GE AF-650 GP Series Guida

GE Consumer & Industrial

Electrical Distribution

AF-650 GPTM

General Purpose Drive

Design Guide

The instructions do not purport to cover all details or variations in equipment nor to provide for every possible

contingency to be met in connection with installation, operation or maintenance. Should further information be

desired or should particular problems arise which are not covered sufficiently for the purchaser’s purposes, the

matter should be referred to the GE company.

AF-650 GP is a trademark of the General Electric Company.

GE Consumer & Industrial

41 Woodford Avenue

Plainville, CT 06062

www.geelectrical.com/drives

130R0361 *MG34H102* DET-618

Contents

1 How to Read this Design Guide

How to Read this Design Guide 5

Symbols 5

Abbreviations 6

Definitions 6

2 Safety and Conformity

Safety Precautions 11

Aggressive Environments 14

3 Introduction to AF-650 GP

Product Overview 15

Control Principle 17

AF-650 GP Controls 17

Control Structure in Advanced Vector Control 18

Control Structure in Flux Sensorless 19

Control Structure in Flux with Motor Feedback 20

Internal Current Control in Advanced Vector Control Mode 20

Local (Hand) and Remote (Auto) Control 21

Reference Limits 23

Scaling of Preset References and Bus References 23

Scaling of Analog and Pulse References and Feedback 24

Dead Band Around Zero 24

Speed PID Control 27

Process PID Control 30

Ziegler Nichols Tuning Method 34

EMC Test Results 36

PELV - Protective Extra Low Voltage 38

Brake Functions in AF-650 GP 40

Mechanical Holding Brake 40

Dynamic Braking 40

Selection of Brake Resistor 40

Mechanical Brake Control 43

Hoist Mechanical Brake 44

Safe Stop of AF-650 GP 48

4 AF-650 GP Selection

Electrical Data - 200-240 V 53

Electrical Data - 380-480 V 55

Electrical Data - 525-600 V 61

Electrical Data - 525-690 V 64

AF-650 GP Design Guide

General Specifications 71

Acoustic Noise 77

du/dt Conditions 77

Special Conditions 81

Automatic Tuning to Ensure Performance 88

5 Mechanical Installation - Unit Sizes 1, 2 and 3

6 Mechanical Installation - Unit Size 4, 5 and 6

Pre-installation 93

Planning the Installation Site 93

Receiving the Frequency Converter 93

Transportation and Unpacking 93

Lifting 94

Mechanical Dimensions 96

Mechanical Installation 103

Terminal Locations - Unit Size 4X 105

Terminal Locations - Unit Size 5X 106

Terminal Locations - Unit Sizes 6X 108

Cooling and Airflow 111

7 Electrical Installation

117

Connections- Unit Sizes 1x, 2x and 3x 117

Connection to Mains and Earthing 118

Motor Connection 121

Relay Connection 124

Connections - Unit Sizes 4, 5 and 6 125

Power Connections 125

Fuses 133

Disconnectors, Circuit Breakers and Contactors 140

Motor Bearing Currents 141

Control Cables and Terminals 141

Control Cable Routing 142

Control Terminals 143

Switches S201, S202, and S801 144

Electrical Installation, Control Terminals 145

Basic Wiring Example 146

Electrical Installation, Control Cables 147

Additional Connections 149

How to Connect a PC to the Frequency Converter 151

The AF-650 GP PC Software 151

Residual Current Device 156

AF-650 GP Design Guide

Final Setup and Test 157

8 Application Examples

159

Encoder Connection 160

Encoder Direction 160

Closed Loop Drive System 161

Programming of Torque Limit and Stop 161

Advanced Mechanical Brake Control for Hoisting Applications 162

Auto Tune 163

Logic Controller Programming 163

LC Application Example 164

Torque Control Open Loop 165

9 Options and Accessories

167

Mounting of Option Modules in Slot A 167

Mounting of Option Modules in Slot B 167

General Purpose Input Output Module OPCGPIO 168

OPCENC Encoder Option Module 171

OPCRES Resolver Option Module 173

OPCRLY Relay Option Module 174

OPC24VPS 24V DC External Supply Module 176

Brake Resistors 177

Remote Mounting Kit for Keypad 177

IP21/IP 4X/ TYPE 1 Unit Kit 179

Sine-wave Filters 180

10 RS-485 Installation and Set-up

181

RS-485 Installation and Set-up 181

Network Configuration 183

Drive Protocol Message Framing Structure - AF-650 GP 183

Examples 188

Modbus RTU Overview 190

Modbus RTU Message Framing Structure 191

How to Access Parameters 195

GE Drive Control Profile 196

Index

206

AF-650 GP Design Guide

1 How to Read this Design Guide

1.1.1 How to Read this Design Guide

This Design Guide will introduce all aspects of your AF-650 GP.

