Rockwell Automation Allen-Bradley PowerFlex AFE Hardware Service Manual
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Rockwell Automation Allen-Bradley PowerFlex AFE Hardware Service Manual

Rockwell Automation Allen-Bradley PowerFlex AFE Hardware Service Manual

Frame 13 on active front end
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Hardware Service Manual
Original Instructions
PowerFlex Active Front End – Frame 13
Catalog Number 20Y
PowerFlex AFE/PowerFlex 700AFE
(400V/480V and 600V/690V)

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Summary of Contents for Rockwell Automation Allen-Bradley PowerFlex AFE

  • Page 1 Hardware Service Manual Original Instructions PowerFlex Active Front End – Frame 13 Catalog Number 20Y PowerFlex AFE/PowerFlex 700AFE (400V/480V and 600V/690V)
  • Page 2 If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

  • Page 3: Table Of Contents

    Remove the DPI Interface Assembly ......38 Install the DPI Interface Assembly ......39 Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 4 Test the Precharge Resistor........79 Replace the Precharge Resistor Assembly ......81 Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 5 Hardware Connections ........126 Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 6 ............141 Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 7: Preface

    MADE IN THE USA (FAC 1B) What Is Not in This Manual This manual does not contain installation, start-up, and programming information. This information is available in the PowerFlex Active Front End User Manual, publication 20Y-UM001. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 8: Additional Resources

    Provides an explanation of the causes of Electrostatic Damage, and how you can guard against its effects. Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system. Product Certifications website, http://www.rockwellautomation.com/global/ Provides declarations of conformity, certificates, and other certification details.

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

    ATTENTION: Only qualified personnel familiar with adjustable frequency AC drives and associated machinery can plan or implement the installation, start- up, and subsequent maintenance of the system. Failure to comply can result in personal injury and/or equipment damage. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 10 Preface Notes: Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 11 ESD control procedures. Static control precautions are required to install, test, service, or repair this assembly. If you are unfamiliar with static control procedures, see Guarding Against Electrostatic Damage, publication 8000-4.5.2, or any other applicable ESD protection handbook. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 12: Create Fault Reports

    911V for 400/480V current limit condition, which can indicate units, or 1200V for 600/690V units. an excess regenerative load. Adjust parameter 076 [Regen Power Lmt]. Monitor incoming AC line for high voltage or voltage transients. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 13 A microprocessor watchdog timeout Cycle the power. has occurred. Replace the control board. See page IGBT Temp Hw The AFE input current has exceeded Check for an excess load. the 1 minute overload rating. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 14 An enable signal is missing from the Check the control wiring. control terminal block, only when Check the position of the J5 hardware jumper J5 is removed on the digital I/O enable jumper. board. Check the digital input programming. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 15 LCL OverTemp The LCL filter has been overheated or Check the LCL filter and signal connection the signal is not connected to input. or verify that digital input 5 is closed. See Chapter Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 16 DC voltage is less than the value set by Check the parameter setting. parameter 078 [DC Bus Lo Alarm]. DCBusHiAlarm DC voltage exceeds the value set by Check the parameter setting. parameter 079 [DC Bus Hi Alarm]. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 17: Common Symptoms And Corrective Actions

    [Reactive I Ref] with a soft (high impedance) current and DC bus Ref] value to zero. Verify if the AFE AC line. voltage. is running on a soft line per the AC line source considerations. Can trip an F7 overload. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 18 Chapter 1 Troubleshooting and Error Codes Notes: Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 19: Afe In Ip20 2500 Mcc Style Enclosure

    Mode Core Input Input Breaker Contactor 3 Phase Fuses F1.1…F1.3 AC Input F2.1 DC Bus Output F2.2 F2.3 F2.4 F2.5 F2.6 Precharge Precharge Precharge Fuses Contactor Circuit R6.1 PowerFlex Active Front End System Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 20: Main Component Locations

