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GE AF-600 FP Operating Instructions Manual

Fan and pump drive (460v/575v 150hp and above).
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GE Consumer & Industrial
Electrical Distribution
AF-600 FP
TM
Fan and Pump Drive
(460V/575V 150HP and above)
Operating Instructions

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Table of Contents

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   Summary of Contents for GE AF-600 FP

  • Page 1 GE Consumer & Industrial Electrical Distribution AF-600 FP Fan and Pump Drive (460V/575V 150HP and above) Operating Instructions...
  • Page 2: Table Of Contents

    AF-600 FP High Power Operating Instructions Contents 1 How to Read these Operating Instructions Copyright, Limitation of Liability and Revision Rights 2 Safety Safety instructions General Warning Before commencing repair work Special conditions Avoid unintended start IT mains 3 Electrical Installation...
  • Page 3 AF-600 FP High Power Operating Instructions Rated Power Mechanical Installation Terminal locations - Unit Size 4X Terminal Locations - Unit Size 5X Terminal Locations - Unit Sizes 6X Cooling and Airflow Field Installation of Options Installation of Duct Cooling Kit in Rittal Units...
  • Page 4 AF-600 FP High Power Operating Instructions PC-## Pump Controller LC-## Logic Controller B-## Braking Functions 8 General Specifications 9 Warnings and Alarms Fault messages Index...
  • Page 5 AF-600 FP High Power Operating Instructions...
  • Page 6: How To Read These Operating Instructions

    In no event shall GE be liable for direct, indirect, special, incidental, or consequential damages arising out of the use, or the inability to use information contained in this manual, even if advised of the possibility of such damages. In particular, GE is not responsible for any costs, including but not limited to those incurred as a result of lost profits or revenue, loss or damage of equipment, loss of computer programs, loss of data, the costs to substitute these, or any claims by third parties.
  • Page 7 Design Guide entails all technical information about the frequency converter and customer design and applications. Programming Guide provides information on how to program and includes complete parameter descriptions. GE technical literature is available in print from your local GE Sales Office or online at: www.geelectrical.com/drives - AF-600 FP Built-in network manuals are available separately.
  • Page 8: Safety

    AF-600 FP High Power Operating Instructions 2 Safety 2.1.1 High voltage warning The voltage of the frequency converter is dangerous whenever it is connected to mains. Incorrect installation of the motor or frequency converter may cause damage to the equipment, serious injury or death. Consequently, it is essential to comply with the instructions in this manual as well as local and national rules and safety regulations.
  • Page 9: Before Commencing Repair Work

    Marine applications with more severe environmental conditions. Other applications might also affect the electrical ratings. Consult the relevant sections in this manual and in the AF-600 FP Design Guide for information about the electrical ratings. Installation requirements: The overall electrical safety of the frequency converter requires special installation considerations regarding: •...
  • Page 10: Avoid Unintended Start

    2.1.10 Software version and approvals: AF-600 FP Fan & Pump Drive AF-600 FP Software version: 2.9.x This manual can be used with all AF-600 FP frequency converters with software version 2.9x. The software version number can be seen from par. ID-43 Software Version. 2.1.11 Disposal instruction Equipment containing electrical components must not be disposed of together with domestic waste.
  • Page 11 AF-600 FP High Power Operating Instructions...
  • Page 12: Electrical Installation

    For protection please see fuse in the tables of the fuse section. Always ensure that proper fusing is made according to local regulation. Use a screened/armoured motor cable to comply with EMC emission specifications. For more information, see EMC specifications in the AF-600 FP/Design Guide.
  • Page 13 AF-600 FP High Power Operating Instructions Screening of cables: Avoid installation with twisted screen ends (pigtails). They spoil the screening effect at higher frequencies. If it is necessary to break the screen to install a motor isolator or motor contactor, the screen must be continued at the lowest possible HF impedance.
  • Page 14 AF-600 FP High Power Operating Instructions Illustration 3.1: Compact IP 21 (NEMA 1) and IP 54 (NEMA 12), Unit Size 41 Illustration 3.2: Compact IP 21 (NEMA 1) and IP 54 (NEMA 12) Unit Size 42 AUX Relay Brake Temp Switch...
  • Page 15 AF-600 FP High Power Operating Instructions Illustration 3.3: Compact IP 00 (Chassis), Unit Size 43 Illustration 3.5: Position of earth terminals IP00 (Chassis), 4X unit sizes Illustration 3.6: Position of earth terminals IP21 (NEMA type 1) and IP54 (NEMA type 12)Unit Size 42...
  • Page 16 AF-600 FP High Power Operating Instructions Illustration 3.7: Compact IP 21 (NEMA 1) and IP 54 (NEMA 12) Unit Size 51 Illustration 3.9: Position of earth terminals IP00 (Chassis), Unit Size 52...
  • Page 17 AF-600 FP High Power Operating Instructions Illustration 3.10: Rectifier Cabinet, unit sizes 61, 62, 63 and 64. 24 V DC, 5 A Loadsharing T1 Output Taps Temp Switch 104 105 Control Transformer Fuses (2 or 4 pieces). See fuse tables for part numbers Manual Motor Starters SMPS Fuse.
  • Page 18 AF-600 FP High Power Operating Instructions Illustration 3.11: Inverter Cabinet, unit sizes 61 and 63. External Temperature Monitoring Motor AUX Relay NAMUR NAMUR Fuse. See fuse tables for part numbers AUX Fan Fan Fuses. See fuse tables for part numbers 101 102 103 SMPS Fuses.
  • Page 19 AF-600 FP High Power Operating Instructions Illustration 3.12: Inverter Cabinet, unit sizes 62 and 64 External Temperature Monitoring Motor AUX Relay NAMUR NAMUR Fuse. See fuse tables for part numbers AUX Fan Fan Fuses. See fuse tables for part numbers 101 102 103 SMPS Fuses.
  • Page 20 Line Fuses, F3 and F4 (3 pieces) See fuse tables for part numbers Contactor Relay Coil (230 VAC). N/C and N/O Aux Contacts Circuit Breaker Shunt Trip Control Terminals (230 VAC or 230 VDC) Please consult GE for more information on these custom options.
  • Page 21 AF-600 FP High Power Operating Instructions 3.1.2 Earthing The following basic issues need to be considered when installing a frequency converter, so as to obtain electromagnetic compatibility (EMC). • Safety earthing: Please note that the frequency converter has a high leakage current and must be earthed appropriately for safety reasons. Apply local safety regulations.
  • Page 22 AF-600 FP High Power Operating Instructions Unit Size Terminal Torque Bolt size 41, 42, 43 and 44 Mains 19 Nm (168 in-lbs) Motor Load sharing 9.5 (84 in-lbs) Brake 51 and 52 Mains Motor 19 NM (168 in-lbs) Load sharing Brake 9.5 (84 in-lbs)
  • Page 23 AF-600 FP High Power Operating Instructions Unit Size 6X Requirements Unit Size 61/63 requirements: Motor phase cable quantities must be 2, 4, 6, or 8 (multiples of 2) to obtain equal amount of wires attached to both inverter module terminals. The cables are required to be equal length within 10% between the inverter module terminals and the first common point of a phase. The recommended common point is the motor terminals.
  • Page 24: Mains Connection

