Industrial Solutions AF-650 GP General Purpose Drive Design and Installation Guide...
Safety AF-650 GP™ Design and Installation Guide Safety Safety Symbols WARNING UNINTENDED START The following symbols are used in this manual: When the frequency converter is connected to AC mains, DC supply, or load sharing, the motor may start at any WARNING time.
Contents AF-650 GP™ Design and Installation Guide Contents 1 Introduction 1.1 Exploded Views 1.1.1 Extended Options Cabinets 1.2 Purpose of the Manual 1.3 Additional Resources 1.4 Product Overview 1.5 Internal Frequency Converter Controller Functions 2 Installation 2.1 Installation Site Check List 2.2 Frequency Converter and Motor Pre-installation Check List...
Contents 3.4 Auto Tune 3.5 Check Motor Rotation 3.6 Local-control Test 3.7 System Start-up 4 User Interface 4.1 Keypad 4.1.1 Keypad Layout 4.1.2 Setting Keypad Display Values 4.1.3 Display Menu Keys 4.1.4 Navigation Keys 4.1.5 Operation Keys 4.2 Back Up and Copying Parameter Settings 4.2.1 Uploading data to the keypad 4.2.2 Downloading Data from the Keypad 4.3 Restoring Default Settings...
Contents AF-650 GP™ Design and Installation Guide 6.4.4 Scaling of Preset References and Bus References 6.4.5 Scaling of Analog and Pulse References and Feedback 6.5 PID Control 6.5.1 Speed PID Control 220.127.116.11 Tuning PID Speed Control 6.5.2 Process PID Control 18.104.22.168 Example of Process PID Control...
Contents 9.1.2 RS485 Bus Termination 9.1.3 EMC Precautions 9.2 Network Configuration 9.2.1 Modbus RTU Message Framing Structure 9.2.2 Modbus RTU Message Structure 22.214.171.124 Start/Stop Field 126.96.36.199 Address Field 188.8.131.52 Function Field 184.108.40.206 Data Field 220.127.116.11 CRC Check Field 9.2.3 Register Addressing 9.2.4 How to Access Parameters 18.104.22.168 Parameter Handling 22.214.171.124 Storage of Data...
Contents AF-650 GP™ Design and Installation Guide 13.1.4 Mains Supply 525–690 V 13.2 General Technical Data 13.3 Fuse Specifications 13.3.1 Recommendations 13.3.2 CE Compliance 13.3.3 Fuse Specifications 13.3.4 NEC and UL Compliance Index MG35M402 DET-767c All rights reserved.
Introduction AF-650 GP™ Design and Installation Guide Keypad Relay 2 (04, 05, 06) Cover Lifting ring RS485 serial bus connector Mounting slot Digital I/O and 24 V supply Grounding clamp (PE) Analog I/O connector Cable strain relief/PE ground Cable strain relief/PE ground...
Introduction Keypad mounting bracket Heat sink fan Control card and mounting plate Gate drive support bracket Power card and mounting plate Capacitor bank Inrush card Balance/High frequency card Inrush card mounting bracket Motor output terminals Top fan (IP20 only) Mains input terminals DC inductor Gatedrive card SCR/Diode modules...
Introduction AF-650 GP™ Design and Installation Guide AUX Relay Temp Switch SMPS Fuse (see chapter 13.3 Fuse Specifications for part number) AUX Fan Line Fan Fuse (see chapter 13.3 Fuse Specifications for part number) Mains ground Load sharing Motor Illustration 1.4 Compact IP21 (NEMA 1) and IP54 (NEMA 12), Unit Sizes 41, 42, 43, 44, 51, 52 MG35M402 DET-767c All rights reserved.
Introduction Illustration 1.5 Position of Ground Terminals IP21 (NEMA Type 1) and IP54 (NEMA Type 12) DET-767c All rights reserved. MG35M402...
Introduction AF-650 GP™ Design and Installation Guide 24 V DC, 5 A Load sharing T1 Output Taps Temp Switch 104 105 Control Transformer Fuses (2 or 4 pieces). See chapter 13.3 Fuse Specifications for part numbers. Manual Motor Starters SMPS Fuse. See chapter 13.3 Fuse Specifications for part numbers.
Introduction External Temperature Monitoring Motor AUX Relay AUX Fan Fan Fuses. See chapter 13.3 Fuse Specifications for part numbers. 101 102 103 SMPS Fuses. See chapter 13.3 Fuse Specifications for part numbers. Illustration 1.7 Inverter Cabinet, Unit Sizes 62 and 64 (Unit Sizes 61 and 63 are similar with two inverter modules) DET-767c All rights reserved.
Introduction AF-650 GP™ Design and Installation Guide 1.1.1 Extended Options Cabinets 1.2 Purpose of the Manual This manual provides detailed information for the instal- If a frequency converter is ordered with brake chopper, it is lation and start-up of the frequency converter.
Introduction 1.4 Product Overview Area Title Functions • Filter the intermediate DC circuit A frequency converter is an electronic motor controller voltage. that converts DC into a variable AC waveform output. The • Prove mains transient frequency and voltage of the output are regulated to protection.
