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AF-600 FP Fan & Pump Drive (230V to 60HP, 460/575V to 125HP Operating Instructions...
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Safety AF-600 FP Operating Instructions Safety WARNING Voltage (V) Minimum Waiting Time (Minutes) HIGH VOLTAGE! 200 - 240 0.75 - 3.7 kW 5.5 - 45 kW Frequency converters contain high voltage when 1 - 5 hp 7 1/2 - 60 hp connected to AC mains input power.
Contents AF-600 FP Operating Instructions Contents 1 Introduction 1.1 Purpose of the Manual 1.2 Additional Resources 1.3 Product Overview 1.4 Internal Drive Controller Functions 1.5 Unit Sizes and Power Ratings 2 Installation 2.1 Installation Site Check List 2.2 Drive and Motor Pre-installation Check List 2.3 Mechanical Installation...
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Contents AF-600 FP Operating Instructions 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...
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Contents AF-600 FP Operating Instructions 9.1 Start Up and Operation 10 Specifications 10.1 Power-dependent Specifications 10.2 General Technical Data 10.3 Fuse Tables 10.3.1 Recommendations 10.3.2 CE Compliance 10.3.3 NEC and UL Compliance 10.3.4 Substitute Fuses for 240 V 10.4 Connection Tightening Torques...
Introduction AF-600 FP Operating Instructions 1 Introduction Illustration 1.1 Exploded View Unit Size 1X Keypad 10 Motor output terminals 96 (U), 97 (V), 98 (W) RS-485 serial bus connector (+68, -69) 11 Relay 1 (01, 02, 03) Analog I/O connector...
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Introduction AF-600 FP Operating Instructions Illustration 1.2 Exploded View Unit Sizes 21, 22, 31, and 32 Keypad Relay 2 (04, 05, 06) Cover Lifting ring RS-485 serial bus connector Mounting slot Digital I/O and 24 V power supply Grounding clamp (PE)
Introduction AF-600 FP Operating Instructions 1.1 Purpose of the Manual This manual is intended to provide detailed information for the installation and start up of the frequency converter. Chapter 2 Installation provides requirements for mechanical and electrical installation, including input, motor, control and serial communications wiring, and control terminal functions.
Introduction AF-600 FP Operating Instructions 1.5 Unit Sizes and Power Ratings References to unit sizes used in this manual are defined in Table 1.2. Unit sizes IP20 / Open Chassis IP55 / Nema 12 Volts 200-240 1-3 HP 5 HP 7.5-15 HP...
Installation AF-600 FP Operating Instructions 2 Installation 2.1 Installation Site Check List 2.3 Mechanical Installation • 2.3.1 Cooling The drive relies on the ambient air for cooling. Observe the limitations on ambient air temperature for optimal operation • To provide cooling airflow, mount the unit to a solid flat surface or to the optional back plate •...
Installation AF-600 FP Operating Instructions 2.3.2 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 •...
Installation AF-600 FP Operating Instructions 2.4 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 mains to the drive input terminals •...
See Illustration 2.5. temperature requirements. • GE recommends that all power connections be made with a minimum 75° C rated copper wire. • See 10.1 Power-dependent Specifications for recommended wire sizes.
Installation AF-600 FP Operating Instructions 2.4.2 Earth (Grounding) Requirements EN/IEC61800-5-1 (Power Drive System Product Standard) requires special care if the leakage current exceeds 3,5mA. Earth grounding must be reinforced in one of the WARNING following ways: GROUNDING HAZARD! • Earth ground wire of at least 10mm For operator safety, it is important to ground drive •...
Installation AF-600 FP Operating Instructions 2.4.2.2 Grounding Using Shielded Cable Use a wire stripper to remove the insulation for proper grounding. Earthing (grounding) clamps are provided for motor wiring Secure the grounding clamp to the stripped (see Illustration 2.7). portion of the wire with the screws provided.
Installation AF-600 FP Operating Instructions Illustration 2.9 Motor, Mains and Earth Wiring for Frame Sizes 1X Illustration 2.11 Motor, Mains and Earth Wiring for Frame Sizes 2X and Above Using Conduit 2.4.4 AC Mains Connection • Size wiring based upon the input current of the drive.
Installation AF-600 FP Operating Instructions • Ground the cable in accordance with grounding instructions provided in 2.4.2 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...
