GE AF-600 FP Series User manual

AF-600 FPTM
Fan & Pump Drive
Quick Guide
Guia rapida
Kurzanleitung
Guide rapide
Guida rapida
130R0288 *MG14E16S*
DET-759A/S/D/F/I
GE
GE Energy
Industrial Solutions
© Copyright GE Industrial Solutions 2011
GE imagination at work
@
Industrial Solutions (formerly Power Protection),
a division of GE Energy, is a first class European
supplier of low and medium voltage products
including wiring devices, residential and
industrial electrical distribution components,
automation products, enclosures and switchboards.
Demand for the company’s products comes from
wholesalers, installers, panelboard builders,
contractors, OEMs and utilities worldwide.
www.ge.com/ex/industrialsolutions
Belgium
GE Industrial Belgium
Nieuwevaart 51
B-9000 Gent
Tel. [phone]
Finland
GE Energy Industrial Solutions
Kuortaneenkatu 2
FI-00510 Helsinki
Tel. [phone]
France
GE Energy Industrial Solutions
Paris Nord 2
13, rue de la Perdrix
F-95958 Roissy CDG Cédex
Tel. [phone]
Germany
GE Energy Industrial Solutions
Vor den Siebenburgen 2
D-50676 Köln
Tel. [phone] - 0
Hungary
GE Hungary Kft.
Vaci ut 81-83.
H-1139 Budapest
Tel. [phone]
South Africa
GE Energy Industrial Solutions
Unit 4, 130 Gazelle Avenue
Corporate Park Midrand 1685
P.O. Box 76672 Wendywood 2144
Tel. [phone]
Spain
GE Energy Industrial Solutions
P.I. Clot del Tufau, s/n
E-08295 Sant Vicenç de Castellet
Tel. [phone]
United Arab Emirates
GE Energy Industrial Solutions
1101, City Tower 2, Sheikh Zayed Road
P.O. Box 11549, Dubai
Tel. [phone]
United Kingdom
GE Energy Industrial Solutions
Houghton Centre
Salthouse Road
Blackmills
Northampton
NN4 7EX
Tel. [phone]
Italy
GE Energy Industrial Solutions
Centro Direzionale Colleoni
Via Paracelso 16
Palazzo Andromeda B1
I-20041 Agrate Brianza (MB)
Tel. [phone]
Netherlands
GE Energy Industrial Solutions
Parallelweg 10
Nl-7482 CA Haaksbergen
Tel. [phone]
Poland
GE Power Controls
Ul. Odrowaza 15
03-310 Warszawa
Tel. [phone]
Portugal
GE Energy Industrial Solutions
Rua Camilo Castelo Branco, 805
Apartado 2770
4401-601 Vila Nova de Gaia
Tel. [phone]
Russia
GE Energy Industrial Solutions
27/8, Electrozavodskaya street
Moscow, 107023
Tel. [phone]
United States of America
GE Energy Industrial Solutions
41 Woodford Avenue
Plainville, CT 06062

1Safety
WARNING
HIGH VOLTAGE!
Frequency converters contain high voltage when
connected to AC mains input 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
Frequency converters are connected to hazardous mains
voltages. 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 drive is connected to AC mains, 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
mains could result in death, serious injury, equipment, or
property damage.
Unintended Start
When the drive is connected to the AC mains, 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 cautions to guard against an
unintended start.
WARNING
DISCHARGE TIME!
Frequency converters contain DC link capacitors that can
remain charged even when AC mains is disconnected. To
avoid electrical hazards, remove AC mains from the 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
200-240 V 0.75-3.7 kW 1-5 HP 4 minutes
5.5-45 kW 7.5-60 HP 15 minutes
380-480 V
0.75-7.5 kW 1-10 HP 4 minutes
11-90 kW 15-125 HP 15 minutes
110-250 kW
150-350 HP 20 minutes
315-1000 kW
450-1350 HP 40 minutes
Voltage Power Size Minimum Waiting
Time
525-600 V
0.75-7.5 kW 1-10 HP 4 minutes
11-90 kW 15-125 HP 15 minutes
110-315 kW
150-400 HP 20 minutes
355-1000 kW
450-1350 HP 30 minutes
525-690 V
11-75 kW
15-125 HP 15 minutes
110-400 kW
150-550 HP 20 minutes
400-1400 kW
600-1900 HP 30 minutes
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
Safety AF-600 FP Quick Guide
DET-759A 1
11

