section and length for the connection of encoders ..................37
Table 3.4.2.2: Encoders setting via S11...S23 Jumpers......................................................................38
Table 3.4.2.3: Encoders connections ..................................................................................................38
Table 3.4.2.4: Assignment of the high density XE connector for a sinusoidal or a digital encoder ....40
Chapter 4 - Wiring Procedure........................................................................................ 41
4.1. Accessing to the Connectors .........................................................................................................41
4.1.1RemovingtheCovers...............................................................................................................41
Figure 4.1.1: Removing the covers (sizes 3002 to 3020) ....................................................................41
Figure 4.1.2: Removing the covers (sizes 3025 to 8200) ....................................................................42
4.2.PowerSection................................................................................................................................43
4.2.1.TerminalAssignmentonPowerSection/CableCross-Section.................................................43
Table 4.2.1.1: Power section terminals from 2 Hp to 20 Hp ..............................................................43
Table 4.2.1.2: Power section terminals from 25 Hp and higher.........................................................43
Table 4.2.1.3: Maximum cable cross section for power terminals ....................................................44
4.3Regulation Section ..........................................................................................................................45
4.3.1RV33Regulation Card..............................................................................................................45
Figure 4.3.1.1: RV33-3 Regulation card switch & jumpers .................................................................45
Table 4.3.1.1: LEDs on regulation card ...............................................................................................45
Table 4.3.1.2: Test points on regulation card......................................................................................45
Table 4.3.1.3: Jumpers on regulation card..........................................................................................46
Table 4.3.1.4: Regulation Card Switch S3 Settings ............................................................................46
4.3.2.TerminalAssignmentsonRegulationSection ...........................................................................47
Table 4.3.2.1: Plug-in Terminal Strip Assignments ..............................................................................47
Table 4.3.2.2: Maximum permissible cable cross-section on the plug-in terminals of the regulator
section............................................................................................................................................48
Table 4.3.2.3: Maximum Control Cable Lengths..................................................................................48
Figure 4.3.1.2: Potentials of the control section .................................................................................49
4.4. Serial Interface...............................................................................................................................50
4.4.1.SerialInterfaceDescription.....................................................................................................50
Figure 4.4.1.1: RS485 Serial Interface................................................................................................50
4.4.2.RS 485SerialInterface ConnectorDescription........................................................................51
Table 4.4.2.1: Assignment of the plug XS connector for the RS 485 serial interface.........................51
4.5. Standard Connection Diagram .......................................................................................................52
4.5.1. AV-300 Connections ...............................................................................................................52
Figure 4.5.1.1: Control sequencing .....................................................................................................52
Figure 4.5.1.2: Example for relay interface .........................................................................................53
Figure 4.5.1.3: Typical connection ......................................................................................................54
4.5.2. Parallel Connection onthe AC (Input)and DC(Intermediate Circuit) Sideof SeveralInverters .55
Figure 4.5.2.1: Parallel Connection on the AC and DC Side of Several Inverters...............................55
4.6. Circuit Protection ...........................................................................................................................56
4.6.1. External fuses of thepowersection ........................................................................................56
Table 4.6.1.1: External Fuse Types for AC input side ..........................................................................56
4.6.2. AC Input Contactors...............................................................................................................57
Table 4.6.2.1: K1M - AC Input Contactors ..........................................................................................57

6 • Table of Contents GEH-6668A AV300i User’s Guide
4.6.3.ExternalFusesofthe PowerSection DCInput Side .................................................................58
Table 4.6.3.1: External fuses type for DC input side ...........................................................................58
4.6.4. Internal Fuses.........................................................................................................................58
Table 4.6.4.1: Internal fuses................................................................................................................58
4.7. Chokes / Filters..............................................................................................................................59
4.7.1. AC Input Chokes ....................................................................................................................59
Table 4.7.1.1: 3-Phase AC Input Chokes.............................................................................................59
4.7.2. Output Chokes........................................................................................................................59
Table 4.7.2.1: Recommended values for output chokes .....................................................................60
4.7.3.InterferenceSuppression Filters .............................................................................................60
4.8. Braking Units .................................................................................................................................61
Figure 4.8.1: Operation with Braking Unit (Principle)..........................................................................61
4.8.1.InternalBrakingUnit ...............................................................................................................61
Figure 4.8.1.1: Connection with internal Braking Unit and external braking resistor..........................61
4.8.2External BrakingResistor .........................................................................................................62
Table 4.8.2.1: Lists and technical data of the external standard resistors for inverters 3002 up to
3075 ...............................................................................................................................................62
Figure 4.8.2.1: Limit operating braking cycle with typical triangular power profile............................62
Figure 4.8.2.2: Braking cycle with TBR / TC = 20%...........................................................................63
Figure 4.8.2.3: Generic braking cycle with triangular profile ..............................................................64
Table 4.8.2.2: Braking thresholds for different Mains .........................................................................65
Table 4.8.2.3: Technical data of the internal braking units .................................................................65
4.9. Buffering the Regulator Supply ......................................................................................................66
Table 4.9.1: DC Link Buffer Time.........................................................................................................66
Figure 4.9.1: Buffering the Regulator Supply by Means of Additional Intermediate Circuit Capacitors
67
4.10. AV-300i Power Dip Ride Through Data and Restart Setup............................................................68
Table 4.10.1: Drive Trip Times, 575-V Threshold .................................................................................69
4.11. Discharge Time of the DC-Link .....................................................................................................70
Table 4.11.1: DC Link Discharge Times...............................................................................................70
Chapter 5 - Drive Operation........................................................................................... 71
Figure 5.1: Parameters sets management ...........................................................................................71
5.1. Keypad ..........................................................................................................................................72
Figure 5.1.1: keypads (on right the optional Led module)..................................................................72
5.1.1. LEDs & buttons ......................................................................................................................72
Table 5.1.1.1: Keypad leds designation ..............................................................................................72
5.1.2. Moving Inside a Menu............................................................................................................74
Figure 5.1.2.1: Moving Inside the Navigation Menu ..........................................................................74
5.1.3.DisplayingParameters............................................................................................................75
5.1.4.Changing/SavingParameters/Password ..............................................................................75
5.1.5. Operating the Drive via the Keypad.........................................................................................78
5.1.5.1. Starting and Stopping the Drive with Keypad........................................................................78
5.1.5.2. Failure register / acknowledge alarms...................................................................................79
5.1.5.3. Motor Potentiometer Function ...............................................................................................80
5.1.5.4. Jog Function ..........................................................................................................................81
5.2. Menu Structure..............................................................................................................................82
5.2.1MainMenuandSubmenu .......................................................................................................83
5.2.2MainMenu,SubmenuandParameters ....................................................................................84
5.3. Start Up.......................................................................................................................................101

