GE Industrial Solutions AF-60 LP User Manual
GE Consumer & Industrial
Electrical Distribution
AF-60 LP
Operating Instructions
TM
Micro Drive
Contents
AF-60 LP™ Micro Drive Operating Instructions
1 Safety
Safety Instructions 5
Software Version and Approvals 6
General Warning 7
Avoid unintended Start 7
Before Commencing Repair Work 8
2 Mechanical Installation
Before Starting 9
Mechanical Dimensions 10
3 Electrical Installation
How to Connect 11
Electrical Installation in General 11
Fuses 12
EMC-Correct Installation 13
Mains Connection 13
Motor Connection 14
5
9
11
Control Terminals 15
Connecting to Control Terminals 16
Switches 16
Power Circuit - Overview 17
Load sharing/Brake 18
4 Programming
How to Programme 19
Programming with DCT-10 Set-up Software 19
Programming with the Keypad 19
Status Menu 21
Quick Menu 21
Quick Menu Parameters 22
Main Menu 25
5 Modbus RTU
Modbus RTU Overview 27
Modbus RTU Message Framing Structure 28
19
27
Remote Terminal Unit 28
Modbus RTU Message Structure 28
Start/Stop Field 28
Address Field 29
Function Field 29
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AF-60 LP™ Micro Drive Operating Instructions
Data Field 29
CRC Check Field 29
Coil/Register Addressing 29
How to Control the frequency converter 31
Function Codes Supported by Modbus RTU 31
Exception and Error Codes 31
How to Access Parameters 32
Parameter Handling 32
Storage of Data 32
IND 32
Text Blocks 32
Conversion Factor 32
Parameter Values 32
Examples 33
Read Coil Status (01
Force/Write Single Coil (05
Force/Write Multiple Coils (0F
Read Holding Registers (03
Preset Single Register (06
Preset Multiple Registers (10
HEX
)
)
HEX
)
HEX
)
HEX
)
HEX
)
HEX
GE Drive Control Profile 37
Control Word According to GE Drive Control Profile 37
Explanation of the Control Bits 37
Status Word According to GE Drive Control Profile (STW) 39
Explanation of the Status Bits 40
Bus Speed Reference Value 41
6 Parameter Overview
Conversion Index 48
Change during operation 48
2-Set-up 48
Type 48
33
33
34
34
35
36
43
0-** Operation/Display 49
1-** Load/Motor 49
2-** Brakes 49
3-** Reference/Ramps 50
4-** Limits/Warnings 50
5-** Digital In/Out 50
6-** Analog In/Out 51
7-** Controllers 51
8-** Comm. and Options 51
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AF-60 LP™ Micro Drive Operating Instructions
13-** Logic Controller 52
14-** Special Functions 52
15-** Drive Information 52
16-** Data Readouts 53
7 Troubleshooting
Alarm, Warning and Extended Status Word 57
8 Specifications
Mains Supply 59
Other Specifications 62
Special Conditions 65
The Purpose of Derating 65
Derating for Ambient Temperature 65
Derating for Low Air Pressure 65
Derating for Running at Low Speeds 65
Options for AF-60 LP™ Micro Drive 66
Index
55
59
67
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AF-60 LP™ Micro Drive Operating Instructions
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AF-60 LP™ Micro Drive Operating Instructions
1 Safety
1.1.1 High Voltage Warning
The voltage of the frequency converter is dangerous whenever it is connected to mains. Incorrect installation of the motor or frequency
converter may cause damage to the equipment, serious injury or death. Consequently, it is essential to comply with the instructions in this
manual as well as local and national rules and safety regulations.
1.1.2 Safety Instructions
Prior to using functions directly or indirectly influencing personal safety (e.g. Fire Mode or other functions either forcing the motor to stop or
attempting to keep it functioning) a thorough risk analysis and system test must be carried through. The system tests must include testing
failure modes regarding the control signalling (analog and digital signals and serial communication.
• Make sure the frequency converter is properly connected to earth.
• Do not remove mains connections, motor connections or other power connections while the frequency converter is connected to power.
• Protect users against supply voltage.
• Protect the motor against overloading according to national and local regulations.
• The earth leakage current exceeds 3.5 mA.
• The [OFF] key is not a safety switch. It does not disconnect the frequency converter from mains.
1
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1.1.3 Software Version and Approvals
1
Operating Instructions
AF-60 LP™ Micro Drive
AF-60 LP™ Micro Drive Operating Instructions
Software Version
Series
This Operating Instructions can
be used for all AF-60 LP™ Micro
Drive frequency converters
with software version 2.1x.
