Download PowerFlex 700AFE Frame 13 Hardware Service Manual

Hardware Service Manual
PowerFlex Active Front End—Frame 13
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.
Summary of Changes
The information below summarizes the changes to this manual since its last
release (January 2010).
Change
Page
Added information for Frame 13 AFE in IP20 2500 MCC Style enclosure.
Throughout
manual
In Chapter 1, revised faults table information.
1-2…1-7
Added new Chapter 2 ‘Active Front End System Overview’.
2-1
Old Chapter 2 is now new Chapter 3 ‘Component Test Procedures’.
3-1
Old Chapter 3 is now new Chapter 4 ‘AFE Power Structure Component Section’.
Reorganized the following Power Structure Access Procedures subsections:
• Subsection ‘Removing/Installing AFE Protective Barriers’ is now first.
• Subsection ‘Removing/Installing the Air Flow Plate’ is now second.
• Subsection ‘Removing/Installing Protective Covers…’ is now third.
4-10
4-12
4-13
Added new Chapter 5 ‘AC Line Switchgear Component Section’.
5-1
Added new Chapter 6 ‘Precharge Component Section’.
6-1
Added new Chapter 7 ‘LCL Filter Component Section’.
7-1
Added new Chapter 8 ‘DC Fuses Component Section’.
8-1
Old Chapter 4 is now new Chapter 9 ‘Startup After Repair’.
9-1
In Appendix B:
• Added Frame 13 Control Wiring Diagram for AFE in IP20 2500 MCC Style enclosure. B-6
• Added Frame 13 Control Wiring Diagram for AFE in IP21 Rittal enclosure.
B-15
• Added all system schematics for Frame 13 AFE in IP20 2500 MCC Style enclosure. B-8…B-14
In Appendix C, added new information and drawings.
Appendix C
In Appendix D:
• Added ‘LCL Filter Assembly’ section.
• Added ‘Precharge Assembly’ section.
• Added ‘AC Line Switchgear’ section.
D-5
D-7
D-9
Added new Appendix E ‘AFE Power One-line System Application Data’.
E-1
PowerFlex Active Front End—Frame 13 Hardware Service Manual
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Summary of Changes
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Table of Contents
Preface
Overview
Who Should Use this Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What is in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
What is Not in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PowerFlex Active Front End Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Understanding Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Cross References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Additional Support Available on Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
General Precautions for Class 1 LED Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 1
P-1
P-1
P-1
P-1
P-2
P-2
P-2
P-2
P-2
P-3
P-3
Troubleshooting and Error Codes
Creating Fault Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Addressing PowerFlex Active Front End Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Common Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Chapter 2
Active Front End System Overview
AFE in IP20 2500 MCC Style Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Component Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Bus Bar Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AFE in IP21 Rittal Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Component Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Main Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Bus Bar Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AFE in IP00 Open Chassis Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 3
Component Test Procedures
Viewing the Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performing Visual Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspecting the Cooling Tunnels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Inspecting the Power Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performing Forward and Reverse Biased Diode Tests for Power Structure . . . . . . . . . . .
Checking Fiber Optic Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Performing Gate Driver Board Resistance Measurements . . . . . . . . . . . . . . . . . . . . . . . .
Checking the AFE Power Structure Fan Inverter Fuses . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 4
2-1
2-1
2-2
2-3
2-4
2-4
2-5
2-6
2-7
3-2
3-2
3-2
3-2
3-3
3-5
3-7
3-8
AFE Power Structure Component Section
Understanding Torque Figures in Assembly Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . .
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing Power from the AFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Control Frame Access Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the DPI Interface Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the DPI Interface Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the I/O Circuit Boards and Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the I/O Circuit Boards and Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . .
4-2
4-2
4-3
4-4
4-4
4-5
4-5
4-6
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Table of Contents
Removing the Fiber Optic Adapter Circuit Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Installing the Fiber Optic Adapter Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Removing the Control Frame (only for AFE in IP21 Rittal enclosure). . . . . . . . . . . . . 4-9
Replacing the Control Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Power Structure Access Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Removing AFE Protective Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Installing AFE Protective Barriers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Removing the AFE Air Flow Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Installing the AFE Air Flow Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Removing Protective Covers from the Power Structure . . . . . . . . . . . . . . . . . . . . . . . 4-13
Installing Protective Covers on the Power Structure . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Removing the Gate Driver Circuit Boards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-13
Installing the Gate Driver Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Removing the ASIC Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-15
Installing the ASIC Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-18
Removing and Installing the Power Structure Fan System . . . . . . . . . . . . . . . . . . . . . 4-18
Removing the Power Structure from the Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Installing the Power Structure in the Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-23
Removing the U, V, or W Phase Assembly from the Power Structure . . . . . . . . . . . . 4-23
Removing the Power Module from the U, V, or W Phase Assembly . . . . . . . . . . . . . 4-25
Installing the Power Module on the U, V, or W Phase Assembly . . . . . . . . . . . . . . . . 4-30
Removing the U, V, or W Phase Assembly DC Bus Capacitors . . . . . . . . . . . . . . . . . 4-30
Installing the U, V, or W Phase Assembly DC Bus Capacitors. . . . . . . . . . . . . . . . . . 4-31
Replacing the Existing Power Structure with a New Power Structure . . . . . . . . . . . . 4-31
Chapter 5
AC Line Switchgear Component Section
AFE in IP20 2500 MCC Style Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
AFE in IP21 Rittal Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Chapter 6
Precharge Component Section
Precharging Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Precharge Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing the Control Transformer (T4) and 24V DC Power Supply (T10). . . . . . . . . . . . .
For AFE in IP20 2500 MCC Style Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
For AFE in IP21 Rittal Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing the Precharge Bridge Using the Power Structure Terminals. . . . . . . . . . . . . . . . .
Replacing the Precharge Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Testing the Precharge Resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the Precharge Resistor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AFE in IP20 2500 MCC Style Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AFE in IP21 Rittal Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 7
6-2
6-2
6-3
6-3
6-4
6-6
6-6
6-7
6-8
6-8
6-8
LCL Filter Component Section
Removing the LCL Filter Protective Barriers and Vented Cover . . . . . . . . . . . . . . . . . . .
Installing the LCL Filter Protective Barriers and Vented Cover . . . . . . . . . . . . . . . . . . . .
Replacing the LCL Filter DC Fan Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Removing the LCL Filter Fan DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the LCL Filter Fan DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Replacing the LCL Filter Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
PowerFlex Active Front End—Frame 13 Hardware Service Manual
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7-2
7-2
7-3
7-5
7-5
Table of Contents
Removing the LCL Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
From the IP20 2500 MCC Style Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
From the IP21 Rittal Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Installing the LCL Filter in the Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Chapter 8
iii
7-6
7-6
7-7
7-8
DC Fuses Component Section
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Fuse Replacement Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Chapter 9
Startup After Repair
Before Applying Power to the AFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Appendix A
Service Tools and Equipment
Software Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Appendix B
Schematic Diagrams
Frame 13 Circuit Board Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Frame 13 Power Structure Power Circuitry Block Diagram. . . . . . . . . . . . . . . . . . . . . . . B-2
Frame 13 Power Module Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Frame 13 Power Structure Main Fan Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4
Frame 13 Power Structure Main Fan Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5
Control Wiring Diagram for Frame 13 in IP20 2500 MCC Style Enclosure . . . . . . . . . . B-6
System Schematics for Frame 13 in IP20 2500 MCC Style Enclosure . . . . . . . . . . . . . . B-8
Control Wiring Diagram for Frame 13 in IP21 Rittal Enclosure . . . . . . . . . . . . . . . . . . B-15
System Schematics for Frame 13 in IP21 Rittal Enclosure . . . . . . . . . . . . . . . . . . . . . . B-16
Appendix C
Connector Descriptions
Circuit Board Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Hardware Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Appendix D
Disassembly/Assembly Diagrams and Spare Parts
AFE Power Structure Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
LCL Filter Assembly (used in IP20 and IP21 enclosures) . . . . . . . . . . . . . . . . . . . . . . . .