    AF-600 FP High Power Operating Instructions 3.1.10 Mains connection Mains must be connected to terminals 91, 92 and 93. Earth is connected to the terminal to the right of terminal 93. Terminal No. Function 91, 92, 93 Mains R/L1, S/L2, T/L3 Earth Check the name plate to ensure that the mains voltage of the frequency converter matches the power supply of your plant.
  • Page 25: Fuses

    Short-circuit protection: The frequency converter must be protected against short-circuit to avoid electrical or fire hazard. GE recommends using the fuses mentioned below to protect service personnel and equipment in case of an internal failure in the drive. The frequency converter provides full short-circuit protection in case of a short-circuit on the motor output.
  • Page 26: Motor Insulation

    AF-600 FP High Power Operating Instructions 525-600 V, unit sizes 4X, 5X and 6X Bussmann SIBA Ferraz-Shawmut Internal AF-600 FP E125085 Amps E180276 E76491 Option JFHR2 JFHR2 JFHR2 Bussmann 150 HP 170M3017 2061032.315 6.6URD30D08A0315 170M3018 200 HP 170M3018 2061032.35 6.6URD30D08A0350...
  • Page 27: Motor Bearing Currents

    AF-600 FP High Power Operating Instructions 3.1.15 Motor Bearing Currents All motors installed with drives 90kW or higher power drives should have NDE (Non-Drive End) insulated bearings installed to eliminate circulating bearing currents. To minimize DE (Drive End) bearing and shaft currents proper grounding of the drive, motor, driven machine, and motor to the driven machine is required.
  • Page 28 AF-600 FP High Power Operating Instructions In the IP 00 (Chassis) and IP 21 (NEMA 1) units it is also possible to connect the network from the top of the unit as shown on the picture to the right. On the IP 21 (NEMA 1) unit a cover plate must be removed.
  • Page 29: Electrical Installation, Control Terminals

    AF-600 FP High Power Operating Instructions 3.1.18 Electrical Installation, Control Terminals To connect the cable to the terminal: Strip insulation by about 9-10 mm Insert a screwdriver in the square hole. Insert the cable in the adjacent circular hole. Remove the screwdriver. The cable is now mounted in the terminal.
  • Page 30: Connection Examples

    AF-600 FP High Power Operating Instructions 3.2 Connection Examples 3.2.1 Start/Stop Terminal 18 = par. E-01 Terminal 18 Digital Input [8] Start Terminal 27 = par. E-03 Terminal 27 Digital Input [0] No operation (Default coast inverse) 3.2.2 Pulse Start/Stop Terminal 18 = par.
  • Page 31 AF-600 FP High Power Operating Instructions 3.2.3 Speed Up/Down Terminals 29/32 = Speed up/down:. Terminal 18 = par. E-01 Terminal 18 Digital Input Start [9] (default) Terminal 27 = par. E-03 Terminal 27 Digital Input Freeze reference [19] Terminal 29 = par. E-04 Terminal 29 Digital Input Speed up [21] Terminal 32 = par.
  • Page 32: Electrical Installation - Additional

    AF-600 FP High Power Operating Instructions 3.3 Electrical Installation - additional 3.3.1 Electrical Installation, Control Cables Illustration 3.18: Diagram showing all electrical terminals without options. Very long control cables and analogue signals may in rare cases and depending on installation result in 50/60 Hz earth loops due to noise from mains supply cables.
  • Page 33 AF-600 FP High Power Operating Instructions Input polarity of control terminals Control cables must be screened/armoured. Connect the wires as described in the Operating Instruction for the frequency converter. Remember to connect the shields in a proper way to ensure optimum...
  • Page 34: Switches S201, S202, And S801