    Active Front End power structure (U1) AC line switchgear Input circuit breaker (Q0) Input fuses (F1.1…F1.3) Input contactor (K1) DC fuses (F2.1…F2.6) AFE control box assembly (on the AFE door and shown with user-installed HIM) Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 21: Main Bus Bar Locations

    AC Bus Bars between Input Circuit Breaker (Q0) and AC Input Fuses (F1.1…F1.3) AC Bus Bars between AC Fuses (F1.1…F1.3) and Input Contactor (K1) AC Power Bus Bars between Input Contactor (K1) and LCL Filter (L1) Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 22: Afe In Ip21 Rittal Enclosure

    Power Structure (U1) Fuses 3 Phase AC Input F2.1 F2.2 DC Bus Output F2.3 F2.4 F2.5 F2.6 Motor Protection Relay Precharge Precharge Precharge Fuses Contactor Circuit R6.1 R6.2 PowerFlex Active Front End System Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 23: Main Component Locations

    Precharge circuit and precharge resistors (R6.1 and R6.2) LCL filter (L1) Active Front End power structure (U1) AC line switchgear Motor-controlled circuit breaker (Q1) Input disconnect (Q0) AFE control assembly (shown with user-installed HIM DC fuses (F2.1…F2.6) Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 24: Bus Bar Locations

    AFE Power Structure (U1) and DC fuses AC bus bars between Main Disconnect (Q0) and Motor-Controlled AC bus bars Circuit Breaker (Q1) between Motor-Controlled Circuit Breaker (Q1) and LCL Filter (L1) AC Input bus bars Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 25: Afe In Ip00 Open Chassis Configuration

    AC Input F1.1-F1.3 F2.1 DC Bus Output F2.2 F2.3 F2.4 Customer- supplied Parts F2.5 F2.6 Customer- supplied Precharge Precharge Precharge Parts Fuses Contactor Circuit R6.1 PowerFlex Active Front End System Customer-supplied Parts Customer-supplied enclosure Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 26 Chapter 2 Active Front End System Overview Notes: Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 27 ESD control procedures. Static control precautions are required to install, test, service, or repair this assembly. If you are unfamiliar with static control procedures, see Guarding Against Electrostatic Damage, publication 8000-4.5.2, or any other applicable ESD protection handbook. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 28: View The Status Indicators

    1. Remove the main cooling fans from the bottom of the power structure. Remove and Install the Power Structure Fan System on page 2. Inspect the tunnels. Clean the heatsinks and tunnels if necessary. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 29: Inspect The Power Structure

    To perform forward and reverse biased diode tests for the power structure, follow these steps. 1. Remove power from the AFE. Remove Power from the AFE on page 2. Remove the protective barriers. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 30 W/T3 (1) The actual voltage reading can vary depending upon your equipment. If your readings are not near 0.5V, verify that the actual voltage that is measured is consistent for the power structure. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 31: Check The Fiber-Optic Connections

    3. Remove the protective front covers and terminal covers from the power structure. Remove Protective Covers from the Power Structure on page 4. Locate the three gate driver boards on the front of the power structure (right-side AFE enclosure). Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 32 7. Disconnect the cables and inspect them for scratches and cracks, and overall integrity. IMPORTANT When mishandled, the ability of fiber-optic cables to transmit data is greatly diminished. 8. Reconnect the cables, replacing any damaged cables. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 33: Perform Gate Driver Board Resistance Measurements

    U, V, or W High (H) U/T1 V/T2 W/T3 IMPORTANT: Connectors X7 and X8 are connected in parallel with connectors X10 and X11, respectively, and therefore do Approx. 0.5 ohms not have to be tested. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

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

    Locate these fuses (shown below) and remove them. b. Use a multi-meter to verify that the fuses are not open. 5. Reinstall the good fuses and replace any open fuse with an equivalent- rated fuse. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 35 Use the instructions in this chapter to remove and install components from the Active Front End. To remove and install components on the power structure and to remove a power module from the power structure, see Power Structure Access Procedures on page Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 36: Understand The Torque Figures In Assembly Diagrams

