GE AF-600 FP Series Guide

GE Consumer & Industrial
Electrical Distribution
AF-600 FPTM
Fan and Pump Drive
Design Guide
The instructions do not purport to cover all details or variations in equipment nor to provide for every possible
contingency to be met in connection with installation, operation or maintenance. Should further information be
desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes, the
matter should be referred to the GE company.
AF-600 FP is a trademark of the General Electric Company.
GE Consumer & Industrial
41 Woodford Avenue
Plainville, CT 06062
www.geelectrical.com/drives
130R0358 *MG11R102* DET-621

Contents
1 How to Read this Design Guide
3
Copyright, Limitation of Liability and Revision Rights 3
Approvals 4
Symbols 4
Abbreviations 5
Definitions 5
2 Introduction to AF-600 FP
11
Safety 11
CE Labelling 13
Aggressive Environments 14
Vibration and Shock 15
Application Examples 22
Control Structures 28
General Aspects of EMC 35
Galvanic Isolation (PELV) 39
PELV - Protective Extra Low Voltage 39
Earth Leakage Current 40
Extreme Running Conditions 40
3 AF-600 FP Selection
45
Options and Accessories 45
4 How to Install
57
Mechanical Dimensions 59
Lifting 64
Electrical Installation 66
Electrical Installation and Control Cables 67
Final Set-Up and Test 82
Additional Connections 84
Motor Insulation 86
Motor Bearing Currents 87
Installation of Misc. Connections 88
Safety 90
EMC-correct Installation 90
Residual Current Device 93
5 Application Examples
95
Start/Stop 95
Pulse Start/Stop 95
Potentiometer Reference 96
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Auto Tune 96
Logic Controller 96
Logic Controller Programming 97
LC Application Example 97
BASIC Cascade Controller 99
Pump Staging with Lead Pump Alternation 100
System Status and Operation 100
Fixed Variable Speed Pump Wiring Diagram 101
Lead Pump Alternation Wiring Diagram 102
Cascade Controller Wiring Diagram 103
Start/Stop Conditions 103
6 RS-485 Installation and Set-up
105
RS-485 Installation and Set-up 105
Drive Protocol Overview 107
Network Configuration 109
Drive Protocol Message Framing Structure 109
Examples 114
Modbus RTU Overview 116
Modbus RTU Message Framing Structure 117
How to Access Parameters 121
Examples 122
GE Drive Control Profile 128
7 General Specifications and Troubleshooting
133
Mains Supply Tables 133
General Specifications 145
Efficiency 149
Acoustic Noise 150
Peak Voltage on Motor 150
Special Conditions 155
Troubleshooting 157
Alarms and Warnings 157
Alarm Words 161
Warning Words 162
Extended Status Words 163
Fault Messages 164
Index
169
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1 How to Read this Design Guide
AF-600 FP
Software version: 1.02
This guide can be used with all AF-600 FP frequency converters with
software version 1.02 or later.
The actual software version number can be read from
par. ID-43 Software Version.
1.1.1 Copyright, Limitation of Liability and Revision Rights
This publication contains information proprietary to GE. By accepting and using this manual the user agrees that the information contained herein will be used
solely for operating equipment from GE or equipment from other vendors provided that such equipment is intended for communication with GE equipment over
a serial communication link. This publication is protected under the Copyright laws of Denmark and most other countries.
GE does not warrant that a software program produced according to the guidelines provided in this manual will function properly in every physical, hardware or
software environment.
Although GE has tested and reviewed the documentation within this manual, GE makes no warranty or representation, neither expressed nor implied, with respect
to this documentation, including its quality, performance, or fitness for a particular purpose.
In no event shall GE be liable for direct, indirect, special, incidental, or consequential damages arising out of the use, or the inability to use information contained
in this manual, even if advised of the possibility of such damages. In particular, GE is not responsible for any costs, including but not limited to those incurred as
a result of lost profits or revenue, loss or damage of equipment, loss of computer programs, loss of data, the costs to substitute these, or any claims by third
parties.
GE reserves the right to revise this publication at any time and to make changes to its contents without prior notice or any obligation to notify former or present
users of such revisions or changes.
