Table of Contents
1
Section Topic
1 Thanks information – DEH40639
2 Installation and Start-up Instructions for AF-600 Redundant Drive Panels – DEH40632
3 Operating and Troubleshooting Instructions for AF-600 Redundant Drive Panels –
DEH40634
4 AF-600 FP User’s Guide (DET – 609) - DEH40637 (Not Included)
5 Appendices – Table of Contents (Current Ratings and Fuse Sizes) – DEH40636
6 In-Warranty Information Form – DEH40638
7 Appendix B – Wire Sizes, Torque and Estimated Watt loss Details – DEH40635
8 Product Drawings – Electrical and Mechanical (Not Included)
DEH40633 AN 12-1007, Rev.04, 04/04/2012
WARNING: Denotes operating procedures and practices that may result
in personal injury or loss of life if not correctly followed
CAUTION: Denotes operating procedures and practices that, if not strictly
observed, may result in damage to, or destruction of equipment.
NOTE: Notes call attention to information that is especially significant
in understanding and operating the equipment.
2
GE Drives wishes to thank you for choosing our adjustable frequency controller
product. We are committed to being the world’s leading supplier of AC adjustable
speed drives by providing the highest quality products as well as the best
documentation and product support available in the industry.
Compiled in this manual is a comprehensive set of documentation for your purchase.
The manual is designed to provide you installation, commissioning, preventative
maintenance, trouble-shooting and proper operating instructions for your GE Drives
adjustable speed drive product. We suggest complete review of the manual by your
personnel prior to installation and subsequent operation of the product.
Before proceeding to the instructions note that throughout this manual are several
warnings, cautions and notes, which are highlighted in, shadowed boxes as shown
below. Please take time to read these special instructions because they contain
important information regarding protection and safety of personnel and equipment.
DEH40639 AN 10-2100 Rev 01, 10/20/2010
CAUTION: Care should be taken when unpacking the panel; improper
use of tools could damage equipment.
WARNING: Improper lifting of enclosure could result in a fatal or
serious injury.
INSTALLATION AND START-UP INSTRUCTIONS FOR
AF-600 REDUNDANT DRIVE PANELS
WARNING: Failure to comply to this instruction could result in a fire
and/or explosion, thus resulting in a fatal or serious injury.
CAUTION: On Wall-Mounted enclosures the panel doors can swing
through 180+ degrees and there are no stops to inhibit the door from hitting
equipment located next to the panel. This could result in damage to the
door mounted switches and indicator lights on the panel door.
3
The following information is provided for reference use during the installation of your AF-600
Redundant Drive Panels. Please note that all equipment shall be installed in accordance with the
2008 edition of NFPA 70 (National Electric Code) along with applicable local codes. This document
provides information pertaining to: inspections, environment, installation, and wiring. The AF-600
Drive User’s Guide DET - 609 and the AF-600 Redundant Drive Panel Operating Instructions
contained in this notebook have additional information and will be referenced through out this
document.
INSPECTION #1 After unpacking your control panel inspect it for damage that may have
occurred during shipment.
If any damage is found please report it to the distributor from which the
panel was purchased.
PREPARING FOR Remove and discard desiccant / drying / silica packs, if included.
INSTALLATION
Before you begin to install the drive panel, make sure the proper
equipment for lifting is available. Refer to the appropriate Outline drawing
for the dimensions, estimated weight, and required clearances for
installation.
Review the Layout and Elementary diagrams before wiring your AF-600
Redundant Drive panel.
ENVIRONMENT AF-600 Redundant Drive Panels are available only in NEMA type 1
Enclosures. The environment must also be totally free from flammable or
combustible vapors and/or dust.
DEH40632 AN 12-1007, Rev.03, 04/04/2012
CAUTION: Damage to equipment will result if panel is operated or
stored below or above stated ambient temperature range.
WARNING: The temperature of the inverter heat sink fins may
reach 90 C (194 F). Thus if not mounted on a heat resistant or a nonflammable surface a fire may occur resulting in a fatal or serious injury,
as well as damage to equipment.
4
The environments for NEMA Type 1 enclosures shall be indoor where the
following condition may exist; falling dirt.
For all enclosure types the ambient temperature must remain in the
range from -10 C (14 F) to 40 C (104 F). Never store or operate panel
below or above ambient range. All wall-mounted enclosures must be
mounted on a non-flammable or heat resistant surface.
