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Why is there a mains current imbalance greater than 3% in my GE Controller?
A mains current imbalance greater than 3% could be due to a problem with the mains power or with the drive unit itself. Try rotating the input power leads into the drive one position: A to B, B to C, C to A.
What causes GE Controller open power fuses or circuit breaker trip?
Open power fuses or a tripped circuit breaker can be caused by a phase-to-phase short, motor overload, or loose connections. Eliminate any shorts detected. Perform a startup test and verify the motor current is within specifications. Tighten any loose connections.
Why is my GE Controller motor not running?
If the motor isn't running, ensure the service switch is not open and the motor connection is secure. If you have a 24V DC option card, make sure mains power is applied. Also, check if the keypad stop is activated – if so, press [Auto] or [Hand] depending on your operation mode. Ensure a valid start signal is applied and the motor coast signal is deactivated. Verify the reference signal source is correctly programmed, wiring is correct, terminal scaling is accurate and reference signal is present.
Explains the manual's objective to provide technical information for repair.
Describes AF-600 FP and AF-650 GP series features and applications.
Details safety precautions and warnings for operating frequency converters.
Introduces the frequency converter's self-diagnostic and display features for troubleshooting.
Explains how to operate and program the frequency converter using the Keypad.
Divides the Keypad into four functional groups: display, menu, navigation, and operation keys.
Details the keypad display lines showing status, operating variables, and messages.
Explains the functions of Status, Quick Menu, Main Menu, and Alarm Log keys.
Describes navigation keys for programming, cursor movement, and speed control.
Details the Hand, Off, Auto, and Reset keys for local operation control.
Provides advice for optimizing operation, display contrast, and parameter management.
Outlines recommended and manual methods for restoring factory settings.
Explains status messages in the display, including operation modes and statuses.
Defines operation modes like Off, Auto, and Hand for drive control.
Explains reference sites: Remote (external signals) and Local (Keypad).
Lists and describes various operational statuses like AC Brake, Auto Tune, Braking, etc.
Details service information available via ID-## parameters, like operating hours and fault logs.
Describes how the converter receives control signals and outputs data.
Explains digital and analog input signals, including terminal connections and types.
Details output signals, including analog, digital, and Form C relay outputs.
Explains the need for programming control terminals and checking signal presence.
Lists terminal functions, associated parameters, and electrical diagrams.
Provides guidelines for correct earthing and cable routing for optimal results.
Provides an overview of the converter's assemblies and circuitry to aid technicians.
Explains the converter's function and its four main sections: rectifier, intermediate, inverter, control.
Describes the control card, microprocessor, PROM, EEPROM, and PWM generation.
Explains the interface section, power card, and gate drive card for isolating high voltage.
Details the high voltage power section, including AC input, bus bars, SCR/diode modules, and IGBTs.
Describes power flow through input terminals, fuses, SCR/diode modules, and soft charge.
Explains the role of the LC filter, DC bus inductor, capacitor banks, and HF filter cards.
Details IGBT switching, output waveforms, current sensors, and module monitoring.
Explains the function of brake IGBTs and resistors for limiting voltage and dissipating energy.
Describes the cooling fan system, activation causes, and speed control mechanisms.
Details fan speed regulation based on IGBT thermal, power card ambient, and control card temperatures.
Explains methods for connecting multiple converters for load sharing.
Details connections for external temperature switches, mains voltage, and auxiliary relays.
Provides essential tips for safe and effective troubleshooting, including power precautions.
Discusses differences in servicing new installations versus older ones and the importance of inspection.
Guides troubleshooting based on symptoms like display errors, motor issues, or alarms.
Lists items requiring visual inspection as part of initial troubleshooting.
Addresses specific fault symptoms like No Display, Intermittent Display, Motor Will not Run, Incorrect Motor Operation.
Steps to troubleshoot a completely dark display or unlit power-on LED.
Explains intermittent display issues due to overload or wiring problems.
Covers common causes for a motor not running, including keypad stops, standby, and incorrect logic.
Addresses issues like wrong speed, unstable speed, rough running, and current problems.
Explains how warnings and alarms are signalled and how to reset them.
Details specific warning and alarm codes, their descriptions, and troubleshooting steps.
Discusses parameters affecting torque control and potential issues with motor operation.
Explains causes of overvoltage trips and methods to overcome them, including dynamic brakes.
Covers monitoring phase loss via DC bus ripple voltage and its effects.
Addresses issues where the converter does not respond to commands due to signal or logic errors.
Highlights issues arising from incorrect parameter settings for motors, references, and I/O.
Discusses problems originating from the motor, wiring, or mechanical load.
Identifies common problems related to failed power components.
Explains overtemperature faults caused by blocked airflow or faulty fans.
Details the implications of open fuses and procedures for checking them.
Discusses issues indicated by overcurrent alarms or false earth fault trips due to current sensors.
Covers EMI concerns, effects, and sources in typical industrial equipment.
Lists detrimental EMI effects like motor speed fluctuations and communication errors.
