GE AF-650 GP Series User manual

AF-650 GPTM
General Purpose Drive
Quick Guide
Guia rapida
Kurzanleitung
Guide rapide
Guida rapida
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 suciently for the purchaser’s purposes, the
matter should be referred to the GE company.
AF-650 GP is a trademark of the General Electric Company.
GE
41 Woodford Avenue
Plainville, CT 06062
www.geelectrical.com/drives
130R0287 *MG34V16S* DET-758/S/D/F/I
GE

1Safety
1.1.1 Safety
WARNING
HIGH VOLTAGE!
Adjustable frequency drives contain high voltage when
connected to AC line power. Installation, start-up, and
maintenance should be performed by qualified personnel
only. Failure to perform installation, start-up, and
maintenance by qualified personnel could result in death
or serious injury.
High Voltage
Adjustable frequency drives are connected to hazardous
AC line voltage. Extreme care should be taken to protect
against shock. Only trained personnel familiar with
electronic equipment should install, start, or maintain this
equipment.
WARNING
UNINTENDED START!
When the adjustable frequency drive is connected to AC
line power, the motor may start at any time. The
adjustable frequency drive, motor, and any driven
equipment must be in operational readiness. Failure to be
in operational readiness when the adjustable frequency
drive is connected to AC line power could result in death,
serious injury, equipment, or property damage.
Unintended Start
When the adjustable frequency drive is connected to the
AC line power, the motor may be started by means of an
external switch, a serial bus command, an input reference
signal, or a cleared fault condition. Use appropriate
precautions to guard against an unintended start.
WARNING
DISCHARGE TIME!
Adjustable frequency drives contain DC link capacitors that
can remain charged even when AC line power is discon-
nected. To avoid electrical hazards, remove AC line power
from the adjustable frequency drive before doing any
service or repair and wait the amount of time specified in
Table 1.1. Failure to wait the specified time after power has
been removed prior to doing service or repair on the unit
could result in death or serious injury.
Voltage Power Size Minimum Waiting
Time
200–240V 0.25–3.7kW 0.33–5HP 4 minutes
5.5–37kW 7.5–50HP 15 minutes
380–480V
0.37–7.5kW 0.5–10HP 4 minutes
11–75kW 15–100HP 15 minutes
90–200kW 125–300HP 20 minutes
250–800kW 350–1200HP 40 minutes
525–600V 0.37–7.5kW 0.5–10HP 4 minutes
11–75kW 15–100HP 15 minutes
525–690V
11–75kW 15–100HP 15 minutes
90–315kW 125–400HP 20 minutes
355–1200kW 500–1350HP 30 minutes
Table 1.1 Discharge Time
Symbols
The following symbols are used in this manual.
WARNING
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may
also be used to alert against unsafe practices.
CAUTION
Indicates a situation that may result in equipment or
property damage-only accidents.
NOTE
Indicates highlighted information that should be observed
in order to avoid mistakes or operate equipment at less
than optimal performance.
Approvals
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2Introduction
Illustration 2.1 Exploded View Unit Sizes 12-13, IP20
NOTE
Please consult the AF-650 GP Instruction Manual for other unit sizes.
1 Keypad 10 Motor output terminals 96 (U), 97 (V), 98 (W)
2 RS-485 serial bus connector (+68, -69) 11 Relay 1 (01, 02, 03)
3 Analog I/O connector 12 Relay 2 (04, 05, 06)
4 Keypad input plug 13 Brake (-81, +82) and load sharing (-88, +89) terminals
5 Analog switches (A53), (A54) 14 Line power input terminals 91 (L1), 92 (L2), 93 (L3)
6 Cable strain relief / PE ground 15 USB connector
7 Decoupling plate 16 Serial bus terminal switch
8 Grounding clamp (PE) 17 Digital I/O and 24 V power supply
9 Shielded cable grounding clamp and strain relief 18 Control cable coverplate
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3 Installation
3.1 Installation Site Checklist
•
The drive relies on the ambient air for cooling.
Observe the limits on ambient air temperature for
optimal operation
•
Ensure that the installation location has sufficient
support strength to mount the drive
•
Keep the drive interior free from dust and dirt.
Ensure that the components stay as clean as
possible. In construction areas, provide a
protective covering. Optional IP54 (NEMA 12)
enclosures may be necessary.
•
Keep the manual, drawings, and diagrams
accessible for detailed installation and operation
instructions. It is important that the manual is
available for equipment operators.
•
Locate equipment as near to the motor as
possible. Keep motor cables as short as possible.
Check the motor characteristics for actual
tolerances. Do not exceed
•
1000 ft [300 m] for unshielded motor
leads
•
500 ft [150 m] for shielded cable.
