1. Manuals
  2. Brands
  3. Allen-Bradley Manuals
  4. Controller
  5. PowerFlex AFE
  6. Hardware service manual

Allen-Bradley PowerFlex AFE Hardware Service Manual

Powerflex active front end – afe frame 10 system
Hide thumbs
Table of Contents

Quick Links

Hardware Service Manual
Original Instructions
PowerFlex Active Front End – Frame 10
Catalog Number 20Y
PowerFlex AFE/PowerFlex 700AFE
(400V/480V and 600V/690V)
Table of Contents
loading

Related Manuals for Allen-Bradley PowerFlex AFE

Summary of Contents for Allen-Bradley PowerFlex AFE

  • Page 1 Hardware Service Manual Original Instructions PowerFlex Active Front End – Frame 10 Catalog Number 20Y PowerFlex AFE/PowerFlex 700AFE (400V/480V and 600V/690V)
  • Page 2 Important User Information Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.

  • Page 3: Table Of Contents

    Table of Contents Preface Summary of Changes ......... . . 7 Intended Audience .
  • Page 4 Table of Contents Remove the I/O Circuit Boards and Control Board ..39 Install the I/O Circuit Boards and Control Board ... . 40 Remove the Fiber-optic Adapter Circuit Board .
  • Page 5 Table of Contents Chapter 7 LCL Filter Component Section Remove the LCL Filter Protective Barrier ..... . . 74 Install the LCL Filter Protective Barrier ......74 Replace the LCL Filter DC Fan Fuses .
  • Page 6 Table of Contents Appendix E AFE Power One-line System Data to Collect..........129 Typical Transformer Winding Types .

  • Page 7: Preface

    Preface Summary of Changes This manual contains new and updated information as indicated in the following table. Topic Page Updated the basic one-line diagram for a Frame 10 AFE in IP20 2500 MCC style Figure 1 on page 19 enclosure to include the factory-installed common mode core at the DC bus output. Updated the system schematics for a Frame 10 AFE in IP20 2500 MCC style enclosure to Figure 19 on page 96 include the factory-installed common mode core at the DC bus output.

  • Page 8: Additional Resources

    You can view or download publications at http://www.rockwellautomation.com/global/literature-library/overview.page. To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative. Spare Parts For spare parts information on PowerFlex 7-Class Architecture-Class Low-Voltage AC Drives, including the PowerFlex Active Front End, click this link: http://www.ab.com/support/abdrives/powerflex70/PF7ReleasedParts.pdf.

  • Page 9: General Precautions For Class 1 Light-Emitting Diode Product

    Preface General Precautions for Class ATTENTION: Hazard of permanent eye damage exists when using optical 1 Light-emitting Diode transmission equipment. This product emits intense light and invisible Product radiation. Do not look into module ports or fiber-optic cable connectors. ATTENTION: The sheet metal cover and mounting screws on the ASIC Board that is on the power structure are energized at (-) DC bus potential high voltage.
  • Page 10 Preface Notes: Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...
  • Page 11 Chapter Troubleshooting and Error Codes ATTENTION: To avoid an electric shock hazard, verify that all power to the PowerFlex® Active Front End has been removed before you perform any service or repairs. ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged completely before servicing.

  • Page 12: Create Fault Reports

    Create Fault Reports Complete fault reports are critical for analysis and repair of modules that are returned to the factory. At a minimum, perform these tasks: • Use an Allen-Bradley® drive configuration tool, such as Connected ™ ™ Components Workbench...
  • Page 13 Troubleshooting and Error Codes Chapter 1 Name Description Action (if appropriate) DC OverVolt The DC bus voltage exceeded the Check if the AFE was in a regenerative maximum value of 911V for 400/480V current limit condition, which can units, or 1200V for 600/690V units. indicate an excess regenerative load.
  • Page 14 Chapter 1 Troubleshooting and Error Codes Name Description Action (if appropriate) Anlg In Loss An analog input is configured to fault Verify parameter 203 or 206 [Anlg In x on a signal loss. A signal loss has Loss] setting. Verify that input signal occurred.
  • Page 15 Troubleshooting and Error Codes Chapter 1 Name Description Action (if appropriate) Port DPI Loss The DPI port has stopped Check the HIM connection. communicating. A SCANport™ device If the adapter was not intentionally was connected to a drive operating DPI disconnected, check the wiring to the devices at 500k baud.
  • Page 16 Chapter 1 Troubleshooting and Error Codes Name Description Action (if appropriate) LCL OverTemp The LCL filter has been overheated or Check the LCL filter and signal the signal is not connected to input. connection or verify that digital input 5 is closed.

  • Page 17: Common Symptoms And Corrective Actions

    Troubleshooting and Error Codes Chapter 1 Common Symptoms and AFE does not start from start, or run inputs that are wired to the terminal block. Corrective Actions Cause Indication Corrective Action AFE is faulted Flashing red status light Clear the fault. Press Stop.
  • Page 18 Chapter 1 Troubleshooting and Error Codes Notes: Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...