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1.1.2 Available Literature for AF-600 FP
-Operating Instructions provide the necessary information for getting the drive up and running.
-Design Guide entails all technical information about the drive and customer design and applications.
-Programming Guide provides information on how to program and includes complete parameter descriptions.
GE technical literature is available in print from your local GE Sales Office or online at: www.geelectrical.com/drives
- AF-600 FP Built-in network manuals are available separately.
1.1.3 Approvals
1.1.4 Symbols
Symbols used in this guide.
NB!
Indicates something to be noted by the reader.
Indicates a general warning.
Indicates a high-voltage warning.
*Indicates default setting
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1.1.5 Abbreviations
Alternating current AC
American wire gauge AWG
Ampere/AMP A
Current limit ILIM
Degrees Celsius °C
Direct current DC
Drive Control Tool PC Software DCT 10
Drive Dependent D-TYPE
Electro Magnetic Compatibility EMC
Electronic Thermal Overload Elec. OL
Gram g
Hertz Hz
Kilohertz kHz
Meter m
Millihenry Inductance mH
Milliampere mA
Millisecond ms
Minute min
Nanofarad nF
Newton Meters Nm
Nominal motor current IM,N
Nominal motor frequency fM,N
Nominal motor power PM,N
Nominal motor voltage UM,N
Parameter par.
Protective Extra Low Voltage PELV
Printed Circuit Board PCB
Rated Inverter Output Current IINV
Revolutions Per Minute RPM
Regenerative terminals Regen
Second s
Synchronous Motor Speed ns
Torque limit TLIM
Volts V
1.1.6 Definitions
Drive:
IDRIVE,MAX
The maximum output current.
IDRIVE,N
The rated output current supplied by the frequency converter.
UDRIVE, MAX
The maximum output voltage.
Input:
Control command
You can start and stop the connected motor by means of keypad and the
digital inputs.
Functions are divided into two groups.
Functions in group 1 have higher priority than functions in group 2.
Group 1 Reset, Coasting stop, Reset and Coasting stop, Quick-stop, DC brak-
ing, Stop and the "Off" key.
Group 2 Start, Pulse start, Reversing, Start reversing, Jog and Freeze output
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Motor:
fJOG
The motor frequency when the jog function is activated (via digital terminals).
fM
The motor frequency.
fMAX
The maximum motor frequency.
fMIN
The minimum motor frequency.
fM,N
The rated motor frequency (nameplate data).
IM
The motor current.
IM,N
The rated motor current (nameplate data).
nM,N
The rated motor speed (nameplate data).
PM,N
The rated motor power (nameplate data).
TM,N
The rated torque (motor).
UM
The instantaneous motor voltage.
UM,N
The rated motor voltage (nameplate data).
Break-away torque
DRIVE
The efficiency of the frequency converter is defined as the ratio between the power output and the power input.
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Start-disable command
A stop command belonging to the group 1 control commands - see this group.
Stop command
See Control commands.
References:
Analog Reference
A signal transmitted to the analog inputs 53 or 54, can be voltage or current.
Bus Reference
A signal transmitted to the serial communication port (drive port).
Preset Reference
A defined preset reference to be set from -100% to +100% of the reference range. Selection of eight preset references via the digital terminals.
Pulse Reference
A pulse frequency signal transmitted to the digital inputs (terminal 29 or 33).
RefMAX
Determines the relationship between the reference input at 100% full scale value (typically 10 V, 20mA) and the resulting reference. The maximum reference value
set in par. F-53 Maximum Reference.
RefMIN
Determines the relationship between the reference input at 0% value (typically 0V, 0mA, 4mA) and the resulting reference. The minimum reference value set in
par. F-52 Minimum Reference
Miscellaneous:
Advanced Vecter Control
If compared with standard voltage/frequency ratio control, Advanced Vecter Control improves the dynamics and the stability, both when the speed reference is
changed and in relation to the load torque.
Analog Inputs
The analog inputs are used for controlling various functions of the frequency converter.
There are two types of analog inputs:
Current input, 0-20 mA and 4-20 mA
Voltage input, 0-10 V DC.