3.2 Adjustable Frequency Drive and Motor
Pre-installation Checklist
•
Compare the model number of unit on the
nameplate to what was ordered to verify the
proper equipment
•
Ensure each of the following are rated for the
same voltage:
Line power
Drive
Motor
•
Ensure that drive output current rating is equal to
or greater than motor full load current for peak
motor performance.
Motor size and drive power must match
for proper overload protection.
If drive rating is less than motor, full
motor output cannot be achieved.
3.3 Mechanical Installation
3.3.1 Cooling
•
To provide cooling airflow, mount the unit to a
solid flat surface or to the optional backplate (see
3.3.3 Mounting)
•
Top and bottom clearance for air cooling must be
provided. Generally, 4–10 in [100–225 mm] is
required. See Illustration 3.1 for clearance
requirements
•
Improper mounting can result in overheating and
reduced performance.
•
Derating for temperatures starting between 104°F
[40°C]) and 122°F [50°C] and elevation 3,300 ft
[1,000 m] above sea level must be considered.
See the equipment Design Guide for detailed
information.
Illustration 3.1 Top and Bottom Cooling Clearance
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Voltage Power Size Clearance a/b
200–240V
0.25–3.7kW 0.33–5HP 100mm / 4in
5.5–22kW 7.5–30HP 200mm / 8in
> 22kW / 30HP 225mm / 10in
380–480V
0.37–7.5kW 0.5–10HP 100mm / 4in
11–45kW 15–60HP 200mm / 8in
> 45kW / 60HP 225mm / 10in
525–600V
0.37–7.5kW 0.5–10HP 100mm / 4in
11–45kW 15–60HP 200mm / 8in
> 45kW / 60HP 225mm / 10in
525–690V all 225mm / 10in
Table 3.1 Minimum Airflow Clearance Requirements
3.3.2 Lifting
•
Check the weight of the unit to determine a safe
lifting method
•
Ensure that the lifting device is suitable for the
task
•
If necessary, plan for a hoist, crane, or forklift with
the appropriate rating to move the unit
•
For lifting, use hoist rings on the unit, when
provided
3.3.3 Mounting
•
Mount the unit vertically
•
The drive allows side by side installation.
•
Ensure that the strength of the mounting location
will support the unit weight
•
Mount the unit to a solid flat surface or to the
optional backplate to provide cooling airflow (see
Illustration 3.2 and Illustration 3.3).
•
Improper mounting can result in overheating and
reduced performance.
•
Use the slotted mounting holes on the unit for
wall mounting, when provided.
Illustration 3.2 Proper Mounting with Backplate
Item A is a backplate properly installed for required airflow
to cool the unit.
Illustration 3.3 Proper Mounting with Railings
NOTE
Backplate is needed when mounted on railings.
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3.4 Electrical Installation
This section contains detailed instructions for wiring the drive. The following tasks are described.
•
Wiring the motor to the drive output terminals
•
Wiring the AC line power to the drive input terminals
•
Connecting control and serial communication wiring
•
After power has been applied, checking input and motor power; programming control terminals for their intended
functions
Illustration 3.4 Basic Wiring Schematic Drawing.
A=Analog, D=Digital
Terminal 37 is used for Safe Stop. For Safe Stop installation instructions, refer to the Design Guide.
*The brake chopper factory option must be ordered to use dynamic braking resistors.
**This is available when ordering the brake chopper option on unit size 23 and above drives.
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3.4.1 Requirements
WARNING
EQUIPMENT HAZARD!
Rotating shafts and electrical equipment can be hazardous.
All electrical work must conform to national and local
electrical codes. It is strongly recommended that instal-
lation, start-up, and maintenance be performed only by
trained and qualified personnel. Failure to follow these
guidelines could result in death or serious injury.
CAUTION
WIRING ISOLATION!
Run input power, motor wiring and control wiring in three
separate metallic conduits or use separated shielded cable
for high frequency noise isolation. Failure to isolate power,
motor and control wiring could result in less than
optimum adjustable frequency drive and associated
equipment performance.
For your safety, comply with the following requirements.
•
Electronic controls equipment is connected to
hazardous AC line voltage. Extreme care should
be taken to protect against electrical hazards
when applying power to the unit.
•
Run motor cables from multiple adjustable
frequency drives separately. Induced voltage from
output motor cables run together can charge
equipment capacitors even with the equipment
turned off and locked out.
Overload and Equipment Protection
•
An electronically activated function within the
adjustable frequency drive provides overload
protection for the motor. The overload calculates
the level of increase to activate timing for the trip
(controller output stop) function. The higher the
current draw, the quicker the trip response. The
overload provides Class 20 motor protection. See
7 Warnings and Alarm for details on the trip
function.