  • Page 19: Afe In Ip20 2500 Mcc Style Enclosure

    Chapter Active Front End System Overview This chapter describes AFE system main components. The chapter groups components that are used in an IP20 2500 MCC Style enclosure, an IP21Rittal enclosure, and main components for the AFE IP00 open chassis configuration. AFE in IP20 2500 MCC Style Main Component Sections Enclosure...

  • Page 20: Main Component Locations

    Chapter 2 Active Front End System Overview Main Component Locations Figure 2 shows the main components of the AFE Frame 10 system in an IP20 2500 MCC Style enclosure. Figure 2 - AFE Frame 10 Main Component Locations in IP20 2500 MCC Style Enclosure Front View Front View (shown with enclosure doors closed)

  • Page 21: Main Bus Bar/Cable Locations

    Active Front End System Overview Chapter 2 Main Bus Bar/Cable Locations There are several sets of bus bar/cables in the AFE Frame 10 system that connect main system components: • Bus cables between input breaker (Q0) and AC fuses (F1.1…F1.3) •...

  • Page 22: Afe In Ip21 Rittal Enclosure

    Chapter 2 Active Front End System Overview AFE in IP21 Rittal Enclosure Main Component Sections Figure 4 shows a basic one-line diagram for an AFE system in an IP21 Rittal enclosure. The main component sections consist of the following items: •...

  • Page 23: Main Component Locations

    Active Front End System Overview Chapter 2 Main Component Locations Figure 5 shows the main components of the AFE Frame 10 system in an IP21 Rittal enclosure. Figure 5 - AFE Frame 10 Main Component Locations in IP21 Rittal Enclosure Front View (shown with enclosure doors removed) Item...

  • Page 24: Bus Bar Locations

    Chapter 2 Active Front End System Overview Bus Bar Locations There are several sets of bus bars in the AFE Frame 10 system that connect main system components: • Bus bars between input disconnect (Q0) and MCCB (Q1) • Bus bars between MCCB (Q1) and the LCL filter (L1) •...

  • Page 25: Afe In Ip00 Open Chassis Configuration

    Active Front End System Overview Chapter 2 AFE in IP00 Open Chassis Figure 7 shows a basic one-line diagram for an AFE system in an IP00, NEMA/UL open chassis configuration, and the parts the customer must Configuration supply. Figure 7 - Basic One-line Diagram for AFE in IP00 Open Chassis Configuration AC Line Switchgear LCL Filter (L1) Power Structure (U1)
  • Page 26 Chapter 2 Active Front End System Overview Notes: Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...
  • Page 27 Chapter Component Test Procedures ATTENTION: The sheet metal cover and mounting screws on the ASIC Board that is on the power structure are energized at (-) DC bus potential high voltage. Risk of electrical shock, injury, or death exists if someone comes into contact with the assembly.

  • Page 28: View The Status Indicators

    Chapter 3 Component Test Procedures View the Status Indicators This section describes the status indicators. Table 1 - AFE Status Indicator Descriptions Item Name Color State Description PWR (power) Green Steady Illuminates when power is applied to the AFE. PORT See the Communication Adapter Status of DPI™...

  • Page 29: Inspect The Power Structure

    Component Test Procedures Chapter 3 Inspect the Power Structure To inspect the power structure, follow these steps. 1. Remove the protective barriers. Remove AFE Protective Barriers on page 2. Remove the protective front cover and terminal cover from the power structure.
  • Page 30 Chapter 3 Component Test Procedures 2. Remove the protective barriers. Remove AFE Protective Barriers on page 3. Disconnect any drives that are connected to the DC bus from the DC bus, or remove the DC bus fuses from the AFE. 4.

  • Page 31: Check Fiber-Optic Connections

    Component Test Procedures Chapter 3 Table 3 - Reverse Biased Diode Tests on Power Structure Meter Leads Nominal Meter Reading U/T1 Meter displays ‘ . 0L’ (zero load) V/T2 W/T3 U/T1 V/T2 W/T3 If the AFE fails any of these measurements, replace the power module in the power structure, or the complete power structure.
  • Page 32 Chapter 3 Component Test Procedures Gate Driver Board ASIC Board 5. Verify that the fiber-optic cables are properly connected between the gate driver board and the ASIC board. IMPORTANT The minimum inside bend radius for fiber-optic cable is 25.4 mm (1 in.).

  • Page 33: Perform Gate Driver Board Resistance Measurements

    Component Test Procedures Chapter 3 Perform Gate Driver Board To perform the gate driver board resistance measurements, follow these steps. Resistance Measurements 1. Remove power from the AFE. Remove Power from the AFE on page 2. If present, remove the protective barriers. Remove AFE Protective Barriers on page 3.

