GE Industrial Solutions AF-600 FP User Manual
AF-600 FP
TM
Fan & Pump Drive
(230V to 60HP, 460/575V to 125HP
Operating Instructions
GE
Safety AF-600 FP Operating Instructions
Safety
WARNING
HIGH VOLTAGE!
Frequency converters contain high voltage when
connected to AC mains input power. Installation, start up,
and maintenance should be performed by qualified
personnel only. Failure to perform installation, start up, and
maintenance by qualified personnel could result in death
or serious injury.
High Voltage
Frequency converts are connected to hazardous mains
voltages. Extreme care should be taken to protect against
shock. Only trained personnel familiar with electronic
equipment should install, start, or maintain this equipment.
WARNING
UNINTENDED START!
When the drive is connected to AC mains, the motor may
start at any time. The drive, motor, and any driven
equipment must be in operational readiness. Failure to be
in operational readiness when the drive is connected to AC
mains could result in death, serious injury, equipment, or
property damage.
Unintended Start
When the drive is connected to the AC mains, the motor
may be started by means of an external switch, a serial bus
command, an input reference signal, or a cleared fault
condition. Use appropriate cautions to guard against an
unintended start.
WARNING
DISCHARGE TIME!
Frequency converters contain DC link capacitors that can
remain charged even when AC mains is disconnected. To
avoid electrical hazards, remove AC mains from the drive
before doing any service or repair and wait the amount of
time specified in Table 1.1. Failure to wait the specified
time after power has been removed prior to doing service
or repair on the unit could result in death or serious injury.
Voltage (V) Minimum Waiting Time (Minutes)
415
200 - 240 0.75 - 3.7 kW
1 - 5 hp
380 - 480 0.75 - 7.5 kW
1 - 10 hp
525 - 600 0.75 - 7.5 kW
1 - 10 hp
High voltage may be present even when the warning LEDs are
off!
Discharge Time
Symbols
The following symbols are used in this manual.
5.5 - 45 kW
7 1/2 - 60 hp
11 - 90 kW
15 - 125 hp
11 - 90 kW
15 - 125 hp
WARNING
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
CAUTION
Indicates a potentially hazardous situation which, if not
avoided, may result in minor or moderate injury. It may
also be used to alert against unsafe practices.
CAUTION
Indicates a situation that may result in equipment or
property-damage-only accidents.
NOTE
Indicates highlighted information that should be regarded
with attention to avoid mistakes or operate equipment at
less than optimal performance.
Approvals
Safety AF-600 FP Operating Instructions
Contents AF-600 FP Operating Instructions
Contents
1 Introduction
1.1 Purpose of the Manual
1.2 Additional Resources
1.3 Product Overview
1.4 Internal Drive Controller Functions
1.5 Unit Sizes and Power Ratings
2 Installation
2.1 Installation Site Check List
2.2 Drive and Motor Pre-installation Check List
2.3 Mechanical Installation
2.3.1 Cooling 8
2.3.2 Lifting 9
2.3.3 Mounting 9
2.3.4 Tightening Torques 9
2.4 Electrical Installation
2.4.1 Requirements 11
2.4.2 Earth (Grounding) Requirements 12
4
6
6
6
6
7
8
8
8
8
10
2.4.2.1 Leakage Current (>3,5mA) 12
2.4.2.2 Grounding Using Shielded Cable 13
2.4.2.3 Grounding Using Conduit 13
2.4.3 Motor Connection 13
2.4.4 AC Mains Connection 14
2.4.5 Control Wiring 15
2.4.5.1 Access 15
2.4.5.2 Control Terminal Types 15
2.4.5.3 Wiring to Control Terminals 16
2.4.5.4 Using Screened Control Cables 17
2.4.5.5 Control Terminal Functions 17
2.4.5.6 Terminal 53 and 54 Switches 17
2.4.6 Serial Communication 18
3 Start Up and Functional Testing
3.1 Pre-start
3.1.1 Safety Inspection 19
3.1.2 Start Up Check List
19
19
20
3.2 Applying Power to the Drive
3.3 Basic Operational Programming
3.4 Auto Tune
3.5 Check Motor Rotation
21
21
21
22
1
Contents AF-600 FP Operating Instructions
3.6 Local-control Test
3.7 System Start Up
4 User Interface
4.1 Keypad
4.1.1 Keypad Layout 24
4.1.2 Setting Keypad Display Values 25
4.1.3 Display Menu Keys 25
4.1.4 Navigation Keys 26
4.1.5 Operation Keys 26
4.2 Back Up and Copying Parameter Settings
4.2.1 Uploading Data to the keypad 27
4.2.2 Downloading Data from the keypad 27
4.3 Restoring Default Settings
4.3.1 Recommended Initialisation 27
4.3.2 Manual Initialisation 27
5 About Drive Programming
22
23
24
24
26
27
28
5.1 Introduction
5.2 Programming Example
5.3 Control Terminal Programming Examples
5.4 International/North American Default Parameter Settings
5.5 Parameter Menu Structure
5.5.1 Quick Menu Structure 32
5.5.2 Main Menu Structure 33
5.6 Remote Programming with DCT-10
6 Application Set-Up Examples
6.1 Introduction
6.2 Application Examples
7 Status Messages
7.1 Status Display
7.2 Status Message Definitions Table
8 Warnings and Alarms
28
28
30
31
32
40
41
41
41
46
46
46
49
8.1 System Monitoring
8.2 Warning and Alarm Types
8.3 Warning and Alarm Displays
8.4 Warning and Alarm Definitions
8.4.1 Fault Messages 51
9 Basic Troubleshooting
2
49
49
49
50
57
Contents AF-600 FP Operating Instructions