Analog Outputs
The analog outputs can supply a signal of 0-20 mA, 4-20 mA, or a digital signal.
Auto Tune
Auto Tune algorithm determines the electrical parameters for the connected motor at standstill.
CT Characteristics
Constant torque characteristics used for screw and scroll refrigeration compressors.
Digital Inputs
The digital inputs can be used for controlling various functions of the frequency converter.
Digital Outputs
The frequency converter features two Solid State outputs that can supply a 24 V DC (max. 40 mA) signal.
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DSP
Digital Signal Processor.
Relay Outputs:
The frequency converter features two programmable Relay Outputs.
Electronic Thermal Overload
Electronic Thermal Overload is a thermal load calculation based on present load and time. Its purpose is to estimate the motor temperature.
Initialising
If initialising is carried out (par. H-03 Restore Factory Settings), the programmable parameters of the frequency converter return to their default settings.
Intermittent Duty Cycle
An intermittent duty rating refers to a sequence of duty cycles. Each cycle consists of an on-load and an off-load period. The operation can be either periodic duty
or none-periodic duty.
keypad
The keypad makes up a complete interface for control and programming of the frequency converter. The is detachable and can be installed up to 3 metres from
the frequency converter, i.e. in a front panel by means of the installation kit option.
lsb
Least significant bit.
MCM
Short for Mille Circular Mil, an American measuring unit for cable cross-section. 1 MCM ≡0.5067 mm2.
msb
Most significant bit.
On-line/Off-line Parameters
Changes to on-line parameters are activated immediately after the data value is changed. Changes to off-line parameters are not activated until you enter [OK]
on the keypad.
PID Controller
The PID controller maintains the desired speed, pressure, temperature, etc. by adjusting the output frequency to match the varying load.
RCD
Residual Current Device.
Set-up
You can save parameter settings in four Set-ups. Change between the four parameter Set-ups and edit one Set-up, while another Set-up is active.
SFAVM
Switching pattern called Stator Flux oriented Asynchronous V ector M odulation (par. F-37 Adv. Switching Pattern).
Slip Compensation
The frequency converter compensates for the motor slip by giving the frequency a supplement that follows the measured motor load keeping the motor speed
almost constant.
Logic Controller (LC)
The LC is a sequence of user defined actions executed when the associated user defined events are evaluated as true by the LC.
Thermistor:
A temperature-dependent resistor placed where the temperature is to be monitored (frequency converter or motor).
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Trip
A state entered in fault situations, e.g. if the frequency converter is subject to an over-temperature or when the frequency converter is protecting the motor,
process or mechanism. Restart is prevented until the cause of the fault has disappeared and the trip state is cancelled by activating reset or, in some cases, by
being programmed to reset automatically. Trip may not be used for personal safety.
Trip Locked
A state entered in fault situations when the frequency converter is protecting itself and requiring physical intervention, e.g. if the frequency converter is subject
to a short circuit on the output. A locked trip can only be cancelled by cutting off mains, removing the cause of the fault, and reconnecting the frequency converter.
Restart is prevented until the trip state is cancelled by activating reset or, in some cases, by being programmed to reset automatically. Trip locked may not be
used for personal safety.
VT Characteristics
Variable torque characteristics used for pumps and fans.
60° AVM
Switching pattern called 60°Asynchronous Vector Modulation (See par. F-37 Adv. Switching Pattern).
1.1.7 Power Factor
The power factor is the relation between I1and IRMS.
Power factor =
3 × U × I
1 × COS ϕ
3 × U × IRMS
The power factor for 3-phase control:
=
I
1×
cos ϕ1
IRMS
=
I
1
IRMS
since cos ϕ1=1
The power factor indicates to which extent the frequency converter imposes
a load on the mains supply.
The lower the power factor, the higher the IRMS for the same kW performance.
IRMS = I
1
2+
I
5
2+
I
7
2+ . . +
In
2
In addition, a high power factor indicates that the different harmonic currents are low.
The frequency converters' built-in DC coils produce a high power factor, which minimizes the imposed load on the mains supply.
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