GE Industrial Solutions AF-600 FP User Manual

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

75C (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