•
Because the motor wiring carries high frequency
current, it is important that wiring for line power,
motor power, and control is run separately. Use
metallic conduit or separated shielded wire.
Failure to isolate power, motor, and control
wiring could result in less than optimum
equipment performance.
•
All adjustable frequency drives must be provided
with short-circuit and overcurrent protection.
Input fusing is required to provide this
protection, see Illustration 3.5. Fuses must be
provided by the installer as part of installation.
See maximum fuse ratings in 9.1.2 CE Compliance.
Illustration 3.5 Fuses
Wire Type and Ratings
•
All wiring must comply with local and national
regulations regarding cross-section and ambient
temperature requirements.
•
GE recommends that all power connections be
made with a minimum 167°F [75°C] rated copper
wire.
3.4.2 Grounding Requirements
WARNING
GROUNDING HAZARD!
For operator safety, it is important to ground drive
properly in accordance with national and local electrical
codes as well as instructions contained within these
instructions. Ground currents are higher than 3.5 mA.
Failure to ground drive properly could result in death or
serious injury.
NOTE
It is the responsibility of the user or certified electrical
installer to ensure correct grounding of the equipment in
accordance with national and local electrical codes and
standards.
•
Follow all local and national electrical codes to
ground electrical equipment properly.
•
Proper protective grounding for equipment with
ground currents higher than 3.5 mA must be
established, see Leakage Current (>3.5 mA)
•
A dedicatedground wire is required for input
power, motor power and control wiring
•
Use the clamps provided with on the equipment
for proper ground connections
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•
Do not ground one drive to another in a “daisy
chain” fashion
•
Keep the ground wire connections as short as
possible
•
Use of high-strand wire to reduce electrical noise
is recommended
•
Follow the motor manufacturer wiring
requirements
3.4.2.1 Leakage Current (>3.5 mA)
Follow national and local codes regarding protective
grounding of equipment with a leakage current > 3.5 mA.
Drive technology implies high frequency switching at high
power. This will generate a leakage current in the ground
connection. A fault current in the drive at the output
power terminals might contain a DC component which can
charge the filter capacitors and cause a transient ground
current. The ground leakage current depends on various
system configurations including RFI filtering, shielded
motor cables, and drive power.
EN/IEC61800-5-1 (Power Drive System Product Standard)
requires special care if the leakage current exceeds 3.5m A.
Grounding must be reinforced in one of the following
ways:
•
Ground wire of at least 0.0155 in
2
[10mm
2
]
•
Two separate ground wires both complying with
the dimensioning rules
See EN 60364-5-54 § 543.7 for further information.
Using RCDs
Where residual current devices (RCDs), also known as
ground leakage circuit breakers (ELCBs), are used, comply
with the following:
Use RCDs of type B only which are capable of
detecting AC and DC currents
Use RCDs with an inrush delay to prevent faults
due to transient ground currents
Dimension RCDs according to the system configu-
ration and environmental considerations
3.4.2.2 Grounding Using Shielded Cable
Grounding clamps are provided for motor wiring (see
Illustration 3.6).
Illustration 3.6 Grounding with Shielded Cable
3.4.3 Motor Connection
WARNING
INDUCED VOLTAGE!
Run output motor cables from multiple adjustable
frequency drives separately. Induced voltage from output
motor cables run together can charge equipment
capacitors even with the equipment turned off and locked
out. Failure to run output motor cables separately could
result in death or serious injury.
•
For maximum wire sizes, see Table 10.1
•
Comply with local and national electrical codes
for cable sizes.
•
Motor wiring knockouts or access panels are
provided at the base of IP21 and higher (Nema 1,
12, and 4/4X Indoor) units
•
Do not install power factor correction capacitors
between the adjustable frequency drive and the
motor
•
Do not wire a starting or pole-changing device
between the adjustable frequency drive and the
motor.
•
Connect the 3-phase motor wiring to terminals
96 (U), 97 (V), and 98 (W).
•
Ground the cable in accordance with grounding
instructions provided.
•
Torque terminals in accordance with the
information provided in
•
Follow the motor manufacturer wiring
requirements
Illustration 3.7 represents line power input, motor, and
ground grounding for basic adjustable frequency drives.
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Actual configurations vary with unit types and optional
equipment.
Illustration 3.7 Example of Motor, Line Power and Ground Wiring
3.4.4 AC Line Power Connection
•
Size wiring based upon the input current of the
drive. For maximum wire sizes, see Table 10.1.