9.1 Start Up and Operation
10 Specifications
10.1 Power-dependent Specifications
10.2 General Technical Data
10.3 Fuse Tables
10.3.1 Recommendations 71
10.3.2 CE Compliance 72
10.3.3 NEC and UL Compliance 77
10.3.4 Substitute Fuses for 240 V 83
10.4 Connection Tightening Torques
Index
57
59
59
66
71
83
84
3
1
Introduction AF-600 FP Operating Instructions
1Introduction
Illustration 1.1 Exploded View Unit Size 1X
1 Keypad 10 Motor output terminals 96 (U), 97 (V), 98 (W)
2 RS-485 serial bus connector (+68, -69) 11 Relay 1 (01, 02, 03)
3 Analog I/O connector 12 Relay 2 (04, 05, 06)
4 Keypad input plug 13 Brake (-81, +82) and load sharing (-88, +89) terminals
5 Analog switches (A53), (A54) 14 Mains input terminals 91 (L1), 92 (L2), 93 (L3)
6 Cable strain relief / PE ground 15 USB connector
7 Decoupling plate 16 Serial bus terminal switch
8 Grounding clamp (PE) 17 Digital I/O and 24 V power supply
9 Shielded cable grounding clamp and strain relief 18 Control cable cover plate
4
Introduction AF-600 FP Operating Instructions
1
1
Illustration 1.2 Exploded View Unit Sizes 21, 22, 31, and 32
1 Keypad 11 Relay 2 (04, 05, 06)
2Cover 12Lifting ring
3 RS-485 serial bus connector 13 Mounting slot
4 Digital I/O and 24 V power supply 14 Grounding clamp (PE)
5 Analog I/O connector 15 Cable strain relief / PE ground
6 Cable strain relief / PE ground 16 Brake terminal (-81, +82)
7 USB connector 17 Load sharing terminal (DC bus) (-88, +89)
8 Serial bus terminal switch 18 Motor output terminals 96 (U), 97 (V), 98 (W)
9 Analog switches (A53), (A54) 19 Mains input terminals 91 (L1), 92 (L2), 93 (L3)
10 Relay 1 (01, 02, 03)
5
1
Introduction AF-600 FP Operating Instructions
1.1 Purpose of the Manual
This manual is intended to provide detailed information for
the installation and start up of the frequency converter.
Chapter 2 Installation provides requirements for
mechanical and electrical installation, including input,
motor, control and serial communications wiring, and
control terminal functions. Chapter 3 Start Up and
Functional Testing provides detailed procedures for start
up, basic operational programming, and functional testing.
The remaining chapters provide supplementary details.
These include user interface, detailed programming,
application examples, start-up troubleshooting, and specifications.
Illustration 1.3 Drive Block Diagram
Area Title Functions
1Mains input
2Rectifier
1.2 Additional Resources
Other resources are available to understand advanced
drive functions and programming.
The Programming Guide provides greater detail
•
in how to work with parameters and many
application examples.
The Design Guide is intended to provide detailed
•
capabilities and functionality to design motor
control systems.
Optional equipment is available that may change
•
some of the procedures described. Be sure to see
the instructions supplied with those options for
specific requirements.
3DC bus
4DC reactors
5 Capacitor bank
1.3 Product Overview
A drive is an electronic motor controller that converts AC
mains input into a variable AC waveform output. The
frequency and voltage of the output are regulated to
control the motor speed or torque. The drive can vary the
speed of the motor in response to system feedback, such
as changing temperature or pressure for controlling fan,
compressor, or pump motors. The drive can also regulate
the motor by responding to remote commands from
external controllers.
In addition, the drive monitors the system and motor
status, issues warnings or alarms for fault conditions, starts
and stops the motor, optimizes energy efficiency, and
offers many more control, monitoring, and efficiency
functions. Operation and monitoring functions are
available as status indications to an outside control system
or serial communication network.
6Inverter
7 Output to motor
8 Control circuitry
1.4 Internal Drive Controller Functions
Table 1.1 Drive Internal Components
Below is a block diagram of the frequency converter's
internal components. See Table 1.1 for their functions.
Three-phase AC mains power
•
supply to the drive
The rectifier bridge converts
•
the AC input to DC current to
supply inverter power
The frequency converter's
•
intermediate DC-bus circuit
handles the DC current
Filter the intermediate DC
•
circuit voltage
Prove line transient protection
•
Reduce RMS current
•
Raise the power factor
•
reflected back to the line
Reduce harmonics on the AC
•
input
Stores the DC power
•
Provides ride-through
•
protection for short power
losses
Converts the DC into a
•
controlled PWM AC waveform
for a controlled variable
output to the motor
Regulated three-phase output
•
power to the motor
Input power, internal
•
processing, output, and motor
current are monitored to
provide efficient operation
and control
User interface and external
•
commands are monitored and
performed
Status output and control can
•
be provided
6
Introduction AF-600 FP Operating Instructions
1.5 Unit Sizes and Power Ratings
References to unit sizes used in this manual are defined in Table 1.2.