  • Page 34: Check The Afe Power Structure Fan Inverter Fuses

    Chapter 3 Component Test Procedures Check the AFE Power To check the AEF power structure fan inverter fuse, follow these steps. Structure Fan Inverter Fuses 1. Remove power from the AFE. Remove Power from the AFE on page 2. If present, remove the protective barriers. Remove AFE Protective Barriers on page 3.
  • Page 35 Chapter AFE Power Structure Component Section ATTENTION: To avoid an electric shock hazard, verify that all power to the PowerFlex® Active Front End has been removed before you perform any service or repairs. ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged completely before servicing.

  • Page 36: Understand Torque Figures In Assembly Diagrams

    Chapter 4 AFE Power Structure Component Section Understand Torque Figures in Icons and numbers in the assembly diagrams indicate how to tighten hardware. Assembly Diagrams Tool Type and Size: Fastener Type • PZ indicates Pozidriv screwdriver bit. • P indicates Phillips screwdriver bit. Pozidriv screw Phillips screw Hexagonal bolt or...

  • Page 37: Remove Power From The Afe

    AFE Power Structure Component Section Chapter 4 Item Hardware Final Torque Motor output terminals on power M8 x 20 hexagonal screws 20 N•m (177 lb•in) structure Power structure output terminals (U, V, M8 x 20 hexagonal screws 14 N•m (124 lb•in) Power structure block (mounting) M10 x 12 hexagonal screws 20 N•m (177 lb•in)

  • Page 38: Control Frame Access Procedures

    Chapter 4 AFE Power Structure Component Section Control Frame Access Remove the DPI Interface Assembly Procedures To remove the DPI interface assembly, follow these steps. 1. Remove power from the AFE. Remove Power from the AFE on page IMPORTANT Before you remove the connections and wires, mark them to avoid incorrect wiring during assembly.

  • Page 39: Install The Dpi Interface Assembly

    AFE Power Structure Component Section Chapter 4 For AFE in IP20 2500 MCC For AFE in IP21 Rittal Style Enclosure Enclosure Door (with DPI interface board Mounting Screws Mounting Screws and HIM) in open position. 0.9 N•m 0.9 N•m (8 lb•in) (8 lb•in) Install the DPI Interface Assembly Install the DPI interface assembly in the reverse order of removal.

  • Page 40: Install The I/O Circuit Boards And Control Board

    Chapter 4 AFE Power Structure Component Section 4. Unplug the serial connection from X7 of the control board. Serial Port (Slot A) 5. Remove the three screws that secure the control board to the control box, and remove the control board. Important: Do not remove the enclosure cover from the control frame.
  • Page 41 AFE Power Structure Component Section Chapter 4 For an AFE in an IP21 Rittal enclosure, do the following: a. To access the control frame, open the enclosure door. b. To open the control frame, loosen the T8 screws. c. Open the control frame, which exposes the back of the control box to access the fiber-optic adapter board.

  • Page 42: Install The Fiber-Optic Adapter Circuit Board

    Chapter 4 AFE Power Structure Component Section IMPORTANT The minimum inside bend radius for fiber-optic cable is 25.4 mm (1 in.). Any bends with a shorter inside radius can permanently damage the fiber-optic cable. Signal attenuation increases with decreased inside bend radii. 5.

  • Page 43: Remove The Control Frame

    AFE Power Structure Component Section Chapter 4 Remove the Control Frame (only for AFE in IP21 Rittal enclosure) To remove the control frame for an AFE in an IP21 Rittal enclosure, follow these steps. 1. Remove power from the AFE. Remove Power from the AFE on page Terminal Block 2.

  • Page 44: Power Structure Access Procedures

    Chapter 4 AFE Power Structure Component Section Power Structure Access To remove and install components on the power structure, and to remove the power module from the power structure, follow these instructions. Procedures IMPORTANT To replace power modules, you must remove the power structure from the AFE enclosure.

  • Page 45: Install The Afe Protective Barriers

    AFE Power Structure Component Section Chapter 4 Install the AFE Protective Barriers Install the protective barriers in reverse order of removal. Remove the AFE Airflow Plate To remove the power structure from the AFE, you must remove the airflow plate. To remove the AFE airflow plate, follow these steps.

  • Page 46: Remove Protective Covers From The Power Structure

    Chapter 4 AFE Power Structure Component Section Remove Protective Covers from the Power Structure To access the internal components of the power structure, you must remove the protective covers. To remove the protective covers from the power structure, follow these steps. 1.
  • Page 47 AFE Power Structure Component Section Chapter 4 1. Remove power from the AFE. Remove Power from the AFE on page 2. If present, remove the protective barriers. Remove AFE Protective Barriers on page 3. Remove the airflow plate. Remove the AFE Airflow Plate on page 4.

