GE Industrial Solutions AF-300C User Manual

Urinves

GEK-85716A

TM Trademark of General Electric Company, U.S.A. These

lnsfwcfions

operation mainfenance. Should lurfherinformafion bo desired or should parficularprobloms arise which are not covered sullicienffy for the purchasers purposes, fhe

mafter should be

nol

purporf

coverall

referred to General

details

E!eclric Comwnv

vafialions

in equipment lo provide for

every possible

confingency

lo be

mef

connecficn with insfallafion

GE Drive Systems

SUPPLEMENT

FOR INSTRUCTION MANUAL GEK-85716A

These

instructions

during

installation, operation, and maintenance. Should further information be desired or should particularproblems arise that are not

covered sufJ?ciently for the purchaser’s purpose,

do not purport to cover all details or variations in equipment, nor to provide for evey possible contingency to be met

tlze

matter should be referred to GE Drive Systems, Salem, Virginia U.S.A.

This supplement contains additional information needed when installing and operating the

AF3OOC

series of inverters. Refer to the information of this supplement in addition to that contained in

GEK-

85716A for the figures, tables, and paragraphs listed in this supplement.

Figure

4-15.

Basic Connection Diagram

Figure S-12. Control Block Diagram

The 3-phase AC circuit breaker shown in these figures is incorrectly illustrated as three breakers. It is actually a single,

3-pole

breaker.

Table 5: Function Code Data Table 6: Function Code Descriptions

Function Code lb, Electronic Thermal Overload Protection, that is built in to the AF-300C series of inverters is factory set as Operational. If the user changes this to Non-Operational, conventional overload protection for the motor and wiring must then be provided by the user. Typical wiring for an overload relay is shown in figure 8-12 of GEK-85716A.

All inverter installations

must

meet the applicable na-

tional (NEC, CEC) and local electrical codes. It is the

system engineer’s responsibility to be certain that the

inverter installation complies with all applicable electrical codes. (If a system engineer is not involved, it is the user’s responsibility.)

(10/14/94)

Page 1 of 1

AF-300C

Inverter

40 to 300 HP

380/400-460

GEK-85716A

Issue Date: August 1994

VAC,

50/60

These instructions do not purport to cover all details or variations in equipment, nor to provide for every possible contingency to be met during installation, operation, and maintenance. Should further information be desired or should particular problems arise that not covered chaser’s purpose, the matter

This document contains proprietary information of General Electric Company, U.S.A. and Is furnished to its customers solely to assist that customer in the instaliatlon, testing, and/or maintenance of the equipment described. This document shall not be reproduced in whole or in part nor shall tents be disclosed to any third party without the written approval of GE Drive Systems, 1501 Roanoke Boulevard, Salem, Virginia 24153, U.S.A.

should

be referred to GE Drive Systems, Salem, Virginia, U.S.A.

sufficiently

for the pur-

tts

con-

Printed in the United States of America.

TABLE OF CONTENTS

Paae

2. DESCRIPTION, COMPONENT IDENTIFICATION,

SAFETY PRECAUTIONS

AND SPECIFICATIONS ........................................................................

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

General Description................................................................................

Inspection Items Upon Delivery ............................................................

Movement and Storage ..........................................................................

l-l

2-I

2-1 2-l

2-l

lnverter Components and Cooling ........................................................ 2-2

TABLE 1: AFSOOC lnverter Standard Specifications

AF300C AFSOOC

3. INSTALLATION GUIDELINES .............................................................. 3-l

lnverter Catalog Numbers

......................................................

lnverter Options (inc. Line Reactors)

Installation Environment ........................................................................

Open Installation Mounting Clearance Enclosed Mounting Installation Guidelines

..................................................

..........................................

AFSOOC Dimensions ..............................................................................

4. WIRING PROCEDURES

......................................................................

Main Circuit Wiring ..................................................................................

Auxiliary Control Power Supply Connections

......................................

..........................

....................................

2-5

2-8

2-9

3-l

3-2

3-4

4-1

4-l

4-2

AC Line Reactor Connection ................................................................ 4-2

DC Reactor Connections ...................................................................... 4-2

Braking Unit and Braking Resistor Connections Ground Terminal Connections

..............................................................

................................

4-3

4-8

Control Circuit Wiring ............................................................................ 4-6

TABLE 2: Terminal Identification/Function TABLE 3: Application of Wiring and Equipment

..........................................

..................................

4-l 0

4-l 3

INVERTER

Before Applying AC Power Inspection

OPERATION ......................................................................

..................................................

Keypad Panel Identification/Function ..................................................

TABLE 4: Keypad and Display Operation

............................................

Display Examples Chart ........................................................................ 5-4

Monitoring Control Signals and lnverter Output

..................................

Setting Function Codes.......................................................................... 5-6

Function of Reset Key After Changing Function Code Data

..............

Fault Indication And Retrieval ................................................................ 5-6

Data Protection

......................................................................................

Trial Keypad Operation (Optional) ........................................................ 5-9

Control Circuit Connection and Operation Actual Operation TABLE 5: Function Code Data

FUNCTION CODE DESCRIPTIONS ....................................................

.................................................................................... 5-l 5

..............................................................

.......................................... 5-l 1

TABLE 6: Function Code Descriptions ................................................

5-1

5-l 5-l 5-2

5-5 5-6 5-9

5-l 7

6-1

6-l

AF-300C

hverters

GEK-85716

TABLE OF CONTENTS

Section

10.

Title

MAINTENANCE AND INSPECTION

Megger Test ............................................................................................

Periodic Parts Replacement Inspection Items

Measurement Points and Meters ..........................................................

TROUBLESHOOTING ..........................................................................

TABLE 7: Fault Description and Operation TABLE 8: Fault Condition Display and Corrective Action..

WARRANTY PARTS AND SERVICE ....................................................

Warranty Coverage ................................................................................

Out-Of-Warranty Procedures ..................................................................

Motors ......................................................................................................

In-Warranty Failure Checklist ..................................................................

