GE AF-650 GP Series User manual

AF-650 GPTM
General Purpose Drive
Design and Installation 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 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
130R0415 *MG35M122* DET-767A
GE

Safety
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.
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 AC
line power, the motor may be started with an external
switch, a serial bus command, an input reference signal, or
a cleared fault condition. Use appropriate caution to guard
against an unintended start.
WARNING
DISCHARGE TIME!
Adjustable frequency drives contain DC link capacitors that
can remain charged even when the adjustable frequency
drive is not powered. To avoid electrical hazards,
disconnect AC line power, any permanent magnet type
motors, and any remote DC link power supplies, including
battery backups, UPS and DC link connections to other
adjustable frequency drives. Wait for the capacitors to fully
discharge before performing any service or repair work.
The wait time required is listed in the Discharge Time table.
Failure to wait for the specified period of time after power
has been removed to do service or repair could result in
death or serious injury.
Voltage Power Size Minimum
Waiting Time
200–240 V 0.25–3.7 kW 1/3–5 HP 4 minutes
5.5–37 kW 7.5–50 HP 15 minutes
380–480 V
0.37–7.5 kW 1/2–10 HP 4 minutes
11–75 kW 15–100 HP 15 minutes
90–200 kW 125–300 HP 20 minutes
250–800 kW 350–1200 HP 40 minutes
525–600 V 0.37–7.5 kW 1/2–10 HP 4 minutes
11–75 kW 15–100 HP 15 minutes
525–690 V
11–75 kW 15–100 HP 15 minutes
90–315 kW 125–400 HP 20 minutes
355–1200 kW 500–1350 HP 30 minutes
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
Table 1.2
Safety AF-650 GP
TM
Design and Installation Guide
DET-767A

Safety AF-650 GP
TM
Design and Installation Guide
DET-767A

Contents
1 Introduction
2-1
1.1 Purpose of the Manual 2-8
1.2 Additional Resources 2-8
1.3 Product Overview 2-8
1.4 Internal Adjustable Frequency Drive Controller Functions 2-8
2 Installation
3-1
2.1 Installation Site Checklist 3-1
2.2 Adjustable Frequency Drive and Motor Pre-installation Checklist 3-1
2.3 Mechanical Installation 3-1
2.3.1 Cooling (100 HP and below) 3-1
2.3.2 Cooling and Airflow (125 HP and above) 3-2
2.3.3 Lifting 3-3
2.3.4 Mounting 3-3
2.3.5 IP21 Drip Shield Installation (Unit Sizes 41 and 42) 3-4
2.4 Field Installation of Options 3-4
2.4.1 Installation of Top-only Duct Cooling Kit 3-4
2.4.2 Installation of Top and Bottom Covers 3-5
2.4.3 Outside Installation /NEMA 3R Kit of Industrial Enclosures 3-5
2.4.4 Installation of IP00 to IP20 Kits 3-5
2.4.5 Installation of cable clamp bracket in open chassis drives. 3-5
2.4.6 Installation on Pedestal 3-5
2.4.7 Installation of Line Power Shield for Adjustable Frequency Drives 3-6
2.4.8 USB Extension Kit 3-6
2.4.9 Installation of 4x or 5x Load Share Option 3-6
2.5 Electrical Installation 3-7
2.5.1 Requirements 3-8
2.5.2 Grounding Requirements 3-8
2.5.2.1 Leakage Current (>3.5 mA) 3-9
2.5.2.2 Grounding Using Shielded Cable 3-9
2.5.3 Motor Connection 3-9
2.5.4 AC Line Power Connection 3-10
2.5.5 Control Wiring 3-10
2.5.5.1 Access 3-10
2.5.5.2 Control Terminal Types 3-11
2.5.5.3 Wiring to Control Terminals 3-12
2.5.5.4 Using Shielded Control Cables 3-12
Contents AF-650 GP
TM
Design and Installation Guide
DET-767A