  • Page 48: Install The Gate Driver Circuit Board

    Chapter 4 AFE Power Structure Component Section 8. Remove the five screws that secure the gate driver board and support bracket to the power structure. Remove Screws Remove Gate Driver Circuit Board Support Bracket Remove Screws 9. Carefully remove the gate driver board and the board support bracket. 10.
  • Page 49 AFE Power Structure Component Section Chapter 4 2. If present, remove the protective barriers. Remove AFE Protective Barriers on page 3. Remove the airflow plate. Remove the AFE Airflow Plate on page 4. Remove the protective front cover and terminal cover from the power structure.
  • Page 50 Chapter 4 AFE Power Structure Component Section ATTENTION: Hazard of permanent eye damage exists when using optical transmission equipment. This product emits intense light and invisible radiation. Do not look into fiber-optic ports or fiber-optic cable connectors. IMPORTANT When mishandled, the ability of fiber-optic cables to transmit data is greatly diminished.

  • Page 51: Install The Asic Circuit Board

    AFE Power Structure Component Section Chapter 4 If the plastic insulator requires replacement, follow these steps. a. Remove the four screws that secure the board holder to the metal frame, and remove the metal frame and insulator. Remove Screws Remove Metal Frame and Insulator b.

  • Page 52: Remove And Install The Power Structure Fan System

    Chapter 4 AFE Power Structure Component Section Remove and Install the Power Structure Fan System There is one main cooling fan on the power structure. For complete details on all fan system-related information, see the PowerFlex 700S, 700H, and 700AFE Drive Fan Systems Installation Instructions, publication PFLEX- IN029, including removal and installation of the following items: •...
  • Page 53 AFE Power Structure Component Section Chapter 4 5. Remove the connections from the DC bus terminals at the top of the power structure. DC Bus Terminals U/T1, V/T2, and W/T3 Connections Ground Connection 6. Remove the U/T1, V/T2, and W/T3 connections from the power structure at the bottom front of the power structure.
  • Page 54 Chapter 4 AFE Power Structure Component Section 11. Remove the four M8 x 20 screws that secure the power structure to the enclosure back panel. For clarity, only the back panel of the enclosure is shown. Remove Screws M8 x 20 6.7 N•m (60 lb•in) Remove Screws...

  • Page 55: Install The Power Structure In The Enclosure

    AFE Power Structure Component Section Chapter 4 Install the Power Structure in the Enclosure Install the power structure in reverse order of removal. See the PowerFlex Active Front End User Manual, publication 20Y-UM001, for fastener torques of AC supply, DC bus input, and ground connection terminations. Remove the Power Module from the Power Structure IMPORTANT Do not attempt to disassemble the power module.
  • Page 56 Chapter 4 AFE Power Structure Component Section 4. To remove the power structure from its mounting chassis, do the following: a. Remove the four M8 x 20 hexagonal screws. b. Remove the three M10 x 20 output cable screws. c. Separate the power structure from its mounting chassis. 5.
  • Page 57 AFE Power Structure Component Section Chapter 4 10. Remove the M5 Pozidriv screws that secure the bus bar terminals to the power structure. 11. Slide the bus bar terminals out of the frame. 12. Remove the bus bar airflow channel from the frame. 13.
  • Page 58 Chapter 4 AFE Power Structure Component Section 16. Remove the screws that secure the snubber capacitors to the power structure, and remove the snubber capacitors. 17. Remove the screws that secure the power bus bar and support insulators to the power structure. Support Insulators Power Bus...
  • Page 59 AFE Power Structure Component Section Chapter 4 20. Remove the screws (see step 19 picture for screw locations) that secure the balancing resistor assemblies to the power structure. Balancing Resistor Assembly Remove Screws 21. Remove the balancing resistor assemblies. 22. Remove the M6 x 12 screws that secure the connective DC bus bars and insulators to the power structure.
  • Page 60 Chapter 4 AFE Power Structure Component Section Location Fasteners Torque M10 x 25 hexagonal screws, M10 spring washers and M10 washers 8 N•m (70 lb•in) M8 x 25 hexagonal screws, M8 spring washers and M8 washers 8 N•m (70 lb•in) M6 x 12 screws 4 N•m (35 lb•in) 23.

  • Page 61: Install The Power Module On The Power Structure

    AFE Power Structure Component Section Chapter 4 24. Remove the M4 x 8 screws that secure the power module to the power structure. 25. Remove the power module. Remove Screws Remove Screws Install the Power Module on the Power Structure Install the power module in reverse order of removal.

  • Page 62: Install The Power Structure Dc Bus Capacitors

    Chapter 4 AFE Power Structure Component Section Tightening torque for reassembly is 1.35 N•m (12 lb•in). We recommend replacing all capacitors at the same time. 5. Repeat step 3 step 4 for each remaining DC bus capacitor being removed. Install the Power Structure DC Bus Capacitors Install the capacitors in reverse order of removal.

  • Page 63: Ac Line Switchgear Component Section

    Chapter AC Line Switchgear Component Section ATTENTION: To avoid an electric shock hazard, verify that all power to the PowerFlex® Active Front End has been removed before you perform any service or repairs. ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged completely before servicing.

