GE - General Electric AF-650 GP Operating Instructions

GE Consumer & Industrial

Electrical Distribution

AF-650 GP

General Purpose Drive

(230V to 50HP, 460/575V to 100HP)

Operating Instructions

Contents

AF-650 GP Operating Instructions

1 How to Read these Operating Instructions

Approvals 3

Symbols 4

Abbreviations 4

2 Safety Instructions and General Warning

High Voltage 5

Avoid Unintended Start 7

Safe Stop of AF-650 GP 7

Safe Stop Installation 8

IT Mains 8

3 How to Install

Mechanical Installation 14

Electrical Installation 16

Connection to Mains and Earthing 17

Motor Connection 19

Fuses 22

Electrical Installation, Control Terminals 26

Connection Examples 27

Electrical Installation, Control Cables 28

Switches S201, S202, and S801 31

Additional Connections 34

Mechanical Brake Control 34

Motor Thermal Protection 34

How to Connect a PC to the frequency converter 35

The AF-650 GP PC Software 35

4 How to Program

The Graphical Keypad 37

How to Program on the Graphical Keypad 37

Quick Setup Parameter List 39

Parameter Lists 46

K-## Keypad Set-up 47

F-## Fundamental Parameters 48

E-## Digital In/Outs 49

C-## Frequency Control Functions 51

P-## Motor Data 52

H-## High Perf Parameters

AN-## Analog In / Out 55

SP-## Special Functions 56

AF-650 GP Operating Instructions

O-## Options/Comms 57

DN-## DevicNet 58

PB-## Profibus 59

ID-## Drive Information 60

DR-## Data Readouts 62

LC-## Logic Controller 64

B-## Braking Functions 65

PI-## PID Controls 66

EC-## Feedback Option 67

RS-## Resolver Interface 68

5 General Specifications

Electrical Data - 200-240 V 69

Electrical Data - 380-500 V 71

Electrical Data - 525-600 V 74

6 Troubleshooting

Warnings/Alarm Messages 83

Index

AF-650 GP Operating Instructions

1 How to Read these Operating Instructions

1.1.1 How to Read these Operating Instructions

AF-650 GP is designed to provide high shaft performance on electrical motors. Please read this manual carefully for proper use. Incorrect handling of the frequency

converter may cause improper operation of the frequency converter or related equipment, shorten lifetime or cause other troubles.

These Operating Instructions will help you get started, install, program, and troubleshoot your AF-650 GP.

. AF-650 GP is a high performance frequency converter for asynchronous as well as permanent motors and handles various kinds of motor control principles such

as volts/hertz, advanced vector control, sensorless vector, and full flux vector control.

Chapter 1, How to Read these Operating Instructions, introduces the manual and informs you about the approvals, symbols, and abbreviations used in this

literature.

Chapter 2, Safety Instructions and General Warnings, entails instructions on how to handle the AF-650 GP correctly.

Chapter 3, How to Install, guides you through mechanical and technical installation.

Chapter 4, How to Program, shows you how to operate and program the AF-650 GP via the Keypad.

Chapter 5, General Specifications, contains technical data about AF-650 GP.

Chapter 6, Troubleshooting, assists you in solving problems that may occur when using AF-650 GP.

Available Literature for AF-650 GP

- The AF-650 GP Design Guide entails all technical information about the drive design and applications including encoder, resolver and relay options.

- The AF-650 GP Profibus Operating Instructions provide the information required for controlling, monitoring and programming the drive via a Profibus

network.

- The AF-650 GP DeviceNet Operating Instructions provide the information required for controlling, monitoring and programming the drive via a DeviceNet

network.

- The AF-650 GP DCT 10 Operating Instructions provide information for installation and use of the software on a PC.

- The AF-650 GP IP21 / Nema 1 kit Instruction provides information for installing the IP21 / Nema 1 field installed option kits..

- The AF-650 GP 24 V DC Backup Instruction provides information for installing the 24 V DC Backup option.

GE technical literature is also available online at www.geelectrical/drives.

1.1.2 Approvals

1.1.3 Symbols

Symbols used in this Operating Instructions.

NB!

Indicates something to be noted by the reader.

Indicates a general warning.

Indicates a high-voltage warning.

AF-650 GP Operating Instructions

∗

Indicates default setting

1.1.4 Abbreviations

Alternating current AC American wire gauge AWG Ampere/AMP A Current limit I Degrees Celsius °C Direct current DC Drive Control Tool PC Software DCT 10 Drive Dependent D-TYPE Electro Magnetic Compatibility EMC Electronic Thermal Overload Elec. OL Gram g Hertz Hz Kilohertz kHz Meter m Millihenry Inductance mH Milliampere mA Millisecond ms Minute min Nanofarad nF Newton Meters Nm Nominal motor current I Nominal motor frequency f Nominal motor power P Nominal motor voltage U Parameter par. Protective Extra Low Voltage PELV Printed Circuit Board PCB Rated Inverter Output Current I Revolutions Per Minute RPM Regenerative terminals Regen Second s Synchronous Motor Speed n Torque limit T Volts V

LIM

M,N

INV

LIM

2 Safety Instructions and General Warning

Equipment containing electrical components may not be disposed of together with domestic waste. It must be separately collected with electrical and electronic waste according to local and currently valid legislation.