    In IP20 enclosure M8 x 20 6.7 N•m (60 lb•in) front bracket M6 x 16 screws 4.5 N•m (40 lb•in) In IP21 enclosure M5 x 12 Torx self-tapping screws 4.5 N•m (40 lb•in) Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 37: Remove Power From The Afe

    4. Check the DC bus voltage between the +DC and -DC terminals, between the +DC terminal and the chassis, and between the -DC terminal and the chassis. The voltage must be zero for all three measurements before proceeding. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 38: Control Frame Access Procedures

    4. Unplug the DPI cable from the X2 connector on the DPI interface board. Back view of the DPI interface board that remains mounted on the back of the control frame. Green Ground Wire (Based on PCB Revision) Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 39: Install The Dpi Interface Assembly

    Note the order of the boards and the keys that help prevent placement of boards in incorrect slots. IMPORTANT: Do not remove the enclosure cover from the control frame. For clarity, the enclosure is shown without the cover. Keys Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

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

    1. Remove power from the AFE. Remove Power from the AFE on page 2. For an AFE in an IP20 2500 MCC Style enclosure, open the control box on the enclosure door to access the control assembly. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 41 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. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

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

    Style Enclosure Enclosure 0.9 N•m 0.9 N•m (8 lb•in) (8 lb•in) Install the Fiber-optic Adapter Circuit Board Install the fiber-optic adapter circuit board in reverse order of removal. See Torque Specifications on page 36 Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 43: Ip21 Rittal Enclosure)

    4. Lift the control frame from the hinges and remove it. Loosen T8 Torx-head Screws Replace the Control Frame Replace the control frame in reverse order of removal. See Torque Specifications on page 36 Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 44: Power Structure Access Procedures

    IP20 2500 MCC Style Enclosure Remove Screws Remove Screws Remove Screws Remove Screws Remove Screws Remove Screws Enclosure Bay for Enclosure Bay for Enclosure Bay for Input Switchgear LCL Filter AFE Power Structure Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 45: Install Afe Protective Barriers

    AFE Power Structure Component Section Removing Protective Barriers for AFE in IP21 Rittal Enclosure Remove Remove Screws Screws Remove Remove Screws Screws Install AFE Protective Barriers Install the protective barriers in reverse order of removal. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 46: Remove The Afe Airflow Plate

    Removing Airflow Plate for AFE in 2500 MCC Style Enclosure IP21 Rittal Enclosure Remove Screws Remove Remove Screws Screws Install the AFE Airflow Plate Install the airflow plate in reverse order of removal. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 47: Remove Protective Covers From The Power Structure

    Install the protective covers on the power structure in reverse order of removal. Torque Specifications on page 36 for torque specifications. Remove the Gate Driver Circuit Boards There are three gate driver circuit boards on the front of the power structure. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 48 Any bends with a shorter inside radius can permanently damage the fiber-optic cable. Signal attenuation increases with decreased inside bend radii. 7. Disconnect the X13, X14, and X15 cables from sockets of the gate driver board, and set them aside. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 49: Install The Gate Driver Circuit Boards

    12. Repeat step 5 through step 11 for each of the remaining gate driver boards. Install the Gate Driver Circuit Boards Install the gate driver circuit boards in the reverse order of removal. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 50: Remove The Asic Circuit Board

    ASIC cover. Remove Screws and ASIC Assembly Cover ASIC Cover Remove -DC Bus Connection 6. Unplug the fan, which mounts on the cover, from connector X11 of the ASIC circuit board. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 51 X15 connectors must be transferred and connected to the new board before installation. 9. Disconnect the X3, X4, X5, X6, and X10 cables from sockets on the front of the ASIC board, and set them aside. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 52 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 Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 53: Install The Asic Circuit Board

    IN029, including removal and installation of the following items: • AC fan inverters • AC fan capacitors • AC main cooling fans • DC fan power supplies • DC main cooling fans • Fan fusing Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 54: Remove The Power Structure From The Enclosure