Precharge Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
AC Line Switchgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Appendix E
D-2
D-5
D-7
D-9
AFE Power One-line System Application Data
Data to Collect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
Typical Transformer Winding Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Index
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
iv
Table of Contents
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Preface
Overview
Who Should Use this
Manual?
This manual is intended for qualified service personnel responsible for
troubleshooting and repairing the PowerFlex® Active Front End (AFE). You
should have previous experience with, and basic understanding of, electrical
terminology, procedures, required troubleshooting equipment, equipment
protection procedures and methods, and safety precautions. See safety
related practices contained in Standard for Electrical Safety in the Work
Place, publication NFPA 70E.
What is in this Manual
This manual contains hardware service information for the Frame 13
PowerFlex Active Front End. Verify that you are working on a Frame 13 by
checking the data nameplate on the AFE. The frame number is printed just
above the serial number.
Data Nameplate on AFE
in IP20 2500 MCC Style Enclosure
0035
Data Nameplate on AFE
in IP21 Rittal Enclosure
Cat No.
J
20D
500 N 0 NNNBNNNN
UL Open Type/IP00
-842
0/435
Frame: 13
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)
Continuous Amps
420/500
630/550
1 Min Overload Amps
AFE
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,
462 - 594 583 - 713
DC Voltage Range
Amps
350
350
Output: 3 Phase, 0 - 320Hz
AC Voltage Range
0 - 400
0 - 460
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
MFD. in 1989 on Nov 9
MADE IN THE USA (FAC 1B)
Series: A
Standard I/O: NONE
Original Firmware No. 2.04
C
UL
Æ
US
LISTED
IND CONT EQ
650V
450 kW
500 kW
Series:
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 #: 13
Serial Number: 2622381652
Serial Number: 2622381652
2622381652
MADE IN THE USA (FAC 1B)
262238165
What is Not in this Manual
This manual does not contain installation, start-up, and programming
information. This information is available in the PowerFlex Active Front
End User Manual, publication 20Y-UM001.
Additional Resources
You can view or download publications at http://
www.rockwellautomation.com/literature. To order paper copies of technical
documentation, contact your local Rockwell Automation distributor or sales
representative.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
P-2
Overview
General Information
The following publications provide general drive information.
Title
Publication
Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives
DRIVES-IN001
Safety Guidelines for the Application, Installation and Maintenance of Solid State Control
SGI-1.1
A Global Reference Guide for Reading Schematic Diagrams
100-2.10
Guarding Against Electrostatic Damage
8000-4.5.2
PowerFlex Active Front End Information
The following publications provide specific AFE 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
For spare parts information for PowerFlex 7-Class Architecture Class Low
Voltage AC Drives, including the PowerFlex Active Front End, go online at
http://www.ab.com/support/abdrives/powerflex70/PF7ReleasedParts.pdf.
Understanding Manual
Conventions
Become familiar with the following conventions used in this manual.
Terms
The following words are used throughout the manual to describe an action.
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
‘Figure 3.1 on page 3-4’ is a cross reference to Figure 3.1 on page 4 of
Chapter 3.
‘Figure C.1 on page C-3’ is a cross reference to Figure C.1 on page 3 of
Appendix C.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Overview
Additional Support
Available on Internet
General Precautions for
Class 1 LED Product
P-3
Additional troubleshooting information and software tools are available on
the Allen-Bradley Drives Technical Support website at http://www.ab.com/
support/abdrives.
!
ATTENTION: Hazard of permanent eye damage exists when
using optical transmission equipment. This product emits intense
light and invisible radiation. Do not look into module ports or
fiber optic cable connectors.
!
ATTENTION: The sheet metal cover and mounting screws on
the ASIC Board located on the power structure are energized at
(-) DC bus potential high voltage. Risk of electrical shock, injury,
or death exists if someone comes into contact with the assembly.
!
!
!
!
!
ATTENTION: To avoid an electric shock hazard, verify that the
voltage on the bus capacitors has discharged completely before
servicing. Check the DC bus voltage between the +DC and -DC
terminals, between the +DC terminal and the chassis, and
between the -DC terminal and the chassis. The voltage must be
zero for all three measurements.
ATTENTION: Potentially fatal voltages can result from
improper usage of an oscilloscope and other test equipment. The
oscilloscope chassis can be at a potentially fatal voltage if not
properly grounded. Use high voltage differential voltage probes
for all voltage measurements with the oscilloscope chassis
correctly grounded to an earth ground.
ATTENTION: The PowerFlex Active Front End contains
electrostatic discharge (ESD) sensitive parts and assemblies that
can be damaged if you do not follow ESD control procedures.
Static control precautions are required to install, test, service, or
repair this unit. If you are unfamiliar with static control
procedures, see Guarding Against Electrostatic Damage,
publication 8000-4.5.2, or any other applicable ESD protection
handbook.
ATTENTION: An incorrectly applied or installed PowerFlex
Active Front End can result in component damage or a reduction
in product life. Wiring or application errors, such as, undersizing
the motor, incorrect or inadequate AC supply, or excessive
ambient temperatures can result in malfunction of the system.
ATTENTION: Only qualified personnel familiar with adjustable
frequency AC drives and associated machinery should plan or
implement the installation, start-up, and subsequent maintenance
of the system. Failure to comply may result in personal injury
and/or equipment damage.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
P-4
Overview
Notes:
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Chapter
1
Troubleshooting and Error Codes
!
!
!
!
ATTENTION: To avoid an electric shock hazard, verify that all
power to the PowerFlex Active Front End has been removed
before performing any servicing or repairs.
ATTENTION: To avoid an electric shock hazard, verify that the
voltage on the bus capacitors has discharged completely before
servicing. Check the DC bus voltage between the +DC and -DC
terminals, between the +DC terminal and the chassis, and
between the -DC terminal and the chassis. The voltage must be
zero for all three measurements.
ATTENTION: Hot surfaces can cause severe burns. Do not
touch the heatsink surface during operation of the PowerFlex
Active Front End. After disconnecting power allow time for
cooling.
ATTENTION: The PowerFlex Active Front End contains
electrostatic discharge (ESD) sensitive parts and assemblies that
can be damaged if you do not follow ESD control procedures.
Static control precautions are required to install, test, service, or
repair this assembly. If you are unfamiliar with static control
procedures, see Guarding Against Electrostatic Damage,
publication 8000-4.5.2, or any other applicable ESD protection
handbook.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
1-2
Troubleshooting and Error Codes
Creating Fault Reports
Complete fault reports are critical for analysis and repair of modules
returned to the factory.
At a minimum, do the following:
• Using an Allen-Bradley drive configuration tool such as Connected
Components Workbench™ software, DriveExplorer™ software, or
DriveExecutive™ software, do the following:
– Upload all parameters from the PowerFlex Active Front End.
– Run the Technical Support Wizard.
