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GE
AF-650 GP & AF-600 FP
TM
High Power Service Manual
Unit Sizes 6x
Operating Instructions

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   Summary of Contents for GE AF-650 GP

  • Page 1 AF-650 GP & AF-600 FP High Power Service Manual Unit Sizes 6x Operating Instructions...
  • Page 2: Table Of Contents

    High Power Service Manual for Unit Sizes 6x Contents 1 Introduction Purpose AF-6 Product Overview For Your Safety Electrostatic Discharge (ESD) Unit Size Definitions Ratings Tables Optional Components Optional Unit Size 6x components Tools Required General Torque Tightening Values Exploded Views 2 Operator Interface and Control Introduction Operating the Frequency Converter...
  • Page 3 High Power Service Manual for Unit Sizes 6x Intermediate Section Inverter Section Brake Option Cooling Fans Fan Speed Control Load Sharing Specific Card Connections 4 Troubleshooting Troubleshooting Tips Exterior Fault Troubleshooting Fault Symptom Troubleshooting Visual Inspection Fault Symptoms No Display Intermittent Display Motor Will not Run Incorrect Motor Operation...
  • Page 4 High Power Service Manual for Unit Sizes 6x Signal Test Board Static Test Procedures Rectifier Module Static Test Inverter Module Static Tests Brake IGBT Test Fan Continuity Test Dynamic Test Procedures Split Bus Mode Warnings No Display Text Input Voltage Test Basic Control Card Voltage Test DC Undervoltage Test Input Imbalance of Supply Voltage Test...
  • Page 5 High Power Service Manual for Unit Sizes 6x DC Link Inductor MDCIC Board 8 Disassembly/Assembly - Inverter Module For Your Safety GE Training Required Inverter Module Inverter Module, Exploded View Internal Access Power Card Upper Capacitor Bank Assembly (without removing power card)
  • Page 6: Introduction

    High Power Service Manual for Unit Sizes 6x 1 Introduction 1.1 Purpose The purpose of this manual is to provide detailed technical information and instructions to enable a qualified technician to identify faults and perform repairs on frequency converters in the unit size 6x range. It provides the reader with a general view of the unit's main assemblies and a description of the internal processing.
  • Page 7: Electrostatic Discharge (esd)

    1200 / 1350 62 / 64 1000 / 1100 1350 / 1550 1200 / 1400 62 / 64 Table 1.2: AF-650 GP 380-480 VAC Table 1.4: AF-650 GP 525-690 VAC 1.6 Ratings Tables 380-480V & DC Voltage Levels 380-500V units...
  • Page 8 High Power Service Manual for Unit Sizes 6x Mains supply 3 x 380-480 V AF-600 FP 1000 1200 1350 Model number AF-650 GP 1000 1200 Light duty (LD) current ratings (110 %): Output current Nominal [A] (380-440 V) 1120 1260...
  • Page 9 High Power Service Manual for Unit Sizes 6x Mains supply 3 x 525 - 690 V Model number AF-600 FP 1050 1150 1350 1550 AF-650 GP 1000 1150 1250 1350 1550 Light duty (LD) current ratings (110 %): Output current...
  • Page 10: Optional Components

    High Power Service Manual for Unit Sizes 6x 1.7 Optional Components 1.7.1 Optional Unit Size 6x components Units are manufactured in different configurations due to the optional com- Optional Component Cabinet Location ponents available. Depending on the unit configuration, optional equipment Mains Options may be mounted in the inverter, rectifier or option cabinet.
  • Page 11: Exploded Views

    High Power Service Manual for Unit Sizes 6x 1.10 Exploded Views Inverter cabinet exploded view (cabinet with 2 inverter modules shown). Units with 3 inverter modules are similar. DC link inductor Module heatsink fan Fan transformer Fan door cover (-)DC bus bar (Optional) brake output bus bar (+)DC bus bar Motor output bus bar...
  • Page 12 High Power Service Manual for Unit Sizes 6x Illustration 1.1: Inverter module exploded view Right side cover plate High frequency board Inverter power card IGBT module Panel connectors Current sensor SMPS fuse and fan fuse Fan assembly Upper capacitor bank assembly Lower capacitor bank assembly DC bus fuses Gate driver card...
  • Page 13 High Power Service Manual for Unit Sizes 6x Rectifier cabinet exploded view Rectifier module Module lifting eye bolts (mounted on vertical strut) DC bus bar Module heatsink fan SMPS fuse Fan door cover (Optional) back AC fuse mounting bracket (T) SMPS fuse (Optional) middle AC fuse mounting bracket (S) Power card...
  • Page 14 High Power Service Manual for Unit Sizes 6x Rectifier module exploded view Rectifier module cover plate Soft charge cards Power card Soft charge card mounting plate Panel connectors SCR module SMPS fuse Fan assembly Power card mounting plate flange Diode module Power card mounting plate Soft charge resistor...
  • Page 15 High Power Service Manual for Unit Sizes 6x Option cabinet exploded view Contactor Circuit breaker or disconnect RFI filter AC mains/line fuses Mains AC power input terminals...
  • Page 16: Operator Interface And Control

    High Power Service Manual for Unit Sizes 6x 2 Operator Interface and Control 2.1 Introduction Frequency converters are designed with self-diagnostic circuitry to isolate fault conditions and activate display messages which greatly simplify troubleshooting and service. The operating status of the frequency converter is displayed in real-time. Virtually every command given to the frequency converter results in some indication on the Keypad display.
  • Page 17: Display Area

    High Power Service Manual for Unit Sizes 6x 2.2.3 Display Area The top line shows controller status when in status mode or two variables selected in par. K-10 Active Set-up, such as direction of rotation or active set- The motor values displayed are selected by parameter choices in par. K-20 Display Line 1.1 Small, par. K-21 Display Line 1.2 Small, par. K-22 Display Line 1.3 Small, par.
  • Page 18: Navigation Keys