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GEH-6668A AV300i User’s Guide
5.3.1 Pre Power Checks.................................................................................................................101
5.3.1.1 Setting Jumpers and Switches.............................................................................................101
5.3.1.2 Checking the Wiring and Auxiliary Voltages........................................................................101
Table 5.3.1.2.1 : Terminals description..............................................................................................102
Table 5.3.1.2.2: Amps/Volts ratio.......................................................................................................102
5.3.2 Power Up Checks..................................................................................................................103
5.3.2.1 Basic Settings of the Drive for all the Regulation Modes.....................................................103
5.3.2.2. Setting Motor Parameters....................................................................................................105
Figure 5.3.2.1.1: Voltage / frequency characteristics .......................................................................106
5.3.2.3. Verify Speed Feedback Setup and Encoder Polarity (Field Oriented Mode) .......................106
5.3.3.SelfTuning............................................................................................................................108
5.3.3.1 List of Self Tune Error Messages ..........................................................................................111
5.3.3.2 Measurement Error Messages..............................................................................................111
5.3.4ManualTuning .......................................................................................................................112
5.3.4.1 V/F Control Mode..................................................................................................................112
5.3.4.1.1 Magnetizing Current in V/f Control.....................................................................................112
5.3.4.1.2 Tuning of Voltage Compensation Parameters ....................................................................112
5.3.4.2 Sensorless Vect Mode ..........................................................................................................112
5.3.4.2.1 Tuning of Voltage Compensation Parameters ....................................................................112
5.3.4.2.2 Checking and Manual Tuning of Magnetizing Current.......................................................113
5.3.4.2.3 Checking and Fine Tuning of Sensorless Parameters........................................................113
5.3.4.2.4 Manual Tuning of Regulator Loops ....................................................................................113
5.3.4.2.4.1 Manual Tuning of Current Regulator...............................................................................114
Figure 5.3.4.1: Current in phase U. Voltage reaches saturation: Gen amplitude and possibly
Generator offset too high. ............................................................................................................114
Figure 5.3.4.2: Current in phase U. Current P is too small. ..............................................................114
5.3.4.2.4.2. Manual Tuning of Flux Regulator...................................................................................115
Figure 5.3.4.3: Current in phase U.Current P is too high..................................................................115
Figure 5.3.4.5: Current in phase U.Current I is too high. ..................................................................115
Figure 5.3.4.6: Current in phase U . Current P/I are set correctly. ..................................................115
Figure 5.3.4.4: Current in phase U . Current P is set correctly. ........................................................115
Figure 5.3.4.7: Above, F current ref; below, Flux. Too high amplitude and/or test generator
frequency. Decrease both............................................................................................................116
Figure 5.3.4.9: Above; F current ref; below, Flux. Flux P set correctly. ...........................................116
Figure 5.3.4.11: Above, F current ref; below, Flux. Flux P are Flux I are set correctly. ...................116
Figure 5.3.4.8: Above, F current ref; below, Flux. Flux P is too high ...............................................116
Figure 5.3.4.10: Above, F current ref; below,Flux. Flux I is too high................................................116
5.3.4.2.4.3. Manual Tuning the Speed Regulator .............................................................................117
Figure 5.3.4.12: Above, Motor speed; below, Torque current. Speed P is too small. ......................117
Figure 5.3.4.13: Above, Motor speed; below, Torque current. Speed P is too high. .......................117
5.3.4.3 Field Oriented Mode .............................................................................................................118
5.3.4.3.1 Checking and Manual Tuning of Magnetizing Current.......................................................118
5.3.4.3.2 Checking and Manual Tuning of Rotor Resistance............................................................118
Figure 5.3.4.14: Above, Motor speed; below, Torque current. Speed I is too high..........................118
Figure 5.3.4.15: Above, Motor speed; below, Torque current. Speed P and Speed I are set correctly.
118
Figure 5.3.4.12: Above, Motor speed; below, Torque current. The rate for Rotor resistance is
incorrect. Change this until the behavior corresponds to Figure 5.3.4.13...................................119
Figure 5.3.4.13: Above, Motor speed; below, Torque current. Correct setting for Rotor resistance.119
5.3.4.3.3 Manual Tuning of Regulator Loops ....................................................................................120
5.3.4.3.3.1 Manual Tuning of Current Regulator...............................................................................121