Some enclosure configurations of AF-600 Redundant Drive Panels require
ventilation to keep the components and inverter within their thermal
recommendations. The enclosure door and sides contains grilles at the
bottom and top to allow for air to circulate through the enclosure.
Ventilation is accomplished by the cooling fan(s) mounted at the bottom
grille(s) pulling air into the enclosure and forcing it out the top grille(s).
The air used for ventilating the enclosure must be free from condensation,
moisture, dirt, dust, and flammable or combustible vapors and/or dust
The recirculation of air leaving the enclosure should be avoided. Air
forced out of the enclosure should not be allowed to circulate back into
the enclosure. All enclosures shall be installed where the doors are able
to completely open. Do not mount enclosure where the air flow into or
out of it may be restricted.
INSTALLATION Panels must be installed per NEC 110.26 and local codes and have
minimum clearance to operate door safely and allow for proper
maintenance as needed, (e.g., access and change filters).
Determine conduit entry and exit locations on the enclosure before
mounting. See the appropriate Outline drawing for recommended
conduit locations.
Allow for input and output power wiring to be located in separate conduit.
No conduit holes are provided in the enclosure; therefore the customer
must install all conduit holes. Place a protective covering over the
components of the panel while installing the conduit holes to prevent
metal shavings or chips from landing on part or electronic boards.
DEH40632 AN 12-1007, Rev.03, 04/04/2012
CAUTION: Failure to cover components from metal shavings may
result in damage to equipment.
5
GROUNDING
All panels/enclosures must be grounded. All exposed metal parts are
connected to ground to prevent contact with a dangerous voltage if
electrical insulations fail.
Each panel contains a grounding bus with provisions for connecting a
field-grounding conductor.
All field wiring shall be copper and have a minimum insulation rating of
75C (167 F).
Size grounding conductors according to local and national codes
Grounding methods must comply to local and national codes.
POWER WIRE
(Greater than 120 VAC)
All field wiring shall be copper and have a minimum insulation rating of
75 C (167 F).
Size all wire based on panel nameplate current ratings in accordance
with local and national codes. Do not use the cable sizes listed in DET 609 & DET – 610 manuals.
All power wiring must be routed away from other wiring. Avoid running
power wiring parallel to other wiring without a minimum separation
distance of four (4) inches. Power wiring should only cross perpendicular
to other wiring.
Input and output power shall be connected as per the wiring diagram.
Incoming power cables should be terminated at line side of the lugs
provided with the Disconnect switch.
Locate terminals (T1, T2, and T3) in the panels and use these terminals to
connect the motor wires. Depending on actual drive panel configuration,
motor cables should be terminated on the load side of the Power
Distribution Blocks.
Refer to Appendix B for Tightening torque details for motor connections.
DEH40632 AN 12-1007, Rev.03, 04/04/2012
CAUTION: Do not connect power supply voltage greater than panel
rated voltage, or damage will occur to equipment.
WARNING: Never connect or disconnect input wiring with voltage
applied, a serious or fatal injury may result.
WARNING: Never connect or disconnect output wiring with
voltage applied, a serious or fatal injury may result.
6
CONTROL WIRING
(120 VAC )
All field wiring shall have a minimum insulation rating of 75 C (167 F).
Size wire according to local and national codes.
All control wiring must be routed away from power wiring. If control
wiring is routed parallel to signal wiring (24 Vdc or less), isolation of the
signal wiring must be maintained. A minimum of four (4) inches is needed
to adequately separate signal and control wiring. If signal wire is UL
recognized shielded cable, separation can be minimized to a one (1) inch
separation.
AF-600 Redundant Drive Panels require no additional control wiring to
operate properly. Additional control interfacing to your control panel can
be accomplished through the panel mounted customer terminal board
“CTB1”. Please reference the appropriate wiring diagram. Torque values
for connecting to “CTB1” are located in the Appendices.
SIGNAL WIRING
(24 VDC or less)
All field wiring shall have a minimum insulation rating of 75 C (167 F).
Size wire according to local and national codes.
All field signal wiring must be twisted and shielded. All shields must be
grounded at one point ONLY. It is recommended to terminate the shield
drains at the signal’s source. Avoid routing signal wiring with power
wiring. If signal wiring is routed with control wiring a minimum separation
of one (1) inch is required.