Installation AF-650 GP™ Design and Installation Guide 2 Installation • 2.1 Installation Site Check List Ensure that the frequency converter output current rating is equal to or greater than motor • The frequency converter relies on the ambient air full load current for peak motor performance: for cooling.
Installation 2.3.2 Cooling and Airflow (125 hp and above) Cooling Cooling can be obtained in different ways, by using the cooling ducts in the bottom and the top of the unit, by taking air in and out the back of the unit or by combining the cooling possibilities. Duct cooling A back-channel cooling kit is available to direct the heat sink cooling air out of the panel when an IP20/chassis frequency converter is installed in a Rittal enclosure.
Installation AF-650 GP™ Design and Installation Guide 2.3.3 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 •...
Installation 2.4 Acoustic Noise The typical values measured at a distance of 1 m from the unit: At reduced fan Full fan speed Unit size speed (50%) [dBA] [dBA] 59.4 70.5 62.8 56.4 67.3 – – 41h/43h/45h – 42h/44h/47h – 61/62/63/64 Table 2.3 Measured Values DET-767c All rights reserved.
Installation AF-650 GP™ Design and Installation Guide 2.5 Electrical Installation This section contains detailed instructions for wiring the frequency converter. The following tasks are described: • Wiring the motor to the frequency converter output terminals. • Wiring the AC mains to the frequency converter input terminals.
• Electronic controls equipment is connected to • GE recommends that all power connections be hazardous mains voltage. Extreme care should be made with a minimum 75 °C rated copper wire. taken to protect against electrical hazards when •...
Installation AF-650 GP™ Design and Installation Guide • 126.96.36.199 Grounding Using Shielded Cable Use the clamps provided with on the equipment for proper ground connections. Grounding clamps are provided for motor wiring (see • Do not ground one frequency converter to Illustration 2.7).
Installation 2.5.5 Control Wiring Illustration 2.8 shows mains input, motor, and grounding for basic frequency converters. Actual configurations vary with unit types and optional equipment. • Isolate control wiring from high-power components in the frequency converter. • If the frequency converter is connected to a thermistor, for PELV isolation, optional thermistor control wiring must be reinforced/double insulated.
Installation AF-650 GP™ Design and Installation Guide optional customer supplied 24 V DC voltage. A digital input for STO (Safe Torque Off) function. • Connector 2 terminals (+)68 and (-)69 are for an RS485 serial communications connection. • Connector 3 provides two analog inputs, one analog output, 10 V DC supply voltage, and commons for the inputs and output.
Installation of equipment faults or less than optimal Terminal description operation. Default Terminal Parameter setting Description See chapter 12 Terminal and Applicable Wire for control Digital inputs/outputs terminal wiring sizes. – +10 V DC 10 V DC analog supply voltage. 15 mA maximum commonly used for potenti- ometer or thermistor.
188.8.131.52 Terminal 37 typical operational mode. Terminal 37 Safe Torque Off function The AF-650 GP is available with Safe Torque Off functionality via control terminal 37. Safe torque off (STO) disables the control voltage of the power semiconductors of the frequency converter output stage which in turn MG35M402 DET-767c All rights reserved.
Installation 2.5.7 Electrical Installation - EMC prevents generating the voltage required to rotate the Precautions motor. To run STO, additional wiring for the frequency converter is required. Refer to Safe Torque Off Operating Instructions for further information. The following is a guideline to good engineering practice when installing frequency converters.
Installation AF-650 GP™ Design and Installation Guide If the installation is not carried out according to the although the immunity requirements are fulfilled. See guideline and if unshielded cables and control wires are chapter 7.1.3 EMC Test Results (Emission). used, some emission requirements are not complied with, Illustration 2.20 EMC-correct Electrical Installation of a Frequency Converter in Cabinet...
Installation Illustration 2.21 Electrical Connection Diagram DET-767c All rights reserved. MG35M402...
Start-up and Functional Tes... AF-650 GP™ Design and Installation Guide 3 Start-up and Functional Testing 3.1 Pre-start 3.1.1 Safety Inspection WARNING HIGH VOLTAGE If input and output connections have been connected improperly, there is potential for high voltage on these terminals.
Start-up and Functional Tes... 3.1.2 Pre-start CAUTION Before applying power to the unit, inspect the entire installation as detailed in Table 3.1. Check mark those items when completed. ☑ Inspect for Description • Auxiliary equipment Look for auxiliary equipment, switches, disconnects, or input fuses/circuit breakers on the input power side of the frequency converter or output side to the motor.
Start-up and Functional Tes... AF-650 GP™ Design and Installation Guide 3.2 Applying Power Select language and press [OK]. Then enter the WARNING motor data in parameters P-02, P-03, P-06, P-07, HIGH VOLTAGE! F-04, and F-05. The information can be found on Frequency converters contain high voltage when the motor nameplate.
Start-up and Functional Tes... • NOTICE Some motors may be unable to run the complete version of the test. In that case, select  Reduced The Hand key on the keypad provides a local start Auto Tune. command to the frequency converter. The [Off] key •...