PARTS REPLACEMENT ......................................................................

TABLE 9: AF3OOC

......................................................................................

lnverter Renewal Parts ..........................................

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . ..*..*......

..................................................................

..........................................

..................

Paae

7-1

7-1 7-1

7-I

7-3

8-l 8-I

9-1

9-1 9-l

9-1

1 o-1

1 O-l

NOTES:

LIST OF FIGURES

Fiuure #

Figure 2-1. Figure 2-2.

Figure 2-3. Figure 2-4. Figure 2-5. Figure 2-6. Figure 3-1. Figure 3-2. Figure 3-3. Figure 4-1. Figure 4-2. Figure 4-3. Figure 4-4. Figure 4-5. Figure 4-6. Figure 4-7. Figure 4-8. Figure 4-9. Figure 4-10. Figure 4-l Figure 4-12. Figure 4-l 3. Figure 4-l 4. Figure Figure 4-l 6. Figure 4-l 7. Figure 4-l 8.

Figure 4-l 9.

Figure 4-20.

Figure 4-21.

Figure 4-22.

Figure 4-23.

Figure 4-24.

Figure 4-25.

4-l

Title

NAMEPLATE DATA IDENTIFICATION

TYPICAL INVERTER COMPONENTS ..........................................................

INVERTER COOLING METHODS ................................................................

KEYPAD PANEL COMPONENT IDENTIFICATION

104X220FA003,004 104X220FA005,006

INVERTER MOUNTING CLEARANCE ..........................................................

INVERTER ENCLOSURE MOUNTING ARRANGEMENTS ........................

INVERTER EXTERNAL DIMENSIONS TERMINAL

AC POWER CONNECTION ..........................................................................

AUXILIARY CONTROL POWER SUPPLY CONNECTIONS DC REACTOR CONNECTION

OUTPUT WIRING CONNECTIONS ..............................................................

BRAKING RESISTOR AND BRAKING UNIT CONNECTIONS

GROUND CONNECTIONS ............................................................................

CONTROL WIRE ROUTING ..........................................................................

FREQUENCY

FAULT RESET CONNECTION ......................................................................

EQUIVALENT CONTROL CIRCUIT FAULT OPEN COLLECTOR CONNECTION

SURGE SUPPRESSOR CONNECTION ......................................................

BASIC CONNECTION DIAGRAM OPERATION FROM KEYPAD REMOTE OPERATION WITH MOMENTARY CONTACTS REMOTE OPERATION WITH MOMENTARY CONTACTS

AND REVERSING CAPABILITY

REMOTE OPERATION WITH MAINTAINED CONTACTS

REMOTE OPERATION WITH MAINTAINED CONTACTS AND REVERSING CAPABILITY

REMOTE OPERATION WITH MAINTAINED CONTACTS

AND JOG FUNCTION ....................................................................................

REMOTE OPERATION WITH MAINTAINED CONTACTS

AND JOG FUNCTION WITH REVERSING CAPABILITY REMOTE OPERATION WITH MOMENTARY CONTACTS

AND AUTO/MANUAL OPERATION ..............................................................

REMOTE OPERATION WITH MOMENTARY CONTACTS AND REVERSING CAPABILITY AND AUTO/MANUAL OPERATION

REMOTE OPERATION WITH MAINTAINED CONTACTS

AND AUTO/MANUAL OPERATION ..............................................................

BLOCKS

RELAY

LINE REACTOR OUTLINE AND SCHEMATIC.. LINE REACTOR OUTLINE AND SCHEMATIC

......................................................................................

......................................................................

SEl-TING/MONITORING

CONTACTS ..........................................................................

........................................................................

.......................................................... 2-l

......................................

........ 2-l 1

.......... 2-12

.......................................................... 3-3

........................ 4-2

.................... 44

TERMINAL CONNECTIONS

.............................................................. 4-8

............................................................

................................................................ 4-l 5

.......................... 4-l 6

.................................................................... 4-l 6

..........................

....................................................................

............................ 4-l 9

........

........ 4-20

Pacle

2-2

2-3

2-4

3-l 3-2

4-I 4-2

4-2 4-3

4-6 4-6 4-7

4-8

4-8 4-8 4-9

4-l 5

4-l 7

4-17

4-l 8

4-20

4-21

. . . III

LIST OF FIGURES

Fiaure

Figure 4-26.

Figure

5-l.

Figure 5-2. Figure 5-3. Figure 5-4.

Figure 5-5.

Figure 5-6. Figure 5-7. Figure 5-6.

Figure 5-9. Figure 5-l 0. Figure 5-l 1. Figure 5-l 2. Figure 5-13. Figure

5-l

Title

REMOTE OPERATION WITH MAINTAINED CONTACTS

AND REVERSING CAPABILITY AND AUTO/MANUAL OPERATION ..........

KEYPAD PANEL COMPONENT IDENTIFICATION ...................................... 5-2

DISPLAY LED INDICATOR IDENTIFICATION ..............................................

FUNCTION CODE

FAULT INDICATIONS .................................................................................... 5-7

ELECTRIC MOTOR ROTATION ....................................................................

FACTORY CONNECTIONS .......................................................................... 5-I 1

EXAMPLE OF COMMONLY USED SIGNALS ..............................................

KEYPAD PANEL

KEYPAD PANEL “RUN” OPERATION EXAMPLE .......................................... 5-l 2

REMOTE OPERATION CONNECTIONS ...................................................... 5-I 3

REMOTE OPERATION EXAMPLE ................................................................ 5-14

MULTI-STEP FREQUENCY OPERATION CONNECTIONS ........................ 5-14

MULTI-STEP FREQUENCY ‘RUN” OPERATION EXAMPLE ........................ 5-15

MULTI-STEP ACCELERATION AND DECELERATION

OPERATION CONNECTIONS ...................................................................... 5-l 6

“06”

AND ‘07’ DATA ........................................................ 5-5

OPERATION CONNECTIONS .......................................... 5-12

Page

4-21

5-4

5-I

5-I I

Figure 5-15.

