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GE AF-600 FP Design Manual
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GE AF-600 FP Design Manual

Fan and pump drive
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GE Consumer & Industrial
Electrical Distribution
AF-600 FP
TM
Fan and Pump Drive
Design Guide

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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 Design Guide...

  • Page 2: Table Of Contents

    Contents 1 How to Read this Design Guide Copyright, Limitation of Liability and Revision Rights Approvals Symbols Abbreviations Definitions 2 Introduction to AF-600 FP Safety CE Labelling Aggressive Environments Vibration and Shock Application Examples Control Structures General Aspects of EMC...
  • Page 3 AF-600 FP Design Guide Auto Tune Logic Controller Logic Controller Programming LC Application Example BASIC Cascade Controller Pump Staging with Lead Pump Alternation System Status and Operation Fixed Variable Speed Pump Wiring Diagram Lead Pump Alternation Wiring Diagram Cascade Controller Wiring Diagram...

  • Page 4: How To Read This Design Guide

    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 5: Approvals

    Design Guide entails all technical information about the drive 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 6: Abbreviations

    AF-600 FP Design Guide 1.1.5 Abbreviations Alternating current American wire gauge Ampere/AMP Current limit Degrees Celsius °C Direct current Drive Control Tool PC Software DCT 10 Drive Dependent D-TYPE Electro Magnetic Compatibility Electronic Thermal Overload Elec. OL Gram Hertz Kilohertz...
  • Page 7 AF-600 FP Design Guide Motor: The motor frequency when the jog function is activated (via digital terminals). The motor frequency. The maximum motor frequency. The minimum motor frequency. The rated motor frequency (nameplate data). The motor current. The rated motor current (nameplate data).
  • Page 8 AF-600 FP Design Guide Start-disable command A stop command belonging to the group 1 control commands - see this group. Stop command See Control commands. References: Analog Reference A signal transmitted to the analog inputs 53 or 54, can be voltage or current.
  • Page 9 AF-600 FP Design Guide Digital Signal Processor. Relay Outputs: The frequency converter features two programmable Relay Outputs. Electronic Thermal Overload Electronic Thermal Overload is a thermal load calculation based on present load and time. Its purpose is to estimate the motor temperature.
  • Page 10 AF-600 FP Design Guide Trip A state entered in fault situations, e.g. if the frequency converter is subject to an over-temperature or when the frequency converter is protecting the motor, process or mechanism. Restart is prevented until the cause of the fault has disappeared and the trip state is cancelled by activating reset or, in some cases, by being programmed to reset automatically.
  • Page 11 AF-600 FP Design Guide...

  • Page 12: Introduction To Af-600 Fp

    Installation at high altitude: 380 - 480 V, unit sizes 1x, 2x and 3x: At altitudes above 2 km, please contact GE regarding PELV. 380 - 480 V, unit sizes 4x, 5x and 6x: At altitudes above 3 km, please contact GE regarding PELV.
  • Page 13 AF-600 FP Design Guide 2.1.2 Caution The frequency converter DC link capacitors remain charged after power has been disconnected. To avoid an electrical shock hazard, disconnect the frequency converter from the mains before carrying out maintenance. Wait at least as follows before doing service on the frequency...

  • Page 14: Ce Labelling

    Frequency converters must be CE labelled in accordance with the low-voltage directive of January 1, 1997. The directive applies to all electrical equipment and appliances used in the 50 - 1000 V AC and the 75 - 1500 V DC voltage ranges. GE CE-labels in accordance with the directive and issues a declaration of conformity upon request.

  • Page 15: Aggressive Environments

    It must be noted that the responsibility for the final EMC properties of the appliance, system or installation rests with the installer. As an aid to the installer, GE has prepared EMC installation guidelines for the Power Drive system. The standards and test levels stated for Power Drive systems are complied with, provided that the EMC-correct instructions for installation are followed, see the section EMC Immunity.

  • Page 16: Vibration And Shock

    Unit Sizes 4x and 5x have a stainless steel back-channel option to provide additional protection in aggressive environments. Proper ventilation is still required for the internal components of the drive. Contact GE for additional information. 2.5 Vibration and Shock...
  • Page 17 AF-600 FP Design Guide Illustration 2.2: When using a frequency converter to reduce fan capacity to 60% - more than 50% energy savings may be ob- tained in typical applications. 2.7.3 Example of Energy Savings As can be seen from the figure (the laws of proportionality), the flow is controlled by changing the RPM. By reducing the speed only 20% from the rated speed, the flow is also reduced by 20%.
  • Page 18 Power 2.7.4 Comparison of Energy Savings The GE frequency converter solution offers major savings compared with traditional energy saving solutions. This is because the frequency converter is able to control fan speed according to thermal load on the system and the fact that the frequency converter has a build-in facility that enables the fre- quency converter to function as a Building Management System, BMS.
  • Page 19 AF-600 FP Design Guide Illustration 2.4: Discharge dampers reduce power consumption somewhat. Inlet Guide Vans offer a 40% reduction but are expensive to install. The GEfrequency converter solution reduces energy consumption with more than 50% and is easy to install.
  • Page 20 AF-600 FP Design Guide Distribution Valve regulation Frequency converter control Hours Power Consumption Power Consumption 42,5 18.615 42,5 18.615 1314 38,5 50.589 29,0 38.106 1752 35,0 61.320 18,5 32.412 1752 31,5 55.188 11,5 20.148 1752 28,0 49.056 11.388 1752 23,0 40.296...
  • Page 21 AF-600 FP Design Guide 2.7.8 Star/Delta Starter or Soft-starter not Required When larger motors are started, it is necessary in many countries to use equipment that limits the start-up current. In more traditional systems, a star/delta starter or soft-starter is widely used. Such motor starters are not required if a frequency converter is used.
  • Page 22 AF-600 FP Design Guide 2.7.11 With a Frequency Converter The figure shows a fan system controlled by frequency converters.