Start-up and Functional Tes... AF-650 GP™ Design and Installation Guide 3.7 System Start-up The procedure in this section requires user-wiring and application programming to be completed. chapter 6 Application Set-Up Examples is intended to help with this task. Other aids to application set-up are listed in chapter 1.3 Additional Resources.
User Interface 4 User Interface 4.1 Keypad 4.1.1 Keypad Layout The keypad is the combined display and keys on the front of the unit. The keypad is the user interface to the frequency converter. The keypad is divided into 4 functional groups (see Illustration 4.1).
User Interface AF-650 GP™ Design and Installation Guide 4.1.2 Setting Keypad Display Values 4.1.3 Display Menu Keys The display area is activated when the frequency converter Menu keys are used for menu access for parameter set-up, receives power from mains voltage, a DC bus terminal, or toggling through status display modes during normal an external 24 V DC supply.
User Interface 4.1.4 Navigation Keys 4.1.5 Operation Keys Navigation keys are used for programming functions and Operation keys are located at the bottom of the keypad. moving the display cursor. The navigation keys also provide speed control in local (hand) operation. There are also 3 frequency converter status indicator lights in this area.
User Interface AF-650 GP™ Design and Installation Guide Restoring the frequency converter parameter settings back WARNING to default values is done by restoring of the frequency UNINTENDED START converter. Restoring can be carried out via When the frequency converter is connected to AC mains, parameter H-03 Restore Factory Settings or manually.
About Programming 5 About Programming 5.1 Introduction Parameter F-52 Minimum Reference. Set minimum internal frequency converter reference to 0 Hz The frequency converter is programmed for its application (this sets the minimum frequency converter functions using parameters. Parameters are accessed by speed at 0 Hz).
About Programming AF-650 GP™ Design and Installation Guide Parameter AN-10 Terminal 53 Low Voltage. Set minimum external voltage reference on Terminal 53 at 0 V. (This sets the minimum input signal at 0 V.) Illustration 5.6 Analog Reference Parameter AN-14 Terminal 53 Low Ref./Feedb.
About Programming Illustration 5.10 Digital In/Out Illustration 5.8 Wiring Example for External Device Providing 0–10 V Control Signal (Frequency Converter Left, External Device Right) Scroll to parameter group E-0# Digital Inputs and press [OK] Scroll to parameter E-01 Terminal 18 Digital Input. 5.3 Control Terminal Programming Press [OK] to access function options.
About Programming AF-650 GP™ Design and Installation Guide 5.4.1 Parameter Data Check Parameter International default North American parameter value default parameter value Press [Quick Menu]. Parameter F-04 Base 50 Hz 60 Hz Scroll to Parameter Data Check and press [OK].
About Programming 5.5.1 Quick Menu Structure K-01 Language K-02 Motor Speed Unit P-02 Motor Power [HP] P-07 Motor Power [kW] F-05 Motor Rated Voltage P-03 Motor Current F-04 Base Frequency P-06 Base Speed F-01 Frequency Setting 1 F-02 Operation Method F-07 Accel Time 1 F-08...
About Programming AF-650 GP™ Design and Installation Guide 5.6 Remote Programming with DCT-10 GE has a software program available for developing, storing, and transferring frequency converter programming. The DCT-10 allows the user to connect a PC to the frequency converter and perform live programming rather than using the keypad.
Application Set-Up Examples 6 Application Set-Up Examples 6.1 Introduction The examples in this section are intended as a quick Parameters reference for common applications. Function Setting • Parameter settings are the regional default values Parameter AN-12 4 mA* unless otherwise indicated (selected in Terminal 53 Low parameter K-03 Regional Settings).
Application Set-Up Examples AF-650 GP™ Design and Installation Guide Parameters Function Setting Parameter E-01 Ter  Start minal 18 Digital Input Parameter E-02 Ter  minal 19 Digital Reversing* Illustration 6.1 Input Parameter E-05 Ter  Preset minal 32 Digital...
Application Set-Up Examples Parameters Function Setting Parameter AN-10 Terminal 53 Low Voltage 0.07 V* Parameter AN-11 10 V* Terminal 53 High Voltage Parameter AN-14 0 RPM Terminal 53 Low Ref./Feedb. Value Parameter AN-15 1500 RPM Terminal 53 High Illustration 6.3 Illustration for Table 6.8 Ref./Feedb.
Application Set-Up Examples AF-650 GP™ Design and Installation Guide CAUTION Parameters Thermistors must use reinforced or double insulation to Function Setting meet PELV insulation requirements. Parameter E-24 F  Mech. unction Relay brake ctrl. Parameters Parameter E-01 T  Start*...
Notes/comments: always the set-up that is edited. If you prefer, you GE 30 mm HOA Cat# (1) can also ignore this and manually control what 104PSG34B & (3) CR104PXC1 set-up you want to edit through K-11.
Application Set-Up Examples AF-650 GP™ Design and Installation Guide • Closed loop in Flux mode with encoder feedback Speed/torque reference offers superior performance in all 4 quadrants The reference to these controls can either be a single and at all motor speeds.