Figure

6-l.

Figure 7-1. Figure 7-2. Figure

6-I.

Figure 6-2. Figure 6-3. Figure 6-4. Figure 6-5. Figure 6-6. Figure 6-7. Figure 6-6. Figure 8-9. Figure 8-10.

MULTI-STEP ACCELERATION AND DECELERATION ‘RUN’

OPERATION EXAMPLE..................................................................................

AF900C

MAIN CIRCUIT MEGGER TEST CONNECTIONS ........................................ 7-l

MEASUREMENT LOCATIONS AND DEVICES EXAMPLE .......................... 7-3

MOTOR RUNS BUT SPEED DOES NOT CHANGE

TROUBLESHOOTING CHART ...................................................................... 8-5

MOTOR ROTATION IS NOT SMOOTH TROUBLESHOOTING CHART ...... 8-6

MOTOR OVERHEATS TROUBLESHOOTING CHART ................................ 8-6

INVERTER

CPU ABNORMAL TROUBLESHOOTING CHART ........................................ 8-7

EXTERNAL FAILURE TROUBLESHOOTING CHART .................................. 8-8

OVERCURRENT TROUBLESHOOTING CHART.......................................... 8-9

OVERVOLTAGE TROUBLESHOOTING CHART .......................................... 8-I 0

UNDERVOLTAGE TROUBLESHOOTING CHART ...................................... 8-10

OVERLOAD TROUBLESHOOTING CHART ................................................

FUNCTION

OVERHEATS TROUBLESHOOTING CHART ............................ 8-7

CODE

MAP.................................................................. 6-I 3

5-I

8-11

LIST OF FIGURES

Fiaure #

Figure

Figure S-13. Figure

Figure 8-15.

Figure 8-16. Figure Figure 6-18.

Table

TABLE 1:

8-l 1.

8-I 2.

8-I

8-l

Title

MOTOR STALLS DURING ACCELERATION

TROUBLESHOOTING CHART

CONTROL BLOCK DIAGRAM ......................................................................

INTERCONNECTION DIAGRAM - 40 HP INVERTERS

INTERCONNECTION DIAGRAM - 50 AND 60 HP INVERTERS ................

INTERCONNECTION DIAGRAM - 75 HP INVERTERS ..............................

INTERCONNECTION DIAGRAM - 100 AND 125 HP INVERTERS ............

INTERCONNECTION DIAGRAM - 150 HP INVERTERS ............................ 8-22

INTERCONNECTION DIAGRAM - 175 TO 300 HP INVERTERS ................

......................................................................

..............................

Pacre

8-11

8-12

8-14

8-16

8-I

S-20

8-24

LIST OF TABLES

AFSOOC

INVERTER STANDARD SPECIFICATIONS .................................. 2-5

Pacae

TABLE 2: TABLE 3: TABLE 4:

TABLE 5: TABLE 6: TABLE 7:

TABLE 8:

TABLE 9:

TERMINAL IDENTIFICATION/FUNCTION .................................................... 4-10

APPLICATION OF WIRING AND EQUIPMENT

KEYPAD AND

FUNCTION CODE DATA .............................................................................. 5-17

FUNCTION CODE DESCRIPTIONS ............................................................ 6-l

FAULT DESCRIPTION AND OPERATION .................................................... 8-l

FAULT CONDITION DISPLAY AND CORRECTIVE ACTION

AF-3OOC INVERTER

DISPLAYOPERATION ..........................................................

RENEWAL PARTS ......................................................

............................................ 4-13

5-2

...................... 8-3

1 O-l

AMOOC lnverters

GEK-85716

NOTES:

Af-300C lnverfers

SAFETY PRECAUTIONS

GEK-85718

WARNING, CAUTION AND NOTE LABELS PLACED ON THE EQUIPMENT

The following format is used on the safety and informative labels placed on the equipment. Read all labels and follow the directions on them whenever working on the equipment.

WARNING:

practices that may result in personal injury or loss of life if not correctly followed.

Denotes operating procedures and

WARNING labels will be red in color with black or white lettering.

CAUTION:

practices that, if not strictly observed, may result in damage to, or destruction of the equipment.

Denotes operating procedures and

CAUTION labels will be amber in color with black letterina.

NOTE:

especially significant in understanding and operating the equipment.

Notes call attention to information that is

WARNING - ELECTRICAL SHOCK AND

BURN HAZARD:

as oscilloscopes to work on live equipment, the

oscilloscope’s chassis should be grounded and a

differential amplifier input should be used. Care should be used in the selection of probes and

leads and in the adjustment of the oscilloscope so

that accurate readings may be made. See instrument

manufacturers instruction book for proper operatlon

and adjustments to the instrument.

WARNING - STRAIN HAZARD: improper

lift

trig

Lift only with adequate equipment and trained personnel.

WARNING

HAZARD:

mounting inverters in hazardous areas such as locations where flammable or combustible vapors or dusts are present. lnverters should be Installed away from motors suitable for use in these locations.

NOTE labels will be white in color with black

letterincr.

WARNING, CAUTION AND NOTE

PARAGRAPHS WITHIN THIS INSTRUCTION

The following paragraphs list some general safety reminders and safety recommendations to be followed when operating or installing this equipment. These safety precautions will be repeated throughout this instruction book where applicable.

WARNING -MECHANICAL MOTION

HAZARD:

motion. it is the responsibility of the user to insure that any such motion does not result in an unsafe condition. Factory provided Interlocks and operating limits should not be bypassed or modified.

inverter systems cause mechanical

WARNING- ELECTRICAL SHOCK

HAZARD:

enclosure houslngs should be grounded in accordance with the National other required standards.

WARNING- MOTOR OVERSPEED

HAZARD:

inverter for operation up to 400 Hz maximum output

frequency, the inverter is capable of running the

motor at up to 8 - 7 times its base speed. Never

operate the motor above its top mechanical speed or a catastrophic failure may occur. the inverter for a top frequency above the safe

mechanical speed for the motor. Consult factory

for any application exceeding 120 Hz.