  • Page 23: Application Examples

    The efficiency comes from utilizing larger fans and larger chillers which have much higher efficiencies than small motors and distributed air-cooled chillers. Savings are also seen from the decreased maintenance requirements. 2.7.14 The AF-600 FP Solution While dampers and IGVs work to maintain a constant pressure in the ductwork, a frequency converter solution saves much more energy and reduces the complexity of the installation.
  • Page 24 By decreasing the air flow, energy used to heat or cool the fresh air is also reduced, adding further savings. Several features of the GE dedicated frequency converter can be utilized to improve the performance of your CAV system. One concern of controlling a ventilation system is poor air quality.
  • Page 25 Several features of the GE dedicated frequency converter, the HVAC frequency converter can be utilized to improve the performance of your cooling tower fans application. As the cooling tower fans drop below a certain speed, the effect the fan has on cooling the water becomes small. Also, when utilizing a gear-box to frequency control the tower fan, a minimum speed of 40-50% may be required.
  • Page 26 20% more efficient than air cooled chillers. 2.7.20 The AF-600 FP solution Frequency converters can be added to condenser water pumps instead of balancing the pumps with a throttling valve or trimming the pump impeller.
  • Page 27 This situation is common in large installations especially when two or more chillers in parallel are installed if primary/ secondary pumping is not utilized. 2.7.22 The AF-600 FP Solution Depending on the size of the system and the size of the primary loop, the energy consumption of the primary loop can become substantial.
  • Page 28 The chiller’s low evaporator temperature safety then trips the chiller requiring a manual reset. This situation is common in large installations especially when two or more chillers in parallel are installed. 2.7.24 The AF-600 FP Solution While the primary-secondary system with two-way valves improves energy savings and eases system control problems, the true energy savings and control potential is realized by adding frequency converters.

  • Page 29: Control Structures

    AF-600 FP Design Guide 2.8 Control Structures 2.8.1 Control Principle Illustration 2.5: Control structures. The frequency converter is a high performance unit for demanding applications. It can handle various kinds of motor control principles such as U/f special motor mode and advanced vector control and can handle normal squirrel cage asynchronous motors.
  • Page 30 AF-600 FP Design Guide 2.8.3 Local (Hand) and Remote (Auto) Control The frequency converter can be operated manually via keypad or remotely via analog/digital inputs or serial bus. If allowed in par. K-40 [Hand] Button on Keypad, par. K-41 [Off] Button on Keypad, par. K-42 [Auto] Button on Keypad, and par. K-43 [Reset] Button on Keypad, it is possible to start and stop the frequency converter bykeypad using the [Hand] and [Off] keys.
  • Page 31 AF-600 FP Design Guide While the default values for the drive’s Closed Loop controller will often provide satisfactory performance, the control of the system can often be optimized by adjusting some of the Closed Loop controller’s parameters. It is also possible to autotune the PI constants.
  • Page 32 AF-600 FP Design Guide Example: A two zone two setpoint application Zone 1 setpoint is 15 bar and the feedback is 5.5 bar. Zone 2 setpoint is 4.4 bar and the feedback is 4.6 bar. If Multi Setpoint Max [14] is selected, Zone 1’s setpoint and feedback are sent to the PID controller, since this has the smaller difference (feedback is higher than setpoint, resulting in a negative difference).
  • Page 33 AF-600 FP Design Guide 2.8.7 Reference Handling Details for Open Loop and Closed Loop operation. A block diagram of how the drive produces the Remote Reference is shown below:.
  • Page 34 AF-600 FP Design Guide The Remote Reference is comprised of: • Preset references. • External references (analog inputs, pulse frequency inputs, digital potentiometer inputs and serial communication bus references). • The Preset relative reference. • Feedback controlled setpoint. Up to 8 preset references can be programmed in the drive. The active preset reference can be selected using digital inputs or the serial communications bus. The reference can also be supplied externally, most commonly from an analog input.
  • Page 35 AF-600 FP Design Guide 1. Start/Stop via switch connected between terminals 12 (+24 V) and 18. 2. Temperature reference via a potentiometer (-5 to +35°C, 0 10 V) connected to terminals 50 (+10 V), 53 (input) and 55 (common). 3. Temperature feedback via transmitter (-10-40°C, 4-20 mA) connected to terminal 54.

  • Page 36: General Aspects Of Emc

    AF-600 FP Design Guide 2.8.10 Tuning the Drive Closed Loop Controller Once the drive’s Closed Loop Controller has been set up, the performance of the controller should be tested. In many cases, its performance may be acceptable using the default values of par. CL-93 PID Proportional Gain and par. CL-94 PID Integral Time. However, in some cases it may be helpful to optimize these parameter values to provide faster system response while still controlling speed overshoot.
  • Page 37 AF-600 FP Design Guide When unscreened cables are used, some emission requirements are not complied with, although the immunity requirements are observed. In order to reduce the interference level from the entire system (unit + installation), make motor and brake cables as short as possible. Avoid placing cables with a sensitive signal level alongside motor and brake cables.
  • Page 38 AF-600 FP Design Guide 2.9.4 General Aspects of Harmonics Emission A frequency converter takes up a non-sinusoidal current from mains, which Harmonic currents increases the input current I . A non-sinusoidal current is transformed by 50 Hz 250 Hz 350 Hz means of a Fourier analysis and split up into sine-wave currents with different frequencies, i.e.
  • Page 39 The immunity requirements for frequency converters depend on the environment where they are installed. The requirements for the industrial environment are higher than the requirements for the home and office environment. All GE frequency converters comply with the requirements for the industrial environment and consequently comply also with the lower requirements for home and office environment with a large safety margin.

  • Page 40: Galvanic Isolation (Pelv)

    Installation at high altitude: 380 - 480 V, unit size 1x, 2x and 3x: At altitudes above 2 km, please contact GE regarding PELV. 380 - 480V, unit size 4x, 5x and 6x: At altitudes above 3 km, please contact GE regarding PELV.