• Collect the AFE system application data shown in Appendix E.
• If possible, record the contents of the fault queue (faults and times of
occurrence).
• Make record of the following:
– Any burn marks on the rectifying module, DC capacitors, inverter
bridge, charging resistors, balancing/precharging resistors, printed
circuit boards, bus bars, cabling, and fiber optic cabling.
– Any liquid and condensation marks on printed circuit boards,
components, and mechanical parts.
– Amount of dust and other additional particles on drive and drive
components.
– Any mechanical damage to the drive and drive components.
• Record the size and type of main fuses.
• Record any other important marks and damage.
• Note grounding type (solid, high resistance, or floating) and source
impedance of the power distribution system.
Addressing PowerFlex
Active Front End Faults
No. Name
Description
Action (if appropriate)
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
Should the fault re-occur, contact
Technical Support.
• faulty operation
• component failure
2
Auxiliary In
The AFE control digital input
interlock is open.
4
DC UnderVolt
The DC bus voltage fell below
Monitor the incoming AC line for low
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].
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-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 (if appropriate)
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 the
ASIC board on the converter).
3. Check for an excess load.
4. Verify that the airflow plate is
installed. See page 4-12.
9
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.
2. Check the fan(s).
3. Check for an excess load.
10
System Fault
A hardware problem exists in the
power structure.
1. Reset the fault and restart.
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.
12
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
• Converter 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.
2. Contact Technical Support.
3. If the problem persists, replace
the converter unit.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
1-4
Troubleshooting and Error Codes
No. Name
Description
Action (if appropriate)
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 in back of the converter fan.
For additional information, see
PowerFlex 700H, 700S, and 700AFE
Drive Fan Systems Installation
Instructions, publication
PFLEX-IN029.
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.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
2. Replace the Control board.See
page 4-5.
Troubleshooting and Error Codes
1-5
No. Name
Description
Action (if appropriate)
58
Start Prevent
Startup has been prevented.
1. Cancel prevention of startup if this
can be done safely.
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. Remove Run Request.
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 digitial 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 4-15) in
the converter unit.
4. Contact Technical Support.
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.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
1-6
Troubleshooting and Error Codes
No. Name
Description
Action (if appropriate)
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 13 LCL Filter
126 LCL Fan Stop
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-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 (if appropriate)
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 fault.
• Press Stop
• Cycle 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.
There is some other start inhibit.
Check status bits of
parameter 100 [Start
Inhibits].
Correct the source of the inhibit.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-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.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-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.
Chapter
2
Active Front End System Overview
This chapter describes AFE system main components and is grouped by
those used in a IP20 2500 MCC Style enclosure, a IP21 Rittal enclosure,
and main components for the AFE IP00 open chassis configuration.
AFE in IP20 2500 MCC Style Main Component Sections
Enclosure
The following figure shows a basic one-line diagram for an AFE system in a
IP20 2500 MCC Style enclosure. The main component sections consist of
the following items:
• AC Line Switchgear consisting of the input circuit breaker (Q0), fuses
(F1.1…F1.3), and input contactor (K1)
• LCL Filter (L1)
• Precharge Circuit
• AFE power structure (U1) with AFE control assembly
• DC Fuses (F2.1…F2.6)
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
LCL Filter (L1)
AFE
Power Structure (U1)
Input
Contactor
Fuses
K1
F1.1…F1.3
L2
L3
U2
U1
V2
W2
V1
W1
C1
C4
C2
C5
C3
PE
U
DC+
DC-
DC
Fuses
F2.1
F2.2
PE
V
DC+
DC-
DC Bus
Output
F2.3
F2.4
C6
PE
PE
W
DC+
DC-
F2.5
F2.6
Precharge
Fuses
F5
Precharge
Contactor
Precharge
Circuit
K6
R6.1
+
PowerFlex
Active Front End System
-
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
2-2
Active Front End System Overview
Main Component Locations
The following figure shows the main components of the AFE Frame 13
system in a IP20 2500 MCC Style enclosure.
Figure 2.2 AFE Frame 13 Main Component Locations in IP20 2500 MCC Style
Enclosure
FRONT VIEW
(shown with enclosure doors removed)
FRONT VIEW
(reduced size - shown with
enclosure doors closed)
Item
Description
➊
Precharge Circuit
➋
Precharge Resistor (R6.1)
➌
LCL Filter (L1)
➍
Active Front End Power Structure (U1)
➎
➏
Input Circuit Breaker (Q0)
AC Line Switchgear
➐
Input Fuses (F1.1…F1.3)
Input Contactor (K1)
➑
DC Fuses (F2.1…F2.6)
➒
AFE Control Box Assembly (on the AFE door and shown with user-installed HIM)
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Active Front End System Overview
2-3
Main Bus Bar Locations
There are several sets of bus bars in the AFE Frame 13 system that connect
main system components:
•
•
•
•
Bus bars between Input Breaker (Q0) and AC Fuses (F1.1…F1.3)
Bus bars between AC Fuses (F1.1…F1.3) and Input Contactor (K1)
Bus bars between Input Contactor (K1) and the LCL Filter (L1)
Bus bars between the AFE Power Structure (U1) and DC Bus
The following figure shows these bus bar locations.
Figure 2.3 AFE Frame 13 Bus Bar Locations in IP20 2500 MCC Style Enclosure
FRONT VIEW
(shown with enclosure doors removed)
DC- bus bar
AC power bus bars
between Input Contactor
(K1) and LCL Filter (L1)
Optional Bus Splice
Kit (not shown)
AC bus bars between
Input Circuit Breaker (Q0)
and AC input fuses
(F1.1…F1.3)
DC+ bus bar
DC bus bars between
AFE Power Structure
(U1) and DC bus
Optional Bus Splice
Kit (not shown)
AC bus bars between AC
fuses (F1.1…F1.3) and
Input Contactor (K1)
AC power bus bars
between Input Contactor
(K1) and LCL Filter (L1)
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
2-4
Active Front End System Overview
AFE in IP21 Rittal Enclosure Main Component Sections
The following figure shows a basic one-line diagram for an AFE system in a
IP21 Rittal enclosure. The main component sections consist of the
following items:
• AC Line Switchgear consisting of the input disconnect (Q0) and
MCCB motor-controlled circuit breaker (Q1)
• LCL Filter (L1)
• Precharge Circuit
• AFE Power Structure (U1) with AFE control assembly
• DC Fuses (F2.1…F2.6)
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
PE
U
DC+
DC-
F2.1
F2.2
PE
V
DC+
DC-
F2.3
F2.4
PE
W
C6
PE
DC+
DC-
F2.5
F2.6
Precharge
Fuses
F6
Motor Protection
Relay
Q5
Precharge
Contactor
Precharge
Circuit
K6
R6.1
+
PowerFlex
Active Front End System
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
-
R6.2
DC Bus
Output
Active Front End System Overview
2-5
Main Component Locations
The following figure shows the main components of the AFE Frame 13
system in a IP21 Rittal enclosure.
Figure 2.5 AFE Frame 13 Main Component Locations in IP21 Rittal Enclosure
FRONT VIEW
(shown with enclosure doors removed)
➐
➌
➋
➍
➎
➏
These components
are located behind this
Control Frame assembly.