The DC link capacitors remain charged after power has been disconnected. To avoid electrical shock hazard, disconnect the frequency con-

verter from mains before carrying out maintenance. When using a PM-motor, make sure it is disconnected. Before doing service on the

frequency converter wait at least the amount of time indicated below:

AF-650 GP Operating Instructions

380 - 500 V 0.25 - 7.5 kW 4 minutes 11 - 75 kW 15 minutes 90 - 200 kW 20 minutes 250 - 800 kW 40 minutes 525 - 690 V 37 - 315 kW 20 minutes 355 - 1000 kW 30 minutes

AF-650 GP

Operating Instructions

Software version: 4.9x

These Operating Instructions can be used for all AF-650 GP frequency converters with software version 4.9x.

The software version number can be seen from par. ID-43 Software Version.

2.1.1 High Voltage

The voltage of the frequency converter is dangerous whenever the frequency converter is connected to mains. Incorrect installation or oper-

ation of the motor or frequency converter may cause damage to the equipment, serious personal injury or death. The instructions in this

manual must consequently be observed, as well as applicable local and national rules and safety regulations.

AF-650 GP Operating Instructions

Installation in high altitudes

380 - 500 V: At altitudes above 3 km, please contact GE regarding PELV.

525 - 690 V: At altitudes above 2 km, please contact GE regarding PELV.

The voltage of the frequency converter is dangerous whenever connected to mains. Incorrect installation of the motor, frequency converter

or network may cause damage to the equipment, serious personal injury or death. Consequently, the instructions in this manual, as well as

national and local rules and safety regulations, must be complied with.

Safety Regulations

1. The mains supply to the frequency converter must be disconnected whenever repair work is to be carried out. Check that the mains supply has been

disconnected and that the necessary time has elapsed before removing motor and mains supply plugs.

2. The [OFF] button on the control panel of the frequency converter does not disconnect the mains supply and consequently it must not be used as a safety

switch.

3. The equipment must be properly earthed, the user must be protected against supply voltage and the motor must be protected against overload in

accordance with applicable national and local regulations.

4. The earth leakage current exceeds 3.5 mA.

5. Protection against motor overload is not included in the factory setting. If this function is desired, set par. F-10 Electronic Overload to data value Elec.

OL trip 1 [4] or data value Elec. OL warning 1 [3].

6. Do not remove the plugs for the motor and mains supply while the frequency converter is connected to mains. Check that the mains supply has been

disconnected and that the necessary time has elapsed before removing motor and mains plugs.

7. Please note that the frequency converter has more voltage sources than L1, L2 and L3, when load sharing (linking of DC intermediate circuit) or external

24 V DC are installed. Check that all voltage sources have been disconnected and that the necessary time has elapsed before commencing repair work.

2.1.2 General Warning

Warning:

Touching the electrical parts 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.

Using AF-650 GP: wait at least 15 minutes.

Shorter time is allowed only if indicated on the nameplate for the specific unit.

Leakage Current

The earth leakage current from the frequency converter exceeds 3.5 mA. To ensure that the earth cable has a good mechanical connection

to the earth connection (terminal 95), the cable cross section must be at least 10 mm

Residual Current Device

This product can cause a D.C. current in the protective conductor. Where a residual current device (RCD) is used for extra protection, only an

RCD of Type B (time delayed) shall be used on the supply side of this product.

Protective earthing of the AF-650 GP and the use of RCD's must always follow national and local regulations.

NB!

For vertical lifting or hoisting applications it is strongly recommended to ensure that the load can be stopped in case of an emergency or a malfunction of a

single part such as a contactor, etc.

If the frequency converter is in alarm mode or in an over voltage situation, the mechanical brake cuts in.

or 2 times rated earth wires terminated separately.

AF-650 GP Operating Instructions

2.1.3 Before Commencing Repair Work

1. Disconnect the frequency converter from mains

2. Disconnect DC bus terminals 88 and 89 from load share applications

3. Wait for discharge of the DC-link. See period of time on the warning label

4. Remove motor cable

2.1.4 Avoid Unintended Start

While the frequency converter is connected to mains, the motor can be started/stopped using digital commands, bus commands, references or via the Keypad.

• Disconnect the frequency converter from mains whenever personal safety considerations make it necessary to avoid unintended start.

• To avoid unintended start, always activate the [OFF] key before changing parameters.

• An electronic fault, temporary overload, a fault in the mains supply, or lost motor connection may cause a stopped motor to start. Frequency converter

with Safe Stop provides protection against unintended start, if the Safe Stop Terminal 37 is on low voltage level or disconnected.

2.1.5 Safe Stop of AF-650 GP

The AF-650 GP can perform the safety function Safe Torque Off (As defined by IEC 61800-5-2) or Stop Category 0 (as defined in EN 60204-1).