8 • Table of Contents GEH-6668A AV300i User’s Guide
5.3.4.3.3.2. Manual Tuning of Flux Regulator...................................................................................121
5.3.4.3.3.3 Manual Tuning the Speed Regulator ..............................................................................122
5.3.5EnhancedRegulatorFeatures.................................................................................................123
5.3.5.1. Setting the Speed Zero Logic ..............................................................................................123
5.3.5.2 Anti Drift Function (Only for Field Oriented Control) .............................................................123
5.3.5.3 Adaptive Speed ...................................................................................................................124
5.3.5.4 Speed-up Function................................................................................................................125
5.3.6Troubleshooting .....................................................................................................................125
Figure 5.3.5.4.1: Above: Actual spd.Below: Motor current jumps with the speedchanges due to a
high moment of inertia.The function Speed-up is not active. ......................................................125
Figure 5.3.5.4.2: Above: Actual spd. Below: Motor current The same drive with Speed-up function
active............................................................................................................................................125
Chapter 6 - Function Description ................................................................................ 127
6.1. Enable Signals..............................................................................................................................128
Figure 6.1.1: Enables via potential free contacts and PLC ...............................................................128
6.1.1. Enable Drive.........................................................................................................................129
6.1.2.Start/Stop.............................................................................................................................129
6.1.3. Fast Stop..............................................................................................................................130
6.1.4. Quick Stop ...........................................................................................................................131
6.1.5.External Fault........................................................................................................................131
6.2. Basic Menu..................................................................................................................................132
6.3. Monitor........................................................................................................................................136
6.4. Drive Parameter...........................................................................................................................140
6.4.1.MotorPlateData ..................................................................................................................140
Figure 6.4.1.1: Motor plate data .......................................................................................................141
6.4.2.MotorParameter ..................................................................................................................145
Figure 6.4.2.1 : Motor parameter ......................................................................................................145
6.4.2.1. Self Tuning ...........................................................................................................................147
6.4.2.2. Sensorless............................................................................................................................150
Figure 6.4.2.2.1: Sensorless..............................................................................................................151
6.4.2.3. V/f Control ............................................................................................................................151
6.4.2.3.1. Voltage Boost....................................................................................................................152
6.4.2.3.2. Slip Compens....................................................................................................................153
6.4.2.3.3. V/f Spd Search.................................................................................................................154
6.4.2.3.4. Energy Save Function......................................................................................................156
6.5. Input Variables.............................................................................................................................157
6.5.1. Ramp Ref .............................................................................................................................157
Figure 6.5.1.1: Ramp references.......................................................................................................158
6.5.2. Speed Ref ............................................................................................................................159
Figure 6.5.2.1: Speed references......................................................................................................159
6.5.3.TorqueCurrent ReferenceValue(TCurrent Ref) ....................................................................160
Figure 6.5.3.1: Torque references .....................................................................................................161
6.6. Limits ..........................................................................................................................................162
6.6.1. Speed Limits ........................................................................................................................162
6.6.2. Current Limits.......................................................................................................................163
Figure 6.6.2.1: Tlim +/- , T lim not gen ............................................................................................164
Figure 6.6.2.3: Current limits in sensorless mode .............................................................................164
6.6.3. Flux Limit..............................................................................................................................166
6.6.4. Voltage Limits ......................................................................................................................166

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GEH-6668A AV300i User’s Guide
6.7. Ramp...........................................................................................................................................167
Figure 6.7.1: Ramp ............................................................................................................................167
6.7.1.Acceleration,Deceleration,QuickStop..................................................................................168
Figure 6.7.1.1: Accel, Decel, and Quick stop ...................................................................................168
6.7.2. Ramp Shape and Control Commands....................................................................................169
Figure 6.7.2.1: Ramp shape ..............................................................................................................170
Figure 6.7.2.2: Ramp delay ...............................................................................................................170
Figure 6.7.2.3: Ramp control.............................................................................................................171
6.8. Speed Regulation.........................................................................................................................172
Figure 6.8.1: Speed regulator............................................................................................................172
6.8.1.SpeedRegulator...................................................................................................................173
6.8.2. Spd Zero Logic.....................................................................................................................174
Figure 6.8.2.1: Speed adaptive and Speed zero logic ......................................................................175
6.8.3.AntiDrift Function.................................................................................................................176
6.8.4. Speed Up.............................................................................................................................177
6.8.5. Droop Function.....................................................................................................................177
Figure 6.8.5.1: Droop compensation.................................................................................................178
6.8.6. Inertia/Loss Comp ................................................................................................................179
Figure 6.8.6.1: Inertia/Loss compensation ........................................................................................179
6.9. Current Regulation .......................................................................................................................181
Figure 6.9.1: Torque current regulator...............................................................................................181
6.10. Flux Regulation ..........................................................................................................................183
Figure 6.10.1: Motor control .............................................................................................................183
6.11. Reg Parameters.........................................................................................................................186
Figure 6.11.1: Reg parameters for sensorless...................................................................................188
6.12 Configuration...............................................................................................................................189
6.12.1.OperatingModeSelection ..................................................................................................189
6.12.2. Speed Base Value, Full Load Current ..................................................................................191
6.12.3.RegulationMode ................................................................................................................191
6.12.4.MagnetizingBoostCurrent,MagnetizingRampTime ...........................................................192
6.12.5. Configuration of the OK Relay (Terminals 80,82) .................................................................192
6.12.6. Encoder Type Selection ......................................................................................................193
Figure 6.12.6.1: Speed Feedback .....................................................................................................194
6.12.7.MainsVoltage,AmbientTemp,ContinuousCurrent,SoftwareVersion .................................197
6.12.8.DimensionFactor,FaceValueFactor...................................................................................198
Figure 6.12.8.1: Calculation using dimension and face value factors ..............................................198
6.12.9. Programmable Alarms........................................................................................................200
Figure 6.12.9.1 : Drive enabling sequence: Main commands = Terminals......................................204
Figure 6.12.9.2 : Drive enabling sequence: Main command = Digital ...........................................205
6.12.10. Address for Bus Operation ...............................................................................................206
6.12.11.Switching Frequency ........................................................................................................206
6.12.12. Password.........................................................................................................................207
6.12.13. Qstp Opt Code .................................................................................................................208
6.12.14. Serial Answer Delay.........................................................................................................208
6.13. I/O Config...................................................................................................................................209
6.13.1. Analog Outputs...................................................................................................................209
Figure 6.13.1.1: Standard Analog output and Option card blocks....................................................210
6.13.2. Analog Inputs.....................................................................................................................212
Figure 6.13.2.1: Analog input ............................................................................................................215

