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Rockwell Automation Allen-Bradley PowerFlex Active Front End Series Hardware Service Manual

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Hardware Service Manual
PowerFlex Active Front End—Frame 10
PowerFlex AFE / PowerFlex 700AFE
(400/480V and 600/690V)

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Summary of Contents for Rockwell Automation Allen-Bradley PowerFlex Active Front End Series

  • Page 1 Hardware Service Manual PowerFlex Active Front End—Frame 10 PowerFlex AFE / PowerFlex 700AFE (400/480V and 600/690V)
  • 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 Summary of Changes The information below summarizes the changes to this manual since its last release (June 2011). Topic Page Added information for Frame 10 AFE in IP20 2500 MCC Style enclosure. Throughout manual PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...
  • Page 4 soc-ii Summary of Changes PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...

  • Page 5: Table Of Contents

    Table of Contents Preface Overview Who Should Use this Manual? ..........P-1 What is in this Manual .
  • Page 6 Table of Contents Removing the Fiber Optic Adapter Circuit Board......4-6 Installing the Fiber Optic Adapter Circuit Board ......4-8 Removing the Control Frame (only for AFE in IP21 Rittal enclosure).
  • Page 7 Table of Contents Removing the LCL Filter ..........7-6 From the IP20 2500 MCC Style Enclosure.
  • Page 8 Table of Contents PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...

  • Page 9: Preface

    End User Manual, publication 20Y-UM001. You can view or download publications at http:// Additional Resources www.rockwellautomation.com/literature. To order paper copies of technical documentation, contact your local Rockwell Automation distributor or sales representative. PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...

  • Page 10: Terms

    Overview General Information The following publications provide general drive information. Title Publication Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives DRIVES-IN001 Safety Guidelines for the Application, Installation and Maintenance of Solid State Control SGI-1.1 A Global Reference Guide for Reading Schematic Diagrams 100-2.10 Guarding Against Electrostatic Damage 8000-4.5.2...

  • Page 11: Additional Support Available On Internet

    Overview Additional troubleshooting information and software tools are available on Additional Support the Allen-Bradley Drives Technical Support website at http://www.ab.com/ Available on Internet support/abdrives. General Precautions for ATTENTION: Hazard of permanent eye damage exists when Class 1 LED Product using optical transmission equipment. This product emits intense light and invisible radiation.
  • Page 12 Overview Notes: PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...

  • Page 13: Chapter 1 Troubleshooting And Error Codes

    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 performing any servicing or repairs. ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged completely before servicing.

  • Page 14: Creating Fault Reports

    Troubleshooting and Error Codes Complete fault reports are critical for analysis and repair of modules Creating Fault Reports returned to the factory. At a minimum, do the following: • Using an Allen-Bradley drive configuration tool such as Connected ™ ™ Components Workbench software, DriveExplorer software, or...
  • Page 15 Troubleshooting and Error Codes Action (if appropriate) No. Name Description DC OverVolt The DC bus voltage exceeded 1. Check if the AFE was in a the maximum value of 911V for regenerative current limit 400/480V units, or 1200V for condition, which may indicate an 600/690V units.
  • Page 16 Troubleshooting and Error Codes Action (if appropriate) No. Name Description LineSync Fail One input of the known phase 1. Check all user-supplied fuses. rotation is missing. 2. Check the AC input line voltage. Phase Loss There is zero current in one of Check supply voltage, fuses, and the three phases.
  • Page 17 Troubleshooting and Error Codes Action (if appropriate) No. Name Description Zero Divide This event occurred because a 1. Cycle the power. mathematical function had a 2. Replace the Control board. See dividend of zero. page 4-5.. Start Prevent Startup has been prevented. 1.
  • Page 18 Troubleshooting and Error Codes Action (if appropriate) No. Name Description 106 MCB-PB Config The AFE rating information 1. Reset the fault. stored on the power board is 2. Cycle the power. incompatible with the Control 3. Replace the Control board on the board.