    AFE in IP21 Rittal Enclosure on page AFE in IP20 2500 MCC Style Enclosure If your AFE is in an IP20 2500 MCC enclosure, continue to remove the power structure with these steps. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 55 Remove the U/T1, V/T2, and W/T3 connections from the power structure at the bottom front of the power structure. c. Remove the ground connections of the power structure from the enclosure PE terminals. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 56 For details, see Lifting and Mounting the PowerFlex Active Front End (AFE)—Frames 10 and 13, publication 20Y-IN001. g. To detach the power structure from its cart assembly, remove the six hexagonal bolts from the upper portion of the chassis backside. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 57 Separate the power structure from its cart assembly, and remove the power structure by using appropriate lifting equipment. AFE in IP21 Rittal Enclosure If your AFE is in an IP21 Rittal enclosure, continue to remove the power structure with these steps. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 58 Remove the output cable screws, and the two hexagonal screws that secure the power structure to the AFE frame. Remove Screws (one each side of enclosure) e. Install the maintenance stand (catalog number 20-MAINSTD) onto the power structure rails. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 59: Install The Power Structure In The Enclosure

    1. Remove the power structure from the AFE enclosure. Remove the Power Structure from the Enclosure on page 2. Remove the ASIC Circuit board. Remove the ASIC Circuit Board on page Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 60 3. Remove the M10 x 25 hexagonal screws that secure the input power cables to the input power terminals on the power structure. Remove Screws and Washers 4. Remove the insulators from between the DC+ and DC- bus bars. Remove Insulators Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 61 6. Remove the three M8 x 20 hexagonal screws from the top section of each phase assembly (U, V, or W) that you want to remove. IMPORTANT Only two screws are shown for each phase assembly in the top section of the drawing. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 62: Phase Assembly

    The following procedure describes removing the power module from one phase assembly. Repeat this procedure for each phase assembly. To remove the power module from the U, V, or W phase assembly, follow these steps. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 63 Channel (only if damaged) 7. Remove the M8 x 20 hexagonal screws that secure the input power cables to the input power bus bar. Tightening torque for reassembly is 14 N•m (124 lb•in). Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 64 10. Remove the screws that secure the snubber capacitors to the U, V, or W phase assembly, and remove the snubber capacitors. Remove Screws 4 N•m (35 lb•in) Remove EMC Cover Remove Screws Remove Screw and Snubber Capacitors 3 N•m (27 lb•in) Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 65 Older Style Balancing Resistors Newer Style Balancing Resistors 4 N•m 3 N•m 4 N•m 3 N•m (35 lb•in) (27 lb•in) (35 lb•in) (27 lb•in) Balancing Resistor Assembly Screws Balancing Resistor Assembly Screws Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 66 (only 1 for 480V unit) Remove all screws holding bus bars and Insulator insulators to AFE frame. Metal Plate Bus Bar Remove Insulator Screws Bus Bar Metal Plate Remove Insulator Screws 690V AFE Input Power Module Shown Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 67: Install The Power Module On The U, V, Or W Phase Assembly

    (step 17 through step 19) in that procedure. Remove the Power Module from the U, V, or W Phase Assembly on page 4. Note the polarity of the capacitors. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 68: Install The U, V, Or W Phase Assembly Dc Bus Capacitors

    1. Remove the old power structure from the enclosure. Remove the Power Structure from the Enclosure on page 4-54. 2. Remove the common mode capacitors from the new Frame 13 power structure that is replacing the old power structure. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 69 V phase assembly module fan housing. e. Carefully remove the power supply voltage feedback board and cover. f. Disconnect the cable from connector J8 on the power supply voltage feedback board. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 70 Secure the cable to the adjacent fan housing so that it is out of the way. 4. Install the new (replacement) power structure. Install the Power Structure in the Enclosure on page Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 71: Ac Line Switchgear Component Section