  • Page 64: Afe In Ip20 2500 Mcc Style Enclosure

    Chapter 5 AC Line Switchgear Component Section AFE in IP20 2500 MCC Style For a PowerFlex AFE system in the IP20 2500 MCC Style enclosure, the AC line switchgear components are the input circuit breaker (Q0), AC input fuses Enclosure (F1.1…F1.3), and input contactor (K1).

  • Page 65: Precharge Component Section

    Chapter Precharge Component Section ATTENTION: To avoid an electric shock hazard, verify that all power to the PowerFlex® Active Front End has been removed before you perform any service or repairs. ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged completely before servicing.

  • Page 66: Precharge Functions

    Chapter 6 Precharge Component Section Precharge Functions The precharge circuitry has two main functions: • Provides AFE system control power. • Provides the precharge circuitry to charge the DC bus. The AFE system is available in both 400/480V AC and 600/690V AC system voltage configurations.

  • Page 67: Test The Control Transformer (T4) And 24V Dc Power

    Precharge Component Section Chapter 6 Table 5 - 600/690 Volt Precharge Fuse Rating Frame Enclosure Style Fuse Fuse Holder Size Amps Type Type IP20 2500 MCC Bussmann DFJ-30 Bussmann CH30J3 IP21 Rittal ABB OFAA000GG32 ABB O540D12000 (1) Fuse holder holds a quantity of three fuses. Test the Control Transformer For AFE in IP20 2500 MCC Style Enclosure (T4) and 24V DC Power Supply...

  • Page 68: For Afe In Ip21 Rittal Enclosure

    Chapter 6 Precharge Component Section 3. Use a digital voltmeter to test the control transformer (T4). a. Measure the primary AC line voltage, which is at the 400…480V AC or 600…690V AC system voltage. b. Measure the control transformer (T4) output voltage, which is approximately 120V AC.
  • Page 69 Precharge Component Section Chapter 6 Front View (shown with enclosure doors removed) 24V DC Power Supply (T10) (behind control frame panel) Control transformer (T4) is mounted directly behind motor-controlled circuit breaker (MCCB). 3. Use a digital voltmeter to test the control transformer (T4). a.

  • Page 70: Test The Precharge Bridge By Using The Power Structure

    Chapter 6 Precharge Component Section Test the Precharge Bridge by To test the precharge bridge by using the power structure terminals, follow these steps. Using the Power Structure Terminals 1. Remove power from the AFE. Remove Power from the AFE on page 2.

  • Page 71: Test The Precharge Resistor

    Precharge Component Section Chapter 6 7. Before removal, note the locations of the DC+, DC–, L1, L2, and L3 wires, and then disconnect these wires. 8. Remove the precharge bridge mounting nuts. 9. Remove and appropriately discard the old precharge bridge. 10.

  • Page 72: Afe In Ip21 Rittal Enclosure

    Chapter 6 Precharge Component Section 3. If present, remove the protective barriers. Remove AFE Protective Barriers on page 4. Disconnect the R6.1 and R6.2 precharge resistor wires from the resistor terminals on the precharge resistor assembly. 5. Remove the two precharge resistor assembly mounting screws that secure the assembly to the bracket on the LCL enclosure bay.

  • Page 73: Rockwell Automation Publication 20Y-Tg001C-En-P - April

    Chapter LCL Filter Component Section ATTENTION: To avoid an electric shock hazard, verify that all power to the PowerFlex® Active Front End has been removed before you perform any service or repairs. ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged completely before servicing.

  • Page 74: Remove The Lcl Filter Protective Barrier

    Chapter 7 LCL Filter Component Section Remove the LCL Filter To remove the LCL filter protective barrier, follow these steps. Protective Barrier 1. Remove power from the AFE. Remove Power from the AFE on page 2. Remove the 16 T25 Torx self-tapping screws that secure the protective barrier.

  • Page 75: Remove The Lcl Filter Fan Dc Power Supply

    LCL Filter Component Section Chapter 7 For complete details on LCL fan system information, see the PowerFlex 700H, 700S, and 700AFE Drive Fan Systems Installation Instructions, publication PFLEX-IN029. Remove the LCL Filter Fan DC Figure 10 Figure 11 show the LCL filter fan DC Power Supply wiring diagram with the connections to the AFE power structure and DC bus.
  • Page 76 Chapter 7 LCL Filter Component Section 1. Remove the LCL filter protective barrier. Remove the LCL Filter Protective Barrier on page 2. Remove the two M4 x 10 mm Pozidriv screws that secure the cover. 3. Remove the cover. 4. Remove the connectors X1, X3, X4, and X8. Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...

  • Page 77: Install The Lcl Filter Fan Dc Power Supply

    LCL Filter Component Section Chapter 7 5. Remove the six fasteners that secure the DC-to-DC power supply. Install the LCL Filter Fan DC Install the DC-to-DC power supply in reverse order of removal. See Torque Specifications on page Power Supply Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...