The software version number
can be read in
parameter 15-43.
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1.1.4 General Warning
AF-60 LP™ Micro Drive Operating Instructions
Warning:
Touching the electrical parts may be fatal - even after the equipment has been disconnected from mains.
Also make sure that other voltage inputs have been disconnected (such as external DC bus power supplies).
Be aware that there may be high voltage on the DC link even when the LEDs are turned off.
Before touching any potentially live parts of the frequency converter, wait at least 4 minutes for all sizes.
Shorter time is allowed only if indicated on the nameplate for the specific unit.
Leakage Current
The earth leakage current from the frequency converter exceeds 3.5 mA. According to IEC 61800-5-1 a reinforced Protective Earth connection
must be ensured by means of a min. 10mm² Cu or an addtional PE wire - with the same cable cross section as the Mains wiring - must be
terminated separately.
Residual Current Device
This product can cause a DC current in the protective conductor. Where a residual current device (RCD) is used for extra protection, only an
RCD of Type B (time delayed) shall be used on the supply side of this product.
Protective earthing of the frequency converter and the use of RCDs must always follow national and local regulations.
Motor overload protection is possible by setting Parameter 1-90 Motor thermal protection to the value Electronic overload trip. For the North
American market: Electronic overload functions provide class 20 motor overload protection, in accordance with NEC.
Installation in high altitudes:
For altitudes above 2 km, please contact GE .
1
1.1.5 IT Mains
IT Mains
Installation on isolated mains source, i.e. IT mains.
Max. supply voltage allowed when connected to mains: 440 V.
As an option, GE offers line filters for improved harmonics performance.
1.1.6 Avoid unintended Start
While the frequency converter is connected to mains, the motor can be started/stopped using digital commands, bus commands, references or via the drive
Keypad.
• Disconnect the frequency converter from mains whenever personal safety considerations make it necessary to avoid unintended start of any motors.
• To avoid unintended start, always activate the [OFF] key before changing parameters.
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1.1.7 Disposal Instruction
1
1.1.8 Before Commencing Repair Work
1.
Disconnect AF-60 LP™ Micro Drive from mains (and external DC supply, if present.)
2. Wait for 4 minutes (M1, M2 and M3) and 15 minutes (M4 and M5) for discharge of the DC-link.
3. Disconnect DC bus terminals and brake terminals (if present)
4. Remove motor cable
AF-60 LP™ Micro Drive Operating Instructions
Equipment containing electrical components must not be disposed of together with domestic waste.
It must be separately collected with electrical and electronic waste according to local and currently valid legislation.
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2 Mechanical Installation
2.1 Before Starting
AF-60 LP™ Micro Drive Operating Instructions
2.1.1 Checklist
When unpacking the frequen cy converter, make sure that the unit is undam-
aged and complete. Check that the packaging contains the following:
•
AF-60 LP™ Micro Drive
•Quick Guide
2.2 Side-by-Side Installation
2
Illustration 2.1: Content of box.
The frequency converter can be mounted side-by-side for IP 20 rating units and requires 100 mm or 3.94 inclearance above and below for cooling. Regarding
surroundings in general, please see chapter 7. Specifications.
Illustration 2.2: Side-by-side installation.
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2.3.1 Mechanical Dimensions
A template for drilling can be found on the flap of the packaging.
2
Illustration 2.3: Mechanical dimensions.
AF-60 LP™ Micro Drive Operating Instructions
1)
Unit
1 X 200-240 V 3 X 200 -240 V 3 X 380-480 V A A (incl. decoupling plate) a B b C Kg
Size
M1 0.18 - 0.75 0.25 - 0.75 0.37 - 0.75 150 205 140.4 70 55 148 1.1
M2 1.5 1.5 1.5 - 2.2 176 230 166.4 75 59 168 1.6
M3 2.2 2.2 -3.7 3.0 - 7.5 239 294 226 90 69 194 3.0
M4 11.0-15.0 292 347.5 272.4 125 97 241 6.0
M5 18.5-22.0 335 387.5 315 165 140 248 9.5
1)
For Keypad with potentiometer, please add 7.6 mm.
Table 2.1: Mechanical Dimensions
Power (kW) Height (mm) Width (mm)
Depth
(mm)
Max. Weight
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3 Electrical Installation
3.1 How to Connect
3.1.1 Electrical Installation in General
AF-60 LP™ Micro Drive Operating Instructions
NB!
All cabling must comply with national and local regulations on cable cross-sections and ambient temperature. Copper conductors required, (60-75° C) recom-
mended.
Details of terminal tightening torques.