    High Power Service Manual for Unit Sizes 6x 2.2.5 Navigation Keys Navigation keys are used for programming functions, moving the display cursor, and speed control in local controller operation. Controller status indicator lights are also located in this area. Back Reverts to the previous step or list in the navigation structure. Cancel The last change or command will be cancelled, as long as the display mode has not changed.
  • Page 19: Tips And Tricks

    High Power Service Manual for Unit Sizes 6x The following control signals will still be available when [Hand] is activated: [Hand] - [Off] - [Auto] - [Reset] keys Coasting stop inverse (motor coasting to stop) Reversing Set-up select Stop command from serial communication Quick stop DC brake Off Stops the connected motor.
  • Page 20 High Power Service Manual for Unit Sizes 6x 2.2.8 Restore Factory Settings There are two ways to restore the drive to factory settings: Recommended restore and manual restore. Please be aware that they have different impact according to the below description. Recommended restore (via par.
  • Page 21: Status Messages

    High Power Service Manual for Unit Sizes 6x 2.3 Status Messages Status messages appear in the bottom of the display - see the example below. The left part of the status line indicates the active operation mode of the frequency converter. The centre part of the status line indicates the references site.
  • Page 22 High Power Service Manual for Unit Sizes 6x Bus Jog 2 PROFIDrive profile was selected in par. O-10 Control Word Profile. The Jog 2 function is activated via serial communication. The motor is running with par. O-91 Bus Jog 2 Speed. Catch up The output frequency is corrected by the value set in par.
  • Page 23 Protection md The AF-650 GP/AF-600 FP has detected a critical status (e.g. an overcurrent, overvoltage). To avoid tripping the frequency converter (alarm), protection mode is activated, which includes reducing the switching frequency to 4 kHz. If possible, protection mode ends after approximately 10 s. Activation of protection mode can be restricted by adjusting the par.
  • Page 24 High Power Service Manual for Unit Sizes 6x Sleep Boost (AF-600 FP only) The boost function in par. AP-45 Setpoint Boost is enabled. This function is only possible in Closed loop operation. Sleep Mode (AF-600 FP only) The sleep mode function is enabled by means of either No Flow Detection or Minimum Speed Detection or via an external signal applied to one of the digital input (parameter group E-##).
  • Page 25: Service Functions

    High Power Service Manual for Unit Sizes 6x 2.4 Service Functions Service information for the frequency converter can be shown on display lines 3 and 4. Included in the data are counters that tabulate operating hours, power ups and trips; fault logs that store frequency converter status values present at the 20 most recent events that stopped the frequency converter;...
  • Page 26: Frequency Converter Inputs And Outputs

    High Power Service Manual for Unit Sizes 6x 2.5 Frequency Converter Inputs and Outputs The frequency converter operates by receiving control input signals. The frequency converter can also output status data or control auxiliary devices. Control input is connected to the frequency converter in three possible ways. One way for frequency converter control is through the Keypad on the front of the frequency converter when operating in local (hand) mode.
  • Page 27: Input Signals

    High Power Service Manual for Unit Sizes 6x 2.5.1 Input signals The frequency converter can receive two types of remote input signals: digital or analog. Digital inputs are wired to terminals 18, 19, 20 (common), 27, 29, 32, and 33. Analog or digital inputs are wired to terminals 53 or 54 and 55 (common). The terminal functions are set by a switch found by removing the Keypad. Some options may include additional terminals.
  • Page 28: Control Terminals

    High Power Service Manual for Unit Sizes 6x 2.6 Control Terminals Control terminals must be programmed. Each terminal has specific functions it is capable of performing and a numbered parameter associated with it. See table Control Terminals and Associated Parameters. The setting selected in the parameter enables the function of the terminal. It is important to confirm that the control terminal is programmed for the correct function.
  • Page 29: Control Terminal Functions

    1 (closed). Terminals 27 and 29 are programmable as digital/pulse outputs. Common for digital inputs. 0–24 VDC input for safety stop AF-650 GP only. Common for analog and digital outputs. Analog and digital outputs for indicating values such as frequency, reference, current and torque. The analog signal is 0/4 to 20 mA at a maximum of 500 Ω.
  • Page 30: Earthing Screened Cables

    High Power Service Manual for Unit Sizes 6x 2.8 Earthing Screened Cables It is recommended that screened control cables be connected with cable clamps at both ends to the metal cabinet of the frequency converter. The table below shows earth cabling for optimal results. Correct earthing Control cables and cables for serial communication must be fitted with cable clamps at both ends to ensure the best possible electrical connection.
  • Page 31 High Power Service Manual for Unit Sizes 6x...
  • Page 32: Internal Frequency Converter Operation

    High Power Service Manual for Unit Sizes 6x 3 Internal Frequency Converter Operation 3.1 General This section is intended to provide an operational overview of the frequency converter’s main assemblies and circuitry. With this information, a repair technician should have a better understanding of the frequency converter's operation and aid in the troubleshooting process. 3.2 Description of Operation A frequency converter is an electronic controller that supplies a regulated amount of AC power to a three phase induction motor in order to control the speed of the motor.
  • Page 33: Logic Section

    High Power Service Manual for Unit Sizes 6x 3.2.1 Logic Section The control card contains most of the logic section (see Illustration below). The primary logic element of the control card is a microprocessor, which supervises and controls all functions of frequency converter operation. In addition, separate PROMs contain the parameters to provide the user with programmable options. These parameters are programmed to enable the frequency converter to meet specific application requirements.
  • Page 34: Logic To Power Interface

    High Power Service Manual for Unit Sizes 6x Two relays for monitoring the status of the frequency converter are located on the power card. These are programmable through parameter group E-##. The relays are Form C, meaning it has one normally open contact and one normally closed contact on a single throw. The contacts of the relay are rated for a maximum load of 240 VAC at 2 Amps resistance.
  • Page 35: Power Section