2Introduction
Illustration 2.1 Exploded View Unit Size 1X
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 Mains 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 cover plate
NOTE
Please consult AF-600 FP Operating Instructions for other unit sizes.
Introduction AF-600 FP Quick Guide
2DET-759A
2
2

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 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 back plate.
•
Top and bottom clearance for air cooling must be
provided. Generally, 100-225 mm (4-10in) is
required.
•
Improper mounting can result in over heating
and reduced performance
•
Derating for temperatures starting between 40°
(104°F) and 50°C (122°F) and elevation 1000 m
(3300 ft) above sea level must be considered. See
the Design Guide for detailed information.
Illustration 3.1 Top and Bottom Cooling Clearance
Installation AF-600 FP Quick Guide
DET-759A 3
3
3

Voltage Power Size Clearance a/b
200-240 V
0.25-3.7 kW 1/3-5 HP 100 mm/4 in
5.5-30 kW 7.5-40 HP 200 mm/8 in
>30 kW/40 HP 225 mm/10 in
380-480 V
0.37-7.5 kW 1/2-10 HP 100 mm/4 in
11-55 kW 15-75 HP 200 mm/8 in
>55 kW/75 HP 225 mm/10 in
525-600 V
0.37-7.5 kW 1/2-10 HP 100 mm/4 in
11-55 kW 15-75 HP 200 mm/8 in
>55 kW/75 HP 225 mm/10 in
525-690 V all 225 mm/10 in
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.
Installation AF-600 FP Quick Guide
4DET-759A
3
3

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 shows a basic electrical connection.
Illustration 3.4 Basic Wiring Schematic Drawing.
Installation AF-600 FP Quick Guide
DET-759A 5
3
3

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 drive and associated equipment performance.
For your safety, comply with the following requirements.
•
Electronic controls equipment is connected to
hazardous mains voltage. Extreme care should be
taken to protect against electrical hazards when
applying power to the unit.
•
Run motor cables from multiple frequency
converters 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
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
Alarms for details on the trip function.
•
Because the motor wiring carries high frequency
current, it is important that wiring for mains,
motor power, and control are 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 frequency converters must be provided with
short-circuit and over-current protection. Input
fusing is required to provide this protection, see
Illustration 3.5. See maximum fuse ratings in
8.2.2 CE Compliance and 8.2.3 Fuse Tables.
Illustration 3.5 Drive 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 75°C rated copper wire.
3.4.2 Earth (Grounding) Requirements
WARNING
GROUNDING HAZARD!
For operator safety, it is important to ground the drive
properly in accordance with national and local electrical
codes as well as instructions contained within this
document. Ground currents are higher than 3,5 mA. Failure
to ground the 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 (earthing) 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 the equipment for
proper ground connections
•
Do not ground one drive to another in a “daisy
chain” fashion
Installation AF-600 FP Quick Guide
6DET-759A
3
3

•
Keep the ground wire connections as short as
possible
•
Using high-strand wire to reduce electrical noise
is recommended
•
Follow 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 3.5 mA.
Grounding must be reinforced in one of the following
ways:
•
Ground wire of at least 0.0155 in
2
[10 mm
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
3.4.2.3 Grounding Using Conduit
CAUTION
GROUNDING HAZARD!
Do not use conduit connected to the drive as a
replacement for proper grounding. Ground currents are
higher than 3.5mA. Improper grounding can result in
personal injury or electrical shorts.
Dedicated grounding clamps are provided (See
Illustration 3.7).
Illustration 3.7 Grounding with Conduit
Installation AF-600 FP Quick Guide
DET-759A 7
3
3