DEH40632 AN 12-1007, Rev.03, 04/04/2012
CAUTION: Do not over-tighten terminal board connectors, damage to
the equipment may occur.
7
AF-600 Redundant Drive Panels require no additional signal wiring to
operate properly. Additional signal interfacing to your control panel can
be accomplished through the panel mounted customer terminal board
“CTB1”. Please reference the appropriate customer interface diagram for
signal interfacing to your control panel. Torque values for connecting to
“CTB1” are located in the Appendices.
If your application requires wiring to the AF-600 FP inverter I/O control
terminal board, use 16 to 18 AWG wire.
Connections on the inverter I/O terminal board should be tight enough
such that a slight tug on the wire will not result in the wire coming
partially or completely out of the terminal board.
MISCELLANEOUS
INFORMATION Refer Appendix B (Table A) for estimated watts loss of the panel.
If your enclosure is equipped with forced ventilation for keeping the
inverter and other components within their thermal recommendations,
the cooling fan(s) used to ventilate your enclosure also need to be cleaned
periodically. Cleaning the cooling fan(s) is recommended to keep the
proper amount of air circulating through the enclosure.
GE Drives recommends that all power connections be checked for proper
tightness every 6 months due to thermal cycling that may occur during
normal operation.
INSPECTION #2 Prior to start-up of your drive panel inspect the following:
The mechanical installation for any safety and local or national code
violation.
The electrical installation for proper connections and any violation of
local or national code.
Proper grounding of equipment.
All field wiring for tight and proper connections (no split wire ends that
may come in contact with adjacent connection points).
No loose hardware, metal shavings, or wiring chips.
All factory wiring for proper tightness that may have became loose
due to shipping vibration.
DEH40632 AN 12-1007, Rev.03, 04/04/2012
OPERATING AND TROUBLESHOOTING INSTRUCTIONS FOR
AF 600 REDUNDANT DRIVE PANELS
8
Your AF 600 Redundant Drive Panel comes with an AF 600 FP Adjustable Frequency Drive from GE Drives
mounted on or in an enclosure, which contains the following equipment.
Ferraz Shawmut Non-Fused Disconnect w/through-the-door lockable handle (or equivalent)
Ferraz Shawmut Fused Disconnect w/through-the-door lockable handle (or equivalent) for 15 HP
Only
GE C-2000
TM
3-Pole Non-Reversing Contactors
GE C-2000TM Selector Switches
P9 Series Pilot lights
GE Type IP Encapsulated or Vacuum Impregnated 115 VAC Control Power Transformer w/fuses
Bussman / Ferraz Shawmut Amp-trap Time-Delay Class J Fuses (or equivalent)
GE Line Reactors (optional)
GE DC Link Reactors (Drive inbuilt)
These instructions are intended as a supplement to the User’s Guide for the AF 600 FP drive. For
programming, operating and troubleshooting instructions for the adjustable frequency drive please refer to
the User’s Guide, which is included with your Redundant Drive panel documentation package.
DET -609 AF 600 FP User’s Guide for up to 60HP @ 208V @ & up to 125HP @460/575
Also included with your Redundant Drive panel documentation package are installation instructions,
electrical and mechanical drawings of your Redundant Drive panel.
DEH40634 AN 11-1018 Rev.02, 09/26/2011
Table of Contents
NOTE: The terms drive and inverter are used interchangeably in this
document.
9
1. Operator Devices page 3
2. Customer Terminal Board page 5
3. AF 600 Drive Terminal Board I/O page 6
4. Adjustments page 7
5. AF 600 FP Drive Function Code Changes page 8
6. Troubleshooting page 10
DEH40634 AN 11-1018 Rev.02, 09/26/2011
WARNING: Although input power is removed from the drive in
the “Off” position this does not guarantee that dangerous voltage levels
are absent. The AF 600 FP drives contain capacitors, which can maintain
dangerous voltage levels for an extended period following removal of AC
input power.
Before touching any potentially live parts of the frequency inverter or
drive, it is always advisable to wait at least 20 mins if not specified.
380-480V, 150-300 HP, wait at least 20 minutes
Shorter time is allowed only if indicated on the nameplate for the
specific unit.
Do not manually drain capacitors.
NOTE: In the event of a drive1 fault need to move switch to “drive2”
from “drive1” Vice-versa.