  • Page 41: Earth Leakage Current

    AF-600 FP Design Guide 2.11 Earth Leakage Current Warning: Touching the electrical ts may be fatal - even after the equipment has been disconnected from mains. Also make sure that other voltage inputs have been disconnected, such as load sharing (linkage of DC intermediate circuit), as well as the motor connection for kinetic back-up.
  • Page 42 AF-600 FP Design Guide 2.13.1 Motor Thermal Protection This is the way GE is protecting the motor from being overheated. It is an electronic feature that simulates a bimetal relay based on internal measurements. The characteristic is shown in the following figure: Illustration 2.8: The X-axis is showing the ratio between I...
  • Page 43 AF-600 FP Design Guide The thermistor cut-out value is > 3 kΩ. Integrate a thermistor (PTC sensor) in the motor for winding protection. Motor protection can be implemented using a range of techniques: PTC sen- sor in motor windings; mechanical thermal switch (Klixon type); or Electronic Thermal Electronic Thermal Overload.
  • Page 44 AF-600 FP Design Guide Check that the chosen supply voltage follows the specification of the used thermistor element. Summary With the Torque limit feature the motor is protected for being overloaded independent of the speed. With the Electronic Thermal Overload the motor is protected for being over heated and there is no need for any further motor protection.
  • Page 45 AF-600 FP Design Guide...

  • Page 46: Fp Selection

    AF-600 FP Design Guide 3 AF-600 FP Selection 3.1 Options and Accessories GE offers a wide range of options and accessories for the frequency converters. 3.1.1 Mounting of Option Modules in Slot B The power to the frequency converter must be disconnected.
  • Page 47 AF-600 FP Design Guide 3.1.2 General Purpose Input Output Module OPCGPIO OPCGPIO General Purpose I/O Option Module is used for extension of the number of digital and analog inputs and outputs of the frequency converter. Contents: OPCGPIO must be fitted into slot B in the frequency converter.
  • Page 48 AF-600 FP Design Guide 3.1.3 Digital Inputs - Terminal X30/1-4 Parameters for set-up: E-53, E-54 and E-55 Number of digital Voltage level Voltage levels Tolerance Max. Input impedance inputs 0-24 V DC PNP type: ± 28 V continuous Approx. 5 k ohm Common = 0 V ±...
  • Page 49 AF-600 FP Design Guide 3.1.7 OPCRLY Relay Option Module The OPCRLY includes 3 pieces of SPDT contacts and must be fitted into option slot B. Electrical Data: Max terminal load (AC-1) (Resistive load) 240 V AC 2A Max terminal load (AC-15 ) (Inductive load @ cosφ...
  • Page 50 AF-600 FP Design Guide 12-13-23 15-21-22-24-31-32-33-34 IMPORTANT! The label MUST be placed on the keypad frame as shown (UL approved). Warning Dual supply How to add the OPCRLY option: • See mounting instructions in the beginning of section Options and Accessories •...
  • Page 51 AF-600 FP Design Guide Do not combine low voltage parts and PELV systems.
  • Page 52 AF-600 FP Design Guide 3.1.8 OPC24VPS 24V DC External Supply Module External 24 V DC Supply An external 24 V DC supply can be installed for low-voltage supply to the control card and any option card installed. This enables full operation of the keypad (including the parameter setting) and networks without mains supplied to the power section.
  • Page 53 AF-600 FP Design Guide 3.1.9 OPCAIO Analog I/O Option Module The Analog I/O card is supposed to be used in the following cases: • Providing battery back-up of clock function on control card • As general extension of analog I/O selection available on control card •...
  • Page 54 AF-600 FP Design Guide Analog inputs - terminal X42/1-6 Parameter group for read out: LG-3#. See also AF-600 FP Programming Guide. Parameter groups for set-up: AO-0#, AO-1#, AO-2# and AO-3#. See also AF-600 FP Programming Guide. 3 x Analog inputs Operating range...
  • Page 55 AF-600 FP Design Guide 3.1.10 Remote Mounting Kit for keypad The keypad can be moved to the front of a cabinet by using the remote build Technical data in kit. The Unit Size is the IP65. The fastening screws must be tightened with...
  • Page 56 If the enclosure kit is used, an IP 20 unit is upgraded to comply with enclosure IP 21/ 4X top/TYPE 1. The IP 4X top can be applied to all standard IP 20 AF-600 FP variants. A – Top cover B –...
  • Page 57 AF-600 FP Design Guide 3.1.12 Output Filters The high speed switching of the frequency converter produces some secondary effects, which influence the motor and the enclosed environment. These side effects are addressed by two different filter types, the du/dt and the Sine-wave filter.

  • Page 58: How To Install

    AF-600 FP Design Guide 4 How to Install...
  • Page 59 AF-600 FP Design Guide...

  • Page 60: Mechanical Dimensions

    AF-600 FP Design Guide...
  • Page 61 AF-600 FP Design Guide...
  • Page 62 AF-600 FP Design Guide...
  • Page 63 AF-600 FP Design Guide...
  • Page 64 AF-600 FP Design Guide 4.1.4 Mechanical Mounting All unit sizes 1x, 2x and 3x allow side-by-side installation. Exception: If a IP21 kit is used, there has to be a clearance between the enclosures. For unit sizes 12, 13, 23, 24 and 33 the minimum clearance is 50 mm, for 34 it is 75 mm.

  • Page 65: Lifting

    AF-600 FP Design Guide 4.1.5 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 66 AF-600 FP Design Guide Illustration 4.6: Recommended lifting method, Unit Size 63 Illustration 4.7: Recommended lifting method, Unit Size 64 (460V, 600 to 900 HP, 575/600V, 900 to 1150 HP). (460V, 1000 to 1200 HP, 575/600V, 1250 to 1350 HP).

