Download PowerFlex 700AFE Frame 10 Hardware Service Manual

Hardware Service Manual
PowerFlex Active Front End—Frame 10
PowerFlex AFE / PowerFlex 700AFE
(400/480V and 600/690V)
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.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required
to be carried out by suitably trained personnel in accordance with applicable code of practice.
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.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
IMPORTANT
Identifies information that is critical for successful application and understanding of the product.
Labels may also be on or inside the equipment to provide specific precautions.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
Allen-Bradley, Rockwell Software, and Rockwell Automation are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
3UMMARYOF#HANGES
4HEINFORMATIONBELOWSUMMARIZESTHECHANGESTOTHISMANUALSINCEITSLAST
RELEASE*UNE
Page
Added information for Frame 10 AFE in IP20 2500 MCC Style enclosure.
Throughout
manual
Topic
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
Summary of Changes
soc-ii
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
4ABLEOF#ONTENTS
Preface
Overview
7HO3HOULD5SETHIS-ANUAL 0
7HATISINTHIS-ANUAL 0
7HATIS.OTINTHIS-ANUAL 0
!DDITIONAL2ESOURCES 0
'ENERAL)NFORMATION 0
0OWER&LEX!CTIVE&RONT%ND)NFORMATION 0
5NDERSTANDING-ANUAL#ONVENTIONS 0
4ERMS 0
#ROSS2EFERENCES 0
!DDITIONAL3UPPORT!VAILABLEON)NTERNET 0
'ENERAL0RECAUTIONSFOR#LASS,%$0RODUCT 0
Chapter 1
Troubleshooting and Error Codes
#REATING&AULT2EPORTS !DDRESSING0OWER&LEX!CTIVE&RONT%ND&AULTS #OMMON3YMPTOMSAND#ORRECTIVE!CTIONS Active Front End System Overview
Chapter 2
!&%IN)0-##3TYLE%NCLOSURE -AIN#OMPONENT3ECTIONS -AIN#OMPONENT,OCATIONS -AIN"US"AR#ABLE,OCATIONS !&%IN)02ITTAL%NCLOSURE -AIN#OMPONENT3ECTIONS -AIN#OMPONENT,OCATIONS "US"AR,OCATIONS !&%IN)0/PEN#HASSIS#ONFIGURATION Chapter 3
Component Test Procedures
6IEWINGTHE3TATUS)NDICATORS 0ERFORMING6ISUAL)NSPECTIONS )NSPECTINGTHE#OOLING4UNNEL )NSPECTINGTHE0OWER3TRUCTURE 0ERFORMING&ORWARDAND2EVERSE"IASED$IODE4ESTSFOR0OWER3TRUCTURE #HECKING&IBER/PTIC#ONNECTIONS 0ERFORMING'ATE$RIVER"OARD2ESISTANCE-EASUREMENTS #HECKINGTHE!&%0OWER3TRUCTURE&AN)NVERTER&USES Chapter 4
AFE Power Structure Component Section
5NDERSTANDING4ORQUE&IGURESIN!SSEMBLY$IAGRAMS 4ORQUE3PECIFICATIONS 2EMOVING0OWERFROMTHE!&% #ONTROL&RAME!CCESS0ROCEDURES 2EMOVINGTHE$0))NTERFACE!SSEMBLY )NSTALLINGTHE$0))NTERFACE!SSEMBLY 2EMOVINGTHE)/#IRCUIT"OARDSAND#ONTROL"OARD )NSTALLINGTHE)/#IRCUIT"OARDSAND#ONTROL"OARD 0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
ii
Table of Contents
2EMOVINGTHE&IBER/PTIC!DAPTER#IRCUIT"OARD
)NSTALLINGTHE&IBER/PTIC!DAPTER#IRCUIT"OARD 2EMOVINGTHE#ONTROL&RAMEONLYFOR!&%IN)02ITTALENCLOSURE
2EPLACINGTHE#ONTROL&RAME
0OWER3TRUCTURE!CCESS0ROCEDURES 2EMOVING!&%0ROTECTIVE"ARRIERS )NSTALLINGTHE!&%0ROTECTIVE"ARRIERS 2EMOVINGTHE!&%!IR&LOW0LATE )NSTALLINGTHE!&%!IR&LOW0LATE 2EMOVING0ROTECTIVE#OVERSFROMTHE0OWER3TRUCTURE )NSTALLING0ROTECTIVE#OVERSONTHE0OWER3TRUCTURE 2EMOVINGTHE'ATE$RIVER#IRCUIT"OARD )NSTALLINGTHE'ATE$RIVER#IRCUIT"OARD
2EMOVINGTHE!3)##IRCUIT"OARD )NSTALLINGTHE!3)##IRCUIT"OARD 2EMOVINGAND)NSTALLINGTHE0OWER3TRUCTURE&AN3YSTEM
2EMOVINGTHE0OWER3TRUCTUREFROMTHE%NCLOSURE )NSTALLINGTHE0OWER3TRUCTUREINTHE%NCLOSURE
2EMOVINGTHE0OWER-ODULEFROMTHE0OWER3TRUCTURE )NSTALLINGTHE0OWER-ODULEONTHE0OWER3TRUCTURE 2EMOVINGTHE0OWER3TRUCTURE$#"US#APACITORS )NSTALLINGTHE0OWER3TRUCTURE$#"US#APACITORS
2EPLACINGTHE%XISTING0OWER3TRUCTUREWITHA.EW0OWER3TRUCTURE Chapter 5
AC Line Switchgear Component Section
!&%IN)0-##3TYLE%NCLOSURE !&%IN)02ITTAL%NCLOSURE Chapter 6
Precharge Component Section
0RECHARGING&UNCTIONS 2EPLACINGTHE0RECHARGE&USE
4ESTINGTHE#ONTROL4RANSFORMER4AND6$#0OWER3UPPLY4
&OR!&%IN)0-##3TYLE%NCLOSURE
&OR!&%IN)02ITTAL%NCLOSURE
4ESTINGTHE0RECHARGE"RIDGE5SINGTHE0OWER3TRUCTURE4ERMINALS
2EPLACINGTHE0RECHARGE"RIDGE 4ESTINGTHE0RECHARGE2ESISTOR
2EPLACINGTHE0RECHARGE2ESISTOR!SSEMBLY !&%IN)0-##3TYLE%NCLOSURE !&%IN)02ITTAL%NCLOSURE Chapter 7
LCL Filter Component Section
2EMOVINGTHE,#,&ILTER0ROTECTIVE"ARRIER )NSTALLINGTHE,#,&ILTER0ROTECTIVE"ARRIER
2EPLACINGTHE,#,&ILTER$#&AN&USES 2EMOVINGTHE,#,&ILTER&AN$#0OWER3UPPLY
)NSTALLINGTHE,#,&ILTER&AN$#0OWER3UPPLY 2EPLACINGTHE,#,&ILTER&AN 0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
Table of Contents
iii
2EMOVINGTHE,#,&ILTER &ROMTHE)0-##3TYLE%NCLOSURE &ROMTHE)02ITTAL%NCLOSURE )NSTALLINGTHE,#,&ILTERINTHE%NCLOSURE Chapter 8
DC Fuses Component Section
/VERVIEW &USE2EPLACEMENT'UIDELINES Chapter 9
Startup After Repair
"EFORE!PPLYING0OWERTOTHE!&% Appendix A
Service Tools and Equipment
3OFTWARE4OOLS !
3ERVICE4OOLS !
Appendix B
Schematic Diagrams
&RAME#IRCUIT"OARD#ONNECTIONS"
&RAME0OWER-ODULE#IRCUITRY"
&RAME0OWER3TRUCTURE-AIN&AN#ONNECTIONS "
#ONTROL7IRING$IAGRAMFOR&RAMEIN)0-##3TYLE%NCLOSURE"
3YSTEM3CHEMATICSFOR&RAMEIN)0-##3TYLE%NCLOSURE "
#ONTROL7IRING$IAGRAMFOR&RAMEIN)02ITTAL%NCLOSURE "
3YSTEM3CHEMATICSFOR&RAME!&%IN)02ITTAL%NCLOSURE"
Appendix C
Connector Descriptions
#IRCUIT"OARD#ONNECTIONS #
(ARDWARE#ONNECTIONS #
Appendix D
Disassembly/Assembly Diagrams and Spare Parts
!&%0OWER3TRUCTURE!SSEMBLY $
,#,&ILTER!SSEMBLYUSEDIN)0AND)0ENCLOSURES $
0RECHARGE!SSEMBLY $
!#,INE3WITCHGEAR $
Appendix E
AFE Power One-line System Application Data
$ATATO#OLLECT%
4YPICAL4RANSFORMER7INDING4YPES%
Index
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
Table of Contents
iv
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
0REFACE
Overview
Who Should Use this
Manual?
4HISMANUALISINTENDEDFORQUALIFIEDSERVICEPERSONNELRESPONSIBLEFOR
TROUBLESHOOTINGANDREPAIRINGTHE0OWER&LEX¤!CTIVE&RONT%ND!&%9OU
SHOULDHAVEPREVIOUSEXPERIENCEWITHANDBASICUNDERSTANDINGOFELECTRICAL
TERMINOLOGYPROCEDURESREQUIREDTROUBLESHOOTINGEQUIPMENTEQUIPMENT
PROTECTIONPROCEDURESANDMETHODSANDSAFETYPRECAUTIONS3EESAFETY
RELATEDPRACTICESCONTAINEDIN3TANDARDFOR%LECTRICAL3AFETYINTHE7ORK
0LACEPUBLICATION.&0!%
What is in this Manual
4HISMANUALCONTAINSHARDWARESERVICEINFORMATIONFORTHE&RAME
0OWER&LEX!CTIVE&RONT%ND6ERIFYTHATYOUAREWORKINGONA&RAMEBY
CHECKINGTHEDATANAMEPLATEONTHE!&%4HEFRAMENUMBERISPRINTEDJUST
ABOVETHESERIALNUMBER
Data Nameplate on AFE
in IP21 Rittal Enclosure
Data Nameplate on AFE
in IP20 2500 MCC Style Enclosure
0035
-842
0/435
Cat No.
20D
500 N 0 NNNBNNNN
J
UL Open Type/IP00
Frame: 10
Serial Number: 12345678
540V
250 kW
Normal Duty Power
200 kW
Heavy Duty Power
Input: DC,
462 - 594
DC Voltage Range
350
Amps
Output: 3 Phase, 0 - 320Hz
AC Voltage Range
0 - 400
50 Hz
Base Hz (default)
420/500
Continuous Amps
630/550
1 Min Overload Amps
!&%
2 Sec Overload
Amps
840/630
MFD. in 1989 on Nov 9
Cat No.
20D
J
300 N 0 NNNBNNNN
UL Open Type/IP00
540V
650V
Normal Duty Power
160 kW
250 kW
Heavy Duty Power
132 kW
200 kW
Input: DC,
DC Voltage Range
462 - 594 583 - 713
Amps
350
350
Output: 3 Phase, 0 - 320Hz
0 - 400
0 - 460
AC Voltage Range
Base Hz (default)
50 Hz
60 Hz
Continuous Amps
300/245
300/245
330/368
330/368
1 Min Overload Amps
450/490
450/490
2 Sec Overload Amps
Series: A
Standard I/O: NONE
Original Firmware No. 2.04
C
UL
Æ
US
LISTED
IND CONT EQ
Series: A
650V
450 kW
500 kW
Standard I/O: NONE
Original Firmware No. 2.04
C
583 - 713
350
UL
Æ
US
LISTED
IND CONT EQ
9D42
0 - 460
60 Hz
420/500
630/550
840/630
Frame #: 10
Serial Number: 2622381652
MFD. in 1989 on Nov 9
Serial Number: 2622381652
MADE IN THE USA (FAC 1B)
MADE IN THE USA (FAC 1B)
4HISMANUALDOESNOTCONTAININSTALLATIONSTARTUPANDPROGRAMMING
INFORMATION4HISINFORMATIONISAVAILABLEINTHE0OWER&LEX!CTIVE&RONT
%ND5SER-ANUALPUBLICATION95-
Additional Resources
9OUCANVIEWORDOWNLOADPUBLICATIONSATHTTP
WWWROCKWELLAUTOMATIONCOMLITERATURE4OORDERPAPERCOPIESOFTECHNICAL
DOCUMENTATIONCONTACTYOURLOCAL2OCKWELL!UTOMATIONDISTRIBUTORORSALES
REPRESENTATIVE
What is Not in this Manual
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
P-2
Overview
General Information
4HEFOLLOWINGPUBLICATIONSPROVIDEGENERALDRIVEINFORMATION
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
PowerFlex Active Front End Information
4HEFOLLOWINGPUBLICATIONSPROVIDESPECIFIC!&%INFORMATION
Title
Publication
PowerFlex Active Front End User Manual
20Y-UM001
PowerFlex 700H, 700S, and 700AFE Drive Fan Systems Installation Instructions PFLEX-IN029
Drives in Common Bus Configurations Application Guidelines
DRIVES-AT002
&ORSPAREPARTSINFORMATIONON0OWER&LEX#LASS!RCHITECTURE#LASS,OW
6OLTAGE!#$RIVESINCLUDINGTHE0OWER&LEX!CTIVE&RONT%NDGOONLINEAT
HTTPWWWABCOMSUPPORTABDRIVESPOWERFLEX0&2ELEASED0ARTSPDF
Understanding Manual
Conventions
"ECOMEFAMILIARWITHTHEFOLLOWINGCONVENTIONSUSEDINTHISMANUAL
Terms
4HEFOLLOWINGWORDSAREUSEDTHROUGHOUTTHEMANUALTODESCRIBEANACTION
Word
Meaning
Can
Possible, able to do something
Cannot
Not possible, not able to do something
May
Permitted, allowed
Must
Unavoidable, you must do this
Shall
Required and necessary
Should
Recommended
Should Not
Not recommended
Cross References
@&IGURE ONPAGE ISACROSSREFERENCETO&IGUREONPAGEOF
#HAPTER
@&IGURE# ONPAGE #ISACROSSREFERENCETO&IGURE#ONPAGEOF
!PPENDIX#
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
Overview
Additional Support
Available on Internet
P-3
!DDITIONALTROUBLESHOOTINGINFORMATIONANDSOFTWARETOOLSAREAVAILABLEON
THE!LLEN"RADLEY$RIVES4ECHNICAL3UPPORTWEBSITEATHTTPWWWABCOM
SUPPORTABDRIVES
General Precautions for
Class 1 LED Product
!44%.4)/.(AZARDOFPERMANENTEYEDAMAGEEXISTSWHEN
USINGOPTICALTRANSMISSIONEQUIPMENT4HISPRODUCTEMITSINTENSE
LIGHTANDINVISIBLERADIATION$ONOTLOOKINTOMODULEPORTSOR
FIBEROPTICCABLECONNECTORS
!44%.4)/.4HESHEETMETALCOVERANDMOUNTINGSCREWSON
THE!3)#"OARDLOCATEDONTHEPOWERSTRUCTUREAREENERGIZEDAT
$#BUSPOTENTIALHIGHVOLTAGE2ISKOFELECTRICALSHOCKINJURY
ORDEATHEXISTSIFSOMEONECOMESINTOCONTACTWITHTHEASSEMBLY
!44%.4)/.0OTENTIALLYFATALVOLTAGESCANRESULTFROM
IMPROPERUSAGEOFANOSCILLOSCOPEANDOTHERTESTEQUIPMENT4HE
OSCILLOSCOPECHASSISCANBEATAPOTENTIALLYFATALVOLTAGEIFNOT
PROPERLYGROUNDED5SEHIGHVOLTAGEDIFFERENTIALVOLTAGEPROBES
FORALLVOLTAGEMEASUREMENTSWITHTHEOSCILLOSCOPECHASSIS
CORRECTLYGROUNDEDTOANEARTHGROUND
!44%.4)/.4HE0OWER&LEX!CTIVE&RONT%NDCONTAINS
ELECTROSTATICDISCHARGE%3$SENSITIVEPARTSANDASSEMBLIESTHAT
CANBEDAMAGEDIFYOUDONOTFOLLOW%3$CONTROLPROCEDURES
3TATICCONTROLPRECAUTIONSAREREQUIREDTOINSTALLTESTSERVICEOR
REPAIRTHISUNIT)FYOUAREUNFAMILIARWITHSTATICCONTROL
PROCEDURESSEE'UARDING!GAINST%LECTROSTATIC$AMAGE
PUBLICATIONORANYOTHERAPPLICABLE%3$PROTECTION
HANDBOOK
!44%.4)/.!NINCORRECTLYAPPLIEDORINSTALLED0OWER&LEX
!CTIVE&RONT%NDCANRESULTINCOMPONENTDAMAGEORAREDUCTION
INPRODUCTLIFE7IRINGORAPPLICATIONERRORSSUCHASUNDERSIZING
THEMOTORINCORRECTORINADEQUATE!#SUPPLYOREXCESSIVE
AMBIENTTEMPERATURESCANRESULTINMALFUNCTIONOFTHESYSTEM
!44%.4)/./NLYQUALIFIEDPERSONNELFAMILIARWITHADJUSTABLE
FREQUENCY!#DRIVESANDASSOCIATEDMACHINERYSHOULDPLANOR
IMPLEMENTTHEINSTALLATIONSTARTUPANDSUBSEQUENTMAINTENANCE
OFTHESYSTEM&AILURETOCOMPLYCANRESULTINPERSONALINJURYAND
OREQUIPMENTDAMAGE
!44%.4)/.4OAVOIDANELECTRICSHOCKHAZARDVERIFYTHATTHE
VOLTAGEONTHEBUSCAPACITORSHASDISCHARGEDCOMPLETELYBEFORE
SERVICING#HECKTHE$#BUSVOLTAGEBETWEENTHE$#AND$#
TERMINALSBETWEENTHE$#TERMINALANDTHECHASSISAND
BETWEENTHE$#TERMINALANDTHECHASSIS4HEVOLTAGEMUSTBE
ZEROFORALLTHREEMEASUREMENTS
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
P-4
Overview
Notes:
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
#HAPTER
Troubleshooting and Error Codes
!44%.4)/.4OAVOIDANELECTRICSHOCKHAZARDVERIFYTHATTHE
VOLTAGEONTHEBUSCAPACITORSHASDISCHARGEDCOMPLETELYBEFORE
SERVICING#HECKTHE$#BUSVOLTAGEBETWEENTHE$#AND$#
TERMINALSBETWEENTHE$#TERMINALANDTHECHASSISAND
BETWEENTHE$#TERMINALANDTHECHASSIS4HEVOLTAGEMUSTBE
ZEROFORALLTHREEMEASUREMENTS
!44%.4)/.(OTSURFACESCANCAUSESEVEREBURNS$ONOT
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!CTIVE&RONT%ND!FTERDISCONNECTINGPOWERALLOWTIMEFOR
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CANBEDAMAGEDIFYOUDONOTFOLLOW%3$CONTROLPROCEDURES
3TATICCONTROLPRECAUTIONSAREREQUIREDTOINSTALLTESTSERVICEOR
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PUBLICATIONORANYOTHERAPPLICABLE%3$PROTECTION
HANDBOOK
!44%.4)/.4OAVOIDANELECTRICSHOCKHAZARDVERIFYTHATALL
POWERTOTHE0OWER&LEX!CTIVE&RONT%NDHASBEENREMOVED
BEFOREPERFORMINGANYSERVICINGORREPAIRS
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
1-2
Troubleshooting and Error Codes
Creating Fault Reports
#OMPLETEFAULTREPORTSARECRITICALFORANALYSISANDREPAIROFMODULES
RETURNEDTOTHEFACTORY
!TAMINIMUMDOTHEFOLLOWING
• 5SINGAN!LLEN"RADLEYDRIVECONFIGURATIONTOOLSUCHAS#ONNECTED
#OMPONENTS7ORKBENCH˜SOFTWARE$RIVE%XPLORER˜SOFTWAREOR
$RIVE%XECUTIVE˜SOFTWAREDOTHEFOLLOWING
n 5PLOADALLPARAMETERSFROMTHE0OWER&LEX!CTIVE&RONT%ND
n 2UNTHE4ECHNICAL3UPPORT7IZARD
• #OLLECTTHE!&%SYSTEMAPPLICATIONDATASHOWNIN!PPENDIX%
• )FPOSSIBLERECORDTHECONTENTSOFTHEFAULTQUEUEFAULTSANDTIMESOF
OCCURRENCE
• -AKERECORDOFTHEFOLLOWING
n !NYBURNMARKSONTHERECTIFYINGMODULE$#CAPACITORSINVERTER
BRIDGECHARGINGRESISTORSBALANCINGPRECHARGINGRESISTORSPRINTED
CIRCUITBOARDSBUSBARSCABLINGANDFIBEROPTICCABLING
n !NYLIQUIDANDCONDENSATIONMARKSONPRINTEDCIRCUITBOARDS
COMPONENTSANDMECHANICALPARTS
n !MOUNTOFDUSTANDOTHERADDITIONALPARTICLESONDRIVEANDDRIVE
COMPONENTS
n !NYMECHANICALDAMAGETOTHEDRIVEANDDRIVECOMPONENTS
• 2ECORDTHESIZEANDTYPEOFMAINFUSES
• 2ECORDANYOTHERIMPORTANTMARKSANDDAMAGE
• .OTEGROUNDINGTYPESOLIDHIGHRESISTANCEORFLOATINGANDSOURCE
IMPEDANCEOFTHEPOWERDISTRIBUTIONSYSTEM
No. Name
Description
Action IFAPPROPRIATE
1
The AFE is still in precharge
because the charging switch
(K20, K6, and K1 for AFE in IP20
2500 MCC Style enclosure or
K20, K6, and Q1 for AFE in IP21
Rittal enclosure) is open.
Reset the fault and restart.
PrechargeActv
Addressing PowerFlex
Active Front End Faults
Should the fault re-occur, contact
Technical Support.
• faulty operation
• component failure
Auxiliary In
The AFE control digital input
interlock is open.
4
DC UnderVolt
Monitor the incoming AC line for low
The DC bus voltage fell below
voltage or power interruption.
the minimum value of 333V for
400/480V units, or 461V for 600/
690V units. You can enable/
disable this fault with parameter
120 [Fault Config].
2
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
Verify wiring to the digital inputs on
the AFE control board are correct.
Troubleshooting and Error Codes
1-3
No. Name
Description
Action IFAPPROPRIATE
5
The DC bus voltage exceeded
the maximum value of 911V for
400/480V units, or 1200V for
600/690V units.
1. Check if the AFE was in a
regenerative current limit
condition, which may indicate an
excess regenerative load.
DC OverVolt
2. Adjust parameter 076 [Regen
Power Lmt].
3. Monitor incoming AC line for high
voltage or voltage transients.
7
Overload
When input current exceeds
125% for 60 seconds or 150%
for 30 seconds. The overload is
a linear type in counting up.
Reduce the current consumption of
the AFE or increase parameter 133
[Cnvrtr OL Factor].
8
HeatsinkOvrTp
The power structure heatsink
temperature has exceeded the
maximum allowable value.
85 °C = Alarm
90 °C = Fault
1. Verify that the maximum ambient
temperature has not been
exceeded.
2. Check the fans (including ASIC
board on the power structure).
3. Check for an excess load.
4. Verify that the airflow plate is
installed. See page 4-11.
IGBT OverTemp
The output transistors have
exceeded their maximum
operating temperature due to an
excessive load.
1. Verify that the maximum ambient
temperature has not been
exceeded.
A hardware problem exists in the
power structure.