  • Page 19: Common Symptoms And Corrective Actions

    Troubleshooting and Error Codes Action (if appropriate) No. Name Description 128 Contact Fdbk The input of the acknowledge 1. Check for closure on the following signal from the main contactor is devices: missing. – For AFE in IP20 enclosure, input contactor (K1) –...
  • Page 20 Troubleshooting and Error Codes Instability in the AC Line Input Current and DC Bus Voltage. Cause Indication Corrective Action AC line voltage more than 5% above Instability in AC line Increase parameter 060 [DC Volt normal. current and DC bus Ref] proportional to the voltage.

  • Page 21: Afe In Ip20 2500 Mcc Style Enclosure

    Chapter Active Front End System Overview This chapter describes AFE system main components and is grouped by those used in a IP20 2500 MCC Style enclosure, a IP21 Rittal enclosure, and main components for the AFE IP00 open chassis configuration. AFE in IP20 2500 MCC Style Main Component Sections Enclosure...

  • Page 22: Main Component Locations

    Active Front End System Overview Main Component Locations The following figure shows the main components of the AFE Frame 10 system in a IP20 2500 MCC Style enclosure. Figure 2.2 AFE Frame 10 Main Component Locations in IP20 2500 MCC Style Enclosure FRONT VIEW FRONT VIEW...

  • Page 23: Main Bus Bar/Cable Locations

    Active Front End System Overview 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) • Bus bars between AC Fuses (F1.1…F1.3) and Input Contactor (K1) •...

  • Page 24: Afe In Ip21 Rittal Enclosure

    Active Front End System Overview AFE in IP21 Rittal Enclosure Main Component Sections The following figure shows a basic one-line diagram for an AFE system in a IP21 Rittal enclosure. The main component sections consist of the following items: • AC Line Switchgear consisting of the input disconnect (Q0) and MCCB motor-controlled circuit breaker (Q1) •...

  • Page 25: Main Component Locations

    Active Front End System Overview Main Component Locations The following figure shows the main components of the AFE Frame 10 system in a IP21 Rittal enclosure. Figure 2.5 AFE Frame 10 Main Component Locations in IP21 Rittal Enclosure FRONT VIEW (shown with enclosure doors removed) Item Description...

  • Page 26: Bus Bar Locations

    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 27: Afe In Ip00 Open Chassis Configuration

    Active Front End System Overview The following figure shows a basic one-line diagram for an AFE system in a AFE in IP00 Open Chassis IP00, NEMA/UL Open Chassis configuration and the parts the customer Configuration must supply. Figure 2.7 Basic One-line Diagram for AFE in IP00 Open Chassis Configuration AC Line Switchgear LCL Filter (L1) Power Structure (U1)
  • Page 28 Active Front End System Overview Notes: PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...

  • Page 29: Chapter 3 Component Test Procedures

    Chapter Component Test Procedures ATTENTION: The sheet metal cover and mounting screws on the ASIC Board located 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. ATTENTION: To avoid an electric shock hazard, verify that all power to the PowerFlex Active Front End has been removed before performing any servicing or repairs.

  • Page 30: Viewing The Status Indicators

    Component Test Procedures Viewing the Status Indicators Table 3.A AFE Status Indicator Descriptions Item Name Color State Description PWR (Power) Green Steady Illuminates when power is applied to the AFE. PORT Status of DPI port internal communication (if present). See the Communication Status of communication adapter (when installed).

  • Page 31: Performing Forward And Reverse Biased Diode Tests For Power Structure

    Component Test Procedures 2. Remove the protective front cover and terminal cover from the power structure. Removing Protective Covers from the Power Structure on page 4-12. 3. Check components for burn marks, breakage, or foil delamination on circuit boards. Check all the boards on the power structure. Replace any of these components if they show evidence of burn marks, breakage, or foil delamination.
  • Page 32 Component Test Procedures 4. Conduct forward and reverse biased diode tests on the power structure. Figure 3.1 Measurement Points for Forward and Reverse Diode Tests B+ (DC+) B– (DC–) U/T1 V/T2 W/T3 Table 3.B Forward Biased Diode Tests on Power Structure Meter Leads Nominal meter reading U/T1...