    AF-600 FP High Power Operating Instructions 3.3.2 Switches S201, S202, and S801 Switches S201 (A53) and S202 (A54) are used to select a current (0-20 mA) or a voltage (-10 to 10 V) configuration of the analog input terminals 53 and 54 respectively.
  • Page 35: Final Set-up And Test

    AF-600 FP High Power Operating Instructions 3.4 Final Set-up and Test To test the set-up and ensure that the frequency converter is running, follow these steps. Step 1. Locate the motor name plate The motor is either star- (Y) or delta- connected (∆). This information is located on the motor name plate data.
  • Page 36 "Report Value” in the [Alarm Log] shows the last measuring sequence carried out by the auto tune, before the frequency converter entered alarm mode. This number along with the description of the alarm will assist you in troubleshooting. If you contact GE for service, make sure to mention number and alarm description.
  • Page 37: Additional Connections

    AF-600 FP High Power Operating Instructions 3.5 Additional Connections 3.5.1 Parallel Connection of Motors The frequency converter can control several parallel-connected motors. The total current consumption of the motors must not exceed the rated output current I for the frequency converter.
  • Page 38: Introduction

    Below is an example of an identification label. This label is situated on the frequency converter and shows the type and options fitted to the unit. See below for details of how to read the the GE Model Number. Illustration 4.1: This example shows a drive nameplate.. Please have the drive Model Number and serial number ready before contacting GE. 4.1.2 AF-600 FP Model Numbering System Diagram...
  • Page 39 AF-600 FP High Power Operating Instructions 4.1.3 Abbreviations and Standards Abbreviations: Terms: SI-units: I-P units: Acceleration ft/s American wire gauge Auto Tune Automatic Motor Tuning °C Celsius Current Current limit Drive Control Tool Joule Energy J = N∙m ft-lb, Btu °F...
  • Page 40: Mechanical Installation

    AF-600 FP High Power Operating Instructions 5 Mechanical Installation 5.1 How to Get Started 5.1.1 About How to Install This chapter covers mechanical and electrical installations to and from power terminals and control card terminals. Electrical installation of options is described in the relevant Operating Instructions and Design Guide.
  • Page 41: Pre-installation

    AF-600 FP High Power Operating Instructions 5.2 Pre-installation 5.2.1 Planning the Installation Site Before performing the installation it is important to plan the installation of the frequency converter. Neglecting this may result in extra work during and after installation. Select the best possible operation site by considering the following (see details on the following pages, and the respective Design Guides): •...
  • Page 42 AF-600 FP High Power Operating Instructions Illustration 5.2: Mounting Template for Unit Size 4X drives (460V, 125 to 300 HP, 575/600V, 125 to 400 HP)
  • Page 43: Lifting

    AF-600 FP High Power Operating Instructions 5.2.4 Lifting Always lift the frequency converter in the dedicated lifting eyes. For all 4X unit size and 52 unit size (IP00) Units, use a bar to avoid bending the lifting holes of the frequency converter.
  • Page 44 AF-600 FP High Power Operating Instructions Illustration 5.6: Recommended lifting method, Unit Size 63 (460V, 600 to 900 HP, 575/600V, 900 to 1150 HP). Illustration 5.7: Recommended lifting method, Unit Size 64 (460V, 1000 to 1200 HP, 575/600V, 1250 to 1350 HP).
  • Page 45: Mechanical Dimensions

    AF-600 FP High Power Operating Instructions...
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  • Page 51 AF-600 FP High Power Operating Instructions Mechanical dimensions , 4X Unit Sizes Unit Size 150 - 200 HP at 460 V 250 - 350 HP at 460 V 150 - 200 HP at 460 V 250 - 350 HP at 460 V...
  • Page 52: Rated Power

    AF-600 FP High Power Operating Instructions 5.2.6 Rated Power Unit Size 21/54 21/54 NEMA Type 1/ Type 12 Type 1/ Type 12 Chassis Chassis 150 - 200 HP at 460 V 250 - 350 HP at 460 V 150 - 200 HP at 460 V...
  • Page 53: Mechanical Installation

    AF-600 FP High Power Operating Instructions 5.3 Mechanical Installation Preparation of the mechanical installation of the frequency converter must be done carefully to ensure a proper result and to avoid additional work during installation. Start taking a close look at the mechanical drawings at the end of this instruction to become familiar with the space demands.
  • Page 54 AF-600 FP High Power Operating Instructions Illustration 5.11: Space in front of IP21/Nema 1 and IP54/Nema 12 drive type, for unit size 63. Illustration 5.10: Space in front of IP21/Nema 1 and IP54/Nema 12 drive type, for unit size 61.
  • Page 55: Terminal Locations - Unit Size 4x

    AF-600 FP High Power Operating Instructions 5.3.3 Terminal locations - Unit Size 4X Take the following position of the terminals into consideration when you design for cables access. Illustration 5.14: Position of power connections, 43/44 Unit Sizes Be aware that the power cables are heavy and hard to bend. Consider the optimum position of the frequency converter for ensuring easy installation of the cables.
  • Page 56: Terminal Locations - Unit Size 5x

    AF-600 FP High Power Operating Instructions 5.3.4 Terminal Locations - Unit Size 5X Terminal locations - Unit Size 51 Take the following position of the terminals into consideration when designing the cable access. Illustration 5.16: IP21 (NEMA Type 1) and IP54 (NEMA Type 12) drive type power connection positions...
  • Page 57 AF-600 FP High Power Operating Instructions Terminal locations - Unit Size 52 Take the following position of the terminals into consideration when designing the cable access. Illustration 5.19: IP00 Open Chassis drive type power connection positions Illustration 5.20: IP00 Open Chassis drive type power connection positions Note that the power cables are heavy and difficult to bend.
  • Page 58: Terminal Locations - Unit Sizes 6x