    High Power Service Manual for Unit Sizes 6x 3.2.3 Power Section The high voltage power section consists of AC input terminals, AC and DC bus bars, fusing, harnessing, AC output, and optional components. The power section (see illustration below) also contains circuitry for the soft charge and SCR/diode modules in the rectifier; the DC bus filter circuitry containing the DC coils, often referred to as the intermediate or DC bus circuit;...
  • Page 36: Sequence Of Operation

    High Power Service Manual for Unit Sizes 6x 3.3 Sequence of Operation 3.3.1 Rectifier and Option Cabinet When input power is first applied to the frequency converter, it enters through the input terminals (L1, L2, L3) and on to the disconnect or/and RFI option, depending on the unit's configuration (see illustration 3-4).
  • Page 37 High Power Service Manual for Unit Sizes 6x NTC2 NTC1 ELO3 EUP3 GLO3 GUP3 ELO2 EUP2 GLO2 GUP2 ELO1 EUP1 GLO1 GUP1 3 2 1...
  • Page 38: Intermediate Section

    High Power Service Manual for Unit Sizes 6x 3.3.2 Intermediate Section Following the rectifier section, voltage passes to the intermediate section. (See following illustration). This rectified voltage is smoothed by an LC filter circuit consisting of the DC bus inductor and the DC bus capacitor banks per each inverter module. The DC bus inductor provides series impedance to changing current.
  • Page 39 High Power Service Manual for Unit Sizes 6x...
  • Page 40: Inverter Section

    By employing a sophisticated control scheme, the frequency converter is capable of delivering a current waveform that nearly replicates a true AC sine wave. This waveform, as generated by the GE Advanced Vector Control PWM principle at the control card, provides optimal performance and minimal losses in the motor.
  • Page 41 High Power Service Manual for Unit Sizes 6x...
  • Page 42: Brake Option

    High Power Service Manual for Unit Sizes 6x 3.3.4 Brake Option For frequency converters equipped with the dynamic brake option, two brake IGBTs along with terminals 81(R-) and 82(R+) are included in each inverter module for connecting an external brake resistor(s). The function of the brake IGBT (see Illustration Brake Option) is to limit the voltage in the intermediate circuit, whenever the maximum voltage limit is exceeded.
  • Page 43 High Power Service Manual for Unit Sizes 6x...
  • Page 44: Cooling Fans

    High Power Service Manual for Unit Sizes 6x 3.3.5 Cooling Fans All frequency converters in this size range are equipped with cooling fans to provide airflow along the heatsinks and within the enclosures. All fans are powered by mains voltage which is stepped down by autotransformers and regulated to 200 or 230 VAC by circuitry provided on the power cards. On/off and high/low speed control of the fans is provided to reduce overall acoustical noise and extend the life of the fans.
  • Page 45: Load Sharing

    High Power Service Manual for Unit Sizes 6x 3.3.7 Load Sharing Units with the built-in load sharing option contain terminals 89 (+) DC and 88 (-) DC. Within the frequency converter, these terminals connect to the DC bus in front of the DC link reactor and bus capacitors.
  • Page 46: Troubleshooting

    High Power Service Manual for Unit Sizes 6x 4 Troubleshooting 4.1 Troubleshooting Tips Before attempting to repair a frequency converter, here are some tips to follow to make the job easier and possibly prevent unnecessary damage to functional components. Ensure that no voltage is present on the frequency converter prior to troubleshooting. Check for the presence of AC input voltage and DC bus voltage and ensure there is none before working on the unit.
  • Page 47: Visual Inspection

    High Power Service Manual for Unit Sizes 6x 4.4 Visual Inspection The table below lists a variety of conditions that require visual inspection as part of any initial troubleshooting procedure. Inspect For Description Auxiliary equipment Look for auxiliary equipment, switches, disconnects, or input fuses/circuit breakers that may reside on either the input power side of frequency converter or the output side to motor.
  • Page 48: Fault Symptoms

    High Power Service Manual for Unit Sizes 6x 4.5 Fault Symptoms 4.5.1 No Display To troubleshoot no display: Check that power is supplied. Cycle power to the unit. Restore the drive. (See section Tips and Tricks.) 4.5.2 Intermittent Display Cutting out or flashing of the entire display and power LED indicates that the power supply (SMPS) is shutting down as a result of being overloaded. This may be due to improper control wiring or a fault within the frequency converter itself.
  • Page 49: Motor Will Not Run

    High Power Service Manual for Unit Sizes 6x 4.5.3 Motor Will not Run In the event that this symptom is detected, first verify that the unit is properly powered up (display is lit) and that there are no warning or alarm messages displayed. The most common cause of this is either incorrect control logic or an incorrectly programmed frequency converter.
  • Page 50: Incorrect Motor Operation

    High Power Service Manual for Unit Sizes 6x 4.5.4 Incorrect Motor Operation Occasionally, a fault can occur where the motor will continue to run, but not in the correct manner. The symptoms and causes may vary considerably. Many of the possible problems are listed below by symptom along with recommended procedures for determining their causes. Wrong speed/unit will not respond to command Possible incorrect reference (speed command).
  • Page 51 High Power Service Manual for Unit Sizes 6x 4.6 Alarms and Warnings A warning or an alarm is signalled by the relevant LED on the front of the frequency converter and indicated by a code on the display. A warning remains active until its cause is no longer present. Under certain circumstances operation of the motor may still be continued. Warning messages may be critical, but are not necessarily so.
  • Page 52 High Power Service Manual for Unit Sizes 6x Description Warning Alarm/Trip Alarm/Trip Lock Parameter Reference 10 Volts low Live zero error AN-01 No motor H-80 Mains phase loss SP-12 DC link voltage high DC link voltage low DC over voltage DC under voltage Inverter overloaded Motor Electronic Thermal Overload over temperature...
  • Page 53 High Power Service Manual for Unit Sizes 6x Description Warning Alarm/Trip Alarm/Trip Lock Parameter Reference Voltage Limit Control Board Over-temperature Heat sink Temperature Low Option Configuration has Changed Safe Stop Activated E-07 Power card temperature Illegal Drive configuration PTC 1 safe stop E-07 Dangerous failure E-07...
  • Page 54 High Power Service Manual for Unit Sizes 6x Alarm Word and Extended Status Word Alarm Word Warning Word Extended Status Word 00000001 Brake Check Brake Check Ramping 00000002 Pwr. Card Temp Pwr. Card Temp Auto Tune Running 00000004 Earth Fault Earth Fault Start CW/CCW 00000008...
  • Page 55: Warning/alarm List