Unit sizes
IP20 / Open Chassis IP55 / Nema 12
Volts1213232433341521223132
200-240 1-3 HP 5 HP 7.5-15 HP 20-25 HP 30-40 HP 50-60 HP 1-5 HP 7.5-15 HP 20 HP 25-40 HP 50-60 HP
380-480 1-5 HP 7.5-10 HP 15-25 HP 25-40 HP 50-75 HP
525-600 - 1-10 HP 15-25 HP 25-40 HP 50-75 HP
100-125
HP 1-10 HP 15-25 HP 25-40 HP 50-75 HP
100-125
HP 1-10 HP 15-25 HP 25-40 HP 50-75 HP
100-125
HP
100-125
HP
1
1
7
Installation AF-600 FP Operating Instructions
2 Installation
2
2.1 Installation Site Check List
The drive relies on the ambient air for cooling.
•
Observe the limitations on ambient air
temperature for optimal operation
Ensure that the installation location has sufficient
•
support strength to mount the drive
Keep the drive interior free from dust and dirt.
•
Ensure that the components stay as clean as
possible. In construction areas, provide a
protective covering. Optional IP55 (NEMA 12)
enclosures may be necessary.
Keep the manual, drawings, and diagrams
•
accessible for detailed installation and operation
instructions. It is important that the manual is
available for equipment operators.
Locate equipment as near to the motor as
•
possible. Keep motor cables as short as possible.
Check the motor characteristics for actual
tolerances. Do not exceed
300m (1000ft) for unshielded motor
•
leads
150m (500ft) for shielded cable.
•
2.3 Mechanical Installation
2.3.1 Cooling
To provide cooling airflow, mount the unit to a
•
solid flat surface or to the optional back plate
(see 2.3.3 Mounting)
Top and bottom clearance for air cooling must be
•
provided. Generally, 100-225mm (4-10in) is
required. See Illustration 2.1 for clearance
requirements
Improper mounting can result in over heating
•
and reduced performance
Derating for temperatures starting between 40°C
•
(104°F) and 50°C (122°F) and elevation 1000m
(3300ft) above sea level must be considered. See
the equipment Design Guide for detailed
information.
2.2 Drive and Motor Pre-installation Check
List
Compare the model number of unit on the
•
nameplate to what was ordered to verify the
proper equipment
Ensure each of the following are rated for same
•
voltage:
Mains (power)
Drive
Motor
Ensure that drive output current rating is equal to
•
or greater than motor full load current for peak
motor performance
Motor size and drive power must match
for proper overload protection
If drive rating is less than motor, full
motor output cannot be achieved
Illustration 2.1 Top and Bottom Cooling Clearance
Size 12 13 - 15 21 22
a/b (mm) 100 100 - 100 200 200
a/b (in) 4 4 - 4 8 8
Size 23 24 31 32 33 34
a/b (mm) 200 200 200 225 200 225
a/b (in) 8 8 8 9 8 9
Table 2.1 Minimum Airflow Clearance Requirements
8
Installation AF-600 FP Operating Instructions
2
2.3.2 Lifting
Check the weight of the unit to determine a safe
•
lifting method
Ensure that the lifting device is suitable for the
•
task
If necessary, plan for a hoist, crane, or forklift with
•
the appropriate rating to move the unit
For lifting, use hoist rings on the unit, when
•
provided
2.3.3 Mounting
Mount the unit vertically
•
The drive allows side by side installation
•
Ensure that the strength of the mounting location
•
will support the unit weight
Mount the unit to a solid flat surface or to the
•
optional back plate to provide cooling airflow
(see Illustration 2.2 and Illustration 2.3)
Improper mounting can result in over heating
•
and reduced performance
Use the slotted mounting holes on the unit for
•
wall mounting, when provided
Illustration 2.3 Proper Mounting with Railings
NOTE
Back plate is needed when mounted on railings.
2.3.4 Tightening Torques
See 10.4 Connection Tightening Torques for proper
tightening specifications.
2
Illustration 2.2 Proper Mounting with Back Plate
Item A is a back plate properly installed for required
airflow to cool the unit.
9
2
Installation AF-600 FP Operating Instructions
2.4 Electrical Installation
This section contains detailed instructions for wiring the drive. The following tasks are described.
Wiring the motor to the drive output terminals
•
Wiring the AC mains to the drive input terminals
•
Connecting control and serial communication wiring
•
After power has been applied, checking input and motor power; programming control terminals for their intended
•
functions
Illustration 2.4 shows a basic electrical connection.
Illustration 2.4 Basic Wiring Schematic Drawing.
10
Installation AF-600 FP Operating Instructions
2
2.4.1 Requirements
WARNING
EQUIPMENT HAZARD!
Rotating shafts and electrical equipment can be hazardous.
All electrical work must conform to national and local
electrical codes. It is strongly recommended that installation, start up, and maintenance be performed only by
trained and qualified personnel. Failure to follow these
guidelines could result in death or serious injury.