Power (kW) Torque (Nm)
Unit Size 1 x 200-240 V 3 x 200-240 V 3 x 380-480 V Line Motor DC connection/Brake Control Terminals Earth Relay
M1 0.18 - 0.75 0.25 - 0.75 0.37 - 0.75 1.4 0.7
M2 1.5 1.5 1.5 - 2.2 1.4 0.7
M3 2.2 2.2 - 3.7 3.0 - 7.5 1.4 0.7
M4 11.0-15.0 1.3 1.3 1.3 0.15 3 0.5
M5 18.5-22.0 1.3 1.3 1.3 0.15 3 0.5
1)
Spade connectors (6.3 mm Faston plugs)
Table 3.1: Tightening of terminals.
Spade
Spade
Spade
1)
1)
1)
0.15 3 0.5
0.15 3 0.5
0.15 3 0.5
3
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AF-60 LP™ Micro Drive Operating Instructions
3.1.2 Fuses
Branch circuit protection:
In order to protect the installation against electrical and fire hazard, all branch circuits in an installation, switch gear, machines etc., must be short-circuited and
overcurrent protected according to national/international regulations.
Short circuit protection:
GE Drive is suitable for a circuit capable of supplying a maximum of 100,000 A
(symmetrical), 480 V maximum.
rms
3
Overcurrent protection:
Provide overload protection to avoid overheating of the cables in the installation. Overcurrent protection must always be carried out according to national
regulations.
Non UL compliance:
If UL/cUL is not to be complied with, GE recommends using the fuses mentioned in the below table, which will ensure compliance with EN50178/IEC61800-5-1:
In case of malfunction, not following the fuse recommendation may result in damage to the frequency converter.
Max. fuses UL
Bussmann Bussmann Bussmann Littel fuse
1 X 200-240 V
Type RK1 Type J Type T Type RK1 Type CC Type RK1 Type gG
1/4 - 1/2 KTN-R15 JKS-15 JJN-15 KLN-R15 ATM-R15 A2K-15R 16A
1 KTN-R25 JKS-25 JJN-25 KLN-R25 ATM-R25 A2K-25R 25A
2 KTN-R35 JKS-35 JJN-35 KLN-R35 - A2K-35R 35A
3 KTN-R50 JKS-50 JJN-50 KLN-R50 - A2K-50R 50A
3 x 200-240 V
1/3 KTN-R10 JKS-10 JJN-10 KLN-R10 ATM-R10 A2K-10R 10A
1/2 KTN-R15 JKS-15 JJN-15 KLN-R15 ATM-R15 A2K-15R 16A
1 KTN-R20 JKS-20 JJN-20 KLN-R20 ATM-R20 A2K-20R 20A
2 KTN-R25 JKS-25 JJN-25 KLN-R25 ATM-R25 A2K-25R 25A
3 KTN-R40 JKS-40 JJN-40 KLN-R40 ATM-R40 A2K-40R 40A
5 KTN-R40 JKS-40 JJN-40 KLN-R40 - A2K-40R 40A
3 x 380-480 V
1/2 - 1 KTS-R10 JKS-10 JJS-10 KLS-R10 ATM-R10 A6K-10R 10A
2 KTS-R15 JKS-15 JJS-15 KLS-R15 ATM-R15 A2K-15R 16A
3 KTS-R20 JKS-20 JJS-20 KLS-R20 ATM-R20 A6K-20R 20A
4 KTS-R40 JKS-40 JJS-40 KLS-R40 ATM-R40 A6K405R 40A
5 KTS-R40 JKS-40 JJS-40 KLS-R40 ATM-R40 A6K-40R 40A
7.5 KTS-R40 JKS-40 JJS-40 KLS-R40 - A6K-40R 40A
10 KTS-R40 JKS-40 JJS-40 KLS-R40 - A6K-40R 40A
15 KTS-R60 JKS-60 JJS-60 KLS-R60 - A6K-60R 63A
20 KTS-R60 JKS-60 JJS-60 KLS-R60 - A6K-60R 63A
25 KTS-R60 JKS-60 JJS-60 KLS-R60 - A6K-60R 80A
30 KTS-R60 JKS-60 JJS-60 KLS-R60 - A6K-60R 80A
Table 3.2: Fuses
Ferraz-
Shawmut
Ferraz-
Shawmut
Max. fuses non UL
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AF-60 LP™ Micro Drive Operating Instructions
3.1.3 EMC-Correct Installation
Following these guidelines is advised, where compliance with EN 61000-6-3/4, EN 55011 or EN 61800-3 First environment is required. If the installation is in EN
61800-3 Second environment, then it is acceptable to deviate from these guidelines. It is however not recommended.