    High Power Service Manual for Unit Sizes 6x 4.6.1 Warning/Alarm List WARNING 1, 10 Volts low: Alarm/warning limits: The 10 V voltage from terminal 50 on the control card is below 10 V. Voltage ranges 3 x 380 - 480/500 V 3 x 525 - 690 V Remove some of the load from terminal 50, as the 10 V supply is overloaded.
  • Page 56 • That the par. P-03 Motor Current is set correctly. software. Record the value of the following parameters and contact your GE supplier: • Motor data in par. P-07 Motor Power [kW] through par. P-06 Base Speed are set correctly.
  • Page 57 High Power Service Manual for Unit Sizes 6x WARNING 23, Internal fan fault ALARM 29, Heatsink temp: The fan warning function is an extra protective function that checks if the fan The maximum temperature of the heatsink has been exceeded. The temper- is running/mounted.
  • Page 58 High Power Service Manual for Unit Sizes 6x ALARM 38, Internal fault: 3072-5122 Parameter value is outside its limits Contact the local GE supplier. 5123 Option in slot A: Hardware incompatible with Control board hardware 5124 Option in slot B: Hardware incompatible with Control Serial port cannot be restored.
  • Page 59 Make sure that the gland plate is properly installed on ALARM 58, Auto Tune internal fault: IP21 and IP54 (NEMA 1 and NEMA 12) frequency converters. Contact the local GE supplier. ALARM 70, Illegal Frequency Configuration: WARNING 59, Current limit: Actual combination of control board and power board is illegal.
  • Page 60 High Power Service Manual for Unit Sizes 6x ALARM 93, Dry pump: ALARM 246, Power card supply A no-flow situation and high speed indicate that the pump has run dry. See This alarm is only for unit size 6x frequency converters. It is equivalent to Alarm parameter group AP-2#.
  • Page 61: After Repair Tests

    High Power Service Manual for Unit Sizes 6x 4.7 After Repair Tests Following any repair to a frequency converter or testing of a frequency converter suspected of being faulty, the following procedure must be followed to ensure that all circuitry in the frequency converter is functioning properly before putting the unit into operation. Perform visual inspection procedures as described in the table Visual Inspection.
  • Page 62: Frequency Converter And Motor Applications

    Par. F-41 Torque Limiter (Braking) sets the limit for frequency converter torque. The factory setting is 160% for AF-650 GP series and 110% for AF-600 FP series and will vary with motor power setting. For example, a frequency converter programmed to operate a smaller rated motor will yield a higher torque limit value than the same frequency converter programmed to operate a larger size motor.
  • Page 63: Overvoltage Trips

    High Power Service Manual for Unit Sizes 6x 5.1.1 Overvoltage Trips This trip occurs when the DC bus voltage reaches its DC bus alarm voltage high (see ratings tables in introductory section). Prior to the trip, the frequency converter will display a high voltage warning. Most times an over voltage condition is due to fast deceleration ramps with respect to the inertia of the load. During deceleration of the load, inertia of the system acts to sustain the running speed.
  • Page 64: Control Logic Problems

    High Power Service Manual for Unit Sizes 6x 5.1.3 Control Logic Problems Problems with control logic can often be difficult to diagnose, since there is usually no associated fault indication. The typical complaint is simply that the frequency converter does not respond to a given command. There are two basic commands that must be given to any frequency converter in order to obtain an output. First, the frequency converter must be told to run (start command).
  • Page 65: Internal Frequency Converter Problems

    High Power Service Manual for Unit Sizes 6x Quite often, the indications of motor problems are similar to those of a defect in the frequency converter itself. To determine whether the problem is internal or external to the frequency converter, disconnect the motor from the frequency converter output terminals. If the three voltage measurements are balanced, the frequency converter is functioning correctly.
  • Page 66: Current Sensor Faults

    High Power Service Manual for Unit Sizes 6x 5.2.3 Current Sensor Faults When a current sensor fails, it is indicated sometimes by an overcurrent alarm that cannot be reset, even with the motor leads disconnected. Most often, however, the frequency converter will experience frequent false earth fault trips. This is due to the DC offset failure mode of the sensors. To explain this it is necessary to investigate the internal makeup of a Hall effect type current sensor.
  • Page 67: Sources Of Emi

    High Power Service Manual for Unit Sizes 6x 5.3.2 Sources of EMI Modern frequency converters (see illustration below) utilise Insulated-Gate Bipolar Transistors (IGBTs) to provide an efficient and cost effective means to create the Pulse Width Modulated (PWM) output waveform necessary for accurate motor control. These devices rapidly switch the fixed DC bus voltage creating a variable frequency, variable voltage PWM waveform.
  • Page 68: Emi Propagation