Application Set-Up Examples 6.3.1 Control Structure in Advanced Vector Control Illustration 6.5 Control Structure in Advanced Vector Control Open Loop and Closed Loop Configurations See Active/Inactive Parameters in Different Drive Control Modes in the Programming Guide for an overview of which control configuration is available, depending on selection of AC motor or PM non-salient motor.
Application Set-Up Examples AF-650 GP™ Design and Installation Guide 6.3.2 Control Structure in Flux Sensorless Illustration 6.6 Control Structure in Flux Sensorless Open Loop and Closed Loop Configurations See Active/Inactive Parameters in Different Drive Control Modes in the Programming Guide for an overview of which control configuration is available, depending on selection of AC motor or PM non-salient motor.
Application Set-Up Examples 6.3.3 Control Structure in Flux with Motor Feedback Illustration 6.7 Control Structure in Flux with Motor Feedback Configuration See Active/Inactive Parameters in Different Drive Control Modes in the Programming Guide for an overview of which control configuration is available, depending on selection of AC motor or PM non-salient motor. In the shown configuration, parameter H-41 Motor Control Principle is set to  Flux w motor feedb and parameter H-40 Configuration Mode is set to  Speed closed loop.
Application Set-Up Examples AF-650 GP™ Design and Installation Guide 6.3.4 Internal Current Control Active reference and configuration mode The active reference can be either the local reference or the remote reference. When the motor current/torque exceed the torque limits set in parameter F-40 Torque Limiter (Driving),...
Application Set-Up Examples [Hand] [Auto] keys Parameter F-02 Op Active reference eration Method Hand Linked to Hand/ Local Auto Hand ⇒ Off Linked to Hand/ Local Auto Auto Linked to Hand/ Remote Auto Auto ⇒ Off Linked to Hand/ Remote Auto All keys Local...
Application Set-Up Examples AF-650 GP™ Design and Installation Guide 6.4.2 Reference Handling Local reference ▲ ▼ The local reference is active when the frequency converter is operated with ‘Hand’ key active. Adjust the reference by [ and [◄]/[►] navigation keys respectively.
Application Set-Up Examples 6.4.3 Reference Limits Parameter F-50 Reference Range, parameter F-52 Minimum Reference and parameter F-53 Maximum Reference define the allowed range of the sum of all references. The sum of all references is clamped when necessary. The relation between the resulting reference (after clamping) and the sum of all references is shown in Illustration 6.12.
Application Set-Up Examples AF-650 GP™ Design and Installation Guide 6.4.5 Scaling of Analog and Pulse References and Feedback References and feedback are scaled from analog and pulse inputs in the same way. The only difference is that a reference above or below the specified minimum and maximum “endpoints”...
Application Set-Up Examples 6.5 PID Control 6.5.1 Speed PID Control Parameter H-40 Configu- Parameter H-41 Motor Control Principle ration Mode Advanced Vector Control Flux Sensorless Flux w/ enc. feedb  Speed open loop Not Active Not Active ACTIVE N.A.  Speed closed loop N.A.
Application Set-Up Examples AF-650 GP™ Design and Installation Guide Parameter Description of function Parameter PI-00 Speed PID Select from which input the Speed PID should get its feedback. Feedback Source Parameter PI-02 Speed PID Propor- The higher the value - the quicker the control. However, too high value may lead to oscillations.
Application Set-Up Examples Function Parameter Setting Check that the ramp settings are within frequency Parameter F-07 Acc Default setting converter capabilities and allowed application operating el Time 1 default setting specifications. parameter F-08 Dec el Time 1 Set acceptable limits for the motor speed and frequency. Parameter F-18 Mot 0 RPM or Speed Low Limit 1500 RPM...
Application Set-Up Examples AF-650 GP™ Design and Installation Guide 184.108.40.206 Tuning PID Speed Control Generally the practical maximum limit of parameter PI-02 Speed PID Proportional Gain is determined by the encoder resolution and the feedback filter time but The following tuning guidelines are relevant when using...
Application Set-Up Examples 220.127.116.11 Example of Process PID Control Illustration 6.19 is an example of a Process PID Control used in a ventilation system. Illustration 6.19 Example - Process PID Control in a Ventilation System In a ventilation system, the temperature is to be settable from -5 to 35 °C with a potentiometer of 0–10 V.
Application Set-Up Examples AF-650 GP™ Design and Installation Guide Step-by-step description Step 1: Select only Proportional Control, meaning that the integral time is selected to the maximum value, while the differentiation time is selected to zero. Step 2: Increase the value of the proportional gain until...
Application Set-Up Examples Parameter Description of function Parameter PI-36 Process PID Diff. Gain Limit If there are quick changes in reference or feedback in a given application - which means that the error changes swiftly - the differentiator may soon become too dominant. This is because it reacts to changes in the error.
Application Set-Up Examples AF-650 GP™ Design and Installation Guide Function Parameter Setting Set min. speed limits F-18 300 RPM Set motor speed max. limit F-17 1500 RPM Set max. output frequency F-03 60 Hz Set S201 or S202 to wanted analog input function (Voltage (V) or current (I)).