WARNING: Potential arc flash and shock hazard
Do not perform any maintenance/work when panel is
Energized. Follow local work rules and proper Personal
Protective Equipment (PPE).
10
1. Operator Devices
Your Redundant Drive panel is equipped with several panel door mounted operator devices, which may
include the following: one (1) through-the-door, lockable, input device disconnect handle; two (2) operator
selector switches; and five (5) indicator lights. The operation of these devices is explained in this section. Refer
to the Drive Terminal Board I/O section of this manual and wiring diagrams for specifics on wiring
connections.
Input Disconnect The purpose of the panel-mounted input disconnect with through-the-door
handle is to provide a local, lockable method of removing all AC input power
from the Redundant Drive panel and AF 600 FP drive.
If your panel includes a Non-fusible Disconnector/Fusible Disconnector, in
addition to providing a manual method of applying and removing AC input
power from the Redundant Drive panel, the Disconnector also provides short
circuit protection for the panel components and the motor.
Drive1-Off- Drive2 The setting of this selector switch determines whether power to the motor will
be from the adjustable frequency drive1 (“Drive1” position) or from drive2
(“Drive2” position). This selector can be changed “on-the-fly” without first
completely stopping the motor. However, when changing from “Drive1” to
“Drive2” mode a short delay is required to be inserted by the operator
(approximately 10 seconds) to allow time for the motor’s rotor flux to decay.
.
DEH40634 AN 11-1018 Rev.02, 09/26/2011
WARNING: Using the Hand operation in the keypad when selector
switch in “Auto” mode may cause control inputs on drive to be ignored
and may result in unintended operations / starting of the drive unit.
CAUTION: Failure to insert enough time delay between operation of
the motor from the drive1 and operation from drive2 can result in a
protective trip of the drive. The time delay is to ensure a safe transition.
11
Hand/Off/Auto Selector This selector is also referred to as the H-O-A switch. In the “Off” position
power will be removed from the motor in both drive “drive 1” and “drive 2”
modes of operation. It should be noted that this will not cause AC input power
to be removed from the drive. To remove drive input power the Disconnector
switch should be placed in the “OFF” position (or) need to take out fuse link
from FSBLK2 & FSBLK3 after Disconnector is moved to “OFF” position.
In “Hand” mode, power will be applied to the motor from either the drive1 or
drive2 according to the Drive1-Off- Drive2 selector. In this mode the inverter’s
frequency reference is determined by the setting of speed pot on the panel if
ordered.
In “Auto” mode, power will be applied to the motor only when a connection is
made between the two remote run contacts on the customer terminal board
inside the panel enclosure. In this mode the inverter’s frequency reference is
determined by a customer supplied 0-10 VDC or 4-20 mA signal
Hand-Off-Auto on the Drive key pad
All AF 600 redundant drive panels include a keypad for programming and
operation of the drive and includes Hand, Off and Auto operation keys /
buttons. When shipped from the factory, the Hand, Off and Auto buttons are
enabled. Pressing the Off button while the drive is running will cause the drive
to decelerate and shut off regardless of the position of the panel’s selector
switches. To resume normal operations when selector switch is in “Auto” (that
is control the unit from its selector switches and analog signal) press the Auto
Button one time
Keypad “Hand” button should only be use to control Drive Operation when the
selector switch is in “Hand”.
For more details on the Hand, Off, and Auto operation keys, refer to manuals
DET-609
DEH40634 AN 11-1018 Rev.02, 09/26/2011
NOTE: Terminal CTB1-1 through CTB1-3 will be at 115V.
WARNING: When the disconnect handle is turned to the “On”
position, terminal board points can be at 115 VAC with respect to
ground. Therefore, prior to making any connections to these points lock
the disconnect handle in the “Off” position. In fact, good safety practice
dictates that prior to servicing any electrical equipment that all sources
of electrical energy be disconnected and “locked out” to avoid
reconnection by a third party unaware of the maintenance efforts
12
Emergency Stop This operator is used to shut off the panel output in case of Emergency.
To restart the panel, Reset the E-stop by turn to release.
Power On Indicator This white light on the panel door indicates that the circuit breaker/disconnect
switch is closed and that AC power is present at the panel input terminals.
Absence of light from this indicator when it should be “ON” may indicate the
presence of a blown fuse(s) on the primary or secondary of the control power
transformer or a blown bulb.