    High Power Service Manual for Unit Sizes 6x 5.3.3 EMI Propagation Frequency converter generated EMI is both conducted to the mains and radiated to nearby conductors. See illustrations below. Drive Motor Stray capacitance Stray capacitance Ground Potential 1 Potential 2 Potential 3 Illustration 5.2: Earth Currents Stray capacitance between the motor conductors, equipment earth, and other nearby conductors results in induced high frequency currents.
  • Page 69 High Power Service Manual for Unit Sizes 6x Drive Motor Stray capacitance AC Line Illustration 5.4: Alternate Signal Conductor Currents High frequency currents can be coupled into the mains supplying the frequency converter when the mains conductors are located close to the motor cables.
  • Page 70: Preventive Measures

    High Power Service Manual for Unit Sizes 6x 5.3.4 Preventive Measures EMI related problems are more effectively alleviated during the design and installation phases rather than after the system is in service. Many of the steps listed here can be implemented at a relatively low cost when compared to the cost for identifying and fixing the problem later in the field. Earthing The frequency converter and motor should be solidly earthed to the equipment frame.
  • Page 71: Proper Emc Installation

    High Power Service Manual for Unit Sizes 6x 5.3.5 Proper EMC Installation Shown in the illustration below is a correct installation with EMC considerations in mind. Although most installations will not follow all the recommended practices the closer an installation resembles this example the better immunity the network will have against EMI. Should EMI problems arise in an installation, refer to this example.
  • Page 72: Test Procedures

    High Power Service Manual for Unit Sizes 6x 6 Test Procedures 6.1 Introduction Touching electrical parts of frequency converter may be fatal even after equipment has been disconnected from AC power. Wait 40 minutes after power has been removed before touching any internal components to ensure that capacitors have fully discharged. This section contains detailed procedures for testing unit size 6x series frequency converters.
  • Page 73: Signal Test Board

    High Power Service Manual for Unit Sizes 6x 6.1.2 Signal Test Board The signal test board can be used to test circuitry within the frequency converter and provides easy access to test points. The test board plugs into the top of the modules.
  • Page 74: Static Test Procedures

    High Power Service Manual for Unit Sizes 6x 6.2 Static Test Procedures All static tests should be made with a meter capable of testing diodes. Use a digital volt/ohm meter (VOM) set on the diode scale or an analog ohmmeter set on Rx100 scale.
  • Page 75: Rectifier Module Static Test

    High Power Service Manual for Unit Sizes 6x 6.2.1 Rectifier Module Static Test Rectifier module test points Rectifier module Module lifting eye bolts (mounted on vertical strut) DC bus bar Module heatsink fan SMPS fuse Fan door cover (Optional) back AC fuse mounting bracket (T) SMPS fuse (Optional) middle AC fuse mounting bracket (S) Power card...
  • Page 76 High Power Service Manual for Unit Sizes 6x 6.2.1.1 Soft Charge Fuse Test This test is used to determine if any of the soft charge fuses are open. Use the 12-pin connector on the top of the rectifier module for testing. L1 to pins 6, 11, and 12 (red wires).
  • Page 77 High Power Service Manual for Unit Sizes 6x Main rectifier circuit test part I Connect positive (+) meter lead to positive (+) DC bus. Connect negative (–) meter lead to terminals L1, L2, and L3 in turn. Each reading should show infinity. The meter will start at a low value and slowly climb towards infinity due to capacitance within the drive being charged by the meter.
  • Page 78: Inverter Module Static Tests

    High Power Service Manual for Unit Sizes 6x 6.2.2 Inverter Module Static Tests The inverter module is primarily made up of the IGBTs used for switching the DC bus voltage to create the output to the motor. The IGBTs are grouped into three per module.
  • Page 79 High Power Service Manual for Unit Sizes 6x 6.2.2.2 Inverter test part I Connect the positive (+) meter lead to the (+) positive DC bus bar. Connect the negative (–) meter lead to terminals U, V, and W in sequence. Top (-)DC link fuse bus bar (+)DC link fuse (-)DC link fuse...
  • Page 80: Brake Igbt Test

    High Power Service Manual for Unit Sizes 6x 6.2.3 Brake IGBT Test This test can only be carried out on units equipped with a dynamic brake option. Remove the safety covers to access the unit. Note the position of the brake jumper bus bars prior to removal. The tops of the bus bars are connected to the motor lead bus bars as referred to in the following test procedures.
  • Page 81: Fan Continuity Test

    High Power Service Manual for Unit Sizes 6x 6.2.4 Fan Continuity Test Make all continuity checks using an ohmmeter set to Rx1 scale. A digital or analog ohmmeter can be used. Some instability may result when measuring resistance of a transformer with a multimeter. This can be reduced by turning off the auto-ranging function and setting the measurement manually. Control Source Fan Location Inverter module 2...
  • Page 82 High Power Service Manual for Unit Sizes 6x Check 4: Inverter Cabinet and Rectifier Cabinet Door Fans This checks the wiring between the Inverter Module and the Cabinet Door Fans. All three door fans are controlled from Inverter Module number 2 (middle inverter module in 62/64 drive or right inverter module in 61/63 drive).
  • Page 83: Dynamic Test Procedures

    High Power Service Manual for Unit Sizes 6x Incorrect reading An incorrect reading indicates a failed fan. Replace the fan. If the fan is OK, the problem is the wire harness inside the module. Remove the module in question and replace the fan wire harness. Check 7: Option Cabinet Door Fan (only 63/64) This checks the wiring between the Rectifier Module and the Option Cabinet Door Fan.
  • Page 84: Warnings

    High Power Service Manual for Unit Sizes 6x 6.3.2 Warnings Never disconnect the input cabling to the frequency converter with power applied due to danger of severe injury or death. Take all the necessary safety precautions for system start up prior to applying power to the frequency converter. For dynamic test procedures, main input power is required and all devices and power supplies connected to mains are energized at rated voltage.
  • Page 85: Basic Control Card Voltage Test