  • Page 33: Checking Fiber Optic Connections

    Component Test Procedures Table 3.C Reverse Biased Diode Tests on Power Structure Meter Leads Nominal meter reading U/T1 V/T2 W/T3 Meter should display ‘.0L’ (zero load) 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 using any of the following options: –...
  • Page 34 Component Test Procedures 4. Locate the Gate Driver board on the front of the power structure (right-side enclosure). 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 35: Performing Gate Driver Board Resistance Measurements

    Component Test Procedures 1. Remove power from the AFE. Performing Gate Driver Board Resistance Removing Power from the AFE on page 4-3. Measurements 2. If present, remove the protective barriers. Removing AFE Protective Barriers on page 4-10. 3. Remove the protective front cover and terminal cover from the power structure.

  • Page 36: Checking The Afe Power Structure Fan Inverter Fuses

    Component Test Procedures 1. Remove power from the AFE. Checking the AFE Power Structure Fan Inverter Fuses Removing Power from the AFE on page 4-3. 2. If present, remove the protective barriers. Removing AFE Protective Barriers on page 4-10. 3. Remove the protective front cover and terminal cover from the power structure.

  • Page 37: Chapter 4 Afe Power Structure Component Section

    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 performing any servicing or repairs. ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged completely before servicing.

  • Page 38: Understanding Torque Figures In Assembly Diagrams

    AFE Power Structure Component Section Icons and numbers in the assembly diagrams indicate how to tighten Understanding Torque hardware. Figures in Assembly Tool Type and Size Diagrams Fastener Type PZ indicates POZIDRIV screwdriver bit P indicates Phillips screwdriver bit POZIDRIV Screw Phillips Screw Hexagonal Bolt...

  • Page 39: Removing Power From The Afe

    AFE Power Structure Component Section Removing Power from the ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged completely before servicing. 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.

  • Page 40: Control Frame Access Procedures

    AFE Power Structure Component Section Control Frame Access Removing the DPI Interface Assembly Procedures 1. Remove power from the AFE. Removing Power from the AFE on page 4-3. Important: Before removing connections and wires, mark them to avoid incorrect wiring during assembly. 2.

  • Page 41: Installing The Dpi Interface Assembly

    AFE Power Structure Component Section Installing the DPI Interface Assembly Install the DPI interface assembly in the reverse order of removal, while referring to Torque Specifications on page 4-2. Removing the I/O Circuit Boards and Control Board 1. Remove power from the AFE. Removing Power from the AFE on page 4-3.

  • Page 42: Installing The I/O Circuit Boards And Control Board

    AFE Power Structure Component Section 5. Remove the three screws that secure the Control board to the Control box, and remove the Control board. NOTE: Do not remove the enclosure cover from the Control Frame. For clarity, the enclosure is shown without the cover. 3 N•m (27 lb•in) Installing the I/O Circuit Boards and Control Board...
  • Page 43 AFE Power Structure Component Section 3. Disconnect the cables from X2 and X3 of the Fiber Optic Adapter board. Important: Note polarity when removing X2 and X3 wires. If polarity is not maintained when re-installing these wires, the ASIC board or fiber optic board can be damaged. X1 disconnects from the Control board when you remove the board from...

  • Page 44: Installing The Fiber Optic Adapter Circuit Board

    AFE Power Structure Component Section 5. Remove the four screws that secure the Fiber Optic Adapter board to the stand-offs on the back of the Control box (IP20) or Control Frame (IP21) and remove the Fiber Optic Adapter board. For AFE in IP20 2500 For AFE in IP21 MCC Style Enclosure Rittal Enclosure...

  • Page 45: Removing The Control Frame (Only For Afe In Ip21 Rittal Enclosure)

    AFE Power Structure Component Section Removing the Control Frame (only for AFE in IP21 Rittal enclosure) 1. Remove power from the AFE. Removing Power from the AFE on page 4-3. terminal block 2. Loosen the T8 Torx-head screws, which secure the Control Frame to the AFE enclosure.

  • Page 46: Power Structure Access Procedures

    4-10 AFE Power Structure Component Section Follow these instructions to remove and install components on the power Power Structure Access structure, and to remove the Power Module from the power structure. Procedures Important: To access Power Modules for replacement requires the power structure to be completely removed from the AFE enclosure.