Explains how IGBT switching creates high frequency EMI.
Illustrates how EMI propagates via earth currents and signal conductors.
Provides measures for alleviating EMI problems through earthing, cable routing, and selection.
Shows an example of correct installation for better immunity against EMI.
Introduces testing procedures for unit size 6x converters and safety precautions.
Lists essential and recommended tools for performing tests.
Describes the signal test board for accessing test points and troubleshooting.
Explains static tests for checking shorted power components without applied power.
Outlines tests for the rectifier module, including fuses and circuit tests.
Details testing the soft charge fuses for continuity.
Describes simultaneous testing of rectifier and soft charge circuits.
Explains static tests for inverter modules, including access to test points.
Procedures for accessing test points by removing bus bars.
Describes the first part of inverter module static testing using a meter.
Describes the second part of inverter module static testing, checking for diode drops.
Describes the third part of inverter module static testing, checking for diode drops.
Describes the fourth part of inverter module static testing, checking for infinity readings.
Explains testing the brake IGBT module for units with a dynamic brake option.
Details continuity checks for fans, fuses, transformers, and wiring.
Checks wiring between inverter modules and door fans.
Checks rectifier heat sink fan and option cabinet door fan wiring.
Checks the resistance of heat sink fans on rectifier and inverter modules.
Checks wiring for the option cabinet door fan.
Explains dynamic testing procedures to trace signal circuitry.
Describes powering the drive in split bus mode for safer dynamic testing.
Lists general warnings for dynamic testing procedures and safety precautions.
Outlines troubleshooting steps for a converter with no display.
Details measuring input line voltage and phase imbalance.
Tests voltage supplies to the control card and keypad.
Explains testing for low DC bus voltage and potential causes.
Details testing for current imbalance across input phases.
Explains testing input current and voltage waveforms using an oscilloscope.
Describes testing gate signals to IGBTs using a signal test board and oscilloscope.
Details testing IGBT switching waveforms for signs of damage.
Outlines testing current sensors for accurate readings at zero speed.
Describes testing current feedback signals using the signal test board.
Verifies presence of signals on digital and analog input terminals.
Details heatsink temperature sensor tests for the inverter module.
Covers heatsink temperature sensor and soft charge rectifier tests for the rectifier module.
Describes testing the soft charge rectifier and resistor for proper functionality.
Outlines procedures for testing after repairs or component replacement.
Provides essential safety warnings before starting module removal.
Details dangers of high voltage and capacitor discharge time before disassembly.
Emphasizes using ESD procedures to protect sensitive electronic components.
Explains interlocked cabinet doors and requirements for opening them.
Lists tools needed for module removal and testing.
Describes the use of a service shelf for supporting heavy modules during removal.
Provides instructions for removing and replacing specific components.
Details the location and removal procedure for AC line fuses in rectifier and options cabinets.
Explains how to access and remove DC link fuses from the inverter.
Provides instructions for removing and reinstalling door fans, noting airflow direction.
Details the procedure for removing and reinstalling heatsink fans.
Step-by-step instructions for removing and reinstalling the rectifier module.
Step-by-step instructions for removing and reinstalling inverter modules.
Instructions for removing and reinstalling the MDCIC mounting panel.
Details the procedure for removing and reinstalling fan transformers.
Provides instructions for removing and reinstalling the DC link inductor.
Step-by-step instructions for removing and reinstalling the MDCIC board.
Emphasizes GE training and certification for repair work.
States that only GE trained technicians should perform repairs.
Introduces the inverter module and provides an exploded view.
Shows an exploded view of the inverter module with numbered parts.
Details how to gain internal access to the inverter module.
Instructions for removing and reinstalling the power card.
Steps for removing the upper capacitor bank assembly.
Instructions for removing the lower capacitor bank assembly.
Steps for removing and reinstalling the high frequency board.
Instructions for removing and reinstalling the gate drive card.
Details the procedure for removing and reinstalling current sensors.
Instructions for removing and reinstalling the optional brake IGBT module.
Steps for removing and reinstalling the IGBT module.
Emphasizes GE training and certification for repair work.
States that only GE trained technicians should perform repairs.
Introduces the rectifier module and provides internal access instructions.
Details how to gain internal access to the rectifier module.
Instructions for removing and reinstalling the power card.
Steps for removing and reinstalling the power card mounting plate.
Instructions for removing and reinstalling the soft charge card.
Details removing and reinstalling the soft charge card mounting plate.
Steps for removing and reinstalling the soft charge resistor.
Instructions for removing and reinstalling the heatsink thermal sensor.
Details removing and reinstalling SCR modules.
Steps for removing and reinstalling the diode module.
Discusses the importance of specialized tools for troubleshooting and servicing.
Explains powering the drive in split-bus mode for safer dynamic testing.
Describes the signal test board for accessing test points and troubleshooting.
Lists pin functions, descriptions, and voltage levels for the signal test board.
Shows the top-level block diagram of the unit size 6x drive.
Provides a block diagram for the rectifier module.
Presents a block diagram for the inverter module.
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