Application Set-Up Examples 6.6.2 Dynamic Braking Dynamic Brake established by: • Resistor brake: A brake IGBT keeps the overvoltage under a certain threshold by directing the brake energy from the motor to the connected brake resistor (parameter B-10 Brake Function = ). •...
Application Set-Up Examples AF-650 GP™ Design and Installation Guide 464923 18.104.22.168 Overvoltage Control 500 V : R = Ω motor 630137 Overvoltage control (OVC) (exclusive brake resistor) can be 600 V : R = Ω motor selected as an alternative brake function in 832664 parameter B-17 Over-voltage Control.
6.6.4 Hoist Mechanical Brake is less than the frequency set in parameter B-21 Activate Brake Speed [RPM] or The General Purpose Drives AF-650 GP features a parameter B-22 Activate Brake Speed [Hz] and only mechanical brake control designed for hoisting if the frequency converter carries out a stop applications.
Application Set-Up Examples AF-650 GP™ Design and Installation Guide defined. Because the torque is defined directly the set-up The moment the brake opens, the load must be is more straightforward for hoisting applications. taken over by the motor. To facilitate the...
Application Set-Up Examples 6.7 Logic Control 6.7.1 Logic Control (LC) Logic Controller (LC) is a sequence of user-defined actions (see parameter LC-52 Logic Controller Action [x]) executed by the LC when the associated user-defined event (see parameter LC-51 Logic Controller Event [x]) is evaluated as Illustration 6.26 Comparators TRUE by the LC.
Application Set-Up Examples AF-650 GP™ Design and Installation Guide See parameter B-10 Brake Function and limit the maximum output speed the frequency converter parameter B-17 Over-voltage Control to select the method can provide used for controlling the DC-link voltage level.
Installation Consideration AF-650 GP™ Design and Installation Guide 7 Installation Consideration 7.1 General Aspects of EMC 7.1.1 General Aspects of EMC Emissions Burst transient is conducted at frequences in the range 150 kHz to 30 MHz. Airborne interference from the frequency converter system in the range 30 MHz to 1 GHz is generated from the inverter, motor cable, and the motor.
Installation Consideration To reduce the interference level from the entire system (unit + installation), make motor and brake cables as short as possible. Avoid placing cables with a sensitive signal level alongside motor and brake cables. Radio interference higher than 50 MHz (airborne) is especially generated by the control electronics.
The immunity requirements for frequency converters depend on the environment where they are installed. The requirements for the industrial environment are higher than the requirements for the home and office environment. All GE frequency converters comply with the requirements for the industrial environment and therefore comply also with the lower requirements for home and office environment with a large safety margin.
Installation Consideration Voltage range: 200–240 V, 380–500 V Basic standard Burst Surge Radiated electromagnetic RF common IEC 61000-4-4 IEC 61000-4-5 field mode voltage 61000-4-2 IEC 61000-4-3 IEC 61000-4-6 Acceptance criterion 2 kV/2 Ω DM Line 4 kV CM — — 10 V 4 kV/12 Ω...
Installation Consideration AF-650 GP™ Design and Installation Guide 7.3.1 Harmonics Emission Requirements 7.4 Galvanic Isolation (PELV) 7.4.1 PELV - Protective Extra Low Voltage Equipment connected to the public supply network: Options Definition PELV offers protection by way of extra low voltage.
GE regarding PELV. shown diagram. 380–500 V, unit size 4x, 4xh, 5x and 6x: At altitudes above 3 km, contact GE regarding PELV. 525–690 V: At altitudes above 2 km, contact GE regarding PELV. 7.5 Derating 7.5.1 Purpose of Derating...
Installation Consideration AF-650 GP™ Design and Installation Guide ─ ─ ─ ─ Typical torque at VT load ─•─•─•─ Max torque with forced cooling ‒‒‒‒‒ Max torque Table 7.7 Legend to Illustration 7.7 Note 1) Over-syncronous speed operation results in the available motor torque decreasing inversely proportional with the increase in speed.
Installation Consideration Make sure that the impedance from frequency converter to building ground is lower that the grounding impedance of the machine. This can be difficult for pumps. Make a direct ground connection between the motor and load motor. Lower the IGBT switching frequency. Modify the inverter waveform, 60°...
Status Messages AF-650 GP™ Design and Installation Guide 8 Status Messages 8.1 Status Display AC Brake AC Brake was selected in parameter B-10 Brake Function. The AC brake over-magnetizes the When the frequency converter is in Status mode, status motor to achieve a controlled slow down.
Status Messages Freeze output The remote reference is active, which holds QStop The motor is decelerating using the present speed. parameter C-23 Quick Stop Decel Time. • • Freeze output was selected as a function Quick stop inverse was selected as a for a digital input.
Status Messages AF-650 GP™ Design and Installation Guide Trip lock An alarm occurred and the motor is stopped. Once the cause of the alarm is cleared, power must be cycled to the frequency converter. The frequency converter can then be reset manually by pressing [Reset] or remotely by control terminals or serial communication.