  • Page 67: Electrical Installation

    AF-600 FP Design Guide 4.2 Electrical Installation 4.2.1 Cables General For the AF-600 FP drives above 125HP, please see AF-600 FP High Power Operating Instructions . Cables General Always comply with national and local regulations on cable cross-sections. Details of terminal tightening torques.

  • Page 68: Electrical Installation And Control Cables

    AF-600 FP Design Guide 4.2.2 Electrical Installation and Control Cables Illustration 4.8: Diagram showing all electrical terminals. Terminal number Terminal description Parameter number Factory default 1+2+3 Terminal 1+2+3-Relay1 E-24 No operation 4+5+6 Terminal 4+5+6-Relay2 E-24 No operation Terminal 12 Supply...
  • Page 69 AF-600 FP Design Guide The common of digital / analog inputs and outputs should be connected to separate common terminals 20, 39, and 55. This will avoid ground current interference among groups. For example, it avoids switching on digital inputs disturbing analog inputs.
  • Page 70 AF-600 FP Design Guide 4.2.5 Unit Size Knock-outs Illustration 4.9: Cable entry holes for unit size 15. The suggested use of the holes are purely recommendations and other solutions are possible. Illustration 4.10: Cable entry holes for unit size 21. The suggested use of the holes are purely recommendations and other solutions are possible.
  • Page 71 AF-600 FP Design Guide Illustration 4.13: Cable entry holes for unit size 22. The suggested use of the holes are purely recommendations and other solutions are possible. Illustration 4.14: Cable entry holes for unit size 31. The suggested use of the holes are purely recommendations and other solutions are possible.
  • Page 72 AF-600 FP Design Guide 4.2.6 Removal of Knockouts for Extra Cables Remove cable entry from the frequency converter (Avoiding foreign parts falling into the frequency converter when removing knockouts) Cable entry has to be supported around the knockout you intend to remove.
  • Page 73 AF-600 FP Design Guide Unit Sizes 41 + 42 Unit Size 51 Cable entries viewed from the bottom of the frequency converter - 1) Mains side 2) Motor side...
  • Page 74 AF-600 FP Design Guide 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 75 The frequency converter is equipped with an internal over current protection that can be used for upstream overload protection (UL-applications excluded). See par. F-43 Current Limit in the AF-600 FP Programming Guide . Fuses must be designed for protection in a circuit capable of supplying a maximum of 100,000 A (symmetrical), 500 V/600 V maximum.
  • Page 76 AF-600 FP Design Guide UL compliance fuses Frequency Ferraz- Ferraz- Bussmann Bussmann Bussmann SIBA Littel fuse converter Shawmut Shawmut 200-240 V Type RK1 Type J Type T Type RK1 Type RK1 Type CC Type RK1 KTN-R10 JKS-10 JJN-10 5017906-010 KLN-R10...
  • Page 77 AF-600 FP Design Guide Ferraz- Bussmann Bussmann SIBA LittelFuse Bussmann Bussmann Internal AF-600 Shawmut E1958 E4273 E180276 E71611 E4274 E125085 Option E60314 JFHR2** T/JDDZ** JFHR2 JFHR2** H/JDDZ** JFHR2* Bussmann JFHR2** 150 HP FWH- JJS- 2061032.315 L50S-300 A50-P300 NOS- 170M3017 170M3018...
  • Page 78 AF-600 FP Design Guide AF-600 FP Bussmann PN* Rating Siba Internal Bussmann Option 750 HP 170M7081 1600 A, 700 V 20 695 32.1600 170M7082 950 HP 170M7081 1600 A, 700 V 20 695 32.1600 170M7082 1050 HP 170M7081 1600 A, 700 V 20 695 32.1600...
  • Page 79 AF-600 FP Design Guide Unit Sizes Bussmann PN* Rating GMC-800MA 800 mA, 250 V Table 4.19: NAMUR Fuse Unit Sizes Bussmann PN* Rating Alternative Fuses LP-CC-6 6 A, 600 V Any listed Class CC, 6 A Table 4.20: Safety Relay Coil Fuse with PILS Relay...
  • Page 80 AF-600 FP Design Guide 4.2.9 Control Terminals Drawing reference numbers: 10 pole plug digital I/O. 3 pole plug RS485 Bus. 6 pole analog I/O. USB Connection. Illustration 4.18: Control terminals (all enclosures) 4.2.10 Control Cable Terminals To mount the cable to the terminal:...
  • Page 81 AF-600 FP Design Guide 4.2.11 Electrical Installation, Control Cables Illustration 4.19: Diagram showing all electrical terminals. Very long control cables and analog signals may in rare cases and depending on installation result in 50/60 Hz earth loops due to noise from mains supply cables.
  • Page 82 AF-600 FP Design Guide Use a clamp from the accessory bag to connect the screen to the 130BA681.10 frequency converter decoupling plate for control cables. See section entitled Earthing of Screened/Armoured Control Cables for the correct termination of control cables.

  • Page 83: Final Set-Up And Test

    AF-600 FP Design Guide 4.3 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 lo- cated on the motor name plate data.
  • Page 84 "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 Service, make sure to mention number and alarm description.

  • Page 85: Additional Connections

    AF-600 FP Design Guide 4.4 Additional Connections 4.4.1 External Fan Supply Unit size 4x, 5x and 6x In case the frequency converter is supplied by DC or if the fan must run independently of the power supply, an external power supply can be applied. The connection is made on the power card.
  • Page 86 AF-600 FP Design Guide 4.4.3 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. When motors are connected in parallel, par. P-04 Auto Tune cannot be used.

  • Page 87: Motor Insulation

    AF-600 FP Design Guide 4.4.4 Direction of Motor Rotation The default setting is clockwise rotation with the frequency converter output connected as follows. Terminal 96 connected to U-phase Terminal 97 connected to V-phase Terminal 98 connected to W-phase The direction of motor rotation is changed by switching two motor phases.

  • Page 88: Motor Bearing Currents

    Use an insulated bearing as recommended by the motor manufacturer (note: Motors from reputable manufacturers will typically have these fitted as standard in motors of this size) If found to be necessary and after consultation with GE: Lower the IGBT switching frequency Modify the inverter waveform, 60°...