It is designed and approved suitable for the requirements of Safety Category 3 in EN 954-1. This functionality is called Safe Stop. Prior to integration and use of

Safe Stop in an installation, a thorough risk analysis on the installation must be carried out in order to determine whether the Safe Stop functionality and safety

category are appropriate and sufficient. In order to install and use the Safe Stop function in accordance with the requirements of Safety Category 3 in EN 954-1,

the related information and instructions of the AF-650 GP Design Guide must be followed! The information and instructions of the Operating Instructions are not

sufficient for a correct and safe use of the Safe Stop functionality!

AF-650 GP Operating Instructions

2.1.6 Safe Stop Installation

To carry out an installation of a Category 0 Stop (EN60204) in conform-

ance with Safety Category 3 (EN954-1), follow these instructions:

1. The bridge (jumper) between Terminal 37 and 24 V DC must be re-

moved. Cutting or breaking the jumper is not sufficient. Remove it

entirely to avoid short-circuiting. See jumper on illustration.

2. Connect terminal 37 to 24 V DC by a short-circuit protected cable.

The 24 V DC voltage supply must be interruptible by an EN954-1

Category 3 circuit interrupt device. If the interrupt device and the

frequency converter are placed in the same installation panel, you

can use a regular cable instead of a protected one.

3. The Safe Stop function only fulfills EN 954-1 Category 3 if it is pro-

tected by a Nema 12 or Nema 4 drive. Open Chassis or Nema 1

drives must be mounted in a Nema 12 or higher cabinet to meet

protection requirements for the Safe Stop functionality.

The illustration below shows a Stopping Category 0 (EN 60204-1) with safety Category 3 (EN 954-1). The circuit interrupt is caused by an opening door contact.

The illustration also shows how to connect a non-safety related hardware coast.

Illustration 2.1: Bridge jumper between terminal 37 and 24 VDC

Illustration 2.2: Illustration of the essential aspects of an installation to achieve a Stopping Category 0 (EN 60204-1) with safety Category 3 (EN 954-1).

2.1.7 IT Mains

par. SP-50 RFI Filter can be used to disable the factory installed A1/B1 RFI filter option. If this is done it will reduce the RFI performance to A2 level. For the 525 -

690 V frequency converters, par. SP-50 RFI Filter is not available as there is no A1/B1 Factory Installed RFI Filter option.

3 How to Install

3.1.1 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.

3.1.2 How to Get Started

AF-650 GP is designed to achieve a quick installation by following the steps described below.

Read the safety instructions before installing the unit.

Mechanical Installation

• Mechanical mounting

Electrical Installation

• Connection to Mains and Protecting Earth

• Motor connection and cables

• Fuses and circuit breakers

• Control terminals - cables

Quick setup

• Keypad

• Auto Tuning of drive

• Programming

AF-650 GP Operating Instructions

Illustration 3.1: Diagram showing basic installation including mains, motor,

start/stop key, and potentiometer for speed adjustment.

AF-650 GP Operating Instructions

Mechanical Dimensions, 1X Unit Sizes

12/13 15

Unit Sizes 12 13 15

IP NEMA

Height

Height of back plate A 268 mm 375 mm 268 mm 375 mm 420 mm Height with de-coupling plate A 374 mm 374 mm - Distance between mounting holes a 257 mm 350 mm 257 mm 350 mm 402 mm

Width

Width of back plate B 90 mm 90 mm 130 mm 130 mm 242 mm Width of back plate with one C option B 130 mm 130 mm 170 mm 170 mm 242 mm Width of back plate with two C options B 150 mm 150 mm 190 mm 190 mm 242 mm Distance between mounting holes b 70 mm 70 mm 110 mm 110 mm 215 mm

Depth

Depth without option A/B C 205 mm 207 mm 205 mm 207 mm 195 mm With option A/B C 220 mm 222 mm 220 mm 222 mm 195 mm

Screw holes

c 8.0 mm 8.0 mm 8.0 mm 8.0 mm 8.25 mm d ø11 mm ø11 mm ø11 mm ø11 mm ø12 mm e ø5.5 mm ø5.5 mm ø5.5 mm ø5.5 mm ø6.5 mm f 9 mm 9 mm 9 mm 9 mm 9 mm

Max weight 4.9 kg 5.3 kg 6.6 kg 7.0 kg 13.5/14.2 kg

0.25-3 kW

(200-240 V)

0.37-4.0 kW

(380-480/ 500 V)

0.75-4 kW

(525-600 V)

Chassis

Nema 1

(380-480/ 500 V)

Chassis

3.7 kW

(200-240 V)

5.5-7.5 kW

(525-600 V)

Nema 1

0.25-3.7 kW (200-240 V)

0.37-7.5 kW

(380-480/ 500 V)

0.75-7.5 kW (525-600 V)

55/66

Nema 12/Nema 4

Mechanical Dimensions, 2X Unit Sizes

21/22 23 24

AF-650 GP Operating Instructions

Unit Sizes 21 22 23 24

IP NEMA

Height

Height of back plate Height with decoupling plate Distance between mounting holes

Width

Width of back plate B 242 mm 242 mm 165 mm 230 mm Width of back plate with one C option Width of back plate with two C options Distance between mounting holes