Drive1 Run Indicator This green light on the panel door indicates that the drive1 output contactor is
energized and the drive1 may output power to the motor. The conditions that
will cause this light to become energized are – Drive1-Off-Drive2 is in the
“Drive1”. Note that this light only means that the drive1 output contactor is
energized and the panel is operating in “Drive1” mode. If the motor’s shaft is
not rotating then it may be due to 1) no run command provided to the drive1
(i.e. H-O-A switch in the “Off” position) 2) No Speed ref. 3) an open load side
disconnect (external to drive panel).
Drive2 Run Indicator This blue light on the panel door indicates that the Drive2 contactor is
energized. In order for this to happen the Drive1-Off- Drive2 selector must be
in the “Drive2” position and the H-O-A switch must be in either the “Hand” or
“Auto” positions (if “Auto” then remote run contacts must also be closed).
Drive1 Fault Indicator This amber light on the panel door indicates that the Drive-1 is reporting a
fault condition.
Drive 2 Fault Indicator This amber light on the panel door indicates that the Drive-2 is reporting a
fault condition.
2. Customer Terminal Board – “CTB”
Inside the panel enclosure there is terminal board for convenient customer connections. The customer
interface drawing provides a visual reference of the terminal board positions with the detailed descriptions
as follows:
DEH40634 AN 11-1018 Rev.02, 09/26/2011
13
CTB1-1 through CTB1-3 Customer Safety Interlocks. Put normally closed contacts between CTB-1
and CTB-3. CTB-2 and CTB-3 provide an additional connection point if
required. An open circuit between these positions will cause the bypass and
drive output contactors to drop out resulting in power being removed from
the motor. These positions come jumpered together from the factory and
require removal of the factory jumpers prior to connecting customer normally
closed contacts.
CTB1-6 through CTB1-7 Auto Run Input. Put normally open remote run contacts between CTB-6 and
CTB-7. Closure between these positions is required for the motor to run in
either Drive-1 or Drive-2 modes when the H-O-A switch is in the “Auto”
position. The positions come jumpered together from the factory.
CTB1-19 through CTB1-21 Analog Speed Reference Input for Drive 1. Connect customer supplied 0-10
VDC or 4-20 mA “Auto” speed reference signal. This signal functions as the
drive’s speed reference when the H-O-A switch is in the “Auto” position. If
utilizing a 0-10 VDC signal, CTB1-19 and CTB1-21 are to be used. If utilizing a
4-20 mA signal, CTB1-19 and CTB1-20 are to be used. CTB1-19 is the
common terminal for either input signal. See the customer interface diagram
for details. Ground bar provided for cable shield grounding.
CTB1-16 through CTB1-18 Analog Speed Reference Input for Drive 2. Connect customer supplied 0-10
VDC or 4-20 mA “Auto” speed reference signal. This signal functions as the
drive’s speed reference when the H-O-A switch is in the “Auto” position. If
utilizing a 0-10 VDC signal, CTB1-16 and CTB1-18 are to be used. If utilizing a
4-20 mA signal, CTB1-16 and CTB1-17 are to be used. CTB1-16 is the
common terminal for either input signal. See the customer interface diagram
for details. Ground bar provided for cable shield grounding.
3. AF 600 FP Drive Terminal Board I/O
Any of the AF 600 FP terminal board I/O points which are not already in use for proper operation of the
bypass panel are available for customer use. The meanings and connection diagrams for these I/O points
are well described and illustrated in the AF 600 FP User’s Guide (DET609 – For up to 60HP@208V and up to
125HP@460/575V) which is supplied with your panel documentation package. However there are several
I/O points, which will find frequent use in bypass panel applications that they are described below for
convenience. Refer to user’s guide DET – 609 for terminal locations. Refer to section 2 and wiring diagram for
details on correct connection points
18 & 33 Need to add wire jumper in between these terminal to prevent users from
starting a drive using keypad Hand when the selector switch is in the off
position
39 & 42 4-20 mA output signal will be available from the drive at terminal 39
and 42
DEH40634 AN 11-1018 Rev.02, 09/26/2011
14
Relay 1 – 01,02,03 Normally open inverter fault contacts. These contacts are utilized to energize
an interposing relay for bypass panel control logic and to provide customers
with a drive fault status via higher rated normally open contacts than those
inherent to the drive.