  • Page 78: Replace The Lcl Filter Fan

    Chapter 7 LCL Filter Component Section Replace the LCL Filter Fan To replace the LCL filter fan, follow these steps. 1. Remove the LCL filter protective barrier. Remove the LCL Filter Protective Barrier on page 2. Disconnect terminal blocks X51 and X53. 3.

  • Page 79: From The Ip20 2500 Mcc Style Enclosure

    LCL Filter Component Section Chapter 7 From the IP20 2500 MCC Style Enclosure To remove the LCL filter from the IP20 2500 MCC Style enclosure, follow these steps. 1. Remove power from the AFE. Remove Power from the AFE on page 2.

  • Page 80: From The Ip21 Rittal Enclosure

    Chapter 7 LCL Filter Component Section 6. Disconnect the AC input power cables (L1, L2, L3) between the input contactor and LCL filter. For cable locations, see Figure 3 on page 7. Disconnect the output cables (U, V, W) between the LCL filter and the AFE power structure.

  • Page 81: Install The Lcl Filter In The Enclosure

    LCL Filter Component Section Chapter 7 4. Remove the X52 terminal block from the LCL filter assembly (upper right side). 5. Remove the four T25 Torx self-tapping screws that secure the front bracket that is shown in Figure 9 on page This bracket holds the LCL filter in the enclosure.
  • Page 82 Chapter 7 LCL Filter Component Section Notes: Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...

  • Page 83: Overview

    An AFE system in an IP20 2500 MCC Style enclosure or IP21 Rittal enclosure contains protective DC bus fuses. IMPORTANT For PowerFlex AFE systems in the IP00 open chassis configuration, you must supply the output fuses. See the PowerFlex Active Front End User Manual, publication 20Y-UM001, for the DC bus output fusing recommendations.

  • Page 84: Fuse Replacement Guidelines

    Chapter 8 DC Fuses Component Section Fuse Replacement Guidelines DC bus fuses are required for short circuit protection. Table 7 Table 8 list the recommended DC bus fuses. Table 7 - 400/480 Volt DC Fusing Frame Fuse Size Enclosure Style Amps Bussman Type Ferraz Shawmut Type...
  • Page 85 DC Fuses Component Section Chapter 8 IMPORTANT Do not apply torque or twisting force to the fuse body. Too much force can damage the fuse. For information about Bussman fuses, click this link: http://www.cooperindustries.com. For information about Ferraz Shawmut fuses, click this link: http://www.ferrazfuses.com.
  • Page 86 Chapter 8 DC Fuses Component Section Notes: Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...

  • Page 87: Technical Support

    PowerFlex Active Front End. Correct the malfunction before continuing. Technical Support See the back cover for Rockwell Automation support contact information. Be prepared to provide the following information when you contact Allen-Bradley® drives technical support: • Product catalog number • Product serial number • Firmware revision level...

  • Page 88: Before You Apply Power To The Afe

    Chapter 9 Startup After Repair Before You Apply Power to Before you apply power to the AFE, follow these steps. the AFE 1. Open the power structure enclosure door. 2. If present, remove the protective barriers. Remove AFE Protective Barriers on page 3.

  • Page 89: Software Tools

    Appendix Service Tools and Equipment Software Tools Connected Components Workbench™ software, DriveExecutive™ software, or DriveExplorer™ software are tools that can be used to upload, download, and monitor system parameters. Service Tools This table describes the basic tools that are needed for repair and maintenance. Item Description Details Oscilloscope...
  • Page 90 Appendix A Service Tools and Equipment Notes: Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...

  • Page 91: Frame 10 Circuit Board Connections

    Appendix Schematic Diagrams Frame 10 Circuit Board This section provides schematic diagrams. Connections Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...

  • Page 92: Frame 10 Power Module Circuitry

    Appendix B Schematic Diagrams Frame 10 Power Module Circuitry Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...

  • Page 93: Frame 10 Power Structure Main Fan Connections

    Schematic Diagrams Appendix B Frame 10 Power Structure Figure 15 - DC Fan Power Supply (all AFEs—in IP20 2500 MCC Style or IP21 Rittal enclosure— January 2013 and later) Main Fan Connections To ASIC Circuit Board X11 (Fan Control) To X51 on the LCL Filter Power Supply Circuit Board For more details, see the...

  • Page 94: Control Wiring Diagram For Frame 10 In Ip20 2500

    Appendix B Schematic Diagrams Control Wiring Diagram for Figure 17 - Control Wiring Diagram for Frame 10 in IP20 2500 MCC Style Enclosure Frame 10 in IP20 2500 MCC Style Enclosure Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...
  • Page 95 Schematic Diagrams Appendix B Figure 18 - Control Wiring Diagram for Frame 10 in IP20 2500 MCC Style Enclosure (continued) Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...