Depth

Depth without option A/B With option A/B C 260 mm 260 mm 262 mm 242 mm

Screw holes

Max weight 23 kg 27 kg 12 kg 23.5 kg

A 480 mm 650 mm 399 mm 520 mm

A - - 420 mm 595 mm

a 454 mm 624 mm 380 mm 495 mm

B 242 mm 242 mm 205 mm 230 mm

B 242 mm 242 mm 225 mm 230 mm

b 210 mm 210 mm 140 mm 200 mm

C 260 mm 260 mm 249 mm 242 mm

c 12 mm 12 mm 8 mm d ø19 mm ø19 mm 12 mm e ø9 mm ø9 mm 6.8 mm 8.5 mm

f 9 mm 9 mm 7.9 mm 15 mm

5.5-7.5 kW

(200-240 V)

11-15 kW

(380-480/500 V)

11-15 kW

(525-600 V)

21/ 55/66

Nema 1/Nema 12

11 kW

(200-240 V)

18.5-22 kW

(380-480/ 500 V)

18.5-22 kW (525-600 V)

55/66

Nema 12/Nema 4

5.5-7.5 kW

(200-240 V)

11-15 kW

(380-480/500 V)

11-15 kW

(525-600 V)

Chassis

11-15 kW

(200-240 V)

18.5-30 kW

(380-480/ 500 V)

18.5-30 kW (525-600 V)

Chassis

Mechanical Dimensions,3X Unit Sizes

AF-650 GP Operating Instructions

31/ 32 33/ 34

Unit Sizes 31 32 33 34

IP NEMA

Height

Height of back plate A 680 mm 770 mm 550 mm 660 mm Height with de-coupling plate Distance between mounting holes

Width

Width of back plate B 308 mm 370 mm 308 mm 370 mm Width of back plate with one C option Width of back plate with two C options Distance between mounting holes

Depth

Depth without option A/B With option A/B C 310 mm 335 mm 333 mm 333 mm

Screw holes

Max weight 45 kg 65 kg 35 kg 50 kg

A 630 mm 800 mm

a 648 mm 739 mm 521 mm 631 mm

B 308 mm 370 mm 308 mm 370 mm

b 272 mm 334 mm 270 mm 330 mm

C 310 mm 335 mm 333 mm 333 mm

c 12.5 mm 12.5 mm d ø19 mm ø19 mm e ø9 mm ø9 mm 8.5 mm 8.5 mm

f 9.8 mm 9.8 mm 17 mm 17 mm

15-22 kW

(200-240 V)

30-45 kW

(380-480/ 500 V)

30-45 kW

(525-600 V)

55/66

Nema 12/Nema 4

30-37 kW

(200-240 V)

55-75 kW

(380-480/ 500 V)

55-90

kW (525-600 V)

55/66

Nema 12/Nema 4

18.5-22 kW (200-240 V)

37-45 kW

(380-480/ 500 V)

37-45 kW

(525-600 V)

Chassis

30-37 kW

(200-240 V)

55-75 kW

(380-480/ 500 V)

55-90 kW

(525-600 V)

Chassis

Accessory Bags: Find the following parts included in the frequency converter accessory bags

Unit Sizes 22 and 23, IP20 Open Chassis Unit Size 15, Nema 12 or Nema 4

AF-650 GP Operating Instructions

Unit Sizes 21 and 22

IP55/Type 12

Unit Sizes 31 and 32, IP55/Nema 12, IP66/Nema 4 Unit Size 23, IP20 Open Chassis Unit Size 24, IP20 Open Chassis 1 + 2 only available in units with brake chopper. For DC link connection (Load sharing) the connector 1 can be ordered separately

Unit Size 23, IP20 Open Chassis Unit Size 24, IP20 Open Chassis

3.2 Mechanical Installation

3.2.1 Mechanical mounting

All IP20 .

If the P21/Nema 1 field installed option kits are installed, there must be a clearance of a minimum of 50mm or 2 inches between drives.

For optimal cooling conditions allow a free air passage above and below the frequency converter. See table below.

Air passage for different Unit Sizes

AF-650 GP Operating Instructions

Unit Size:

a (mm): 100 100 100 200 200 200 200 200 225 200 225

b (mm): 100 100 100 200 200 200 200 200 225 200 225

Table 3.1:

1. Drill holes in accordance with the measurements given.

2. You must provide screws suitable for the surface on which you want to mount the frequency converter. Retighten all four screws.

12 13 15 21 22 23 24 31 32 33 34

Table 3.2: Mounting Unit Sizes 15, 21, 22, 23, 24, 31, 32, 33 and 34 on a non-solid back wall, the drive must be provided with a back plate A due to insufficient

cooling air over the heat sink.

AF-650 GP Operating Instructions

3.2.2 Panel Through Mounting

A Panel Through Mount Kit is available for frequency converter series AF-600 FP, .

In order to increase heatsink cooling and reduce panel depth, the frequency converter may be mounted in a through panel. Furthermore the in-built fan can then

be removed.

The kit is available for Unit Sizes 15 through 32 (230V, 1/3 to 50HP and 460V/575V 1/2 to 100HP) .

NB!

This kit cannot be used with cast front covers. No cover or imminent plastic cover must be used instead.

For more information please contact GE.

AF-650 GP Operating Instructions

3.3 Electrical Installation

NB!