➊
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
Motor-controlled Circuit Breaker (Q1)
➎
AC Line
Switchgear
➏
AFE Control Assembly (shown with user-installed HIM
➐
DC Fuses (F2.1…F2.6)
Input Disconnect (Q0)
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Publication 20Y-TG002B-EN-P
2-6
Active Front End System Overview
Bus Bar Locations
There are several sets of bus bars in the AFE Frame 13 system that connect
main system components:
•
•
•
•
Bus bars between Input Disconnect (Q0) and MCCB (Q1)
Bus bars between MCCB (Q1) and the LCL Filter (L1)
Bus bars between the LCL Filter (L1) and AFE Power Structure (U1)
Bus bars between the AFE Power Structure (U1) and DC Bus Bars
The following figure shows these bus bar locations.
Figure 2.6 AFE Frame 13 Bus Bar Locations in IP21 Rittal Enclosure
FRONT VIEW
(shown with enclosure doors removed)
DC+ bus bar
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)
DC- bus bar
DC bus bars between
AFE Power Structure (U1)
and DC fuses
AC bus bars between
Main Disconnect (Q0)
and Motor-Controlled
Circuit Breaker (Q1)
AC Input
bus bars
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
2-7
Active Front End System Overview
AFE in IP00 Open Chassis
Configuration
The following figure shows a basic one-line diagram for an AFE system in a
IP00, NEMA/UL Open Chassis configuration and the parts the customer
must supply.
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
PE
U
DC+
DC-
DC
Fuses
F2.1
F2.2
PE
V
DC+
DC-
DC Bus
Output
F2.3
F2.4
PE
W
C6
PE
DC+
DC-
F2.5
F2.6
Precharge
Fuses
F5
Precharge
Contactor
Customersupplied
Parts
Precharge
Circuit
K6
R6.1
+
PowerFlex
Active Front End System
Customer-supplied Parts
-
Customer-supplied enclosure
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
2-8
Active Front End System Overview
Notes:
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Chapter
3
Component Test Procedures
!
ATTENTION: The sheet metal cover and mounting screws on
the ASIC Board located on the power structure are energized at
(-) DC bus potential high voltage. Risk of electrical shock, injury,
or death exists if someone comes into contact with the assembly.
!
ATTENTION: To avoid an electric shock hazard, verify that all
power to the PowerFlex Active Front End has been removed
before performing any servicing or repairs.
!
ATTENTION: To avoid an electric shock hazard, verify that the
voltage on the bus capacitors has discharged completely before
servicing. Check the DC bus voltage between the +DC and -DC
terminals, between the +DC terminal and the chassis, and
between the -DC terminal and the chassis. The voltage must be
zero for all three measurements.
!
ATTENTION: Hot surfaces can cause severe burns. Do not
touch the heatsink surface during operation of the PowerFlex
Active Front End. After disconnecting power allow time for
cooling.
!
ATTENTION: Hazard of permanent eye damage exists when
using optical transmission equipment. This product emits intense
light and invisible radiation. Do not look into fiber optic ports or
fiber optic cable connectors.
!
ATTENTION: The PowerFlex Active Front End contains
electrostatic discharge (ESD) sensitive parts and assemblies that
can be damaged if you do not follow ESD control procedures.
Static control precautions are required to install, test, service, or
repair this assembly. If you are unfamiliar with static control
procedures, see Guarding Against Electrostatic Damage,
publication 8000-4.5.2, or any other applicable ESD protection
handbook.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-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
Lights when power is applied to the AFE.
➋
PORT (1)
MOD
(1)
NET A (1)
NET B
(1)
Performing Visual
Inspections
Status of DPI port internal communication (if present).
See to the Communication
Adapter User Manual,
publication 20COMM-UMxxx
(1)
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.
Important: Always remove power from the Active Front End before
performing visual inspections. See Removing Power from the
AFE on page 4-3.
Inspecting the Cooling Tunnels
1. Remove the main cooling fans from the bottom of the power structure.
For details, see the PowerFlex 700S, 700H, and 700AFE Drive Fan
Systems Installation Instructions, publication PFLEX-IN029.
2. Inspect the tunnels.
Clean the heatsinks and tunnels if necessary.
Inspecting the Power Structure
1. Remove the protective barriers.
See Removing AFE Protective Barriers on page 4-10.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Component Test Procedures
3-3
2. Remove the protective front covers and terminal covers from the power
structure for each phase (U, V, and W).
See Removing Protective Covers from the Power Structure on
page 4-13.
3. Check components for burn marks, breakage, or foil delamination on
circuit boards.
Check all the boards on the power structure.
Replace any of these components if they show evidence of burn marks,
breakage, or foil delamination.
A forward biased diode test checks the semiconductor junctions between
Performing Forward and
Reverse Biased Diode Tests the terminals and measures the voltage drop across those junctions. To pass
each test, the meter must display a voltage near 0.5V. If the test finds a
for Power Structure
short, the meter displays ‘.000’. If the test finds an open circuit or reversed
polarity, the meter displays ‘.0L’ (zero load).
Important: The actual voltage readings can vary depending upon your
equipment. If your readings are not near the indicated values in
the following tables, verify that the actual voltage measured is
consistent for the Power module.
A reverse biased diode test finds an open circuit, and the meter displays
‘.0L’ (zero load).
-
+
~.0L
~0.5V
-
+
Forward biased test
on PN-junction
Reverse biased test
on PN-junction
1. Remove power from the AFE.
See Removing Power from the AFE on page 4-3.
2. Remove the protective barriers.
See Removing AFE Protective Barriers on page 4-10.
3. Disconnect any drives connected to the DC bus from the DC bus, or
remove the DC bus fuses from the AFE.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
3-4
Component Test Procedures
4. Conduct forward and reverse biased diode tests on the power structure.
Figure 3.1 Measurement Points for Forward and Reverse Diode Tests
Front View
(AFE in IP20 2500 MCC Style Enclosure shown with doors removed)
Front View
(AFE in IP21 Rittal Enclosure shown with doors removed)
➊
➊
➋
➋
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)
Location
(see above)
Nominal meter reading
➊
Value should gradually rise to about 0.5V (1)
➋
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.
Table 3.C Reverse Biased Diode Tests on Power Structure
Meter Leads
+
U/T1
-
Location
(see above)
Nominal meter reading
DC-
V/T2
DC-
W/T3
DC-
DC+
U/T1
DC+
V/T2
DC+
W/T3
➊
Meter should display ‘.0L’ (zero load)
➋
If the AFE fails any of these measurements, replace all Power Modules
for each line phase in the power structure, or the complete power
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Component Test Procedures
3-5
structure using any of the following options:
– Contact your local representative to schedule On-site Services.
– Contact your local representative to make arrangements to return the
power structure to the factory for repair by Remanufacturing
Services.
– For an AFE not covered under factory warranty, a customer has the
option of repairing the power structure using procedures described in
this manual.
Checking Fiber Optic
Connections
Damaged or improperly connected fiber optic cables can cause apparent
Gate Driver board malfunctions. For fiber optic cable connections, see
page C-1, page C-2, and page C-3.
1. Remove power from the AFE.
See Removing Power from the AFE on page 4-3.
2. If present, remove the protective barriers.
See Removing AFE Protective Barriers on page 4-10.
3. Remove the protective front covers and terminal covers from the power
structure.
See Removing Protective Covers from the Power Structure on
page 4-13.
4. Locate the three Gate Driver boards on the front of the power structure
(right-side AFE enclosure).