WARNING - PERSONAL INJURY HAZARD:

Carry the inverter only by the body, not by the terminals or top cover. Equipment movement

should only be performed by trained personnel.

When using instruments such

practices can cause serious or fatal injury.

FIRE AND EXPLOSION

Fires or explosions might result from

hazardous

All

motor bases and equipment

Because it is possible to configure the

areas, even if used with

Electric

Never

Code or

configure

1-l

AF-300C

lnverters

GEK-85716

WARNING - BURN AND SHOCK HAZARD:

Shut off the AC power supply before making the output connections. Voltage may be present between the output terminals even though the verter Is stopped. Make sure that the “CHARGE LED indicator has gone out before making any output connections.

in-

WARNING - BURN AND SHOCK HAZARD:

Do not conduct any inspections until after disconnecting the power supply and after the “CHARGE” LED indicator on the inverter has gone out.

CAUTION: Do not connect power

output terminals

onlv to the power terminal; (Ll , L2,

CAUTION: Do not connect power

brakina resistor connection terminals short-circuit between P-N or P-DB terminals, and do not connect anv resistance with a resistance value less than the standard application brakina resistor.

CAUTION:

control circuit terminals (except 30A, B, Cl.

WARNING -MECHANICAL MOTION HAZARD:

Function Code 01 displays zero. If Function Code 13 or 15 contains a non-zero number, the motor will run when a RUN comand Is glven even If the frequency reference is zero.

When the frequency reference is zero,

CAUTION:

dotward) and REV-CM (reverse) terminals. Do not

use a contactor (for ON/OFFoperation) on the line side of the inverter for RUN and STOP.

CAUTION:

WARNING -MECHANICAL MOTION

HAZARD:

with the ‘Local/Remote” switch in the “Local” position, pressing the FWD or REV key will cause the motor to rotate. Any RUN permissives that may be wired to the FWD or REV terminals are ignored.

When running from the Keypad Panel

WARNING - PERSONAL INJURY HAZARD:

To prevent personal caused by equipment malfunction, only adequately trained persons should modify any programmable inverter.

Injury

or equipment damage

side of the inverter for ON/OFF operation.

CAUTION: The AC

KVA ratina should be Horsepower ratina of the invetter, but not areater than 500 greater than 500

reactor (optional; must be pruchased seperatelv) on

the line side of the inverter. A Line Reactor is also

required if an SCR Tvpe controller and/or Power Factor Correction Capacitors are used on the same power lines.

supplv

to the

(U,

Do not connect power

For RUN and STOP, use the FWD-CM

Do not use a contactor on the output

KVA.

If an AC

KVA

Connect power supply

L3).

SUPDIV

to the

(P, DB).

Supplv

is to be used, install a line

Power Transformer

treater

than 1.5 times the

SUPPIV

Power Transformer

Never

SUDPIV

to the

WARNING - FIRE HAZARD: Use

namic braking resistors that are provided by GE

Drive Systems. These are special resistors that have a thermal fuse built in that opens if the resistor gets too hot. This fuse should only open

If the DB transistor In the lnverter or DB unit fails short circuited. The resistor will need to be replaced if this happens.

CAUTION: When removinn or

handle them bv the connector onlv and not bv the wire itself. Be careful not to mix wires when recon-

nectina them.

CAUTION:

that exceeds the standard specification fluctuation permissible. lf excessive voltaae is applied to the invetter, damaae to the internal components will result.

Do not connect power

replacina

only’dy-

SUPPIV

voltage

wires,

voltaae

l-2

CAUTION:

output side of the invetter.

CAUTION:

ground wire connected.

CAUTION:

consult the TROUBLESHOOTING section of this

instruction book, and after correctina the problem, resume operation. Do not reset the fault alarm

automaticallv bv external seauence, etc.

CAUTION:

the inverter terminals or on the control circuit terminals.

Do not connect filter capacitors on the

Do not operate the inverter without the

If the inverter’s fault alarm is activated,

Do not perform a meaaer test between

AF-300C lnverfers

GEK-85718

CAUTION: Motor Thermal Overload protection

must be provided, either bv motor thermoswitch, external motor overload relav, or inverter electronic thermal overload.

CAUTION: Because the ambient temperature

oreatlv affects inverter life and reliabilitv, do not install

the inverter in anv location that exceeds the allowable temperature. Leave the ventilation cover attached for temperatures of 40 deqrees C or below, and remove the cover for temperatures between 40 and 56 dearees

C. If the cover needs to be removed, another of enclosure The inverter should not be operated when the ambient temperature is above 50 dearees C.

CAUTION:

densor

inverter will overheat and be damaoed due to harmonics.

CAUTION:

be kept as far awav as possible from the main power wirinq to prevent operational error due to noise interference. Never install both tvoes of wirino in the same duct or conduit. (A separation distance of 10 centimeters 14 inches1 or more is recommended.) If the control circuit wiring must cross the main power wir- inn, it should cross at a rioht anale (see Fiaure

may

be required for

Do not connect a phase advance con-

in the output wires. The

The control circuit terminal wirinn should

safetv

condenser

tvpe

purposes.

and

4-81.

CAUTION: Use shielded or twisted wire for the

control circuit wirina lwirina should be as short as

possible, i.e. 20 meters

outer coverino of the shielded wires to the inverter around terminal and leave the other end uncon-

nected, but taped.)

CAUTION:

relavs or solenoid tvpe coils, etc. that mav be close to

the inverter or used with the inverter.

NOTE: Always read the complete instructions prior to

applyingpoweror troubleshooting the equipmentand follow al/procedures step by step.

NOTE: The motor chassis should be grounded to earth ground through a separate ground lead from all other equipment ground leads to prevent noise coupling.

NOTE: Readandheedall WARNING, CAUTION, and

NOTE labels posted on the equipment.