  • Page 47: Removing The Afe Air Flow Plate

    AFE Power Structure Component Section 4-11 Removing the AFE Air Flow Plate You must remove the Air Flow Plate to remove the power structure from the AFE. 1. Remove power from the AFE. Removing Power from the AFE on page 4-3.

  • Page 48: Removing Protective Covers From The Power Structure

    4-12 AFE Power Structure Component Section Removing Protective Covers from the Power Structure You must remove the protective covers to access the internal components of the power structure. 1. Remove power from the AFE. Removing Power from the AFE on page 4-3.
  • Page 49 AFE Power Structure Component Section 4-13 3. Remove the Air Flow Plate. Removing the AFE Air Flow Plate on page 4-11. 4. Remove the protective front cover and terminal cover from the power structure. Removing Protective Covers from the Power Structure on page 4-12.

  • Page 50: Installing The Gate Driver Circuit Board

    4-14 AFE Power Structure Component Section 10. Carefully remove the two plastic screws that secure the Gate Driver board screening plate to the power structure and remove the screening plate. 11. Remove the two stand-offs that support the Gate Driver board. Remove plastic screws Remove screening plate Remove stand-offs...
  • Page 51 AFE Power Structure Component Section 4-15 5. Remove the four screws that secure the ASIC cover to the ASIC assembly, remove the -DC bus connection from the ASIC cover, and remove the ASIC cover. Remove Remove screws screws and cover ASIC cover ASIC Remove -DC...
  • Page 52 4-16 AFE Power Structure Component Section 10. Remove the four screws that secure the ASIC assembly to the power structure and remove the ASIC assembly. 11. Remove the screw and detach the four plastic standoffs that secure the ASIC board to the ASIC chassis, and remove the ASIC board. Remove screw Remove ASIC circuit board from chassis If the plastic insulator requires replacement, do the following:...

  • Page 53: Installing The Asic Circuit Board

    AFE Power Structure Component Section 4-17 Installing the ASIC Circuit Board Install the ASIC circuit board in reverse order of removal, while referring to Torque Specifications on page 4-2. Reconnect cables and jumpers to the ASIC board, while referring to Figure B.1 on page B-1.
  • Page 54 4-18 AFE Power Structure Component Section 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 55: Installing The Power Structure In The Enclosure

    AFE Power Structure Component Section 4-19 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 56: Removing The Power Module From The Power Structure

    4-20 AFE Power Structure Component Section Removing the Power Module from the Power Structure Important: Do not attempt to disassemble the Power Module. 1. Remove the power structure from the AFE enclosure. Removing the Power Structure from the Enclosure on page 4-17.
  • Page 57 AFE Power Structure Component Section 4-21 5. Remove the power structure side panel to access the internal components. Side Panel 6. Place the power structure on its heatsink side for easy access to the internal components. 7. Remove the Gate Driver Circuit board. Removing the Gate Driver Circuit Board on page 4-12.
  • Page 58 4-22 AFE Power Structure Component Section 13. 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). 14. Cut and remove the cable ties that secure the input power cables to the EMC cover plate and remove the cables.
  • Page 59 AFE Power Structure Component Section 4-23 17. Remove the screws that secure the power bus bar and support insulators to the power structure. Support insulators Power bus bar Remove screws 18. Remove the power bus bar and insulators. Tightening torque for reassembly is 14 N•m (124 lb•in). 19.
  • Page 60 4-24 AFE Power Structure Component Section 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 61 AFE Power Structure Component Section 4-25 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 62: Installing The Power Module On The Power Structure

    4-26 AFE Power Structure Component Section 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 Installing the Power Module on the Power Structure Install the Power module in reverse order of removal, while referring to Torque Specifications on page 4-2.

  • Page 63: Installing The Power Structure Dc Bus Capacitors

    AFE Power Structure Component Section 4-27 4. Remove the capacitor. Tightening torque for reassembly is 1.35 N•m (12 lb•in). We recommend replacing all capacitors at the same time. 5. Repeat steps 3 and 4 for each remaining DC bus capacitor being removed.
  • Page 64 4-28 AFE Power Structure Component Section Notes: PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...