    ESD control procedures. Static control precautions are required to install, test, service, or repair this assembly. If you are unfamiliar with static control procedures, see Guarding Against Electrostatic Damage, publication 8000-4.5.2, or any other applicable ESD protection handbook. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 72: Afe In Ip20 2500 Mcc Style Enclosure

    MCCB. The trip mechanism controls the MCCB functionality. See the PowerFlex Active Front End User Manual, publication 20Y-UM001, for the AC input fusing and MCCB protection recommendations. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 73: Precharge Component Section

    ESD control procedures. Static control precautions are required to install, test, service, or repair this assembly. If you are unfamiliar with static control procedures, see Guarding Against Electrostatic Damage, publication 8000-4.5.2, or any other applicable ESD protection handbook. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 74: Precharging Functions

    (1) Precharge fuse designation is F5 for AFE in IP20 2500 MCC style enclosure. (2) Precharge fuse designation is F6 for AFE in IP 21 Rittal enclosure. (3) Precharge fuse holder holds a quantity of three fuses. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 75: Power Supply (T10)

    ATTENTION: Perform these tests only with qualified personnel. During these tests, the AFE is powered. Take proper precautions to avoid injury from electric shock. 2. Locate the control transformer (T4) and 24V DC power supply (T10). Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 76 If these measurements are not within ±10%, perform these other steps. c. Power down the AFE. d. Remove the 24V DC output wires of the power supply (T10). e. Power up the AFE and retest by repeating step a step Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 77: For Afe In Ip21 Rittal Enclosure

    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 230V AC. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 78: Test The Precharge Bridge Using The Power Structure Terminals

    Meter displays charging voltage. (1) The actual voltage reading can vary depending upon your equipment. If your readings are not near 0.48V, verify that the actual voltage that is measured is consistent for the power structure. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 79: Replace The Precharge Bridge

    • Between the (–) side of the precharge resistor R6.2 and the (–) terminal on the TB of the precharge circuit. IMPORTANT This measurement only applies to an AFE in an IP21 Rittal enclosure. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 80 The engineered value can change the value of the precharge resistance. See the PowerFlex Active Front End User Manual, publication 20Y-UM001, for total DC bus capacitance limits for the precharging circuit. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 81: Replace The Precharge Resistor Assembly

    6. Disconnect the white wires from the terminal block by the bridge. 7. Remove the mounting screws from the failed precharge resistor, and appropriately discard the resistor. 8. Install the new precharge resistor in reverse order of removal. See Torque Specifications on page Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 82 Chapter 6 Precharge Component Section Notes: Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 83 ESD control procedures. Static control precautions are required to install, test, service, or repair this assembly. If you are unfamiliar with static control procedures, see Guarding Against Electrostatic Damage, publication 8000-4.5.2, or any other applicable ESD protection handbook. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 84: Remove The Lcl Filter Protective Barriers And Vented Cover

    IMPORTANT Replace LCL filter fan fuses with only ATQ8 (Ferraz Shawmut) fuses. For complete details on LCL fan system information, see PowerFlex 700H, 700S, and 700AFE Drive Fan Systems Installation Instructions, publication PFLEX-IN029. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 85: Remove The Lcl Filter Fan Dc Power Supply

    (If a keypad is not attached, see the indicator through the keypad base.) Wait 5 more minutes before doing any work on the DC-to-DC power supply to let it completely discharge. Do not open the cover until after this time has expired. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 86 1. Remove the LCL filter protective barriers. Remove the LCL Filter Protective Barriers and Vented Cover on page 7-84. 2. Remove the two M4 x 10 mm Pozidriv screws that secure the cover. 3. Remove the cover. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 87: Install The Lcl Filter Fan Dc Power Supply

    Power Supply Replace the LCL Filter Fan To replace the LCL filter fan, follow these steps. 1. Remove the LCL filter protective barriers. Remove the LCL Filter Protective Barriers and Vented Cover on page Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 88: Remove The Lcl Filter