Gate Driver Boards
ASIC Board
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
3-6
Component Test Procedures
5. Verify that the fiber optic cables are properly connected between the
Gate Driver boards and the ASIC board.
Important:The minimum inside bend radius for fiber-optic cable is
25.4 mm (1 in.). Any bends with a shorter inside radius can
permanently damage the fiber optic cable. Signal
attenuation increases with decreased inside bend radii.
6. Verify that the fiber optic cables are properly connected between the
ASIC board and the Fiber Optic Adapter circuit board.
7. Disconnect the cables and inspect them for scratches and cracks, and
overall integrity.
Important:When mishandled, the ability of fiber optic cables to
transmit data is greatly diminished.
8. Reconnect the cables, replacing any damaged cables.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
3-7
Component Test Procedures
Performing Gate Driver
Board Resistance
Measurements
1. Remove power from the AFE.
See Removing Power from the AFE on page 4-3.
2. If present, remove the protective barriers.
See Removing AFE Protective Barriers on page 4-10.
3. Remove the protective front covers and terminal covers from the power
structure for each phase (U, V, and W).
See Removing Protective Covers from the Power Structure on
page 4-13.
There are three Gate Driver boards on the power structure, one for each
phase (U, V, and W).
4. Measure the power transistor gate interface resistance for each phase
(U, V, and W):
– The resistance from each ignition pin to the branch emitter pin
(connectors X10 and X11) is approximately 166 ohms.
– The resistance from the X10 branch emitter pin to the same branch
power terminal (U/T1, V/T2, and W/T3) is approximately 0.5 ohms.
– The resistance from the X11 branch emitter to the same branch DCbus terminal is approximately 0.5 ohms.
If any of the gate interfaces fails this test, replace the appropriate (left,
middle or right) power module. See Removing the Power Module from
the U, V, or W Phase Assembly on page 4-25.
Approx. 0.5 ohms
DC-
Gate Interface for
U, V or W Low (L)
DC-
DC-
Emitter
Approx.166 ohms
Extinguishing
Ignition
U/T1
V/T2
X12
X9
X11
X8
X10
X7
X11
W/T3
Emitter
Extinguishing
Approx. 166 ohms
H4
H2
Ignition
X10
Gate Interface for
U, V or W High (H)
U/T1
V/T2
Approx. 0.5 ohms
W/T3
Note: Connectors X7 and X8 are connected in
parallel with connectors X10 and X11, respectively,
and therefore do not have to be tested.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
3-8
Component Test Procedures
1. Remove power from the AFE.
Checking the AFE Power
Structure Fan Inverter Fuses
See Removing Power from the AFE on page 4-3.
2. If present, remove the protective barriers.
See Removing AFE Protective Barriers on page 4-10.
3. Remove the protective front covers and terminal covers from the power
structure for each phase (U, V, and W).
See Removing Protective Covers from the Power Structure on
page 4-13.
4. A pair of fuses (F1 and F2) feed DC Bus power to each fan inverter.
a. Locate these fuses (shown below) and remove them.
b. Using a multi-meter, verify that they are not open.
5. Reinstall the good fuses and replace any open fuse with an
equivalent-rated fuse.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Chapter
4
AFE Power Structure Component Section
!
!
ATTENTION: To avoid an electric shock hazard, verify that all
power to the PowerFlex Active Front End has been removed
before performing any servicing or repairs.
ATTENTION: To avoid an electric shock hazard, verify that the
voltage on the bus capacitors has discharged completely before
servicing. Check the DC bus voltage between the +DC and -DC
terminals, between the +DC terminal and the chassis, and
between the -DC terminal and the chassis. The voltage must be
zero for all three measurements.
!
ATTENTION: The sheet metal cover and mounting screws on
the ASIC Board located on the power structure are energized at
(-) DC bus potential high voltage. Risk of electrical shock, injury,
or death exists if someone comes into contact with the assembly.
!
ATTENTION: Hot surfaces can cause severe burns. Do not
touch the heatsink surface during operation of the PowerFlex
Active Front End. After disconnecting power allow time for
cooling.
!
ATTENTION: Hazard of permanent eye damage exists when
using optical transmission equipment. This product emits intense
light and invisible radiation. Do not look into fiber optic ports or
fiber optic cable connectors.
!
ATTENTION: The PowerFlex Active Front End contains
electrostatic discharge (ESD) sensitive parts and assemblies that
can be damaged if you do not follow ESD control procedures.
Static control precautions are required to install, test, service, or
repair this assembly. If you are unfamiliar with static control
procedures, see Guarding Against Electrostatic Damage,
publication 8000-4.5.2, or any other applicable ESD protection
handbook.
Use the instructions in this chapter to remove and install components from
the Active Front End. To remove and install components on the power
structure and to remove a Power Module from the power structure, see
Power Structure Access Procedures on page 4-10.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
4-2
AFE Power Structure Component Section
Understanding Torque
Figures in Assembly
Diagrams
Icons and numbers in the assembly diagrams indicate how to tighten
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
The following table lists fastener torque specifications for the circuit boards
and main components of the Active Front End.
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
LCL Filter Upper
In IP20 Encl.
Front Bracket
In IP21 Encl.
Power Structure Input
In IP20 Encl.
Terminals (U, V, W)
In IP21 Encl.
Power Structure Block (Mounting)
Power Structure DC Bus In IP20 Encl.
Terminals
In IP21 Encl.
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
M10 x 40 bolt
M8 x 20 bolt
M10 x 12 hexagonal screw
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)
37.9 N•m (336 lb•in)
20 N•m (177 lb•in)
20 N•m (177 lb•in)
M6 x 16 POZIDRIV
M5 x 10 POZIDRIV
M5 x 16 POZIDRIV
3 N•m (27 lb•in)
3 N•m (27 lb•in)
POZIDRIV® is a registered trademark of the Phillips Screw Company.
Phillips® is a registered trademark of Phillips Screw Company.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
AFE Power Structure Component Section
Removing Power from the
AFE
!
4-3
ATTENTION: To avoid an electric shock hazard, verify that the
voltage on the bus capacitors has discharged completely before
servicing. Check the DC bus voltage between the +DC and -DC
terminals, between the +DC terminal and the chassis, and
between the -DC terminal and the chassis. The voltage must be
zero for all three measurements.
Remove power before making or breaking cable connections.
When you remove or insert a cable connector with power
applied, an electrical arc can occur. An electrical arc can cause
personal injury or property damage by the following:
• Sending an erroneous signal to your system’s field devices,
causing unintended machine motion.
• Causing an explosion in a hazardous environment.
Electrical arcing causes excessive wear to contacts on both the
module and its mating connector. Worn contacts can create
electrical resistance.
1. Turn off and lock out input power.
L1
L2
L3
I
O
2. Wait five minutes.
3. Verify that there is no voltage at the AFE input power terminals.
4. Check the DC bus voltage between the +DC and -DC terminals,
between the +DC terminal and the chassis, and between the -DC
terminal and the chassis.
The voltage must be zero for all three measurements before proceeding.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
4-4
AFE Power Structure Component Section
Control Frame Access
Procedures
Removing the DPI Interface Assembly
1. Remove power from the AFE.
See Removing Power from the AFE on page 4-3.
Important: Before removing connections and wires, mark them to
avoid incorrect wiring during assembly.