2.5.5.5 Control Terminal Functions 3-13
2.5.5.6 Terminal 53 and 54 Switches 3-13
2.5.5.7 Terminal 37 3-14
2.5.6 Serial Communication 3-14
3 Start Up and Functional Testing
4-1
3.1 Pre-start 4-1
3.1.1 Safety Inspection 4-1
3.2 Applying Power to the Adjustable Frequency Drive 4-3
3.3 Basic Operational Programming 4-3
3.4 Auto Tune 4-4
3.5 Check Motor Rotation 4-4
3.6 Local Control Test 4-4
3.7 System Start-up 4-5
4 User Interface
5-1
4.1 Keypad 5-1
4.1.1 Keypad Layout 5-1
4.1.2 Setting Keypad Display Values 5-2
4.1.3 Display 5-2
4.1.4 Navigation Keys 5-3
4.1.5 Operation Keys 5-3
4.2 Back Up and Copying Parameter Settings 5-3
4.2.1 Uploading Data to the Keypad 5-4
4.2.2 Downloading Data from the Keypad 5-4
4.3 Restoring Default Settings 5-4
4.3.1 Recommended Initialization 5-4
4.3.2 Manual Initialization 5-4
5 About Programming
6-1
5.1 Introduction 6-1
5.2 Programming Example 6-1
5.3 Control Terminal Programming Examples 6-3
5.4 International/North American Default Parameter Settings 6-4
5.5 Parameter Menu Structure 6-4
5.5.1 Quick Menu Structure 6-5
5.5.2 Main Menu Structure 6-6
5.6 Remote Programming with DCT-10 6-9
6 Application Setup Examples
7-1
Contents AF-650 GP
TM
Design and Installation Guide
DET-767A

6.1 Introduction 7-1
6.2 Application Examples 7-1
6.3 Controls 7-5
6.3.1 AF-650 GP Controls 7-5
6.3.2 Control Structure in Advanced Vector Control 7-7
6.3.3 Control Structure in Flux Sensorless 7-8
6.3.4 Control Structure in Flux with Motor Feedback 7-9
6.3.5 Internal Current Control 7-9
6.4 References 7-9
6.4.1 Local (Hand) and Remote (Auto) Control 7-9
6.4.2 Reference Handling 7-11
6.4.3 Reference Limits 7-12
6.4.4 Scaling of Preset References and Bus References 7-12
6.4.5 Scaling of Analog and Pulse References and Feedback 7-13
6.5 PID Control 7-14
6.5.1 Speed PID Control 7-14
6.5.1.1 Tuning PID speed control 7-16
6.5.2 Process PID Control 7-17
6.5.2.1 Example of Process PID Control 7-18
6.5.2.2 Ziegler Nichols Tuning Method 7-18
6.6 Brake Functions 7-22
6.6.1 Mechanical Holding Brake 7-22
6.6.2 Dynamic Braking 7-22
6.6.2.1 Selection of Brake Resistor 7-22
6.6.2.2 Brake Resistor Cabling 7-24
6.6.2.3 Overvoltage Control 7-24
6.6.3 Mechanical Brake Control 7-24
6.6.4 Hoist Mechanical Brake 7-25
6.7 Logic Controller 7-26
6.8 Extreme Running Conditions 7-28
6.9 Motor Thermal Protection 7-28
6.10 Safe Stop 7-29
6.10.1.1 Terminal 37 Safe Stop Function 7-30
6.10.1.2 Safe Stop Commissioning Test 7-33
6.11 Certificates 7-35
7 Installation Consideration
8-1
7.1 General Aspects of EMC 8-1
7.2 Immunity Requirements 8-3
Contents AF-650 GP
TM
Design and Installation Guide
DET-767A

7.3 General Aspects of Harmonics Emission 8-4
7.4 Galvanic Isolation (PELV) 8-5
7.4.1 PELV - Protective Extra Low Voltage 8-5
7.5 Derating 8-6
7.6 Motor Insulation 8-7
7.7 Motor Bearing Currents 8-7
8 Status Messages
9-1
8.1 Status Display 9-1
8.2 Status Message Definitions Table 9-1
9 RS-485 Installation and Setup
10-1
9.1 Installation and Setup 10-1
9.1.2 RS-485 Bus Termination 10-1
9.1.3 EMC Precautions 10-1
9.2 Network Configuration 10-1
9.2.1 Adjustable Frequency Drive with Modbus RTU 10-1
9.2.2 Modbus RTU Message Framing Structure 10-1
9.2.3 Modbus RTU Message Structure 10-2
9.2.3.1 Start/Stop Field 10-2
9.2.3.2 Address Field 10-2
9.2.3.3 Function Field 10-2
9.2.3.4 Data Field 10-3
9.2.3.5 CRC Check Field 10-3
9.2.4 Register Addressing 10-3
9.2.5 How to Access Parameters 10-6
9.2.5.1 Parameter Handling 10-6
9.2.5.2 Storage of Data 10-6
9.2.5.3 IND 10-6
9.2.5.4 Text Blocks 10-6
9.2.5.5 Conversion Factor 10-6
9.2.5.6 Parameter Values 10-7
9.3 Drive Control Profile 10-7
10 Warnings and Alarms
11-1
10.1 System Monitoring 11-1
10.2 Warning and Alarm Types 11-1
10.3 Warning and Alarm Displays 11-1
10.4 Warning and Alarm Definitions 11-2
Contents AF-650 GP
TM
Design and Installation Guide
DET-767A