    Remove the LCL Filter Protective Barriers and Vented Cover on page 3. Remove the airflow plate. Remove the AFE Airflow Plate on page 4. Remove the X51 and X53 terminal blocks from the LCL fan assembly. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 89 DETAIL B 7. See Figure 13 on page 90, Detail C, and remove the six M10 x 10 washer hex nuts and associated hardware that secure the input bus bars to the LCL filter. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 90: From The Ip21 Rittal Enclosure

    Remove Power from the AFE on page 2. Remove the LCL filter protective barriers. Remove the LCL Filter Protective Barriers and Vented Cover on page 3. Remove the X51 and X53 terminal blocks from the LCL fan assembly. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 91: Install The Lcl Filter In The Enclosure

    9. Slide the LCL filter out of the enclosure. IMPORTANT Ramps can be required due to enclosure floor mismatch. Install the LCL Filter in the Install the LCL filter in reverse order of removal. See Torque Specifications on page Enclosure Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 92 Chapter 7 LCL Filter Component Section Notes: Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 93: Overview

    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. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 94: Fuse Replacement Guidelines

    26 N•m M10 x 50 (132.8 lb•in) (230.1 lb•in) M12 x 35 15 N•m 46 N•m M12 x 50 (132.8 lb•in) (407.1 lb•in) M12 x 40 15 N•m 46 N•m (132.8 lb•in) (407.1 lb•in) Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 95 IMPORTANT Do not apply torque or twisting force to the fuse body. Too much force can damage the fuse. For information about Bussmann fuses, click this link: http://www.cooperindustries.com. For information about Ferraz Shawmut fuses, click this link: http://www.ferrazfuses.com. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 96 Chapter 8 DC Fuses Component Section Notes: Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 97: Technical Support

    User-supplied voltages can exist even when main AC power is not applied to the 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: •...
  • Page 98 AFE. 7. Verify that the control power voltage is correct. 8. Whenever possible, isolate the AFE from the rest of the DC bus system to enable the AFE to be powered separately. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 99: Software Tools

    Agilent HFBR-4593 Polishing Kit, consisting of a Polishing Fixture, 600 grit abrasive paper, and 3 mm pink lapping film (3M Company, OC3-14). For Agilent HFBR-4532 latching connectors and HFBR-RL cable. See Agilent publications 5988-9777EN and 5988-3625EN. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 100 Appendix A Service Tools and Equipment Notes: Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 101: Frame 13 Circuit Board Connections

    (24V DC Digital Option Option NET B (DPI Comm. (Digital Output Input with Board Board Option) Option) DPI Assembly Analog I/O) External DPI 20C-DPI1 Analog Digital DPI Comm. Inputs Option Board (10) (8/10) Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 102: Frame 13 Power Structure Power Circuitry Block Diagram

    DC Bus Output Module V / L2 F2.4 W / L3 Measure L/R Gate Driver Bd. F2.5 Phase Module F2.6 Measure L/R Gate Driver Bd. Charge Relay +24V 0EVA External Wiring ASIC Shown Dashed Board Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 103: Frame 13 Power Module Circuitry

    Appendix B Schematic Diagrams Frame 13 Power Module Circuitry W_LO W_LO W_HI W_HI TERM W TERM W V_LO V_LO V_HI V_HI TERM V TERM V U_LO U_LO U_HI U_HI TERM U TERM U Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 104: Frame 13 Power Structure Main Fan Connections

    W Phase Fan Module Power Supply Circuit Board DC Main Fan Isolated 48V DC V Phase Fan Module Power Supply Circuit Board DC Main Fan Isolated 48V DC U Phase Fan Module Power Supply Circuit Board Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 105: Frame 13 Power Structure Main Fan Connections

    Appendix B Schematic Diagrams Frame 13 Power Structure Main Fan Connections Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 106: Control Wiring Diagram For Frame 13 In Ip20 2500