1. Reset the fault and restart.
9
2. Check the fan(s).
3. Check for an excess load.
10
System Fault
2. Verify the fiber optic connections.
3. Verify ASIC Board jumper
connections from X9 to X15 (see
Figure B.1 on page B-1).
4. Contact Technical Support.
5. If the problem persists, replace or
repair the power structure.
AC OverCurr
The AC line current has
exceeded the hardware current
limit.
Check for an excessive load or other
causes of excess current.
13
Ground Fault
A current path to earth ground
exists that is greater than the
parameter 082 [Ground I Lvl]
value. The current must appear
for 800 milliseconds before the
unit will fault.
Using a digital voltmeter to check for
low impedance to ground, verify the
bus cables/bars between the:
• Disconnect and AC input lines
• Power structure and LCL Filter
• For AFE in IP20 enclosure:
– Q0 input breaker and K1 input
contactor, which includes the
precharge disconnect
– LCL Filter and K1 input cont.
• For AFE in IP21 enclosure:
– Q1 (MCCB) and Q0 disconnect
switch, which includes the
precharge disconnect
– LCL Filter and Q1 (MCCB)
14
Power Structure
Fault
A hardware problem exists in the
power structure.
1. Cycle the power.
12
2. Contact Technical Support.
3. If the problem persists, replace
the converter unit.
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
1-4
Troubleshooting and Error Codes
No. Name
Description
Action IFAPPROPRIATE
17
One input of the known phase
rotation is missing.
1. Check all user-supplied fuses.
LineSync Fail
2. Check the AC input line voltage.
21
Phase Loss
There is zero current in one of
the three phases.
Check supply voltage, fuses, and
cable.
29
Anlg In Loss
An analog input is configured to
fault on a signal loss. A signal
loss has occurred. Configure this
fault with parameter 203 or 206
[Anlg In x Loss].
1. Verify parameter 203 or 206 [Anlg
In x Loss] setting. Input signal
level should be greater than or
equal to 1.5V or 3 mA.
A microprocessor watchdog
timeout has occurred.
1. Cycle the power.
30
MicroWatchdog
2. Check for broken/loose
connections at the inputs.
2. Replace the Control board. See
page 4-5.
31
IGBT Temp Hw
The AFE input current has
exceeded the 1 minute overload
rating.
Check for an excess load.
32
Fan Cooling
Fan is not energized at start
command. This includes the
power structure or LCL Filter
fans.
1. If the LCL Filter fan is not
operating, check the fan DC
power supply board located in
front of the LCL Filter fan.
2. If the power structure fan is not
operating, check the fan inverter
board located behind the fan.
33
AutoReset Lim
The AFE unsuccessfully
attempted to reset a fault and
resumed running for the
programmed number in
parameter 053 [Auto Rstrt Tries].
You can enable/disable this fault
with parameter 120 [Fault
Config].
Correct the cause and manually clear
the fault.
34
CAN Bus Flt
A sent message was not
acknowledged.
1. Cycle the power.
2. Replace the Control board on the
power structure. See page 4-5..
35
Application
Problem in application software
with task overload.
Contact Technical Support.
37
HeatsinkUndTp
The ambient temperature
around the power structure
heatsink is too low.
Raise the ambient temperature.
44
Device Change
The new power unit or option
board installed is a different
type.
Clear the fault and verify the correct
parameters for the new option board.
45
Device Add
A new option board was added.
Clear the fault.
47
NvsReadChksum
There was an error reading
parameters 019 [Motoring
MWh], 020 [Regen MWh], and
021 [Elapsed Run Time] from
EEPROM.
1. Cycle the power.
For additional information, see
PowerFlex 700H, 700S, and 700AFE
Drive Fan Systems Installation
Instructions, publication
PFLEX-IN029.
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
2. Replace the Control board. See
page 4-5..
Troubleshooting and Error Codes
1-5
No. Name
Description
Action IFAPPROPRIATE
54
This event occurred because a
mathematical function had a
dividend of zero.
1. Cycle the power.
Startup has been prevented.
1. Cancel prevention of startup if this
can be done safely.
58
Zero Divide
Start Prevent
2. Replace the Control board. See
page 4-5..
2. Remove Run Request.
65
I/O Removed
An I/O option board has been
removed.
Clear the fault.
70
Power Unit
Incorrect output power device
operation.
1. Check the power structure for
damaged components. Replace if
defective.
2. Replace the power structure.
71
Periph Loss
The 20-COMM-x communication
adapter has a fault on the
network side.
Check the DPI device event queue
and corresponding fault information
for the device.
81
Port DPI Loss
The DPI port has stopped
communicating. A SCANport
device was connected to a drive
operating DPI devices at 500k
baud.
1. Check the HIM connection.
2. If the adapter was not intentionally
disconnected, check the wiring to
the port. Replace the wiring, port
expander, adapters, Control
board, or complete AFE as
required.
3. If an adapter was intentionally
disconnected and the [Logic
Mask] bit for that adapter is set to
‘1’, this fault will occur. To disable
this fault, set the bit in parameter
154 [Logic Mask] to ‘0’ for the port
in which the adapter is connected.
94
Hardware Enbl
100 Param Chksum
An enable signal is missing from
the control terminal block, only
when jumper J5 is removed on
the digital I/O board.
1. Check the control wiring.
The checksum read from the
Control board does not match
the checksum calculated.
1. Restore the AFE to the factory
defaults.
2. Check the position of the J5
hardware enable jumper.
3. Check the digital input
programming.
2. Cycle the power.
3. Replace the Control board in the
power structure. See page 4-5..
104 PwrBrd Chksum
The checksum read from the
EEPROM does not match the
checksum calculated from the
EEPROM data.
1. Cycle the power.
2. Check the fiber optics between
the Fiber Optic Adapter board and
the ASIC board. See page C-1,
page C-2, and page C-3 for
connections.
3. Replace the Fiber Optic Adapter
board (see page 4-6) and/or the
ASIC board (see page 4-14) in
the power structure.
4. Contact Technical Support.
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
1-6
Troubleshooting and Error Codes
No. Name
Description
Action IFAPPROPRIATE
106 MCB-PB Config
The AFE rating information
stored on the power board is
incompatible with the Control
board.
1. Reset the fault.
2. Cycle the power.
3. Replace the Control board on the
power structure. See page 4-5..
4. Contact Technical Support.
107 New IO Option
A new option board was added
to the Control board.
1. Clear the fault and verify the
correct parameters for the new
option board.
2. Reprogram parameters as
necessary.
113 Fatal App
A Fatal Application error has
occurred.
1. Cycle the power.
120 I/O Change
An option board has been
replaced.
Reset the fault.
121 I/O Comm Loss
A defective option board or I/O
board slot.
1. Check the Control board-to-I/O
option board connection.
2. Replace the Control board on the
power structure. See page 4-5..
2. Verify the ground integrity from
the Control board to the option
board.
3. Replace the Control board and/or
I/O board. See page 4-5..
125 LCL OverTemp
The LCL Filter has been
overheated or the signal is not
connected to input.
Check the LCL Filter and signal
connection or verify that digital input
5 is closed. See Chapter 7.
There are nine total thermal switches connected in series
to monitor temperature inside the coil of each filter inductor.
X52
Thermal Switch 1
Thermal Switch 9
To Digital
Input 5
X52 is located on the LCL FIlter.
X52 approximate
location
Frame 10 LCL Filter
126 LCL Fan Stop
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
The LCL fan has been stopped.
Check the LCL fan. See Chapter 7.
NOTE: This fault occurs only when
the user has manually programmed a
digital input as option ‘5’.
Troubleshooting and Error Codes
1-7
No. Name
Description
Action IFAPPROPRIATE
128 Contact Fdbk
The input of the acknowledge
signal from the main contactor is
missing.
1. Check for closure on the following
devices:
– For AFE in IP20 enclosure,
input contactor (K1)
– For AFE in IP21 enclosure,
MCCB (Q1)
2. Check digital input 4 on the
Control board of the power
structure.
133 DigInConflict
Digital input functions are in
conflict.
Check the parameter settings of
parameters 221…226.
138 DCRefLowLim
DC voltage reference is less
than the limit in parameter 080
[DC Ref Lo Lmt].
1. Check the parameter setting.
2. Verify the bus voltage to be above
the parameter value.
3. Troubleshoot the cause of the low
voltage condition.
139 DCRefHighLim
DC voltage reference exceeds
the limit in parameter 081 [DC
Ref Hi Lmt].
1. Check the parameter setting.
2. Verify the bus voltage to be below
the parameter value.
3. Troubleshoot the cause of the
high voltage condition.
Common Symptoms and
Corrective Actions
140 DCBusLoAlarm
DC voltage is less than the value
set by parameter 078 [DC Bus
Lo Alarm].
Check the parameter setting.
141 DCBusHiAlarm
DC voltage exceeds the value
set by parameter 079 [DC Bus
Hi Alarm].
Check the parameter setting.
AFE does not Start from Start or Run Inputs wired to the terminal block.
Cause
Indication
Corrective Action
AFE is faulted
Flashing red status
light
Clear the fault.
• Press Stop.
• Cycle the power.
• Set parameter 121 [Fault
Clear] to ‘1’.
• ‘Clear Faults’ on the HIM
Diagnostic menu.
Incorrect input wiring. See the ‘Control
Wiring’ section in the PowerFlex Active
Front End User Manual, publication
20Y-UM001, for information.
None
Wire inputs correctly and/or
install jumper.
None
Program parameters 221…226
[Digital Inx Sel] for correct inputs.
NOTE: Jumper from terminal 17 to 20
is required when using the 24V DC
internal supply.
Incorrect digital input programming.
Run programming may be
missing.
Check status bits of
parameter 100 [Start
Inhibits].
Correct the source of the inhibit.
There is some other start inhibit.
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
1-8
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
normal.
Instability in AC line
current and DC bus
voltage.
Increase parameter 060 [DC Volt
Ref] proportional to the
percentage of the AC line voltage
above nominal.
May trip on fault F7
‘Overload’.
Negative reactive I Ref on parameter
065 [Reactive I Ref] with a soft (high
impedance) AC line.
Instability in AC line
current and DC bus
voltage.
May trip an F7
overload.
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
Change parameter 065 [Reactive
I Ref] value to zero. Verify if the
AFE is running on a soft line per
the AC line source
considerations.
#HAPTER
Active Front End System Overview
4HISCHAPTERDESCRIBES!&%SYSTEMMAINCOMPONENTSANDISGROUPEDBY
THOSEUSEDINA)0-##3TYLEENCLOSUREA)02ITTALENCLOSURE
ANDMAINCOMPONENTSFORTHE!&%)0OPENCHASSISCONFIGURATION
AFE in IP20 2500 MCC Style Main Component Sections
Enclosure
4HEFOLLOWINGFIGURESHOWSABASICONELINEDIAGRAMFORAN!&%SYSTEMINA
)0-##3TYLEENCLOSURE4HEMAINCOMPONENTSECTIONSCONSISTOF
THEFOLLOWINGITEMS
• !#,INE3WITCHGEARCONSISTINGOFTHEINPUTCIRCUITBREAKER1FUSES
&&ANDINPUTCONTACTOR+
• ,#,&ILTER,
• 0RECHARGE#IRCUIT
• !&%POWERSTRUCTURE5WITH!&%CONTROLASSEMBLY
• $#&USES&AND&
Figure 2.1 Basic One-line Diagram for AFE in IP20 2500 MCC Style Enclosure
AC Line Switchgear
3 Phase
AC Input
L1
Input
Breaker
Q0
Input
Contactor
K1
Fuses
F1.1-F1.3
L2
L3
LCL Filter (L1)
AFE
Power Structure (U1)
U2
U1
V2
W2
V1
W1
C1
C4
C2
C5
C3
C6
Precharge
Fuses
F5
U1
DC
Fuses
U
V
W
PE
DC+
DC-
F2.1
F2.2
DC Bus
Output
PE
Precharge
Contactor
Precharge
Circuit
K6
R6.1
+
R6.2
-
PowerFlex
Active Front End System
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
2-2
Active Front End System Overview
Main Component Locations
4HEFOLLOWINGFIGURESHOWSTHEMAINCOMPONENTSOFTHE!&%&RAME
SYSTEMINA)0-##3TYLEENCLOSURE
Figure 2.2 AFE Frame 10 Main Component Locations in IP20 2500 MCC Style
Enclosure
FRONT VIEW
(shown with enclosure doors closed)
FRONT VIEW
(shown with enclosure doors removed)
Item
Description
➊
Precharge Circuit and Precharge Resistor (R6.1 and R6.2)
➋
LCL Filter (L1)
➌
Active Front End Power Structure (U1)
➍
➎
➏
Input Circuit Breaker (Q0)
AC Line Switchgear
Input Fuses (F1.1…F1.3)
Input Contactor (K1)
DC Fuses (F2.1 and F2.2)
➑
AFE Control Box Assembly (on the AFE door and shown with user-installed HIM)
➐
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
Active Front End System Overview
2-3
Main Bus Bar/Cable Locations
4HEREARESEVERALSETSOFBUSBARCABLESINTHE!&%&RAMESYSTEMTHAT
CONNECTMAINSYSTEMCOMPONENTS
•
•
•
•
"USCABLESBETWEEN)NPUT"REAKER1AND!#&USES&x&
"USBARSBETWEEN!#&USES&x&AND)NPUT#ONTACTOR+
"USCABLESBETWEEN)NPUT#ONTACTOR+ANDTHE,#,&ILTER,
"USBARSBETWEENTHE!&%0OWER3TRUCTURE5AND$#"US
4HEFOLLOWINGFIGURESHOWSTHESEBUSBARCABLELOCATIONS
Figure 2.3 AFE Frame 10 Bus Bar/Cable Locations in IP20 2500 MCC Style Enclosure
FRONT VIEW
(shown with enclosure doors removed)
DC bus bars between
AFE Power Structure (U1)
and DC bus
DC+ bus bar
Optional Bus
Splice Kit shown
AC power cables between
Input Circuit Breaker (Q0)
and AC input fuses
(F1.1…F1.3)
Optional Bus
Splice Kit shown
AC input fuse bus link
DC- bus bar
AC power cables between
Input Contactor (K1) and
LCL Filter (L1)
AC power cables between
LCL Filter (L1) and AFE
Power Structure (U1)
AC bus bars between AC
fuses (F1.1…F1.3) and
Input Contactor (K1)
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
2-4
Active Front End System Overview
AFE in IP21 Rittal Enclosure Main Component Sections
4HEFOLLOWINGFIGURESHOWSABASICONELINEDIAGRAMFORAN!&%SYSTEMINA
)02ITTALENCLOSURE4HEMAINCOMPONENTSECTIONSCONSISTOFTHE
FOLLOWINGITEMS
• !#,INE3WITCHGEARCONSISTINGOFTHEINPUTDISCONNECT1AND
-##"MOTORCONTROLLEDCIRCUITBREAKER1
• ,#,&ILTER,
• 0RECHARGE#IRCUIT
• !&%POWERSTRUCTURE5WITH!&%CONTROLASSEMBLY
• $#&USES&AND&
Figure 2.4 Basic One-line Diagram for AFE in IP21 Rittal Enclosure
AC Line
Switchgear
3 Phase
AC Input
Q0
AFE
Power Structure (U1)
LCL Filter (L1)
DC
Fuses
Q1
L1
L2
L3
U2
U1
V2
W2
V1
W1
C1
C4
C2
C5
C3
C6
Precharge
Fuses
F6
U1
U
V
W
PE
DC+
DC-
PE
Motor Protection
Relay
Q5
Precharge
Contactor
Precharge
Circuit
K6
R6.1
+
PowerFlex
Active Front End System
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
-
R6.2
F2.1
F2.2
DC Bus
Output
Active Front End System Overview
2-5
Main Component Locations
4HEFOLLOWINGFIGURESHOWSTHEMAINCOMPONENTSOFTHE!&%&RAME
SYSTEMINA)02ITTALENCLOSURE
Figure 2.5 AFE Frame 10 Main Component Locations in IP21 Rittal Enclosure
FRONT VIEW
(shown with enclosure doors removed)
Item
Description
➊
Precharge Circuit and Precharge Resistors (R6.1 and R6.2)
➋
LCL Filter (L1)
➌
Active Front End Power Structure (U1)
➍
➎
AC Line
Switchgear
Motor-controlled Circuit Breaker (Q1)
Input Disconnect (Q0)
AFE Control Assembly (shown with user-installed HIM)
➐
DC Fuses (F2.1 and F2.2)
➏
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
2-6
Active Front End System Overview
Bus Bar Locations
4HEREARESEVERALSETSOFBUSBARSINTHE!&%&RAMESYSTEMTHATCONNECT
MAINSYSTEMCOMPONENTS
•
•
•
•
"USBARSBETWEEN)NPUT$ISCONNECT1AND-##"1
"USBARSBETWEEN-##"1ANDTHE,#,&ILTER,
"USBARSBETWEENTHE,#,&ILTER,AND!&%0OWER3TRUCTURE5
"USBARSBETWEENTHE!&%0OWER3TRUCTURE5AND$#"US"ARS
4HEFOLLOWINGFIGURESHOWSTHESEBUSBARLOCATIONS
Figure 2.6 AFE Frame 10 Bus Bar Locations in IP21 Rittal Enclosure
FRONT VIEW
(shown with enclosure doors removed)
DC+ bus bar
DC- bus bar
DC bus bars between
AFE Power Structure (U1)
and DC fuses
AC bus bars
between LCL Filter (L1)
and AFE Power Structure (U1)
AC bus bars
between Motor-Controlled
Circuit Breaker (Q1)
and LCL Filter (L1)
AC bus bars between
Input Disconnect (Q0)
and Motor-Controlled
Circuit Breaker (Q1)
AC Input
bus bars
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
Active Front End System Overview
2-7
4HEFOLLOWINGFIGURESHOWSABASICONELINEDIAGRAMFORAN!&%SYSTEMINA
)0.%-!5,/PEN#HASSISCONFIGURATIONANDTHEPARTSTHECUSTOMER
MUSTSUPPLY
AFE in IP00 Open Chassis
Configuration
Figure 2.7 Basic One-line Diagram for AFE in IP00 Open Chassis Configuration
AC Line Switchgear
3 Phase
AC Input
Input
Breaker
Q0
LCL Filter (L1)
Input
Contactor
K1
Fuses
F1.1-F1.3
L1
L2
L3
Customersupplied
Parts
AFE
Power Structure (U1)
U2
U1
V2
W2
V1
W1
C1
C4
C2
C5
C3
C6
U1
DC
Fuses
U
V
W
PE
DC+
DC-
F2.1
F2.2
DC Bus
Output
PE
Customersupplied
Parts
Precharge
Contactor
Precharge
Circuit
Precharge
Fuses
F5
K6
R6.1
+
PowerFlex
Active Front End System
Customer-supplied enclosure
Customer-supplied Parts
R6.2
-
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
2-8
Active Front End System Overview
Notes:
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
#HAPTER
Component Test Procedures
!44%.4)/.4HESHEETMETALCOVERANDMOUNTINGSCREWSON
THE!3)#"OARDLOCATEDONTHEPOWERSTRUCTUREAREENERGIZEDAT
$#BUSPOTENTIALHIGHVOLTAGE2ISKOFELECTRICALSHOCKINJURY
ORDEATHEXISTSIFSOMEONECOMESINTOCONTACTWITHTHEASSEMBLY
!44%.4)/.4OAVOIDANELECTRICSHOCKHAZARDVERIFYTHATALL
POWERTOTHE0OWER&LEX!CTIVE&RONT%NDHASBEENREMOVED
BEFOREPERFORMINGANYSERVICINGORREPAIRS
!44%.4)/.(OTSURFACESCANCAUSESEVEREBURNS$ONOT
TOUCHTHEHEATSINKSURFACEDURINGOPERATIONOFTHE0OWER&LEX
!CTIVE&RONT%ND!FTERDISCONNECTINGPOWERALLOWTIMEFOR
COOLING
!44%.4)/.(AZARDOFPERMANENTEYEDAMAGEEXISTSWHEN
USINGOPTICALTRANSMISSIONEQUIPMENT4HISPRODUCTEMITSINTENSE
LIGHTANDINVISIBLERADIATION$ONOTLOOKINTOFIBEROPTICPORTSOR
FIBEROPTICCABLECONNECTORS
!44%.4)/.4HE0OWER&LEX!CTIVE&RONT%NDCONTAINS
ELECTROSTATICDISCHARGE%3$SENSITIVEPARTSANDASSEMBLIESTHAT
CANBEDAMAGEDIFYOUDONOTFOLLOW%3$CONTROLPROCEDURES
3TATICCONTROLPRECAUTIONSAREREQUIREDTOINSTALLTESTSERVICEOR
REPAIRTHISASSEMBLY)FYOUAREUNFAMILIARWITHSTATICCONTROL
PROCEDURESSEE'UARDING!GAINST%LECTROSTATIC$AMAGE
PUBLICATIONORANYOTHERAPPLICABLE%3$PROTECTION
HANDBOOK
!44%.4)/.4OAVOIDANELECTRICSHOCKHAZARDVERIFYTHATTHE
VOLTAGEONTHEBUSCAPACITORSHASDISCHARGEDCOMPLETELYBEFORE
SERVICING#HECKTHE$#BUSVOLTAGEBETWEENTHE$#AND$#
TERMINALSBETWEENTHE$#TERMINALANDTHECHASSISAND
BETWEENTHE$#TERMINALANDTHECHASSIS4HEVOLTAGEMUSTBE
ZEROFORALLTHREEMEASUREMENTS
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
3-2
Component Test Procedures
Viewing the Status
Indicators
➊
➋
Table 3.A AFE Status Indicator Descriptions
Item
Name
Color
State
Description
➊
PWR (Power)
Green
Steady
Illuminates when power is applied to the AFE.
➋
PORT (1)
MOD (1)
(1)
Performing Visual
Inspections
NET A
(1)
NET B
(1)
Status of DPI port internal communication (if present).
See the Communication
Adapter User Manual,
publication 20COMM-UMxxx
Status of communication adapter (when installed).
Status of network (if connected).
Status of secondary network (if connected).
These indicators operate only when a 20-COMM-X communication adapter is installed in the AFE and operating on the connected
network.