10 • Table of Contents GEH-6668A AV300i User’s Guide
Figure 6.13.2.2: Window comparator ...............................................................................................216
6.13.3. Digital Outputs....................................................................................................................218
Figure 6.13.3.1: Digital Outputs and Option card .............................................................................218
6.13.4. Digital Inputs ......................................................................................................................219
Figure 6.13.4.1: Digital Input and Option card..................................................................................220
6.13.5.Speed ReferencefromEncoder Input(Tach FollowerFunction) ...........................................221
Figure 6.13.5.1: Tach follower ..........................................................................................................221
Figure 6.13.5.1: Example of application of the encoder reference..................................................222
6.14. Additional Speed Functions........................................................................................................224
6.14.1. Auto Capture......................................................................................................................224
6.14.2. Adaptive Spd Reg ..............................................................................................................225
Figure 6.14.2.1: Adaptive speed regulation.......................................................................................226
6.14.3. Speed Control ....................................................................................................................227
Figure 6.14.3.1: “Speed threshold” (up) and “Set speed” (down) messages ..................................228
6.14.4. Speed Zero ........................................................................................................................228
Figure 6.14.4.1: Speed zero ..............................................................................................................229
6.15. Functions ...................................................................................................................................230
6.15.1.MotorPotentiometer...........................................................................................................230
Figure 6.15.1.1: Example of the external activation of the motor potentiometer function................230
6.15.2. Jog Function.......................................................................................................................232
Figure 6.15.2.1: Example of external activation in Jog function.......................................................233
6.15.3. Multi Speed Fct..................................................................................................................234
Figure 6.15.3.1: Selection of different reference values via terminal strip .......................................235
Table 6.15.3.1: Multispeed selection ................................................................................................236
Figure 6.15.3.2: Multi speed function...............................................................................................236
6.15.4. Multi Ramp Fct...................................................................................................................237
Table 6.15.4.1: Ramp selection.........................................................................................................239
Figure 6.15.4.1: Selection of different ramps via the terminal strip ..................................................240
Figure 6.15.4.2: Multi ramp selection via signals .............................................................................240
6.15.5. Stop Control .......................................................................................................................241
Figure 6.15.5.1 Start and stop management.....................................................................................241
6.15.6. Speed Draw Function .........................................................................................................243
Figure 6.15.6.1 Speed draw block diagram ......................................................................................243
Figure 6.15.6.2 Rubber calender example ........................................................................................244
6.15.7.Motor SetupFunction .........................................................................................................245
Figure 6.15.7.1: Dual motor setup.....................................................................................................245
Table 6.15.7.1 : Motor setup parameters list ....................................................................................247
6.15.8. Overload Control ................................................................................................................248
6.15.9.BrakingUnitFunction..........................................................................................................251
Figure 6.15.9.1: Brake unit function..................................................................................................252
6.15.10.PowerlossStopFunction ..................................................................................................253
Figure 6.15.10.1: Power loss stop function. Drive stopped after PL time-out ..................................256
Figure 6.15.10.2: Power loss stop function. AC mains restored and drive stopped before PL time-out
257
Figure 6.15.10.3: Power loss stop function. Operation with RS-300 / CS300 sources ....................258
6.16.Special Functions .......................................................................................................................259
6.16.1. Test Generator....................................................................................................................259
Figure 6.16.1.1: Test generator output..............................................................................................259
6.16.2.TemperatureCompensationoftheRotorResistance............................................................260