    AF-600 FP High Power Operating Instructions Illustration 5.22: Terminal in details Power connections can be made to positions A or B 5.3.5 Terminal Locations - Unit Sizes 6X Terminal locations - Unit Sizes 61 and 63 Illustration 5.23: Terminal locations - Inverter Cabinet - 61 and 63 (front, left and right side view)
  • Page 59 AF-600 FP High Power Operating Instructions Terminal locations - Unit Sizes 62/64 Illustration 5.24: Terminal locations - Inverter Cabinet - 62 and 64 (front, left and right side view) 1) Ground bar Terminal locations - Rectifier (Unit Sizes 61, 62, 63 and 64) Illustration 5.25: Terminal locations - Rectifier (Left side, front and right side view)
  • Page 60 AF-600 FP High Power Operating Instructions Terminal locations - Options Cabinet (Unit Sizes 63 and 64) Illustration 5.26: Terminal locations - Options Cabinet (Left side, front and right side view) 1) Ground bar Terminal locations - Options Cabinet with circuit breaker/ molded case switch (Unit Sizes 63 and 64) Illustration 5.27: Terminal locations - Options Cabinet with circuit breaker/ molded case switch (Left side, front and right side view)
  • Page 61: Cooling And Airflow

    A dedicated option has been developed to optimize installation of IP00/chassis drive types in Rittal TS8 Units utilizing the fan of the frequency converter for forced air cooling of the backchannel. Please consult GE for more details. The air out the top of the Unit could but ducted outside a facility so the heat loses from the backchannel are not dissipated within the control room reducing air- conditioning requirements of the facility.
  • Page 62 AF-600 FP High Power Operating Instructions Illustration 5.28: Lifting method for mounting drive on wall 5.3.8 Gland/Conduit Entry - IP21 (NEMA 1) and IP54 (NEMA12) Cables are connected through the gland plate from the bottom. Remove the plate and plan where to place the entry for the glands or conduits. Prepare holes in the marked area on the drawing.
  • Page 63 AF-600 FP High Power Operating Instructions Unit Size 61 Unit Size 62 Unit Size 63 Unit Size 64 Unit Size 61 to 64: Cable entries viewed from the bottom of the frequency converter - 1) Place conduits in marked areas...
  • Page 64 AF-600 FP High Power Operating Instructions Illustration 5.29: Mounting of bottom plate,51Unit Size . The bottom plate of the 51 Unit Size can be mounted from either in- or outside of the Unit Size, allowing flexibility in the installation process, i.e. if mounted from the bottom the glands and cables can be mounted before the frequency converter is placed on the pedestal.
  • Page 65: Field Installation Of Options

    This section deals with the installation of IP00 / chassis enclosed frequency converters with duct work cooling kits in Rittal Units. In addition to the Unit a 200 mm base/plinth is required. Please consult GE for more details on these field installed options.
  • Page 66 Mounting templates and top/bottom cut out for Rittal Unit. All fasteners are either: • 10 mm, M5 Nuts torque to 2.3 Nm (20 in-lbs) • T25 Torx screws torque to 2.3 Nm (20 in-lbs) Please consult GE for more details on duct kits for AF-600 FP drives...
  • Page 67 AF-600 FP High Power Operating Instructions External ducts If additional duct work is added externally to the Rittal cabinet the pressure drop in the ducting must be calculated. Use the charts below to derate the frequency converter according to the pressure drop.
  • Page 68: Installation On Pedestal

    IP21/NEMA 1 or IP54/NEMA 12 degrees of Unit pro- tections. Illustration 5.35: Drive on pedestal There is one pedestal that fits both Unit Sizes 41 and 42. Please consult GE for more information. The pedestal is standard for Unit Size 51. Required Tools: •...
  • Page 69 Illustration 5.37: Drill master for fixing holes in floor. Mount the drive on the pedestal and fix it with the included bolts to the ped- estal as shown on the illustration. Illustration 5.38: Mounting of drive to pedestal Please consult GE for more details on the pedestal kits.
  • Page 70: Installation Of Mains Shield For Frequency Converters

    5.5 Panel Options 5.5.1 Unit Size 6X Panel Options Please note that these options are all special order. Please consult GE for more information. Space Heaters and Thermostat Mounted on the cabinet interior of Unit Size 6X frequency converters, space heaters controlled via automatic thermostat help control humidity inside the Unit, extending the lifetime of drive components in damp environments.
  • Page 71 AF-600 FP High Power Operating Instructions Insulation Resistance Monitor (IRM) Designed for monitoring of insulation resistance between system conductors and ground in ungrounded supply mains or mains with connection to ground through a high impedance (such as IT systems). Two individually adjustable relays (N.O. or N.C.) allow separate setpoints for pre-warning and alarm conditions.
  • Page 72: How To Operate The Frequency Converter