•
Comply with local and national electrical codes
for cable sizes.
•
Connect 3-phase AC input power wiring to
terminals L1, L2, and L3 (see Illustration 3.7).
•
Depending on the configuration of the
equipment, input power will be connected to the
line power input terminals or the input
disconnect.
•
Ground the cable in accordance with grounding
instructions provided in 3.4.2 Grounding
Requirements
•
All adjustable frequency drives may be used with
an isolated input source as well as with ground
reference power lines. When supplied from an
isolated line power source (IT line or floating
delta) or TT/TN-S power line with a grounded leg
(grounded delta), set 14-50 RFI Filter to OFF.
When off, the internal RFI filter capacitors
between the chassis and the intermediate circuit
are isolated to avoid damage to the intermediate
circuit and to reduce ground capacity currents in
accordance with IEC 61800-3.
3.4.5 Control Wiring
•
Isolate control wiring from high power
components in the adjustable frequency drive.
•
If the adjustable frequency drive is connected to
a thermistor, for PELV isolation, optional
thermistor control wiring must be reinforced/
double insulated. A 24 VDC supply voltage is
recommended.
3.4.5.1 Access
•
Remove access coverplate with a screwdriver. See
Illustration 3.8.
•
Or remove front cover by loosening attaching
screws. See Illustration 3.9.
Tightening torque for front cover is 2.0Nm for
unit size 15 and 2.2Nm for unit sizes 2X and 3X.
Illustration 3.8 Control Wiring Access for IP20 / Open Chassis
Enclosures
Illustration 3.9 Control Wiring Access for IP55 / Nema 12 and
IP66 / Nema 4/4X Indoor
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3.4.5.2 Control Terminal Types
Illustration 3.10 and shows the removable adjustable
frequency drive connectors. Terminal functions and default
settings are summarized in Table 3.2.
Illustration 3.10 Control Terminal Locations
Illustration 3.11 Terminal Numbers
•
Connector 1 provides four programmable digital
input terminals, two additional digital terminals
programmable as either input or output, a 24V
DC terminal supply voltage, and a common DC
voltage for optional customer-supplied 24 V. A
digital input for STO (Safe Torque Off) function.
•
Connector 2 terminals (+)68 and (-)69 are for an
RS-485 serial communications connection
•
Connector 3 provides two analog inputs, one
analog output, 10V DC supply voltage, and
commons for the inputs and output
•
Connector 4 is a USB port available for use with
the DCT-10
•
Also provided are two Form C relay outputs that
are in various locations depending upon the
adjustable frequency drive configuration and size.
•
Some options available for ordering with the unit
may provide additional terminals. See the manual
provided with the equipment option.
See 8.1 General Technical Data for terminal ratings details.
Terminal description
Terminal Parameter
Default
setting Description
Digital inputs/outputs
12, 13 - +24V DC 24 V DC supply
voltage. Maximum
output current is
200mA total for all
24V loads. Usable for
digital inputs and
external transducers.
18 E-01 [8] Start
Digital inputs.
19 E-02 [10] Reversing
32 E-05 [0] No
operation
33 E-06 [0] No
operation
27 E-03 [0] No
operation
Selectable for either
digital input or
output. Default setting
is input.
29 E-04 [14] JOG
20 - Common for digital
inputs and 0V
potential for 24V
supply.
37 - Safe Torque
Off (STO)
Safe input. Used for
STO.
Analog inputs/outputs
39 - Common for analog
output
42 AN-50 [0] No
operation
Programmable analog
output. The analog
signal is 0–20 mA or
4–20 mA at a
maximum of 500
Ω
50 - +10V DC 10V DC analog supply
voltage. 15mA
maximum commonly
used for potenti-
ometer or thermistor.
53 AN-1# Reference Analog input.
Selectable for voltage
or current. Switches
A53 and A54 select
mA or V.
54 AN-2# Feedback
55 - Common for analog
input
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Terminal description
Terminal Parameter
Default
setting Description
Serial communication
61 - Integrated RC filter for
cable screen. ONLY for
connecting the shield
when experiencing
EMC problems.
68 (+) O-3# RS-485 Interface. A
control card switch is
provided for
termination resistance.
69 (-) O-3#
Relays
01, 02, 03 E-24
[0] No
operation
Form C relay output.
Usable for AC or DC
voltage and resistive
or inductive loads.
04, 05, 06 E-24 [0] No
operation
Table 3.2 Terminal Description
3.4.5.3 Wiring to Control Terminals
Control terminal connectors can be unplugged from the
drive for ease of installation, as shown in Illustration 3.10.
1. Open the contact by inserting a small screwdriver
into the slot above or below the contact, as
shown in Illustration 3.12.