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GEH-6668A AV300i User’s Guide
6.16.3SavingParameters.LoadingDefaultFactorySettings,LifeTime............................................261
6.16.4.FailureRegister ..................................................................................................................261
6.16.5.Signal Adaptation(LinksFunction) ......................................................................................262
Figure 6.16.5.1: Structure of the signal adaptation ..........................................................................263
6.16.6. Pads ..................................................................................................................................265
Figure 6.16.6.1: Bus pads .................................................................................................................267
6.16.7. DC Braking.........................................................................................................................268
Figure 6.16.7.1: DC Braking function ................................................................................................268
6.17 Options .......................................................................................................................................270
6.17.1 Option 1 ..............................................................................................................................270
6.17.1.1 Process Data Channel.........................................................................................................271
6.17.2 Option 2 ..............................................................................................................................274
6.17.3. PID Function.......................................................................................................................275
Figure 6.17.3.1: PID function ............................................................................................................276
6.17.3.1. General..............................................................................................................................277
6.17.3.2. Inputs / Outputs.................................................................................................................277
6.17.3.3. Feed - Forward .................................................................................................................278
Figure 6.17.3.1: Feed-forward block description ..............................................................................278
6.17.3.4. PID Function......................................................................................................................280
Figure 6.17.3.2: Feedback block description ....................................................................................280
6.17.3.5. Proportional - Integral Block...............................................................................................282
Figure 6.17.3.3: PI block description ................................................................................................282
6.17.3.6. Proportional - Derivative Control Block.............................................................................286
Figure 6.17.3.4: PD block description...............................................................................................286
6.17.3.7. Output Reference..............................................................................................................288
Figure 6.17.3.5: Output reference block description.........................................................................288
6.17.3.8. Function of Calculation for Initial Diameter ......................................................................290
Figure 6.17.3.6: Diameter calculation block description...................................................................290
Figure 6.17.3.7: Diameter calculation...............................................................................................291
6.17.3.9. Procedure of Calculation for Initial Diameter.....................................................................292
6.17.3.10. Examples of Application.................................................................................................293
Figure 6.17.3.8: Nip-roll control with dancer....................................................................................293
Figure 6.17.3.9: Nip-rolls control with load cell................................................................................296
Figure 6.17.3.10 Winder/Unwinder control with dancer ..................................................................299
Figure 6.17.3.11: Diameter calculation .............................................................................................303
Figure 6.17.3.12 Winder/unwinder control with diameter sensor.....................................................304
Figure 6.17.3.13: Relation between transducer signal and winder/unwinder diameter...................305
Figure 6.17.3.14: Pressure control for pumps and extruder..............................................................306
6.17.3.11. Generic PID ......................................................................................................................309
6.17.3.12. Application Note ..............................................................................................................313
Figure 6.17.3.15 Example with small and large diameter .................................................................313
Figure 6.17.3.16: Relation between PI I gain PID and PI I output PID............................................314
6.18. Drivecom ...................................................................................................................................315
6.18.1. Control Word, Status Word, Malfunction Code...................................................................315
6.18.2. Speed ................................................................................................................................316
6.18.3. Speed Limitation.................................................................................................................317
6.18.4.Acceleration/Deceleration .................................................................................................318
Figure 6.18.4.1: Accel and Decel......................................................................................................318
6.18.5.FactorFunction...................................................................................................................319
6.19. Service.......................................................................................................................................320

12 • Table of Contents GEH-6668A AV300i User’s Guide
Chapter 7 - Maintenance............................................................................................. 321
7.1. Care.............................................................................................................................................321
7.2. Service.........................................................................................................................................321
7.3. Repairs ........................................................................................................................................321
7.4. Customer Service ........................................................................................................................321
Chapter 8 - Troubleshooting ........................................................................................ 323
Failure alarms in the keypad display.................................................................................................323
Other faults ........................................................................................................................................326
Chapter 9 - Block Diagram .......................................................................................... 329
AV-300i Inverter Overview ................................................................................................................329
Digital Inputs/Outputs & Mapping Standard and Option Cards .........................................................330
Analog Inputs/Outputs & Mapping ....................................................................................................331
Speed Reference Generation ............................................................................................................332
Speed / Torque Regulation ................................................................................................................333
Ramp Reference Block......................................................................................................................334
Speed Regulator ................................................................................................................................335
Speed Regulator PI part.....................................................................................................................336
Droop Compensation .........................................................................................................................337
Inertia / Loss Compensation ..............................................................................................................338
Torque Current Regulator...................................................................................................................339
Speed Feedback................................................................................................................................340
Motor Control.....................................................................................................................................341
Motor Parameters..............................................................................................................................342
Sensorless Parameters ......................................................................................................................343
V/Hz Functions...................................................................................................................................344
Speed Threshold / Speed Control......................................................................................................345
Speed Adaptive and Speed Zero Logic.............................................................................................346
PID Function ......................................................................................................................................347
Start and Stop Management.............................................................................................................348
Power Loss Stop Control ...................................................................................................................349
Jog Function......................................................................................................................................350
Motor Potentiometer..........................................................................................................................351
Multi Speed .......................................................................................................................................352
Dual Motor Setup ..............................................................................................................................353
Brake Unit Function ...........................................................................................................................354
DC Braking Function ..........................................................................................................................355
Dimension Factor / Face Value Factor ...............................................................................................356
PAD Parameters.................................................................................................................................357
Links Function....................................................................................................................................358
Test Generator ...................................................................................................................................359
Alarm Mapping..................................................................................................................................360
Chapter 10 - Parameters Lists .................................................................................... 361
10.1. List of all Parameters .................................................................................................................361
10.2. List of all Parameters in Numeric Order .....................................................................................388
10.3. Parameters in Alphabetical Order ..............................................................................................412
10.4. List of High Priority Parameters .................................................................................................424
10.5. Load Motor Parameter...............................................................................................................426
AV300i Index................................................................................................................ 427