CAUTION
WIRING ISOLATION!
Run input power, motor wiring and control wiring in three
separate metallic conduits or use separated shielded cable
for high frequency noise isolation. Failure to isolate power,
motor and control wiring could result in less than
optimum drive and associated equipment performance.
2
For your safety, comply with the following requirements.
Electronic controls equipment is connected to
•
hazardous mains voltage. Extreme care should be
taken to protect against electrical hazards when
applying power to the unit.
Run motor cables from multiple frequency
•
converters separately. Induced voltage from
output motor cables run together can charge
equipment capacitors even with the equipment
turned off and locked out.
Overload and Equipment Protection
An electronically activated function within the
•
drive provides overload protection for the motor.
The overload calculates the level of increase to
activate timing for the trip (controller output
stop) function. The higher the current draw, the
quicker the trip response. The overload provides
Class 20 motor protection. See 8 Warnings and
Alarms for details on the trip function.
Because the motor wiring carries high frequency
•
current, it is important that wiring for mains,
motor power, and control are run separately. Use
metallic conduit or separated shielded wire.
Failure to isolate power, motor, and control
wiring could result in less than optimum
equipment performance. See Illustration 2.5.
Illustration 2.5 Proper Electrical Installation Using Conduit
All frequency converters must be provided with
•
short-circuit and over-current protection. Input
fusing is required to provide this protection, see
Illustration 2.6. See maximum fuse ratings in
10.3 Fuse Tables.
Illustration 2.6 Drive Fuses
Wire Type and Ratings
All wiring must comply with local and national
•
regulations regarding cross-section and ambient
temperature requirements.
GE recommends that all power connections be
•
made with a minimum 75° C rated copper wire.
See 10.1 Power-dependent Specifications for
•
recommended wire sizes.
11
Installation AF-600 FP Operating Instructions
2
2.4.2 Earth (Grounding) Requirements
WARNING
GROUNDING HAZARD!
For operator safety, it is important to ground drive
properly in accordance with national and local electrical
codes as well as instructions contained within these
instructions. Ground currents are higher than 3,5mA.
Failure to ground drive properly could result in death or
serious injury.
NOTE
It is the responsibility of the user or certified electrical
installer to ensure correct grounding (earthing) of the
equipment in accordance with national and local electrical
codes and standards.
Follow all local and national electrical codes to
•
ground electrical equipment properly
Proper protective grounding for equipment with
•
ground currents higher than 3,5mA must be
established, see Leakage Current (>3,5mA)
A dedicatedground wire is required for input
•
power, motor power and control wiring
Use the clamps provided with on the equipment
•
for proper ground connections
Do not ground one drive to another in a “daisy
•
chain” fashion
Keep the ground wire connections as short as
•
possible
Use of high-strand wire to reduce electrical noise
•
is recommended
Follow motor manufacturer wiring requirements
•
2.4.2.1 Leakage Current (>3,5mA)
EN/IEC61800-5-1 (Power Drive System Product Standard)
requires special care if the leakage current exceeds 3,5mA.
Earth grounding must be reinforced in one of the
following ways:
Earth ground wire of at least 10mm
•
Two separate earth ground wires both complying
•
with the dimensioning rules
See EN 60364-5-54 § 543.7 for further information.
Using RCDs
Where residual current devices (RCDs), also known as earth
leakage circuit breakers (ELCBs), are used, comply with the
following:
Use RCDs of type B only which are capable of
detecting AC and DC currents
Use RCDs with an inrush delay to prevent faults
due to transient earth currents
Dimension RCDs according to the system configuration and environmental considerations
2
Follow national and local codes regarding protective
earthing of equipment with a leakage current > 3,5mA.
Drive technology implies high frequency switching at high
power. This will generate a leakage current in the earth
connection. A fault current in the drive at the output
power terminals might contain a DC component which can
charge the filter capacitors and cause a transient earth
current. The earth leakage current depends on various
system configurations including RFI filtering, screened
motor cables, and drive power.
12
Installation AF-600 FP Operating Instructions
2
2.4.2.2 Grounding Using Shielded Cable
Earthing (grounding) clamps are provided for motor wiring
(see Illustration 2.7).
Illustration 2.7 Grounding with Shielded Cable
2.4.2.3 Grounding Using Conduit
CAUTION
GROUNDING HAZARD!
Do not use conduit connected to the drive as a
replacement for proper grounding. Ground currents are
higher than 3.5mA. Improper grounding can result in
personal injury or electrical shorts.
Dedicated grounding clamps are provided (See
Illustration 2.8).
1. Use a wire stripper to remove the insulation for
proper grounding.
2. Secure the grounding clamp to the stripped
portion of the wire with the screws provided.
3. Secure the grounding wire to the grounding
clamp provided.
2.4.3 Motor Connection
WARNING
INDUCED VOLTAGE!
Run output motor cables from multiple frequency
converters separately. Induced voltage from output motor
cables run together can charge equipment capacitors even
with the equipment turned off and locked out. Failure to
run output motor cables separately could result in death
or serious injury.