Illustration 3.8 Motor, Mains and Earth Wiring for Frame Sizes 2X
and Above Using Shielded Cable
1. Use a wire stripper to remove the insulation for
proper grounding.
2. Secure the grounding clamp to the stripped
portion of the wire with the screws provided.
3. Secure the grounding wire to the grounding
clamp provided.
3.4.3 Motor Connection
WARNING
INDUCED VOLTAGE!
Run output motor cables from multiple frequency
converters 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.
•
Comply with local and national electrical codes
for cable sizes, see 9.1.1 Cables
•
Motor wiring knockouts or access panels are
provided at the base of IP55/Nema 12 and IP66 /
Nema 4X Indoor unit
•
Do not install power factor correction capacitors
between the drive and the motor
•
Do not wire a starting or pole-changing device
between the 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
•
Follow motor manufacturer wiring requirements
The three following illustrations represent mains input,
motor, and earth grounding for basic frequency converters.
Actual configurations vary with unit types and optional
equipment.
3.4.4 AC Mains Connection
•
Size wiring based upon the input current of the
drive.
•
Comply with local and national electrical codes
for cable sizes, see 9.1.1 Cables.
•
Connect 3-phase AC input power wiring to
terminals L1, L2, and L3.
•
Input power will be connected to the mains input
terminals.
•
Ground the cable in accordance with grounding
instructions provided in 3.4.2 Earth (Grounding)
Requirements
•
All frequency converters may be used with an
isolated input source as well as with ground
reference power lines. When supplied from an
isolated mains source (IT mains or floating delta)
or TT/TN-S mains with a grounded leg (grounded
delta), set SP-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
earth capacity currents in accordance with IEC
61800-3.
3.4.5 Control Wiring
•
Isolate control wiring from high power
components in the drive.
•
If the drive is connected to a thermistor, for PELV
isolation, optional thermistor control wiring must
be reinforced/double insulated. A 24 V DC supply
voltage is recommended.
3.4.5.1 Access
•
Remove access coverplate with a screwdriver. See
Illustration 3.9.
•
Or remove front cover by loosening attaching
screws. See Illustration 3.10.
Tightening torque for front cover is 2.0 Nm for
unit size 15 and 2.2 Nm for unit sizes 2X and 3X.
Installation AF-600 FP Quick Guide
8DET-759A
3
3

Illustration 3.9 Control Wiring Access for IP20/Open Chassis
Enclosures
Illustration 3.10 Control Wiring Access for IP55/Nema 12 and
IP66/Nema 4/4X Indoor
3.4.5.2 Control Terminal Types
Illustration 3.14 shows the removable drive connectors.
Terminal functions and default settings are summarized in
Table 3.2.
Illustration 3.11 Control Terminal Locations
•
Connector 1 provides four programmable digital
inputs terminals, two additional digital terminals
programmable as either input or output, a 24 V
DC terminal supply voltage, and a common for
optional customer supplied 24 V DC voltage
•
Connector 2 terminals (+)68 and (-)69 are for an
RS-485 serial communications connection
•
Connector 3 provides two analog inputs, one
analog output, 10 V DC supply voltage, and
commons for the inputs and output
•
Connector 4 is a USB port available for use with
the
•
Also provided are two Form C relay outputs that
are in various locations depending upon the 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.
Installation AF-600 FP Quick Guide
DET-759A 9
3
3

Terminal Description
Digital Inputs/Outputs
Terminal Parameter
Default
Setting Description
12, 13 - +24V DC 24V DC supply
voltage. Maximum
output current is
200mA total for all
24V loads. Useable for
digital inputs and
external transducers.
18 E-01 [8] Start
Digital inputs.
19 E-02 [0] No
operation
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.
Analog Inputs/Outputs
39 - Common for analog
output
42 AN-50 Speed 0 -
High Limit
Programmable analog
output. The analog
signal is 0–20mA or
4–20mA 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
Serial Communication
61 - Integrated RC filter for
cable shield. 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#
Terminal Description
Digital Inputs/Outputs
Terminal Parameter
Default
Setting Description
Relays
01, 02, 03 E-24 [0] [0] Alarm Form C relay output.
Usable for AC or DC
voltage and resistive
or inductive loads.
04, 05, 06 E-24 [1] [0] Running
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 3.12.
Illustration 3.12 Unplugging Control Terminals
1. Open the contact by inserting a small screwdriver
into the slot above or below the contact, as
shown in Illustration 3.13.
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 3.13 Connecting Control Wiring
Installation AF-600 FP Quick Guide
10 DET-759A
3
3