)MPORTANT !LWAYSREMOVEPOWERFROMTHE!CTIVE&RONT%NDBEFORE
PERFORMINGVISUALINSPECTIONS3EE2EMOVING0OWERFROMTHE
!&% ONPAGE Inspecting the Cooling Tunnel
2EMOVETHEMAINCOOLINGFANFROMTHEBOTTOMOFTHEPOWERSTRUCTURE
3EE2EMOVINGAND)NSTALLINGTHE0OWER3TRUCTURE&AN3YSTEM ON
PAGE )NSPECTTHETUNNEL
#LEANTHEHEATSINKANDTUNNELIFNECESSARY
Inspecting the Power Structure
2EMOVETHEPROTECTIVEBARRIERS
3EE2EMOVING!&%0ROTECTIVE"ARRIERS ONPAGE 0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
Component Test Procedures
3-3
2EMOVETHEPROTECTIVEFRONTCOVERANDTERMINALCOVERFROMTHEPOWER
STRUCTURE
3EE2EMOVING0ROTECTIVE#OVERSFROMTHE0OWER3TRUCTURE ON
PAGE #HECKCOMPONENTSFORBURNMARKSBREAKAGEORFOILDELAMINATIONON
CIRCUITBOARDS
#HECKALLTHEBOARDSONTHEPOWERSTRUCTURE
2EPLACEANYOFTHESECOMPONENTSIFTHEYSHOWEVIDENCEOFBURNMARKS
BREAKAGEORFOILDELAMINATION
!FORWARDBIASEDDIODETESTCHECKSTHESEMICONDUCTORJUNCTIONSBETWEEN
Performing Forward and
Reverse Biased Diode Tests THETERMINALSANDMEASURESTHEVOLTAGEDROPACROSSTHOSEJUNCTIONS4OPASS
EACHTESTTHEMETERMUSTDISPLAYAVOLTAGENEAR6)FTHETESTFINDSA
for Power Structure
SHORTTHEMETERDISPLAYS@)FTHETESTFINDSANOPENCIRCUITORREVERSED
POLARITYTHEMETERDISPLAYS@,ZEROLOAD
)MPORTANT 4HEACTUALVOLTAGEREADINGSCANVARYDEPENDINGUPONYOUR
EQUIPMENT)FYOURREADINGSARENOTNEARTHEINDICATEDVALUESIN
THEFOLLOWINGTABLESVERIFYTHATTHEACTUALVOLTAGEMEASUREDIS
CONSISTENTFORTHE0OWERMODULE
!REVERSEBIASEDDIODETESTFINDSANOPENCIRCUITANDTHEMETERDISPLAYS
@,ZEROLOAD
-
+
^,
^6
-
+
Forward biased test
on PN-junction
Reverse biased test
on PN-junction
2EMOVEPOWERFROMTHE!&%
3EE2EMOVING0OWERFROMTHE!&% ONPAGE 2EMOVETHEPROTECTIVEBARRIERS
3EE2EMOVING!&%0ROTECTIVE"ARRIERS ONPAGE $ISCONNECTANYDRIVESCONNECTEDTOTHE$#BUSFROMTHE$#BUSOR
REMOVETHE$#BUSFUSESFROMTHE!&%
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
3-4
Component Test Procedures
#ONDUCTFORWARDANDREVERSEBIASEDDIODETESTSONTHEPOWERSTRUCTURE
Figure 3.1 Measurement Points for Forward and Reverse Diode Tests
B+ (DC+)
B– (DC–)
U/T1
V/T2
W/T3
PE
Table 3.B Forward Biased Diode Tests on Power Structure
Meter Leads
+
DC-
U/T1
DC-
V/T2
DC-
W/T3
U/T1
DC+
V/T2
DC+
W/T3
DC+
(1)
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
-
Nominal meter reading
Value should gradually rise to about 0.5V (1)
The actual voltage reading can vary depending upon your equipment. If your
readings are not near 0.5V, verify that the actual voltage measured is
consistent for the power structure.
Component Test Procedures
3-5
Table 3.C Reverse Biased Diode Tests on Power Structure
Meter Leads
+
-
U/T1
DC-
V/T2
DC-
W/T3
DC-
DC+
U/T1
DC+
V/T2
DC+
W/T3
Nominal meter reading
Meter should display ‘.0L’ (zero load)
)FTHE!&%FAILSANYOFTHESEMEASUREMENTSREPLACETHE0OWER-ODULE
INTHEPOWERSTRUCTUREORTHECOMPLETEPOWERSTRUCTUREUSINGANYOFTHE
FOLLOWINGOPTIONS
n #ONTACTYOURLOCALREPRESENTATIVETOSCHEDULE/NSITE3ERVICES
n #ONTACTYOURLOCALREPRESENTATIVETOMAKEARRANGEMENTSTORETURNTHE
POWERSTRUCTURETOTHEFACTORYFORREPAIRBY2EMANUFACTURING
3ERVICES
Checking Fiber Optic
Connections
n &ORAN!&%NOTCOVEREDUNDERFACTORYWARRANTYACUSTOMERHASTHE
OPTIONOFREPAIRINGTHEPOWERSTRUCTUREUSINGPROCEDURESDESCRIBEDIN
THISMANUAL
$AMAGEDORIMPROPERLYCONNECTEDFIBEROPTICCABLESCANCAUSEAPPARENT
'ATE$RIVERBOARDMALFUNCTIONS&ORFIBEROPTICCABLECONNECTIONSSEE
PAGE #PAGE #ANDPAGE #
2EMOVEPOWERFROMTHE!&%
3EE2EMOVING0OWERFROMTHE!&% ONPAGE )FPRESENTREMOVETHEPROTECTIVEBARRIERS
2EMOVETHEPROTECTIVEFRONTCOVERANDTERMINALCOVERFROMTHEPOWER
STRUCTURE
3EE2EMOVING0ROTECTIVE#OVERSFROMTHE0OWER3TRUCTURE ON
PAGE 3EE2EMOVING!&%0ROTECTIVE"ARRIERS ONPAGE 0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
3-6
Component Test Procedures
,OCATETHE'ATE$RIVERBOARDONTHEFRONTOFTHEPOWERSTRUCTURE
RIGHTSIDEENCLOSURE
Gate Driver Board
ASIC Board
6ERIFYTHATTHEFIBEROPTICCABLESAREPROPERLYCONNECTEDBETWEENTHE
'ATE$RIVERBOARDANDTHE!3)#BOARD
)MPORTANT 4HEMINIMUMINSIDEBENDRADIUSFORFIBEROPTICCABLEIS
MMIN!NYBENDSWITHASHORTERINSIDERADIUSCAN
PERMANENTLYDAMAGETHEFIBEROPTICCABLE3IGNAL
ATTENUATIONINCREASESWITHDECREASEDINSIDEBENDRADII
6ERIFYTHATTHEFIBEROPTICCABLESAREPROPERLYCONNECTEDBETWEENTHE
!3)#BOARDANDTHE&IBER/PTIC!DAPTERCIRCUITBOARD
$ISCONNECTTHECABLESANDINSPECTTHEMFORSCRATCHESANDCRACKSAND
OVERALLINTEGRITY
)MPORTANT 7HENMISHANDLEDTHEABILITYOFFIBEROPTICCABLESTO
TRANSMITDATAISGREATLYDIMINISHED
2ECONNECTTHECABLESREPLACINGANYDAMAGEDCABLES
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
Component Test Procedures
Performing Gate Driver
Board Resistance
Measurements
3-7
2EMOVEPOWERFROMTHE!&%
3EE2EMOVING0OWERFROMTHE!&% ONPAGE )FPRESENTREMOVETHEPROTECTIVEBARRIERS
3EE2EMOVING!&%0ROTECTIVE"ARRIERS ONPAGE 2EMOVETHEPROTECTIVEFRONTCOVERANDTERMINALCOVERFROMTHEPOWER
STRUCTURE
3EE2EMOVING0ROTECTIVE#OVERSFROMTHE0OWER3TRUCTURE ON
PAGE 4HEREISONE'ATE$RIVERBOARD
-EASURETHEGATEINTERFACERESISTANCEFOREACH56AND7PHASE
/UTPUT0OWERTRANSISTOR
n 4HERESISTANCEFROMEACHIGNITIONPINTOTHEBRANCHEMITTERPIN
CONNECTORS8AND8ISAPPROXIMATELYOHMS
n 4HERESISTANCEFROMTHE8BRANCHEMITTERPINTOTHESAMEBRANCH
OUTPUTPOWERTERMINAL5464AND74ISAPPROXIMATELY
OHMS
n 4HERESISTANCEFROMTHE8BRANCHEMITTERTOTHESAMEBRANCH$#
BUSTERMINALISAPPROXIMATELYOHMS
)FANYOFTHEGATEINTERFACESFAILSTHISTESTREPLACETHEPOWERMODULE
3EE2EMOVINGTHE0OWER-ODULEFROMTHE0OWER3TRUCTURE ON
PAGE Approx. 0.5 ohms
Gate Interface for
U, V or W Low (L)
DC-
X30
Emitter
Approx.166 ohms
X24
Extinguishing
Ignition
X29
X23
X22
Emitter
Approx.166 ohms
Extinguishing
Ignition
X28
Gate Interface for
U, V or W High (H)
W/T3 V/T2 U/T1
Approx. 0.5 ohms
Note: Connectors X22 and X23 are connected in
parallel with connectors X28 and X29 respectively
and, therefore, do not have to be tested.
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
3-8
Component Test Procedures
2EMOVEPOWERFROMTHE!&%
Checking the AFE Power
Structure Fan Inverter Fuses
3EE2EMOVING0OWERFROMTHE!&% ONPAGE )FPRESENTREMOVETHEPROTECTIVEBARRIERS
3EE2EMOVING!&%0ROTECTIVE"ARRIERS ONPAGE 2EMOVETHEPROTECTIVEFRONTCOVERANDTERMINALCOVERFROMTHEPOWER
STRUCTURE
3EE2EMOVING0ROTECTIVE#OVERSFROMTHE0OWER3TRUCTURE ON
PAGE !PAIROFFUSES&AND&FEED$#"USPOWERTOTHEFANINVERTER
A ,OCATETHESEFUSESSHOWNBELOWANDREMOVETHEM
B 5SINGAMULTIMETERVERIFYTHATTHEYARENOTOPEN
2EINSTALLTHEGOODFUSESANDREPLACEANYOPENFUSEWITHAN
EQUIVALENTRATEDFUSE
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
#HAPTER
AFE Power Structure Component Section
!44%.4)/.4OAVOIDANELECTRICSHOCKHAZARDVERIFYTHATTHE
VOLTAGEONTHEBUSCAPACITORSHASDISCHARGEDCOMPLETELYBEFORE
SERVICING#HECKTHE$#BUSVOLTAGEBETWEENTHE$#AND$#
TERMINALSBETWEENTHE$#TERMINALANDTHECHASSISAND
BETWEENTHE$#TERMINALANDTHECHASSIS4HEVOLTAGEMUSTBE
ZEROFORALLTHREEMEASUREMENTS
!44%.4)/.(OTSURFACESCANCAUSESEVEREBURNS$ONOT
TOUCHTHEHEATSINKSURFACEDURINGOPERATIONOFTHE0OWER&LEX
!CTIVE&RONT%ND!FTERDISCONNECTINGPOWERALLOWTIMEFOR
COOLING
!44%.4)/.(AZARDOFPERMANENTEYEDAMAGEEXISTSWHEN
USINGOPTICALTRANSMISSIONEQUIPMENT4HISPRODUCTEMITSINTENSE
LIGHTANDINVISIBLERADIATION$ONOTLOOKINTOFIBEROPTICPORTSOR
FIBEROPTICCABLECONNECTORS
!44%.4)/.4HESHEETMETALCOVERANDMOUNTINGSCREWSON
THE!3)#"OARDLOCATEDONTHEPOWERSTRUCTUREAREENERGIZEDAT
$#BUSPOTENTIALHIGHVOLTAGE2ISKOFELECTRICALSHOCKINJURY
ORDEATHEXISTSIFSOMEONECOMESINTOCONTACTWITHTHEASSEMBLY
!44%.4)/.4OAVOIDANELECTRICSHOCKHAZARDVERIFYTHATALL
POWERTOTHE0OWER&LEX!CTIVE&RONT%NDHASBEENREMOVED
BEFOREPERFORMINGANYSERVICINGORREPAIRS
!44%.4)/.4HE0OWER&LEX!CTIVE&RONT%NDCONTAINS
ELECTROSTATICDISCHARGE%3$SENSITIVEPARTSANDASSEMBLIESTHAT
CANBEDAMAGEDIFYOUDONOTFOLLOW%3$CONTROLPROCEDURES
3TATICCONTROLPRECAUTIONSAREREQUIREDTOINSTALLTESTSERVICEOR
REPAIRTHISASSEMBLY)FYOUAREUNFAMILIARWITHSTATICCONTROL
PROCEDURESSEE'UARDING!GAINST%LECTROSTATIC$AMAGE
PUBLICATIONORANYOTHERAPPLICABLE%3$PROTECTION
HANDBOOK
5SETHEINSTRUCTIONSINTHISCHAPTERTOREMOVEANDINSTALLCOMPONENTSFROM
THE!CTIVE&RONT%ND4OREMOVEANDINSTALLCOMPONENTSONTHEPOWER
STRUCTUREANDTOREMOVETHE0OWER-ODULEFROMTHEPOWERSTRUCTURESEE
0OWER3TRUCTURE!CCESS0ROCEDURES ONPAGE 0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
4-2
AFE Power Structure Component Section
Understanding Torque
Figures in Assembly
Diagrams
)CONSANDNUMBERSINTHEASSEMBLYDIAGRAMSINDICATEHOWTOTIGHTEN
HARDWARE
Tool Type and Size
PZ indicates POZIDRIV screwdriver bit
P indicates Phillips screwdriver bit
Fastener Type
POZIDRIV
Screw
Phillips Screw
Hexagonal Bolt
or Standoff
Hexagonal
Screw
PZ2
4 N•m
(35 lb•in)
Tightening Torque
Hexagonal Nut
Torx Head
Screw
Torque Specifications
4HEFOLLOWINGTABLELISTSFASTENERTORQUESPECIFICATIONSFORTHECIRCUITBOARDS
ANDMAINCOMPONENTSOFTHE!CTIVE&RONT%ND
Item
AC Input Terminals
ASIC Circuit Board (Mounting)
ASIC Circuit Board Cover
ASIC Fan
Capacitor
DC-/DC+ Terminals
DC Connective Bus Bars
DPI/HIM Assembly Door
DPI/HIM Assembly (Mounting)
Fan Inverter Assembly
Fan Inverter Fuse Base
Fan Inverter Fuse Holder
Gate Driver Circuit Board (Mounting)
Main Cooling Fan (Mounting)
Precharge Bridge
Wire Fasteners
Assembly
Mounting
Precharge Bridge Resistor Assembly
In IP20 Encl.
LCL Filter Upper
Front Bracket
In IP21 Encl.
LCL Filter Lower Front Bracket (IP20 encl.)
Motor Output Terminals on Power Structure
Power Structure Output Terminals (U, V, W)
Power Structure Block (Mounting)
Power Structure DC Bus Input Terminals
Protective Covers on
Front
Power Structure
Terminal
Hardware
M10 nut
M4 x 8 POZIDRIV screws
M4 x 8 POZIDRIV screws
M4 x 16 POZIDRIV screws
M4 x 8 self tapping screws
M6 x 20 POZIDRIV screws
M10 x 20 hexagonal screws
M8 x 25 hexagonal socket-head screws
M6 x 12 POZIDRIV screws
M3 x 6 Phillips screws
M3 x 6 Phillips screws
M5 x 10 POZIDRIV screws
M4 x 8 POZIDRIV screws
M4 x 8 POZIDRIV screws
M4 x 8 POZIDRIV screws
M5 x 10 POZIDRIV screws
M5 x 12 machine screws
M5 nuts
M5 x 12 Torx self tapping screws
M8 x 20 / M6 x 16 screws
M5 x 12 Torx self tapping screws
M8 x 20 screws
M8 x 20 hexagonal screws
M8 x 20 hexagonal screws
M10 x 12 hexagonal screws
M6 x 16 POZIDRIV screws
M5 x 10 POZIDRIV screws
M5 x 16 POZIDRIV screws
POZIDRIV® is a registered trademark of the Phillips Screw Company.
Phillips® is a registered trademark of Phillips Screw Company.
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
Final Torque
40 N•m (354 lb•in)
0.9 N•m (8 lb•in)
0.9 N•m (8 lb•in)
0.4 N•m (3.5 lb•in)
1 N•m (9 lb•in)
5 N•m (44 lb•in)
8 N•m (71 lb•in)
8 N•m (71 lb•in)
4 N•m (35 lb•in)
0.9 N•m (8 lb•in)
0.9 N•m (8 lb•in)
4 N•m (35 lb•in)
3 N•m (27 lb•in)
3 N•m (27 lb•in)
1.35 N•m (12 lb•in)
3 N•m (27 lb•in)
4.5 N•m (40 lb•in)
3.9 N•m (35 lb•in)
4.5 N•m (40 lb•in)
6.7 N•m (60 lb•in) / 4.5 N•m (40 lb•in)
4.5 N•m (40 lb•in)
6.7 N•m (60 lb•in)
20 N•m (177 lb•in)
14 N•m (124 lb•in)
20 N•m (177 lb•in)
4 N•m (35 lb•in)
3 N•m (27 lb•in)
3 N•m (27 lb•in)
AFE Power Structure Component Section
Removing Power from the
AFE
4-3
!44%.4)/.4OAVOIDANELECTRICSHOCKHAZARDVERIFYTHATTHE
VOLTAGEONTHEBUSCAPACITORSHASDISCHARGEDCOMPLETELYBEFORE
SERVICING#HECKTHE$#BUSVOLTAGEBETWEENTHE$#AND$#
TERMINALSBETWEENTHE$#TERMINALANDTHECHASSISAND
BETWEENTHE$#TERMINALANDTHECHASSIS4HEVOLTAGEMUSTBE
ZEROFORALLTHREEMEASUREMENTS
2EMOVEPOWERBEFOREMAKINGORBREAKINGCABLECONNECTIONS
7HENYOUREMOVEORINSERTACABLECONNECTORWITHPOWER
APPLIEDANELECTRICALARCCANOCCUR!NELECTRICALARCCANCAUSE
PERSONALINJURYORPROPERTYDAMAGEBYTHEFOLLOWING
• 3ENDINGANERRONEOUSSIGNALTOYOURSYSTEMSFIELDDEVICES
CAUSINGUNINTENDEDMACHINEMOTION
• #AUSINGANEXPLOSIONINAHAZARDOUSENVIRONMENT
%LECTRICALARCINGCAUSESEXCESSIVEWEARTOCONTACTSONBOTHTHE
MODULEANDITSMATINGCONNECTOR7ORNCONTACTSCANCREATE
ELECTRICALRESISTANCE
4URNOFFANDLOCKOUTINPUTPOWER
L1
L2
L3
I
O
7AITFIVEMINUTES
6ERIFYTHATTHEREISNOVOLTAGEATTHE!&%INPUTPOWERTERMINALS
#HECKTHE$#BUSVOLTAGEBETWEENTHE$#AND$#TERMINALS
BETWEENTHE$#TERMINALANDTHECHASSISANDBETWEENTHE$#
TERMINALANDTHECHASSIS
4HEVOLTAGEMUSTBEZEROFORALLTHREEMEASUREMENTSBEFOREPROCEEDING
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
4-4
AFE Power Structure Component Section
Control Frame Access
Procedures
Removing the DPI Interface Assembly
2EMOVEPOWERFROMTHE!&%
3EE2EMOVING0OWERFROMTHE!&% ONPAGE )MPORTANT "EFOREREMOVINGCONNECTIONSANDWIRESMARKTHEMTO
AVOIDINCORRECTWIRINGDURINGASSEMBLY
&ORAN!&%INA)0-##3TYLEENCLOSUREDISREGARDTHISSTEP
&ORAN!&%INA)02ITTALENCLOSURELOCATETHECONTROLASSEMBLYITEM
IN&IGUREANDREMOVETHETWOSCREWSFROMTHEFRONTOFTHE$0)
HINGEDASSEMBLY
For AFE in IP20 2500
MCC Style Enclosure
For AFE in IP21
Rittal Enclosure
Remove
screws
P1
0.9 N•m
(8 lb•in)
&ORAN!&%INA)0-##3TYLEENCLOSUREOPENTHECONTROLBOX
DOORTOACCESSTHE$0)INTERFACEBOARD
&ORAN!&%INA)02ITTALENCLOSUREOPENTHEHINGEDASSEMBLYTHAT
HOLDSTHE$0)INTERFACEBOARD
5NPLUGTHE$0)CABLEFROMTHE8CONNECTORONTHE$0)INTERFACE
BOARD
Back view of the DPI
interface board which
remains mounted on the
back of the Control Frame.
X2
X4
Green Ground Wire*
* Based on PCB Revision
2EMOVETHEFOURSCREWSANDTHEASSEMBLYFROMTHE#ONTROL&RAME
For AFE in IP20 2500
MCC Style Enclosure
Mounting screws
P1
0.9 N•m
(8 lb•in)
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
For AFE in IP21
Rittal Enclosure
Mounting screws
P1
0.9 N•m
(8 lb•in)
Door (with
DPI interface
board and
HIM) in open
position
AFE Power Structure Component Section
4-5
Installing the DPI Interface Assembly
)NSTALLTHE$0)INTERFACEASSEMBLYINTHEREVERSEORDEROFREMOVALWHILE
REFERRINGTO4ORQUE3PECIFICATIONS ONPAGE Removing the I/O Circuit Boards and Control Board
2EMOVEPOWERFROMTHE!&%
3EE2EMOVING0OWERFROMTHE!&% ONPAGE &ORAN!&%INA)0-##3TYLEENCLOSUREOPENTHECONTROLBOX
ANDCAREFULLYUNPLUGTHE$0)CABLEANDANY)/CABLES
&ORAN!&%INA)02ITTALENCLOSUREOPENTHEENCLOSURETHATCONTAINS
THECONTROLAND)/CIRCUITBOARDSANDCAREFULLYUNPLUGTHE$0)CABLE
ANDANY)/CABLES
2EMOVETHE)/BOARDSFROMTHE#ONTROLBOARDANDENCLOSURE
.OTETHEORDEROFTHEBOARDSANDTHEKEYSWHICHPREVENTPLACEMENTOF
BOARDSININCORRECTSLOTS
NOTE: Do not remove the
enclosure cover from the Control
Frame. For clarity, the enclosure
is shown without the cover.
Keys
5NPLUGTHESERIALCONNECTIONFROM8OFTHE#ONTROLBOARD
X6 (Slot E)
X5 (Slot D)
X4 (Slot C)
X2
(Slot A)
X3 (Slot B)
X7
Serial Port
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
4-6
AFE Power Structure Component Section
2EMOVETHETHREESCREWSTHATSECURETHE#ONTROLBOARDTOTHE#ONTROL
BOXANDREMOVETHE#ONTROLBOARD
NOTE: Do not remove the
enclosure cover from the Control
Frame. For clarity, the enclosure
is shown without the cover.