    AF-600 FP High Power Operating Instructions 6 How to operate the frequency converter 6.1.1 Two ways of operating The frequency converter can be operated in 2 ways: keypad RS-485 serial communication or USB, both for PC connection If the frequency converter is fitted with network option module, please refer to relevant documentation.
  • Page 73 AF-600 FP High Power Operating Instructions The display is divided into 3 sections: Top section (a) shows the status when in status mode or up to 2 variables when not in status mode and in the case of Alarm/Warning. The number of the Active Set-up (selected as the Active Set-up in par. K-10 Active Set-up) is shown. When programming in another Set-up than the Active Set-up, the number of the Set-up being programmed appears to the right in brackets.
  • Page 74 AF-600 FP High Power Operating Instructions Status display III: This state displays the event and action of the Logic Controller. For further information, see section Logic Controller. The Bottom section always shows the state of the frequency converter in Status mode.
  • Page 75 AF-600 FP High Power Operating Instructions Keypad Keys Menu keys The menu keys are divided into functions. The keys below the display and indicator lamps are used for parameter set-up, including choice of display indication during normal operation. [Status] The [Status] key indicates the status of the frequency converter and/or the motor. 3 different readouts can be chosen by pressing the [Status] key: 5 line readouts, 4 line readouts or Logic Controller.
  • Page 76 AF-600 FP High Power Operating Instructions [Info] The [Info] key displays information about a command, parameter, or function in any display window. [Info] provides detailed information when needed. Exit Info mode by pressing either [Info], [Back], or [Cancel]. Navigation Keys The four navigation arrows are used to navigate between the different choices available in [Quick Menu], [Main Menu] and [Alarm Log].
  • Page 77 To control or program the frequency converter from a PC, install the PC-based Drive Control Tool DCT 10.. The PC is connected via a standard (host/device) USB cable, or via the RS-485 interface as shown in the AF-600 FP Design Guide, chapter How to Install > Installation of misc.
  • Page 78 PC-based Drive Control Tool DCT 10 All Frequency converters are equipped with a serial communication port. GE provides a PC tool for communication between PC and frequency converter, PC- based Drive Control Tool DCT 10. Please check the section on Available Literature for detailed information on this tool.
  • Page 79: Tips And Tricks

    Choose “Write to drive” All parameter settings are now transferred to the frequency converter. A separate manual forDrives Control Tool DCT 10 Software is available: from GE or the web: www.geelectrical.com/drives. The Drives Control Tool DCT 10 Software Modules The following modules are included in the software package:...
  • Page 80 AF-600 FP High Power Operating Instructions Data transfer from Keypad to Frequency converter: Go to par. K-50 Keypad Copy Press the [OK] key Select “All from Keypad” Press the [OK] key The parameter settings stored in the GLCP are now transferred to the frequency converter indicated by the progress bar. When 100% is reached, press [OK].
  • Page 81 AF-600 FP High Power Operating Instructions...
  • Page 82: How To Program

    AF-600 FP High Power Operating Instructions 7 How to Program 7.1.1 Group Title Function K-## Operation and Display Parameters used to program the Keypad including: selection of language; selection of which variables are displayed at each position in the display (e.g. static duct pressure or condenser water return temperature can be displayed with the setpoint in small digits in the top row and feedback in large digits in the centre of the dispay);...
  • Page 83 The Main Menu provides access to all parameters for detailed application programming. All digital input/output and analog input/output terminals are multifunctional. All terminals have factory default functions suitable for the majority of AF-600 FP applications but if other special functions are required, they must be programmed as explained in parameter group E-## or AN-##.
  • Page 84: Quick Menu Mode

    Efficient Parameter Set-up for AF-600 FP Applications The parameters can easily be set up for the vast majority of the AF-600 FP applications only by using the [Quick Setup] option. After pressing [Quick Menu], the different choices in the Quick Menu are listed.
  • Page 85 Unit and par. K-03 Regional Settings depend on which region of the world the frequency converter is supplied to but can be re-programmed as required. For a detailed information about settings and programming, please see the AF-600 FP Programming Guide...
  • Page 86 AF-600 FP High Power Operating Instructions K-01 Language Option: Function: Defines the language to be used in the display. The frequency converter is delivered with 4 different languages. [0] * English Part of Language packages 1 - 4 P-07 Motor Power [kW]...
  • Page 87 AF-600 FP High Power Operating Instructions P-08 Motor Rotation Check Option: Function: Following installation and connection of the motor, this function allows the correct motor rotation direc- tion to be verified. Enabling this function overrides any bus commands or digital inputs, except External Interlock.
  • Page 88 AF-600 FP High Power Operating Instructions F-17 Motor Speed High Limit [RPM] Range: Function: 1500. RPM* [par. H-11 - 60000. RPM] Enter the maximum limit for motor speed. The Motor Speed High Limit can be set to correspond to the manufacturer’s maximum rated motor.
  • Page 89: Macros