Available literature for AF-650 GP

-The AF-650 GP Operating Instructions DET-607 provide the neccessary information for getting the drive up and running.

-The AF-650 GP High Power Operating Instructions DET-608

-The AF-650 GP Design Guide DET-619 entails all technical information about the drive and customer design and applications.

-The AF-650 GP Programming Guide DET-618 provides information on how to programme and includes complete parameter descriptions.

-The AF-650 GP Profibus Operating Instructions DET-629 provide the information required for controlling, monitoring and programming the drive via a

Profibus network.

-The AF-650 GP DeviceNet Operating Instructions DET-623 provide the information required for controlling, monitoring and programming the drive via

a DeviceNet network.

GE technical literature is also available online at www.geelectrical.com/drives

1.1.2 Symbols

Symbols used in this guide.

NB!

Indicates something to be noted by the reader.

Indicates a general warning.

Indicates a high-voltage warning.

*Indicates default setting

AF-650 GP Design Guide

1.1.3 Abbreviations

Alternating current AC

American wire gauge AWG

Ampere/AMP A

Current limit ILIM

Degrees Celsius °C

Direct current DC

Drive Control Tool PC Software DCT 10

Drive Dependent D-TYPE

Electro Magnetic Compatibility EMC

Electronic Thermal Overload Elec. OL

Gram g

Hertz Hz

Kilohertz kHz

Meter m

Millihenry Inductance mH

Milliampere mA

Millisecond ms

Minute min

Nanofarad nF

Newton Meters Nm

Nominal motor current IM,N

Nominal motor frequency fM,N

Nominal motor power PM,N

Nominal motor voltage UM,N

Parameter par.

Protective Extra Low Voltage PELV

Printed Circuit Board PCB

Rated Inverter Output Current IINV

Revolutions Per Minute RPM

Regenerative terminals Regen

Second s

Synchronous Motor Speed ns

Torque limit TLIM

Volts V

1.1.4 Definitions

Frequency converter:

Coast

The motor shaft is in free mode. No torque on motor.

IDRIVE,MAX

The maximum output current.

IDRIVE,N

The rated output current supplied by the frequency converter.

UDRIVE, MAX

The maximum output voltage.

Input:

Control command

Start and stop the connected motor by means of Keypad and the digital in-

puts.

Functions are divided into two groups.

Functions in group 1 have higher priority than functions in group 2.

Group 1 Reset, Coasting stop, Reset and Coasting stop,

Quick-stop, DC braking, Stop and the "Off" key.

Group 2 Start, Pulse start, Reversing, Start reversing,

Jog and Freeze output

Motor:

fJOG

The motor frequency when the jog function is activated (via digital terminals).

AF-650 GP Design Guide

Motor frequency. Output from the frequency converter. Output frequency is related to the shaft speed on motor depending on number of poles and slip frequency.

fMAX

The maximum output frequency the frequency converter applies on its output. The maximum output frequency is set in limit par. F-16, F-17 and F-03.

fMIN

The minimum motor frequency from frequency converter. Default 0 Hz.

fM,N

The rated motor frequency (nameplate data).

The motor current.

IM,N

The rated motor current (nameplate data).

nM,N

The rated motor speed (nameplate data).

Synchronous motor speed

=2×

par

−04 × 60

par

−01

PM,N

The rated motor power (nameplate data).

TM,N

The rated torque (motor).

The instantaneous motor voltage.

UM,N

The rated motor voltage (nameplate data).

Break-away torque

DRIVE

The efficiency of the frequency converter is defined as the ratio between the power output and the power input.

Start-disable command

A stop command belonging to the group 1 control commands - see this group.

AF-650 GP Design Guide

Stop command

See Control commands.

References:

Advanced Vector Control

If compared with standard voltage/frequency ratio control, Adv. Vector Control) improves the dynamics and the stability, both when thespeed reference is changed

and in relation to the load torque.

Analog Reference

An analog signal applied to input 53 or 54. The signal can be either Voltage 0-10V or -10 -+10V. Current signal 0-20 mA or 4-20 mA.

Binary Reference

A signal applied to the serial communication port (RS 485 term 68 – 69).

Preset Reference

A defined preset reference to be set from -100% to +100% of the reference range. Selection of eight preset references via the digital terminals.

Pulse Reference

A pulse reference applied to term 29 or 33, selected by par. E-04 or E-06 [32]. Scaling in par. group E-6#.