  • Page 89: Installation Of Misc. Connections

    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 90 AF-600 FP Design Guide DCT 10 Set-up Software DCT 10 has been designed as an easy to use interactive tool for setting parameters in our frequency converters. The PC-based Configuration Tool DCT 10 will be useful for: • Planning a communication network off-line. DCT 10 contains a complete frequency converter database •...

  • Page 91: Safety

    AF-600 FP Design Guide 4.6 Safety 4.6.1 High Voltage Test Carry out a high voltage test by short-circuiting terminals U, V, W, L and L . Energize maximum 2.15 kV DC for 380-480V frequency converters and 2.525 kV DC for 525-690V frequency converters for one second between this short-circuit and the chassis.
  • Page 92 AF-600 FP Design Guide Illustration 4.21: EMC-correct electrical installation of a frequency converter in cabinet. Illustration 4.22: Electrical connection diagram.
  • Page 93 4.7.2 Use of EMC-Correct Cables GE recommends braided screened/armoured cables to optimise EMC immunity of the control cables and the EMC emission from the motor cables. The ability of a cable to reduce the in- and outgoing radiation of electric noise depends on the transfer impedance (Z ).

  • Page 94: Residual Current Device

    AF-600 FP Design Guide 4.7.3 Earthing of Screened/Armoured Control Cables Generally speaking, control cables must be braided screened/armoured and the screen must be connected by means of a cable clamp at both ends to the metal cabinet of the unit.
  • Page 95 AF-600 FP Design Guide...

  • Page 96: Application Examples

    AF-600 FP Design Guide 5 Application Examples 5.1.1 Start/Stop Terminal 18 = start/stop par. E-01 Terminal 18 Digital Input [8] Start Terminal 27 = No operation par. E-03 Terminal 27 Digital Input [0] No operation Par. E-01 Terminal 18 Digital Input = Start (default) Par.