    High Power Service Manual for Unit Sizes 6x Incorrect reading An incorrect reading here requires that the main supply be investigated further. Typical items to check would be: Open (blown) input fuses or tripped circuit breakers Open disconnects or line side contactors Problems with the power distribution system Open (blown) input fuses or tripped circuit breakers usually indicate a more serious problem.
  • Page 86: Input Imbalance Of Supply Voltage Test

    High Power Service Manual for Unit Sizes 6x 6.3.7 Input Imbalance of Supply Voltage Test Theoretically, the current drawn on all three input phases should be equal. Some imbalance may be seen, however, due to variations in the phase to phase input voltage and, to some degree, single phase loads within the frequency converter itself.
  • Page 87: Input Waveform Test

    High Power Service Manual for Unit Sizes 6x 6.3.8 Input Waveform Test Testing the current waveform on the input of the frequency converter can assist in troubleshooting mains phase loss conditions or suspected problems with the SCR/diode modules. Phase loss caused by the mains supply can be easily detected. In addition, the rectifier section is controlled by SCR/diode modules. Should one of the SCR/diode modules become defective or the gate signal to the SCR lost, the frequency converter will respond the same as loss of one of the phases.
  • Page 88 High Power Service Manual for Unit Sizes 6x With a phase loss, the current waveform of the remaining phases would take on the appearance shown below. Illustration 6.5: Input Current Waveform with Phase Loss. Always verify the condition of the input voltage waveform before forming a conclusion. The current waveform will follow the voltage waveform. If the voltage waveform is incorrect proceed to investigate the reason for the AC supply problem.
  • Page 89: Gate Signal Test

    High Power Service Manual for Unit Sizes 6x 6.3.9 Gate Signal Test Remove the output bus bars from all inverter modules. Power drive in split bus mode. (See split bus powering). Connect a 24VDC power supply to the (+) and (-) DC bus bars. Connect the signal test board (p/n 6KAF6H8437) to the 30 pin connector at the top of the inverter module.
  • Page 90: Igbt Switching Test

    High Power Service Manual for Unit Sizes 6x 6.3.10 IGBT Switching Test Power the unit in the split bus mode as described in the gate signal test procedure. Observe the phase-to- phase output waveforms on all three phases with the oscilloscope. All waveform readings should appear similar to the below figure.
  • Page 91: Testing Current Feedback With The Signal Test Board

    High Power Service Manual for Unit Sizes 6x Incorrect reading If an incorrect reading was obtained from the above tests, further tests of the current feedback signals are required using the signal test board. See Testing Current Feedback with the Signal Test Board. 6.3.12 Testing Current Feedback with the Signal Test Board If the control card parameters are setup to provide holding torque while at zero speed, the current displayed will be greater than expected.
  • Page 92: Input Terminal Signal Test

    High Power Service Manual for Unit Sizes 6x 6.3.13 Input Terminal Signal Test The presence of signals on either the digital or analog input terminals of the drive can be verified on the drive display. Digital or analog input status can be selected in the display using the [DISPLAY MODE] key and the [+] and [-] keys on the keypad.
  • Page 93 High Power Service Manual for Unit Sizes 6x Verify the reference voltage power supply is correct as follows. With a voltmeter measure voltage at control card terminal 50 with respect to terminal 55. Meter should read between 9.2 and 11.2 VDC. If the 10 V supply voltage is not present, conduct the Control Card Voltage Test earlier in this section.
  • Page 94: Module-level Static Test Procedures

    High Power Service Manual for Unit Sizes 6x 6.4 Module-level Static Test Procedures 6.4.1 Inverter Module Heatsink Temperature Sensor Test Remove the inverter module from the drive in accordance with disassembly procedures. The temperature sensor is an NTC (negative temperature coefficient) device. As a result, high resistance means low temperature. As temperature decreases, resistance increases.
  • Page 95 High Power Service Manual for Unit Sizes 6x Connect the positive (+) meter lead to the negative (-) MK3 (C). Connect the negative (-) meter lead to MK1 terminals R, S, and T in sequence. Each reading should show a diode drop. Reverse the meter leads with the negative (-) meter lead to the negative (-) MK3 (C).
  • Page 96: After Repair Drive Test

    High Power Service Manual for Unit Sizes 6x 6.5 After Repair Drive Test 6.5.1 Procedure Following any repair to a frequency converter or testing of a frequency converter suspected of being faulty, the following procedure must be followed to ensure that all circuitry in the frequency converter is functioning properly before putting the unit into operation.
  • Page 97 High Power Service Manual for Unit Sizes 6x...
  • Page 98: Top Level Module Removal Instructions

    High Power Service Manual for Unit Sizes 6x 7 Top Level Module Removal Instructions 7.1 Before Proceeding 7.1.1 High Voltage Warning Frequency converters contain dangerous voltages when connected to mains voltage. No disassembly should be attempted with power applied. Remove power to the frequency converter and wait at least 40 minutes to let the frequency converter capacitors fully discharge. Only a competent technician should carry out service.
  • Page 99: Tools Required

    The rectifier and inverter modules weigh up to 136 kg/300 lbs each and require special handling. An easy to assemble service shelf, part number 6KAF6H8835, is available from GE to provide support of the modules for removal from the units. This shelf, or other suitable support equipment, is recommended.
  • Page 100: Instructions

    High Power Service Manual for Unit Sizes 6x 7.2 Instructions 7.2.1 AC Line Input Fuses AC Fuse Location AC line fuses are optional. AC fuses are located in the rectifier cabinet if they are the only power option added to the frequency converter. If additional power options are present, the AC fuses will be located in the options cabinet.
  • Page 101: Dc Link Fuses

    High Power Service Manual for Unit Sizes 6x 7.2.2 DC Link Fuses There are two DC link fuses for each inverter located on top of the inverter. Remove covers from inverter cabinet to gain access. Remove bus bars securing top of fuses by removing attaching bolts (8mm). Remove bolts securing bottom of fuses (8mm).
  • Page 102: Door Fans