For maximum wire sizes see 10.1 Power-dependent
•
Specifications
Comply with local and national electrical codes
•
for cable sizes
Motor wiring knockouts or access panels are
•
provided at the base of IP55 / Nema 12 units
Do not install power factor correction capacitors
•
between the drive and the motor
Do not wire a starting or pole-changing device
•
between the drive and the motor
Connect the 3-phase motor wiring to terminals
•
96 (U), 97 (V), and 98 (W)
Ground the cable in accordance with grounding
•
instructions provided
Torque terminals in accordance with the
•
information provided in 10.4.1 Connection
Tightening Torques
Follow motor manufacturer wiring requirements
•
The three following illustrations represent mains input,
motor, and earth grounding for basic frequency converters.
Actual configurations vary with unit types and optional
equipment.
2
Illustration 2.8 Grounding with Conduit
13
2
Installation AF-600 FP Operating Instructions
Illustration 2.9 Motor, Mains and Earth Wiring for Frame Sizes 1X
Illustration 2.11 Motor, Mains and Earth Wiring for Frame Sizes
2X and Above Using Conduit
Illustration 2.10 Motor, Mains and Earth Wiring for Frame Sizes
2X and Above Using Shielded Cable
2.4.4 AC Mains Connection
Size wiring based upon the input current of the
•
drive. For maximum wire sizes see 10.1 Power-
dependent Specifications.
Comply with local and national electrical codes
•
for cable sizes.
Connect 3-phase AC input power wiring to
•
terminals L1, L2, and L3 (see Illustration 2.12).
Input power will be connected to the mains input
•
terminals.
14
Illustration 2.12 Connecting to AC Mains
Installation AF-600 FP Operating Instructions
2
Ground the cable in accordance with grounding
•
instructions provided in 2.4.2 Earth (Grounding)
Requirements
All frequency converters may be used with an
•
isolated input source as well as with ground
reference power lines. When supplied from an
isolated mains source (IT mains or floating delta)
or TT/TN-S mains with a grounded leg (grounded
delta), set SP-50 RFI Filter to OFF. When off, the
internal RFI filter capacitors between the chassis
and the intermediate circuit are isolated to avoid
damage to the intermediate circuit and to reduce
earth capacity currents in accordance with IEC
61800-3.
Illustration 2.14 Control Wiring Access for IP55 / Nema 12
enclosures
2.4.5.2 Control Terminal Types
2
130BT334.11
2.4.5 Control Wiring
Isolate control wiring from high power
•
components in the drive.
If the drive is connected to a thermistor, for PELV
•
isolation, optional thermistor control wiring must
be reinforced/double insulated. A 24 VDC supply
voltage is recommended.
2.4.5.1 Access
Remove access cover plate with a screw driver.
•
See Illustration 2.13.
Or remove front cover by loosening attaching
•
screws. See Illustration 2.14.
Tightening torque for front cover is 2.0Nm for
unit size 15 and 2.2Nm for unit sizes 2X and 3X.
Illustration 2.18 shows the removable drive connectors.
Terminal functions and default settings are summarized in
Table 2.2.
130BT248
Illustration 2.13 Control Wiring Access for IP20 / Open chassis
enclosures
Illustration 2.15 Control Terminal Locations
Connector 1 provides four programmable digital
•
inputs terminals, two additional digital terminals
programmable as either input or output, a 24V
DC terminal supply voltage, and a common for
optional customer supplied 24V DC voltage
Connector 2 terminals (+)68 and (-)69 are for an
•
RS-485 serial communications connection
Connector 3 provides two analog inputs, one
•
analog output, 10V DC supply voltage, and
commons for the inputs and output
15
Installation AF-600 FP Operating Instructions
2
Connector 4 is a USB port available for use with
•
the DCT-10
Also provided are two Form C relay outputs that
•
are in various locations depending upon the drive
configuration and size
Some options available for ordering with the unit
•
may provide additional terminals. See the manual
provided with the equipment option.
See 10.2 General Technical Data for terminal ratings details.
Terminal Description
Digital Inputs/Outputs
Default
Terminal Parameter
12, 13 - +24V DC 24V DC supply
18 E-01 [8] Start
19 E-02 [0] No
32 E-05 [0] No
33 E-06 [0] No
27 E-03 [0] No
29 E-04 [14] JOG
20 - Common for digital
39 -
42 AN-50 Speed 0 -
50 - +10V DC 10V DC analog supply
53 AN-1# Reference Analog input.
54 AN-2# Feedback
Setting Description
operation
operation
operation
operation
Analog Inputs/Outputs
High Limit
voltage. Maximum
output current is
200mA total for all
24V loads. Useable for
digital inputs and
external transducers.
Digital inputs.
Selectable for either
digital input or
output. Default setting
is input.
inputs and 0V
potential for 24V
supply.
Common for analog
output
Programmable analog
output. The analog
signal is 0-20mA or
4-20mA at a
maximum of 500
voltage. 15mA
maximum commonly
used for potenti-
ometer or thermistor.
Selectable for voltage
or current. Switches
A53 and A54 select
mA or V.
Ω
Terminal Description
Digital Inputs/Outputs
Default
Terminal Parameter
55 -
61 -
68 (+) O-3# RS-485 Interface. A
69 (-) O-3#
01, 02, 03 E-24 [0] [0] Alarm Form C relay output.