  • Page 97: Potentiometer Reference

    This disturbs the auto tune function. 5.1.5 Logic Controller New useful facility in the AF-600 FP frequency converter is the Logic Controller (LC). In applications where a PLC is generating a simple sequence the LC may take over elementary tasks from the main control.
  • Page 98 AF-600 FP Design Guide 5.1.6 Logic Controller Programming The Logic Controller (LC) is essentially a sequence of user defined actions (see par. LC-52 Logic Controller Action) executed by the LC when the associated user defined event (see par. LC-51 Logic Controller Event) is evaluated as TRUE by the LC.
  • Page 99 AF-600 FP Design Guide Set Preset reference 0 to first preset speed (par. C-05 Multi-step Frequency 1 - 8 [0]) in percentage of Max reference speed (par. F-53 Maximum Reference). Ex.: Set preset reference 1 to second preset speed (par. C-05 Multi-step Frequency 1 - 8 [1] Ex.: 0 % (zero).
  • Page 100 AF-600 FP Design Guide 5.1.8 BASIC Cascade Controller The BASIC Cascade Controller is used for pump applications where a certain pressure (“head”) or level needs to be maintained over a wide dynamic range. Running a large pump at variable speed over a wide for range is not an ideal solution because of low pump efficiency and because there is a practical limit of about 25% rated full load speed for running a pump.
  • Page 101 AF-600 FP Design Guide When the Cascade Controller is enabled and running normally and the frequency converter issues a trip alarm, the system head is maintained by staging and destaging fixed speed pumps. To prevent frequent staging and destaging and minimize pressure fluxuations, a wider Fixed Speed Bandwidth is used instead of the Staging bandwidth.
  • Page 102 AF-600 FP Design Guide 5.1.11 Fixed Variable Speed Pump Wiring Diagram...
  • Page 103 AF-600 FP Design Guide 5.1.12 Lead Pump Alternation Wiring Diagram Every pump must be connected to two contactors (K1/K2 and K3/K4) with a mechanical interlock. Thermal relays or other motor protection devices must be applied according to local regulation and/or individual demands.
  • Page 104 AF-600 FP Design Guide 5.1.13 Cascade Controller Wiring Diagram The wiring diagram shows an example with the built in BASIC Cascade Controller with one variable speed pump (lead) and two fixed speed pumps, a 4-20 mA transmitter and System Safety Interlock.
  • Page 105 AF-600 FP Design Guide...
  • Page 106 AF-600 FP Design Guide 6 RS-485 Installation and Set-up 6.1 RS-485 Installation and Set-up 6.1.1 Overview RS-485 is a two-wire bus interface compatible with multi-drop network topology, i.e. nodes can be connected as a bus, or via drop cables from a common trunk line.
  • Page 107 AF-600 FP Design Guide 6.1.3 Frequency Converter Hardware Setup Use the terminator dip switch on the main control board of the frequency converter to terminate the RS-485 bus. Terminator Switch Factory Setting The factory setting for the dip switch is OFF.
  • Page 108 When crossing is unavoidable, the RS-485 cable must cross motor and brake resistor cables at an angle of 90 degrees. 6.2 Drive Protocol Overview The Drive protocol, also referred to as Drive bus or Standard bus, is the GE standard network. It defines an access technique according to the master-slave principle for communications via a serial bus.
  • Page 109 AF-600 FP Design Guide 6.2.1 Drive with Modbus RTU The Drive protocol provides access to the Control Word and Bus Reference of the frequency converter. The Control Word allows the Modbus master to control several important functions of the frequency converter: •...
  • Page 110 AF-600 FP Design Guide 6.3 Network Configuration 6.3.1 Frequency Converter Set-up Set the following parameters to enable the Drive protocol for the frequency converter. Parameter Parameter Setting Number Name O-30 Protocol Drive O-31 Address 1 - 126 O-32 Baud Rate...
  • Page 111 AF-600 FP Design Guide 6.4.4 Frequency Converter Address (ADR) Two different address formats are used. The address range of the frequency converter is either 1-31 or 1-126. 1. Address format 1-31: Bit 7 = 0 (address format 1-31 active) Bit 6 is not used...
  • Page 112 AF-600 FP Design Guide Text block: The text block is used to read or write texts via the data block. 6.4.7 The PKE Field The PKE field contains two sub-fields: Parameter command and response AK, and Parameter number PNU: Bits no. 12-15 transfer parameter commands from master to slave and return processed slave responses to the master.
  • Page 113 AF-600 FP Design Guide If the command cannot be performed, the slave sends this response: 0111 Command cannot be performed - and issues the following fault report in the parameter value (PWE): PWE low (Hex) Fault Report The parameter number used does not exit...
  • Page 114 AF-600 FP Design Guide 6.4.11 Data Types Supported by the Frequency Converter Unsigned means that there is no operational sign in the telegram. Data types Description Integer 16 Integer 32 Unsigned 8 Unsigned 16 Unsigned 32 Text string Byte string...
  • Page 115 AF-600 FP Design Guide 6.5 Examples All parameters in the AF-600FP is named with one or two letters, a "-" and a number e.g. F-07. To access parameters the following table has to be used because letters cannot be addressed.
  • Page 116 AF-600 FP Design Guide 6.5.1 Writing a Parameter Value Change par. F-15 Motor Speed High Limit [Hz] to 100 Hz. Write the data in EEPROM. PKE = E00F Hex - Write single word in par. F-15 Motor Speed High Limit [Hz]...
  • Page 117 AF-600 FP Design Guide 6.6 Modbus RTU Overview 6.6.1 Assumptions These operating instructions assume that the installed controller supports the interfaces in this document and that all the requirements stipulated in the controller, as well as the frequency converter, are strictly observed, along with all limitations therein.
  • Page 118 AF-600 FP Design Guide 6.7 Network Configuration To enable Modbus RTU on the frequency converter, set the following parameters: Parameter Number Parameter name Setting O-30 Protocol Modbus RTU O-31 Address 1 - 247 O-32 Baud Rate 2400 - 115200 O-33...
  • Page 119 AF-600 FP Design Guide 6.8.3 Start / Stop Field Messages start with a silent period of at least 3.5 character intervals. This is implemented as a multiple of character intervals at the selected network baud rate (shown as Start T1-T2-T3-T4). The first field to be transmitted is the device address. Following the last transmitted character, a similar period of at least 3.5 character intervals marks the end of the message.
  • Page 120 AF-600 FP Design Guide Coil Number Description Signal Direction 1-16 Frequency converter control word (see table below) Master to slave 17-32 Frequency converter speed or set-point reference Range 0x0 – 0xFFFF (-200% ... ~200%) Master to slave 33-48 Frequency converter status word (see table below)