    High Power Service Manual for Unit Sizes 6x 7.2.3 Door Fans Disconnect the leads from the terminal strip on the fan, noting the correct terminal that each wire is connected to for reassembly. Remove the four (8mm) mounting nuts from each corner of the fan assembly. Remove fan assembly from mounting/filter housing assembly in door.
  • Page 103: Rectifier Module

    High Power Service Manual for Unit Sizes 6x 7.2.5 Rectifier Module Remove center mounted safety cover from rectifier module by removing screws (8mm). Remove top mounted safety cover from rectifier module by removing screws (8mm). Remove two DC bus bars from top of rectifier by removing four nuts (8mm) securing each bus bar (two on each end of bus bar). Remove three AC input power bus bars in order to free module for removal.
  • Page 104: Inverter Module

    High Power Service Manual for Unit Sizes 6x 7.2.6 Inverter Module Remove safety covers from front of inverter module by removing attaching screws. If present, remove two (optional) brake bus bars by removing four screws (M8), one on each end of both bus bars. Remove three output motor bus bars by removing six screws (M8), one on each end of each bus bars.
  • Page 105: Mdcic Mounting Panel

    High Power Service Manual for Unit Sizes 6x 7.2.7 MDCIC Mounting Panel Remove top mounted safety cover from inverter module by removing attaching screws (8mm). Disconnect ribbon cable from control card. Before removing MDCIC ribbon cable from each inverter module, note which cable connects to each module for reassembly. Remove MDCIC ribbon cable from each inverter module.
  • Page 106: Fan Transformers

    High Power Service Manual for Unit Sizes 6x 7.2.8 Fan Transformers Remove MDCIC panel in accordance with instructions. Disconnect electrical connector from fan transformer. Remove nut (M8) from center of fan transformer securing transformer to panel. Reinstall fan transformer in reverse order of this procedure. 130BX255.10 Fan transformer Fan transformer connector (step 2)
  • Page 107: Dc Link Inductor

    High Power Service Manual for Unit Sizes 6x 7.2.9 DC Link Inductor Remove MDCIC panel in accordance with instructions. (Fan transformers do not need to be removed.) Remove 2 bus bars covering inductor by removing four screws (8mm) on each bus bar. Remove 4 mounting bracket bus bars that bus bars removed previously in Step 2 were mounted to by removing screw (8mm) from each mounting bracket.
  • Page 108 High Power Service Manual for Unit Sizes 6x 130BX254.10 DC link inductor (step 5) Short bus bars (step 4) Mounting bracket bus bar (step 3) Angle bracket bus bar (not removed)
  • Page 109: Mdcic Board

    High Power Service Manual for Unit Sizes 6x 7.2.10 MDCIC Board Remove two screws from left side of MDCIC cover. Disconnect ribbon cable from left side of MDCIC board by gently pulling connector to left (as opposed to pulling connector out toward you). Swing cover door open to access MDCIC board.
  • Page 110 High Power Service Manual for Unit Sizes 6x 130BX267.10 MDCIC cover (step 3) MDCIC mounting panel Scaling card (step 5) Ribbon cable (step 4) MK101 connector (step 5) Left-side ribbon cable (step 2) MDCIC board attaching screw (step 6)
  • Page 111 High Power Service Manual for Unit Sizes 6x...
  • Page 112: Disassembly/assembly - Inverter Module

    8.1.1 GE Training Required Only GE trained and certified technicians are permitted to test and repair components within the unit modules. The procedures described in this section are intended for GE qualified technicians. Repair work conducted by non-certified technicians can result in personal injury or equipment damage.
  • Page 113: Internal Access

    High Power Service Manual for Unit Sizes 6x 8.2.2 Internal Access Remove inverter module from frequency converter in accordance with instruction in section Inverter Module. Remove right side panel from inverter module by removing four nuts (10 mm). Note for reassembly 2 studs on panel edge. This side mounts to front of unit for reassembly.
  • Page 114: Lower Capacitor Bank Assembly

    High Power Service Manual for Unit Sizes 6x 8.2.5 Lower Capacitor Bank Assembly Disconnect cables from gate drive card connectors MK100, MK102, MK103, MK104, MK106, and, if unit has a brake option MK105. Remove six electrical connection nuts (8mm) securing capacitor bank assembly. These nuts are recessed in the gap between the upper and lower capacitor banks.
  • Page 115: High Frequency Board

    High Power Service Manual for Unit Sizes 6x 8.2.6 High Frequency Board Remove upper capacitor bank assembly in accordance with instructions. Disconnect cable from connector MK100 on high frequency board. Remove two screws (T25) from high frequency board. Remove one nut (8mm) from high frequency board standoff and remove board. Reassembly is done in reverse order.
  • Page 116: Gate Drive Card

    High Power Service Manual for Unit Sizes 6x 8.2.7 Gate Drive Card Disconnect cables from gate drive card connectors MK100, MK102, MK103, MK104, MK106, and, if unit has a brake option MK105. Remove gate drive card by removing 6 mounting screws (T25) from standoffs. Reinstall in reverse order of this procedure.
  • Page 117: Current Sensor

    High Power Service Manual for Unit Sizes 6x 8.2.8 Current Sensor NOTE: There are two types of current sensors, 500A or 1000A, depending on the size of the unit. Removal for both are the same except for an additional final step for the 1000A sensor.
  • Page 118: Brake Igbt Module (optional)

    High Power Service Manual for Unit Sizes 6x 8.2.9 Brake IGBT Module (Optional) Attaching nut (step 4) Brake IGBT cable (step 3) Left attached bus bar (step 4) Brake IGBT module Jumper bus bar between brakes (step 5) IGBT-Ind bus bar assembly (steps 9 and 10) Attaching nut (step 5) Snubber capacitor (step 7) IGBT-Ind bus bar assembly (step 6)
  • Page 119: Igbt Module