Chapter 0 Safety Precautions • 13
GEH-6668 AV300i User’s Guide
Chapter 0 - Safety Precautions / Precautions de Securité
NOTE!The terms “Inverter”, “Controller” and “Drive” are sometimes used interchangably through-
out the industry. We will use the term “Drive” in this document
Les mots “Inverter”, “Controller” et “Drive” sont interchangeables dans le domaine
industriel. Nous utiliserons dans ce manuel seulement le mot “Drive”.
WARNING!/ATTENTION!
- According to the EEC standards the AV300i and accessories must be used only after checking that the
machine has been produced using those safety devices required by the 89/392/EEC set of rules.
Drive systems cause mechanical motion. It is the responsibility of the user to insure that any such motion
does not result in an unsafe condition. Factory provided interlocks and operating limits should not be
bypassed or modified.
- Never open the device or covers while the AC Input power supply is switched on. Minimum time to wait
before working on the terminals or internal devices is listed in section 5.11 of this instruction book.
- If the front plate has to be removed because the ambient temperature is higher than 40 degrees, the user has
to ensure that no occasional contact with live parts will occur.
- Always connect the Drive to the protective ground (PE) via the marked connection terminals (PE2) and the
housing (PE1). Adjustable Frequency Drives and AC Input filters have ground discharge currents greater
than 3.5 mA. EN 50178 specifies that with discharge currents greater than 3.5 mA the protective conductor
ground connection (PE1) must be fixed type and doubled for redundancy.
- The drive may cause accidental motion in the event of a failure, even if it is disabled, unless it has been
disconnected from the AC input feeder.
- Selon les normes EEC, les drives AV300i et leurs accessoires doivent être employés seulement après avoir
verifié que la machine ait été produit avec les même dispositifs de sécurité demandés par la réglementation
89/392/EEC concernant le secteur de l’industrie.
Lessystèmes provoquent des mouvements mécaniques. L’utilisateurestresponsabledelasécurité concernant
les mouvements mécaniques. Les dispositifs de sécurité prévues par l’usine et les limitations operationelles
ne doivent être dépassés ou modifiés.
- Ne jamais ouvrir l’appareil lorsqu’il est suns tension. Le temps minimum d’attente avant de pouvoir travailler
sur les bornes ou bien à l’intérieur de l’appareil est indiqué dans la section 5.11 (this instruction book).
- Si la plaque frontale doit être enlevée pour un fonctionnement avec la température de l’environnement plus
haute que 40°C, l’utilisateur doit s’assurer, par des moyens opportuns, qu’aucun contact occasionnel ne
puisse arriver avec les parties sous tension.
- L’appaeil peut rédémarrer de façon accidentel en cas d’anomalie, sauf s’il a été déconnecté du reseau.
- Effectuer toujours des connexions de terre (PE) par le biais des bornes (PE2) et du chassis (PE1). Le
courant de dispersion vers la terre est supérieur à 3,5 mA. Selon EN 50178 il faut prévoir dans ces cas une
double connexion à terre.
WARNING! - ELECTRICAL SHOCK AND BURN HAZARD /
ATTENTION! – DÉCHARGE ÉLECTRIQUE ET RISQUE DE BRÚLURE :
When using instruments such as oscilloscopes to work on live equipment, the oscilloscope’s chassis should be
grounded and a differential amplifier input should be used. Care should be used in the selection of probes and
leads and in the adjustment of the oscilloscope so that accurate readings may be made. See instrument
manufacturer’s instruction book for proper operation and adjustments to the instrument.

14 • Chapter 0 Safety Precautions GEH-6668 AV300i User’s Guide
Lors de l’utilisation d’instruments (par example oscilloscope) sur des systémes en marche, le chassis de
l’oscilloscope doit être relié à la terre et un amplificateur différentiel devrait être utilisé en entrée.
Les sondes et conducteurs doivent être choissis avec soin pour effectuer les meilleures mesures à l’aide
d’un oscilloscope. Voir le manuel d’instruction pour une utilisation correcte des instruments.
WARNING! - FIRE AND EXPLOSION HAZARD / ATTENTION! – RISQUE D’INCENDIES ET D’EXPLOSIONS:
Fires or explosions might result from mounting Drives in hazardous areas such as locations where flammable or
combustible vapors or dusts are present. Drives should be installed away from hazardous areas, even if used
with motors suitable for use in these locations.
L’utilisation des drives dans des zônes à risques (présence de vapeurs ou de poussières inflammables), peut
provoquer des incendies ou des explosions. Les drives doivent être installés loin des zônes dangeureuses, et
équipés de moteurs appropriés.
WARNING! - STRAIN HAZARD / ATTENTION À L’ÉLÉVATION:
Improperliftingpracticescancauseseriousorfatalinjury.Liftonlywithadequateequipmentandtrainedpersonnel.
Une élévation inappropriée peut causer des dommages sérieux ou fatals. Il doit être élevé seulement avec des
moyens appropriés et par du personnel qualifié.
WARNING! - POWER SUPPLY AND GROUNDING / ATTENTION ! ALIMENTATION PUISSANCE ET MISE À LA TERRE
In case of a three phase supply not symmetrical to ground, an insulation loss of one of the devices connected to
the same network can cause functional problem to the drive, if the use of a delta /star transformer is avoided.
1 The drives are designed to be powered from standard three phase lines that are electrically symmetrical with
respect to ground (TN or TT network).
2 In case of supply with IT network, the use of wye/delta transformer is mandatory, with a secondary three
phase wiring referred to ground.
Please refer to the following connection sample.
Si le réseau n'est pas équilibré par rapport à la terre et qu'il n'y a pas de transformateur raingle/étoile,
une mauvaise isolation d'un appareil électrique connecté au même réseau que le variateur peut lui causer
des troubles de fonctionnement.
1 Les variateurs sont prévus pour être alimentés par un réseau triphasé équilibré avec un régime de
neutre standard (TN ou TT).
2 Si le régime de neutre est IT, nous vous recommendons d'utiliser un tranformateur triangle/étoile avec
point milieu ramené à la terre
Vous pouvez trouver ci-après des exemples de câblage.
Safety
ground
L1
L2
L3
Earth
U1/L1
V1/L2
W1/L3
U2/T1
V2/T2
W2/T3
PE2/
All wires (including motor ground) must
be connected inside the motor terminal box
AC OUTPUT
CHOKE
AC Main Supply
AC INPUT
CHOKE
PE1/