  • Page 96: Mcc Style Enclosure

    Appendix B Schematic Diagrams System Schematics for Frame The following system schematics are for the AFE Frame 10 in an IP20 2500 MCC Style enclosure. The PowerFlex® AFE catalog number has an enclosure 10 in IP20 2500 MCC Style code of P for standard color (or W for optional gray color) as shown in this Enclosure example catalog string.
  • Page 97 Schematic Diagrams Appendix B Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...
  • Page 98 Appendix B Schematic Diagrams Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...
  • Page 99 Schematic Diagrams Appendix B Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...
  • Page 100 Appendix B Schematic Diagrams Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...
  • Page 101 Schematic Diagrams Appendix B Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...
  • Page 102 Appendix B Schematic Diagrams Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...

  • Page 103: Control Wiring Diagram For Frame 10 In Ip21 Rittal Enclosure

    Schematic Diagrams Appendix B Control Wiring Diagram for Frame 10 in IP21 Rittal Enclosure N.O. Remote Operation of Motor Controlled Circuit Breaker (Optional) N.O. N.O. NOTE: Unused terminals are not shown. N.O. N.O. N.O. 230V AC Control Power N.O. N.O. N.O.

  • Page 104: System Schematics For Frame 10 Afe In Ip21 Rittal Enclosure

    System Schematics for Frame The following system schematics are for the AFE Frame 10 in an IP21 Rittal enclosure. The PowerFlex AFE catalog number has an enclosure code of A as 10 AFE in IP21 Rittal shown in the example catalog string. For other enclosure designs, contact the Enclosure supplier of the system for the system schematics.
  • Page 105 Schematic Diagrams Appendix B Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...
  • Page 106 Appendix B Schematic Diagrams Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...
  • Page 107 Schematic Diagrams Appendix B Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...
  • Page 108 Appendix B Schematic Diagrams Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...
  • Page 109 Schematic Diagrams Appendix B Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...
  • Page 110 Appendix B Schematic Diagrams Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...
  • Page 111 Schematic Diagrams Appendix B Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...
  • Page 112 Appendix B Schematic Diagrams Notes: Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...

  • Page 113: Circuit Board Connections

    Appendix Connector Descriptions Circuit Board Connections The following tables detail the connection points for the Frame 10 PowerFlex® Active Front End circuit boards and components. Table 9 - Fiber-optic Adapter Board-to-ASIC Circuit Board Connections Fiber-optic Type Signal Description: Type ASIC Board Fiber Connector Adapter Connector Reference to ASIC Board Gate_Enable...
  • Page 114 Appendix C Connector Descriptions Table 10 - ASIC Board-to-Gate Driver Board Connections ASIC Board Gate Driver Board Signal Description ‘U’ phase Ribbon Cable Signal Description Pin 1 U_Feedback Pin 2 U_Power_OK Pin 3 U_DTR Pin 4 U_ETR Pin 5 U_ITR Pin 6 U_DC- Pin 7...
  • Page 115 Connector Descriptions Appendix C Figure 35 - Fiber-optic Cable Routing Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...

  • Page 116: Hardware Connections

    Appendix C Connector Descriptions Hardware Connections This section describes the hardware connections. Figure 36 - AFE Power Structure Fan Inverter Circuit Board Connectors Table 11 - ASIC Board - AFE Power Structure Fan Inverter Board Connections ASIC Board Connector Signal Description AFE Power Structure Fan Inverter Board Connector...
  • Page 117 MADE IN THE USA (FAC 1B) 26223816 MADE IN THE USA (FAC 1B) A complete list of spare parts for the Frame 10 PowerFlex Active Front End is available on the Allen-Bradley website at http://www.ab.com/support/abdrives/powerflex70/PF7ReleasedParts.pdf. Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...

  • Page 118: Afe Power Structure Assembly

    Appendix D Disassembly/Assembly Diagrams and Spare Parts AFE Power Structure Figure 38 - AFE Power Structure Assembly External Components Assembly ATTENTION: The sheet metal cover and mounting screws on the ASIC Board that is located on the power structure are energized at (-) DC bus potential high voltage.
  • Page 119 Disassembly/Assembly Diagrams and Spare Parts Appendix D Table 13 - AFE Power Structure Assembly External Component Part Numbers (Continued) Part Name Cat. No. Power structure 400/480V (460 A) SK-Y1-PWRMOD-D460 600/690V (325 A) SK-Y1-PWRMOD-E325 Maintenance stand 20-MAINSTD (1) For additional AC fan system information, see publication PFLEX-IN029. Figure 39 - AFE Power Structure Assembly Internal Components EMC Cover DC Bus Bar Assembly...
  • Page 120 Appendix D Disassembly/Assembly Diagrams and Spare Parts Table 14 - AFE Power Structure Assembly Internal Component Part Numbers (Continued) Part Name Cat. No. EMC cover Gate driver board 400/480V SK-Y1-GDB1-F10D 600/690V SK-Y1-GDB1-F10E Power module 400/480V SK-Y1-QOUT-D460 600/690V SK-Y1-QOUT-E325 Power bus bar Screening plate (for gate driver board) Snubber capacitor assembly ATTENTION: The sheet metal cover and mounting screws on the ASIC Board...
  • Page 121 Disassembly/Assembly Diagrams and Spare Parts Appendix D Figure 40 - AFE Power Structure ASIC Assembly ASIC Assembly Cover ASIC Board ASIC Insulator ASIC Assembly Bracket Table 15 - AFE Power Structure ASIC Assembly Part Numbers Part Name Cat. No. ASIC assembly bracket Included in 20-FR10850 ASIC assembly cover ASIC assembly insulator...