    High Power Service Manual for Unit Sizes 6x Reassembly Replace IGBT brake module in accordance with instructions included with replacement module. Reassemble in reverse order of this procedure. The special torque requirements on the instructions included with the replacement module. 8.2.10 IGBT Module Remove both upper and lower capacitor bank assemblies in accordance with instructions.
  • Page 120 High Power Service Manual for Unit Sizes 6x 130BX259.10 IGBT module (step 10) Snubber capacitor (step 6) High frequency board (step 2) IGBT capacitor bus bar (step 7) IGBT-Ind bus bar assembly (steps 5 and 9) Current sensor (step 3)
  • Page 121 High Power Service Manual for Unit Sizes 6x...
  • Page 122: Disassembly/assembly - Rectifier Module

    9.1.1 GE Training Required Only GE trained and certified technicians are permitted to test and repair components within the unit modules. The procedures described in this section are intended for GE qualified technicians. Repair work conducted by non-certified technicians can result in personal injury or equipment damage.
  • Page 123: Power Card

    High Power Service Manual for Unit Sizes 6x 9.2.2 Power Card Disconnect cabling from power card: MK100, MK102, MK103, MK104, MK105, MK106, MK108, MK110, Mk112, and FK102. Remove power card by removing seven screws (T25) and detach plastic standoff at top right corner of power card. Insulation sheet behind power card can be left in place.
  • Page 124: Power Card Mounting Plate

    High Power Service Manual for Unit Sizes 6x 9.2.3 Power Card Mounting Plate Disconnect two fast-on connectors from fuse block attached to power card mounting plate flange. Disconnect from power card connectors MK100, MK103, MK104, MK105, MK106, and MK110. Disconnect three cable connectors (6-pin, 8-pin, and 12-pin) from power card mounting panel flange. Cable connectors disconnect from back side of flange.
  • Page 125: Soft Charge Card

    High Power Service Manual for Unit Sizes 6x 9.2.4 Soft Charge Card Remove power card mounting plate in accordance with instructions. From soft charge card, disconnect connectors MK1, MK2, Mk3, and MK4. Remove soft charge card from mounting plate by removing four screws (T25) fastening card to mounting plate. Note insulation sheet below soft charge card.
  • Page 126: Soft Charge Card Mounting Plate

    High Power Service Manual for Unit Sizes 6x 9.2.5 Soft Charge Card Mounting Plate Remove power card mounting plate in accordance with instructions. Remove R (red), S (white), and T (black) ring lugs from input power bus bar. Two soft charge cards are present for units with two inverter modules, three soft charge cards for units with three inverter modules.
  • Page 127: Soft Charge Resistor

    High Power Service Manual for Unit Sizes 6x 9.2.6 Soft Charge Resistor Remove power card mounting plate in accordance with instructions. Remove soft charge mounting plate in accordance with instructions. Note: soft charge resistors are mounted on side panel; one on each side for units with two inductors, an additional one for units with three inverters. Loosen bottom 8mm nut.
  • Page 128: Heatsink Thermal Sensor

    High Power Service Manual for Unit Sizes 6x 9.2.7 Heatsink Thermal Sensor Remove power card mounting plate in accordance with instructions. Remove soft charge mounting plate in accordance with instructions. Remove heatsink thermal sensor by removing screw fastener (T20) mounting sensor to heatsink. Reinstall in reverse order of this procedure.
  • Page 129: Diode Module

    High Power Service Manual for Unit Sizes 6x 9.2.9 Diode Module Remove power card mounting plate in accordance with instructions. Remove soft charge mounting plate in accordance with instructions. Remove two mounting nuts (17mm) from diode module, one on AC input side and one on (-)DC side of module. Remove diode module by removing four retaining screws (T30) and washers from corners of module.
  • Page 130: Special Test Equipment

    Test equipment described in this section is available from GE. Using the test cable allows powering the frequency converter without having to charge DC bus capacitors. Main input power is required and all devices and power supplies connected to mains are energised at rated voltage.
  • Page 131: Signal Test Board (p/n 6kaf6h8437)

    High Power Service Manual for Unit Sizes 6x 10.1.2 Signal Test Board (p/n 6KAF6H8437) The signal test board provides access to a variety of signals that can be helpful in troubleshooting the frequency converter. The signal test board is plugged into the 30 pin panel connector on the top of each inverter module.
  • Page 132 High Power Service Manual for Unit Sizes 6x Pin No. Schematic Function Description Reading Using a Digital Voltmeter Acronym Current sensed, .937 VACpeak @ 165% of CT current rating. AC waveform @ output frequency of the frequency U phase, not condi- tioned converter.
  • Page 133 High Power Service Manual for Unit Sizes 6x Pin No. Schematic Function Description Reading Using a Digital Voltmeter Acronym HI_LOW Control signal from Signal to switch fan speeds between high and low +5VDC = fans on high, Power Card Otherwise, 0VDC. SCR_DIS Control signal for SCR Indicates SCR front end is enabled or disabled.
  • Page 134: Block Diagrams

    High Power Service Manual for Unit Sizes 6x 11 Block Diagrams...
  • Page 135 High Power Service Manual for Unit Sizes 6x...
  • Page 136 High Power Service Manual for Unit Sizes 6x TO INVERTERS 1, 2, & 3 12-PIN...
  • Page 137 High Power Service Manual for Unit Sizes 6x NTC2 NTC1 ELO1 EUP1 GLO1 GUP1 NTC2 FK102 NTC1 ELO1 EUP1 GLO1 GUP1 NTC2 NTC1 ELO1 EUP1 GLO1 GUP1...
  • Page 138 GE company. AF-650 GP and AF-600 FP are trademarks of the General Electric Company. 41 Woodford Avenue Plainville, CT 06062 www.geelectrical.com/drives...

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