2. For an AFE in a IP20 2500 MCC Style enclosure, disregard this step.
For an AFE in a IP21 Rittal enclosure, locate the control assembly (item
6 in Figure 2.5), and remove the two screws from the front of the DPI
hinged assembly.
For AFE in IP20 2500
MCC Style Enclosure
For AFE in IP21
Rittal Enclosure
Remove
screws
P1
0.9 N•m
(8 lb•in)
3. For an AFE in a IP20 2500 MCC Style enclosure, open the control box
door to access the DPI interface board.
For an AFE in a IP21 Rittal enclosure, open the hinged assembly that
holds the DPI interface board.
4. Unplug the DPI cable from the X2 connector on the DPI 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
5. Remove the four screws and the assembly from the Control Frame.
For AFE in IP20 2500
MCC Style Enclosure
Mounting screws
P1
0.9 N•m
(8 lb•in)
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-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
Install the DPI interface assembly in the reverse order of removal, while
referring to Torque Specifications on page 4-2.
Removing the I/O Circuit Boards and Control Box
1. Remove power from the AFE.
See Removing Power from the AFE on page 4-3.
2. For an AFE in a IP20 2500 MCC Style enclosure, open the control box
and carefully unplug the DPI cable and any I/O cables.
For an AFE in a IP21 Rittal enclosure, open the enclosure that contains
the control and I/O circuit boards and carefully unplug the DPI cable
and any I/O cables.
3. Remove the I/O boards from the Control board and enclosure.
Note the order of the boards and the keys which prevent placement of
boards in incorrect slots.
NOTE: Do not remove the
enclosure cover from the Control
Frame. For clarity, the enclosure
is shown without the cover.
Keys
4. Unplug the serial connection from X7 of the Control board.
X6 (Slot E)
X5 (Slot D)
X4 (Slot C)
X2
(Slot A)
X3 (Slot B)
X7
Serial Port
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
4-6
AFE Power Structure Component Section
5. To remove the Control box, remove the three screws that secure it to the
Control Frame.
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 Box
Install the control box and I/O circuit boards in reverse order of removal,
while referring to Torque Specifications on page 4-2.
Removing the Fiber Optic Adapter Circuit Board
1. Remove power from the AFE.
See Removing Power from the AFE on page 4-3.
2. For an AFE in a IP20 2500 MCC Style enclosure, open the control box
on the enclosure door to access the Control assembly.
For an AFE in a IP21 Rittal enclosure, see the following drawing and do
perform these substeps:
Loosen T8
Torx-head
screws
a. Open the enclosure door to access the Control Frame.
b. Loosen the T8 screws to open the Control Frame.
c. Swing open the Control Frame, which exposes the back of the
Control box to access the fiber optic adapter board.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
AFE Power Structure Component Section
4-7
3. Disconnect the cables from X2 and X3 of the Fiber Optic Adapter
board.
Important: Note polarity when removing X2 and X3 wires. If polarity
is not maintained when re-installing these wires, the ASIC
board or fiber optic board can be damaged.
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
4. Carefully disconnect the fiber optic cables from the right side of the
circuit board, and carefully set them aside.
Important: When mishandled, the ability of fiber optic cables to
transmit data is greatly diminished.
!
ATTENTION: Hazard of permanent eye damage exists when
using optical transmission equipment. This product emits intense
light and invisible radiation. Do not look into fiber optic ports or
fiber optic cable connectors.
Important: The minimum inside bend radius for fiber-optic cable is
25.4 mm (1 in.). Any bends with a shorter inside radius can
permanently damage the fiber optic cable. Signal
attenuation increases with decreased inside bend radii.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
4-8
AFE Power Structure Component Section
5. Remove the four screws that secure the Fiber Optic Adapter board to
the stand-offs on the back of the Control box (IP20) or Control Frame
(IP21) and remove the Fiber Optic Adapter board.
For AFE in IP20 2500
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
Install the Fiber Optic Adapter circuit board in reverse order of removal,
while referring to Torque Specifications on page 4-2.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
AFE Power Structure Component Section
4-9
Removing the Control Frame (only for AFE in IP21 Rittal enclosure)
1. Remove power from the AFE.
See Removing Power from the AFE on page 4-3.
X50
terminal block
2. Loosen the T8 Torx-head screws, which secure the Control Frame to the
AFE enclosure.
3. Swing the Control Frame out and away from the power structure.
4. Lift the Control Frame from the hinges and remove it.
Loosen T8
Torx-head
screws
Replacing the Control Frame
Replace the control frame in reverse order of removal, while referring to
Torque Specifications on page 4-2.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
4-10
AFE Power Structure Component Section
Power Structure Access
Procedures
Follow these instructions to remove and install components on the power
structure, and to remove Power Modules from the power structure.
Important: To access Power Modules for replacement requires the power
structure to be completely removed from the AFE enclosure.
Removing AFE Protective Barriers
1. Remove power from the AFE.
See Removing Power from the AFE on page 4-3.
2. Remove the screws that secure the protective barriers to the AFE
enclosure.
3. Remove the protective barriers.
Removing Protective Barriers for
AFE in IP20 2500 MCC Style Enclosure
Remove
screws
Remove
screws
Remove
screws
Remove
screws
Remove
screws
Remove
screws
Enclosure Bay for
Input Switchgear
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Enclosure Bay for
LCL Filter
Enclosure Bay for
AFE Power Structure
AFE Power Structure Component Section
4-11
Removing Protective Barriers for
AFE in IP21 Rittal Enclosure
Remove
screws
Remove
screws
Remove
screws
Remove
screws
Installing AFE Protective Barriers
Install the protective barriers in reverse order of removal.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
4-12
AFE Power Structure Component Section
Removing the AFE Air Flow Plate
You must remove the Air Flow Plate to remove the power structure from the
AFE.
1. Remove power from the AFE.
See Removing Power from the AFE on page 4-3.
2. If present, remove the protective barriers.
See Removing AFE Protective Barriers on page 4-10.
3. For an AFE in a IP20 2500 MCC Style enclosure, remove the four
M6 x 16 screws that secure the Air Flow Plate to the AFE, and remove
the two M6 x 16 screws that secure the Air Flow Plate to the LCL filter.
For an AFE in a IP21 Rittal enclosure, remove the four T8 Torx-head
screws that secure the Air Flow Plate to the AFE.
4. Slide the Air Flow Plate from the AFE.
Removing Air Flow Plate for
AFE in IP20 2500 MCC Style Enclosure
Removing Air Flow Plate for
AFE in IP21 Rittal Enclosure
Remove
screws
Remove
screws
Installing the AFE Air Flow Plate
Install the Air Flow Plate in reverse order of removal.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Remove
screws
AFE Power Structure Component Section
4-13
Removing Protective Covers from the Power Structure
You must remove the protective covers to access internal components of the
power structure.
1. Remove power from the AFE.
See Removing Power from the AFE on page 4-3.
2. If present, remove the protective barriers.
See Removing AFE Protective Barriers on page 4-10.
3. Remove the four M5 POZIDRIV screws that secure the protective front
covers and terminal covers to the power structure.
4. Remove the covers.
NOTE: You need to remove only the terminal covers to gain access to
the cooling fan connections.
Front Covers
Terminal Covers
Installing Protective Covers on the Power Structure
Install the protective covers on the power structure in reverse order of
removal, while referring to Torque Specifications on page 4-2.
Removing the Gate Driver Circuit Boards
There are three Gate Driver circuit boards on the front of the power structure.