11 Basic Troubleshooting
12-1
11.1 Start Up and Operation 12-1
12 Terminal and Applicable Wire
13-1
12.1 Cables 13-1
13 Specifications
14-1
13.1 Power-dependent Specifications 14-1
13.1.1 Power, Currents and Enclosures 14-1
13.1.2 Dimensions, Unit Size 1x 14-3
13.1.3 Dimensions, Unit Size 2x 14-5
13.1.4 Dimensions, Unit Size 3x 14-7
13.1.5 Dimensions, Unit Size 4x 14-9
13.1.6 Dimensions, Unit Size 5x 14-11
13.1.7 Dimensions, Unit Size 6x 14-12
13.2 General Technical Data 14-14
13.3 Fuse Specifications 14-19
13.3.2 Recommendations 14-19
13.3.3 CE Compliance 14-19
13.3.4 Fuse Tables 14-20
15 Index
15-1
Contents AF-650 GP
TM
Design and Installation Guide
DET-767A

Contents AF-650 GP
TM
Design and Installation Guide
DET-767A

1Introduction
Figure 1.1 Exploded View Unit Size 12 and 13
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 cover plate
Table 1.1
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DET-767A 1-1
11

Figure 1.2 Exploded View Unit Sizes 15, 21, 22, 31, and 32
1 Keypad 11 Relay 2 (04, 05, 06)
2Cover 12Liftingring
3 RS-485 serial bus connector 13 Mounting slot
4 Digital I/O and 24 V power supply 14 Grounding clamp (PE)
5 Analog I/O connector 15 Cable strain relief / PE ground
6 Cable strain relief/PE ground 16 Brake terminal (-81, +82)
7 USB connector 17 Load sharing terminal (DC bus) (-88, +89)
8 Serial bus terminal switch 18 Motor output terminals 96 (U), 97 (V), 98 (W)
9 Analog switches (A53), (A54) 19 Line power input terminals 91 (L1), 92 (L2), 93 (L3)
10 Relay 1 (01, 02, 03)
Table 1.2
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Design and Installation Guide
1-2 DET-767A
1
1

Figure 1.3 Exploded View Unit Sizes 41h, 42h, 43h, 44h
1 Local control panel mounting bracket 10 Heatsink fan
2 Control card and mounting plate 11 Gate drive support bracket
3 Power card and mounting plate 12 Capacitor bank
4 Inrush card 13 Balance/High frequency card
5 Inrush card mounting bracket 14 Motor output terminals
6 Top fan (IP20 only) 15 Line power input terminals
7 DC inductor 16 Gate drive card
8 SCR/Diode modules 17 (optional) RFI filter
9 IGBT modules
Table 1.3
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Figure 1.4 Compact IP21 (NEMA 1) and IP54 (NEMA 12), Unit
Sizes 41, 42, 43, 44, 51, 52
1) AUX Relay
01 02 03
04 05 06
2) Temp Switch 6) SMPS Fuse (see 13.3 Fuse Specifications for part number)
106 104 105 7) AUX Fan
3) Line 100 101 102 103
R S T L1 L2 L1 L2
91 92 93 8) Fan Fuse (see 13.3 Fuse Specifications for part number)
L1 L2 L3 9) Mains ground
4) Load sharing 10) Motor
-DC +DC U V W
88 89 96 97 98
T1 T2 T3
Table 1.4
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Design and Installation Guide
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1

Figure 1.5 Position of Ground Terminals IP21 (NEMA Type 1) and
IP54 (NEMA Type 12)
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Design and Installation Guide
DET-767A 1-5
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Figure 1.6 Rectifier Cabinet, unit sizes 61, 62, 63 and 64
1) 24 V DC, 5 A 5) Load sharing
T1 Output Taps -DC +DC
Temp Switch 88 89
106 104 105 6) Control Transformer Fuses (2 or 4 pieces). See 13.3 Fuse Specifications for part
numbers
2) Manual Motor Starters 7) SMPS Fuse. See 13.3 Fuse Specifications for part numbers
3) 30 A Fuse Protected Power Terminals 8) Manual Motor Controller fuses (3 or 6 pieces). See 13.3 Fuse Specifications for part
numbers
4) Line 9) Line Fuses, unit sizes 61 and 62 (3 pieces). See 13.3 Fuse Specifications for part
numbers
R S T 10) 30 Amp Fuse Protected Power fuses
L1 L2 L3
Table 1.5
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Design and Installation Guide
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1