04, 05, 06 E-24 [1] [0] Running
Table 2.2 Terminal Description
Setting Description
Serial Communication
Relays
Common for analog
input
Integrated RC-Filter for
cable screen. ONLY for
connecting the screen
when experiencing
EMC problems.
control card switch is
provided for
termination resistance.
Usable for AC or DC
voltage and resistive
or inductive loads.
2.4.5.3 Wiring to Control Terminals
Control terminal connectors can be unplugged from the
drive for ease of installation, as shown in Illustration 2.16.
Illustration 2.16 Unplugging Control Terminals
1. Open the contact by inserting a small screwdriver
into the slot above or below the contact, as
shown in Illustration 2.17.
2. Insert the bared control wire into the contact.
3. Remove the screwdriver to fasten the control wire
into the contact.
4. Ensure the contact is firmly established and not
loose. Loose control wiring can be the source of
equipment faults or less than optimal operation.
16
Installation AF-600 FP Operating Instructions
2
See 10.1 Power-dependent Specifications for control terminal
wiring sizes.
See 6 Application Set-Up Examples for typical control wiring
connections.
Illustration 2.17 Connecting Control Wiring
2.4.5.4 Using Screened Control Cables
Correct screening
The preferred method in most cases is to secure control
and serial communication cables with screening clamps
provided at both ends to ensure best possible high
frequency cable contact.
50/60Hz ground loops
With very long control cables, ground loops may occur. To
eliminate ground loops, connect one end of the screen-toground with a 100nF capacitor (keeping leads short).
2.4.5.5 Control Terminal Functions
Drive functions are commanded by receiving control input
signals.
Each terminal must be programmed for the
•
function it will be supporting in the parameters
associated with that terminal. SeeTable 2.2 for
terminals and associated parameters.
It is important to confirm that the control
•
terminal is programmed for the correct function.
See 4 User Interface for details on accessing
parameters and for details on programming.
The default terminal programming is intended to
•
initiate drive functioning in a typical operational
mode.
2.4.5.6 Terminal 53 and 54 Switches
Analog input terminals 53 and 54 can select
•
either voltage (0 to 10V) or current (0/4-20mA)
input signals
Remove power to the drive before changing
•
switch positions
Set switches A53 and A54 to select the signal
•
type. U selects voltage, I selects current.
The switches are accessible when the keypad has
•
been removed (see Illustration 2.18). Note that
some option cards available for the unit may
cover these switches and must be removed to
change switch settings. Always remove power to
the unit before removing option cards.
Terminal 53 default is for a speed reference signal
•
in open loop set in DR-61 Terminal 53 Switch
Setting
Terminal 54 default is for a feedback signal in
•
closed loop set in DR-63 Terminal 54 Switch
Setting
2
Avoid EMC noise on serial communication
To eliminate low-frequency noise between frequency
converters, connect one end of the screen to terminal 61.
This terminal is connected to ground via an internal RC
link. Use twisted-pair cables to reduce interference
between conductors.
17
2
Installation AF-600 FP Operating Instructions
For basic serial communication set-up, select the following
1. Protocol type in O-30 Protocol.
2. Drive address in O-31 Address.
3.
•
130BT310.10
Illustration 2.18 Location of Terminals 53 and 54 Switches
•
•
2.4.6 Serial Communication
Connect RS-485 serial communication wiring to terminals
(+)68 and (-)69.
Screened serial communication cable is
•
recommended
See 2.4.2 Earth (Grounding) Requirements for
•
proper grounding
•
Baud rate in O-32 Drive Port Baud Rate.
Four communication protocols are internal to the
drive. Follow motor manufacturer wiring
requirements.
Drive profile
Modbus RTU
Metasys N2
Apogee FLN
Functions can be programmed remotely using
the protocol software and RS-485 connection or
in parameter group O-## Options / Comms
Selecting a specific communication protocol
changes various default parameter settings to
match that protocol’s specifications along with
making additional protocol-specific parameters
available
Option cards which install into the drive are
available to provide additional communication
protocols. See the option-card documentation for
installation and operation instructions
®
®
Illustration 2.19 Serial Communication Wiring Diagram
18
Start Up and Functional Tes... AF-600 FP Operating Instructions
3
3 Start Up and Functional Testing
3.1 Pre-start
3.1.1 Safety Inspection
WARNING
HIGH VOLTAGE!
If input and output connections have been connected
improperly, there is potential for high voltage on these
terminals. If power leads for multiple motors are
improperly run in same conduit, there is potential for
leakage current to charge capacitors within the drive, even
when disconnected from mains input. For initial start up,
make no assumptions about power components. Follow
pre-start procedures. Failure to follow pre-start procedures
could result in personal injury or damage to equipment.
1. Input power to the unit must be OFF and locked
out. Do not rely on the drive disconnect switches
for input power isolation.
2. Verify that there is no voltage on input terminals
L1 (91), L2 (92), and L3 (93), phase-to-phase and
phase-to-ground,
3. Verify that there is no voltage on output
terminals 96 (U), 97 (V), and 98 (W), phase-tophase and phase-to-ground.
4. Confirm continuity of the motor by measuring
ohm values on U-V (96-97), V-W (97-98), and W-U
(98-96).
5. Check for proper grounding of the drive as well
as the motor.