Install a suppressor in parallel with any

165

feet1 or less). (Connect

NOTES;

1-3

AF-JOOC /wetters

GEK-85718

/VOTES:

l-4

AF-300C

DESCRIPTION, COMPONENT

Inverters

GEK-85716

IDENTIFICATION, AND SPECIFICATIONS,

GENERAL DESCRIPTION

The

AF-300CTM

versions (380-460 VAC @ 50Hz; 400-460 VAC @ 60 Hz). All of the inverters use two Processing Units’

to provide high performance in all applications.

General data and specifications for each individual inverter are listed on the nameplate attached to the inverter (see Figure 2-1 for nameplate example). See

TABLE 1 for a complete listing of all

specifications. lnverter operation and Function Code setting can be

performedfromthe“Keypad Panef’thatalsofeatures

an LED Data Monitor Display. Eleven Touch Keys and the LOCAL/REMOTE switch arefurnished on the Keypad Panel for operation and Function Code adjustment. Operation Monitoring, Function Code

Setting, Fault Monitoring, Data Protection, Reset, and

Mode Changeover can all be performed from the

Touch Panel. Operation Commands and Frequency

Setting Commands can also be entered from the Keypad Panel. (See Figure 2-4 for Keypad Panel component identification and function.)

TM - Trademark of General Electric Company, U.S.A.

inverter is available in 40 to 300 HP

18bit

“Central

(CPUs)

for multifunction processing

AFSOOC

inverter

INSPECTION ITEMS UPON DELIVERY

Upon receipt of the inverter, inspect equipment for the following items:

1. Check the nameplate to insure that the inverter specifications correspond to those ordered.

2. Inspect the unit for any damage that may have occurred during shipment.

-- lf

there are any problems or questions regarding the above, contact the distributor that the inverter was purchased from.

MOVEMENT AND STORAGE

WARNING - PERSONAL INJURY HAZARD:

Carry the inverter only by the body, not by the terminals or top cover. Equipment movement should only be performed by trained personnel.

For temporary storage after delivery, the following guidelines should be followed:

Ambienttemperature range in the storage area should be between -25 to

2. Leave inverter in its packing carton to avoid exposure to dust and potential damage.

Avoid placing the inverter directly on a concrete floor or in a location exposed to direct sunlight.

(Store on a stand or shelf.)

+65

degrees C.

Figure 2-1.

NAMEPLATE DATA IDENTIFICATION

2-l

AF-300C lnverfers

GEK-85716

4. Avoid storage in humid environments or in atmospheres that contain corrosive gases such

as sulferized gas, ammonia gas, or chlorine

gas.

NOTE:

lfrhe inverref is stored or insralledin a locarion

where construction work is still being done, keep the

inverfer prorecred from exposure until

it is to be placed in service.

water and dust

This pedastal should mount to the bottom of the inverter.

NOTE: inverrers

for ‘cooling inside

the

enclosure” is required,

repositioned (see Figure 2-3).

The mounting adapter, positioned at either the top or

bottom of the enclosure, must be located in accordance with the installation/cooling method.

With the “cooled outside the enclosure” method, the

INVERTER COMPONENTS AND COOLING

Refer to Figure 2-2 for identification and location of inverter components. There are two types of cooling methods depending on the installation method, “cooled inside control enclosure’ and Vooled outside control enclosure’ (see Figure 2-3).

cooling fan is mounted externally and approximately 60% of the total heat generated by the inverter is discharged outside the unit.

NOTE:

When the cooling fan is insralled ourside the control enclosure, it must be periodically cleaned (especially in dus& environments).

lnverters rated 200,250, and 300 HP can be mounted “Cooled Inside Control Enclosure”. However, a mounting pedastal will need to be constructed that can support the weight of the inverter.

Mounting Adaptor

are shipped

rhe

wirh

the adapter mounted

enclosure’. If *cooling outside

the

adapter must be

Control Cooling Fan Charge

Contactor

Keypad

Panel

AC Line .

Fuses (3)

Mounting Adaptor

Figure 2-2.

TYPICAL

INVERTER

COMPONENTS

Main Control Card

(Base Driver is integral

on this Card)

Control Circuit Terminal Board

Ground Fault Detection Card

Main Circuit

Terminal Board

2-2

lnverter Cooled Inside

The Control Enclosure

lnverter Cooled Outside

The Control Enclosure

t t

----

COOLING AIR

t t

COOLING AIR

MOUNTING AND

UFilNG

ADAPTER

Figure 2-3.

INVERTER

COOLING METHODS

MOUNTING AND LIFTING ADAPTER

AF-300C

Invetters

GEK-85716

FUNCTION

ED Selection Indicator

FAST

LOCAL

Figure

LED Indicator

three sections as follows:

Function Display - Displays in two digits the

selected Function Code number.

Data Display -

data, Function Code setting data, and the fault codes.

-The LED Indicator is made up of

Displays in four digits the operation

2-4. KEYPAD PANEL COMPONENT IDENTIFICATION

DATA

Unit Indicators

Unit Indicator - The LED on the left of each unit

symbol corresponds to the contents of the data display.

NOTE:

except W, W, and

All letters are displayed in upper case

UP.

Touch Kevs - There are eleven Touch Keys and the LOCAL/REMOTE switch that perform the following

functions: (See Section 5 for a description of each individual key.)

Function

Operation Monitoring Monitor the operation status of the inverter. Function Code Setting:

Fault Monitoring

Set Data Protection

Reset

Operation Mode Selection

Operation Commands

Frequency Setting Commands

Basic Function Codes Auxiliary Function Codes Set data required for control.

Calibration Function Codes Adjust output signals to match with instruments

Set data required for operation.

externally installed. Display and retrieval of the Fault Code and the

operating conditions at the time of the fault. Protect set data against accidental modification. Data reset at Function Code setting, reset to returr

to operation monitoring mode after completing the

setting, fault reset, and Error Displav Reset.

Switch for changing between “Local” and “Remote’

modes of operation.