PZ2
3 N•m
(27 lb•in)
Installing the I/O Circuit Boards and Control Board
)NSTALLTHE#ONTROLAND)/CIRCUITBOARDSINREVERSEORDEROFREMOVALWHILE
REFERRINGTO4ORQUE3PECIFICATIONS ONPAGE Removing the Fiber Optic Adapter Circuit Board
2EMOVEPOWERFROMTHE!&%
3EE2EMOVING0OWERFROMTHE!&% ONPAGE &ORAN!&%INA)0-##3TYLEENCLOSUREOPENTHECONTROLBOX
ONTHEENCLOSUREDOORTOACCESSTHE#ONTROLASSEMBLY
&ORAN!&%INA)02ITTALENCLOSUREDOTHEFOLLOWING
A /PENTHEENCLOSUREDOORTOACCESSTHE#ONTROL&RAME
B ,OOSENTHE4SCREWSTOOPENTHE#ONTROL&RAME
C 3WINGOPENTHE#ONTROL&RAMEWHICHEXPOSESTHEBACKOFTHE
#ONTROLBOXTOACCESSTHEFIBEROPTICADAPTERBOARD
Loosen T8
Torx-head
screws
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
AFE Power Structure Component Section
4-7
$ISCONNECTTHECABLESFROM8AND8OFTHE&IBER/PTIC!DAPTER
BOARD
)MPORTANT .OTEPOLARITYWHENREMOVING8AND8WIRES)FPOLARITY
ISNOTMAINTAINEDWHENREINSTALLINGTHESEWIRESTHE!3)#
BOARDORFIBEROPTICBOARDCANBEDAMAGED
X3
X1 disconnects from the
Control board when you
remove the board from
the Control Frame
H7
H6
H5
H4
H3
Sockets for
Fiber Optic
cables
H2
Connects to
24V DC power
H1
X2
#AREFULLYDISCONNECTTHEFIBEROPTICCABLESFROMTHERIGHTSIDEOFTHE
CIRCUITBOARDANDCAREFULLYSETTHEMASIDE
)MPORTANT 7HENMISHANDLEDTHEABILITYOFFIBEROPTICCABLESTO
TRANSMITDATAISGREATLYDIMINISHED
!44%.4)/.(AZARDOFPERMANENTEYEDAMAGEEXISTSWHEN
USINGOPTICALTRANSMISSIONEQUIPMENT4HISPRODUCTEMITSINTENSE
LIGHTANDINVISIBLERADIATION$ONOTLOOKINTOFIBEROPTICPORTSOR
FIBEROPTICCABLECONNECTORS
)MPORTANT 4HEMINIMUMINSIDEBENDRADIUSFORFIBEROPTICCABLEIS
MMIN!NYBENDSWITHASHORTERINSIDERADIUSCAN
PERMANENTLYDAMAGETHEFIBEROPTICCABLE3IGNAL
ATTENUATIONINCREASESWITHDECREASEDINSIDEBENDRADII
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
4-8
AFE Power Structure Component Section
2EMOVETHEFOURSCREWSTHATSECURETHE&IBER/PTIC!DAPTERBOARDTO
THESTANDOFFSONTHEBACKOFTHE#ONTROLBOX)0OR#ONTROL&RAME
)0ANDREMOVETHE&IBER/PTIC!DAPTERBOARD
For AFE in IP20 2500
MCC Style Enclosure
For AFE in IP21
Rittal Enclosure
PZ2
0.9 N•m
(8 lb•in)
PZ2
0.9 N•m
(8 lb•in)
Installing the Fiber Optic Adapter Circuit Board
)NSTALLTHE&IBER/PTIC!DAPTERCIRCUITBOARDINREVERSEORDEROFREMOVAL
WHILEREFERRINGTO4ORQUE3PECIFICATIONS ONPAGE 0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
AFE Power Structure Component Section
4-9
Removing the Control Frame (only for AFE in IP21 Rittal enclosure)
2EMOVEPOWERFROMTHE!&%
3EE2EMOVING0OWERFROMTHE!&% ONPAGE X50
terminal block
,OOSENTHE44ORXHEADSCREWSWHICHSECURETHE#ONTROL&RAMETOTHE
!&%ENCLOSURE
3WINGTHE#ONTROL&RAMEOUTANDAWAYFROMTHEPOWERSTRUCTURE
,IFTTHE#ONTROL&RAMEFROMTHEHINGESANDREMOVEIT
Loosen T8
Torx-head
screws
Replacing the Control Frame
2EPLACETHECONTROLFRAMEINREVERSEORDEROFREMOVALWHILEREFERRINGTO
4ORQUE3PECIFICATIONS ONPAGE 0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
4-10
AFE Power Structure Component Section
Power Structure Access
Procedures
&OLLOWTHESEINSTRUCTIONSTOREMOVEANDINSTALLCOMPONENTSONTHEPOWER
STRUCTUREANDTOREMOVETHE0OWER-ODULEFROMTHEPOWERSTRUCTURE
)MPORTANT 4OACCESS0OWER-ODULESFORREPLACEMENTREQUIRESTHEPOWER
STRUCTURETOBECOMPLETELYREMOVEDFROMTHE!&%ENCLOSURE
Removing AFE Protective Barriers
2EMOVEPOWERFROMTHE!&%
3EE2EMOVING0OWERFROMTHE!&% ONPAGE 2EMOVETHESCREWSTHATSECURETHEPROTECTIVEBARRIERSTOTHE!&%
ENCLOSURE
2EMOVETHEPROTECTIVEBARRIERS
Removing Protective Barriers for
AFE in IP21 Rittal Enclosure
Removing Protective Barriers for
AFE in IP20 2500 MCC Style Enclosure
Remove
screws
Remove
screws
Remove
screws
Installing the AFE Protective Barriers
)NSTALLTHEPROTECTIVEBARRIERSINREVERSEORDEROFREMOVAL
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
Remove
screws
AFE Power Structure Component Section
4-11
Removing the AFE Air Flow Plate
9OUMUSTREMOVETHE!IR&LOW0LATETOREMOVETHEPOWERSTRUCTUREFROMTHE
!&%
2EMOVEPOWERFROMTHE!&%
3EE2EMOVING0OWERFROMTHE!&% ONPAGE )FPRESENTREMOVETHEPROTECTIVEBARRIERS
3EE2EMOVING!&%0ROTECTIVE"ARRIERS ONPAGE &ORAN!&%INA)0-##3TYLEENCLOSUREREMOVETHEFOUR
-XSCREWSTHATSECURETHE!IR&LOW0LATETOTHE!&%
&ORAN!&%INA)02ITTALENCLOSUREREMOVETHEFOUR44ORXHEAD
SCREWSTHATSECURETHE!IR&LOW0LATETOTHE!&%
3LIDETHE!IR&LOW0LATEFROMTHE!&%
Removing Air Flow Plate for
AFE in IP21 Rittal Enclosure
Removing Air Flow Plate for
AFE in IP20 2500 MCC Style Enclosure
Remove
screws
Remove
screws
Remove
screws
Installing the AFE Air Flow Plate
)NSTALLTHE!IR&LOW0LATEINREVERSEORDEROFREMOVAL
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
4-12
AFE Power Structure Component Section
Removing Protective Covers from the Power Structure
9OUMUSTREMOVETHEPROTECTIVECOVERSTOACCESSTHEINTERNALCOMPONENTSOF
THEPOWERSTRUCTURE
2EMOVEPOWERFROMTHE!&%
3EE2EMOVING0OWERFROMTHE!&% ONPAGE )FPRESENTREMOVETHEPROTECTIVEBARRIERS
3EE2EMOVING!&%0ROTECTIVE"ARRIERS ONPAGE 2EMOVETHEFOUR-0/:)$2)6SCREWSTHATSECURETHEPROTECTIVEFRONT
COVERANDTERMINALCOVERTOTHEPOWERSTRUCTURE
2EMOVETHECOVERS
./4%9OUNEEDTOREMOVEONLYTHETERMINALCOVERTOGAINACCESSTO
THECOOLINGFANCONNECTIONS
Front Cover
Terminal Cover
Installing Protective Covers on the Power Structure
)NSTALLTHEPROTECTIVECOVERSONTHEPOWERSTRUCTUREINREVERSEORDEROF
REMOVALWHILEREFERRINGTO4ORQUE3PECIFICATIONS ONPAGE Removing the Gate Driver Circuit Board
4HEREISONE'ATE$RIVERCIRCUITBOARDONTHEFRONTOFTHEPOWERSTRUCTURE
2EMOVEPOWERFROMTHE!&%
3EE2EMOVING0OWERFROMTHE!&% ONPAGE )FPRESENTREMOVETHEPROTECTIVEBARRIERS
3EE2EMOVING!&%0ROTECTIVE"ARRIERS ONPAGE 0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
AFE Power Structure Component Section
4-13
2EMOVETHE!IR&LOW0LATE
3EE2EMOVINGTHE!&%!IR&LOW0LATE ONPAGE 2EMOVETHEPROTECTIVEFRONTCOVERANDTERMINALCOVERFROMTHEPOWER
STRUCTURE
3EE2EMOVING0ROTECTIVE#OVERSFROMTHE0OWER3TRUCTURE ON
PAGE 5NSCREWTHETERMINALSFORTHE$#SUPPLYFROM8OFTHE'ATE
$RIVERBOARD
/BSERVEPOLARITYWHENREMOVINGFORLATERREATTACHMENT
#AREFULLYUNPLUGTHEFIBEROPTICCABLESFROMSOCKETSALONGTHEBOTTOMOF
THE'ATE$RIVERBOARDANDCAREFULLYSETTHEMASIDE
)MPORTANT 7HENMISHANDLEDTHEABILITYOFFIBEROPTICCABLESTO
TRANSMITDATAISGREATLYDIMINISHED
!44%.4)/.(AZARDOFPERMANENTEYEDAMAGEEXISTSWHEN
USINGOPTICALTRANSMISSIONEQUIPMENT4HISPRODUCTEMITSINTENSE
LIGHTANDINVISIBLERADIATION$ONOTLOOKINTOFIBEROPTICPORTSOR
FIBEROPTICCABLECONNECTORS
)MPORTANT 4HEMINIMUMINSIDEBENDRADIUSFORFIBEROPTICCABLEIS
MMIN!NYBENDSWITHASHORTERINSIDERADIUSCAN
PERMANENTLYDAMAGETHEFIBEROPTICCABLE3IGNAL
ATTENUATIONINCREASESWITHDECREASEDINSIDEBENDRADII
$ISCONNECTTHE88AND8CABLESFROMSOCKETSOFTHE'ATE
$RIVERBOARDANDSETTHEMASIDE
2EMOVETHEFIVESCREWSTHATSECURETHE'ATE$RIVERBOARDANDSUPPORT
BRACKETTOTHEPOWERSTRUCTURE
Remove screws
Remove Gate Driver circuit
board support bracket
Remove screws
#AREFULLYREMOVETHE'ATE$RIVERBOARDANDTHEBOARDSUPPORTBRACKET
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
4-14
AFE Power Structure Component Section
#AREFULLYREMOVETHETWOPLASTICSCREWSTHATSECURETHE'ATE$RIVER
BOARDSCREENINGPLATETOTHEPOWERSTRUCTUREANDREMOVETHESCREENING
PLATE
2EMOVETHETWOSTANDOFFSTHATSUPPORTTHE'ATE$RIVERBOARD
Remove plastic screws
Remove screening plate
Remove stand-offs
Installing the Gate Driver Circuit Board
)NSTALLTHE'ATE$RIVERCIRCUITBOARDINTHEREVERSEORDEROFREMOVAL
Removing the ASIC Circuit Board
2EMOVEPOWERFROMTHE!&%
3EE2EMOVING0OWERFROMTHE!&% ONPAGE )FPRESENTREMOVETHEPROTECTIVEBARRIERS
3EE2EMOVING!&%0ROTECTIVE"ARRIERS ONPAGE 2EMOVETHE!IR&LOW0LATE
3EE2EMOVINGTHE!&%!IR&LOW0LATE ONPAGE 2EMOVETHEPROTECTIVEFRONTCOVERANDTERMINALCOVERFROMTHEPOWER
STRUCTURE
3EE2EMOVING0ROTECTIVE#OVERSFROMTHE0OWER3TRUCTURE ON
PAGE 0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
!44%.4)/.4HESHEETMETALCOVERANDMOUNTINGSCREWSON
THE!3)#CIRCUITBOARDLOCATEDONTHEPOWERSTRUCTUREARE
ENERGIZEDAT$#BUSPOTENTIALHIGHVOLTAGE2ISKOFELECTRICAL
SHOCKINJURYORDEATHEXISTSIFSOMEONECOMESINTOCONTACTWITH
THEASSEMBLY
AFE Power Structure Component Section
4-15
2EMOVETHEFOURSCREWSTHATSECURETHE!3)#COVERTOTHE!3)#
ASSEMBLYREMOVETHE$#BUSCONNECTIONFROMTHE!3)#COVERAND
REMOVETHE!3)#COVER
Remove
screws
Remove screws
and cover
ASIC cover
Remove -DC
bus connection
ASIC
assembly
5NPLUGTHEFANWHICHMOUNTSONTHECOVERFROMCONNECTOR8OFTHE
!3)#CIRCUITBOARD
#AREFULLYUNPLUGTHEFIBEROPTICCABLES(THROUGH(FROMSOCKETSON
THE!3)#BOARDANDCAREFULLYSETTHEMASIDE
)MPORTANT 7HENMISHANDLEDTHEABILITYOFFIBEROPTICCABLESTO
TRANSMITDATAISGREATLYDIMINISHED
!44%.4)/.(AZARDOFPERMANENTEYEDAMAGEEXISTSWHEN
USINGOPTICALTRANSMISSIONEQUIPMENT4HISPRODUCTEMITSINTENSE
LIGHTANDINVISIBLERADIATION$ONOTLOOKINTOFIBEROPTICPORTSOR
FIBEROPTICCABLECONNECTORS
)MPORTANT 4HEMINIMUMINSIDEBENDRADIUSFORFIBEROPTICCABLEIS
MMIN!NYBENDSWITHASHORTERINSIDERADIUSCAN
PERMANENTLYDAMAGETHEFIBEROPTICCABLE3IGNAL
ATTENUATIONINCREASESWITHDECREASEDINSIDEBENDRADII
$ISCONNECTTHE8TERMINALBLOCKANDTHE8TERMINALCONNECTORS
.OTE7HENREPLACINGTHEEXISTING!3)#BOARDWITHANEWBOARDTHE
8AND8CONNECTORSMUSTBETRANSFERREDANDCONNECTEDTOTHENEW
BOARDBEFOREINSTALLATION
$ISCONNECTTHE8888AND8CABLESFROMSOCKETSONTHE
FRONTOFTHE!3)#BOARDANDSETTHEMASIDE
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
4-16
AFE Power Structure Component Section
2EMOVETHEFOURSCREWSTHATSECURETHE!3)#ASSEMBLYTOTHEPOWER
STRUCTUREANDREMOVETHE!3)#ASSEMBLY
2EMOVETHESCREWANDDETACHTHEFOURPLASTICSTANDOFFSTHATSECURETHE
!3)#BOARDTOTHE!3)#CHASSISANDREMOVETHE!3)#BOARD
Remove screw
Remove ASIC circuit board from chassis
)FTHEPLASTICINSULATORREQUIRESREPLACEMENTDOTHEFOLLOWING
A 2EMOVETHEFOURSCREWSTHATSECURETHEBOARDHOLDERTOTHEMETAL
FRAMEANDREMOVETHEMETALFRAMEANDINSULATOR
Remove screws
Remove metal frame and insulator
B #AREFULLYREMOVETHEFOURFASTENERSTHATSECURETHEINSULATORTOTHE
METALFRAMEANDREMOVETHEINSULATOR
Remove insulator
Remove fasteners
C 2EPLACETHEINSULATOR
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
AFE Power Structure Component Section
4-17
Installing the ASIC Circuit Board
)NSTALLTHE!3)#CIRCUITBOARDINREVERSEORDEROFREMOVALWHILEREFERRINGTO
4ORQUE3PECIFICATIONS ONPAGE 2ECONNECTCABLESANDJUMPERSTOTHE
!3)#BOARDWHILEREFERRINGTO&IGURE" ONPAGE "
!44%.4)/.4HESHEETMETALCOVERANDMOUNTINGSCREWSON
THE!3)#CIRCUITBOARDLOCATEDONTHEPOWERSTRUCTUREARE
ENERGIZEDAT$#BUSPOTENTIALHIGHVOLTAGE2ISKOFELECTRICAL
SHOCKINJURYORDEATHEXISTSIFSOMEONECOMESINTOCONTACTWITH
THEASSEMBLY6ERIFYTHATTHE$#BUSWIREISPROPERLYCONNECTED
TOTHE!3)#CHASSISCOVER
Removing and Installing the Power Structure Fan System
4HEREISONE-AIN#OOLING&ANONTHEPOWERSTRUCTURE&ORCOMPLETEDETAILS
ONALLFANSYSTEMRELATEDINFORMATIONSEETHE0OWER&LEX3(AND
!&%$RIVE&AN3YSTEMS)NSTALLATION)NSTRUCTIONSPUBLICATION
0&,%8).INCLUDINGREMOVALANDINSTALLATIONOFTHEFOLLOWINGITEMS
•
•
•
•
•
•
!#FANINVERTERS
!#FANCAPACITORS
!#MAINCOOLINGFANS
$#FANPOWERSUPPLIES
$#MAINCOOLINGFANS
&ANFUSING
Removing the Power Structure from the Enclosure
)MPORTANT 0OWERSTRUCTUREREMOVALISREQUIREDONLYWHENITORITSINTERNAL
COMPONENTS0OWER-ODULE$#BUSCAPACITORSBALANCING
RESISTORSANDSOFORTHNEEDSTOBEREPLACED
2EMOVEPOWERFROMTHE!&%
3EE2EMOVING0OWERFROMTHE!&% ONPAGE )FPRESENTREMOVETHEPROTECTIVEBARRIERS
3EE2EMOVING!&%0ROTECTIVE"ARRIERS ONPAGE 2EMOVETHE!IR&LOW0LATE
3EE2EMOVINGTHE!&%!IR&LOW0LATE ONPAGE 2EMOVETHE$#AND$#WIRESFROMTHE&AN)NVERTER&USEASSEMBLY
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
4-18
AFE Power Structure Component Section
2EMOVETHECONNECTIONSFROMTHE$#BUSTERMINALSATTHETOPOFTHE
POWERSTRUCTURE
DC Bus Terminals
U/T1, V/T2, and
W/T3 Connections
Ground
Connection PE
2EMOVETHE5464AND74CONNECTIONSFROMTHEPOWER
STRUCTUREATTHEBOTTOMFRONTOFTHEPOWERSTRUCTURE
2EMOVETHEGROUNDCONNECTIONFROMTHEREAROFTHEPOWERSTRUCTURE
$ISCONNECTTHESEVENFIBEROPTICCABLESCONNECTEDTOTHEFIBEROPTIC
ADAPTERBOARDLOCATEDBEHINDTHECONTROLASSEMBLYFOR!&%IN)0
-##3TYLEENCLOSUREORTHE#ONTROL&RAMEFOR!&%IN)0
2ITTALENCLOSURE
&ORLOCATIONOFCONNECTIONSSEE2EMOVINGTHE&IBER/PTIC!DAPTER
#IRCUIT"OARD ONPAGE 2EMOVETHEPROTECTIVEFRONTCOVERANDTERMINALCOVERFROMTHEPOWER
STRUCTURETOACCESSTHE8FANCONNECTOR
3EE2EMOVING0ROTECTIVE#OVERSFROMTHE0OWER3TRUCTURE ON
PAGE 2EMOVETHE8FANCONNECTOR
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
AFE Power Structure Component Section
4-19
2EMOVETHEFOUR-XSCREWSTHATSECURETHEPOWERSTRUCTURETOTHE
ENCLOSUREBACKPANEL
For clarity, only the
back panel of the
enclosure is shown.