  • Page 65: Chapter 5 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 performing any servicing or repairs. ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged completely before servicing.

  • Page 66: Afe In Ip20 2500 Mcc Style Enclosure

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

  • Page 67: Chapter 6 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 performing any servicing or repairs. ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged completely before servicing.

  • Page 68: Precharging Functions

    Precharge Component Section The precharge circuitry has two main functions: Precharging Functions • It provides AFE system control power. • It 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 69: Testing The Control Transformer (T4) And 24V Dc Power Supply (T10)

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

  • Page 70: For Afe In Ip21 Rittal Enclosure

    Precharge Component Section b. Measure the control transformer (T4) output voltage, which is approximately 120V AC. If these measurements are not within ±10%, perform these other steps. c. Power down the AFE. d. Remove the output (secondary) wires. e. Power up the AFE and retest by repeating steps a and b. The control transformer (T4) may require replacement if these measurements continue to be outside of the ±10% tolerance.
  • Page 71 Precharge Component Section 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 72: Testing The Precharge Bridge Using The Power Structure Terminals

    Precharge Component Section 1. Remove power from the AFE. Testing the Precharge Bridge Using the Power Removing Power from the AFE on page 4-3. Structure Terminals 2. If present, remove the protective barriers. Removing AFE Protective Barriers on page 4-10. 3.

  • Page 73: Testing The Precharge Resistor

    Precharge Component Section 8. Remove the precharge bridge mounting nuts. 9. Remove and appropriately discard the old precharge bridge. 10. Install the new precharge bridge in reverse order of removal, while referring to Torque Specifications on page 4-2. 1. Remove power from the AFE. Testing the Precharge Resistor Removing Power from the AFE on page...

  • Page 74: Replacing The Precharge Resistor Assembly

    Precharge Component Section Replacing the Precharge AFE in IP20 2500 MCC Style Enclosure Resistor Assembly 1. Remove power from the AFE. Removing Power from the AFE on page 4-3. 2. Open the LCL Filter enclosure door. 3. If present, remove the protective barriers. Removing AFE Protective Barriers on page 4-10.

  • Page 75: Chapter 7 Lcl Filter Component Section

    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 performing any servicing or repairs. ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged completely before servicing.

  • Page 76: Removing The Lcl Filter Protective Barrier

    LCL Filter Component Section 1. Remove power from the AFE. Removing the LCL Filter Protective Barrier Removing Power from the AFE on page 4-3. 2. Remove the sixteen T25 Torx self-tapping screws that secure the protective barrier. 3. Remove the protective barrier from the LCL Filter enclosure. Figure 7.1 Removing LCL Filter Protective Barrier FRONT VIEW AFE and LCL Filter in IP21 Rittal enclosures...

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

    LCL Filter Component Section The following figures show the LCL Filter fan DC Power Supply wiring Removing the LCL Filter Fan diagram with the connections to the AFE power structure and DC bus. DC Power Supply For complete details on LCL fan system information, see the PowerFlex 700H, 700S, and 700AFE Drive Fan Systems Installation Instructions, publication PFLEX-IN029.
  • Page 78 LCL Filter Component Section 1. Remove the LCL Filter protective barrier. Removing the LCL Filter Protective Barrier on page 7-2. 2. Remove the two M4 x 10 mm POZIDRIVE screws that secure the cover. 3. Remove the cover. 4. Remove the connectors X1, X3, X4, and X8. PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...

  • Page 79: Installing The Lcl Filter Fan Dc Power Supply

    LCL Filter Component Section 5. Remove the six fasteners that secure the DC-to-DC power supply. Install the DC-to-DC power supply in reverse order of removal, while Installing the LCL Filter Fan referring to Torque Specifications on page 4-2. DC Power Supply 1.

  • Page 80: From The Ip20 2500 Mcc Style Enclosure

    LCL Filter Component Section 4. Lower the front fan sheet metal edge and slide it forward to remove the alignment studs from their respective holes in the fan frame sheet metal. 5. Slide out the fan assembly. 6. Remove the LCL Filter Fan DC Power supply. Removing the LCL Filter Fan DC Power Supply on page 7-3.
  • Page 81 LCL Filter Component Section Figure 7.4 Removing LCL Filter from AFE in IP20 2500 MCC Style Enclosure DETAIL B DETAIL A Remove Two Screws 6. Disconnect the AC input power cables (L1, L2, L3) between the input contactor and LCL Filter. For cable locations, see Figure 2.3 on page 2-3.