Relay 2 – 04,05,06 Normally open programmable contacts. These contacts have been
configured to provide a drive running status for customer use. This status is
then used to energize an interposing relay to provide customers with drive
running status via higher rated normally open contacts than those inherent to
the drive. .
54, 55 Used for drive speed reference inputs
29 Jog (Digital input)
Drive will be programmed (Parameter C20) to run at preset speed (50Hz jog
frequency)
1,2,3,4,5 DEVICE NET Communications (with option card)
62,63,66,67,CS PROFIBUS/BACNET Communications (with option card)
79,80 LONWORKS Communications (with option card)
68,69,61 RS485 Port / Modbus / Metasys / Apogee Communications
4. Adjustments
The AF 600 FP & Redundant Drive panel has several user settable adjustments, which allow it to be tailored
specifically for your 3-phase induction motor. Setting these adjustments appropriately is an important factor
in ensuring that applicable safety codes are met and that your bypass panel, wiring, and motor are
adequately protected. The following list comprises all of the user adjustable devices/components inside the
AF 600 FP & Bypass panel. The user may wish to have a copy of NFPA 70-2008 (commonly known as the
National Electric Code or simply NEC) available for reference when setting these adjustments.
Input Fuses Main input fuses are provided standard with your AF 600 FP & Redundant
Drive panel. In general there are two configurations that utilize input fuses; 1)
input disconnect with load side separately mounted fuses and 2) input Fused
Disconnect where the fuses are an integral part of the disconnect. If your
panel was ordered with 8% line reactor then it will have main input fuse
connected prior to reactor, This fuses will provide shirt circuit protection for
15HP with 8% reactor or without 8% reactor fusible Disconnector itself will
have integral fuses. The main input fuses provided with your bypass panel
has been closely coordinated to provide short circuit protection for the
inverter along with short circuit and over current protection for the motor. In
“Drive1” or “Drive2” mode of operation, the fuses only provide short circuit
protection due to the fact that the inverter has inherent over current
DEH40634 AN 11-1018 Rev.02, 09/26/2011
15
protection.
UL listed Class J time-delay fuses are provided with your panel. These fuses
have been sized in accordance to NEC section 450-52 and Table 450-152.
NEC states fuses of this type are to be sized at 175% of motor full-load amps
(FLA). Due to the fact that actual motor FLA along with starting current
requirements vary between manufacturer and motor types the fuses
provided are based on standard NEC motor data. Verify that the input fuse
amp rating is less than or equal to the actual motor FLA * 1.75. In the case
where the actual motor FLA * 1.75 is less than the provided fuses amp rating
then smaller fuses may need to be installed to be in compliance with NEC
section 430-52 and Table 430-152. Please note exception 1 to NEC 430-52,
which states that where the calculated fuse amp rating does not correspond
to a standard fuse size the next higher standard fuse size may be used. In
cases where the fuses provided is not sufficient for the starting current
requirements of the motor, please note exception 2-b to NEC 430-52.
Exception 2-b states the rating of a time-delay fuse may be increased but
shall not exceed 225% of the motor FLA in any case. In the case where a
larger or smaller fuse is required, a limiting factor in the bypass panel may be
the fuse holder. The appendices provide a table for the maximum fuse size
permitted in the existing fuse holder.
5. AF 600 FP Drive Function Code Changes
The AF 600 FP Adjustable Frequency Drive has programmable function. A complete description of these
function codes can be found in DET – 609 manuals. The purpose of this section is to identify those function
codes, which changed from the factory drive defaults for panel installation.
Live Zero Time Out Time (AN00) Set to “10” seconds
Live Zero Time Out Function (AN01) Set to “3” Jogging
Terminal 53 Live Zero (AN17) Set to “0” Disabled
Terminal 54 Live Zero (AN27) Set to “1” Enabled
Jog Speed (C20) Set to “50” Hz
Frequency Command 2 (C30) Set to “2” Analog Input 54
Terminal 27 Digital Input (E03) Set to “2” Coast inverse
Terminal 32 Digital Input (E05) Set to “14” Jog
Terminal 33 Digital Input (E06) Set to “6” Stop Inverse
DEH40634 AN 11-1018 Rev.02, 09/26/2011
16
Relay 1 (E24) Set to “9” Alarm
Relay 2 (E24) Set to “5”Running
Electronic Overload (F10) Set to “4” Elec OL Trip 1
Motor Thermistor Input (F12) Set to “0” None
Auto-Reset (Times) (H04) Set to “13” Infinite Auto Reset
Drive Programming
Auto-Tune
In the event that it is desired to “auto-tune” the drive to the connected motor, reference the following
instructions along with the AF 600 FP User’s Guide (DET – 609):
With power applied to the panel –
1) Place the Hand/Off/Auto, and Drive1/Off/Drive2 selector switches in the “Off”, and “Drive1” positions
respectively.