6. Inspect the drive for loose connections on
terminals.
7. Record the following motor-nameplate data:
power, voltage, frequency, full load current, and
nominal speed. These values are needed to
program motor nameplate data later.
8. Confirm that the supply voltage matches voltage
of drive and motor.
3
19
Start Up and Functional Tes... AF-600 FP Operating Instructions
3.1.2 Start Up Check List
CAUTION
Before applying power to the unit, inspect the entire installation as detailed in Table 3.1. Check mark those items when
completed.
3
Inspect for Description
Auxiliary equipment
Cable routing
Control wiring
Cooling clearance
EMC considerations
Environmental considerations
Fusing and circuit breakers
Grounding
Input and output power wiring
Panel interior
Switches
Vibration
Look for auxiliary equipment, switches, disconnects, or input fuses/circuit
•
breakers that may reside on input power side of drive or output side to motor.
Examine their operational readiness and ensure that they are ready in all
respects for operation at full speed.
Check function and installation of any sensors used for feedback to drive
•
Remove power factor correction caps on motor(s), if present
•
Ensure that input power, motor wiring, and control wiring are separated or in
•
three separate metallic conduits for high frequency noise isolation
Check for broken or damaged wires and loose connections
•
Check that control wiring is isolated from power and motor wiring for noise
•
immunity
Check the voltage source of the signals, if necessary
•
The use of shielded cable or twisted pair is recommended. Ensure that the
•
shield is terminated correctly.
Measure that top and bottom clearance is adequate to ensure proper air flow
•
for cooling
Check for proper installation regarding electromagnetic compatibility
•
See equipment label for the maximum ambient operating temperature limits
•
Humidity levels must be 5-95% non-condensing
•
Check for proper fusing or circuit breakers
•
Check that all fuses are inserted firmly and in operational condition and that all
•
circuit breakers are in the open position
The unit requires a ground wire from its chassis to the building ground
•
Check for good ground connections that are tight and free of oxidation
•
Grounding to conduit or mounting the back panel to a metal surface is not a
•
suitable ground
Check for loose connections
•
Check that motor and mains are in separate conduit or separated screened
•
cables
Inspect that the unit interior is free of dirt, metal chips, moisture, and corrosion
•
Ensure that all switch and disconnect settings are in the proper position
•
Check that the unit is mounted solidly or that shock mounts are used, as
•
necessary
Look for any unusual amount of vibration the unit may be subjected to
•
☑
Table 3.1 Start Up Check List
20
Start Up and Functional Tes... AF-600 FP Operating Instructions
3
3.2 Applying Power to the Drive
WARNING
HIGH VOLTAGE!
Frequency converters contain high voltage when
connected to AC mains. Installation, start-up and
maintenance should be performed by qualified personnel
only. Failure to perform installation, start-up and
maintenance by qualified personnel could result in death
or serious injury.
WARNING
UNINTENDED START!
When drive is connected to AC mains, the motor may start
at any time. The drive, motor, and any driven equipment
must be in operational readiness. Failure to be in
operational readiness when the drive is connected to AC
mains could result in death, serious injury, equipment, or
property damage.
1. Confirm input voltage is balanced within 3%. If
not, correct input voltage imbalance before
proceeding. Repeat procedure after voltage
correction.
2. Ensure optional equipment wiring, if present,
matches installation application.
3. Ensure that all operator devices are in the OFF
position. Panel doors closed or cover mounted.
4. Apply power to the unit. DO NOT start the drive
at this time. For units with a disconnect switch,
turn to the ON position to apply power to the
drive.
3.3 Basic Operational Programming
Drives require basic operational programming prior to
running for best performance. Basic operational
programming requires entering motor-nameplate data for
the motor being operated and the minimum and
maximum motor speeds. Enter data in accordance with the
following procedure. Parameter settings recommended are
intended for start up and checkout purposes. Application
settings may vary. See 4 User Interface for detailed
instructions on entering data through the keypad.
Enter data with power ON, but prior to operating the
drive.
1. Press [Quick Menu] on the keypad.
3. Use the navigation keys to scroll to Quick Start
and press [OK].
4. Select language and press [OK]. Then enter the
motor data in parameters P-02, P-03, P-06, P-07,
F-04 and F-05. The information can be found on
the motor nameplate. The entire quick menu is
shown in 5.5.1 Quick Menu Structure
P-07 Motor Power [kW] or P-02 Motor
Power [HP]
F-05 Motor Rated Voltage
F-04 Base Frequency
P-03 Motor Current
P-06 Base Speed
5. F-07 Accel Time 1 is recommended as 60 seconds
for fans or 10 seconds for pumps.
6. F-08 Decel Time 1 is recommended as 60 seconds
for fans or 10 seconds for pumps.
7. For F-10 enter Elec OL Trip 1 for Class 20
overload protection. For further information,
please see 2.4.1 Requirements
8. For F-16 Motor Speed Low Limit [Hz] enter the
application requirements. If these values are
unknown at this time, the following values are
recommended. These values will ensure initial
drive operation. However, take any precautions
necessary to prevent equipment damage. Make
sure that the recommended values are safe to
use for functional testing before starting the
equipment.