Installation AF-600 FP Operating Instructions • Connector 4 is a USB port available for use with Terminal Description the DCT-10 Digital Inputs/Outputs Default • Also provided are two Form C relay outputs that Terminal Parameter Setting Description are in various locations depending upon the drive...
Installation AF-600 FP Operating Instructions 2.4.5.5 Control Terminal Functions See 10.1 Power-dependent Specifications for control terminal wiring sizes. Drive functions are commanded by receiving control input See 6 Application Set-Up Examples for typical control wiring signals. connections. • Each terminal must be programmed for the function it will be supporting in the parameters associated with that terminal.
Installation AF-600 FP Operating Instructions For basic serial communication set-up, select the following Protocol type in O-30 Protocol. Drive address in O-31 Address. Baud rate in O-32 Drive Port Baud Rate. • Four communication protocols are internal to the drive. Follow motor manufacturer wiring requirements.
Start Up and Functional Tes... AF-600 FP Operating Instructions 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... AF-600 FP Operating Instructions 3.1.2 Start Up Check List 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 •...
Start Up and Functional Tes... AF-600 FP Operating Instructions 3.2 Applying Power to the Drive WARNING Select language and press [OK]. Then enter the 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... AF-600 FP Operating Instructions NOTE istics with the data entered in P-02, P-03, P-06, P-07, F-04 and F-05. The hand key on the keypad provides a local start • command to the drive. The OFF key provides the stop It does not cause the motor to run or harm to function.
Start Up and Functional Tes... AF-600 FP Operating Instructions 3.7 System Start Up The procedure in this section requires user-wiring and application programming to be completed. is intended to help with this task. Other aids to application set-up are listed in 1.2 Additional Resources. The following procedure is recommended after application set-up by the user is completed.
User Interface AF-600 FP Operating Instructions 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 four functional groups (see Illustration 4.1).
User Interface AF-600 FP Operating Instructions 4.1.2 Setting Keypad Display Values Function Status Press to show operational information. • In Auto mode, press and hold to toggle The display area is activated when the frequency converter between status read-out displays receives power from mains voltage, a DC bus terminal, or an external 24V supply.
User Interface AF-600 FP Operating Instructions 4.1.4 Navigation Keys Navigation keys are used for programming functions and moving the display cursor. The navigation keys also provide speed control in local (hand) operation. Three drive status indicator lights are also located in this area.
User Interface AF-600 FP Operating Instructions 4.2.1 Uploading Data to the keypad 4.3.1 Recommended Initialisation Press [OFF] to stop the motor before uploading Press [Main Menu] twice to access parameters. or downloading data. Scroll to H-03 Restore Factory Settings. Go to K-50 Keypad Copy.
About Drive Programming AF-600 FP Operating Instructions 5 About Drive Programming 5.1 Introduction The drive is programmed for its application functions using Parameter Data Set parameters. Parameter are accessed by pressing either [Quick Menu] or [Main Menu] on the keypad. (See 4 User Interface for details on using the keypad function keys.)
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About Drive Programming AF-600 FP Operating Instructions F-52 Minimum Reference. Set minimum internal Analog Input 53 drive reference to 0Hz. (This sets the minimum drive speed at 0Hz.) AN-10 Terminal 53 Low Voltage. Set minimum external voltage reference on Terminal 53 at 0V.
About Drive Programming AF-600 FP Operating Instructions AN-14 Terminal 53 Low Ref./Feedb. Value. Set minimum speed reference on Terminal 53 at 20Hz. (This tells the drive that the minimum voltage received on Terminal 53 (0V) equals 20Hz output.) Illustration 5.1 Wiring Example for External Device Providing 0-10V Control Signal 5.3 Control Terminal Programming...
About Drive Programming AF-600 FP Operating Instructions Scroll to parameter group E-## Digital In/Out and Parameter International North American press [OK]. Default Parameter Default Parameter Value Value F-04 Base 50Hz 60Hz Frequency F-53 Maximum 50Hz 60Hz Reference F-54 Reference External/Preset...
About Drive Programming AF-600 FP Operating Instructions 5.5.1 Quick Menu Structure Quick Start 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...