Cables General

All cabling must comply with national and local regulations on cable cross-sections and ambient temperature. Copper (60/75°C) conductors are recommended.

Aluminium Conductors

Terminals can accept aluminium conductors but the conductor surface has to be clean and the oxidation must be removed and sealed by neutral acid-free

Vaseline grease before the conductor is connected.

Furthermore the terminal screw must be retightened after two days due to softness of the aluminium. It is crucial to keep the connection a gas tight joint, otherwise

the aluminium surface will oxidize again.

Tightening-up Torque Unit Size 200 - 240 V 380 - 500 V 525 - 690 V Cable for: Tightening up torque 11 0.25-1.5 kW 0.37-1.5 kW - Mains, Brake resistor, load sharing, Motor ca12 0.25-2.2 kW 0.37-4 kW 0.75-4 kW 13 3-3.7 kW 5.5-7.5 kW 5.5-7.5 kW 15 3-3.7 kW 5.5-7.5 kW 0.75-7.5 kW 21 5.5-7.5 kW 11-15 kW - Mains, Brake resistor, load sharing, Motor ca-

22 11 kW 18.5-22 kW - Mains, Brake resistor, load sharing cables 4.5 Nm

23 5.5-7.5 kW 11-15 kW - Mains, Brake resistor, load sharing, Motor ca-

24 11-15 kW 18.5-30 kW - Mains, Brake resistor, load sharing, Motor ca-

31 15-22 kW 30-45 kW - Mains, Brake resistor, load sharing cables 10 Nm

32 30-37 kW 55-75 kW - Mains, motor cables

33 18.5-22 kW 30-37 kW - Mains, Brake resistor, load sharing, Motor ca-

34 37-45 kW 55-75 kW - Mains, motor cables

bles

bles Relay 0.5-0.6 Nm Earth 2-3 Nm

Motor cables 4.5 Nm Relay 0.5-0.6 Nm Earth 2-3 Nm

bles Relay 0.5-0.6 Nm Earth 2-3 Nm

Motor cables 10 Nm Relay 0.5-0.6 Nm Earth 2-3 Nm

Load Sharing, brake cables 14 Nm Relay 0.5-0.6 Nm Earth 2-3 Nm

bles Relay 0.5-0.6 Nm Earth 2-3 Nm

Load Sharing, brake cables 14 Nm Relay 0.5-0.6 Nm Earth 2-3 Nm

0.5-0.6 Nm

1.8 Nm

4.5 Nm

14 Nm (up to 95 mm2) 24 Nm (over 95 mm

10 Nm

14 Nm (up to 95 mm2) 24 Nm (over 95 mm

)

3.3.1 Removal of Knockouts for Extra Cables

1. Remove cable entry from the frequency converter (Avoiding foreign parts falling into the frequency converter when removing knockouts)

2. Cable entry has to be supported around the knockout you intend to remove.

3. The knockout can now be removed with a strong mandrel and a hammer.

4. Remove burrs from the hole.

5. Mount Cable entry on frequency converter.

AF-650 GP Operating Instructions

3.3.2 Connection to Mains and Earthing

NB!

The plug connector for power is plugable on frequency converters up to 7.5 kW.

1. Fit the two screws in the de-coupling plate, slide it into place and tighten the screws.

2. Make sure the frequency converter is properly earthed. Connect to earth connection (terminal 95). Use screw from the accessory bag.

3. Place plug connector 91(L1), 92(L2), 93(L3) from the accessory bag onto the terminals labelled MAINS at the bottom of the frequency converter.

4. Attach mains wires to the mains plug connector.

5. Support the cable with the supporting enclosed brackets.

NB!

Check that mains voltage corresponds to the mains voltage of the name plate.

IT Mains

Do not connect 400 V frequency converters with RFI-filters to mains supplies with a voltage between phase and earth of more than 440 V.

The earth connection cable cross section must be at least 10 mm2 or 2 x rated mains wires terminated separately according to EN 50178.

The mains connection is fitted to the mains switch if this is included.

Mains connection for Unit Sizes 12 and 13 IP20 Open Chassis drive types

(230V to 5HP, 460V/575V to 10HP):

Mains connector (IP 55/66)Unit Size 15 Nema 12 or Nema 4 drive types

(230V to 5HP, 460V/575V to 10HP)

AF-650 GP Operating Instructions

Illustration 3.2: Mains connection for unit sizes 21 and 22 Nema 12 or Nema

4 drive types (230V, 7.5 to 15HP, 460V/575V, 15 to 30HP).

Illustration 3.4: Mains connection for unit size 24 IP20 Open Chassis drive

type (230V, 15 to 20HP, 460V/575V, 25 to 40HP).

Illustration 3.3: Mains connection for unit size 23 IP20 Open Chassis drive

type (230V, 7.5 to 10HP, 460V/575V, 15 to 25HP).

Illustration 3.5: Mains connection for unit sizes 31 and 32 Nema 12 or Nema

4 drive types (230V, 20 to 50HP, 460V, 40 to 100HP, 575V, 40 to 125HP).

AF-650 GP Operating Instructions

Illustration 3.6: Mains connection for unit size 33 IP20 Open Chassis drive

type (230V, 25 to 30HP, 460V/575V, 50 to 60HP).