Chapter 0 Safety Precautions • 15
GEH-6668 AV300i User’s Guide
WARNING! - ELECTRIC SHOCK HAZARD / ATTENTION! - CAS DE DECHARGE ELECTRIQUE:
- Drives and motors must be grounded according to NEC and local codes.
- Replace all covers before applying power to the Drive. Failure to do so may result in death or serious injury.
- Adjustable frequency drives are electrical apparatus for use in industrial installations. Parts of the Drives are
at high voltage during operation. The electrical installation and the opening of the device should therefore
only be carried out by qualified personnel. Improper installation of motors or Drives may therefore cause
the failure of the device as well as serious injury to persons or material damage. Follow the instructions
given in this manual and observe the local and national safety regulations applicable.
- Tous les moteurs et les drives doivent être mis à la terre selon le Code Electrique National ou équivalent.
- Remettre tous les capots avant de mettre sous tension le drive. Des erreurs peuvent provoquer de sérieux
accidents ou même la mort.
- Les drives à fréquence variable sont des dispositifs électriques utilisés dans des installations industriels.
Une partie des drives sont sous tension pendant l’operation. L’installation électrique et l’ouverture des
drives devrait être executé uniquement par du personel qualifié. De mauvaises installations de moteurs ou
de drives peuvent provoquer des dommages materiels ou blesser des personnes.On doit suivir les instruc-
tions donneés dans ce manuel et observer les régles nationales de sécurité.
CAUTION! / PRECAUTION!:
- Do not connect power supply voltage that exceeds the standard specification voltage fluctuation permissi-
ble. If excessive voltage is applied to the Drive, damage to the internal components will result.
- Do not operate the Drive without the ground wire connected. The motor chassis should be grounded to earth
through a ground lead separate from all other equipment ground leads to prevent noise coupling.
- The grounding connector shall be sized in accordance with the NEC or Canadian Electrical Code. The
connection shall be made by a UL listed or CSA certified closed-loop terminal connector sized for the wire
gauge involved. The connector is to be fixed using the crimp tool specified by the connector manufacturer.
- Do not perform a megger test between the Drive terminals or on the control circuit terminals.
- Because the ambient temperature greatly affects Drive life and reliability, do not install the Drive in any
location that exceeds the allowable temperature. Leave the ventilation cover attached for temperatures of
104° F (40° C) or below.
- If the Drive’s Fault Alarm is activated, consult the TROUBLESHOOTING section of this instruction book, and
after correcting the problem, resume operation. Do not reset the alarm automatically by external sequence, etc.
- Be sure to remove the desicant dryer packet(s) when unpacking the Drive. (If not removed these packets
may become lodged in the fan or air passages and cause the Drive to overheat).
- The Drive must be mounted on a wall that is constructed of heat resistant material. While the Drive is
operating, the temperature of the Drive's cooling fins can rise to a temperature of 194° F (90°C).
- Do not touch or damage any components when handling the device. Changing of isolation gaps or removing
the isolation covers is not permissible.
- Protect the device from disallowed environmental conditions (temperature, humidity, shock etc.)
- No voltage should be connected to the output of the frequency inverter (terminals U2, V2 W2). The parallel
connection of several frequency inverters via the outputs and the direct connection of the inputs and outputs
(bypass) are not permissible.
- A capacitative load (e.g. Var compensation capacitors) should not be connected to the output of the fre-
quency inverter (terminals U2, V2, W2).
- The electrical commissioning should only be carried out by qualified personnel, who are also responsible
for the provision of a suitable ground connection and a protected power supply feeder in accordance with
the local and national regulations. The motor must be protected against overloads.
- No dielectric tests should be carried out on parts of the frequency inverter. A suitable measuring instrument
(internal resistance of at least 10 kΩ/V) should be used for measuring the signal voltages.