Remove screws
M8 x 20
6.7 N•m
(60 lb•in)
Remove screws
0ARTIALLYPULLTHEPOWERSTRUCTUREFORWARDFROMTHEENCLOSURETOEXPOSE
THELIFTINGHOLES
3ECUREAPPROPRIATELIFTINGAPPARATUSTOTHEPOWERSTRUCTUREAND
COMPLETELYREMOVETHEPOWERSTRUCTUREAPPROXIMATELYLBKG
FROMTHEENCLOSURE
Installing the Power Structure in the Enclosure
)NSTALLTHEPOWERSTRUCTUREINREVERSEORDEROFREMOVAL3EETHE0OWER&LEX
!CTIVE&RONT%ND5SER-ANUALPUBLICATION95-FORTIGHTENING
TORQUESOF!#SUPPLY$#BUSINPUTANDGROUNDCONNECTIONTERMINATIONS
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
4-20
AFE Power Structure Component Section
Removing the Power Module from the Power Structure
)MPORTANT $ONOTATTEMPTTODISASSEMBLETHE0OWER-ODULE
2EMOVETHEPOWERSTRUCTUREFROMTHE!&%ENCLOSURE
3EE2EMOVINGTHE0OWER3TRUCTUREFROMTHE%NCLOSURE ONPAGE )MPORTANT "EFORETHEINTERNALCOMPONENTS0OWER-ODULE$#BUS
CAPACITORSBALANCINGRESISTORSANDSOFORTHOFTHEPOWER
STRUCTURECANBEACCESSEDTHEPOWERSTRUCTUREMUSTBE
REMOVEDFROMITSMOUNTINGCHASSIS
0LACETHEPOWERSTRUCTUREONAFLATSURFACEFORSTABILITY
0LACETHEPOWERSTRUCTUREONITSBACKSIDETOFACILITATEPOWERSTRUCTURE
REMOVALFROMITSMOUNTINGCHASSIS
Remove screws
M8 x 20
20 N•m
(177 lb•in)
Backside of
Power Structure
Power Structure
Mounting Chassis
Output cable
fastening screws
M10 x 20
40 N•m
(354 lb•in)
Remove screws
M8 x 20
20 N•m
(177 lb•in)
4OREMOVETHEPOWERSTRUCTUREFROMITSMOUNTINGCHASSISDOTHE
FOLLOWING
A 2EMOVETHEFOUR-XHEXAGONALSCREWS
B 2EMOVETHETHREE-XOUTPUTCABLEFASTENINGSCREWS
C 3EPARATETHEPOWERSTRUCTUREFROMITSMOUNTINGCHASSIS
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
AFE Power Structure Component Section
4-21
2EMOVETHEPOWERSTRUCTURESIDEPANELTOACCESSTHEINTERNALCOMPONENTS
Side Panel
0LACETHEPOWERSTRUCTUREONITSHEATSINKSIDEFOREASYACCESSTOTHE
INTERNALCOMPONENTS
2EMOVETHE'ATE$RIVER#IRCUITBOARD
3EE2EMOVINGTHE'ATE$RIVER#IRCUIT"OARD ONPAGE 2EMOVETHECAPACITORLEADSFROMTHE$#INPUTBUSBARSATTHETOPOFTHE
POWERSTRUCTURE
2EMOVETHEINSULATORHOLDINGPLATEFROMBETWEENTHEBUSBARTERMINALS
Remove screws
PZ2
4 N•m
(35 lb•in)
Remove insulator holding plate
Remove bus bar terminals
Remove airflow channel
2EMOVETHE-0/:)$2)6SCREWSTHATSECURETHEBUSBARTERMINALSTO
THEPOWERSTRUCTURE
3LIDETHEBUSBARTERMINALSOUTOFTHEFRAME
2EMOVETHEBUSBARAIRFLOWCHANNELFROMTHEFRAME
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
4-22
AFE Power Structure Component Section
2EMOVETHE-XHEXAGONALSCREWSTHATSECURETHEINPUTPOWER
CABLESTOTHEINPUTPOWERBUSBAR
4IGHTENINGTORQUEFORREASSEMBLYIS.sMLBsIN
#UTANDREMOVETHECABLETIESTHATSECURETHEINPUTPOWERCABLESTOTHE
%-#COVERPLATEANDREMOVETHECABLES
Remove screws and
input power cables
Cut cable ties
2EMOVETHE-X0/:)$2)6AND-X0/:)$2)6SCREWSTHAT
SECURETHE%-#COVERTOTHE!&%ANDREMOVETHECOVER
Remove screws
PZ2
4 N•m
(35 lb•in)
Remove EMC cover
Remove screw and
snubber capacitors
Remove screws
PZ2
3 N•m
(27 lb•in)
2EMOVETHESCREWSTHATSECURETHESNUBBERCAPACITORSTOTHEPOWER
STRUCTUREANDREMOVETHESNUBBERCAPACITORS
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
AFE Power Structure Component Section
4-23
2EMOVETHESCREWSTHATSECURETHEPOWERBUSBARANDSUPPORTINSULATORS
TOTHEPOWERSTRUCTURE
Support
insulators
Power
bus bar
Remove screws
2EMOVETHEPOWERBUSBARANDINSULATORS
4IGHTENINGTORQUEFORREASSEMBLYIS.sMLBsIN
$ISCONNECTTHE"ALANCING2ESISTORASSEMBLYWIRESFROMTHE$#BUS
BARS
Remove wire
connections from
DC bus bar end
Older Style Balancing
Resistor Assembly
P2
4 N•m
(35 lb•in)
Newer Style Balancing
Resistor Assembly
P2
4 N•m
(35 lb•in)
PZ2
3 N•m
(27 lb•in)
Assembly mounting screws
Assembly mounting screws
PZ2
3 N•m
(27 lb•in)
Remove wire
connections
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
4-24
AFE Power Structure Component Section
2EMOVETHESCREWSSEESTEPPICTUREFORSCREWLOCATIONSTHATSECURE
THE"ALANCING2ESISTORASSEMBLIESTOTHEPOWERSTRUCTURE
Balancing resistor
assembly
Remove screws
2EMOVETHE"ALANCING2ESISTORASSEMBLIES
2EMOVETHE-XSCREWSTHATSECURETHE#ONNECTIVE$#BUSBARS
ANDINSULATORSTOTHEPOWERSTRUCTURE
DC+ bus bar
DC- bus bar
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
Insulator
AFE Power Structure Component Section
4-25
Location
Fasteners
Torque
➊
M10 x 25 hexagonal screws, M10 spring washers and M10 washers
8 N•m (70 lb•in)
➋
M8 x 25 hexagonal screws, M8 spring washers and M8 washers
8 N•m (70 lb•in)
➌
M6 x 12 screws
4 N•m (35 lb•in)
➊
➋
➌
2EMOVETHE#ONNECTIVE$#BUSBARSANDINSULATORS
4IGHTENINGTORQUEFORREASSEMBLYIS.sMLBsIN
Bus bar
Insulator
Bus bar
Insulator
Remove all screws holding bus
bars and insulators to AFE frame
Metal plate
Remove
screws
Bus bar
Metal plate
Insulator
Remove
screws
690V AFE
Power Structure
shown
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
4-26
AFE Power Structure Component Section
2EMOVETHE-XSCREWSTHATSECURETHE0OWER-ODULETOTHEPOWER
STRUCTURE
2EMOVETHE0OWER-ODULE
Remove screws
Remove screws
Installing the Power Module on the Power Structure
)NSTALLTHE0OWERMODULEINREVERSEORDEROFREMOVALWHILEREFERRINGTO
4ORQUE3PECIFICATIONS ONPAGE Removing the Power Structure DC Bus Capacitors
3EE2EMOVINGTHE0OWER-ODULEFROMTHE0OWER3TRUCTURE ON
PAGE ANDPERFORMSTEPSTHROUGH
$ONOTPERFORMSTEPSANDˆREMOVALOFTHE0OWER-ODULEISNOT
NECESSARYTOREPLACETHE$#BUSCAPACITORS
.OTETHEPOLARITYOFTHECAPACITORS
2EMOVETHEFOUR-XSCREWSTHATSECURETHECAPACITORTOTHEPOWER
STRUCTURE
Remove screws
Remove screws
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
AFE Power Structure Component Section
4-27
2EMOVETHECAPACITOR
4IGHTENINGTORQUEFORREASSEMBLYIS.sMLBsIN7E
RECOMMENDREPLACINGALLCAPACITORSATTHESAMETIME
2EPEATSTEPSANDFOREACHREMAINING$#BUSCAPACITORBEING
REMOVED
Installing the Power Structure DC Bus Capacitors
)NSTALLTHECAPACITORSINREVERSEORDEROFREMOVAL-AKESURETOOBSERVETHE
POLARITYOFTHECAPACITORSASNOTEDINREMOVALSTEPABOVE
Replacing the Existing Power Structure with a New Power Structure
7HENREPLACINGTHEPOWERSTRUCTUREWITHANEWONEITISIMPORTANTTONOTE
THATTHECOMMONMODECAPACITORSINTHENEWPOWERSTRUCTUREMUSTBE
REMOVED5SETHEFOLLOWINGPROCEDURETOREPLACETHEPOWERSTRUCTURE
2EMOVETHEOLDPOWERSTRUCTUREFROMTHEENCLOSURE
3EE2EMOVINGTHE0OWER3TRUCTUREFROMTHE%NCLOSURE ONPAGE 2EMOVETHECOMMONMODECAPACITORSFROMTHENEW&RAMEPOWER
STRUCTURETHATISREPLACINGTHEOLDPOWERSTRUCTURE
&ORTHEPROCEDURETOREMOVETHECOMMONMODECAPACITORSSEETHE
0OWER&LEX!CTIVE&RONT%ND5SER-ANUALPUBLICATION95-
2EFERTO#HAPTERSECTION@$ISCONNECTING#OMMON-ODE#APACITORS
ANDSUBSECTION@&RAME0OWER3TRUCTURE4HESEINSTRUCTIONSAPPLYTO
AN!&%INA)0-##3TYLEENCLOSUREORAN!&%INA)02ITTAL
ENCLOSURE
)NSTALLTHENEWREPLACEMENTPOWERSTRUCTURE
3EE)NSTALLINGTHE0OWER3TRUCTUREINTHE%NCLOSURE ONPAGE 0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
4-28
AFE Power Structure Component Section
Notes:
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
#HAPTER
AC Line Switchgear Component Section
!44%.4)/.4OAVOIDANELECTRICSHOCKHAZARDVERIFYTHATTHE
VOLTAGEONTHEBUSCAPACITORSHASDISCHARGEDCOMPLETELYBEFORE
SERVICING#HECKTHE$#BUSVOLTAGEBETWEENTHE$#AND$#
TERMINALSBETWEENTHE$#TERMINALANDTHECHASSISAND
BETWEENTHE$#TERMINALANDTHECHASSIS4HEVOLTAGEMUSTBE
ZEROFORALLTHREEMEASUREMENTS
!44%.4)/.(OTSURFACESCANCAUSESEVEREBURNS$ONOT
TOUCHTHEHEATSINKSURFACEDURINGOPERATIONOFTHE0OWER&LEX
!CTIVE&RONT%ND!FTERDISCONNECTINGPOWERALLOWTIMEFOR
COOLING
!44%.4)/.(AZARDOFPERMANENTEYEDAMAGEEXISTSWHEN
USINGOPTICALTRANSMISSIONEQUIPMENT4HISPRODUCTEMITSINTENSE
LIGHTANDINVISIBLERADIATION$ONOTLOOKINTOFIBEROPTICPORTSOR
FIBEROPTICCABLECONNECTORS
!44%.4)/.4HESHEETMETALCOVERANDMOUNTINGSCREWSON
THE!3)#"OARDLOCATEDONTHEPOWERSTRUCTUREAREENERGIZEDAT
$#BUSPOTENTIALHIGHVOLTAGE2ISKOFELECTRICALSHOCKINJURY
ORDEATHEXISTSIFSOMEONECOMESINTOCONTACTWITHTHEASSEMBLY
!44%.4)/.4HE0OWER&LEX!CTIVE&RONT%NDCONTAINS
ELECTROSTATICDISCHARGE%3$SENSITIVEPARTSANDASSEMBLIESTHAT
CANBEDAMAGEDIFYOUDONOTFOLLOW%3$CONTROLPROCEDURES
3TATICCONTROLPRECAUTIONSAREREQUIREDTOINSTALLTESTSERVICEOR
REPAIRTHISASSEMBLY)FYOUAREUNFAMILIARWITHSTATICCONTROL
PROCEDURESSEE'UARDING!GAINST%LECTROSTATIC$AMAGE
PUBLICATIONORANYOTHERAPPLICABLE%3$PROTECTION
HANDBOOK
!44%.4)/.4OAVOIDANELECTRICSHOCKHAZARDVERIFYTHATALL
POWERTOTHE0OWER&LEX!CTIVE&RONT%NDHASBEENREMOVED
BEFOREPERFORMINGANYSERVICINGORREPAIRS
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
5-2
AC Line Switchgear Component Section
AFE in IP20 2500 MCC Style &ORA0OWER&LEX!&%SYSTEMINTHE)0-##3TYLEENCLOSURETHE
!#LINESWITCHGEARCOMPONENTSARETHEINPUTCIRCUITBREAKER1!#INPUT
Enclosure
FUSES&x&ANDINPUTCONTACTOR+
4HEINPUTCIRCUITBREAKEREITHERCONNECTSORDISCONNECTSTHE!&%SYSTEMTO
THE!#LINE4HEINPUTCONTACTORCONNECTSTHEINTERNAL!&%SYSTEM!#LINE
TOTHE!&%POWERSTRUCTURETHROUGHTHE,#,FILTER4HE!&%POWER
STRUCTURECONTAINSTHECONTROLLOGICTHATOPENSORCLOSESTHEINPUTCONTACTOR
3EETHE0OWER&LEX!CTIVE&RONT%ND5SER-ANUALPUBLICATION
95-FORTHE!#INPUTFUSINGANDCIRCUITBREAKERPROTECTION
RECOMMENDATIONS
AFE in IP21 Rittal Enclosure &ORA0OWER&LEX!&%SYSTEMINTHE)02ITTALENCLOSURETHE!#LINE
SWITCHGEARCOMPONENTSARETHEINPUTDISCONNECT1AND-##"1
3EETHE0OWER&LEX!CTIVE&RONT%ND5SER-ANUALPUBLICATION
95-FORTHE!#INPUTFUSINGAND-##"PROTECTION
RECOMMENDATIONS
4HEINPUTDISCONNECTEITHERCONNECTSORDISCONNECTSTHE!&%SYSTEMTOTHE
!#LINE4HE-##"CONNECTSTHEINTERNAL!&%SYSTEM!#LINETOTHE!&%
POWERSTRUCTURETHROUGHTHE,#,FILTER4HE!&%POWERSTRUCTURECONTAINS
THECONTROLLOGICTHATENABLESORDISABLESTHERESETTABLETRIPMECHANISMTHAT
ISINTEGRATEDINTOTHE-##"4HETRIPMECHANISMCONTROLSTHE-##"
FUNCTIONALITY
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
#HAPTER
Precharge Component Section
!44%.4)/.4OAVOIDANELECTRICSHOCKHAZARDVERIFYTHATTHE
VOLTAGEONTHEBUSCAPACITORSHASDISCHARGEDCOMPLETELYBEFORE
SERVICING#HECKTHE$#BUSVOLTAGEBETWEENTHE$#AND$#
TERMINALSBETWEENTHE$#TERMINALANDTHECHASSISAND
BETWEENTHE$#TERMINALANDTHECHASSIS4HEVOLTAGEMUSTBE
ZEROFORALLTHREEMEASUREMENTS
!44%.4)/.(OTSURFACESCANCAUSESEVEREBURNS$ONOT
TOUCHTHEHEATSINKSURFACEDURINGOPERATIONOFTHE0OWER&LEX
!CTIVE&RONT%ND!FTERDISCONNECTINGPOWERALLOWTIMEFOR
COOLING
!44%.4)/.(AZARDOFPERMANENTEYEDAMAGEEXISTSWHEN
USINGOPTICALTRANSMISSIONEQUIPMENT4HISPRODUCTEMITSINTENSE
LIGHTANDINVISIBLERADIATION$ONOTLOOKINTOFIBEROPTICPORTSOR
FIBEROPTICCABLECONNECTORS
!44%.4)/.4HESHEETMETALCOVERANDMOUNTINGSCREWSON
THE!3)#"OARDLOCATEDONTHEPOWERSTRUCTUREAREENERGIZEDAT
$#BUSPOTENTIALHIGHVOLTAGE2ISKOFELECTRICALSHOCKINJURY
ORDEATHEXISTSIFSOMEONECOMESINTOCONTACTWITHTHEASSEMBLY
!44%.4)/.4HE0OWER&LEX!CTIVE&RONT%NDCONTAINS
ELECTROSTATICDISCHARGE%3$SENSITIVEPARTSANDASSEMBLIESTHAT
CANBEDAMAGEDIFYOUDONOTFOLLOW%3$CONTROLPROCEDURES
3TATICCONTROLPRECAUTIONSAREREQUIREDTOINSTALLTESTSERVICEOR
REPAIRTHISASSEMBLY)FYOUAREUNFAMILIARWITHSTATICCONTROL
PROCEDURESSEE'UARDING!GAINST%LECTROSTATIC$AMAGE
PUBLICATIONORANYOTHERAPPLICABLE%3$PROTECTION
HANDBOOK
!44%.4)/.4OAVOIDANELECTRICSHOCKHAZARDVERIFYTHATALL
POWERTOTHE0OWER&LEX!CTIVE&RONT%NDHASBEENREMOVED
BEFOREPERFORMINGANYSERVICINGORREPAIRS
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
6-2
Precharge Component Section
Precharging Functions
4HEPRECHARGECIRCUITRYHASTWOMAINFUNCTIONS
• )TPROVIDES!&%SYSTEMCONTROLPOWER
• )TPROVIDESTHEPRECHARGECIRCUITRYTOCHARGETHE$#BUS
4HE!&%SYSTEMISAVAILABLEINBOTH6!#AND6!#
SYSTEMVOLTAGECONFIGURATIONS#ONTROLLOGICVOLTAGESAREASFOLLOWS
• &ORAN!&%INA)0-##3TYLEENCLOSUREITIS6!#SINGLE
PHASEANDALSO6$#POWER
• &ORAN!&%INA)02ITTALENCLOSUREITIS6!#SINGLEPHASEAND
ALSO6$#POWER
4HEPRECHARGECIRCUITRYLETSTHE$#CAPACITORSLOCATEDINTHE!&%POWER
STRUCTURETOBEPROPERLYCHARGEDWITHINLINECURRENTLIMITINGRESISTORSTO
$#BUSVOLTAGEMAGNITUDES
3EETHE0OWER&LEX!CTIVE&RONT%ND5SER-ANUALPUBLICATION
95-FORTHEMINIMUMANDMAXIMUMSYSTEMCAPACITANCE
REQUIREMENTS
Replacing the Precharge
Fuse
4HEPRECHARGEFUSEASSEMBLYFORAN!&%INA)0ENCLOSUREISLOCATEDIN
THEPOWERSTRUCTUREENCLOSURE&ORAN!&%INA)0ENCLOSURETHE
PRECHARGEFUSEASSEMBLYISLOCATEDINTHE,#,&ILTERENCLOSURE
2EMOVEPOWERFROMTHE!&%
3EE2EMOVING0OWERFROMTHE!&% ONPAGE /PENTHEAPPROPRIATEENCLOSUREDOOR
)FPRESENTREMOVETHEPROTECTIVEBARRIERS
3EE2EMOVING!&%0ROTECTIVE"ARRIERS ONPAGE 3LIDETHEFUSESLEEVEOUTFROMTHEFUSEHOLDER
2EMOVETHEFUSEFROMTHESLEEVEANDAPPROPRIATELYDISCARDTHEOLDFUSE
3EETHEAPPROPRIATETABLEBELOWFORTHERECOMMENDEDNEWREPLACEMENT
FUSEANDINSTALLTHEFUSEINREVERSEORDEROFREMOVAL
Table 6.A 400/480 Volt Precharge Fuse Rating
Frame
Size
Enclosure Style
10
(1)
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
Fuse Holder (1)
Fuse
Amps
Type
Type
IP20 2500 MCC
30
Bussmann DFJ-30
Bussmann CH30J3
IP21 Rittal
32
ABB OFAF000H32
ABB O540D12000
Fuse holder holds a quantity of three fuses.
Precharge Component Section
6-3
Table 6.B 600/690 Volt Precharge Fuse Rating
Frame
Size
Enclosure Style
10
(1)
Testing the Control
Transformer (T4) and 24V
DC Power Supply (T10)
Fuse Holder (1)
Fuse
Amps
Type
Type
IP20 2500 MCC
30
Bussmann DFJ-30
Bussmann CH30J3
IP21 Rittal
32
ABB OFAA000GG32
ABB O540D12000
Fuse holder holds a quantity of three fuses.
For AFE in IP20 2500 MCC Style Enclosure
)FPRESENTREMOVETHEPROTECTIVEBARRIERS
3EE2EMOVING!&%0ROTECTIVE"ARRIERS ONPAGE !44%.4)/.4HESETESTSMUSTBEPERFORMEDBYQUALIFIED
PERSONNEL$URINGTHESETESTSTHE!&%ISPOWERED4AKEPROPER
PRECAUTIONSTOAVOIDINJURYFROMELECTRICALSHOCK
,OCATETHECONTROLTRANSFORMER4AND6$#POWERSUPPLY4
4HECONTROLTRANSFORMER4ISLOCATEDONTHELEFTSIDEOFTHEINPUT
CIRCUITBREAKER14HE6$#POWERSUPPLY4ISLOCATEDINTHE
BOTTOMOFTHECONTROLBOX
FRONT VIEW
(shown with enclosure doors removed)
Control Transformer (T4)
Control Box
(located on front of enclosure door;
shown with control box cover removed)
24V DC Power Supply (T10)
5SEADIGITALVOLTMETERTOTESTTHECONTROLTRANSFORMER4
A -EASURETHEPRIMARY!#LINEVOLTAGEWHICHISATTHEx6
!#ORx6!#SYSTEMVOLTAGE
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
6-4
Precharge Component Section
B -EASURETHECONTROLTRANSFORMER4OUTPUTVOLTAGEWHICHIS
APPROXIMATELY6!#
)FTHESEMEASUREMENTSARENOTWITHIN›PERFORMTHESEOTHERSTEPS
C 0OWERDOWNTHE!&%
D 2EMOVETHEOUTPUTSECONDARYWIRES
E 0OWERUPTHE!&%ANDRETESTBYREPEATINGSTEPSAANDB
4HECONTROLTRANSFORMER4MAYREQUIREREPLACEMENTIFTHESE
MEASUREMENTSCONTINUETOBEOUTSIDEOFTHE›TOLERANCE
5SEADIGITALVOLTMETERTOTESTTHE6$#POWERSUPPLY4
A -EASURETHEPRIMARYVOLTAGEWHICHIS6!#
B -EASURETHEPOWERSUPPLY4OUTPUTVOLTAGEWHICHIS
APPROXIMATELY6$#
)FTHESEMEASUREMENTSARENOTWITHIN›PERFORMTHESEOTHERSTEPS
C 0OWERDOWNTHE!&%
D 2EMOVETHE6$#OUTPUTWIRESOFTHEPOWERSUPPLY4
E 0OWERUPTHE!&%ANDRETESTBYREPEATINGSTEPSAANDB
4HE6$#POWERSUPPLY4MAYREQUIREREPLACEMENTIFTHESE
MEASUREMENTSCONTINUETOBEOUTSIDEOFTHE›TOLERANCE
For AFE in IP21 Rittal Enclosure
)FPRESENTREMOVETHEPROTECTIVEBARRIERS
3EE2EMOVING!&%0ROTECTIVE"ARRIERS ONPAGE !44%.4)/.4HESETESTSMUSTBEPERFORMEDBYQUALIFIED
PERSONNEL$URINGTHESETESTSTHE!&%ISPOWERED4AKEPROPER
PRECAUTIONSTOAVOIDINJURYFROMELECTRICALSHOCK
,OCATETHECONTROLTRANSFORMER4AND6$#POWERSUPPLY4
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
4HECONTROLTRANSFORMER4ISLOCATEDBEHINDTHE#ONTROL&RAME4HE
6$#POWERSUPPLY4ISLOCATEDONASUBPANELINFRONTOFTHE
COMPONENTSSHOWNINTHEFRONTVIEW
Precharge Component Section
6-5
FRONT VIEW
(shown with enclosure doors removed)
24V DC Power Supply (T10)
(behind Control Frame panel)
Control Transformer (T4)
is mounted directly
behind Motor-Controlled
Circuit Breaker (MCCB).
5SEADIGITALVOLTMETERTOTESTTHECONTROLTRANSFORMER4
A -EASURETHEPRIMARY!#LINEVOLTAGEWHICHISATTHEx6
!#ORx6!#SYSTEMVOLTAGE
B -EASURETHECONTROLTRANSFORMER4OUTPUTVOLTAGEWHICHIS
APPROXIMATELY6!#
)FTHESEMEASUREMENTSARENOTWITHIN›PERFORMTHESEOTHERSTEPS
C 0OWERDOWNTHE!&%
D 2EMOVETHEOUTPUTSECONDARYWIRES
E 0OWERUPTHE!&%ANDRETESTBYREPEATINGSTEPSAANDB
4HECONTROLTRANSFORMER4MAYREQUIREREPLACEMENTIFTHESE
MEASUREMENTSCONTINUETOBEOUTSIDEOFTHE›TOLERANCE
5SEADIGITALVOLTMETERTOTESTTHE6$#POWERSUPPLY4
A -EASURETHEPRIMARYVOLTAGEWHICHIS6!#
B -EASURETHEPOWERSUPPLY4OUTPUTVOLTAGEWHICHIS
APPROXIMATELY6$#
)FTHESEMEASUREMENTSARENOTWITHIN›PERFORMTHESEOTHERSTEPS
C 0OWERDOWNTHE!&%
D 2EMOVETHE6$#OUTPUTWIRESOFTHEPOWERSUPPLY4
E 0OWERUPTHE!&%ANDRETESTBYREPEATINGSTEPSAANDB
4HE6$#POWERSUPPLY4MAYREQUIREREPLACEMENTIFTHESE
MEASUREMENTSCONTINUETOBEOUTSIDEOFTHE›TOLERANCE
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
6-6
Precharge Component Section
Testing the Precharge
Bridge Using the Power
Structure Terminals
2EMOVEPOWERFROMTHE!&%
3EE2EMOVING0OWERFROMTHE!&% ONPAGE )FPRESENTREMOVETHEPROTECTIVEBARRIERS
3EE2EMOVING!&%0ROTECTIVE"ARRIERS ONPAGE 4OTESTTHEPRECHARGEBRIDGEMEASURETHEPOINTSONTHEPOWERSTRUCTURE
LISTEDINTHETABLEBELOW
Table 6.C Precharge Bridge Tests on Power Structure
Meter Leads
+
-
DC-
L1
DC-
L2
DC-
L3
L1
DC+
L2
DC+
L3
DC+
L1
DC-
L2
DC-
L3
DC-
DC+
L1
DC+
L2
DC+
L3
(1)
Replacing the Precharge
Bridge
Nominal Meter Reading
Test Point Locations
Value should gradually rise to about 0.48V (1)
+
LI
L2
-
L3
Meter should display charging voltage
The actual voltage reading can vary depending upon your equipment. If your readings are not near
0.48V, verify that the actual voltage measured is consistent for the power structure.