Forward, Reverse, and Stop commands can entered in the “Local” mode.

Increase and decrease reference frequency commands can be entered in the “Local’ mode.

Description

2-4

AF-300C

lnwetiers

GEK-85718

TABLE 1: AF-300C

inverter HP (400460 VAC)

Standard Applicable

Motors460V (KW)

OUTPUT:

Rated Capacity-460V (KVA}

Rated Output Current46OV (Amps)I60

Rated Output Voltage (*2)

Rated Output Frequency (*3)

Overload Current Rating

POWER SUPPLY:

Rated input AC Voltage

Allowable Fluctuations

(*l)

INVERTER

50 60 75 100 125

37 45 55 75 90

57 69 65 75

3-Pk

%se,

50 - 120 Hertz Base Frequency

150% for 1 minute duration (inverse time characteristic)

3-Phase, 3-Wire Type, 400-460 VAC @ 60 Hertz, 380-460 VAC @ 50 Hertz

Voltage:

STANDARD SPECIFICATIONS

SPECIFIC

114 134

91 112 150 176

3-Wire Type, 400-460 VAC

+lO%,

-15%; Voltage Unbalance: Within 3%; Frequency: +/-5%

4TION

150 175 200 250 300

110 132 166 200 220

160 193 232 287 316

210 253 304 377 415

Control System

Output Frequency Range

CONTROL:

Frequency/Temperature Fluctuation (Stability)

Frequency Setting Resolution

Voltage/Frequency Characteristics w/F)

Torque Boost

Acceleration/Deceleration Chacteristics

Control Torque

(*3)

Sinusoidal Wave PWM With Flux Control

0.5 - 120 Hz (0.5 to 5.0 Hz start frequency; 50 to 120 Hz base frequency)

Analog Setting - Maximum frequency

Digital Setting - Maximum frequency +/-0.01% (at

Analog Setting - 0.1% (0,05Hz/50Hz) of maximum frequency

Digital Setting - 0.1 Hz (0.01 Hz/50Hz)

Voltage - 320-460

Base Frequency - 50 to 120 Hz voltage and frequency.)

21 selectable patterns plus energy conservation mode.

0.2 to 3600 seconds, four Accel/Decel time settings available. Three patterns available (Linear,

Standard: Regenerative Brake, (DC Link Pump-Up) DC injection Brake,

Optional: Dynamic Brake, 100% (5% Duty Cycle).

VAC (Adjustable independently for both

Starting Frequency of O-60 Hz at O-l 0 Seconds Time

+/-O-2%

‘s’

Curve, Logarithmic Curve)

(at

25oC, +/-1OoC)

-1OoC

O-10%

Voltage for

+5OoC)

(*I) Indicates rated capacity when rated output voltage is 440 VAC.

(9)

It is not possible for output voltage to exceed power supply voltage.

(*3) Consult distributor for operation above 120

Hertz.

2-5

AF-300C

lnverters GEK-85716

TABLE 1: AF-300C

ITEM

inverter HP (400-46OV)

CONTROL: (continued),

Torque Limit Control

Automatic Acceleration and

Deceration Operation

Slip Compensation Control Multi-Step Frequency Setting

Up-Down Control

Momentary Power Failure Restart inverter Bypass Logic Bias Frequency Setting (*4)

INVERTER

40 50 60 75 100 125 150 175 200 250 300

Output current can be limited within a range of approximately 30% to 150% (1% step).

Can be used to avoid DC Link overvoltage trips caused by motor

regeneration during deceleration. Maintains motor at constant speed with load fluctuations. Seven adjustable frequency presets can be selected via three external

contacts. External momentary contacts can be used to control frequency increase

decrease. After momentary power failure, automatic restart is possible. Allows switching the motor between the inverter and the power line. Magnitude of the bias added to the frequency reference signal can be set

from 0 to 100% (1% step).

STANDARD SPECIFICATIONS (continued)

SPECIFICATION

ant

Frequency Jump

Reversing Operation By Frequency Setting Signal Characteristics

Upper and Lower Limiters of Output Frequency

PFiOTECTiON/DETECTiON:

OPERATION:

Frequency Reference Signals

input Signals

Output Signals

Up to three resonant frequencies can be skipped. Width adjustable from

0 - 5 Hertz (IHz

Makes bipolar frequency reference input possible. (Reverse motor rotation by changing frequency reference voltage polarity, rather than by using REV-CM contact.)

Output frequency can be limited to a specified range (overiding frequency reference).

Stall Prevention, Overcurrent, Overvoltage, Undervoltage, instantaneous Power Failure, lnverter Overload, Motor Overload (electronic thermal action), External Failure (external thermal action), CPU Abnormal, Output Short Circuit, Ground Fault (for inverter protection only), and Input Surge.

Frequency Reference (Voltage Input): 0 to Current input: 4 to 20 Ma DC.

Forward Command, Reverse Command, Self-Holding Selection, Current Input Selection, Multi-Frequency Setting, Up-Down Control, Accel/Decel Selection, Free-Run Command, lnverter Bypass Command, Output Switch Interlock Selection, External Alarm input, Alarm Reset Input, and Ground

Protection

Contact Outputs:

Open Collector outputs:

Input.

step).

+/-lo

VDC (0 to +/-5VDC).

Power-Side (or Motor-Side) electromagnetic contact0

command, Fault Relay Output..

See Section 6, Function Code 45.

Tim<

(*4) Bias does not affect operation when frequency command comes from the Keypad Panel.

2-6

AF-300C

lnverfers

GEK-85718

TABLE 1: AF-300C

ITEM

lnverter HP (400-460 VAC)

INDICATION:

Frequency Meter Output

Touch Panel LED Operation:

ISetting:

Al-

LED Indication (charge light)

ENVIRONMENT:

Installation Location

INVERTER

40 50 60 75 100 125 150 175 200 250 300

Analog - 0 to Output Frequency, Set Frequency, Synchronous Speed, Output Current,

Output Voltage, Load Revolution Speed, and Presence of Input and Output Signals.