About Drive Programming AF-600 FP Operating Instructions 5.6 Remote Programming with DCT-10 GE has a software program available for developing, storing, and transferring drive programming. The DCT-10 allows the user to connect a PC to the drive and perform live programming rather than using the keypad. Also, all drive programming can be done off-line and simply downloaded into drive.
Application Set-Up Examples AF-600 FP Operating Instructions 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 AN-20 Terminal...
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Application Set-Up Examples AF-600 FP Operating Instructions Parameters Parameters Function Setting Function Setting AN-10 Terminal E-01 Terminal 18 [8] Start* 53 Low Voltage 0.07V* Digital Input AN-11 Terminal 10V* E-03 Terminal 27 [7] External 53 High Voltage Digital Input Interlock...
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Application Set-Up Examples AF-600 FP Operating Instructions Parameters Parameters Function Setting Function Setting E-01 Terminal 18 E-02 Terminal 19 [1] Reset Digital Input [8] Start* Digital Input E-02 Terminal 19 [52] Run * = Default Value Digital Input Permissive Notes/comments:...
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Application Set-Up Examples AF-600 FP Operating Instructions will always be the set-up that is edited. If you Parameters prefer you can also ignore this and manually Function Setting control what set-up you want to edit through par. K-11. O-30 Protocol...
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Application Set-Up Examples AF-600 FP Operating Instructions Parameters Function Setting F-10 Electronic Overload Thermistor trip F-12 Motor [1] Analog Thermistor Input input 53 * = Default Value Notes/comments: If only a warning is desired, F-10 Electronic Overload should be set to [1] Thermistor warning.
Status Messages AF-600 FP Operating Instructions 7 Status Messages 7.1 Status Display 7.2 Status Message Definitions Table When the drive is in status mode, status messages are The next three tables define the meaning of the status generated automatically from within the drive and appear message display words.
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Status Messages AF-600 FP Operating Instructions Operation Status Operation Status DC Hold DC hold is selected in H-80 Function at Stop OVC control Overvoltage control was activated in B-17 Over- and a stop command is active. The motor is voltage Control. The connected motor is held by a DC current set in B-00 DC Hold supplying the drive with generative energy.
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Status Messages AF-600 FP Operating Instructions Operation Status Start delay In F-24 Holding Time, a delay starting time was set. A start command is activated and the motor will start after the start delay time expires. Start fwd/rev Start forward and start reverse were selected as functions for two different digital inputs.
Warnings and Alarms AF-600 FP Operating Instructions 8 Warnings and Alarms 8.1 System Monitoring 8.3 Warning and Alarm Displays The drive monitors the condition of its input power, output, and motor factors as well as other system performance indicators. A warning or alarm may not necessarily indicate a problem internal to the drive itself.
Warnings and Alarms AF-600 FP Operating Instructions 8.4 Warning and Alarm Definitions Table 8.1 defines whether a warning is issued prior to an alarm, and whether the alarm trips the unit or trip locks the unit. Description Warning Alarm/Trip Alarm/Trip Lock...
Warnings and Alarms AF-600 FP Operating Instructions Description Warning Alarm/Trip Alarm/Trip Lock Parameter Reference Auto Tune calibration failed Auto Tune check U and I Auto Tune low I Auto Tune motor too big Auto Tune motor too small Auto Tune Parameter out of range...
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Warnings and Alarms AF-600 FP Operating Instructions WARNING/ALARM 2, Live zero error Troubleshooting: This warning or alarm will only appear if programmed by Check that the supply voltage matches the drive the user in AN-01 Live Zero Timeout Function. The signal on voltage.
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Warnings and Alarms AF-600 FP Operating Instructions Troubleshooting Troubleshooting: Check for motor overheating. Remove power to the drive and repair the earth fault. Check if the motor is mechanically overloaded. Check for earth faults in the motor by measuring When using terminal 53 or 54, check that the...
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Check for loose or missing wiring Cycle power to the drive and check that the fan It may be necessary to contact your GE supplier or service operates briefly at start up. department. Note the code number for further trouble- shooting directions.
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WARNING 40, Overload of digital output terminal 27 ALARM 50, Auto tune calibration failed Check the load connected to terminal 27 or remove short- Contact your GE supplier or GE Service Department. circuit connection. Check E-00 Digital I/O Mode and ALARM 51, Auto tune check U and I E-51 Terminal 27 Mode.