Fan = 20Hz
Pump = 20Hz
Compressor = 30Hz
9. In F-15 Motor Speed High Limit [Hz] enter the
motor frequency from F-04 Base Frequency.
This concludes the quick set-up procedure. Press [Status]
to return to the operational display.
In P-04 Auto Tune select Reduced Auto Tune or Full Auto
Tune and follow on-screen instructions. See 3.4 Auto Tune
3.4 Auto Tune
Auto tune is a test procedure that measures the electrical
characteristics of the motor to optimize compatibility
between the drive and the motor.
The drive builds a mathematical model of the
•
motor for regulating output motor current. The
procedure also tests the input phase balance of
electrical power. It compares the motor character-
3
21
Start Up and Functional Tes... AF-600 FP Operating Instructions
3
istics with the data entered in P-02, P-03, P-06,
P-07, F-04 and F-05.
It does not cause the motor to run or harm to
•
the motor
Some motors may be unable to run the complete
•
version of the test. In that case, select Reduced
Auto Tune
If an output filter is connected to the motor,
•
select Reduced Auto Tune
If warnings or alarms occur, see 8 Warnings and
•
Alarms
Run this procedure on a cold motor for best
•
results
3.5 Check Motor Rotation
Prior to running the drive, check the motor rotation. The
motor will run briefly at 5Hz or the minimum frequency set
in F-16 Motor Speed Low Limit [Hz].
1. Press [Main Menu] twice on the keypad.
2. Enter Parameter Data Set and scroll to P-## Motor
Data and press [OK] to enter.
3. Scroll to P-08 Motor Rotation Check.
4. Press [OK].
5. Scroll to Enable.
The following text will appear: Note! Motor may run in
wrong direction.
6. Press [OK].
7. Follow the on-screen instructions.
To change the direction of rotation, remove power to the
drive and wait for power to discharge. Reverse the
connection of any two of the three motor cables on the
motor or drive side of the connection.
NOTE
The hand key on the keypad provides a local start
command to the drive. The OFF key provides the stop
function.
When operating in local mode, the up and down arrows
on the keypad increase and decrease the speed output of
the drive. The left and right arrow keys move the display
cursor in the numeric display.
1. Press [Hand].
2.
Accelerate the drive by pressing [
Moving the cursor left of the decimal point
provides quicker input changes.
3. Note any acceleration problems.
4. Press [OFF].
5. Note any deceleration problems.
If acceleration problems were encountered
If warnings or alarms occur, see 8 Warnings and
•
Alarms
Check that motor data is entered correctly
•
Increase the accel time in F-07 Accel Time 1
•
Increase current limit in F-43 Current Limit
•
Increase torque limit in F-40 Torque Limiter
•
(Driving)
If deceleration problems were encountered
If warnings or alarms occur, see 8 Warnings and
•
Alarms
Check that motor data is entered correctly
•
Increase the decel time in F-08 Decel Time 1
•
See 8.4 Warning and Alarm Definitions for resetting the
drive after a trip.
] to full speed.
▲
3.6 Local-control Test
CAUTION
MOTOR START!
Ensure that the motor, system, and any attached
equipment is ready for start. It is the responsibility of the
user to ensure safe operation under any operational
condition. Failure to ensure that the motor, system, and
any attached equipment is ready for start could result in
personal injury or equipment damage.
22
NOTE
3.1 Pre-start through 3.6 Local-control Test in this chapter
concludes the procedures for applying power to the drive,
basic programming, set-up, and functional testing.
Start Up and Functional Tes... AF-600 FP Operating Instructions
3
3.7 System Start Up
The procedure in this section requires user-wiring and
application programming to be completed. is intended to
help with this task. Other aids to application set-up are
listed in 1.2 Additional Resources. The following procedure
is recommended after application set-up by the user is
completed.
CAUTION
MOTOR START!
Ensure that the motor, system, and any attached
equipment is ready for start. It is the responsibility of the
user to ensure safe operation under any operational
condition. Failure to ensure that the motor, system, and
any attached equipment is ready for start could result in
personal injury or equipment damage.
1. Press [Auto].
2. Ensure that external control functions are
properly wired to the drive and all programming
completed.
3. Apply an external run command.
4. Adjust the speed reference throughout the speed
range.
5. Remove the external run command.
6. Note any problems.
If warnings or alarms occur, see 8 Warnings and Alarms.
3
23
User Interface AF-600 FP Operating Instructions
4 User Interface
4.1 Keypad
4
The keypad is the combined display and keys on the front
of the unit. The keypad is the user interface to the
frequency converter.
The keypad has several user functions.
Start, stop, and control speed when in local
•
control
Display operational data, status, warnings and
•
cautions
Programming frequency converter functions
•
Manually reset the frequency converter after a
•
fault when auto-reset is inactive
NOTE
The display contrast can be adjusted by pressing [STATUS]
and the up/ down key.
4.1.1 Keypad Layout
The keypad is divided into four functional groups (see
Illustration 4.1).
24
Illustration 4.1 Keypad
a. Display area.
b. Display menu keys for changing the display to
show status options, programming, or error
message history.
c. Navigation keys for programming functions,
moving the display cursor, and speed control in
local operation. Also included are the status
indicator lights.
d. Operational mode keys and reset.
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