Figure 1.7 Inverter Cabinet, Unit Sizes 62 and 64
(Unit Sizes 61 and 63 are similar with two inverter modules)
1) External Temperature Monitoring 6) Motor
2) AUX Relay U V W
01 02 03 96 97 98
04 05 06 T1 T2 T3
4) AUX Fan 8) Fan Fuses. See 13.3 Fuse Specifications for part numbers
100 101 102 103 9) SMPS Fuses. See 13.3 Fuse Specifications for part numbers
L1 L2 L1 L2
Table 1.6
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1.1 Purpose of the Manual
This manual is intended to provide detailed information for
the installation and start-up of the adjustable frequency
drive. provides requirements for mechanical and electrical
installation, including input, motor, control and serial
communications wiring, and control terminal functions.
provides detailed procedures for start-up, basic operational
programming, and functional testing. The remaining
chapters provide supplementary details. These details
include user interface, detailed programming, application
examples, start-up troubleshooting, and specifications.
1.2 Additional Resources
Other resources are available to understand advanced
adjustable frequency drive functions and programming.
•
The Programming Guide DET-618 provides greater
detail on working with parameters and many
application examples.
•
Optional equipment is available that may change
some of the procedures described. Reference the
instructions supplied with those options for
specific requirements. Contact the local GE
supplier or visit the GE website for downloads or
additional information.
1.3 Product Overview
An adjustable frequency drive is an electronic motor
controller that converts AC line power input into a variable
AC waveform output. The frequency and voltage of the
output are regulated to control the motor speed or torque.
The adjustable frequency drive can vary the speed of the
motor in response to system feedback, such as position
sensors on a conveyor belt. The adjustable frequency drive
can also regulate the motor by responding to remote
commands from external controllers.
In addition, the adjustable frequency drive monitors the
system and motor status, issues warnings or alarms for
fault conditions, starts and stops the motor, optimizes
energy efficiency, and offers many more control,
monitoring, and efficiency functions. Operation and
monitoring functions are available as status indications to
an outside control system or serial communication
network.
1.4 Internal Adjustable Frequency Drive
Controller Functions
Figure 1.8 is a block diagram of the adjustable frequency
drive's internal components. See Table 1.7 for their
functions.
Figure 1.8 Adjustable Frequency Drive Block Diagram
Area Title Functions
1 Line power input
•
Three-phase AC line power
supply to the adjustable
frequency drive
2Rectifier
•
The rectifier bridge converts
the AC input to DC current to
supply inverter power
3DCbus
•
Intermediate DC bus circuit
handles the DC current
4DCreactors
•
Filter the intermediate DC
circuit voltage
•
Provide line transient
protection
•
Reduce RMS current
•
Raise the power factor
reflected back to the line
•
Reduce harmonics on the AC
input
5 Capacitor bank
•
Stores the DC power
•
Provides ride-through
protection for short power
losses
6Inverter
•
Converts the DC into a
controlled PWM AC waveform
for a controlled variable
output to the motor
7 Output to motor
•
Regulated three-phase output
power to the motor
Introduction AF-650 GP
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Design and Installation Guide
1-8 DET-767A
1
1

Area Title Functions
8 Control circuitry
•
Input power, internal
processing, output, and motor
current are monitored to
provide efficient operation
and control
•
User interface and external
commands are monitored and
performed
•
Status output and control can
be provided
Table 1.7 Adjustable Frequency Drive Internal Components
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1

2 Installation
2.1 Installation Site Checklist
•
The adjustable frequency drive relies on the
ambient air for cooling. Observe the limitations
on ambient air temperature for optimal operation
•
Ensure that the installation location has sufficient
support strength to mount the adjustable
frequency drive
•
Keep the adjustable frequency 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
•
300 m (1000 ft) for unshielded motor
leads
•
150 m (500 ft) for shielded cable.
2.2 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
Adjustable frequency drive
Motor
•
Ensure that the adjustable frequency drive output
current rating is equal to or greater than motor
full load current for peak motor performance
Motor size and adjustable frequency
drive power must match for proper
overload protection
If adjustable frequency drive rating is
less than motor, full motor output
cannot be achieved
2.3 Mechanical Installation
2.3.1 Cooling (100 HP and below)
•
To provide cooling airflow, mount the unit to a
solid flat surface or to the optional backplate (see
2.3.4 Mounting)
•
Top and bottom clearance for air cooling must be
provided. Generally, 100–225 mm (4–10 in) is
required. See Figure 2.1 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.
Figure 2.1 Top and Bottom Cooling Clearance
Size 12-15 21-24 31, 33 32, 34
a/b (inch
[mm]) 3.94 [100] 7.87 [200] 7.87 [200] 8.86 [225]
Table 2.1 Minimum Airflow Clearance Requirements
Installation AF-650 GP
TM
Design and Installation Guide
DET-767A 2-1
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