Indication of Function Code and Set Data (Refer to Function Code List).

OCI -

Deceleration, OC3 - Overcurrent During Constant Speed, OV LV - Undervoltage, Motor Overload, OH2 - External Failure, Err0 - CPU Abnormal or Failure, and Failure History (three previous failure indications).

Lights up when DC Link capacitors are charged (DC Link voltage is present),

Indoors, altitude of 3281 ft (1000 meters) or less, free of direct sunlight, corrosive gas, and dust. Motor wiring should be less than 66 feet, otherwise wire separation of 4 inches may be required.

STANDARD

+lO

VDC, Pulse Frequency - (6 to 100) x Output Frequency.

Overcurrent During Acceleration, OC2 - Overcurrent During

SPECfFlCATlONS

SPECIFICATION

OLl -

lnvener Overload, OH1 - lnverter Overheat,

(continued)

Overvoltage,

Ol2 -

Ambient Temperature

Humidity

Vibration Temperature During Transportation

APPROXIMATE WEIGHTS

Pounds Kilograms

-10 to

+5ooc

20 to 90% Relative Humidity (free of condensation).

0.5G or less.

-25 to

+6Y

95 95 221 221 221 276 331 419 419

30 35 43 43

100 100 100 125 150 190 190

2-7

AF-300C lnverters GEK-85718

TABLE 1: AF-300C INVERTER STANDARD SPECIFICATIONS (continued)

ITEM

lnverter HP (400460 VAC)

Efficiencv and Loss:

Loss

(w)

Efficiencv (%I Constant Torque Load:

Base Speed Full Load

0.75 Base Speed Full Load

0.5 Base Speed Full Load

0.25 Base Speed Full Load

Efficiencv (%I Pump or Fan:

0.8 Base Speed 64% Load

0.6 Base Speed 36% Load

0.4 Base Speed 16% Load

1280

1520 1800I2050

95.9 96.0

94.7 94.9

74.2 175.0 76.5

SPECIFICATION

96.3 96.6

87.9

95.8

95.4

95.3

94.4

94.9

74.8 77.7

95.3 95.5

79.4 79.6 78.4 79.3

95.8

79.9

AFSOOC Catalog Numbers

HP Rating

40 50 60 75

100 6VAF3431 OOC-- -(I)

(1) The two character

No dash or characters - inverter is not UL listed or CSA approved.

Al - lnverter is UL listed only. A2 - lnvener is UL listed and CSA approved.

positions

(41

)

VAC,

3=Phase, 50160

Cataloq

6VAF34304OC6VAF34305OC6VAF34306OC6VAF343075C--

No.

-(l)

following a dash in the catalog number designate the following:

2-8

Rating

125 150

200 250

300 6VAF3433OOG-

Hertz)

Cataloq No.

6VAF343125C-6VAF34315OC-6VAF3432OOC6VAF34325OC,

-(l)

AMOOC

lnverters

GEK-85718

INVERTER OPTIONS

Various options are available for the These options can be ordered from the supplier of the inverter per the GE Catalog Number shown on the chart within this paragraph. The General Electric Company ‘6v” catalog numbers are coded as shown in the following Examples:

Example: (Non-HP Related

6VKAAA3AANN*

6V - GE Drives Products Operation K - Option Kit

AAA -

Applicable Series (1,2, or 3 characters) 3 - AF-300 Family of invetters

AA -

Option Abreviation

NN - Option Size/Length (if applicable)

alphabetical character, N = Numerical char.

AFSOOC

Items)

Inverter.

NOTE: Option charts are divided into horsepower

relatedandnon-horsepowerrelateditems. Checkthe

horsepower of the inverter before ordering options to be sure the correct option is ordered.

Example: (HP Related

6VKA3NAANN*

6V - GE Drives Products Operation

K - Option Kit

AAA -

Applicable Series 3 - AF-300 Family of inverters N - Voltage

AA - Option Abreviation

NN - Horsepower Rating (2 or 3 characters)

Items1

AF-300C HORSEPOWER RELATED OPTIONS - Braking Units and Braking Resistors

(See Section 4 for recommended wiring.)

Horsepower Braklng Unit

6VKC34BU

Quantity Req. Braklng Resistor

6VKC34BR

Quantity Req. Capacity Resistance (Ohms)

NOTE:If the braking unit or resistor overheats, the thermal switch opens which turns off the braking unit

transistors and trips the inverter on an “OH2’ fault (provided thermal interlocks are wired correctly).

recommended braking unit and resistor combinations willprovide up to

duty cycle (maximum continuous ON time of braking unit is 60 seconds). *Total value, not for one resistor.

---

(KW)

40 50 60 75

050 050

1 1 1 1 1 1

040

050 060 075

3.6 4.8 6.0 7.2 9.6* 12.0* 14.4* 18.0* 19.2* 24.0” 28.8*

15 12

075 075 150 150

1 1

7.5 6.0* 5.0* 3.75* 3.33* 3.0* 2.5* 1.88”

100 125

050 060 2 2

150 175

150 175 150 150 150 1 1

075 060 050 060

100% braking torque with a maximum 5%

3 4

200 250 300

2 2 2

075

4 4

These

2-9

AF-300C NON-HORSEPOWER

Description

RS-422/485 Card

BCD Card Amps Signal Card Output Signal Card 6VKC3AC Pulse Tach Feedback Card

Catalog #

6VKC3RS 6VKC3BC 6VKC3AS

6VKC3TF

R&ATED

Description GE Catalan

Relay Unit 6VKC3RY Keypad Cable - 2M 6VKC3CBO2 Speed Potentiometer

RFI

OPTIONS

6VKC3SP

Reactor 6VKABC3RF

CAUTION:

the Inverter, but not greater than 10 times the HP ratinq of the lnverter or 500 KVA (whichever is oreater). If an AC Power Supplv Transformer qreater than this is to be used, install a Line Reactor (must be purchased

seperatelv] on the line side of the Inverter. A Line Reactor

factor correction capacitors are used on the same

The AC Power Suoplv Transformer KVA rating should be oreater than 1.5 times the HP ratino of

also required if an SCRtvpe controller and/or power

power

lines.