1. Remove power from the AFE.
See Removing Power from the AFE on page 4-3.
2. If present, remove the protective barriers.
See Removing AFE Protective Barriers on page 4-10.
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4-14
AFE Power Structure Component Section
3. Remove the Air Flow Plate.
See Removing the AFE Air Flow Plate on page 4-12.
4. Remove the protective front covers and terminal covers from the power
structure.
See Removing Protective Covers from the Power Structure on
page 4-13.
5. Unscrew the terminals for the DC +/- supply from X1 of the first Gate
Driver board.
Observe polarity when removing for later re-attachment.
6. Carefully unplug the fiber optic cables from sockets along the bottom of
the Gate Driver board, and carefully set them aside.
Important: When mishandled, the ability of fiber optic cables to
transmit data is greatly diminished.
!
ATTENTION: Hazard of permanent eye damage exists when
using optical transmission equipment. This product emits intense
light and invisible radiation. Do not look into fiber optic ports or
fiber optic cable connectors.
Important: The minimum inside bend radius for fiber optic cable is
25.4 mm (1 in.). Any bends with a shorter inside radius can
permanently damage the fiber optic cable. Signal
attenuation increases with decreased inside bend radii.
7. Disconnect the X13, X14, and X15 cables from sockets of the Gate
Driver board, and set them aside.
8. Remove the five screws that secure the Gate Driver board and support
bracket to the power structure.
Remove screws
Remove Gate Driver circuit
board support bracket
Remove screws
9. Carefully remove the Gate Driver board and the board support bracket.
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Publication 20Y-TG002B-EN-P
AFE Power Structure Component Section
4-15
10. Carefully remove the two plastic screws that secure the Gate Driver
board screening plate to the power structure and remove the screening
plate.
11. Remove the two stand-offs that support the Gate Driver board.
Remove plastic screws
Remove screening plate
Remove stand-offs
12. Repeat steps 5 through 11 for each of the remaining Gate Driver boards.
Installing the Gate Driver Circuit Boards
Install the Gate Driver circuit boards in the reverse order of removal.
Removing the ASIC Circuit Board
1. Remove power from the AFE.
See Removing Power from the AFE on page 4-3.
2. If present, remove the protective barriers.
See Removing AFE Protective Barriers on page 4-10.
3. Remove the Air Flow Plate.
See Removing the AFE Air Flow Plate on page 4-12.
4. Remove the protective front covers and terminal covers from the power
structure.
See Removing Protective Covers from the Power Structure on
page 4-13.
!
ATTENTION: The sheet metal cover and mounting screws on
the ASIC circuit board located on the power structure are
energized at (-) DC bus potential high voltage. Risk of electrical
shock, injury, or death exists if someone comes into contact with
the assembly.
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Publication 20Y-TG002B-EN-P
4-16
AFE Power Structure Component Section
5. Remove the four screws that secure the ASIC cover to the ASIC
assembly, remove the -DC bus connection from the ACSIC cover, and
remove the ASIC cover.
ASIC
assembly
Remove screws
and cover
ASIC cover
Remove -DC bus connection
6. Unplug the fan, which mounts on the cover, from connector X11 of the
ASIC circuit board.
7. Carefully unplug the fiber optic cables H1 through H7 from sockets on
the ASIC board, and carefully set them aside.
Important: When mishandled, the ability of fiber optic cables to
transmit data is greatly diminished.
!
ATTENTION: Hazard of permanent eye damage exists when
using optical transmission equipment. This product emits intense
light and invisible radiation. Do not look into fiber optic ports or
fiber optic cable connectors.
Important: The minimum inside bend radius for fiber optic cable is
25.4 mm (1 in.). Any bends with a shorter inside radius can
permanently damage the fiber optic cable. Signal
attenuation increases with decreased inside bend radii.
8. Disconnect the X9 terminal block and the X15 terminal connectors.
Note: When replacing the existing ASIC board with a new board, the
X9 and X15 connectors must be transferred and connected to the new
board before installation.
9. Disconnect the X3, X4, X5, X6, and X10 cables from sockets on the
front of the ASIC board, and set them aside.
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AFE Power Structure Component Section
4-17
10. Remove the four screws that secure the ASIC assembly to the power
structure and remove the ASIC assembly.
Remove screws
Remove ASIC assembly
Removes screws
11. Remove the screw and detach the four plastic standoffs that secure the
ASIC board to the ASIC chassis, and remove the ASIC board.
Remove screw
Remove ASIC circuit board from chassis
If the plastic insulator requires replacement, do the following:
a. Remove the four screws that secure the board holder to the metal
frame, and remove the metal frame and insulator.
Remove screws
Remove metal frame and insulator
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Publication 20Y-TG002B-EN-P
4-18
AFE Power Structure Component Section
b. Carefully remove the four fasteners that secure the insulator to the
metal frame, and remove the insulator.
Remove insulator
Remove fasteners
c. Replace the insulator.
Installing the ASIC Circuit Board
Install the ASIC circuit board in reverse order of removal, while referring to
Torque Specifications on page 4-2. Reconnect cables and jumpers to the
ASIC board, while referring to Figure B.1 on page B-1.
!
ATTENTION: The sheet metal cover and mounting screws on
the ASIC circuit board located on the power structure are
energized at (-) DC bus potential high voltage. Risk of electrical
shock, injury, or death exists if someone comes into contact with
the assembly. Verify that the -DC bus wire is properly connected
to the ASIC chassis cover.
Removing and Installing the Power Structure Fan System
There are three Main Cooling Fans on the power structure. For complete
details on all fan system-related information, see the PowerFlex 700S,
700H, and 700AFE Drive Fan Systems Installation Instructions, publication
PFLEX-IN029, including removal and installation of the following items:
•
•
•
•
•
•
AC fan inverters
AC fan capacitors
AC main cooling fans
DC fan power supplies
DC main cooling fans
Fan fusing
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Publication 20Y-TG002B-EN-P
AFE Power Structure Component Section
4-19
Removing the Power Structure from the Enclosure
Important: Power structure removal is required only when it, or its internal
components (Power Module, DC bus capacitors, balancing
resistors, and so forth) needs to be replaced.
1. Remove power from the AFE.
See Removing Power from the AFE on page 4-3.
2. If present, remove the protective barriers.
See Removing AFE Protective Barriers on page 4-10.
3. Remove the Air Flow Plate.
See Removing the AFE Air Flow Plate on page 4-12.
4. Remove the DC+ and DC- wires from the Fan Inverter Fuse assemblies.
5. Disconnect the seven fiber optic cables connected to the fiber optic
adapter board located behind the control assembly (for AFE in IP20
2500 MCC Style enclosure) or the Control Frame (for AFE inIP21
Rittal enclosure).
For location of connections, see Removing the Fiber Optic Adapter
Circuit Board on page 4-6.
6. Depending on the enclosure in which the AFE is installed, follow the
appropriate procedure below to remove the power structure from the
enclosure.
AFE in IP20 2500 MCC Style Enclosure
a. Disassemble the four M10 x 50 bolts and associated hardware that
secure the DC+ and DC- bus bars of the AFE power structure to the
MCC bus.