  • Page 121 AF-600 FP Design Guide 6.8.9 How to Control the Frequency Converter This section describes codes which can be used in the function and data fields of a Modbus RTU message. For a complete description of all the message fields please refer to the section Modbus RTU Message Framing Structure.
  • Page 122 AF-600 FP Design Guide 6.9 How to Access Parameters 6.9.1 Parameter Handling The PNU (Parameter Number) is translated from the register address contained in the Modbus read or write message. The parameter number is translated to Modbus as (10 x parameter number) DECIMAL.
  • Page 123 AF-600 FP Design Guide 6.10 Examples The following examples illustrate various Modbus RTU commands. If an error occurs, please refer to the Exception Codes section. 6.10.1 Read Coil Status (01 HEX) Description This function reads the ON/OFF status of discrete outputs (coils) in the frequency converter. Broadcast is never supported for reads.
  • Page 124 AF-600 FP Design Guide 6.10.2 Force/Write Single Coil (05 HEX) Description This function forces a writes a coil to either ON or OFF. When broadcast the function forces the same coil references in all attached slaves. Query The query message specifies the coil 65 (parameter write control) to be forced. Coil addresses start at zero, i.e. coil 65 is addressed as 64. Force Data = 00 00HEX (OFF) or FF 00HEX (ON).
  • Page 125 AF-600 FP Design Guide 6.10.3 Force/Write Multiple Coils (0F HEX) This function forces each coil in a sequence of coils to either ON or OFF. When broadcast the function forces the same coil references in all attached slaves. . The query message specifies the coils 17 to 32 (speed set-point) to be forced.
  • Page 126 AF-600 FP Design Guide 6.10.4 Read Holding Registers (03 HEX) Description This function reads the contents of holding registers in the slave. Query The query message specifies the starting register and quantity of registers to be read. Register addresses start at zero, i.e. registers 1-4 are addressed as 0-3.
  • Page 127 AF-600 FP Design Guide 6.10.5 Preset Single Register (06 HEX) Description This function presets a value into a single holding register. Query The query message specifies the register reference to be preset. Register addresses start at zero, i.e. register 1 is addressed as 0.
  • Page 128 AF-600 FP Design Guide 6.10.6 Preset Multiple Registers (10 HEX) Description This function presets values into a sequence of holding registers. Query The query message specifies the register references to be preset. Register addresses start at zero, i.e. register 1 is addressed as 0. Example of a request to preset two registers (set parameter P-03 = 738 (7.38 A)):...
  • Page 129 AF-600 FP Design Guide 6.11 GE Drive Control Profile 6.11.1 Control Word According to Drive Profile(par. O-10 Control Word Profile = Drive profile) Bit value = 0 Bit value = 1 Reference value external selection lsb Reference value external selection msb...
  • Page 130 AF-600 FP Design Guide Bit 03, Coasting: Bit 03 = ’0’: The frequency converter immediately "lets go" of the motor, (the output transistors are "shut off") and it coasts to a standstill. Bit 03 = ’1’: The frequency converter starts the motor if the other starting conditions are met.
  • Page 131 AF-600 FP Design Guide Bit 13/14, Selection of set-up: Set-up Bit 14 Bit 13 Use bits 13 and 14 to choose from the four menu set-ups according to the shown table: . The function is only possible when Multi Set-Ups is selected in par. K-10 Active Set-up.
  • Page 132 AF-600 FP Design Guide Bit 04, No error/error (no trip): Bit 04 = ’0’: The frequency converter is not in fault mode. Bit 04 = “1”: The frequency converter shows an error but does not trip. Bit 05, Not used: Bit 05 is not used in the status word.
  • Page 133 AF-600 FP Design Guide 6.11.3 Bus Speed Reference Value Speed reference value is transmitted to the frequency converter in a relative value in %. The value is transmitted in the form of a 16-bit word; in integers (0-32767) the value 16384 (4000 Hex) corresponds to 100%. Negative figures are formatted by means of 2’s complement.
  • Page 134 AF-600 FP Design Guide 7 General Specifications and Troubleshooting 7.1 Mains Supply Tables Mains supply 200 - 240 VAC Light duty (LD) 110% for 1 minute Typical Shaft Output [kW] 0.75 IP 20 / Chassis IP 55 / NEMA 12...
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  • Page 139 AF-600 FP Design Guide 7.1.1 Mains Supply High Power Mains Supply 3 x 380 - 480 VAC Typical Shaft output at 400 V [kW] Typical Shaft output at 460 V [HP] Unit Size IP21 Unit Size IP54 Unit Size IP00...
  • Page 140 AF-600 FP Design Guide Mains Supply 3 x 380 - 480 VAC Typical Shaft output at 400 V [kW] Typical Shaft output at 460 V [HP] Unit Size IP21 Unit SizeIP54 Unit Size IP00 Output current Continuous (at 400 V) [A]...
  • Page 141 AF-600 FP Design Guide Mains Supply 3 x 380 - 480 VAC Typical Shaft output 1000 at 400 V [kW] Typical Shaft output 1000 1200 1350 at 460 V [HP] Unit Size IP21, 54 without/ with options 61/63 61/63 61/63...
  • Page 142 AF-600 FP Design Guide Mains Supply 3 x 525- 690 VAC 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 Continuous (at 550 V) [A]...
  • Page 143 AF-600 FP Design Guide Mains Supply 3 x 525 - 690 VAC Typical Shaft output at 550 V [kW] Typical Shaft output at 575 V [HP] Typical Shaft output at 690 V [kW] Unit Size IP21 Unit Size IP54 Unit Size IP00...
  • Page 144 AF-600 FP Design Guide Mains Supply 3 x 525 - 690 VAC Typical Shaft output at 550 V [kW] Typical Shaft output at 575 V [HP] Typical Shaft output at 690 V [HP] Unit Size IP21 Unit Size IP54 Unit Size IP00...
  • Page 145 AF-600 FP Design Guide Mains Supply 3 x 525 - 690 VAC Typical Shaft output at 1000 550 V [kW] Typical Shaft output at 1050 1150 1350 575 V [HP] Typical Shaft output at 1000 1200 690 V [HP] Unit Size IP21, 54 with-...
  • Page 146 AF-600 FP Design Guide 7.2 General Specifications Mains supply (L1, L2, L3): 200-240 V ±10%, 380-480 V ±10%, , 525-600 V ±10%, 525-690 V ±10% Supply voltage Mains voltage low / mains drop-out: During low mains voltage or a mains drop-out, the drive continues until the intermediate circuit voltage drops below the minimum stop level, which corresponds typically to 15% below the drive's lowest rated supply voltage.
  • Page 147 AF-600 FP Design Guide 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 148 AF-600 FP Design Guide 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 149 - with full output power of typical EFF2 motors (up to 90% output current) max. 45 ° C - at full continuous Drive output current For more information on derating see the AF-600 FP Design Guide, section on Special Conditions. Minimum ambient temperature during full-scale operation 0 °C Minimum ambient temperature at reduced performance - 10 °C...
  • Page 150 The above example shows the efficiency of a 55 kW, 380-480 VAC frequency converter at 25% load at 25 Hz. The graph is showing 0.97 - rated efficiency for a 55 kW AF-600 FP is 0.98. The actual efficiency is then: 0.97x0.98=0.95.