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.
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
To eliminate low-frequency noise between adjustable
frequency drives, connect one end of the shield to
terminal 61. This terminal is connected to ground via an
internal RC link. Use twisted-pair cables to reduce
interference between conductors.
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. See Table 3.2 for
terminals and associated parameters.
•
It is important to confirm that the control
terminal is programmed for the correct function.
•
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 (0 to 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 3.14). 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 3.14 Location of Terminals 53 and 54 Switches
Installation AF-600 FP Quick Guide
DET-759A 11
3
3

3.4.6 Serial Communication
Connect RS-485 serial communication wiring to terminals
(+)68 and (-)69.
•
Shielded serial communication cable is
recommended
•
See 3.4.2 Earth (Grounding) Requirements for
proper grounding
Illustration 3.15 Serial Communication Wiring Diagram
For basic serial communication set-up, select the following
1. Protocol type in O-30 Protocol.
2. Drive address in O-31 Address.
3. Baud rate in O-32 Drive Port Baud Rate.
•
Four communication protocols are internal to the
drive. Follow the motor manufacturer wiring
requirements.
Drive profile
Modbus RTU
Metasys N2
®
Apogee FLN
®
•
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 install into the drive are
available to provide additional communication
protocols. See the option-card documentation for
installation and operation instructions
Installation AF-600 FP Quick Guide
12 DET-759A
3
3

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.
Start Up and Functional Tes... AF-600 FP Quick Guide
DET-759A 13
4
4

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
Start Up and Functional Tes... AF-600 FP Quick Guide
14 DET-759A
4
4

4.2 Applying Power to the Drive
WARNING
HIGH VOLTAGE!
Adjustable frequency drives contain high voltage when
connected to AC line power. Installation, startup and
maintenance should be performed by qualified personnel
only. Failure to perform installation, startup and
maintenance by qualified personnel could result in death
or serious injury.
WARNING
UNINTENDED START!
When 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
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.
Enter data with power ON, but prior to operating the
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 (induction motors only, for PM
motors, skip these parameters for now). The
information can be found on the motor
nameplate. The entire quick menu is shown in
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. F-07 Accel Time 1 is recommended as 60 seconds
for fans or 10 seconds for pumps.
5. F-08 Decel Time 1 is recommended as 60 seconds
for fans or 10 seconds for pumps.
6. For F-10 enter Elec OL Trip 1 for Class 20
overload protection. For further information,
please see 3.4.1 Requirements
7. For F-16 Motor Speed Low Limit [Hz] enter the
application requirements. If these values are
unknown at this time, the following values are
recommended. These values will ensure initial
drive operation. However, take any precautions
necessary to prevent equipment damage. Make
sure that the recommended values are safe to
use for functional testing before starting the
equipment.
Fan = 20 Hz
Pump = 20 Hz
Compressor = 30 Hz
8. In F-15 Motor Speed High Limit [Hz] enter the
motor frequency from F-04 Base Frequency.
This concludes the quick set-up procedure. Press [Status]
to return to the operational display.
In P-04 Auto Tune select Reduced Auto Tune or Full Auto
Tune and follow on-screen instructions. See 4.4 Auto Tune
Start Up and Functional Tes... AF-600 FP Quick Guide
DET-759A 15
4
4