Illustration 3.7: Mains connection for unit size 34 IP20 Open Chassis drive

type (230V, 40 to 50HP, 460V, 75 to 100HP, 575V, 75 to 125HP).

3.3.3 Motor Connection

NB!

Use a screened/armoured motor cable to comply with EMC emission specifications. For more information, see EMC Test Results.

See section General Specifications for correct dimensioning of motor cable cross-section and length.

Screening of cables: Avoid installation with twisted screen ends (pigtails). 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.

Connect the motor cable screen to both the decoupling plate of the frequency converter and to the metal housing of the motor.

Make the screen connections with the largest possible surface area (cable clamp). This is done by using the supplied installation devices in the frequency converter.

If it is necessary to split the screen to install a motor isolator or motor relay, the screen must be continued with the lowest possible HF impedance.

Cable-length and cross-section: The frequency converter has been tested with a given length of cable and a given cross-section of that cable. If the cross-section

is increased, the cable capacitance - and thus the leakage current - may increase, and the cable length must be reduced correspondingly. Keep the motor cable

as short as possible to reduce the noise level and leakage currents.

Switching frequency: When frequency converters are used together with Sine-wave filters to reduce the acoustic noise from a motor, the switching frequency

must be set according to the Sine-wave filter instruction in par. F-26 Motor Noise (Carrier Freq).

1. Fasten decoupling plate to the bottom of the frequency converter with screws and washers from the accessory bag.

2. Attach motor cable to terminals 96 (U), 97 (V), 98 (W).

3. Connect to earth connection (terminal 99) on decoupling plate with screws from the accessory bag.

4. Insert plug connectors 96 (U), 97 (V), 98 (W) (up to 7.5 kW) and motor cable to terminals labelled MOTOR.

5. Fasten screened cable to decoupling plate with screws and washers from the accessory bag.

All types of three-phase asynchronous standard motors can be connected to the frequency converter. Normally, small motors are star-connected (230/400 V, Y).

Large motors are normally delta-connected (400/690 V, Δ). Refer to the motor name plate for correct connection mode and voltage.

Illustration 3.8: Motor connection for units sizes 12 and 13 IP20 Open Chassis

drive types (230V to 5HP, 460V/575V to 10HP)

AF-650 GP Operating Instructions

Illustration 3.9: Motor connection for unit size 15 Nema 12 or Nema 4 drive

types (230V to 5HP, 460V/575V to 10HP)

Illustration 3.10: Motor connection for unit sizes 21 and 22 Nema 12 or Nema

4 drive types (230V, 7.5 to 15HP, 460V/575V, 15 to 30HP)

Illustration 3.12: Motor connection for for unit size 24 IP20 Open Chassis

drive type (230V, 15 to 20HP, 460V/575V, 25 to 40HP).

Illustration 3.11: Motor connection for for unit size 23 IP20 Open Chassis

drive type (230V, 7.5 to 10HP, 460V/575V, 15 to 25HP).

Illustration 3.13: Motor connection for unit sizes 31 and 32 Nema 12 or Nema

4 drive types (230V, 20 to 50HP, 460V, 40 to 100HP, 575V, 40 to 125HP)

AF-650 GP Operating Instructions

Illustration 3.14: Motor connection for unit sizes 33 and 34 IP20 Open Chas-

sis drive types (230V, 25 to 50HP, 460V, 50 to 100HP, 575V, 50 to 125HP).

Illustration 3.15: Cable entry holes for unit size 21. The suggested use of the

holes are purely recommendations and other solutions are possible.

Illustration 3.16: Cable entry holes for unit size 22. The suggested use of the

holes are purely recommendations and other solutions are possible.

Term. no.

U1 V1 W1

Protected Earth Connection

96 97 98 99

U V W

W2 U2 V2 6 wires out of motor

Motor voltage 0-100% of mains voltage.

Delta-connected

Star-connected U2, V2, W2

Illustration 3.17: Cable entry holes for unit size 31. The suggested use of the

holes are purely recommendations and other solutions are possible.

Illustration 3.18: Cable entry holes for unit size 32. The suggested use of the

holes are purely recommendations and other solutions are possible.

3 wires out of motor

U2, V2 and W2 to be interconnected separately.

AF-650 GP Operating Instructions

3.3.4 Fuses

Branch circuit protection:

In order to protect the installation against electrical and fire hazard, all branch circuits in an installation, switch gear, machines etc., must be short-circuited and

overcurrent protected according to national/international regulations.

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.

Overcurrent protection:

Provide overload protection to avoid fire hazard due to overheating of the cables in the installation. Fuses or circuit breakers can be used to provide the overcurrent

protection in the installation. Overcurrent protection must always be carried out according to national regulations.

The AF-650 GP drive is suitable in a circuit capable of supplying a maximum of 100,000 A

Non UL compliance

If UL/cUL is not to be complied with, we recommend using the following fuses, which will ensure compliance with EN50178:

In case of malfunction, not following the recommendation may result in unnecessary damage to the frequency converter.