2. Insert the bared control wire into the contact.
3. Remove the screwdriver to fasten the control wire
into the contact.
4. Ensure the contact is firmly established and not
loose. Loose control wiring can be the source of
equipment faults or less than optimal operation.
Illustration 3.12 Connecting Control Wiring
3.4.5.4 Using Shielded Control Cables
Correct shielding
The preferred method in most cases is to secure control
and serial communication cables with shielding clamps
provided at both ends to ensure best possible high
frequency cable contact.
If the ground potential between the adjustable frequency
drive and the PLC is different, electric noise may occur that
will disturb the entire system. Solve this problem by fitting
an equalizing cable next to the control cable. Minimum
cable cross-section: 0.025 in
2
(16 mm
2)
.
50/60Hz ground loops
With very long control cables, ground loops may occur. To
eliminate ground loops, connect one end of the shield-to-
ground with a 100nF capacitor (keeping leads short).
Avoid EMC noise on serial communication
This terminal is grounded via an internal RC link. Use
twisted-pair cables to reduce interference between
conductors. The recommended method is shown below:
Alternatively, the connection to terminal 61 can be
omitted:
3.4.5.5 Control Terminal Functions
Drive functions are commanded by receiving control input
signals.
•
Each terminal must be programmed for the
function it will be supporting in the parameters
associated with that terminal. SeeTable 3.2 for
terminals and associated parameters.
•
It is important to confirm that the control
terminal is programmed for the correct function.
See 5 User Interface for details on accessing
parameters and for details on programming.
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•
The default terminal programming is intended to
initiate drive functioning in a typical operational
mode.
3.4.5.6 Terminal 53 and 54 Switches
•
Analog input terminals 53 and 54 can select
either voltage (-10–10V) or current (0/4–20mA)
input signals
•
Remove power to the drive before changing
switch positions
•
Set switches A53 and A54 to select the signal
type. U selects voltage, I selects current.
•
The switches are accessible when the Keypad has
been removed (see Illustration 3.13). Note that
some option cards available for the unit may
cover these switches and must be removed to
change switch settings. Always remove power to
the unit before removing option cards.
•
Terminal 53 default is for a speed reference signal
in open-loop set in DR-61 Terminal 53 Switch
Setting
•
Terminal 54 default is for a feedback signal in
closed-loop set in DR-63 Terminal 54 Switch
Setting
130BT310.10
Illustration 3.13 Location of Terminals 53 and 54 Switches and
Bus Termination Switch
3.4.5.7 Terminal 37
Terminal 37 Safe Stop Function
The AF-650 GP and is available with safe stop functionality
via control terminal 37. Safe stop disables the control
voltage of the power semiconductors of the drive output
stage which in turn prevents generating the voltage
required to rotate the motor. When the Safe Stop (T37) is
activated, the drive issues an alarm, trips the unit, and
coasts the motor to a stop. Manual restart is required. The
safe stop function can be used for stopping the drive in
emergency stop situations. In the normal operating mode
when safe stop is not required, use the adjustable
frequency drive’s regular stop function instead. When
automatic restart is used – the requirements under ISO
12100-2 paragraph 5.3.2.5 must be fulfilled.
Liability Conditions
It is the responsibility of the user to ensure personnel
installing and operating the Safe Stop function:
•
Read and understand the safety regulations
concerning health and safety/accident prevention
•
Understand the generic and safety guidelines
given in this description and the extended
description in the Design Guide
•
Have a good knowledge of the generic and safety
standards applicable to the specific application
User is defined as: integrator, operator, servicing,
maintenance staff.
Standards
Use of safe stop on terminal 37 requires that the user
satisfies all provisions for safety including relevant laws,
regulations and guidelines. The optional safe stop function
complies with the following standards.
EN 954-1: 1996 Category 3
IEC 60204-1: 2005 category 0 – uncontrolled stop
IEC 61508: 1998 SIL2
IEC 61800-5-2: 2007 – safe torque off (STO)
function
IEC 62061: 2005 SIL CL2
ISO 13849-1: 2006 Category 3 PL d
ISO 14118: 2000 (EN 1037) – prevention of
unexpected start-up
The information and instructions of the instruction manual
are not sufficient for a proper and safe use of the safe stop
functionality. The related information and instructions of
the relevant Design Guide must be followed.
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Protective Measures
•
Safety engineering systems may only be installed
and commissioned by qualified and skilled
personnel
•
The unit must be installed in an IP54 cabinet or
in an equivalent environment
•
The cable between terminal 37 and the external
safety device must be short circuit protected
according to ISO 13849-2 table D.4
•
If any external forces influence the motor axis
(e.g. suspended loads), additional measures (e.g. a
safety holding brake) are required in order to
eliminate hazards.