  • Page 82: From The Ip21 Rittal Enclosure

    LCL Filter Component Section 8. Slide the LCL Filter out of the enclosure. Note that ramps (customer-supplied) shown below may be required due to enclosure floor mismatch. From the IP21 Rittal Enclosure 1. Remove power from the AFE. Removing Power from the AFE on page 4-3.

  • Page 83: Installing The Lcl Filter In The Enclosure

    LCL Filter Component Section 8. Slide the LCL Filter out of the enclosure. Note that ramps (customer-supplied) shown below may be required due to enclosure floor mismatch. LCL Filter Removed from Enclosure Install the LCL Filter in reverse order of removal, while referring to Torque Installing the LCL Filter in Specifications on page...
  • Page 84 7-10 LCL Filter Component Section Notes: PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...

  • Page 85: Chapter 8 Dc Fuses Component Section

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

  • Page 86: Fuse Replacement Guidelines

    DC Fuses Component Section DC bus fuses are required for short circuit protection. The following tables Fuse Replacement list the recommended DC bus fuses. Guidelines Table 8.A 400/480 Volt DC Fusing Fuse Frame Size Enclosure Style Amps Bussman Type Ferraz Shawmut Type IP20 2500 MCC 1100 170M6499...
  • Page 87 DC Fuses Component Section For more information about Bussmann fuses, go online at http://www.cooperindustries.com. For more information about Ferraz Shawmut fuses, go online at http://www.ferrazfuses.com. PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...
  • Page 88 DC Fuses Component Section Notes: PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...

  • Page 89: Chapter 9 Startup After Repair

    Chapter Startup After Repair ATTENTION: The sheet metal cover and mounting screws on the ASIC Board located 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. ATTENTION: Power must be applied to the PowerFlex Active Front End to perform the following start-up procedure.

  • Page 90: Before Applying Power To The Afe

    Startup After Repair 1. Open the power structure enclosure door. Before Applying Power to the AFE 2. If present, remove the protective barriers. Removing AFE Protective Barriers on page 4-10. 3. Check for zero volts between DC+ and DC-. 4. Perform forward and reverse biased diode tests, using a digital multimeter.

  • Page 91: Appendix A Service Tools And Equipment

    Appendix Service Tools and Equipment Connected Components Workbench software, DriveExecutive software, or Software Tools DriveExplorer software are tools that can be used for uploading, downloading, and monitoring system parameters. The following list contains the basic service tools needed for repair and Service Tools maintenance measurements.
  • Page 92 Service Tools and Equipment Notes: PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...

  • Page 93: Appendix B Schematic Diagrams

    Appendix Schematic Diagrams Frame 10 Circuit Board Connections PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...

  • Page 94: Frame 10 Power Module Circuitry

    Schematic Diagrams Frame 10 Power Module Circuitry PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...

  • Page 95: Frame 10 Power Structure Main Fan Connections

    Schematic Diagrams Frame 10 Power Structure 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 DC Main Fan PowerFlex 700S, 700H, and 700AFE Drive Fan Systems Installation Instructions, publication PFLEX-IN029.

  • Page 96: Control Wiring Diagram For Frame 10 In Ip20 2500 Mcc Style Enclosure

    Schematic Diagrams Control Wiring Diagram for Frame 10 in IP20 2500 MCC Style Enclosure Figure B.5 Control Wiring Diagram for Frame 10 in IP20 2500 MCC Style Enclosure PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...
  • Page 97 Schematic Diagrams PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...