RefMAX

Determines the relationship between the reference input at 100% full scale value (typically 10 V, 20mA) and the resulting reference. The maximum reference value

set in par. F-53 Maximum Reference.

RefMIN

Determines the relationship between the reference input at 0% value (typically 0V, 0mA, 4mA) and the resulting reference. The minimum reference value set in

par. F-52 Minimum Reference.

Miscellaneous:

Analog Inputs

The analog inputs are used for controlling various functions of the frequency converter.

There are two types of analog inputs:

Current input, 0-20 mA and 4-20 mA

Voltage input, 0-10 V DC

Voltage input, -10 - +10 V DC.

Analog Outputs

The analog outputs can supply a signal of 0-20 mA, 4-20 mA.

Auto Tuning

The Auto Tune algorithm determines the electrical parameters for the connected motor at standstill.

Brake Resistor

The brake resistor is a module capable of absorbing the brake power generated in regenerative braking. This regenerative braking power increases the intermediate

circuit voltage and a brake chopper ensures that the power is transmitted to the brake resistor.

CT Characteristics

Constant torque characteristics used for all applications such as conveyor belts, displacement pumps and cranes.

Digital Inputs

The digital inputs can be used for controlling various functions of the frequency converter.

Digital Outputs

The frequency converter features two Solid State outputs that can supply a 24 V DC (max. 40 mA) signal.

DSP

Digital Signal Processor.

Electronic Thermal Overload

The Electronic Overload is a thermal load calculation based on present load and time. Its purpose is to estimate the motor temperature.

Hiperface®

Hiperface®is a registered trademark by Stegmann.

Intermittent Duty Cycle

An intermittent duty rating refers to a sequence of duty cycles. Each cycle consists of an on-load and an off-load period. The operation can be either periodic duty

or non-periodic duty.

AF-650 GP Design Guide

Keypad

The Keypad makes up a complete interface for control and programming of the frequency converter. The Keypad is detachable and can be installed up to 10ft/

3M from the frequency converter, i.e. in a front panel with the optional Remote Keypad Mounting Kit (RMKYPDAC)..

Logic Controller (LC)

The LC is a sequence of user defined actions executed when the associated user defined events are evaluated as true by the Logic Controller. (Parameter group

LC-##).

lsb

Least significant bit.

msb

Most significant bit.

MCM

Short for Mille Circular Mil, an American measuring unit for cable cross-section. 1 MCM = 0.5067 mm2.

On-line/Off-line Parameters

Changes to on-line parameters are activated immediately after the data value is changed. Changes to off-line parameters are not activated until you enter [OK]

on the Keypad.

Process PID

The PID regulator maintains the desired speed, pressure, temperature, etc. by adjusting the output frequency to match the varying load.

PCD

Process Data

Pulse Input/Incremental Encoder

An external digital sensor used for feedback information of motor speed and direction. Encoders are used for high speed accuracy feedback and in high dynamic

applications. The encoder connection is either via term 32 and 32 or encoder option OPCENC.

RCD

Residual Current Device.

Set-up

You can save parameter settings in four Set-ups. Change between the four parameter Set-ups and edit one Set-up, while another Set-up is active.

SFAVM

Switching pattern called Stator Flux oriented Asynchronous Vector Modulation (par. F-37 Adv. Switching Pattern).

Slip Compensation

The frequency converter compensates for the motor slip by giving the frequency a supplement that follows the measured motor load keeping the motor speed

almost constant..

STW

Status Word

Drive Standard Bus

Includes RS 485 bus with Drive protocol or MC protocol. See par. O-30 Protocol.

Thermistor:

A temperature-dependent resistor placed where the temperature is to be monitored (frequency converter or motor).

THD

Total Harmonic Distortion state the total contribution of harmonic.

Trip

A state entered in fault situations, e.g. if the frequency converter is subject to an over-temperature or when the frequency converter is protecting the motor,

process or mechanism. Restart is prevented until the cause of the fault has disappeared and the trip state is cancelled by activating reset or, in some cases, by

being programmed to reset automatically. Trip may not be used for personal safety.

Trip Locked

A state entered in fault situations when the frequency converter is protecting itself and requiring physical intervention, e.g. if the frequency converter is subject

to a short circuit on the output. A locked trip can only be cancelled by cutting off mains, removing the cause of the fault, and reconnecting the frequency converter.

Restart is prevented until the trip state is cancelled by activating reset or, in some cases, by being programmed to reset automatically. Trip may not be used for

personal safety.

AF-650 GP Design Guide