RS485 Installation and Set-... 9 RS485 Installation and Set-up 9.1 Installation and Set-up 9.2 Network Configuration 9.1.1 Network Connection To enable Modbus RTU on the frequency converter, set the parameters in Table 9.1. One or more frequency converters can be connected to a control (or master) using the RS485 standardized interface.
RS485 Installation and Set-... AF-650 GP™ Design and Installation Guide during ‘silent’ intervals. When the first field (the address an exception response). For a normal response, the slave field) is received, each frequency converter or device simply echoes the original function code. For an exception decodes it to determine which device is being addressed.
RS485 Installation and Set-... programmable controller is addressed as coil 0000 in the Code Name Meaning data address field of a Modbus message. Coil 127 decimal Illegal data A value contained in the query data field is addressed as coil 007EHEX (126 decimal). value is not an allowable value for server (or Holding register 40001 is addressed as register 0000 in the...
RS485 Installation and Set-... AF-650 GP™ Design and Installation Guide 9.2.4 How to Access Parameters Coil Control not ready Control ready 22.214.171.124 Parameter Handling Frequency converter not Frequency converter ready ready Coasting stop Safety closed The PNU (Parameter Number) is translated from the...
RS485 Installation and Set-... 126.96.36.199 Conversion Factor 9.3 Drive Control Profile 9.3.1 Control Word According to Drive The different attributes for each parameter can be seen in Profile (parameter O-10 Control Word the section on factory settings. Since a parameter value Profile = Drive profile) can only be transferred as a whole number, a conversion factor must be used to transfer decimals.
RS485 Installation and Set-... AF-650 GP™ Design and Installation Guide Bit 06, Ramp stop/start Programmed ref. Parameter Bit 01 Bit 00 Bit 06 = 0: Causes a stop and makes the motor speed value decel to stop via the selected decel parameter.
RS485 Installation and Set-... 9.3.2 Status Word According to Drive Bit 04, No error/error (no trip) Profile (STW) (parameter O-10 Control Bit 04 = 0: The frequency converter is not in fault mode. Word Profile = Drive profile) Bit 04 = 1: The frequency converter shows an error but does not trip.
RS485 Installation and Set-... AF-650 GP™ Design and Installation Guide All bits in the STW are set to 0 if the connection between the InterBus option and the frequency converter is lost, or an internal communication problem has occurred. 9.3.3 Bus Speed Reference Value Speed reference value is transmitted to the frequency converter in a relative value in %.
Warnings and Alarms 10 Warnings and Alarms 10.1 System Monitoring 10.3 Warning and Alarm Displays The frequency converter monitors the condition of its input power, output, and motor factors, and other system performance indicators. A warning or alarm does not necessarily indicate a problem internally in the frequency converter.
Warnings and Alarms AF-650 GP™ Design and Installation Guide If an alarm cannot be reset, the reason may be that its Warning LED Alarm LED cause has not been rectified, or the alarm is trip-locked Warning (see also Table 10.2).
Warnings and Alarms Description Warning Alarm/Trip Alarm/Trip Lock Parameter reference 10 Volts low – Live zero error Parameter AN-01 Live Zero Timeout Function No motor Parameter H-80 Function at Stop Mains phase loss Parameter SP-12 Functio n at Line Imbalance DC link voltage high –...
Warnings and Alarms AF-650 GP™ Design and Installation Guide Description Warning Alarm/Trip Alarm/Trip Lock Parameter reference Overload of Digital Output Terminal 29 Parameter E-00 Digital I/O Mode, parameter E-52 Terminal 29 Mode Ovrld X30/6-7 – Ext. Supply (option) – Earth Fault 2 –...
Warnings and Alarms AF-650 GP™ Design and Installation Guide Alarm Word Alarm Word 2 Warning Word Warning Extended Word 2 Status Word Alarm Word Extended Status Word 00000100 Motor Electronic Reserved Motor Electronic OL Reserved Output Current Low OL Over (A10)
Warnings and Alarms 10.4 Warning and Alarm Definitions Troubleshooting • Extend the ramp time. WARNING 1, 10 Volts low • Change the ramp type. The control card voltage is less than 10 V from terminal 50. • Activate the functions in parameter B-10 Brake Remove some of the load from terminal 50, as the 10 V supply is overloaded.
Warnings and Alarms AF-650 GP™ Design and Installation Guide • Ensure that the motor data in parameters P-02, WARNING/ALARM 13, Over current P-03, P-06, P-07, F-04, and F-05 are set correctly. The inverter peak current limit (approximately 200% of the rated current) is exceeded.
Warnings and Alarms WARNING/ALARM 17, Control word timeout For frequency converters with DC fans, there is a feedback There is no communication with the frequency converter. sensor mounted in the fan. If the fan is commanded to run The warning is only active when parameter O-04 Control and there is no feedback from the sensor, this alarm Word Timeout Function is not set to  Off.
• Check for loose or missing wiring. • Incorrect airflow clearance above and below the It may be necessary to contact GE Service or the supplier. frequency converter. Note the code number for further troubleshooting • Blocked airflow around the frequency converter.