    Appendix B Schematic Diagrams Control Wiring Diagram for Frame 13 in IP20 2500 MCC Figure 19 - Control Wiring Diagram for Frame 13 in IP20 2500 MCC Style Enclosure Style Enclosure Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 107 Appendix B Schematic Diagrams Figure 20 - Control Wiring Diagram for Frame 13 in IP20 2500 MCC Style Enclosure (continued) Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 108: Mcc Style Enclosure

    P for standard color (or W for optional gray color) as shown in the Enclosure example catalog string. For other enclosure designs, contact the supplier of the system for the system schematics. Position 1…3 5…7 Factory-installed Common Mode Core Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 109 Appendix B Schematic Diagrams Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 110 Appendix B Schematic Diagrams Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 111 Appendix B Schematic Diagrams Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 112 Appendix B Schematic Diagrams Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 113 Appendix B Schematic Diagrams Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 114 Appendix B Schematic Diagrams Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 115: Control Wiring Diagram For Frame 13 In Ip21 Rittal Enclosure

    AOUTC AOUT2 DIN1 DIN2 DIN3 DIN4 DIN5 DIN6 D_COM D_COM +24V 24VCOM ABCD ABCD ABCD ABCD 20C-DA1-4 -A16.1 -A11 SLOT A MC Control 20C-DO1 20C-DPI1 -A12.1 -A13 SLOT B SLOT E 72 Inverter Enable Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 116: System Schematics For Frame 13 In Ip21 Rittal Enclosure

    The PowerFlex AFE catalog number has an enclosure code of A as 13 in IP21 Rittal Enclosure shown in the example catalog string. For other enclosure designs, contact the supplier of the system for the system schematics. Position 1…3 5…7 Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 117 Appendix B Schematic Diagrams Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 118 Appendix B Schematic Diagrams Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 119 Appendix B Schematic Diagrams Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 120 Appendix B Schematic Diagrams Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 121 Appendix B Schematic Diagrams Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 122 Appendix B Schematic Diagrams Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 123: Circuit Board Connections

    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. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 124 (connect UH to UH, UL to UL, and so forth) H11 (VL) (VL) H4 H10 (VH) (VH) H2 H9 (UL) (UL) H4 H8 (UH) (UH) H2 DTR = N Desat ETR = Phase I ITR = Phase overcurrent Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 125 Appendix C Connector Descriptions Figure 36 - Fiber-optic Cable Routing Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 126: Hardware Connections

    Signal Description Phase U Fan Connector Inverter Board Connector From +15V From FAN_CONTROL NEXT FAN_ALARM From For part number information, see the PowerFlex 700H, 700S, and 700AFE Drive Fan Systems Installation Instructions, publication PFLEX-IN029. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 127 Connector Descriptions Figure 38 - LCL Filter Fan Inverter Circuit Board Connectors Table 14 - LCL Filter Fan Inverter Circuit Board Connections LCL Filter DC Fan LCL Filter DC Fan Inverter Board Assembly Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 128 Appendix C Connector Descriptions Notes: Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 129 MADE IN THE USA (FAC 1B) 26223816 MADE IN THE USA (FAC 1B) A complete list of spare parts for the Frame 13 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-TG002C-EN-P - April 2017...

  • Page 130: Afe Power Structure Assembly

    Fan inverter fuse (only AC fan system) 20-PP20202 Terminal covers Front covers Power structure 400/480V (1300 A) SK-Y1-PWRMOD-D1K3 600/690V (1030 A) SK-Y1-PWRMOD-E1K0 Maintenance stand 20-MAINSTD (1) For additional AC fan system information, see publication PFLEX-IN029. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 131 Electrolytic capacitors ELKO 3300 μF 420V for 400/480V AFE 20-PP01005 ELKO 5600 μF 420V for 600/690V AFE 20-PP01099 EMC cover Gate driver board 400/480V SK-H1-GDB1-F1314D 600/690V SK-H1-GDB1-F1314E Power module 400/480V SK-H1-QOUT-D1K3 600/690V SK-H1-QOUT-E1K0 Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 132 Part Name Cat. No. ASIC assembly bracket Included in 20-FR10850 ASIC assembly cover ASIC assembly insulator ASIC board 400/480V AFE SK-H1-ASICBD-D1300 600/690V AFE SK-H1-ASICBD-E1030 Fiber-optic cable set 20-PP09017 (1) The ASIC board is unprogrammed. Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 133: Lcl Filter Assembly (Used In Ip20 And Ip21 Enclosures)