    7.1.3 Macros The Macros provide quick and easy access to all parameters required for the majority of AF-600 FP applications including most VAV and CAV supply and return fans, cooling tower fans, Primary, Secondary and Condenser Water Pumps and other pump, fan and compressor applications.
  • Page 90 AF-600 FP High Power Operating Instructions 130BT116.10 Illustration 7.1: Step 6: Use the up/down navigation keys to change the delay time. The Quick Menu parameters are grouped in the following way: Application Settings Fan Macros Pump Macros Compressor Macros par. AP-60 Broken Belt Function par.
  • Page 91 CL-72 PID Output Change par. CL-73 Minimum Feedback Level par. CL-74 Maximum Feedback Level par. CL-79 PID Autotuning See also AF-600 FP Programming Guide for a detailed description of the Quick Menu parameter groups. AN-00 Live Zero Timeout Time Range: Function:...
  • Page 92 AF-600 FP High Power Operating Instructions par. AN-01 Live Zero Timeout Function par. O-04 Control Word Timeout Function The output frequency of the frequency converter can be: • [1] frozen at the present value • [2] overruled to stop •...
  • Page 93 AF-600 FP High Power Operating Instructions AN-16 Terminal 53 Filter Time Constant Range: Function: 0.001 s* [0.001 - 10.000 s] Enter the time constant. This is a first-order digital low pass filter time constant for suppressing electrical noise in terminal 53. A high time constant value improves dampening but also increases the time delay through the filter.
  • Page 94 AF-600 FP High Power Operating Instructions AN-50 Terminal 42 Output Option: Function: Select the function of Terminal 42 as an analog current output. [0] * No operation [100] Output frequency 0 - 100 Hz [101] Reference Minimum reference - Maximum reference...
  • Page 95 AF-600 FP High Power Operating Instructions AN-52 Terminal 42 Output Max Scale Range: Function: 100.00 %* [0.00 - 200.00 %] Scale for the maximum output (20 mA) of the analog signal at terminal 42. Set the value to be the percentage of the full range of the variable selected in par. AN-50 Terminal 42 Output.
  • Page 96 AF-600 FP High Power Operating Instructions EXAMPLE 2: Variable= FEEDBACK, range= -200% to +200% Range needed for output= 0-100% Output signal 0 or 4 mA is needed at 0% (50% of range) - set par. AN-51 Terminal 42 Output Min Scale to 50% Output signal 20 mA is needed at 100% (75% of range) - set par.
  • Page 97 AF-600 FP High Power Operating Instructions AP-23 No-Flow Function Option: Function: Common actions for Low Power Detection and Low Speed Detection (Individual selections not possible). [0] * Sleep Mode Warning Messages in the keypad display (if mounted) and/or signal via a relay or a digital output.
  • Page 98 AF-600 FP High Power Operating Instructions AP-62 Broken Belt Delay Range: Function: 10 s* [0 - 600 s] Sets the time for which the Broken Belt conditions must be active before carrying out the action selected in par. AP-60 Broken Belt Function.
  • Page 99 AF-600 FP High Power Operating Instructions AP-62 Broken Belt Delay Range: Function: 10 s* [0 - 600 s] Sets the time for which the Broken Belt conditions must be active before carrying out the action selected in par. AP-60 Broken Belt Function.
  • Page 100 AF-600 FP High Power Operating Instructions The decel ramp time is automatically adjusted to avoid tripping of the frequency converter. C-05 Multi-step Frequency 1 - 8 Array [8] Range: Function: 0.00 %* [-100.00 - 100.00 %] Enter up to eight different preset references (0-7) in this parameter, using array programming. The preset reference is stated as a percentage of the value Ref (par.
  • Page 101 AF-600 FP High Power Operating Instructions CL-00 Feedback 1 Source Option: Function: Up to three different feedback signals can be used to provide the feedback signal for the frequency converter’s PID Controller. This parameter defines which input will be used as the source of the first feedback signal.
  • Page 102 AF-600 FP High Power Operating Instructions Analog input X30/12 Analog Input X42/1 [10] Analog Input X42/3 [11] Analog Input X42/5 [100] Bus feedback 1 [101] Bus feedback 2 [102] Bus feedback 3 CL-04 Feedback 2 Conversion Option: Function: See par. CL-01 Feedback 1 Conversion for details.
  • Page 103 AF-600 FP High Power Operating Instructions Any unused feedbacks must be set to No Function in par. CL-00 Feedback 1 Source, par. CL-03 Feedback 2 Source, or par. CL-06 Feedback 3 Source. The sum of Setpoint 1 and any other references that are enabled (see par. C-30 and par. C-34) will be used as the PID Controller’s set-point reference.
  • Page 104 Example 1 – Multi zone, single setpoint In an office building, a VAV (variable air volume) AF-600 FP system must ensure a minimum pressure at selected VAV boxes. Due to the varying pressure losses in each duct, the pressure at each VAV box cannot be assumed to be the same. The minimum pressure required is the same for all VAV boxes. This control method can be set up by setting par.