16 • Chapter 0 Safety Precautions GEH-6668 AV300i User’s Guide
- Ne pas raccorder de tension d’alimentation dépassant la fluctuation de tension permise par les normes.
Dans le cas d’ une alimentation en tension excessive, des composants internes peuvent être endommagés.
- Ne pas faire fonctionner le drive sans prise de terre. Le chassis du moteur doit être mis à la terre à
l’aide d’un connecteur de terre separé des autres pour éviter le couplage des perturbations. Le
connecteur de terre devrait être dimensionné selon la norme NEC ou le Canadian Electrical code. Le
raccordement devrait être fait par un connecteur certifié et mentionné à boucle fermé par les normes
CSA et UL et dimensionné pour l’épaisseur du cable correspondant. Le connecteur doit être fixé a
l’aide d’un instrument de serrage specifié par le producteur du connecteur.
- Ne pas exécuter un test megger entre les bornes du drive ou entre les bornes du circuit de contrôle.
- Étant donné que la température ambiante influe sur la vie et la fiabilité du drive, on ne devrait pas
installer le drive dans des places ou la temperature permise est dépassée. Laisser le capot de ventila-
tion en place pour températures de 104°F (40°C) ou inférieures.
-Si la Fault Alarm du drive est activée, consulter la section du manuel concernant les défauts et après
avoir corrigé l’erreur, reprendre l’opération. Ne pas réiniliatiser l’alarme automatiquement par une
séquence externe, etc….
-Lors du déballage du drive, retirer le sachet déshydraté. (Si celui-ci n’est pas retiré, il empêche la
ventilation et provoque une surchauffe du drive).
-Le drive doit être monté sur un mur construit avec des matériaux résistants à la chaleur. Pendant le
fonctionnement du drive, la température des ailettes du dissipateur thermique peut arriver à 194°F (90°).
- Manipuler l’appareil de façon à ne pas toucher ou endommager des parties. Il n’est pas permis de
changer les distances d’isolement ou bien d’enlever des matériaux isolants ou des capots.
-Protéger l’appareil contre des effets extérieurs non permis (température, humidité, chocs etc.).
- Aucune tension ne doit être appliquée sur la sortie du convertisseur (bornes U2, V2 et W2). Il n’est
pas permis de raccorder la sortie de plusieurs convertisseurs en parallèle, ni d’effectuer une connexion
directe de l’entrée avec la sortie du convertisseur (Bypass).
- Aucune charge capacitive ne doit être connectée à la sortie du convertisseur (bornes U2, V2 et W2)
(par exemple des condensateurs de mise en phase).
- La mise en service électrique doit être effectuée par un personnel qualifié. Ce dernier est responsable
de l’existence d’une connexion de terre adéquate et d’une protection des câbles d’alimentation selon
les prescriptions locales et nationales. Le moteur doit être protégé contre la surcharge
- Il ne faut pas éxécuter de tests de rigidité diélectrique sur des parties du convertisseurs. Pour mesurer
les tensions, des signaux, il faut utiliser des instruments de mesure appropriés (résistance interne
minimale 10 k
Ω /V).
NOTE!IftheDriveshavebeenstoredforlonger than two years, the operation of the DC link capacitors
may be impaired. Before commissioning devices that have been stored for long periods,
connect them to a power supply for two hours with no load connected in order to regenerate
the capacitors, (the input voltage has to be applied without enabling the inverter).
En cas de stockage des convertisseurs pendant plus de deux ans, il faut tenir compte
du fait que les condensateurs du circuit intermédiaire gardent leurs caractéristiques
d’origine seulement s’ils sont alimentés avant trois ans, à partir de leur date de fabri-
cation. Avant la mise en service des appareils, qui sont restés stockés aussi longtemps,
il est conseillé d’alimenter les convertisseurs pendant au moins deux heures, pour
récupérer les caractéristiques d’origine des condensateurs: appliquer une tension
d’entrée sans activer le convertisseur (Disable).

Chapter1 - Function and Features • 17
GEH-6668 AV300i User’s Guide
Chapter 1 - Function and Features (Overview)
The AV-300i is a field-oriented vector Drive with excellent speed control properties and a high torque.
Available control modes are:
- Field oriented with speed sensor
- Field oriented without speed sensor (Sensorless vect mode)
- V/f control
Space vector modulation keeps the noise level to a minimum.
- Output voltage up to 98% of input voltage
- Self tuning procedure for current, flux and speed regulators
The Drives are fitted with IGBTs (insulated gate bipolar transistors).
The output is protected against ground fault and phase to phase output short.
Regulator power supply via switched-mode power supply unit from the DC Bus circuit. Power supply backup in
the event of short-term voltage dips.
Galvanic isolation between control section and command terminals.
Analog inputs designed as differential inputs.
Simple operation of the drive
- via the terminal strip
- via the user-friendly keypad
- via the PC program supplied and the RS485 serial interface
- via a fieldbus connection (optional): PROFIBUS-DP or GENIUS.
- Toolboxconfigurationtool
Fault register storing the last ten fault alarms with the associated lifetime.
Overload control
Engaging a running motor
Three freely configurable analog inputs on the standard device
Expansion of the analog / digital outputs and analog / digital inputs via option cards
Reference value entry and actual value display as a percentage of a user-defined dimension
Speed and torque current regulation possible
Adaptive speed regulation
Speed-related alarms
Motor potentiometer function (Increase/Decrease speed by command)
Jog operation
8 internal speed reference values
4 internal ramps
PID control
Controlled stop in case of AC mains power loss.

18 • Chapter1 - Function and Features GEH-6668 AV300i User’s Guide
Notes:

Chapter 2 - Inspection Procedure, ..., Standard Specification • 19
GEH-6668A AV300i User’s Guide
Chapter 2 - Inspection Procedure, Component Identification and
Standard Specification
2.1. Upon Delivery Inspection Procedures
2.1.1. General
A high degree of care is taken in packing the AV-300i Drives and preparing them for delivery. They should only
be transported with suitable transport equipment (see weight data). Observe the instructions printed on the
packaging. This also applies when the device is unpacked and installed in the control cabinet.
Upon delivery, check the following:
- the packaging for any external damage
- whether the delivery note matches your order.
Open the packaging with suitable tools. Check whether:
- any parts were damaged during transport
- the device type corresponds to your order
In the event of any damage or of an incomplete or incorrect delivery please notify the responsible sales offfices
immediately.
The devices should only be stored in dry rooms within the specified temperature ranges .
NOTE!A certain degree of moisture condensation is permissible if this arises from changes in
temperature (see section 2.4.1, “Permissible Environmental Conditions”). This does not,
however, apply when the devices are in operation. Always ensure that there is no moisture
condensation in devices that are connected to the power supply!
2.1.2. Inverter Type Designation
The technical specification of the AV-300i Drive is stated in the type code. Example:
Figure 2.1.2.1: Inverter type designation
6K AVI 5 3 002 N 1 A 1
GE Industrial Control Product
AV-300i product
Input voltage (5=575 VAC)
Phases for input voltage (3= 3 phase)
Drive rating in Horsepower with 150% overload for 60s (1)
Drive Options (2)
Enclosure type (1=IP20)
Major revision level
Minor revision level

GE Industrial Systems
+ 1 540 387 7000
www.GEindustrial.com
General Electric Company
1501 Roanoke Blvd.
Salem, VA 24153-6492 USA
GEH-6668A
040211
SIEI
February 2004, for 575 VAC AV-300i Ver. 1.XX
1S9G72