2) For Full Auto tuning follow the instruction below
Quick Menu
Ok
Quick start
Ok
Once Up arrow
Ok
P-04 Auto Tuning
Ok
[1] Full Auto tune
Ok
Follow the Keypad direction Note: If the panel has a load reactor, select “Reduced
Auto tune”.
DEH40634 AN 11-1018 Rev.02, 09/26/2011
17
6. Troubleshooting
Drive1 and Drive2 Motor Rotation
If careful attention to phase rotation is not made during connection of the panel to the three-phase power
supply and motor, then there is only a one chance in four that the motor will rotate correctly in both drive1
and drive2 modes.
The other three possibilities and the corresponding corrective actions are as follows:
Problem: Motor turns correctly in Drive2 mode and incorrectly in Drive1 mode.
Solution: Swap the leads at the drive’s output terminals.
Problem: Motor turns correctly in Drive1 mode and incorrectly in Drive2 mode.
Solution: Swap the leads at the drive’s output terminals.
Problem: Motor turns incorrectly in both modes.
Solution: Swap the leads at the motor leads on the contactor's output terminals.
Drive Fault Codes
Refer to FP troubleshooting guide.
DEH40634 AN 11-1018 Rev.02, 09/26/2011
18
AF-600 FP User’s Guide
DET -609 AF 600 FP User’s Guide for up to 60HP @ 208V @ & up to
125HP @460/575
To be inserted here along with any other GEI for any
Options, which may be included
DEH40637 AN 10-2100, Rev.01, 10/20/2010
Appendices – Table of Contents
19
Table A 460 VAC Panel Current Ratings and Maximum Allowable Fuse Sizes
In-Warranty Information Form
DEH40636 AN 11-1018, Rev.02, 09/26/2011
VAC Panel
VAC Panel
Max Allowable
Hp Rating
Current Rating
Fuse Size
15
21
33.25
20
27
43.75
25
34
54.25
30
40
63.00
40
52
82.25
50
65
103.25
60
80
127.75
75
96
166.25
100
130
206.50
125
156
253.75
20
Table A
AF 600 Redundant Drive Panels – 460 VAC
Current Ratings and Maximum Fuse Sizes
DEH40636 AN 11-1018, Rev.02, 09/26/2011
21
In-Warranty Information Form
The purpose of this form is to provide specific information to GE Drives to aid in
expediting part replacement and/or troubleshooting assistance for AF-600 FP
Redundant Drive panels. The following information is required prior to any assistance
being provided.
Panel Model Number :
Panel Serial Number :
Start-Up Date:
Failure Date:
I. Application Information:
Input Transformer: _____ kVA Wiring distance between motor & drive ______ ft.
Power Factor Correction Capacitors: _____ Yes ( _______ Microfarad) _____ No
Other Equipment on Same Power: _____ Yes _____ No
If Yes, what? ______________________________________________________
II. Function Code Different From Factory Settings:
FC Setting FC Setting
III. Failure Message:
Latest Fault Previous Fault
IV. Status When Failure Occurred (check one):
_____ Power Up _____ Running _____ Inverter Mode _____ Bypass Mode
V. Description Of Failure:
______________________________________________________________________________
______________________________________________________________________________
DEH40638 AN 10-2100, Rev.01, 10/20/2010
22
Once all the required information above is acquired, contact the following number for
assistance:
GE Industrial Systems
Phone: 1-800-533-5885 (24hrs.)
VI. To aid in part replacement please fill complete the following:
To: ______________________ From: _____________________
Fax: _____________________ Fax: ______________________
Phone: ____________________ Phone: ____________________
The following is the ship to address for all warranty replacement items:
Company Name
________________________________________________________________
________________________________________________________________
Street Address
________________________________________________________________
________________________________________________________________
City State Zip Code
________________________________________________________________
Attention
________________________________________________________________
Rm, Dept., Suite, Division, etc.