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Warnings and Alarms AF-600 FP Operating Instructions WARNING 66, Heatsink temperature low WARNING 97, Stop delayed The drive is too cold to operate. This warning is based on Stopping the motor has been delayed due to short cycle the temperature sensor in the IGBT module.
Basic Troubleshooting AF-600 FP Operating Instructions 9 Basic Troubleshooting 9.1 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...
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Basic Troubleshooting AF-600 FP Operating Instructions Symptom Possible Cause Test Solution Motor rotation limit Check that H-08 Reverse Lock is Program correct settings. programmed correctly. Active reversing signal Check if a reversing command is Deactivate reversing signal. Motor running in wrong...
Specifications AF-600 FP Operating Instructions 10.2 General Technical Data Mains supply (L1, L2, L3): 200-240V ±10%, 380-480V ±10%, 525-600V ±10%, Supply voltage Mains voltage low / mains drop-out: During low mains voltage or a mains drop-out, the drive continues until the intermediate circuit voltage drops below the minimum stop level, which corresponds typically to 15% below the drive's lowest rated supply voltage.
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Specifications AF-600 FP Operating Instructions Analog inputs: Number of analog inputs Terminal number 53, 54 Modes Voltage or current Mode select Switches A53 and A54 Voltage mode Switch A53/A54 = (U) Voltage level 0 to + 10V (scaleable) Input resistance, R approx.
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Specifications AF-600 FP Operating Instructions Digital output: Programmable digital/pulse outputs Terminal number 27, 29 Voltage level at digital/frequency output 0 - 24 V Max. output current (sink or source) 40 mA Max. load at frequency output 1 kΩ Max. capacitive load at frequency output...
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- with full output power of typical EFF2 motors (up to 90% output current) max. 45 °C - at full continuous Drive output current For more information on derating see the AF-600 FP Design Guide, section on Special Conditions. Minimum ambient temperature during full-scale operation 0°C Minimum ambient temperature at reduced performance - 10°C...
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Specifications AF-600 FP Operating Instructions Protection and Features: • Electronic thermal overload motor protection against overload. • Temperature monitoring of the heatsink ensures that the drive trips if the temperature reaches 95°C ± 5°C. An overload temperature cannot be reset until the temperature of the heatsink is below 70°C ± 5°C (Guideline - these temperatures may vary for different power sizes, enclosures etc.).
NOTE The recommendations given do not cover Branch circuit protection for UL. Short-circuit protection: GE recommends using the fuses/Circuit Breakers mentioned below to protect service personnel and property in case of component break-down in the drive. Over current protection: The drive provides overload protection to limit threats to human life, property damage and to avoid fire hazard due to overheating of the cables in the installation.
10.3.2 CE Compliance Fuses or Circuit Breakers are mandatory to comply with IEC 60364. GE recommend using a selection of the following. The fuses below are suitable for use on a circuit capable of delivering 100,000 Arms (symmetrical), 240V, or 480V, or 500V, or 600V depending on the drive voltage rating.
Specifications AF-600 FP Operating Instructions 10.3.3 NEC and UL Compliance Fuses or Circuit Breakers are mandatory to comply with NEC 2009. We recommend using a selection of the following The fuses below are suitable for use on a circuit capable of delivering 100,000 Arms (symmetrical), 240V, or 480V, or 600V depending on the drive voltage rating.
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Specifications AF-600 FP Operating Instructions Recommended max. fuse Ferraz- Ferraz- AF-600 1-phase AF-600 3-phase SIBA Littel fuse Shawmut Shawmut [HP] [HP] Type RK1 Type RK1 Type CC Type RK1 5017906-006 KLS-R-6 ATM-R-6 A6K-10-6 5017906-010 KLS-R-10 ATM-R-10 A6K-10-R 5017906-020 KLS-R-20 ATM-R-20...
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Specifications AF-600 FP Operating Instructions Recommended max. fuse AF-600 Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann [HP] Type RK1 Type J Type T Type CC Type CC Type CC KTS-R-5 JKS-5 JJS-6 FNQ-R-5 KTK-R-5 LP-CC-5 KTS-R-10 JKS-10 JJS-10 FNQ-R-10 KTK-R-10 LP-CC-10...
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