2EMOVEPOWERFROMTHE!&%
3EE2EMOVING0OWERFROMTHE!&% ONPAGE /PENTHEPOWERSTRUCTUREENCLOSUREDOOR
)FPRESENTREMOVETHEPROTECTIVEBARRIERS
3EE2EMOVING!&%0ROTECTIVE"ARRIERS ONPAGE 2EMOVETHEPROTECTIVEFRONTCOVERANDTERMINALCOVERFROMTHEPOWER
STRUCTURE
3EE2EMOVING0ROTECTIVE#OVERSFROMTHE0OWER3TRUCTURE ON
PAGE 2EMOVETHEFOUR0/:)$2)6%SCREWSTHATSECURETHEBRIDGEPROTECTIVE
COVER
2EMOVETHEBRIDGEPROTECTIVECOVER
0RIORTOREMOVALNOTETHELOCATIONSOFTHE$#$#n,,AND,
WIRESANDTHENDISCONNECTTHESEWIRES
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
Precharge Component Section
6-7
2EMOVETHEPRECHARGEBRIDGEMOUNTINGNUTS
2EMOVEANDAPPROPRIATELYDISCARDTHEOLDPRECHARGEBRIDGE
)NSTALLTHENEWPRECHARGEBRIDGEINREVERSEORDEROFREMOVALWHILE
REFERRINGTO4ORQUE3PECIFICATIONS ONPAGE Testing the Precharge
Resistor
2EMOVEPOWERFROMTHE!&%
3EE2EMOVING0OWERFROMTHE!&% ONPAGE /PENTHE,#,&ILTERENCLOSUREDOOR
)FPRESENTREMOVETHEPROTECTIVEBARRIERS
3EE2EMOVING!&%0ROTECTIVE"ARRIERS ONPAGE -EASURETHERESISTANCEBETWEENTHEFOLLOWINGTWOPOINTSWITHAN
OHMMETER
n "ETWEENTHESIDEOFTHEPRECHARGERESISTOR2ANDTHE
TERMINALONTHE4"OFTHEPRECHARGECIRCUIT
n "ETWEENTHEnSIDEOFTHEPRECHARGERESISTOR2ANDTHEn
TERMINALONTHE4"OFTHEPRECHARGECIRCUIT
4HEPRECHARGERESISTANCEISAPPROXIMATELYOHMSFOREACH
MEASUREMENTFORAN!&%INA)0-##3TYLEENCLOSUREOR
OHMSFOREACHMEASUREMENTFORAN!&%INA)02ITTALENCLOSURE)F
THEMEASUREDVALUEISNOTCORRECTDISCONNECTARESISTORWIREAND
REMEASUREAGAIN)FTHEMEASUREDVALUEISSTILLNOTCORRECTREPLACETHE
PRECHARGERESISTOR
)MPORTANT6ERIFYTHATTHEPRECHARGERESISTORHASNOTBEENENGINEEREDTO
ADIFFERENTVALUEBYTHESYSTEMENGINEERTOACCOMMODATEA
LARGERSYSTEMCAPACITANCEASTHISMAYCHANGETHEVALUEOF
THEPRECHARGERESISTANCE3EETHE0OWER&LEX!CTIVE&RONT
%ND5SER-ANUALPUBLICATION95-FORTOTAL$#
BUSCAPACITANCELIMITSFORTHEPRECHARGINGCIRCUIT
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
6-8
Precharge Component Section
Replacing the Precharge
Resistor Assembly
AFE in IP20 2500 MCC Style Enclosure
2EMOVEPOWERFROMTHE!&%
3EE2EMOVING0OWERFROMTHE!&% ONPAGE /PENTHE,#,&ILTERENCLOSUREDOOR
)FPRESENTREMOVETHEPROTECTIVEBARRIERS
3EE2EMOVING!&%0ROTECTIVE"ARRIERS ONPAGE $ISCONNECTTHE2AND2PRECHARGERESISTORWIRESFROMTHERESISTOR
TERMINALSONTHEPRECHARGERESISTORASSEMBLY
2EMOVETHETWOPRECHARGERESISTORASSEMBLYMOUNTINGSCREWSTHAT
SECURETHEASSEMBLYTOTHEBRACKETONTHE,#,ENCLOSUREBAY
2EMOVETHEMOUNTINGSCREWSFROMTHEFAILEDPRECHARGERESISTORAND
APPROPRIATELYDISCARDTHERESISTOR
)NSTALLTHENEWPRECHARGERESISTORINREVERSEORDEROFREMOVALWHILE
REFERRINGTO4ORQUE3PECIFICATIONS ONPAGE AFE in IP21 Rittal Enclosure
2EMOVEPOWERFROMTHE!&%
3EE2EMOVING0OWERFROMTHE!&% ONPAGE /PENTHE,#,&ILTERENCLOSUREDOOR
)FPRESENTREMOVETHEPROTECTIVEBARRIERS
3EE2EMOVING!&%0ROTECTIVE"ARRIERS ONPAGE $ISCONNECTTHEWIRESFROMTHEANDTERMINALSONTHEPRECHARGE
RESISTORASSEMBLY
6ERIFYTHATTHECAPACITORONTHEBRIDGEANDTERMINALSISSTILLINTHE
CIRCUIT
$ISCONNECTTHEWHITEWIRESFROMTHETERMINALBLOCKBYTHEBRIDGE
2EMOVETHEMOUNTINGSCREWSFROMTHEFAILEDPRECHARGERESISTORAND
APPROPRIATELYDISCARDTHERESISTOR
)NSTALLTHENEWPRECHARGERESISTORINREVERSEORDEROFREMOVALWHILE
REFERRINGTO4ORQUE3PECIFICATIONS ONPAGE 0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
#HAPTER
LCL Filter Component Section
!44%.4)/.4OAVOIDANELECTRICSHOCKHAZARDVERIFYTHATTHE
VOLTAGEONTHEBUSCAPACITORSHASDISCHARGEDCOMPLETELYBEFORE
SERVICING#HECKTHE$#BUSVOLTAGEBETWEENTHE$#AND$#
TERMINALSBETWEENTHE$#TERMINALANDTHECHASSISAND
BETWEENTHE$#TERMINALANDTHECHASSIS4HEVOLTAGEMUSTBE
ZEROFORALLTHREEMEASUREMENTS
!44%.4)/.(OTSURFACESCANCAUSESEVEREBURNS$ONOT
TOUCHTHEHEATSINKSURFACEDURINGOPERATIONOFTHE0OWER&LEX
!CTIVE&RONT%ND!FTERDISCONNECTINGPOWERALLOWTIMEFOR
COOLING
!44%.4)/.(AZARDOFPERMANENTEYEDAMAGEEXISTSWHEN
USINGOPTICALTRANSMISSIONEQUIPMENT4HISPRODUCTEMITSINTENSE
LIGHTANDINVISIBLERADIATION$ONOTLOOKINTOFIBEROPTICPORTSOR
FIBEROPTICCABLECONNECTORS
!44%.4)/.4HESHEETMETALCOVERANDMOUNTINGSCREWSON
THE!3)#"OARDLOCATEDONTHEPOWERSTRUCTUREAREENERGIZEDAT
$#BUSPOTENTIALHIGHVOLTAGE2ISKOFELECTRICALSHOCKINJURY
ORDEATHEXISTSIFSOMEONECOMESINTOCONTACTWITHTHEASSEMBLY
!44%.4)/.4HE0OWER&LEX!CTIVE&RONT%NDCONTAINS
ELECTROSTATICDISCHARGE%3$SENSITIVEPARTSANDASSEMBLIESTHAT
CANBEDAMAGEDIFYOUDONOTFOLLOW%3$CONTROLPROCEDURES
3TATICCONTROLPRECAUTIONSAREREQUIREDTOINSTALLTESTSERVICEOR
REPAIRTHISASSEMBLY)FYOUAREUNFAMILIARWITHSTATICCONTROL
PROCEDURESSEE'UARDING!GAINST%LECTROSTATIC$AMAGE
PUBLICATIONORANYOTHERAPPLICABLE%3$PROTECTION
HANDBOOK
!44%.4)/.4OAVOIDANELECTRICSHOCKHAZARDVERIFYTHATALL
POWERTOTHE0OWER&LEX!CTIVE&RONT%NDHASBEENREMOVED
BEFOREPERFORMINGANYSERVICINGORREPAIRS
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
7-2
LCL Filter Component Section
Removing the LCL Filter
Protective Barrier
2EMOVEPOWERFROMTHE!&%
3EE2EMOVING0OWERFROMTHE!&% ONPAGE 2EMOVETHESIXTEEN44ORXSELFTAPPINGSCREWSTHATSECURETHE
PROTECTIVEBARRIER
2EMOVETHEPROTECTIVEBARRIERFROMTHE,#,&ILTERENCLOSURE
Figure 7.1 Removing LCL Filter Protective Barrier
FRONT VIEW
AFE and LCL Filter in IP21 Rittal enclosures
(shown with doors removed)
LCL Filter DC Fan Fuses
(located on sidewall)
Front Bracket (removal is
required only when removing
LCL Filter from enclosure bay)
Protective Barrier
LCL Filter Fan and
DC Power Supply
(behind cover)
Installing the LCL Filter
Protective Barrier
2EINSTALLTHEPROTECTIVEBARRIERINREVERSEORDEROFREMOVALWHILEREFERRING
TO4ORQUE3PECIFICATIONS ONPAGE Replacing the LCL Filter DC 4HE,#,&ILTER$#FANFUSESARELOCATEDONTHEINTERIORSIDEWALLABOVETHE
,#,&ILTERASSEMBLY
Fan Fuses
)MPORTANT 2EPLACE,#,&ILTERFANFUSESWITHONLY!41&ERRAZ
3HAWMUTFUSES
&ORCOMPLETEDETAILSON,#,FANSYSTEMINFORMATIONSEETHE0OWER&LEX
(3AND!&%$RIVE&AN3YSTEMS)NSTALLATION)NSTRUCTIONS
PUBLICATION0&,%8).
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
LCL Filter Component Section
7-3
Removing the LCL Filter Fan 4HEFOLLOWINGFIGURESSHOWTHE,#,&ILTERFAN$#0OWER3UPPLYWIRING
DIAGRAMWITHTHECONNECTIONSTOTHE!&%POWERSTRUCTUREAND$#BUS
DC Power Supply
&ORCOMPLETEDETAILSON,#,FANSYSTEMINFORMATIONSEETHE0OWER&LEX
(3AND!&%$RIVE&AN3YSTEMS)NSTALLATION)NSTRUCTIONS
PUBLICATION0&,%8).
Figure 7.2 LCL Filter Fan DC Power Supply Wiring Diagram (older version)
LCL Filter
X1
KLIXON
Fan
X1
Fuse
X53 (3-pin)
+ Pin = DC+ (supply)
- Pin = DC- (supply)
X4
Fan DC Power
Supply PCB
X3
AFE Power Structure
X52 (4-pin)
Pin 1 = KLIXON
Pin 4 = KLIXON
DC Bus
X3
X51 (4-pin)
Pin 1 = +16.5V
Pin 3 = (fan control)
Pin 5 = (fan alarm)
X8
X3 on AFE Power Structure
Figure 7.3 LCL Filter Fan DC Power Supply Wiring Diagram (newer version)
,#,&ILTER
8
+,)8/.
&AN
8
8
&AN$#0OWER
3UPPLY0#"
8
8
!&%0OWER3TRUCTURE
8PIN
0IN+,)8/.
0IN+,)8/.
&USE
8PIN
0IN$#SUPPLY
n0IN$#nSUPPLY
$#"US
8PIN
0IN6
0INFANCONTROL
0INn$#
0INFANALARM
8ON!&%0OWER3TRUCTURE
0IN
0IN
0IN
&LYING,EADTOn$#"US
)MPORTANT "EFOREDOINGANYWORKDISCONNECTTHE!&%POWERSTRUCTURE
FROMTHE!#SUPPLYANDWAITUNTILTHEFANSTOPSANDTHE
INDICATORSONTHEKEYPADTURNOFF)FAKEYPADISNOTATTACHED
SEETHEINDICATORTHROUGHTHEKEYPADBASE7AITMORE
MINUTESBEFOREDOINGANYWORKONTHE$#TO$#POWERSUPPLY
TOLETITCOMPLETELYDISCHARGE&URTHERMOREDONOTOPENTHE
COVERUNTILAFTERTHISTIMEHASEXPIRED
X51
X53
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
7-4
LCL Filter Component Section
2EMOVETHE,#,&ILTERPROTECTIVEBARRIER
3EE2EMOVINGTHE,#,&ILTER0ROTECTIVE"ARRIER ONPAGE 2EMOVETHETWO-XMM0/:)$2)6%SCREWSTHATSECURETHECOVER
2EMOVETHECOVER
2EMOVETHECONNECTORS888AND8
X8
X3
X1
X4
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
LCL Filter Component Section
7-5
2EMOVETHESIXFASTENERSTHATSECURETHE$#TO$#POWERSUPPLY
Installing the LCL Filter Fan
DC Power Supply
)NSTALLTHE$#TO$#POWERSUPPLYINREVERSEORDEROFREMOVALWHILE
REFERRINGTO4ORQUE3PECIFICATIONS ONPAGE Replacing the LCL Filter Fan 2EMOVETHE,#,&ILTERPROTECTIVEBARRIER
3EE2EMOVINGTHE,#,&ILTER0ROTECTIVE"ARRIER ONPAGE $ISCONNECTTERMINALBLOCKS8AND8
X51
X53
2EMOVETHETWOMMHEXAGONALBOLTS
LCL FILTER
RIGHT SIDE VIEW
Hexagonal
bolt location
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
7-6
LCL Filter Component Section
,OWERTHEFRONTFANSHEETMETALEDGEANDSLIDEITFORWARDTOREMOVETHE
ALIGNMENTSTUDSFROMTHEIRRESPECTIVEHOLESINTHEFANFRAMESHEETMETAL
3LIDEOUTTHEFANASSEMBLY
2EMOVETHE,#,&ILTER&AN$#0OWERSUPPLY
3EE2EMOVINGTHE,#,&ILTER&AN$#0OWER3UPPLY ONPAGE 2EINSTALLTHE,#,&ILTER&ANINREVERSEORDEROFREMOVALWHILEREFERRING
TO4ORQUE3PECIFICATIONS ONPAGE .OTETHEFOLLOWING,#,&ILTERAIRFLOWCOOLINGREQUIREMENTS
Removing the LCL Filter
LCL FIlter
Required Air Flow
LCL 460
1100 m3/hr
LCL 1300
1300 m3/hr
4HEPROCEDURESTOREMOVETHE,#,&ILTERARESLIGHTLYDIFFERENTDEPENDINGON
THEENCLOSUREINWHICHITISINSTALLED
From the IP20 2500 MCC Style Enclosure
2EMOVEPOWERFROMTHE!&%
3EE2EMOVING0OWERFROMTHE!&% ONPAGE 2EMOVETHE,#,&ILTERPROTECTIVEBARRIER
3EE2EMOVINGTHE,#,&ILTER0ROTECTIVE"ARRIER ONPAGE 2EMOVETHE8AND8TERMINALBLOCKSFROMTHE,#,FANASSEMBLY
2EMOVETHE8TERMINALBLOCKFROMTHE,#,&ILTERASSEMBLYUPPER
RIGHTSIDE
2EMOVETHELOWERANDUPPERFRONTBRACKETSTHATHOLDTHE,#,&ILTERIN
THEENCLOSURESEE&IGURE
A 3EE$ETAIL!ANDREMOVETHETWO-XSCREWS
B 3EE$ETAIL"ANDREMOVETHETHREE-XSCREWS
C 3EE$ETAIL"ANDREMOVETHESIX-XSCREWS
4HISBRACKETHOLDSTHE,#,&ILTERINTHEENCLOSURE
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
LCL Filter Component Section
7-7
Figure 7.4 Removing LCL Filter from AFE in IP20 2500 MCC Style Enclosure
DETAIL B
DETAIL A
Remove
Two Screws
$ISCONNECTTHE!#INPUTPOWERCABLES,,,BETWEENTHEINPUT
CONTACTORAND,#,&ILTER
&ORCABLELOCATIONSSEE&IGURE ONPAGE $ISCONNECTTHEOUTPUTCABLES567BETWEENTHE,#,&ILTERANDTHE
!&%POWERSTRUCTURE
!44%.4)/.4HE,#,&ILTERISHEAVY4OAVOIDPERSONAL
INJURYORDAMAGETOTHEEQUIPMENTUSECAUTIONWHENREMOVING
THE,#,&ILTERFROMTHEENCLOSURE
&ORCABLELOCATIONSSEE&IGURE ONPAGE 0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
7-8
LCL Filter Component Section
3LIDETHE,#,&ILTEROUTOFTHEENCLOSURE
.OTETHATRAMPSCUSTOMERSUPPLIEDSHOWNBELOWMAYBEREQUIREDDUE
TOENCLOSUREFLOORMISMATCH
From the IP21 Rittal Enclosure
2EMOVEPOWERFROMTHE!&%
3EE2EMOVING0OWERFROMTHE!&% ONPAGE 2EMOVETHE,#,&ILTERPROTECTIVEBARRIER
3EE2EMOVINGTHE,#,&ILTER0ROTECTIVE"ARRIER ONPAGE 2EMOVETHE8AND8TERMINALBLOCKSFROMTHE,#,FANASSEMBLY
2EMOVETHE8TERMINALBLOCKFROMTHE,#,&ILTERASSEMBLYUPPER
RIGHTSIDE
2EMOVETHEFOUR44ORXSELFTAPPINGSCREWSTHATSECURETHEFRONT
BRACKETSHOWNIN&IGURE
4HISBRACKETHOLDSTHE,#,&ILTERINTHEENCLOSURE
$ISCONNECTTHE!#INPUTBUSBARS,,,BETWEENTHE-##"AND
,#,&ILTER
&ORBUSBARLOCATIONSSEE&IGURE ONPAGE $ISCONNECTTHEOUTPUTBUSBARS567BETWEENTHE,#,&ILTERAND
THE!&%POWERSTRUCTURE
&ORBUSBARLOCATIONSSEE&IGURE ONPAGE 0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
!44%.4)/.4HE,#,&ILTERISHEAVY4OAVOIDPERSONAL
INJURYORDAMAGETOTHEEQUIPMENTUSECAUTIONWHENREMOVING
THE,#,&ILTERFROMTHEENCLOSURE
LCL Filter Component Section
7-9
3LIDETHE,#,&ILTEROUTOFTHEENCLOSURE
.OTETHATRAMPSCUSTOMERSUPPLIEDSHOWNBELOWMAYBEREQUIREDDUE
TOENCLOSUREFLOORMISMATCH
LCL Filter
Removed from Enclosure
)NSTALLTHE,#,&ILTERINREVERSEORDEROFREMOVALWHILEREFERRINGTO4ORQUE
3PECIFICATIONS ONPAGE Installing the LCL Filter in
the Enclosure
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
7-10
LCL Filter Component Section
Notes:
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
#HAPTER
DC Fuses Component Section
!44%.4)/.(OTSURFACESCANCAUSESEVEREBURNS$ONOT
TOUCHTHEHEATSINKSURFACEDURINGOPERATIONOFTHE0OWER&LEX
!CTIVE&RONT%ND!FTERDISCONNECTINGPOWERALLOWTIMEFOR
COOLING
!44%.4)/.(AZARDOFPERMANENTEYEDAMAGEEXISTSWHEN
USINGOPTICALTRANSMISSIONEQUIPMENT4HISPRODUCTEMITSINTENSE
LIGHTANDINVISIBLERADIATION$ONOTLOOKINTOFIBEROPTICPORTSOR
FIBEROPTICCABLECONNECTORS
!44%.4)/.4OAVOIDANELECTRICSHOCKHAZARDVERIFYTHATTHE
VOLTAGEONTHEBUSCAPACITORSHASDISCHARGEDCOMPLETELYBEFORE
SERVICING#HECKTHE$#BUSVOLTAGEBETWEENTHE$#AND$#
TERMINALSBETWEENTHE$#TERMINALANDTHECHASSISAND
BETWEENTHE$#TERMINALANDTHECHASSIS4HEVOLTAGEMUSTBE
ZEROFORALLTHREEMEASUREMENTS
!44%.4)/.4HESHEETMETALCOVERANDMOUNTINGSCREWSON
THE!3)#"OARDLOCATEDONTHEPOWERSTRUCTUREAREENERGIZEDAT
$#BUSPOTENTIALHIGHVOLTAGE2ISKOFELECTRICALSHOCKINJURY
ORDEATHEXISTSIFSOMEONECOMESINTOCONTACTWITHTHEASSEMBLY
Overview
!44%.4)/.4OAVOIDANELECTRICSHOCKHAZARDVERIFYTHATALL
POWERTOTHE0OWER&LEX!CTIVE&RONT%NDHASBEENREMOVED
BEFOREPERFORMINGANYSERVICINGORREPAIRS
!44%.4)/.4HE0OWER&LEX!CTIVE&RONT%NDCONTAINS
ELECTROSTATICDISCHARGE%3$SENSITIVEPARTSANDASSEMBLIESTHAT
CANBEDAMAGEDIFYOUDONOTFOLLOW%3$CONTROLPROCEDURES
3TATICCONTROLPRECAUTIONSAREREQUIREDTOINSTALLTESTSERVICEOR
REPAIRTHISASSEMBLY)FYOUAREUNFAMILIARWITHSTATICCONTROL
PROCEDURESSEE'UARDING!GAINST%LECTROSTATIC$AMAGE
PUBLICATIONORANYOTHERAPPLICABLE%3$PROTECTION
HANDBOOK
!N!&%SYSTEMINA)0-##3TYLEENCLOSUREOR)02ITTAL
ENCLOSURECONTAINSPROTECTIVE$#BUSFUSES
)MPORTANT &OR0OWER&LEX!&%SYSTEMSINTHE)0/PEN#HASSIS
CONFIGURATIONOUTPUTFUSESMUSTBESUPPLIEDBYTHEUSER
3EETHE0OWER&LEX!CTIVE&RONT%ND5SER-ANUALPUBLICATION
95-FORTHE$#BUSOUTPUTFUSINGRECOMMENDATIONS
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
8-2
DC Fuses Component Section
Fuse Replacement
Guidelines
$#BUSFUSESAREREQUIREDFORSHORTCIRCUITPROTECTION4HEFOLLOWINGTABLES
LISTTHERECOMMENDED$#BUSFUSES
Table 8.A 400/480 Volt DC Fusing
Frame AFE
Size
Enclosure Style
IP20 2500 MCC
10
IP21 Rittal
Fuse
Amps
Bussman Type
Ferraz Shawmut Type
1100
170M6499
—
1100
—
PC73UD95V11CTF
1250
170M6566
—
Amps
Bussman Type
Ferraz Shawmut Type
630
170M6454
—
630
—
PC73UD13C630TF
700
170M6305
—
Table 8.B 600/690 Volt DC Fusing
Frame AFE
Size
Enclosure Style
IP20 2500 MCC
10
IP21 Rittal
Fuse
4OREPLACEFUSESUSETHEFOLLOWINGPROCEDURE
2EMOVEPOWERFROMTHE!&%
3EE2EMOVING0OWERFROMTHE!&% ONPAGE /PENTHEPOWERSTRUCTUREENCLOSUREDOOR
)FPRESENTREMOVETHEPROTECTIVEBARRIERS
3EE2EMOVING!&%0ROTECTIVE"ARRIERS ONPAGE 2EMOVEANDDISCARDTHEBLOWNFUSE
)NSERTTHEFUSEBODYBETWEENTHEBUSBARS
4URNTHETHREADEDRODINTOTHEFUSEBODY
(OLDTHETHREADEDRODWITHTHEHEXKEYWHILETIGHTENINGTHENUTTOTHE
SPECIFIEDTORQUE
0LACETHE"ELLEVILLEDOMEDWASHERANDHEXAGONALNUTONTHETHREADED
RODANDHANDTIGHTEN
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
Stud Tightening
Stud Type Torque, max
Nut Tightening
Torque, max
M8 x 30
M8 x 35
10 N•m
(88.5 lb•in)
13.5 N•m
(132.8 lb•in)
M10 x 30
M10 x 50
15 N•m
(132.8 lb•in)
26 N•m
(230.1 lb•in)
M12 x 35
M12 x 50
15 N•m
(132.8 lb•in)
46 N•m
(407.1 lb•in)
M12 x 40
15 N•m
(132.8 lb•in)
46 N•m
(407.1 lb•in)
)MPORTANT $ONOTAPPLYTORQUEORTWISTINGFORCETOTHEFUSEBODYAS
THISCANDAMAGETHEFUSE
DC Fuses Component Section
8-3
&ORMOREINFORMATIONABOUT"USSMANNFUSESGOONLINEAT
HTTPWWWCOOPERINDUSTRIESCOM
&ORMOREINFORMATIONABOUT&ERRAZ3HAWMUTFUSESGOONLINEAT
HTTPWWWFERRAZFUSESCOM
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
8-4
DC Fuses Component Section
Notes:
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
#HAPTER
Startup After Repair
Phone
!44%.4)/.4HESHEETMETALCOVERANDMOUNTINGSCREWSON
THE!3)#"OARDLOCATEDONTHEPOWERSTRUCTUREAREENERGIZEDAT
$#BUSPOTENTIALHIGHVOLTAGE2ISKOFELECTRICALSHOCKINJURY
ORDEATHEXISTSIFSOMEONECOMESINTOCONTACTWITHTHEASSEMBLY
!44%.4)/.0OWERMUSTBEAPPLIEDTOTHE0OWER&LEX!CTIVE
&RONT%NDTOPERFORMTHEFOLLOWINGSTARTUPPROCEDURE3OMEOF
THEVOLTAGESPRESENTAREATINCOMINGLINEPOTENTIAL4OAVOID
ELECTRICSHOCKHAZARDORDAMAGETOEQUIPMENTONLYQUALIFIED
SERVICEPERSONNELSHOULDPERFORMTHEFOLLOWINGPROCEDURE
4HOROUGHLYREADANDUNDERSTANDTHEPROCEDUREBEFOREBEGINNING
$URINGSTARTUPIFONEOFTHESEPREPOWERUPCHECKSREVEALSA
CONCERNDONOTPROCEED2EMOVEPOWERINCLUDINGUSERSUPPLIED
CONTROLVOLTAGES5SERSUPPLIEDVOLTAGESCANEXISTEVENWHEN
MAIN!#POWERISNOTAPPLIEDTOTHE0OWER&LEX!CTIVE&RONT
%ND#ORRECTTHEMALFUNCTIONBEFORECONTINUING
United States/
Canada
1.262.512.8176 (7 AM - 6 PM CST)
1.440.646.5800 (24 hour support)
Outside United
States/Canada
You can access the phone number for your country via the
Internet:
• Go to http://www.ab.com
• Click on3UPPORT (http://support.rockwellautomation.com/)
• Under #ONTACT#USTOMER3UPPORT, click on 0HONE3UPPORT
Internet
⇒
Go to http://www.ab.com/support/abdrives/
E-mail
⇒
[email protected]
"EPREPAREDTOPROVIDETHEFOLLOWINGINFORMATIONWHENYOUCONTACT
!LLEN"RADLEY$RIVES4ECHNICAL3UPPORT
• 0RODUCT#ATALOG.UMBER
• 0RODUCT3ERIAL.UMBER
• &IRMWARE2EVISION,EVEL
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
9-2
Startup After Repair
Before Applying Power to
the AFE
/PENTHEPOWERSTRUCTUREENCLOSUREDOOR
)FPRESENTREMOVETHEPROTECTIVEBARRIERS
3EE2EMOVING!&%0ROTECTIVE"ARRIERS ONPAGE #HECKFORZEROVOLTSBETWEEN$#AND$#
0ERFORMFORWARDANDREVERSEBIASEDDIODETESTSUSINGADIGITAL
MULTIMETER
3EE0ERFORMING&ORWARDAND2EVERSE"IASED$IODE4ESTSFOR0OWER
3TRUCTURE ONPAGE #ONFIRMTHATALLWIRINGTOTHE!&%!#INPUTGROUND$#BUSAND)/
ISCONNECTEDTOTHECORRECT!&%TERMINALSANDISSECURE
6ERIFYTHAT!#LINEPOWERATTHEDISCONNECTDEVICEISWITHINTHERATED
VALUEOFTHE!&%
6ERIFYTHATTHECONTROLPOWERVOLTAGEISCORRECT
7HENEVERPOSSIBLEISOLATETHE!&%FROMTHERESTOFTHE$#BUSSYSTEM
TOENABLETHE!&%TOBEPOWEREDSEPARATELY
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
!PPENDIX
!