  • Page 151 AF-600 FP Design Guide 7.4 Acoustic Noise The acoustic noise from the frequency converter comes from three sources: DC intermediate circuit coils. Integral fan. RFI filter choke. The typical values measured at a distance of 1 m from the unit:...
  • Page 152 AF-600 FP Design Guide Frequency Converter, 7.5 HP, 200-240 V Rise time dU/dt Cable Mains Vpeak length [m] voltage [V] [μsec] [kV] [kV/μsec] 0.226 0.616 2.142 0.262 0.626 1.908 0.650 0.614 0.757 0.745 0.612 0.655 Frequency Converter, 10 HP, 200-240 V...
  • Page 153 AF-600 FP Design Guide Frequency Converter, 50 HP, 200-240 V Rise time dU/dt Cable Mains Vpeak length [m] voltage [V] [μsec] [kV] [kV/μsec] 0.300 0.598 1.593 0.536 0.566 0.843 0.776 0.546 0.559 Frequency Converter, 60 HP, 200-240 V Rise time...
  • Page 154 AF-600 FP Design Guide Frequency Converter, 25 HP, 380-480 V Rise time dU/dt Cable Mains Vpeak length [m] voltage [V] [μsec] [kV] [kV/μsec] 0.344 1.040 2.442 1.000 1.190 0.950 1.400 1.040 0.596 Frequency Converter, 30 HP, 380-480 V Rise time...
  • Page 155 [kV/μsec] 0.71 1.165 1.389 0.61 0.942 1.233 0.80 0.906 0.904 0.82 0.760 0.743 Table 7.5: 1: With GE dU/dt filter. Frequency Converter, 150-400 HP, 525-690 V Rise time dU/dt Cable Mains Vpeak length [m] voltage [V] [μsec] [kV] [kV/μsec] 0.38 1.513...
  • Page 156 ) should be derated in accordance with the shown diagram. Illustration 7.2: Derating of output current versus altitude at T for unit sizes 1x, 2x and 3x. At altitudes above 2 km, please contact GE regarding AMB, MAX PELV. An alternative is to lower the ambient temperature at high altitudes and thereby ensure 100% output current at high altitudes. As an example of how to read the graph, the situation at 2 km is elaborated.
  • Page 157 In the graphs shown below, the typical VT curve is below the maximum torque with de-rating and maximum torque with forced cooling at all speeds. Maximum load for a standard motor at 40 °C driven by an AF-600 FP drive Legend: ─...
  • Page 158 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 the 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 159 AF-600 FP Design Guide 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 Elec.
  • Page 160 AF-600 FP Design Guide Description Warning Alarm/Trip Alarm/Trip Lock Parameter Reference Illegal Drive configuration Dangerous Failure Safe Stop Auto Restart Power Unit Setup Reduced power mode Illegal PS config Drive Restored to Factory Settings Profibus/Profisafe Error Analog input 54 wrong settings...
  • Page 161 AF-600 FP Design Guide Alarm Word and Extended Status Word Alarm Word Warning Word Extended Status Word 00000001 Ramping 00000002 Pwr. Card Temp Pwr. Card Temp Auto Tune Running 00000004 Earth Fault Earth Fault Start CW/CCW 00000008 Ctrl.Card Temp Ctrl.Card Temp...
  • Page 162 AF-600 FP Design Guide 7.7.2 Alarm Words Alarm word, par. DR-90 Alarm Word Alarm word 2, par. DR-91 Alarm Word 2 Alarm Word Alarm Word 2 (Hex) (par. DR-90 Alarm Word) (Hex) (par. DR-91 Alarm Word 2) 00000001 00000001 Service Trip, read / Write...
  • Page 163 AF-600 FP Design Guide 7.7.3 Warning Words Warning word , par. DR-92 Warning Word Warning word 2, par. DR-93 Warning Word 2 Warning Word Warning Word 2 (Hex) (par. DR-92 Warning Word) (Hex) (par. DR-93 Warning Word 2) 00000001 00000001...
  • Page 164 AF-600 FP Design Guide 7.7.4 Extended Status Words Extended status word, par. DR-94 Ext. Status Word Extended status word 2, par. DR-95 Ext. Status Word 2 Extended Status Word Extended Status Word 2 (par. DR-95 Ext. (Hex) (par. DR-94 Ext. Status Word)
  • Page 165 AF-600 FP Design Guide 7.7.5 Fault Messages WARNING 1, 10 volts low WARNING/ALARM 9, Inverter overloaded The control card voltage is below 10 V from terminal 50. 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 166 The fan warning function is an extra protection function that checks if the fan It may be necessary to contact your GE supplier. Some typical alarm mes- is running / mounted. The fan warning can be disabled in par. SP-53 Fan sages: Monitor ([0] Disabled).
  • Page 167 The 24 V DC is measured on the control card. The external V DC backup power 1381 Option C0 did not respond when calculating Platform Ver- supply may be overloaded, otherwise contact your GE supplier. sion. 1382 Option C1 did not respond when calculating Platform Ver- WARNING 48, 1.8 V supply low...
  • Page 168 AF-600 FP Design Guide WARNING 60, External interlock ALARM 95, Broken belt External interlock has been activated. To resume normal operation, apply 24 Torque is below the torque level set for no load, indicating a broken belt. See V DC to the terminal programmed for external interlock and reset the fre- parameter group AP-6#.
  • Page 169 AF-600 FP Design Guide 2 = middle inverter module in 62 or 64 drive. 2 = right inverter module in 61 or 63 drive. 3 = right inverter module in 62 or 64 drive. 5 = rectifier module. ALARM 248, Illegal power section configuration This alarm is only for 6x unit size drives.
  • Page 170 AF-600 FP Design Guide Index 0 - 10 Vdc 0-20 Ma 3 Setpoint Pid Controller 4-20 Ma Abbreviations Accessory Bags Acoustic Noise Advanced Vecter Control Aggressive Environments Air Humidity Alarm Word Alarm/warning Code List 158, 159 Alarms And Warnings Aluminium Conductors...
  • Page 171 AF-600 FP Design Guide Constant Air Volume Control Cable Terminals Control Cables Control Cables 68, 80 Control Cables 67, 80 Control Card Performance Control Card, 10 V Dc Output Control Card, 24 V Dc Output Control Card, Rs-485 Serial Communication:...
  • Page 172 AF-600 FP Design Guide Fan System Controlled By Frequency Converters Fault Messages Field Mounting Final Set-up And Test Flow Meter Freeze Output Frequency Converter Hardware Setup Frequency Converter Set-up Frequency Converter With Modbus Rtu Function Codes Supported By Modbus Rtu...
  • Page 173 AF-600 FP Design Guide Mechanical Dimensions Mechanical Dimensions Mechanical Dimensions - High Power Mechanical Mounting Modbus Communication Modbus Exception Codes Moment Of Inertia Motor Cables Motor Cables Motor Name Plate Motor Name Plate Data Motor Output Motor Parameters Motor Phases...
  • Page 174 AF-600 FP Design Guide Radiated Emission Rated Motor Speed 8, 40 Read Holding Registers (03 Hex) Real-time Clock (rtc) Reference Handling Relay Output Relay Outputs Removal Of Knockouts For Extra Cables Residual Current Device 40, 93 Return Fan Rise Time...
  • Page 175 AF-600 FP Design Guide Use Of Emc-correct Cables Variable (quadratic) Torque Applications (vt) Variable Air Volume Variable Control Of Flow And Pressure Varying Flow Over 1 Year Vibration And Shock Vibrations Voltage Level Warning Against Unintended Start Warning Word Warning Word 2...
  • Page 176 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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