  • Page 98: System Schematics For Frame 10 In Ip20 2500 Mcc Style Enclosure

    Schematic Diagrams System Schematics for Frame 10 in IP20 2500 MCC Style Enclosure The following system schematics are for the AFE Frame 10 in a IP20 2500 MCC Style enclosure. The PowerFlex AFE catalog number has an enclosure code of P for standard color (or W for optional gray color) as shown in the example catalog string below.
  • Page 99 Schematic Diagrams PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...
  • Page 100 Schematic Diagrams PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...
  • Page 101 Schematic Diagrams PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...
  • Page 102 B-10 Schematic Diagrams PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...
  • Page 103 Schematic Diagrams B-11 PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...
  • Page 104 B-12 Schematic Diagrams PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...

  • Page 105: Control Wiring Diagram For Frame 10 In Ip21 Rittal Enclosure

    Schematic Diagrams B-13 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. N.O.

  • Page 106: System Schematics For Frame 10 Afe In Ip21 Rittal Enclosure

    B-14 Schematic Diagrams System Schematics for Frame 10 AFE in IP21 Rittal Enclosure The following system schematics are for the AFE Frame 10 in a IP21 Rittal enclosure. The PowerFlex AFE catalog number has an enclosure code of A as shown in the example catalog string below. For other enclosure designs, contact the supplier of the system for the system schematics.
  • Page 107 Schematic Diagrams B-15 PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...
  • Page 108 B-16 Schematic Diagrams PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...
  • Page 109 Schematic Diagrams B-17 PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...
  • Page 110 B-18 Schematic Diagrams PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...
  • Page 111 Schematic Diagrams B-19 PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...
  • Page 112 B-20 Schematic Diagrams PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...
  • Page 113 Schematic Diagrams B-21 PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...
  • Page 114 B-22 Schematic Diagrams Notes: PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...

  • Page 115: Circuit Board Connections

    Appendix Connector Descriptions The following tables detail the connection points for the Frame 10 Circuit Board Connections PowerFlex Active Front End circuit boards and components. Table C.A Fiber Optic Adapter Board-to-ASIC Circuit Board Connections Fiber Optic Signal Description: ASIC Board Fiber Adapter Connector Type Reference to ASIC Board Type Connector...
  • Page 116 Connector Descriptions Table C.B 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 Pin 8 U_DC-_I...
  • Page 117 Connector Descriptions Figure C.1 Fiber Optic Cable Routing PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...

  • Page 118: Hardware Connections

    Connector Descriptions Hardware Connections Figure C.2 AFE Power Structure Fan Inverter Circuit Board Connectors Table C.C ASIC Board - AFE Power Structure Fan Inverter Board Connections AFE Power Structure Fan Inverter Board ASIC Board Connector Signal Description Connector From ASIC_+15V From FAN_CONTROL FAN_ALARM...
  • Page 119 Appendix Disassembly/Assembly Diagrams and Spare Parts Diagram Page AFE Power Structure Assembly External Components AFE Power Structure Assembly Internal Components AFE Power Structure ASIC Assembly LCL Filter Assembly LCL Filter Power Supply Assembly LCL Filter Fan Assembly Precharge Assembly for AFE in IP20 2500 MCC Style Enclosure Precharge Assembly for AFE in IP21 Rittal Enclosure AC Line Switchgear Components for AFE in IP20 2500 MCC Style Enclosure AC Line Switchgear Components for AFE in IP21 Rittal Enclosure...

  • Page 120: Afe Power Structure Assembly

    Disassembly/Assembly Diagrams and Spare Parts AFE Power Structure Figure D.1 AFE Power Structure Assembly External Components Assembly ATTENTION: The sheet metal cover and mounting screws on the ASIC Board located 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 121 Disassembly/Assembly Diagrams and Spare Parts Figure D.2 AFE Power Structure Assembly Internal Components EMC Cover DC Bus Bar Assembly Snubber Capacitor Assembly Power Bus Bar Electrolytic Capacitors Balancing Resistors Power Module (IGBTs) DC Bus Bar Terminal Assembly AC Fan Inverter Assembly or DC Fan Power Supply (see publication PFLEX-IN029 for complete details)
  • Page 122 Disassembly/Assembly Diagrams and Spare Parts ATTENTION: The sheet metal cover and mounting screws on the ASIC Board located 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. Figure D.3 AFE Power Structure ASIC Assembly ASIC Assembly Cover ASIC Board...