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 P-02, P-03, P-06,
P-07, F-04 and F-05.
•
It does not cause the motor to run or harm to
the motor
•
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
Alarms
•
Run this procedure on a cold motor for best
results
4.5 Check Motor Rotation
Prior to running the drive, check the motor rotation. The
motor will run briefly at 5Hz or the minimum frequency set
in F-16 Motor Speed Low Limit [Hz].
1. Press [Main Menu] twice on the keypad.
2. Enter Parameter Data Set and scroll to P-## Motor
Data and press [OK] to enter.
3. Scroll to P-08 Motor Rotation Check.
4. Press [OK].
5. Scroll to Enable.
The following text will appear: Note! Motor may run in
wrong direction.
6. Press [OK].
7. Follow the on-screen instructions.
To change the direction of rotation, remove power to the
drive and wait for power to discharge. Reverse the
connection of any two of the three motor cables on the
motor or drive side of the connection.
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
•
Check that motor data is entered correctly
•
Increase the accel 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
•
Check that motor data is entered correctly
•
Increase the decel time in F-08 Decel Time 1
See 7.1 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
concludes the procedures for applying power to the drive,
basic programming, set-up, and functional testing.
Start Up and Functional Tes... AF-600 FP Quick Guide
16 DET-759A
4
4

4.7 System Start Up
The procedure in this section requires user-wiring and
application programming to be completed. is intended to
help with this task. 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.
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 Alarms.
Start Up and Functional Tes... AF-600 FP Quick Guide
DET-759A 17
4
4

5 User Interface
5.1 Keypad
The keypad is the combined display and keys on the front
of the unit. The keypad is the user interface to the
adjustable frequency drive.
The keypad has several user functions.
•
Start, stop, and control speed when in local
control
•
Display operational data, status, warnings and
cautions
•
Programming adjustable frequency drive
functions
•
Manually reset the adjustable frequency drive
after a fault when auto-reset is inactive
NOTE
The display contrast can be adjusted by pressing [STATUS]
and the up/down key.
5.1.1 Keypad Layout
The keypad is divided into four functional groups (see
Illustration 5.1).
Illustration 5.1 Keypad
a. Display area.
b. Display menu keys for changing the display to
show status options, programming, or error
message history.
c. Navigation keys for programming functions,
moving the display cursor, and speed control in
local operation. Also included are the status
indicator lights.
d. Operational mode keys and reset.
User Interface AF-600 FP Quick Guide
18 DET-759A
5
5

5.1.2 Setting Keypad Display Values
The display area is activated when the adjustable
frequency drive receives power from AC line voltage, a DC
bus terminal, or an external 24 V supply.
The information displayed on the keypad can be
customized for user application.
•
Each display readout has a parameter associated
with it.
•
Options are selected in the menu Keypad Set-up.
•
Display 2 has an alternate larger display option.
•
The adjustable frequency drive status at the
bottom line of the display is generated automat-
ically and is not selectable.
Display Parameter number Default setting
1.1 K-20 Motor RPMs
1.2 K-21 Motor current
1.3 K-22 Motor power (kW)
2 K-23 Motor frequency
3 K-24 Reference in percent
5.1.3 Display Menu Keys
Menu keys are used for menu access for parameter set-up,
toggling through status display modes during normal
operation, and viewing fault log data.
Key Function
Status Press to show operational information.
•
In Auto mode, press and hold to toggle
between status read-out displays
•
Press repeatedly to scroll through each
status display.
•
Press and hold [Status] plus [
▲
] or [
▼
] to
adjust the display brightness
•
The symbol in the upper right corner of the
display shows the direction of motor
rotation and which set-up is active. This is
not programmable.
Quick Menu Allows access to programming parameters for
initial set-up instructions and many detailed
application instructions.
•
Press to access Quick Start for sequenced
instructions to program the basic frequency
controller set-up
•
Press to access Fan Macros, Pump Macros,
Compressor Macros, or Closed Loop for
sequenced instructions to program
applications
•
Press to access Trending for realtime
logging on keypad display.
•
Press to access Parameter Data Check for
changes in parameter data set.
•
Follow the sequence of parameters as
presented for the function set-up
Main Menu Allows access to all programming parameters.
•
Press twice to access top-level index
•
Press once to return to the last location
accessed.
•
Press and hold to enter a parameter
number for direct access to that parameter.
Alarm Log Displays a list of current warnings, the last 10
alarms, and the maintenance log.
•
For details about the drive before it entered
the alarm mode, select the alarm number
using the navigation keys and press [OK].
User Interface AF-600 FP Quick Guide
DET-759A 19
5
5