Safe Stop Installation and Set-up
WARNING
SAFE STOP FUNCTION!
The safe stop function does NOT isolate AC line voltage to
the drive or auxiliary circuits. Perform work on electrical
parts of the drive or the motor only after isolating the AC
line voltage supply and waiting the length of time
specified under Safety in this manual. Failure to isolate the
AC line voltage supply from the unit and waiting the time
specified could result in death or serious injury.
•
It is not recommended to stop the drive by using
the Safe Torque Off function. If a running drive is
stopped by using the function, the unit will trip
and stop by coasting. If this is not acceptable,
e.g. causes danger, the drive and machinery must
be stopped using the appropriate stopping mode
before using this function. Depending on the
application, a mechanical brake may be required.
•
Concerning synchronous and permanent magnet
motor adjustable frequency drives in case of a
multiple IGBT power semiconductor failure: In
spite of the activation of the Safe torque off
function, the drive system can produce an
alignment torque which maximally rotates the
motor shaft by 180/p degrees. p denotes the pole
pair number.
•
This function is suitable for performing
mechanical work on the drive system or affected
area of a machine only. It does not provide
electrical safety. This function should not be used
as a control for starting and/or stopping the
drive.
The following requirements have to be met to perform a
safe installation of the drive:
1. Remove the jumper wire between control
terminals 37 and 12 or 13. Cutting or breaking
the jumper is not sufficient to avoid short-
circuiting. (See jumper on Illustration 3.14.)
2. Connect an external Safety monitoring relay via a
NO safety function (the instruction for the safety
device must be followed) to terminal 37 (safe
stop) and either terminal 12 or 13 (24V DC). The
safety monitoring relay must comply with
Category 3 (EN 954-1) / PL “d” (ISO 13849-1).
Illustration 3.14 Jumper between Terminal 12/13 (24V) and 37
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Illustration 3.15 Installation to Achieve a Stopping Category 0 (EN 60204-1) with Safety Cat. 3 (EN 954-1) / PL “d” (ISO 13849-1).
1 Safety device Cat. 3 (circuit interrupt device, possibly
with release input)
7Inverter
2Doorcontact 8 Motor
3 Contactor (Coast) 9 5V DC
4Drive 10 Safechannel
5 Line power 11 Short-circuit protected cable (if not inside installation cabinet)
6 Control board
Safe Stop Commissioning Test
After installation and before first operation, perform a commissioning test of the installation making use of safe stop. In
addition, perform the test after each modification of the installation.
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3.4.6 Serial Communication
Connect RS-485 serial communication wiring to terminals
(+)68 and (-)69.
•
A shielded serial communication cable is
recommended
•
See 3.4.2 Grounding Requirements for proper
grounding
Illustration 3.16 Serial Communication Wiring Diagram
For basic serial communication set-up, select the following
1. Protocol type in O-30 Protocol.
2. Adjustable frequency drive address in
O-31 Address.
3. Baud rate in O-32 Drive Port Baud Rate.
•
Two communication protocols are internal to the
drive.
Drive profile
Modbus RTU
•
Functions can be programmed remotely using
the protocol software and RS-485 connection or
in parameter group O-## Options / Comms
•
Selecting a specific communication protocol
changes various default parameter settings to
match that protocol’s specifications along with
making additional protocol-specific parameters
available.
•
Option cards which can be installed in the
adjustable frequency drive are available to
provide additional communication protocols. See
the option card documentation for installation
and operation manual.
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4 Start Up and Functional Testing
4.1 Pre-start
4.1.1 Safety Inspection
WARNING
HIGH VOLTAGE!
If input and output connections have been connected
improperly, there is potential for high voltage on these
terminals. If power leads for multiple motors are
improperly run through the same conduit, there is a
potential for leakage current to charge capacitors within
the drive, even when disconnected from line power input.
For initial start-up, make no assumptions about power
components. Follow pre-start procedures. Failure to follow
pre-start procedures could result in personal injury or
damage to equipment.
1. Input power to the unit must be OFF and locked
out. Do not rely on the drive disconnect switches
for input power isolation.
2. Verify that there is no voltage on input terminals
L1 (91), L2 (92), and L3 (93), phase-to-phase and
phase-to-ground,
3. Verify that there is no voltage on output
terminals 96 (U), 97 (V), and 98 (W), phase-to-
phase and phase-to-ground.
4. Confirm continuity of the motor by measuring
ohm values on U-V (96-97), V-W (97-98), and W-U
(98-96).