  • Page 123: Lcl Filter Assembly (Used In Ip20 And Ip21 Enclosures

    Disassembly/Assembly Diagrams and Spare Parts LCL Filter Assembly (used Figure D.4 LCL Filter Assembly in IP20 and IP21 enclosures) LCL Filter Assembly LCL Capacitor Assembly LCL High Frequency Capacitor Assembly Table D.D LCL Filter Assembly Part Numbers Part Name Part No. LCL Filter Assembly 400/480V SK-Y1-LCL1-D460...
  • Page 124 Disassembly/Assembly Diagrams and Spare Parts Figure D.5 LCL Filter Power Supply Assembly Table D.E LCL Filter Power Supply Assembly Part Numbers Part No. Part Name Universal Kit Discontinued July 2014 400/480V SK-Y1-DCPS1-D460 LCL Filter SK-Y1-DCPS2-F10 Power Supply 600/690V SK-Y1-DCPS1-F325 LCL Fan Wire Kit SK-Y1-HF1-DF This kit can be used for either voltage class.

  • Page 125: Precharge Assembly

    Disassembly/Assembly Diagrams and Spare Parts Precharge Assembly Figure D.7 Precharge Assembly for AFE in IP20 2500 MCC Style Enclosure FRONT VIEW (shown with enclosure doors removed) • Precharge Fuse and Fuse Holder Precharge • Precharge Kit Resistors • Control Transformer (T4) •...
  • Page 126 Disassembly/Assembly Diagrams and Spare Parts Figure D.8 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 • Control Transformer Motor Protection Relay •...

  • Page 127: Ac Line Switchgear

    Disassembly/Assembly Diagrams and Spare Parts AC Line Switchgear Figure D.9 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 AC Input Fuses...
  • Page 128 D-10 Disassembly/Assembly Diagrams and Spare Parts Figure D.10 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 D.J AC Line Switchgear Part Numbers for AFE in IP21 Rittal Enclosure Part Name Part No.

  • Page 129: Afe Power One-Line System Application Data

    Appendix AFE Power One-line System Application Data Collect the following AFE system data before contacting Allen-Bradley Data to Collect Drives Technical Support. Utility Transformer Delta-Delta, Delta-Wye, etc. Type Input Volts Output Volts None, Solid, High Resistive Ground Cable Length: __________________________ Cable Type: _____________________________ Secondary Transformer Type...

  • Page 130: Typical Transformer Winding Types

    AFE Power One-line System Application Data The following diagrams show typical transformer winding types. Typical Transformer Winding Types Delta-Wye with Grounded Wye Neutral Delta-Delta with Grounded Leg Four-Wire Connected Secondary Delta Ungrounded Secondary PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...
  • Page 131 Index AC line switchgear DC fuses components overview, 8-1 AFE in IP20 2500 MCC Style replacement guidelines, 8-2 enclosure, D-9 de-energizing the AFE, 4-3 AFE in IP21 Rittal enclosure, diagnostic status indicators, 3-2 D-10 diode test overview, 5-1 forward biased, 3-3 Active Front End system overview, 2-1 reverse biased, 3-3 additional resources...
  • Page 132 Index-2 LCL filter performing assembly parts, D-5 forward biased diode test, 3-3 fan DC power supply gate driver board resistance installation, 7-5 measurements, 3-7 removal, 7-3 reverse biased diode test, 3-3 visual inspections, 3-2 fan replacement, 7-5 fuse replacement, 7-2 powering down, 4-3 removing from precharge...
  • Page 133 Index-3 removing testing AFE air flow plate, 4-11 control transformer and 24V DC power supply, 6-3 AFE protective barriers, 4-10 forward biased diode, 3-3 ASIC circuit board, 4-14 gate driver board resistance, 3-7 control frame (only AFE in IP21 Rittal enclosure), 4-9 precharge bridge, 6-6 DPI/HIM assembly, 4-4...
  • Page 134 Index-4 PowerFlex Active Front End—Frame 10 Hardware Service Manual Publication 20Y-TG001B-EN-P...
  • Page 136 New Product Satisfaction Return Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility. However, if your product is not functioning and needs to be returned, follow these procedures.

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