Service Tools and Equipment
Software Tools
#ONNECTED#OMPONENTS7ORKBENCHSOFTWARE$RIVE%XECUTIVESOFTWAREOR
$RIVE%XPLORERSOFTWAREARETOOLSTHATCANBEUSEDFORUPLOADING
DOWNLOADINGANDMONITORINGSYSTEMPARAMETERS
Service Tools
4HEFOLLOWINGLISTCONTAINSTHEBASICSERVICETOOLSNEEDEDFORREPAIRAND
MAINTENANCEMEASUREMENTS
Item Description
Details
Oscilloscope
Portable, digitizing, dual-channel scope with isolation
2
Current clamp
1000A (ac, rms), signal output
3
High voltage differential probe
P5210 or equivalent
4
Soldering station
Soldering / de-soldering
5
Flash light
—
1
Multi meter
Digital multimeter, capable of AC and DC voltage, continuity, resistance, capacitance
measurements, and forward diode bias tests. Fluke Model 87 III or equivalent.
7
Insulation tester
1000V DC
8
Torque wrench
1…12 N•m
9
Torque wrench
6…50 N•m
10
box wrench
7 mm, 8 mm, 10 mm, 13 mm, 17 mm, 19 mm, 22 mm
11
socket extension
230 mm
12
Wrench
7 mm, 8 mm, 10 mm, 13 mm, 17 mm, 19 mm, 22 mm
13
Allen wrench
—
14
Wire cutter
—
15
Nose pliers
—
16
Crimping tools
For cable terminals 1, 5…240
6
17
Angle wrench
—
18
Flat nose screw driver
7 x 2 mm
19
POZIDRIV screw driver
#1, #2, #3
20
Phillips screw driver
#1, #2, #3
21
Torx screw driver
#25
Hexagonal wrench
#4, #5, #6
23
ESD-protected place of work
Working surface, floor covering, seat, and ground connections
24
ESD-protective clothing
Wrist wrap, shoes, overall clothing (coat)
25
Power supply (service)
Capacity of three phase service 400/500/690V AC, 30A
26
20-MAINSTND maintenance stand
Maintenance stand for removing power structure from AFE enclosure
27
Fiber-optic repair kit
Agilent HFBR-4593 Polishing Kit, consisting of a Polishing Fixture, 600 grit abrasive
paper, and 3 mm pink lapping film (3M Company, OC3-14).
22
For Agilent HFBR-4532 latching connectors and HFBR-RL cable. See Agilent
publications 5988-9777EN and 5988-3625EN.
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
A-2
Service Tools and Equipment
Notes:
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
!PPENDIX
"
Schematic Diagrams
Figure B.1 Frame 10 Circuit Board Connections
Frame 10 Circuit Board Connections
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
B-2
Schematic Diagrams
Figure B.2 Frame 10 Power Module Circuitry
Frame 10 Power Module Circuitry
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
Schematic Diagrams
B-3
Frame 10 Power Structure Main Fan Connections
To ASIC
Circuit Board X11
(Fan Control)
3
4
For more details, see the
PowerFlex 700S, 700H, and
700AFE Drive Fan Systems
Installation Instructions,
publication PFLEX-IN029.
To X51 on the
LCL Filter Power
Supply Circuit Board
DC Main Fan
X81
X8
X3
X82
Isolated 48V DC Power
Supply Circuit Board
Fan Module
X2
DC+
DC-
Figure B.3 DC Fan Power Supply (all AFEs—in IP20 2500 MCC Style or IP21 Rittal
enclosure—January 2013 and later)
From Power
Board X10
From ASIC
Board X11
4
F1
F2
Switch Setting
To indicate the following:
S1
Off
50 Hz fan motor frequency
S2
Off
220 V AC motor voltage
S3
On
230 V AC motor voltage
S4
Off
Not used
For more details, see the
PowerFlex 700S, 700H, and
700AFE Drive Fan Systems
Installation Instructions,
publication PFLEX-IN029.
Area Under Main Power Terminal Strip
–
Black 6
S1-4
S1-3
S1-2
S1-1
+
Off Off On Off
X8
X2
Fan Frequency
Converter
S1 - Setup Switch
X3
Area Under Fan Power Supply Plate
X4
X5
Black 2
Black 1
Black 5
2.2 μF
10 M7
M1
Main Fan
Blue
Black
M
Black 4
2.2 μF
10 M7
Brown
Yellow/
Green
Black 3
7 μF
Fan Area
Figure B.4 AC Fan Power Supply (only AFE Power Structure in IP21 Rittal
enclosure—December 2012 and earlier)
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
B-4
Schematic Diagrams
CONTROL UNIT
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
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
1
X3
7
5
3
1
-
X2
+
A16.1
A1.1
6
4
2
2
1
A12.1
A11
AIA1-
2
R1
21
AIA1+
3
22
MAIN CONTACTOR
CONTROL
AIA2-
R1
23
AIA2+
4
Fault Reset
(optional)
To Indicator
Enable
Remote Operation of
Power Contactor
(optional)
5
-10Vref
6
PotGND
7
FAULT
+10Vref
R2
X1
8
24
A BC D
AOUT1
9
25
X2
AOUTC
10
R3
26
A BC D
AOUT2
X3
DIN1
11
B
A
12
X6
DIN2
A BC D
13
DIN3
14
NXOPTA2
20C-D01
SLOT B
DIN4
15
DIN5
16
DIN6
17
D_COM
18
20C-DPI1 SLOT C DPI
D_COM
19
+24V
20
A14
DPI
20C-DPI1 SLOT C
20C-DA1-A
Basic I/O
SLOT A
24VCOM
Schematic Diagrams
B-5
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
6182
6181
I
Switch handle
3s
12s
I = 6I1
I
DC+
DC–
41
42
42
Figure B.6 Frame 10 in IP20 2500 MCC Style Enclosure – Sheet 6 (400/480V and 600/690V)
40
41
39
38
37
40
39
38
BUS BAR
36
37
35
30
29
28
27
26
25
24
23
34
6242
22
21
20
19
18
17
16
15
14
13
12
11
10
09
08
07
06
05
04
03
02
01
36
6241
6200 6201 6202
6172 6173 6174
L1 /8-A2
L2 /8-A2
H
35
N
G
33
DC+
DC–
t1
0.1s
0.25s
I = 8In
Factory default settings are based
on 40 ˚C ambient temperature.
*In = 600A for 400/480V.
*In = 400A for 600/690V.
Switch Key:
L
t1
I2 =
Inx∑
S I3 =
F
34
X70 Wire
Connected to -DC secondary side of
fan inverter fuses in power structure
(CAUTION: High Voltage -DC bus potential)
TF11 /7-G15
/7-G7 TF+1
In = *
Inx
TRIP SETTING
E
32
6180
7070
6050
6051
6052
D
31
%$#VT
6250 6251 6252
6130 6131 6132
C
33
CABLE
CABLE
BUS BAR
CABLE
B
MAIN CIRCUIT
32
A
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
09
08
07
06
05
04
03
02
01
0.4
+
0.04
0.08
0.16
0.32
0
0
0
0
1
1.5
2
5.5
0
0
0
0
ON
100
%
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
OFF
50
B-6
Schematic Diagrams
System Schematics for Frame 10 in IP20 2500 MCC Style Enclosure
4HEFOLLOWINGSYSTEMSCHEMATICSAREFORTHE!&%&RAMEINA)0
-##3TYLEENCLOSURE4HE0OWER&LEX!&%CATALOGNUMBERHASAN
ENCLOSURECODEOF0FORSTANDARDCOLOROR7FOROPTIONALGRAYCOLORAS
SHOWNINTHEEXAMPLECATALOGSTRINGBELOW&OROTHERENCLOSUREDESIGNS
CONTACTTHESUPPLIEROFTHESYSTEMFORTHESYSTEMSCHEMATICS
0OSITION
20Y
D
460
P
0
A
N
N
A
N
A
0
A
B
C
D
E
F
G
H
I
J
K
L
6300
2
X3
1
2
9120 9140
7
8151
22
7271
23
7
8
9
10
4
11
PWM ON
12
63
14
12
13
65
42
Figure B.7 Frame 10 in IP20 2500 MCC Style Enclosure – Sheet 7 (400/480V and 600/690V)
41
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
42
A14
9
PE
1
40
7330
20
+24V 24VCOM
20C-DA1-A
Basic I/O
SLOT A
19
H5
41
INVERTER
ENABLE
X3 66
7273
26
18
D_COM D_COM
17
7170
1
13
12
11
10
09
08
39
25
NXOPTA2
20C-D01
SLOT B
DIN6
16
H3.1
2
34
2
32
K4 31
/-E61
7121
14
K4 11
/-E31
7120
12
65, 64
07
06
05
04
03
02
01
40
31 -H12
11 -H12
21 /11-C25
A2
A1
24
R3
DIN5
15
6180
X1
7070
H
38
14
12
24
22
34
32
FAULT
K4
7272
R2
DIN4
14
14
K1 13
/10-E32
7140
K20 11
/11-F32
7130 7160
X3
64
G
39
MAIN CONTACTOR
CONTROL
21
R1
6
FAULT RESET
3
X3
FAULT RESET
(OPTIONAL)
MAIN CONTACTOR
ON REQUEST
MAIN CONTACTOR
ACKNOWLEDGE
-10Vref PotGND +10Vref AOUT1 AOUTC AOUT2
DIN1
DIN2
DIN3
A BC D
A BC D
A BC D
B X6
X1
X2
X3
A
5
S11
F
TF+1 /6-C16
37
A12.1
R1
MAIN CONTACTOR
CONTROL
AIA2+
4
CONTROL UNIT
E
AFE READY
38
/6-C31 OF1
A11
AIA2-
3
D
AFE FAULT
37
36
35
34
33
32
31
30
29
28
27
26
25
24
6310
/9-D14 24DCV--
23
A16.1
X2
AIA1+
AIA1-
21
/9-D13 24DCV-+
22
2
A1.1
1
/6-C30 AP1
C
20
19
18
17
16
15
14
13
12
11
10
09
08
07
06
05
04
03
B
/10-F8 K1.1CL
02
A
K1.1CC /10-F15
LCL OVER TEMP
/6-C18 TF11
01
Schematic Diagrams
B-7
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
8170
15
16
17
18
16
17
18
20
21
20
21
23
24
23
24
27
28
29
30
31
32
33
27
28
29
30
31
32
33
36
37
38
39
40
41
42
36
37
38
39
40
41
42
Figure B.8 Frame 10 in IP20 2500 MCC Style Enclosure – Sheet 8 (400/480V and 600/690V)
35
35
34
26
26
34
25
25
8220
22
22
8210
19
19
8170 8171 8172
14
15
13
13
14
12
12
11
06
05
04
03
02
01
10
H
11
G
09
F
10
E
08
Note: 1 & 2
8151
D
09
C
07
8090 8091
6050 6051
B
08
A
07
06
05
04
03
02
01
B-8
Schematic Diagrams
8170
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
18
19
20
21
22
23
24
25
26
27
28
29
30
31
32
33
36
37
38
39
40
41
42
36
37
38
39
40
41
42
Figure B.9 Frame 10 in IP20 2500 MCC Style Enclosure – Sheet 9 (400/480V and 600/690V)
35
35
34
16
17
34
15
16
14
13
15
14
9140
12
13
11
12
06
05
04
03
02
01
10
H
11
G
09
F
10
9120
8151
E
08
D
09
C
07
B
08
A
07
06
05
04
03
02
01
Schematic Diagrams
B-9
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
14
15
16
17
15
16
17
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
20
21
22
23
20
21
22
23
28
29
30
28
29
30
38
39
40
41
42
39
40
41
42
Figure B.10 Frame 10 in IP20 2500 MCC Style Enclosure – Sheet 10 (400/480V and 600/690V)
37
38
35
35
36
34
34
37
33
33
36
32
32
31
27
27
10310
26
26
31
25
25
24
19
19
24
18
18
8170
13
14
11140
12
13
7271
11
12
06
05
04
03
02
01
10
H
11
G
09
F
10
8151
E
08
D
09
C
07
B
08
A
07
06
05
04
03
02
01
B-10
Schematic Diagrams
11160
11120
11141
11142
F
G
H
06
05
04
03
02
01
11270
15
11240
14
15
17
18
17
18
22
22
27
37
38
39
40
41
42
Figure B.11 Frame 10 in IP20 2500 MCC Style Enclosure – Sheet 11 (400/480V and 600/690V)
38
39
40
41
42
34
34
36
33
33
37
32
32
35
31
31
36
30
30
B-11
35
29
29
28
26
27
28
25
26
24
25
24
11280
21
21
23
20
20
23
19
19
11140
16
16
11140
13
14
12
11
10
13
12
11
10
09
8151
E
08
D
09
C
07
8170
8151
B
08
A
07
06
05
04
03
02
01
Schematic Diagrams
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
X1
2
3
Tag Name
Q0
F1
F2
F3
F4
F5
F6
F11
Circuit Breaker
42
Figure B.12 Frame 10 in IP20 2500 MCC Style Enclosure – Sheet 12 (Terminal Block Layout, and Circuit Breaker and Fuse Ratings)
41
42
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
09
40
1
3
2
1
1
3
2
2
Quantity
08
07
06
05
04
03
02
01
41
Current Rating
600-690V
400-480V
400A
600A
630A
800A
630A
1100A
6A
6A
6A
6A
30A
30A
8A
6A
8A
8A
H
39
Fuse
G
CIRCUIT BREAKER AND FUSE RATINGS
Component
F
40
INTERNAL CONNECTION
For 400/480V or
600/690V AC Input
1
INTERNAL CONNECTION
FAN TB
INTERNAL CONNECTION
Fan TB Door One (Numbering Details)
E
38
X3
D
39
1
2
3
4
5
6
7
8
11
12
13
14
15
16
17
18
19
27
28
29
30
57
58
59
60
61
62
63
64
65
66
67
68
X1 (Jumper and Numbering Details)
To User-supplied Connection (see User Manual for more details)
X3 (External Connection and Numbering Details)
TERMINAL BLOCKS LAYOUT
C
38
37
36
35
34
33
32
31
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
09
08
07
06
INTERNAL CONNECTION
05
Remote Stop
04
Remote Start
03
B
Fault Reset
(optional)
Inverter
Enable Input
02
A
Move this wire
to the terminal
that matches the
AC line voltage
01
INTERNAL CONNECTION
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
57
58
60
61
63
64
65
66
400
480
600
690
B-12
Schematic Diagrams
Schematic Diagrams
B-13
Control Wiring Diagram for Frame 10 in IP21 Rittal Enclosure
X1
S6
57
58
60
61
Remote Operation of
Motor Controlled Circuit Breaker
(Optional)
N.O.
N.O.
N.O.
NOTE: Unused terminals are not shown.
N.O.
N.O.
N.O.
1
2
3
4
5
6
7
8
9
10
11
12
H5
230V AC
Control Power
1
2
T4
F3
L1
N
S10
1
2
3
N.O.
4
N.O.
Q1
U2
U1
95
98
96
A1
5
6
D1
C2
C1
C11
22
21
31
34
S11
N.O.
K20
A1
A2
11
N.O.
14
21
N.O.
24
K4
A1
A2
11
N.O.
14
21
N.O.
24
H3.1
1
2
T10
F10
K6
L
N
24V+
24VPE
L1
A1
A2
13
N.O.
14
X1
Fault
63
Reset
64
(Optional)
1
4
(Terminal
Block X52)
A1
13
14
-A1.1
1
2
3
4
5
6
7
8
9
10
11
12
13
14
AIA1- AIA1+ AIA2- AIA2+ -10Vref PotGND +10Vref AOUT1 AOUTC AOUT2 DIN1 DIN2 DIN3 DIN4
ABCD
ABCD
ABCD
ABCD
J2
J3
J4
J1
15
DIN5
16
17
18
-A16.1
X2 -A11
R1 MC Control R1
R2
2
-A12.1
21
22
23
24
25
X1
20
20C-DA1-4
SLOT A
PE
R3
X3
1
19
DIN6 D_COM D_COM +24V 24VCOM
20C-DO1
SLOT B
26
-A13
20C-DPI1
SLOT E
66 Inverter Enable
Figure B.13 Control Wiring Diagram for Frame 10 in IP21 Rittal Enclosure
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
F
E
D
C
B
A
1
-L1
-Q1
2
4
3
2
1
-U1
U
V
-F2.1
1100A
U
V
B+
W
L3
W
B-
PE
2
1
-F2.2
1100A
1
2
3
PE
X51
M
4
3
1
-
X53 +
4
3
2
X52 1
OF1 /7-2D
AP1 /7-2D
TF11 /7-6C
/7-7B TF+1
Older Version
Q/1 SY
11 95
5 12 14 96 98
6
5
L3
I >> I >> I >>
2
4
6
3
L2
1
L1
L1 L2
-Q0
MAIN CIRCUIT
3
-F11
8A
2
1
4
4
3
5
-U1
U
1
2
3
4
5
6
7
V
PE
X3
DC+ DC–
+
24V DC
–
1
2
3
– DC Bus
W
OF1 /7-2D
X70 Wire
Connected to -DC
secondary side of
fan inverter fuses
in power structure
(CAUTION: High
Voltage -DC bus
potential)
TF11 /7-6C
/7-7B TF+1
AP1 /7-2D
Newer Version
6
-Q5
7
3
2
2
1
+
4
L2
4
3
I>
3
4
3
-R6.2
-C1
L1
2
1
I>
1
2
-X6 +
-R6.1
-V6
-K6
/11-2E
-F6
1
6
-
2
1
-
L3
6
5
I>
5
6
5
8
B+
B-
L1 /8-1A
L2 /8-1A
F
E
D
C
B
A
Figure B.14 Frame 10 in IP21 Rittal Enclosure – Sheet 6 (400/480V and 600/690V)
PE
B-14
Schematic Diagrams
System Schematics for Frame 10 AFE in IP21 Rittal Enclosure
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20Y
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460
A
0
A
N
N
A
N
A
0
A
B
C
D
E
F
G
H
I
J
K
L
Figure B.15 Frame 10 in IP21 Rittal Enclosure – Sheet 7 (400/480V and 600/690V)
B-15
Schematic Diagrams
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
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Figure B.16 Frame 10 in IP21 Rittal Enclosure – Sheet 8A (only 400/480V)
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Schematic Diagrams
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Figure B.17 Frame 10 in IP21 Rittal Enclosure – Sheet 8B (only 600/690V)
Schematic Diagrams
B-17
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
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Figure B.18 Frame 10 in IP21 Rittal Enclosure – Sheet 9 (400/480V and 600/690V)
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B-18
Schematic Diagrams
F
E
D
C
/9-8F 1N
15
-X1
5
-X1
-X39
-H5
-X39
2
2
1
1
MCCB FAULT
-S6
3
-S11
4
3
3
14
13
-X5 6
-X1 29
-X1 28
27
30
CBR -5C
UV /11-3B
UV1 /11-5D
D2
YU
-X5 8
-Q1
D1
-X5 7
54
A12.1/2
5
11
9
M
A1
U2
S2
-Q1
10
-X5 20
-Q1 5
/6-2B 6
-X5 21
12
CBCL /7-3E
U1
S1
RO2
13
YC
C11
/7-4E CBCC
6
16
6
7
8
1N /11-1F
1L /11-1A
F
E
D
C
B
A
Figure B.19 Frame 10 in IP21 Rittal Enclosure – Sheet 10 (400/480V and 600/690V)
-X1
95
-Q1
/6-2B 98 96
5 4
-X5
RESET
4
CIRCUIT BREAKERS
UNDER VOLTAGE TRIP
-3F CBR
B
/9-8A 1L
2
/7-3E CBCO
A
1
Schematic Diagrams
B-19
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
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Figure B.20 Frame 10 in IP21 Rittal Enclosure – Sheet 11 (400/480V and 600/690V)
./4%7HENTHE3SWITCHISINTHEhvPOSITIONTHE-##"1AND
THECHARGINGCONTACTOR+WILLOPENINDEPENDENTOFTHE
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Schematic Diagrams
Figure B.21 Frame 10 in IP21 Rittal Enclosure – Sheet 12 (400/480V and 600/690V)
B-21
Schematic Diagrams
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
B-22
Schematic Diagrams
Notes:
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
!PPENDIX
#
Connector Descriptions
Circuit Board Connections
4HEFOLLOWINGTABLESDETAILTHECONNECTIONPOINTSFORTHE&RAME
0OWER&LEX!CTIVE&RONT%NDCIRCUITBOARDSANDCOMPONENTS
Table C.A Fiber Optic Adapter Board-to-ASIC Circuit Board Connections
Fiber Optic
Adapter Connector
Type
Signal Description:
Reference to ASIC Board Type
ASIC Board Fiber
Connector (1)
H1
TX
Gate_Enable
RX
H1
H2
TX
U_Gate
RX
H2
H3
TX
V_Gate
RX
H3
H4
TX
W_Gate
RX
H4
H5
TX
A/D Convert
RX
H5
H6
TX
VBUS_RX
RX
H6
H7
RX
VBUS_TX
TX
H7
X2
From
+24V DC Power
To
X10
X3
From
Auxiliary 24V DC Power
Supply
To
T10 power supply
connector
(1)
See Figure C.1 on page C-3 for ASIC board fiber optic connectors.