Warnings and Alarms WARNING 42, Overload of digital output on X30/6 or Text overload of digital output on X30/7 2064–2072 H081x: Option in slot x has restarted. For terminal X30/6, check the load connected to terminal 2080–2088 H082x: Option in slot x has issued a powerup-wait. X30/6 or remove the short circuit connection.
H-22 Motor Feedback Loss Timeout. During a commissioning procedure, the function could be effective. ALARM 50, Auto tune calibration failed Contact the GE supplier or GE service department. WARNING 62, Output frequency at maximum limit The output frequency has reached the value set in...
H-25 Tracking Error and The control card and power card are incompatible. To parameter H-27 Tracking Error Ramping. check compatibility, contact the GE supplier with the model number from the unit nameplate and the part ALARM 79, Illegal power section configuration numbers of the cards.
Warnings and Alarms AF-650 GP™ Design and Installation Guide WARNING/ALARM 104, Mixing fan fault WARNING 255, Digital output X49/7 overload The fan is not operating. The fan monitor checks that the Digital output X49/7 is overloaded. fan is spinning at power-up or whenever the mixing fan is ALARM 430, PWM Disabled turned on.
Basic Troubleshooting 11 Basic Troubleshooting 11.1 Start Up and Operation Symptom Possible cause Test Solution Missing input power. See Table 3.1. Check the input power source. Missing or open fuses, or circuit See Open fuses and Tripped circuit Follow the recommendations breaker tripped.
Basic Troubleshooting AF-650 GP™ Design and Installation Guide Symptom Possible cause Test Solution Motor rotation limit. Check that parameter H-08 Reverse Program correct settings. Lock is programmed correctly. Motor running in wrong Active reversing signal. Check if a reversing command is Deactivate reversing signal.
Basic Troubleshooting Symptom Possible cause Test Solution Bypass critical frequencies by using parameters in parameter group C-0#. Acoustic noise or vibration Turn off overmodulation in Check if noise and/or vibration (for example a fan blade is Resonances, for example in the parameter F-38 Overmodulation.
Specifications 13 Specifications 13.1 Electrical Data 13.1.1 Mains Supply 200–240 V Type designation 0.34 hp 0.5 hp 0.75 hp 1.0 hp 1.5 hp 2.0 hp 3.0 hp 5.0 hp Typical shaft output [kW] 0.25 0.37 0.55 0.75 Enclosure protection rating IP20, IP21 Enclosure protection rating IP55, IP66 14/15 14/15...
Specifications AF-650 GP™ Design and Installation Guide Type designation 7.5 hp 10 hp 15 hp Heavy duty/Ligth duty Typical shaft output [kW] Unit Size IP20 Enclosure protection rating IP21, IP55, IP66 Output current Continuous (200–240 V) [A] 24.2 30.8 30.8 46.2...
Specifications 13.1.2 Mains Supply 380–500 V Type designation 0.5 hp 0.75 hp 1.0 hp 1.5 hp 2.0 hp 3.0 hp 4.0 hp 5.0 hp 7.5 hp 10 hp Typical shaft output [kW] 0.37 0.55 0.75 Enclosure protection rating IP20, IP21 Enclosure protection rating IP55, IP66 14/15 14/15...
Specifications AF-650 GP™ Design and Installation Guide Type designation 15 hp 20 hp 25 hp 30 hp Heavy duty/Ligth duty Typical shaft output [kW] 18.5 18.5 Typical shaft output [hp] at 460 V Unit Size IP20 Unit Size IP21, IP55, IP66 Output current Continuous (380–440 V) [A]...
Specifications Type designation 40 hp 50 hp 60 hp 75 hp 100 hp Heavy duty/Ligth duty Typical shaft output [kW] Unit Size IP20 Unit Size IP21, IP55, IP66 Output current Continuous (380–440 V) [A] Intermittent (60 s overload) 91.5 80.3 (380–440 V) [A] Continuous (441–500 V) [A] Intermittent (60 s overload)
Specifications AF-650 GP™ Design and Installation Guide AF-650 GP 125 hp 150 hp 175 hp 250 hp 300 hp 350 hp Heavy duty/Ligth duty* Typical shaft output at 400 V [kW] Typical shaft output at 460 V [hp] Typical shaft ouptut at 500 V [kW]...
Specifications AF-650 GP 450 hp 500 hp 550 hp Heavy duty/Light duty* Typical shaft output at 400 V [kW] Typical shaft output at 460 V [hp] Typical shaft output at 500 V [kW] IP21/NEMA 1 Drive Type IP54/NEMA 12 drive type...
Specifications AF-650 GP™ Design and Installation Guide AF-650 GP 600 hp 650 hp 750 hp 900 hp 1000 hp 1200 hp Heavy duty/Light duty* Typical shaft output at 400 V [kW] 1000 Typical shaft output at 460 V [hp] 1000...
Specifications increase. Keypad and typical control card power consumptions are included. Options and customer load can add up to 30 W to the losses, though usually a fully loaded control card and options for slots A and B each add only 4 W. 4) Measured using 5 m (16.4 ft) screened motor cables at rated load and rated frequency.