AC LINE REACTORS FOR

AF-300C INVERTERS (See Caution)

200 460 250 460 300 460

For input voltages other than 460, Contact General Electric Company, Drives Products Operation.

Amps shown are at 460 VAC input voltage.

***AC Line Reactors may also be required for inverters rated

700

provided with the inverter.

NOTE:

peak (non-saturating) current rating of the reactor is greater

than 2.8 times the input current rating of the inverter.

232 295 FA005*** 287 370 316 400

UP and above even though a DC Link reacfor is

If reactors are supplied by others, be sure that the

FAOOG*** FAOOG***

2-10

75 50 50

AF-300C

lnveriters

GEK-85718

104X22OFAOO3

104X220FA004

123456

NOTE: AU DIMENSIONS ARE IN INCHES.

104X22OFAOOl. 002.

I--“‘-7

104X225FAOO4

LZl

GO3

4 5

S/16

HOLES

2 3

IN. MTG.

(WY.

+.,, I_

Reactor

104X22OFAOO3 104X22OFAOO4

Toierece of

4AWG

is required, use #4 solid or two

Figure 2-5.

i-l-

0.125 inches

H dlA.

(1 EACH TERM.)

Dlmensions (inches) A B C* D

3.125 5.563 0.875

3.625 7.250 0.625

#IO

stranded

104X220FA003,004

LINE REACTOR OUTLINE AND SCHEMATIC

HOLE

I.c’A’-I

k.56

Terminal Weight Board

1.750 16-6

1.50

(#4

stranded will not fit in connector).

AWG** 37

----

S/16

MTG. SLOTS

(pounds)

5/6

LONG

{QlY.

2-11

AWOOC lnwerfers

NOTES:

All dimensions in inches (not drawn to scale). Dimension tolerance of +/-0.09 unless otherwise indicated. Reactor may be slightly different than shown.

GEK-85716

TYPICAL TERMINAL CONNECTION

(QUANTllYl 6)

1O4X2!tOFAOO5. 006

T-

I-

(OUTLINE)

S/18

IN.

HOLES

MTG.

(STY.

Reactor

104X22OFAOO5 1 104X220FA006 1

Figure 2-6.

Dlmensions (inches) A

5.00 1 8.875 1 1.00

5.50 1 12.50 1

104X22OFAOO5,006

iC(max)lD

.875 1

Weight

(min)

.I25 1

7.250

1.00

LINE REACTOR OUTLINE AND SCHEMATIC

8.50

2-12

IO.406 1 IO.531 1

1.00

1.250

AF-300C lnverters GEK-85718

3. INSTALLATION GUIDELINES

INSTALLATION ENVIRONMENT

Install the inverter in a location that meets the following requirements:

-- The ambient temperature is between -lCPC and

+5OoC (+14oF

The relative humidity is between 20% and 90%. Avoid any location subject to dew condensation, freezing, or where the inverterwould come

in contact with water.

-- Do not install in any location subject to direct sunlight, dust, corrosive gas, inflammable gas, water vapor, or oil mist.

The inverter should be installed at an elevation below 1000 meters (3281 feet) and vibration should be less than

Motor wiring should be less than 66 feet. Otherwise, wire seperation of 4 inches may be required.

OSG.

+122+).

OPEN INSTALLATION MOUNTING CLEARANCE

NOTE: When installing two or more in close proximity, allow sufficient shown in Figure 3-1 and install them in a hori-

zontal row.

row, atleast 79.7inches

provided between each one to prevent the

ambient temperature from rising.

See the appropriate view in Figure 33 for the location of mounting holes.

-- Install the rubber bushings supplied with the inverter into the cable openings in the wiring lead-in plate to prevent cable damage and to minimize dust entry.

If they must be installed in a vertical

(SOcm)

4.8 inches

(120

mm)

inverfers

space as

spacemust be

CAUTION:

affects inverter life and reliabilitv, do not install the invetter in any location that exceeds the allowable temperatures.

Install the inverter perpendicular to the ground and with the lettering right side up. (If the inverter is installed up-side-down or horizontally, heat build-up will occur.)

Install at a sufficient distance from other equipment, walls, or wiring ducts as shown in Figure

3-l (these clearances are required to allow for proper cooling air circulation).

CAUTION:

ture of the coolina fins of the inverter rise to ap- proximatelv 90 decrees C (194 dearees R. For this reason, the mountinq wall must be of heat resistant material.

Because the ambient temperature

Durinq operation, the tempera-

oreatlv

4.8 inches

(120

mm)

4.8 inches (120 mm)

‘lgure

3-1. INVERTER MOUNTING CLEARANCE

(Open Installation)

4.8 inches (120 mm)

3-1

ENCLOSED MOUNTING INSTALLATION

GUIDELINES

When mounting inverter(s) inside of an enclosure, the temperature inside of the enclosure should not exceed 50%

Do not install the inverter in a small sealed enclosure or mount other heat-generating components near the inverter within the enclosure.

Cooling fans are to be installed in such a way that the cooling air passes through the ing components.

(122oF).

heat-generat-

NOTE:

verter or Cooling Fan mayprevent the air temperature within the enclosure from being reduced to the specified value, even though the cooling fan is of the proper capacity.

When installing more than one inverter within the same enclosure, arrange them horizontally as shown in Figure 3-2. If the invetters must be arranged vertically, provide a partition board between the inverters to negate the heat generated by the lower unit from affecting the upper one (see Figure 3-2).

Improper installation positions of the In-

AIR OUT

Horizontal Arrangement

COOLING

FANS

M0$’

Vertical Arrangement

AIR OUT~

AIR OUT

PARTITION

BOARD

Figure

3-2.

INVERTER

AIR IN

ENCLOSURE MOUNTING ARRANGEMENTS

3-2

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