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)MPORTANT 4HEMINIMUMINSIDEBENDRADIUSFORFIBEROPTICCABLEIS
MMIN!NYBENDSWITHASHORTERINSIDERADIUSCAN
PERMANENTLYDAMAGETHEFIBEROPTICCABLE3IGNALATTENUATION
INCREASESWITHDECREASEDINSIDEBENDRADII
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LIGHTANDINVISIBLERADIATION$ONOTLOOKINTOFIBEROPTICPORTSOR
FIBEROPTICCABLECONNECTORS
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
C-2
Connector Descriptions
Table C.B ASIC Board-to-Gate Driver Board Connections
ASIC Board
Gate Driver Board
Signal Description
X3
X13
‘U’ phase
X14
‘V’ phase
X15
X5
H13 (WL)
H12 (WH)
H11 (VL)
H10 (VH)
H9 (UL)
H8 (UH)
DTR = N Desat
ETR = Phase I2T
ITR = Phase Overcurrent
(1)
(2)
(3)
(WL) H9
(WH) H8
(VL) H7
(VH) H6
(UL) H5
(UH) H4
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
‘W’ phase
Ribbon Cable
Signal Description
Pin 1
Pin 2
U_Feedback
U_Power_OK
Pin 3
Pin 4
U_DTR (1)
U_ETR (2)
Pin 5
Pin 6
U_ITR (3)
U_DC-
Pin 7
Pin 8
UI
U_DC-_I
Pin 9
Pin 10
U_TEMP
U_DC-T
Ribbon Cable
Signal Description
Pin 1
Pin 2
V_Feedback
V_Power_OK
Pin 3
Pin 4
V_DTR (1)
V_ETR (2)
Pin 5
Pin 6
V_ITR (3)
V_DC-
Pin 7
Pin 8
VI
V_DC-_I
Pin 9
Pin 10
V_TEMP
V_DC-T
Ribbon Cable
Signal Description
Pin 1
Pin 2
W_Feedback
W_Power_OK
Pin 3
Pin 4
W_DTR (1)
W_ETR (2)
Pin 5
Pin 6
W_ITR (3)
W_DC-
Pin 7
Pin 8
WI
W_DC-_I
Pin 9
Pin 10
W_TEMP
W_DC-T
X4
Fiber Optic Gate Signals
(connect UH to UH, UL to UL, and so forth)
H4
H3
H2
H5
H4
H3
H2
Seven
Fiber Optic
Cables
H5
ASIC Board
X3
H13 H12 H11 H10 H9
X11
X2
H1
X15
For ASIC board part number
information, see Table D.C on page D-4.
X4
H1
H6
H7 H6
H7
X5
X2
X3
Fiber Optic
Adapter Board
Six
Fiber Optic
Cables
For Gate Driver board part number
information, see Table D.B on page D-3.
Gate Driver Board
Connector Descriptions
C-3
Figure C.1 Fiber Optic Cable Routing
H8
X9
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
C-4
Connector Descriptions
Hardware Connections
Figure C.2 AFE Power Structure Fan Inverter Circuit Board Connectors
X3
X8
Table C.C ASIC Board - AFE Power Structure Fan Inverter Board Connections
ASIC Board Connector (1)
X11
(1)
Pin
Signal Description
Pin
AFE Power Structure
Fan Inverter Board
Connector
X8
From
2
ASIC_+15V
To
2
From
3
FAN_CONTROL
To
3
To
4
FAN_ALARM
From
7
See Figure C.1 on page C-3 for ASIC board connectors.
&ORPARTNUMBERINFORMATIONSEETHE0OWER&LEX(3AND!&%
$RIVE&AN3YSTEMS)NSTALLATION)NSTRUCTIONSPUBLICATION0&,%8).
Figure C.3 LCL Filter Fan Inverter Circuit Board Connectors
X3
X4
X8
X1
Table C.D LCL Filter Fan Inverter Circuit Board Connections
LCL Filter DC
Fan Assembly
X1
X1
X3
X3
X8
X51
X4
X53
LCL Filter DC Fan
Inverter Board
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
!PPENDIX
$
Disassembly/Assembly Diagrams and Spare Parts
Diagram
Page
AFE Power Structure Assembly External Components
D-2
AFE Power Structure Assembly Internal Components
D-3
AFE Power Structure ASIC Assembly
D-4
LCL Filter Assembly
D-5
LCL Filter Power Supply Assembly
D-6
LCL Filter Fan Assembly
D-6
Precharge Assembly for AFE in IP20 2500 MCC Style Enclosure
D-7
Precharge Assembly for AFE in IP21 Rittal Enclosure
D-8
AC Line Switchgear Components for AFE in IP20 2500 MCC Style Enclosure
D-9
AC Line Switchgear Components for AFE in IP21 Rittal Enclosure
D-10
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0OWER&LEX!CTIVE&RONT%ND4HESERIALNUMBERISLOCATEDONTHEDATA
NAMEPLATEONTHE#ONTROL&RAMEJUSTABOVETHEBARCODE
Data Nameplate on AFE
in IP20 2500 MCC Style Enclosure
Data Nameplate on AFE
in IP21 Rittal Enclosure
0035
-842
0/435
Frame: 10
Serial Number: 12345678
Cat No.
20D
500 N 0 NNNBNNNN
J
UL Open Type/IP00
540V
250 kW
Normal Duty Power
200 kW
Heavy Duty Power
Input: DC,
462 - 594
DC Voltage Range
Amps
350
Output: 3 Phase, 0 - 320Hz
AC Voltage Range
0 - 400
50 Hz
Base Hz (default)
Continuous Amps
420/500
630/550
1 Min Overload Amps
!&%
2 Sec Overload
Amps
840/630
MFD. in 1989 on Nov 9
Cat No.
20D
J
300 N 0 NNNBNNNN
UL Open Type/IP00
540V
650V
160 kW
250 kW
Normal Duty Power
132 kW
200 kW
Heavy Duty Power
Input: DC,
DC Voltage Range
462 - 594 583 - 713
350
350
Amps
Output: 3 Phase, 0 - 320Hz
AC Voltage Range
0 - 400
0 - 460
50 Hz
60 Hz
Base Hz (default)
300/245
300/245
Continuous Amps
330/368
330/368
1 Min Overload Amps
2 Sec Overload Amps
450/490
450/490
Series: A
Standard I/O: NONE
Original Firmware No. 2.04
C
UL
Æ
US
LISTED
IND CONT EQ
450 kW
500 kW
Frame #: 10
583 - 713
350
0 - 460
60 Hz
420/500
630/550
840/630
Frame #: 10
Serial Number: 2622381987
MFD. in 2005 on Feb 29
Serial Number: 2622381652
MADE IN THE USA (FAC 1B)
MADE IN THE USA (FAC 1B)
!COMPLETELISTOFSPAREPARTSFORTHE&RAME0OWER&LEX!CTIVE&RONT%ND
ISAVAILABLEONTHE!LLEN"RADLEYWEBSITEAT
HTTPWWWABCOMSUPPORTABDRIVESPOWERFLEX0&2ELEASED0ARTSPDF
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
D-2
Disassembly/Assembly Diagrams and Spare Parts
AFE Power Structure
Assembly
Figure D.1 AFE Power Structure Assembly External Components
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Side Cover
ASIC Assembly
Upgrade Kit
Front Cover
Terminal Cover
Fuse Holder
for Fan Inverter
Mounting
Rack
Table D.A AFE Power Structure Assembly External Component Part Numbers
Part Name
Part No.
ASIC Assembly Upgrade Kit (without ASIC Board)
20-FR10850
Bus Bar Assembly
n/a
Fuse Holder for Fan Inverter (only AC fan system)
20-PP20300 (1)
Fan Inverter Fuse (only AC fan system)
20-PP20202 (1)
Terminal Cover
n/a
Front Cover
Power Structure
n/a
400/480V (460A)
600/690V (325A)
Maintenance Stand
(1)
SK-Y1-PWRMOD-D460
SK-Y1-PWRMOD-E325
20-MAINSTD
For additional AC fan system information, see publication PFLEX-IN029.
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
Disassembly/Assembly Diagrams and Spare Parts
D-3
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)
Air Flow Channel
Main Cooling Fan Assembly
(see publication PFLEX-IN029
for complete details)
Screening Plate
Gate Drive Board
Table D.B AFE Power Structure Assembly Internal Component Part Numbers
Part Name
Part No.
Air Flow Channel
n/a
Balancing Resistors
n/a
DC Bus Bar Assembly
n/a
DC Bus Bar Terminal Assembly
n/a
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
Power Module
n/a
400/480V
SK-Y1-GDB1-F10D
600/690V
SK-Y1-GDB1-F10E
400/480V
SK-Y1-QOUT-D460
600/690V
SK-Y1-QOUT-E325
n/a
Screening Plate (for Gate Driver Board)
n/a
Snubber Capacitor Assembly
n/a
Power Bus Bar
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
D-4
Disassembly/Assembly Diagrams and Spare Parts
!44%.4)/.4HESHEETMETALCOVERANDMOUNTINGSCREWSON
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ORDEATHEXISTSIFSOMEONECOMESINTOCONTACTWITHTHEASSEMBLY
Figure D.3 AFE Power Structure ASIC Assembly
ASIC Assembly Cover
ASIC Board
ASIC Insulator
ASIC Assembly Bracket
Table D.C AFE Power Structure ASIC Assembly Part Numbers
Part Name
Part No.
ASIC Assembly Bracket
ASIC Assembly Cover
Included in 20-FR10850
ASIC Assembly Insulator
ASIC Board (1) 400/480V AFE
SK-H1-ASICBD-D460
600/690V AFE
SK-H1-ASICBD-E325
Fiber Optic Cable Set
The ASIC board is unprogrammed.
(1)
0OWER&LEX!CTIVE&RONT%NDˆ&RAME(ARDWARE3ERVICE-ANUAL
Publication 20Y-TG001B-EN-P
20-PP09017
Disassembly/Assembly Diagrams and Spare Parts
LCL Filter Assembly (used
in IP20 and IP21 enclosures)
D-5
Figure D.4 LCL Filter Assembly
LCL Filter
Assembly
LCL Capacitor
Assembly
LCL High Frequency
Capacitor Assembly
Table D.D LCL Filter Assembly Part Numbers
Part Name
LCL Filter Assembly
Part No.
400/480V
SK-Y1-LCL1-D460
600/690V
SK-Y1-LCL1-E325
LCL High Frequency
Capacitor Assembly
20 μF 400/480V
SK-Y1-CAPHF2-DF
10 μF 600/690V
SK-Y1-CAPHF1-DF
LCL Capacitor Assembly
120 μF 400/480V
SK-Y1-CAPLCL1-D425
53 μF 600/690V
SK-Y1-CAPLCL1-F325
SK-Y1-F11-F10
LCL Filter Inverter Fan Fuse
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D-6
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
LCL Filter
Power Supply
Discontinued July 2014 (2)
Universal Kit
400/480V
600/690V
SK-Y1-DCPS2-F10 (1)
LCL Fan Wire Kit
SK-Y1-DCPS1-D460
SK-Y1-DCPS1-F325
SK-Y1-HF1-DF
(1)
This kit can be used for either voltage class.
(2)
These discontinued kits are no longer available, but spares inventory is applicable.
Figure D.6 LCL Filter Fan Assembly
Table D.F LCL Filter Fan Assembly Part Number
Part No.
Main Fan, 48V DC
SK-Y1-DCFAN1
Part Name
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Publication 20Y-TG001B-EN-P
Disassembly/Assembly Diagrams and Spare Parts
Precharge Assembly
D-7
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 Kit
• Control Transformer (T4)
• Control Transformer
Primary Fuse and Fuse
Holder
Precharge
Resistors
Control Box
(located on front of enclosure door;
shown with control box cover removed)
Control Transformer (T10)
Secondary Fuse and
Fuse Holder
Table D.G Precharge Assembly Part Numbers for AFE in IP20 2500 MCC Style
Enclosure
Part Name
Part No.
Precharge Fuse
SK-Y1-MCCF5-F10
Precharge Fuse Holder
SK-Y1-MCCF5FUSEHOLDER-F10
Precharge Kit
(1)
SK-Y1-PRE2-F10
Control Transformer (T4), 1500VA
Control Transformer
Primary Fuse
SK-R1-OFANXFMR
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
Kit includes diode bridge (V6), two resistors (R6.1 and R6.2), and a snubber capacitor (C1).
(1)
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D-8
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
• Control Transformer
Circuit Breaker
24V DC Power Supply (T10)
and Circuit Breaker
Control Transformer (T4);
mounted directly behind
Motor Controlled Circuit
Breaker (MCCB)
Table D.H Precharge Assembly Part Numbers for AFE in IP21 Rittal Enclosure
Part Name
Precharge Fuse
Part No.
400/480V
SK-Y1-F6-D
600/690V
SK-Y1-F6-F
Fuse Disconnect Switch
SK-Y1-F6DISC-DF
Precharge Kit (1)
SK-Y1-PRE1-F10DF
Control Transformer (T4), 750VA
400/480V
SK-Y1-T4-D
600/690V
SK-Y1-T4-F
Control Transformer Motor Protection Relay
SK-Y1-Q4-DF
Control Transformer Circuit
Breaker, 4A
400/480V
SK-Y1-F3-D
600/690V
SK-Y1-F3-F
24V DC Power Supply (T10)
SK-Y1-T10-DF
24V DC Power Supply Circuit Breaker, 2A
SK-Y1-F10-DF
Precharge Motor Protection Relay
SK-Y1-Q5-F10
Kit includes diode bridge (V6), contactor (K6), two resistors (R6.1 and R6.2), and a
snubber capacitor (C1).
(1)
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Publication 20Y-TG001B-EN-P
Disassembly/Assembly Diagrams and Spare Parts
AC Line Switchgear
D-9
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
Bus Bars between
Input Contactor and
AC Input Fuses
Input Contactor
Table D.I AC Line Switchgear Part Numbers for AFE in IP20 2500 MCC Style Enclosure
Part Name
Part No.
AC Input Fuses
400/480V
600/690V
SK-Y1-MCCF1-F10F
DC Bus Fuses
400/480V
SK-Y1-MCCF2-D
600/690V
SK-Y1-MCCF2-F
Input Circuit Breaker
SK-Y1-MCCF1-F10D
400/480V
SK-Y1-MCCQ0-F10D
600/690V
SK-Y1-MCCQ0-F10F
Input Contactor
100-D420ED11
Input Circuit Breaker Handle Mechanism
SK-Y1-HANDLE-F10
Bus Link between Input Circuit Breaker and AC Input Fuses
SK-Y1-BUSCB-F10
Bus Bars between Input Contactor and AC Input Fuses
SK-Y1-BUSCNTCT-F10
Fan Blower Kit
SK-R1-OFAN12-F8
LCL Filter Bay Door Fan Kit (two at top of door; not shown)
20-750-FAN3-F8
Bus Splice Kit (not shown; optional)
SK-Y1-BUSSPLICE-F10
MCC Bus Splice Barrier Kit (not shown; optional) (1)
SK-Y1-MCCBARRIER
The MCC Bus Splice Barrier kit must be used when installing a Bus Splice kit (SK-Y1-BUSSPLICE-F10).
(1)
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Publication 20Y-TG001B-EN-P
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.
230V AC
SK-Y1-K20-DF
24V DC
SK-Y1-K4-DF
Input Disconnect Switch
SK-Y1-Q0-F10
Motor Controlled Circuit Breaker
SK-Y1-Q1-F10
Control Circuit Relay
(not shown)
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Publication 20Y-TG001B-EN-P
%
!PPENDIX
AFE Power One-line System Application Data
#OLLECTTHEFOLLOWING!&%SYSTEMDATABEFORECONTACTING!LLEN"RADLEY
$RIVES4ECHNICAL3UPPORT
Data to Collect
Utility
Type
Input Volts
Output Volts
kVA
Z
Ground
Transformer
Delta-Delta, Delta-Wye, etc.
None, Solid, High Resistive
Cable Length: __________________________ Cable Type: _____________________________
Secondary
Type
Input Volts
Output Volts
kVA
Z
Ground
Transformer
None, Solid, High Resistive
Cable Length: __________________________ Cable Type: _____________________________
❑ Line Reactor Mfgr./Cat Num: __________________________
❑ Isolation Xfmr Mfgr./Cat Num: __________________________
% Impedance: _________
% Impedance: _________
❑ Input Contactor
SCR Bus
Supply
AFE
AFE Cat Num: ____________________________
SCR Cat Num: _______________________
❑ Output Contactor
Cable Length: __________________________ Cable Type: _____________________________
Drive
Drive
Drive Cat Num: ____________________________
❑ Output Reactor
❑ Terminator
Mfgr./Cat Num: __________________________
Mfgr./Cat Num: __________________________
Cable Length: __________________________ Cable Type: _____________________________
Motor
Motor
Motor Mfgr.
Volts
Amps
RPM
Hz
Power
Design No.
Encoder
Brake
Motor Heater
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E-2
AFE Power One-line System Application Data
Typical Transformer
Winding Types
4HEFOLLOWINGDIAGRAMSSHOWTYPICALTRANSFORMERWINDINGTYPES
$ELTA7YEWITH'ROUNDED7YE.EUTRAL
$ELTA$ELTAWITH'ROUNDED,EG
OR
&OUR7IRE#ONNECTED3ECONDARY$ELTA
OR
5NGROUNDED3ECONDARY
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Publication 20Y-TG001B-EN-P
)NDEX
A
AC line switchgear
components
AFE in IP20 2500 MCC Style
enclosure, D-9
AFE in IP21 Rittal enclosure,
D-10
overview, 5-1
Active Front End system overview, 2-1
additional resources
publications, P-2
website, P-1
AFE power structure
ASIC assembly parts, D-4
checking fan inverter fuses, 3-8
external components, D-2
internal components, D-3
assembly/disassembly diagrams, D-1
B
bus bar locations
AFE in IP20 2500 MCC Style enclosure,
2-3
AFE in IP21 Rittal enclosure, 2-6
D
DC fuses
overview, 8-1
replacement guidelines, 8-2
de-energizing the AFE, 4-3
diagnostic status indicators, 3-2
diode test
forward biased, 3-3
reverse biased, 3-3
disassembly/assembly diagrams, D-1
E
external components of AFE power
structure, D-2
F
fan inverter fuse checking, 3-8
faults
creating reports, 1-2
list, 1-2
fiber optic
cable routing connections, C-3
connection checking, 3-5
forward biased diode test, 3-3
checking
fan inverter fuses, 3-8
fiber optic connections, 3-5
circuit board connections, C-1
common symptoms and corrective actions,
1-7
component test procedures, 3-1
connections for
circuit boards, C-1
fiber optic cable routing, C-3
control transformer and 24V DC power
supply testing, 6-3
control wiring diagram
AFE in IP20 2500 MCC Style enclosure,
B-4
AFE in IP21 Rittal enclosure, B-13
creating fault reports, 1-2
G
gate driver board resistance
measurements, 3-7
general precautions, P-3
H
hardware connections, C-4
hardware faults, 1-2
I
input disconnect
AFE in IP20 2500 MCC Style enclosure,
5-2
AFE in IP21 Rittal enclosure, 5-2
inspecting
cooling tunnel, 3-2
power structure, 3-2
internal components of AFE power
structure, D-3
C
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Publication 20Y-TG001B-EN-P
Index-2
L
LCL filter
assembly parts, D-5
fan DC power supply
installation, 7-5
removal, 7-3
fan replacement, 7-5
fuse replacement, 7-2
removing from
IP20 2500 MCC Style enclosure,
7-6
IP21 Rittal enclosure, 7-8
removing protective cover, 7-2
M
main component locations
AFE in IP20 2500 MCC Style enclosure,
2-2
AFE in IP21 Rittal enclosure, 2-5
main component sections
AFE in IP20 2500 MCC Style enclosure,
2-1
AFE in IP21 Rittal enclosure, 2-4
measurement points for forward and reverse
diode tests, 3-4
motor-controlled circuit breaker (MCCB),
5-2
O
one-line diagram
AFE in IP00 open chassis configuration,
2-7
AFE in IP20 2500 MCC Style enclosure,
2-1
AFE in IP21 Rittal enclosure, 2-4
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P
performing
forward biased diode test, 3-3
gate driver board resistance
measurements, 3-7
reverse biased diode test, 3-3
visual inspections, 3-2
powering down, 4-3
precharge
assembly parts
AFE in IP20 2500 MCC Style
enclosure, D-7
AFE in IP21 Rittal enclosure, D-8
bridge replacement, 6-6
bridge testing, 6-6
fuse replacement, 6-2
resistor replacement, 6-8
testing control transformer and 24V DC
power supply, 6-3
testing resistor, 6-7
precharging functions, 6-2
Index-3
R
removing
AFE air flow plate, 4-11
AFE protective barriers, 4-10
ASIC circuit board, 4-14
control frame (only AFE in IP21 Rittal
enclosure), 4-9
DPI/HIM assembly, 4-4
fiber optic adapter circuit board, 4-6
gate driver circuit board, 4-12
I/O circuit boards and control board, 4-5
LCL filter
fan DC power supply, 7-3
from IP20 2500 MCC Style
enclosure, 7-6
from IP21 Rittal enclosure, 7-8
protective cover, 7-2
power from the AFE, 4-3
power module from the power structure,
4-20
power structure DC bus capacitors,
4-26
power structure from the enclosure,
4-17
power structure main cooling fan, 4-17
protective covers from the power
structure, 4-12
replacing power structure with a new power
structure, 4-27
resources
publications, P-2
website, P-1
reverse biased diode test, 3-3
T
testing
control transformer and 24V DC power
supply, 6-3
forward biased diode, 3-3
gate driver board resistance, 3-7
precharge bridge, 6-6
precharge resistor, 6-7
reverse biased diode, 3-3
torque specifications, 4-2
troubleshooting and error codes, 1-1
turning off the AFE, 4-3
V
viewing the status indicators, 3-2
visual inspections, 3-2
W
website
additional resources, P-1
spare parts, P-2, D-1
schematic diagrams, B-1
service tools, A-1
software tools, A-1
spare parts
information, D-1
website, P-2, D-1
startup after repair, 9-1
status indicators, 3-2
system overview, 2-1
S
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Index-4
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Publication 20Y-TG001B-EN-P
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Publication 20Y-TG001B-EN-P - November 2014
Supersedes Publication 20Y-TG001A-EN-P - June 2011
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