  • Page 105 AF-600 FP High Power Operating Instructions CL-21 Setpoint 1 Range: Function: 0.000 Proc- [-999999.999 - 999999.999 Proc- Setpoint 1 is used in Closed Loop Mode to enter a setpoint reference that is used by the frequency con- essCtrlUnit* essCtrlUnit] verter’s PID Controller. See the description of par. CL-20 Feedback Function.
  • Page 106 AF-600 FP High Power Operating Instructions Latched start [10] Reversing [11] Start reversing [14] [15] Preset reference on [16] Preset ref bit 0 [17] Preset ref bit 1 [18] Preset ref bit 2 [19] Freeze reference [20] Freeze output [21]...
  • Page 107 AF-600 FP High Power Operating Instructions [16] Preset ref bit 0 [17] Preset ref bit 1 [18] Preset ref bit 2 [19] Freeze reference [20] Freeze output [21] Speed up [22] Speed down [23] Set-up select bit 0 [24] Set-up select bit 1...
  • Page 108 AF-600 FP High Power Operating Instructions [15] Preset reference on [16] Preset ref bit 0 [17] Preset ref bit 1 [18] Preset ref bit 2 [19] Freeze reference [20] Freeze output [21] Speed up [22] Speed down [23] Set-up select bit 0...
  • Page 109 AF-600 FP High Power Operating Instructions [20] Freeze output [21] Speed up [22] Speed down [23] Set-up select bit 0 [24] Set-up select bit 1 [30] Counter input [32] Pulse input [34] Ramp bit 0 [36] Line failure inverse [37]...
  • Page 110 AF-600 FP High Power Operating Instructions [13] Below current, low [14] Above current, high [15] Out of speed range [16] Below speed, low [17] Above speed, high [18] Out of feedb. range [19] Below feedback, low [20] Above feedback, high...
  • Page 111 AF-600 FP High Power Operating Instructions [168] Hand mode [169] Auto mode [180] Clock Fault [181] Prev. Maintenance [190] No-Flow [191] Dry Pump [192] End Of Curve [193] Sleep Mode [194] Broken Belt [195] Bypass Valve Control [196] Fire Mode [197] Fire Mode was Act.
  • Page 112 AF-600 FP High Power Operating Instructions [30] Ext. Closed Loop 1 [31] Ext. Closed Loop 2 [32] Ext. Closed Loop 3 F-10 Electronic Overload Option: Function: The frequency converter determines the motor temperature for motor protection in two different ways: •...
  • Page 113 AF-600 FP High Power Operating Instructions F-12 Motor Thermistor Input Option: Function: Select the input to which the thermistor (PTC sensor) should be connected. An analog input option [1] or [2] cannot be selected if the analog input is already in use as a reference source (selected in par.
  • Page 114 AF-600 FP High Power Operating Instructions F-52 Minimum Reference Range: Function: 0.000 Refer- [-999999.999 - par. P-03 Reference- Enter the Minimum Reference. The Minimum Reference is the lowest value obtainable by summing all enceFeed- FeedbackUnit] references. The Minimum Reference value and unit matches the configuration choice made in par.
  • Page 115 AF-600 FP High Power Operating Instructions This parameter cannot be changed when motor is running. When set for Closed Loop, the commands Reversing and Start Reversing will not reverse the direction of the motor. H-43 Torque Characteristics Option: Function: Compressor torque Compressor [0]: For speed control of screw and scroll compressors.
  • Page 116 AF-600 FP High Power Operating Instructions H-80 Function at Stop Option: Function: Select the frequency converter function after a stop command or after the speed is ramped down to the settings in par. H-81 Min Speed for Function at Stop [RPM].
  • Page 117 AF-600 FP High Power Operating Instructions 7.1.4 Main Menu Mode The keypad provides access to the main menu mode. Select the Main Menu mode by pressing the [Main Menu] key. Illustration 6.2 shows the resulting read-out, which appears on the display of the keypad.
  • Page 118 AF-600 FP High Power Operating Instructions Choose a parameter group from the Main Menu and Press [OK]. Then further select the parameter sub-groups by using the up and down arrows and then Press [OK]. The middle section of the keypad display shows the parameters. Press [OK] to select parameters and now the display shows that selected parameter's value.
  • Page 119 AF-600 FP High Power Operating Instructions 7.1.7 Changing a Text Value If the selected parameter is a text value, change the text value by means of the up/down navigation keys. The up key increases the value, and the down key decreases the value. Place the cursor on the value to be saved and press [OK].
  • Page 120 AF-600 FP High Power Operating Instructions Use the up/down navigation keys to change the data value. The up key en- larges the data value, and the down key reduces the data value. Place the cursor on the value to be saved and press [OK].
  • Page 121: K-## Keypad Set-up