5. Check for proper grounding of the drive as well
as the motor.
6. Inspect the drive for loose connections on
terminals.
7. Record the following motor nameplate data:
power, voltage, frequency, full load current, and
nominal speed. These values are needed to
program motor nameplate data later.
8. Confirm that the supply voltage matches voltage
of drive and motor.
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4.1.2 Start-up Check List
CAUTION
Before applying power to the unit, inspect the entire installation as detailed in Table 4.1. Check mark those items when
completed.
Inspect for Description ☑
Auxiliary equipment
•
Look for auxiliary equipment, switches, disconnects, or input fuses/circuit
breakers that may reside on the input power side of the adjustable frequency
drive or output side to the motor. Ensure that they are ready for full speed
operation.
•
Check function and installation of any sensors used for feedback to the drive.
•
Remove power factor correction caps on motor(s), if present.
Cable routing
•
Ensure that input power, motor wiring, and control wiring are separated or in
three separate metallic conduits for high frequency noise isolation.
Control wiring
•
Check for broken or damaged wires and loose connections.
•
Check that control wiring is isolated from power and motor wiring for noise
immunity.
•
Check the voltage source of the signals, if necessary.
•
The use of shielded cable or twisted pair is recommended. Ensure that the
shield is terminated correctly.
Cooling clearance
•
Measure to make sure that the top and bottom clearance is adequate to
ensure proper airflow for cooling.
EMC considerations
•
Check for proper installation regarding electromagnetic compatibility.
Environmental considerations
•
See equipment label for the maximum ambient operating temperature limits.
•
Humidity levels must be 5%–95% non-condensing.
Fusing and circuit breakers
•
Check for proper fusing or circuit breakers.
•
Check that all fuses are inserted firmly and in operational condition and that all
circuit breakers are in the open position.
Grounding
•
The unit requires a ground wire from its chassis to the building ground.
•
Check for good ground connections that are tight and free of oxidation.
•
Grounding to conduit or mounting the back panel to a metal surface is not a
suitable ground.
Input and output power wiring
•
Check for loose connections.
•
Check that motor and line power are in separate conduits or separated
shielded cables.
Panel interior
•
Inspect to ensure that the unit interior is free of dirt, metal chips, moisture, and
corrosion.
Switches
•
Ensure that all switch and disconnect settings are in the proper positions.
Vibration
•
Check that the unit is mounted solidly or that shock mounts are used, as
necessary.
•
Check for an unusual amount of vibration.
Table 4.1 Start-up Check List
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4.2 Applying Power to the Adjustable Frequency Drive
WARNING
HIGH VOLTAGE!
Adjustable frequency drives contain high voltage when
connected to AC line power. Installation, start-up and
maintenance should be performed by qualified personnel
only. Failure to perform installation, start-up and
maintenance by qualified personnel could result in death
or serious injury.
WARNING
UNINTENDED START!
When adjustable frequency drive is connected to AC line
power, the motor may start at any time. The drive, motor,
and any driven equipment must be in operational
readiness. Failure to be in operational readiness when the
drive is connected to AC line power could result in death,
serious injury, equipment, or property damage.
1. Confirm input voltage is balanced within 3%. If
not, correct input voltage imbalance before
proceeding. Repeat procedure after voltage
correction.
2. Ensure optional equipment wiring, if present,
matches installation application.
3. Ensure that all operator devices are in the OFF
position. Panel doors closed or cover mounted.
4. Apply power to the unit. DO NOT start the drive
at this time. For units with a disconnect switch,
turn to the ON position to apply power to the
drive.
4.3 Basic Operational Programming
Adjustable frequency drives require basic operational
programming prior to running for best performance. Basic
operational programming requires entering motor
nameplate data for the motor being operated and the
minimum and maximum motor speeds. Enter data in
accordance with the following procedure. Parameter
settings recommended are intended for start-up and
checkout purposes. Application settings may vary. See
5 User Interface for detailed instructions on entering data
through the Keypad.
Enter data with power ON, but prior to operating the
adjustable frequency drive.
1. Press [Quick Menu] on the Keypad.
2. Use the navigation keys to scroll to Quick Start
and press [OK].
3. Select language and press [OK]. Then enter the
motor data in parameters P-02, P-03, P-06, P-07,
F-04 and F-05. The information can be found on
the motor nameplate.
P-07 Motor Power [kW] or P-02 Motor
Power [HP]
F-05 Motor Rated Voltage
F-04 Base Frequency
P-03 Motor Current
P-06 Base Speed
4. Enter 3-15 Reference Resource 1 and press [OK].
5. Enter 3-13 Reference Site. Local, Remote, or Linked
to Hand/Auto. In local, the reference is entered
on the keypad, and in remote, that reference is
sourced depending on .