Maximum cable cross-section for disconnect 6,4,4 (10,12,12) ] ([AWG]) Estimated power loss at rated maximum load Efficiency 0.97 0.97 0.97 0.97 0.97 0.97 0.97 0.97 Table 13.10 Mains Supply 525–600 V (AF-650 GP only), 1–10 hp MG35M402 DET-767c All rights reserved.
Specifications Type designation 15 hp 20 hp 25 hp 30 hp 40 hp Heavy duty/Light duty Typical shaft output [kW] 18.5 18.5 Typical shaft output [hp] at 575 V Unit Size IP20 Unit SizeIP21, IP55, IP66 Output current Continuous (525–550 V) [A] Intermittent (525–550 V) [A] Continuous (551–600 V) [A] Intermittent (551–600 V) [A]...
Specifications AF-650 GP™ Design and Installation Guide Type designation 50 hp 60 hp 75 hp 100 hp Heavy duty/Light duty Typical shaft output [kW] Typical shaft output [hp] at 575 V Unit Size IP20 Unit Size IP21, IP55, IP66 Output current Continuous (525–550 V) [A]...
Specifications 13.1.4 Mains Supply 525–690 V Type designation 1.5 hp 2.0 hp 2.2 hp 4.0 hp 5.0 hp 7.5 hp 10 hp Heavy Duty/Light Duty HO/NO HO/NO HO/NO HO/NO HO/NO HO/NO HO/NO Typical shaft output [kW/(hp)] 1.1 (1.5) 1.5 (2.0) 2.2 (3.0) 3.0 (4.0) 4.0 (5.0)
Specifications AF-650 GP™ Design and Installation Guide Type designation 40 hp 50 hp 60 hp 75 hp 100 hp Heavy Duty/Light Duty Typical shaft output at 550 V [kW/(hp)] (30) (40) (40) (50) (50) (60) (60) (75) (75) (100) Typical shaft output at 690 V [kW/(hp)]...
Mains voltage low/mains drop-out: During low mains voltage or a mains drop-out, the AF-650 GP drive continues until the DC-link voltage drops below the minimum stop level, which corresponds typically to 15% below the frequency converter's lowest rated supply voltage. Power-up and full torque cannot be expected at mains voltage lower than 10% below the frequency converter's lowest rated supply voltage.
Specifications AF-650 GP™ Design and Installation Guide Typical input current at 24 V 50 mA rms Typical input current at 20 V 60 mA rms Input capacitance 400 nF All digital inputs are galvanically isolated from the supply voltage (PELV) and other high voltage terminals.
Specifications Digital output Programmable digital/pulse outputs Terminal number 27, 29 Voltage level at digital/frequency output 0–24 V Maximum output current (sink or source) 40 mA Maximum load at frequency output 1 kΩ Maximum capacitive load at frequency output 10 nF Minimum output frequency at frequency output 0 Hz Maximum output frequency at frequency output...
Specifications AF-650 GP™ Design and Installation Guide 2)3) Maximum terminal load (AC-1) on 4–5 (NO) (resistive load) overvoltage cat. II 400 V AC, 2 A on 4–5 (NO) (inductive load @ cosφ 0.4) Maximum terminal load (AC-15) 240 V AC, 0.2 A Maximum terminal load (DC-1) on 4–5 (NO) (resistive load)
Fuses or circuit breakers are mandatory to comply with IEC lation. The frequency converter is equipped with an 60364. GE recommend using a selection of the following. internal overcurrent protection (parameter F-43 Current Limit) that can be used for upstream overload protection The fuses below are suitable for use on a circuit capable of (UL applications excluded).
The fuses below are suitable for use on a circuit capable of delivering 100000 Arms (symmetrical), 240 V, or 500 V, or 600 V depending on the frequency converter voltage rating. With the proper fusing, the drive Short Circuit Current Rating (SCCR) is 100000 Arms. Recommended maximum fuse AF-650 GP Bussmann Bussmann Bussmann...
Specifications Recommended maximum fuse Ferraz- Ferraz- AF-650 GP SIBA Littelfuse Shawmut Shawmut [kW (hp)] Type RK1 Type RK1 Type CC Type RK1 0.37–0.75 5017906-006 KLS-R-6 ATM-R-6 A6K-6-R (1/2–1) 1.5–2.2 5017906-010 KLS-R-10 ATM-R-10 A6K-10-R (2–3) 3.7 (5) 5017906-020 KLS-R-20 ATM-R-20 A6K-20-R 5.5 (7.5)
Specifications AF-650 GP™ Design and Installation Guide Recommended maximum fuse AF-650 GP Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann [kW (hp)] Type RK1 Type J Type T Type CC Type CC Type CC 0.75 (1) KTS-R-5 JKS-5 JJS-6 FNQ-R-5 KTK-R-5 LP-CC-5 1.5–2.2...
Index Windmilling....................ii Wire sizes..................20, 21 DET-767c All rights reserved. MG35M402...
Index AF-650 GP™ Design and Installation Guide MG35M402 DET-767c All rights reserved.
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-650 GP are trademarks of the General Electric Company. 41 Woodford Avenue Plainville, CT 06062 www.geindustrial.com/drives...