  • Page 122: Lcl Filter Assembly (Used In Ip20 And Ip21 Enclosures)

    Appendix D Disassembly/Assembly Diagrams and Spare Parts LCL Filter Assembly (used in Figure 41 - LCL Filter Assembly IP20 and IP21 enclosures) LCL Filter Assembly LCL Capacitor Assembly LCL High Frequency Capacitor Assembly Table 16 - LCL Filter Assembly Part Numbers Part Name Cat.
  • Page 123 Disassembly/Assembly Diagrams and Spare Parts Appendix D Figure 42 - LCL Filter Power Supply Assembly Table 17 - LCL Filter Power Supply Assembly Part Numbers Part Name Cat. No. Universal Kit Discontinued July 2014 LCL filter power supply 400/480V SK-Y1-DCPS2-F10 SK-Y1-DCPS1-D460 600/690V SK-Y1-DCPS1-F325...

  • Page 124: Precharge Assembly

    Appendix D Disassembly/Assembly Diagrams and Spare Parts Precharge Assembly Figure 44 - Precharge Assembly for AFE in IP20 2500 MCC Style Enclosure Front View (shown with enclosure doors removed) • Precharge Fuse and Fuse Holder • Precharge Kit Precharge • Control Transformer (T4) Resistors •...
  • Page 125 Disassembly/Assembly Diagrams and Spare Parts Appendix D Figure 45 - Precharge Assembly for AFE in IP21 Rittal Enclosure Front View (shown with enclosure doors removed) • Precharge Fuse • Precharge Kit • Precharge Motor Protection Relay • Fuse Disconnect Switch •...

  • Page 126: Ac Line Switchgear

    Appendix D Disassembly/Assembly Diagrams and Spare Parts AC Line Switchgear Figure 46 - AC Line Switchgear Components for AFE in IP20 2500 MCC Style Enclosure Front View (shown with enclosure doors removed) Fan Blower Kit Input Circuit Breaker DC Bus Fuses Bus Link between Input Circuit Breaker and AC Input Fuses...
  • Page 127 Disassembly/Assembly Diagrams and Spare Parts Appendix D Figure 47 - AC Line Switchgear Components for AFE in IP21 Rittal Enclosure Front View (shown with enclosure doors removed) Motor Controlled Circuit Breaker Input Disconnect Switch Table 22 - AC Line Switchgear Part Numbers for AFE in IP21 Rittal Enclosure Part Name Cat.
  • Page 128 Appendix D Disassembly/Assembly Diagrams and Spare Parts Notes: Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...

  • Page 129: Data To Collect

    Appendix AFE Power One-line System Application Data Data to Collect Collect the following AFE system data before contacting Allen-Bradley® drives technical support. Utility Transformer Delta-Delta, Delta-Wye, or Other Type Input Volts Output Volts None, Solid, High Resistive Ground Cable Length:__________________________Cable Type:________________________________...

  • Page 130: Typical Transformer Winding Types

    Appendix E AFE Power One-line System Application Data Typical Transformer Winding The diagrams in this section show typical transformer winding types. Types Figure 48 - Delta-Wye with Grounded Wye Neutral Figure 49 - Delta-Delta with Grounded Leg, or Four-Wire Connected Secondary Delta Figure 50 - Ungrounded Secondary Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017...

  • Page 131: Index

    Index AC input fuses 64 external components of AFE power structure AC line switchgear components AFE in IP20 2500 MCC Style enclosure AFE in IP21 Rittal enclosure 127 fan inverter fuse checking 34 overview 63 fault reports 12 AC line switchgear components 64 faults Active Front End system overview 19 creating reports 12...
  • Page 132 Index from IP21 Rittal enclosure 80 main component locations protective cover 74 AFE in IP20 2500 MCC Style enclosure 20 power from the AFE 37 AFE in IP21 Rittal enclosure 23 power module from the power structure 55 main component sections power structure DC bus capacitors 61 power structure from the enclosure 52 AFE in IP20 2500 MCC Style enclosure 19...
  • Page 134 Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page. Allen-Bradley, Connected Components Workbench, DPI, DriveExecutive, DriveExplorer, PowerFlex, SCANport, Rockwell Automation, and Rockwell Software are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

This manual is also suitable for:

20yPowerflex 700 afe

Table of Contents