6. Enter the accel/decel time in 3-41 Ramp 1 Ramp
up Time and 3-42 Ramp 1 Ramp Down Time.
7. For 1-90 Motor Thermal Protection enter Elec OL
Trip 1 for Class 20 overload protection. For
further information, please see 3.4.1 Requirements.
8. For 4-13 Motor Speed High Limit [RPM] or
4-14 Motor Speed High Limit [Hz], enter the
application requirements.
9. For 4-11 Motor Speed Low Limit [RPM] or
4-12 Motor Speed Low Limit [Hz], enter the
application requirements.
10. Set 4-10 Motor Speed Direction to Clockwise,
Counterclockwise or Both directions.
11. In 1-29 Automatic Motor Adaptation (AMA), select
Reduced Auto Tune or Full Auto Tune and follow
on-screen instructions. See 4.4 Auto Tune
This concludes the quick set-up procedure. Press [Status]
to return to the operational display.
4.4 Auto Tune
Auto tune is a test procedure that measures the electrical
characteristics of the motor to optimize compatibility
between the drive and the motor.
•
The drive builds a mathematical model of the
motor for regulating output motor current. The
procedure also tests the input phase balance of
electrical power. It compares the motor character-
istics with the data entered in parameters P-0#.
•
It does not cause the motor to run or harm to
the motor
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•
Some motors may be unable to run the complete
version of the test. In that case, select Reduced
Auto Tune
•
If an output filter is connected to the motor,
select Reduced Auto Tune.
•
If warnings or alarms occur, see 7 Warnings and
Alarm
4.5 Check Motor Rotation
Prior to running the adjustable frequency drive, check the
motor rotation.
1. Press [Hand].
2. Press [►] for positive speed reference.
3. Check that the speed displayed is positive.
When H-48 Clockwise Direction is set to [0]* Normal (default
clockwise):
4a. Verify that the motor turns clockwise.
5a. Verify that the Keypad direction arrow is
clockwise.
When H-48 Clockwise Direction is set to [1] Inverse (counter-
clockwise):
4b. Verify that the motor turns counterclockwise.
5b. Verify that the Keypad direction arrow is
counterclockwise.
4.6 Local Control Test
CAUTION
MOTOR START!
Ensure that the motor, system, and any attached
equipment is ready for start. It is the responsibility of the
user to ensure safe operation under any operational
condition. Failure to ensure that the motor, system, and
any attached equipment is ready for start could result in
personal injury or equipment damage.
NOTE
The Hand key on the Keypad provides a local start
command to the drive. The OFF key provides the stop
function.
When operating in local mode, the up and down arrows
on the Keypad increase and decrease the speed output of
the drive. The left and right arrow keys move the display
cursor in the numeric display.
1. Press [Hand].
2. Accelerate the drive by pressing [
▲
] to full speed.
Moving the cursor left of the decimal point
provides quicker input changes.
3. Note any acceleration problems.
4. Press [OFF].
5. Note any deceleration problems.
If acceleration problems were encountered
•
If warnings or alarms occur, see 7 Warnings and
Alarm
•
Check that motor data is entered correctly
•
Increase the ramp time in F-07 Accel Time 1
•
Increase current limit in F-43 Current Limit
•
Increase torque limit in F-40 Torque Limiter
(Driving)
If deceleration problems were encountered
•
If warnings or alarms occur, see 7 Warnings and
Alarm
•
Check that motor data is entered correctly
•
Increase the ramp time in F-08 Decel Time 1
•
Enable overvoltage control in B-17 Over-voltage
Control
See 7.4 Warning and Alarm Definitions for resetting the
drive after a trip.
NOTE
4.1 Pre-start through 4.6 Local Control Test in this chapter
conclude the procedures for applying power to the drive,
basic programming, set-up, and functional testing.
4.7 System Start-up
The procedure in this section requires user-wiring and
application programming to be completed. The following
procedure is recommended after application set-up by the
user is completed.
CAUTION
MOTOR START!
Ensure that the motor, system, and any attached
equipment is ready for start. It is the responsibility of the
user to ensure safe operation under any operational
condition. Failure to ensure that the motor, system, and
any attached equipment is ready for start could result in
personal injury or equipment damage.
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1. Press [Auto].
2. Ensure that external control functions are
properly wired to the drive and all programming
completed.
3. Apply an external run command.
4. Adjust the speed reference throughout the speed
range.
5. Remove the external run command.
6. Note any problems.
If warnings or alarms occur, see 7 Warnings and Alarm.
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