AF-650 GP 1/3 to 1 HP 10A 200-240 V type gG 2 to 3 HP 20A 200-240 V type gG 5 HP 32A 200-240 V type gG

7.5 to 10 HP 63A 380-500 V type gG 15 HP 80A 380-500 V type gG

20 to 25 HP 125A 380-500 V type gG 30 HP 160A 380-500 V type aR 40 HP 200A 380-500 V type aR 50 HP 250A 380-500 V type aR

1) Max. fuses - refer to national/international regulations to select an appropriate fuse size.

AF-650 GP 3 to 5 HP 10A 380-500 V type gG 3 to 5 HP 20A 380-500 V type gG

7.5 to 10 HP 32A 380-500 V type gG 15 to 25 HP 63A 380-500 V type gG 30 HP 80A 380-500 V type gG 40 HP 100A 380-500 V type gG 50 HP 125A 380-500 V type gG 60 HP 160A 380-500 V type aR 75 to 100 HP 250A 380-500 V type aR

Max. fuse size

(symmetrical), 500 V maximum.

rms

Voltage Type

UL Compliance

200-240 V

AF-650 GP Operating Instructions

AF-650 GP HP Type RK1 Type J Type T Type CC Type CC Type CC 1/3 to 1/2 HP KTN-R05 JKS-05 JJN-06 FNQ-R-5 KTK-R-5 LP-CC-5 1 HP KTN-R10 JKS-10 JJN-10 FNQ-R-10 KTK-R-10 LP-CC-10 2 HP KTN-R15 JKS-15 JJN-15 FNQ-R-15 KTK-R-15 LP-CC-15 3 HP KTN-R20 JKS-20 JJN-20 FNQ-R-20 KTK-R-20 LP-CC-20 5 HP KTN-R30 JKS-30 JJN-30 FNQ-R-30 KTK-R-30 LP-CC-30

7.5 HP KTN-R50 KS-50 JJN-50 - - 10 HP KTN-R60 JKS-60 JJN-60 - - 15 HP KTN-R80 JKS-80 JJN-80 - - 20 to 25 HP KTN-R125 JKS-150 JJN-125 - - -

AF-650 GP SIBA Littel fuse

HP Type RK1 Type RK1 Type CC Type RK1 1/3 to 1/2 HP 5017906-005 KLN-R05 ATM-R05 A2K-05R 1 HP 5017906-010 KLN-R10 ATM-R10 A2K-10R 2 HP 5017906-016 KLN-R15 ATM-R15 A2K-15R 3 HP 5017906-020 KLN-R20 ATM-R20 A2K-20R 5 HP 5012406-032 KLN-R30 ATM-R30 A2K-30R

7.5 HP 5014006-050 KLN-R50 - A2K-50R 10 HP 5014006-063 KLN-R60 - A2K-60R 15 HP 5014006-080 KLN-R80 - A2K-80R 20 to 25 HP 2028220-125 KLN-R125 - A2K-125R

AF-650 GP Bussmann SIBA Littel fuse

HP Type JFHR2 Type RK1 JFHR2 JFHR2 30 HP FWX-150 2028220-150 L25S-150 A25X-150 40 HP FWX-200 2028220-200 L25S-200 A25X-200 50 HP FWX-250 2028220-250 L25S-250 A25X-250

Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann

Ferraz-

Shawmut

Ferraz-

Shawmut

Ferraz-

Shawmut

KTS-fuses from Bussmann may substitute KTN for 240 V frequency converters.

FWH-fuses from Bussmann may substitute FWX for 240 V frequency converters.

KLSR fuses from LITTEL FUSE may substitute KLNR fuses for 240 V frequency converters.

L50S fuses from LITTEL FUSE may substitute L50S fuses for 240 V frequency converters.

A6KR fuses from FERRAZ SHAWMUT may substitute A2KR for 240 V frequency converters.

A50X fuses from FERRAZ SHAWMUT may substitute A25X for 240 V frequency converters.

380-500 V

AF-650 GP HP Type RK1 Type J Type T Type CC Type CC Type CC 1/2 to 1 HP KTS-R6 JKS-6 JJS-6 FNQ-R-6 KTK-R-6 LP-CC-6 2 to 3 HP KTS-R10 JKS-10 JJS-10 FNQ-R-10 KTK-R-10 LP-CC-10 5 HP KTS-R20 JKS-20 JJS-20 FNQ-R-20 KTK-R-20 LP-CC-20

7.5 HP KTS-R25 JKS-25 JJS-25 FNQ-R-25 KTK-R-25 LP-CC-25 10 HP KTS-R30 JKS-30 JJS-30 FNQ-R-30 KTK-R-30 LP-CC-30 15 HP KTS-R40 JKS-40 JJS-40 - - 20 HP KTS-R50 JKS-50 JJS-50 - - 25 HP KTS-R60 JKS-60 JJS-60 - - 30 HP KTS-R80 JKS-80 JJS-80 - - 40 HP KTS-R100 JKS-100 JJS-100 - - 50 HP KTS-R125 JKS-150 JJS-150 - - 60 HP KTS-R150 JKS-150 JJS-150 - - -

Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann

AF-650 GP Operating Instructions

AF-650 GP SIBA Littel fuse

HP Type RK1 Type RK1 Type CC Type RK1 1/2 to 1 HP 5017906-006 KLS-R6 ATM-R6 A6K-6R 2 to 3 HP 5017906-010 KLS-R10 ATM-R10 A6K-10R 5 HP 5017906-020 KLS-R20 ATM-R20 A6K-20R

7.5 HP 5017906-025 KLS-R25 ATM-R25 A6K-25R 10 HP 5012406-032 KLS-R30 ATM-R30 A6K-30R 15 HP 5014006-040 KLS-R40 - A6K-40R 20 HP 5014006-050 KLS-R50 - A6K-50R 25 HP 5014006-063 KLS-R60 - A6K-60R 30 HP 2028220-100 KLS-R80 - A6K-80R 40 HP 2028220-125 KLS-R100 - A6K-100R 50 HP 2028220-125 KLS-R125 - A6K-125R 60 HP 2028220-160 KLS-R150 - A6K-150R

AF-650 GP Bussmann Bussmann Bussmann Bussmann HP JFHR2 Type H Type T JFHR2 75 HP FWH-200 - - 100 HP FWH-250 - - -

AF-650 GP SIBA Littel fuse

HP Type RK1 JFHR2 JFHR2 JFHR2 75 HP 2028220-200 L50S-225 - A50-P225 100 HP 2028220-250 L50S-250 A50-P250

Ferraz-Shawmut A50QS fuses may be substituted for A50P fuses.

170M fuses shown from Bussmann use the -/80 visual indicator. –TN/80 Type T, -/110 or TN/110 Type T indicator fuses of the same size and amperage

may be substituted.

550 - 600V

AF-650 GP HP Type RK1 Type J Type T Type CC Type CC Type CC 1 to 2 HP KTS-R-5 JKS-5 JJS-6 FNQ-R-5 KTK-R-5 LP-CC-5 3 to 5 HP KTS-R10 JKS-10 JJS-10 FNQ-R-10 KTK-R-10 LP-CC-10

7.5 to 10 HP KTS-R20 JKS-20 JJS-20 FNQ-R-20 KTK-R-20 LP-CC-20

Bussmann Bussmann Bussmann Bussmann Bussmann Bussmann

Ferraz-

Shawmut

Ferraz-

Shawmut

Ferraz-

Shawmut

Ferraz-

Shawmut

AF-650 GP SIBA Littel fuse

HP Type RK1 Type RK1 Type RK1 1 to 2 HP 5017906-005 KLSR005 A6K-5R 3 to 5 HP 5017906-010 KLSR010 A6K-10R

7.5 to 10 HP 5017906-020 KLSR020 A6K-20R

AF-650 GP Bussmann SIBA

HP JFHR2 Type RK1 Type RK1 50 HP 170M3013 2061032.125 6.6URD30D08A0125 60 HP 170M3014 2061032.160 6.6URD30D08A0160 75 HP 170M3015 2061032.200 6.6URD30D08A0200 100 HP 170M3015 2061032.200 6.6URD30D08A0200

170M fuses shown from Bussmann use the -/80 visual indicator. –TN/80 Type T, -/110 or TN/110 Type T indicator fuses of the same size and amperage

may be substituted.

Ferraz-

Shawmut

Ferraz-

Shawmut

3.3.5 Access to Control Terminals

All terminals to the control cables are located underneath the terminal cover

on the front the IP20 Open Chassis and IP20 with Nema 1 field installed kits..

Remove the terminal cover with a screwdriver.

Remove front-cover of Nema 12 and Nema 4 drive types to access control

terminals. When replacing the front-cover, please ensure proper fastening by

applying a torque of 2 Nm.

AF-650 GP Operating Instructions

130BT248

Illustration 3.19: Access to control terminals for unit sizes 12, 13, 23, 24, 33,

and 34

130BT334.11

Illustration 3.20: Access to control terminals for unit sizes 15, 21, 22, 31, and

3.3.6 Electrical Installation, Control Terminals

To mount the cable to the terminal:

1. Strip insulation of 9-10 mm

in the square hole.

Insert a screwdriver

3. Insert the cable in the adjacent circular hole.

4. Remove the screw driver. The cable is now mounted to the terminal.

To remove the cable from the terminal:

Insert a screwdriver

2. Pull out the cable.

Max. 0.4 x 2.5 mm

AF-650 GP Operating Instructions

3.4 Connection Examples

3.4.1 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)

Terminal 37 = Safe stop

AF-650 GP Operating Instructions

3.4.2 Pulse Start/Stop

Terminal 18 = par. E-01 Terminal 18 Digital InputLatched start, [9]

Terminal 27= par. E-03 Terminal 27 Digital InputStop inverse, [6]

Terminal 37 = Safe stop

3.4.3 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. E-05 Terminal 32 Digital Input Speed down [22]

3.4.4 Potentiometer Reference

Voltage reference via a potentiometer:

Reference Source 1 = [1] Analog input 53 (default)

Terminal 53, Low Voltage = 0 Volt

Terminal 53, High Voltage = 10 Volt

Terminal 53, Low Ref./Feedback = 0 RPM

Terminal 53, High Ref./Feedback = 1500 RPM

Switch S201 = OFF (U)

AF-650 GP Operating Instructions

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