    The vast majority of AF-600 FP applications can be programmed using the Quick Menu button and selecting the parameters under Quick Setup. Descriptions and default settings of parameters may be found under the section Parameter Lists at the back of this manual.
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  • Page 151: General Specifications

    Starting torque maximum 135% up to 0.5 sec. Overload torque (Constant torque) maximum 110% for 1 min. *Percentage relates to AF-600 FP Drive's nominal torque. Cable lengths and cross sections: Max. motor cable length, screened/armoured AF-600 FP Drive: 150 m Max.
  • Page 152 AF-600 FP High Power Operating Instructions Analog inputs: Number of analog inputs Terminal number 53, 54 Modes Voltage or current Mode select Switch S201 and switch S202 Voltage mode Switch S201/switch S202 = OFF (U) Voltage level : 0 to + 10 V (scaleable) Input resistance, R approx.
  • Page 153 AF-600 FP High Power 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...
  • Page 154 70 °C ± 5°C (Guideline - these temperatures may vary for different power sizes, enclosures etc.). AF-600 FP Drive has an auto derating function to avoid it's heatsink reaching 95 deg C.
  • Page 155 AF-600 FP High Power Operating Instructions Mains Supply 3 x 380 - 480 VAC P110 P132 P160 P200 P250 Typical Shaft output at 400 V [kW] Typical Shaft output at 460 V [HP] Unit Size IP21 Unit Size IP54 Unit Size IP00...
  • Page 156 AF-600 FP High Power Operating Instructions Mains Supply 3 x 380 - 480 VAC P315 P355 P400 P450 Typical Shaft output at 400 V [kW] Typical Shaft output at 460 V [HP] Unit Size IP21 Unit SizeIP54 Unit Size IP00...
  • Page 157 AF-600 FP High Power Operating Instructions Mains Supply 3 x 380 - 480 VAC P500 P560 P630 P710 P800 P1M0 Typical Shaft output 1000 at 400 V [kW] Typical Shaft output 1000 1200 1350 at 460 V [HP] Unit Size IP21, 54...
  • Page 158 AF-600 FP High Power Operating Instructions Mains Supply 3 x 525- 600 VAC P110 P132 P160 P200 Typical Shaft output at 550 V [kW] Typical Shaft output at 575 V [HP] Unit Size IP21 Unit Size IP54 Unit Size IP00...
  • Page 159 AF-600 FP High Power Operating Instructions Mains Supply 3 x 525- 600 VAC P250 P315 P355 Typical Shaft output at 550 V [kW] Typical Shaft output at 575 V [HP] Unit Size IP21 Unit Size IP54 Unit Size IP00 Output current...
  • Page 160 AF-600 FP High Power Operating Instructions Mains Supply 3 x 525- 600 VAC P400 P450 P500 Typical Shaft output at 550 V [kW] Typical Shaft output at 575 V [HP] Unit Size IP21 Unit Size IP54 Unit Size IP00 Output current...
  • Page 161 AF-600 FP High Power Operating Instructions Mains Supply 3 x 525- 600 VAC P560 P670 P750 P850 P1M0 Typical Shaft output at 1000 550 V [kW] Typical Shaft output at 1050 1150 1350 575 V [HP] Unit Size IP21, 54 with-...
  • Page 162 AF-600 FP High Power Operating Instructions...
  • Page 163 By using the [RESET] control button on the keypad. Via a digital input with the “Reset” function. Via serial communication/optional network. By resetting automatically using the [Auto Reset] function, which is a default setting for AF-600 FP Drive. see par. H-04 Auto-Reset (Times) in AF-600 FP Programming Guide After a manual reset using the [RESET] button on the Keypad, the [AUTO] or [HAND] button must be pressed to restart the motor.
  • Page 164 AF-600 FP High Power Operating Instructions Description Warning Alarm/Trip Alarm/Trip Lock Parameter Reference 10 Volts low Live zero error par. AN-01 No motor par. H-80 Mains phase loss par. SP-12 DC link voltage high DC link voltage low DC over voltage...
  • Page 165 AF-600 FP High Power Operating Instructions Description Warning Alarm/Trip Alarm/Trip Lock Parameter Reference Heatsink temp Heatsink sensor Pwr.card supply Pwr.card temp Illegal PS config New spare part New Model Number Table 9.3: Alarm/Warning code list (X) Dependent on parameter 1) Can not be Auto reset via par. H-04 Auto-Reset (Times) A trip is the action when an alarm has appeared.
  • Page 166: Fault Messages

    AF-600 FP High Power Operating Instructions 9.1.1 Fault messages WARNING 1, 10 Volts low: WARNING/ALARM 9, Inverter overloaded: The 10 V voltage from terminal 50 on the control card is below 10 V. The frequency converter is about to cut out because of an overload (too high Remove some of the load from terminal 50, as the 10 V supply is overloaded.
  • Page 167 Check parameters par. E-00 Digital I/O Mode and par. E-51 Terminal 27 ALARM 38, Internal fault: Mode. By this alarm it may be necessary to contact your GE supplier. Some typical alarm messages: WARNING 41, Overload of Digital Output Terminal 29: Check the load connected to terminal 29 or remove short-circuit connection.
  • Page 168 AF-600 FP High Power Operating Instructions WARNING 49, Speed limit: ALARM 70, Illegal Frequency Converter Configuration: The speed has been limited by range in par. F-18 Motor Speed Low Limit Actual combination of control board and power board is illegal.
  • Page 169 The power or Switch Mode Power Supply has been exchanged. The frequency converter type code must be restored in the EEPROM. Remember to select ‘Save to EEPROM’ to complete. ALARM 251, New Type Code: The Frequency Converter has got a new GE Model Number.
  • Page 170: Index

    AF-600 FP High Power Operating Instructions Index 24 Vdc Power Supply 30-amp, Fuse-protected Terminals Abbreviations And Standards Accel Time 1 F-07 Acceleration Time Access To Control Terminals Af-600 Fp Model Numbering System Diagram Airflow Analog Inputs Analog Output Auto Tune...
  • Page 171 AF-600 FP High Power Operating Instructions Drip Shield Installation Drive Control Tool Dct 10 Drives With Factory Installed A1/b1 Rfi Filter Option: Dry Pump Function Duct Cooling Duct Work Cooling Kits Earth Leakage Current Earthing Elcb Relays Electrical Installation 28, 31...
  • Page 172 AF-600 FP High Power Operating Instructions [Jog Speed Hz] C-20 Keypad Kit Contents Kty Sensor Language K-01 Leakage Current Leds Lifting Literature Live Zero Timeout Function Live Zero Timeout Time AN-00 Load Sharing Low Power Detection AP-21 Low Speed Detection AP-22...
  • Page 173 AF-600 FP High Power Operating Instructions Ordering Output Performance (u, V, W) Over-voltage Control B-17 Parallel Connection Of Motors Parameter Selection Pc Software Tools Pedestal Installation Pid Integral Time CL-94 Pid Normal/ Inverse Control Pid Proportional Gain CL-93 Pid Proportional Gain, 20-93...
  • Page 174 AF-600 FP High Power Operating Instructions Terminal 27 Digital Input E-03 Terminal 27 Mode E-51 Terminal 29 Digital Input E-04 Terminal 29 Mode Terminal 32 Digital Input E-05 Terminal 33 Digital Input E-06 Terminal 42 Output AN-50 Terminal 42 Output Max Scale AN-52...
  • Page 175 GE company. AF-600 FP is a trademark of the General Electric Company. GE Consumer & Industrial 41 Woodford Avenue Plainville, CT 06062 www.geelectrical.com/drives...

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