________________________________________________________________
DEH40638 AN 10-2100, Rev.01, 10/20/2010
Table 1
Wire Sizes and Torque Requirements for 460 VAC Panels
Table 2
UL508 Requirement- Tightening torque
Table A
Redundant drive panel
In-Warranty Information Form
Device
AF - 600 Hp Rating(s)
Minimum Wire
Size
Maximum
Wire Size
Required Torque
NON FUSED
DISCONNECTOR AND
FUSE BLOCK
15 through 30Hp
# 14 AWG
# 4 AWG
Note 1
40 through 50Hp
# 8 AWG
1/0
Note 1
60 through 75Hp
# 8 AWG
1/0
Note 1
100 through 125Hp
# 4 AWG
300 MCM
Note 1
FUSED DISCONNECTOR
15 through 30
# 10 AWG
# 3 AWG
Note 1
40 through 50
# 14 AWG
# 2/0 AWG
Note 1
60 through 100
# 6 AWG
# 3/0 AWG
Note 1
125 through 250
# 2 AWG
# 600MCM
Note 1
Drive output power
Terminal Board
15 through 25
# 10 AWG
# 7 AWG
16 lb.in
30 through 40
# 35 AWG
# 2 AWG
40 lb.in
50 through 75
# 50 AWG
1/0
89 lb.in
100
# 95 AWG
4/0
212 lb.in
125
# 120 MCM
250MCM
212 lb.in
Power Distribution Blocks
15 through 100
# 2/0 AWG
# 14 AWG
Note 1
125
# 350 (1) MCM
# 6 (1) AWG
Note 1
125
# 2 (3) AWG
# 14 (3) AWG
Note 1
Control Terminal Board
2 through 125
# 26 AWG
# 10 AWG
Note 1
Note (1): For unmentioned torques, Refer UL508A tables in tab "UL508A" in the same excel file
Appendix B – Wire Sizes, Torque and Estimated Watt loss Details
23
Table 1
DEH40635 AN 12-1007 Rev.02, 04/04/2012
UL508 Requirement
Table 54.1 , Tightening torque for screws
Test wire size installed
in connector (AWG)
Tightening torque (lb in.)
Slotted head no 10 and large
Hexagonal head - external drive
socket wrench
Slot width - 0.047 inch
or less and slot length
1/4 inch or less
Slot width
- 0.047
inch or
slot
length -
over 1/4
inch
Split bolt connectors
other
connectors
18-10
20
35
80
75
8
25
40
80
75
6-4
35
45
165
110 3 35
50
275
150 2 40
50
275
150 1 -
50
275
150
1/0 - 2/0
-
50
385
180
3/0-4/0
-
50
500
250
250-350
-
50
650
325
400
-
50
825
375
500
-
50
825
375
600-750
-
50
1000
375
800-1000
-
50
1100
500
1250-2000
-
-
1100
600
Note : For values of slot width or length not corresponding to those specified, the largest torque
value associated with the conductor size shall be marked. Slot width is the normal design value.
Slot length shall be measured at the bottom of the slot
24
Table 2
DEH40635 AN 12-1007 Rev.02, 04/04/2012
Table 54.2 , Tightening torque for slotted head screws
smaller than No. 10 intended for use with 8 AWG or
smaller conductors
Slot length of screwa
Tightening torque, lb.in
Slot width of screwb
smaller than 0.047 in
Slot width
of screwb
0.047 in
and
larger
<5/32
7 9 5/32
7
12
3/16
7
12
7/32
7
12
1/4
9
12
9/32
-
15
Above 9/32
-
20
a
For slot length of intermediate values, torques
pertaining to next shorter length shall be utilized. For
screws with multiple tightening means, the largest
torques value associated with the conductor size shall be
marked. Slot length shall be measured
b
Slot width is the nominal design value
Table 54.3 , Tightening torque for socket
head screws
Socket size across flat
in inches
Tightening torque in
lb.in
1/8
45
5/32
100
3/16
120
7/32
150
1/4
200
5/16
275
3/8
375
1/2
500
9/16
600
25
DEH40635 AN 12-1007 Rev.02, 04/04/2012
Redundant drive panel
HP
Ratings
Estimated Watt Loss
(Watts) at
460V
15
432
20
572
25
673
30
731
40
934
50
1009
60
1258
75
1527
100
1912
125
2039
26
Table A
DEH40635 AN 12-1007 Rev.02, 04/04/2012
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