Good engineering practice to ensure EMC-correct electrical installation:
• Use only braided screened/armoured motor cables and control cables.
The screen should provide a minimum coverage of 80%.The screen material must be metal, not limited to but typically copper, aluminium, steel or lead.
There are no special requirements for the mains cable.
• Installations using rigid metal conduits are not required to use screened cable, but the motor cable must be installed in conduit separate from the control
and mains cables. Full connection of the conduit from the drive to the motor is required. The EMC performance of flexible conduits varies a lot and
information from the manufacturer must be obtained.
• Connect the screen/armour/conduit to earth at both ends for motor cables and control cables.
• Avoid terminating the screen/armour with twisted ends (pigtails). Such a termination increases the high frequency impedance of the screen, which
reduces its effectiveness at high frequencies. Use low impedance cable clamps or glands instead.
• Ensure good electrical contact between the de-coupling plate and the metal chassis of the frequency converter, see Instruction
• Avoid using unscreened/unarmoured motor or control cables inside cabinets housing the drive(s), where possible.
3.2 Mains Connection
3
3.2.1 Connecting to Mains
Step 1: First mount earth cable.
Step 2: Mount wires in terminals L1/L, L2 and L3/N and tighten.
For 3-phase connection, connect wires to all three terminals.
For single-phase connection, connect wires to terminals L1/L and L3/N.
Illustration 3.1: Mounting of earth cable and mains wires.
Illustration 3.2: Three-phase and single-phase wire connec-
tions.
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3.3 Motor Connection
3.3.1 How to Connect the Motor
See the chapter Specifications for correct dimensioning of motor cable cross-section and length.
• Use a shielded/armored motor cable to comply with EMC emission specifications, and connect this cable to both the decoupling plate and the motor
3
metal.
• Keep motor cable as short as possible to reduce the noise level and leakage currents.
All types of three-phased asynchronous standard motors can be connected
to the frequency converter. Normally, small motors are star-connected
(230/400 V, Δ/Y). Large motors are delta-connected (400/690 V, Δ/Y). Refer to
motor nameplate for correct connection and voltage.
AF-60 LP™ Micro Drive Operating Instructions
Step 1: First, mount the earth cable.
Step 2: Connect wires to terminals either in star or delta-connection. See mo-
tor nameplate for further information.
Illustration 3.3: Star and delta connections.
Illustration 3.4: Mounting of earth cable and motor wires.
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For EMC correct installation, use optional de-coupling plate, see chapter Op-
tions for frequency converter.
3.4 Control Terminals
3.4.1 Access to Control Terminals
All control cable terminals are located underneath the terminal cover in front
of the frequency converter. Remove the terminal cover using a screwdriver.
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3
Illustration 3.5: Frequency converter with de-coupling plate
NB!
See back of terminal cover for outlines of control terminals and switches.
Illustration 3.6: Removing terminal cover.
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AF-60 LP™ Micro Drive Operating Instructions
3.4.2 Connecting to Control Terminals
This illustration shows all control terminals of the frequency converter. Applying Start (term. 18) and an analog reference (term. 53 or 60) make the frequency
converter run.
3
Illustration 3.7: Overview of control terminals in PNP-configuration and factory setting.
3.5 Switches
NB!
Do not operate switches with power on the frequency converter.
Bus termination:
Switch BUS TER pos. ON terminates the RS485 port, terminals 68, 69. See
power circuit drawing.
Default setting = Off.
S200 Switches 1-4:
Switch 1: *OFF = PNP terminals 29
ON = NPN terminals 29
Switch 2: *OFF = PNP terminal 18, 19, 27 and 33
ON = NPN terminal 18, 19, 27 and 33
Switch 3: No function
Switch 4: *OFF = Terminal 53 0 - 10 V
ON = Terminal 53 0/4 - 20 mA
* = default setting
Table 3.3: Settings for S200 Switches 1-4
Illustration 3.8: S640 Bus termination.
Illustration 3.9: S200 Switches 1-4.
16
NB!
Parameter 6-19 must be set according to Switch 4 position.
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3.6 Power Circuit - Overview
3.6.1 Power Circuit - Overview
AF-60 LP™ Micro Drive Operating Instructions
3
Illustration 3.10: Diagram showing all electrical terminals.
* Brake (BR+ and BR-) are not applicable for Unit Size M1.
Brake resistors are available from GE.
Improved power factor and EMC performance can be achieved by installing optional GE line filters.
GE power filters can also be used for load sharing.