    400/480V SK-Y1-LCL1-D1K3 600/690V SK-Y1-LCL1-E1K0 LCL high-frequency capacitor 25 μF 400/480V SK-Y1-CAPHF3-DF assembly 20 μF 600/690V SK-Y1-CAPHF2-DF LCL capacitor assembly 120 μF 400/480V SK-Y1-CAPLCL1-D1K3 53 μF 600/690V SK-Y1-CAPLCL1-F1K0 LCL filter inverter fan fuse SK-Y1-F11-F10 Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 134 (2) These discontinued kits are no longer available, but spares inventory is applicable. Figure 44 - LCL Filter Fan Assembly Table 20 - LCL Filter Fan Assembly Catalog Number Part Name Cat. No. Main fan, 48V DC SK-Y1-DCFAN1 Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 135: Precharge Assembly

    Control transformer primary fuse 400/480V SK-Y1-MCCF6-D 600/690V SK-Y1-MCCF6-F Control transformer primary fuse holder SK-Y1-MCCF6FUSEHOLDER Control transformer (T10) secondary fuse/holder SK-Y1-MCCF3F4 (1) Kit includes diode bridge (V6), one resistor (R6.1), and a snubber capacitor (C1). Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 136 SK-Y1-T10-DF 24V DC power supply circuit breaker, 2 A SK-Y1-F10-DF Precharge motor protection relay SK-Y1-Q5-F13 (1) Kit includes diode bridge (V6), contactor (K6), two resistors (R6.1 and R6.2), and a snubber capacitor (C1). Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 137: Ac Line Switchgear

    MCC bus splice barrier kit (not shown; optional) SK-Y1-MCCBARRIER (1) The MCC bus splice barrier kit must be used when installing a right-side bus splice kit (SK-Y1-BUSSPLICE-F13R) or a left-side bus splice kit (SK-Y1-BUSSPLICE-F13R). Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 138 Table 24 - AC Line Switchgear Part Numbers for AFE in IP21 Rittal Enclosure Part Name Part No. Control circuit relay 230V AC SK-Y1-K20-DF 24V DC SK-Y1-K4-DF Input disconnect switch SK-Y1-Q0-F13 Motor controlled circuit breaker SK-Y1-Q1-F13 Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 139: Data To Collect

    Output Contactor Cable Length:___________________________Cable Type:______________________________ Drive Cat. No.:________________________________________________________________ Drive Drive Output Reactor Mfgr./Cat. No.:_________________________________________________ Terminator Mfgr./Cat. No.:_________________________________________________ Cable Length:__________________________Cable Type:_______________________________ Motor Manufacturer Motor Motor Volts Amps Power Design No. Encoder Brake Motor Heater Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 140: Typical Transformer Winding Types

    The following diagrams show typical transformer winding types. Types Figure 49 - Delta-Wye with Grounded Wye Neutral Figure 50 - Delta-Delta with Grounded Leg or Four-Wire Connected Secondary Delta Figure 51 - Ungrounded Secondary Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...

  • Page 141: Index

    AFE in IP20 2500 MCC Style enclosure 19 AFE in IP21 Rittal enclosure 22 measurement points for forward and external components of AFE power structure reverse diode tests 30 motor-controlled circuit breaker (MCCB) 72 Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 142 53 protective covers from the power structure U, V, or W phase assembly from AFE power structure 59 replacing power structure with a new power structure 68 reverse biased diode tests 29 Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017...
  • Page 144 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.

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