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3.6.2 Load sharing/Brake
Use 6.3 mm insulated Faston Plugs designed for high voltage for DC (Load Sharing and brake).
Load sharing: Connect terminals UDC- and UDC/BR+.
Brake: Connect terminals BR- and UDC/BR+ (Not applicable for Unit Size M1).
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3
Note that voltage levels of up to 850 V DC may occur between terminals
UDC+/BR+ and UDC-. Not short circuit protected.
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AF-60 LP™ Micro Drive Operating Instructions
4 Programming
4.1 How to Programme
4.1.1 Programming with DCT-10 Set-up Software
The frequency converter can be programmed from a PC via RS485 com-port by installing the DCT-10 Set-up Software.
This software can be downloaded from the GE Web site: www.geelectrical.com/drives
4.1.2 Programming with the Keypad
The Keypad is divided into four functional groups:
1. Numeric display.
2. Menu key.
3. Navigation keys.
4. Operation keys and indicator lights (LEDs).
NB!
Parameters should be changed in numerical order. Certain parameter values are affected by preceding changes.
4
Illustration 4.1: Keypad with potentiometer
The display:
A number of information can be read from the display.
Set-up number shows the active set-up and the edit set-up. If the same set-
up acts as both active and edit set-up, only that set-up number is shown
(factory setting).
When active and edit set-up differ, both numbers are shown in the display
(Setup 12). The number flashing, indicates the edit set-up.
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Illustration 4.2: Indicating Set-up
19
The small digits to the left are the selected parameter number.
The large digits in the middle of the display show the value of the selected
parameter.
4
The right side of the display shows the unit of the selected parameter. This
can be either Hz, A, V, kW, HP, %, s or RPM.
AF-60 LP™ Micro Drive Operating Instructions
Illustration 4.3: Indicating selected par. no.
Illustration 4.4: Indicating value of selected par.
Illustration 4.5: Indicating unit of selected par.
Motor direction is shown to the bottom left of the display - indicated by a
small arrow pointing either clockwise or counterclockwise.
Illustration 4.6: Indicating motor direction
Use the [MENU] key to select one of the following menus:
Status Menu:
The Status Menu is either in Readout Mode or Hand Mode. In Readout Mode the value of the currently selected readout parameter is shown in the display.
In Hand Mode the local Keypad reference is displayed.
Quick Menu:
Displays Quick Menu parameters and their settings. Parameters in the Quick Menu can be accessed and edited from here. Most applications can be run by setting
the parameters in the Quick Menus.
Main Menu:
Displays Main Menu parameters and their settings. All parameters can be accessed and edited here. A parameter overview is found later in this manual.
Indicator lights:
• Green LED: The frequency converter is on.
• Yellow LED: Indicates a warning. Please see section Troubleshooting
• Flashing red LED: Indicates an alarm. Please see section Troubleshooting
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AF-60 LP™ Micro Drive Operating Instructions
Navigation Keys:
[Back]: For moving to the previous step or layer in the navigation structure.
Arrows [
[OK]: For selecting a parameter and for accepting changes to parameter settings.
Operation Keys:
A yellow light above the operation keys indicates the active key.
[Hand ]: Starts the motor and enables control of the frequency converter via the Keypad.
[Off/Reset]: The motor stops except in alarm mode. In that case the motor will be reset.
[Auto ]: The frequency converter is controlled either via control terminals or serial communication.
[Potentiometer] Keypad: The potentiometer works in two ways depending on the mode in which the frequency converter is running.
In Auto Mode the potentiometer acts as an extra programmable analog input.
In Hand Mode the potentiometer controls local reference.
] [▼]: For maneuvering between parameter groups, parameters and within parameters.
▲
4.2 Status Menu
After power up the Status Menu is active. Use the [MENU] key to toggle be-
tween Status, Quick Menu and Main Menu.
4
Arrows [
The display indicates the status mode with a small arrow above “Status”.
] and [▼] toggles between the choices in each menu.
▲
4.3 Quick Menu
The Quick Menu gives easy access to the most frequently used parameters.
1. To enter the Quick Menu, press [MENU] key until indicator in display
is placed above Quick Menu.
2.
3.
4. Press [OK] to select a parameter.
5.
6. Press [OK] to accept the change.
7. To exit, press either [Back] twice to enter Status, or press [Menu]
] [▼] to select either QM1 or QM2, then press [OK].
Use [
▲
Use [
] [▼] to browse through the parameters in the Quick Menu.
▲
] [▼] to change the value of a parameter setting.
Use [
▲
once to enter Main Menu.
Illustration 4.7: Indicating Status mode
Illustration 4.8: Indicating Quick Menu mode
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