AFE in IP20 2500 MCC Style Enclosure
(shown with enclosure doors removed)
DC Bus
Connections
M10 x 50
11.3 N•m
(100 lb•in)
U/T1, V/T2, and
W/T3 Connections
M10 x 40
40 N•m
(354 lb•in)
Ground Connections
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4-20
AFE Power Structure Component Section
b. Remove the U/T1, V/T2, and W/T3 connections from the power
structure at the bottom front of the power structure.
c. Remove the ground connections of the power structure from the
enclosure PE terminals.
d. Remove eight M6 x 16 screws that secure the cart assembly to the
enclosure.
Remove screws
Cart Assembly
M6 x 16
4.5 N•m
(40 lb•in)
Remove screws
.
!
ATTENTION: The cart assembly is heavy. To avoid
personal injury or damage to the equipment, use caution when
removing the cart assembly from the enclosure.
e. Roll the cart assembly which contains the power structure outward
from the enclosure.
Note that ramps may be required due to floor mismatch.
When replacing the complete power structure, continue with the
following substeps. When replacing components within an individual
phase assembly, see Removing the U, V, or W Phase Assembly from the
Power Structure on page 4-23.
f.
Secure appropriate lifting cables or chains to the recommended lift
points on the power structure, and tighten the cables or chains.
For details, see Lifting and Mounting the PowerFlex Active Front
End (AFE)—Frames 10 and 13, publication 20Y-IN001.
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Publication 20Y-TG002B-EN-P
AFE Power Structure Component Section
4-21
g. Remove the six hexagonal bolts from the upper portion of the
chassis backside and the six hexagonal bolts from the lower portion
of the chassis backside to detach the power structure from its cart
assembly.
Remove Six Hexagonal
Bolts on Upper Portion
Remove Six Hexagonal
Bolts on Lower Portion
Back of Cart Assembly
h. Remove the six hexagonal screws (three on each lower side) to
detach the power structure from its cart assembly.
Remove screws
(three on each lower
side of power structure)
i.
Remove the six DC output fuses (two per phase) from the power
structure bus bars.
For DC fuse removal instructions, see Fuse Replacement
Guidelines on page 8-2.
j.
Separate the power structure from its cart assembly, and remove the
power structure by using appropriate lifting equipment.
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Publication 20Y-TG002B-EN-P
4-22
AFE Power Structure Component Section
AFE in IP21 Rittal Enclosure
a. Remove the six DC bus fuses from the terminal connections at the
top of the power structure.
DC Bus Fuse
Terminal Connections
AFE in IP21 Rittal Enclosure
(shown with enclosure doors removed)
Front View
U/T1
V/T2
W/T3
Input Power
Terminals
Side View
U/T1, V/T2, and
W/T3 Connections
Ground
Connection
b. Remove the U/T1, V/T2, and W/T3 connections from the power
structure at the front of the power structure.
c. Remove the ground connections of the power structure from the
enclosure PE terminals.
d. Remove the output cable fastening screws, and the two hexagonal
screws that secure the power structure to the AFE frame.
Remove screws
(one each side
of enclosure)
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Publication 20Y-TG002B-EN-P
AFE Power Structure Component Section
4-23
e. Install the Maintenance Stand (catalog number 20-MAINSTD) onto
the power structure rails.
For details, see Installation Instructions - PowerFlex 700S/700H
High Power Maintenance Stand, publication PFLEX-IN014.
!
f.
ATTENTION: The power structure is heavy. To avoid
personal injury or damage to the equipment, use caution when
removing the power structure from the enclosure.
Slide the power structure outward onto the rails of the optional
Maintenance Stand.
Installing the Power Structure in the Enclosure
Install the power structure in reverse order of removal. See the PowerFlex
Active Front End User Manual, publication 20Y-UM001, for tightening
torques of AC supply, DC bus input, and ground connection terminations.
Removing the U, V, or W Phase Assembly from the Power Structure
Important: Do not attempt to disassemble the Power Module within the U,
V, or W Phase Assembly.
1. Remove the power structure from the AFE enclosure.
See Removing the Power Structure from the Enclosure on page 4-19.
2. Remove the ASIC Circuit board.
See Removing the ASIC Circuit Board on page 4-15.
3. Remove the M10 x 25 hexagonal screws that secure the input power
cables to the Input Power terminals on the power structure.
Remove screws
and washers
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Publication 20Y-TG002B-EN-P
4-24
AFE Power Structure Component Section
4. Remove the insulators from between the DC+ and DC- bus bars.
Remove insulators
5. Remove the M6 x 12 screws that secure the Connective DC Bus Bars
and insulators to the Phase Assembly.
DC+ bus bar
Insulator
DC- bus bar
Location
Fasteners
Qty
Torque
1.
M10 x 20 hexagonal screws, M10 spring washers and M10 washers
6
8 N•m (70 lb•in)
2.
M8 x 25 hexagonal screws, M8 spring washers and M8 washers
6
8 N•m (70 lb•in)
3.
M6 x 12 screws
2
4 N•m (35 lb•in)
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Publication 20Y-TG002B-EN-P
AFE Power Structure Component Section
4-25
6. Remove the three M8 x 20 hexagonal screws from the top section of
each Phase Assembly (U, V, or W) that you want to remove.
Note that only two screws are shown for each Phase Assembly in the
top section of the drawing.
Remove
screws
Remove
screws
7. Remove three M8 x 20 hexagonal screws from the bottom section of
each Phase Assembly (U, V, or W) that you want to remove.
Note that only one screw is shown for each Phase Assembly in the
bottom section of the drawing.
8. Disconnect the three input power cables from the lower section of the
Phase Assembly that you want to remove.
9. Remove the Phase Assembly by using appropriate lifting equipment.
Removing the Power Module from the U, V, or W Phase Assembly
Important: Do not attempt to disassemble the Power Module within the U,
V, or W Phase Assembly.
Important: When replacing a damaged Power Module, it is recommended
to replace all three Power Modules to avoid potential failure on
the remaining Power Modules due to residual damage.
The following procedure describes removing the Power Module from one
Phase Assembly. Repeat this procedure for each Phase Assembly.
1. Remove the power structure from the AFE enclosure.
See Removing the Power Structure from the Enclosure on page 4-19.
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Publication 20Y-TG002B-EN-P
4-26
AFE Power Structure Component Section
2. Remove the U, V, or W Phase Assembly from the power structure.
See Removing the U, V, or W Phase Assembly from the Power
Structure on page 4-23.
3. Remove the insulator holding plate from between the bus bar terminals.
4. Remove the M5 POZIDRIV screws that secure the bus bar terminals to
the power structure.
5. Slide the bus bar terminals out of the Phase Assembly.
6. If the bus bar Airflow Channel is damaged, remove and replace it.
Remove screws
PZ2
4 N•m
(35 lb•in)
Remove insulator holding plate
Remove bus bar terminals
Optional - remove airflow
channel (only if damaged)
7. Remove the M8 x 20 hexagonal screws that secure the input power
cables to the input power bus bar.
Tightening torque for reassembly is 14 N•m (124 lb•in).
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Publication 20Y-TG002B-EN-P
AFE Power Structure Component Section
4-27
8. Cut and remove the cable ties that secure the input power cables to the
EMC cover plate and remove the cables.
Remove screws and
output power cables
Cut cable ties
9. Remove the M5 x 10 POZIDRIV and M4 x 8 POZIDRIV screws that
secure the EMC cover to the AFE, and remove the cover.
10. Remove the screws that secure the Snubber Capacitors to the U, V, or W
Phase Assembly, and remove the Snubber Capacitors.
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)
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Publication 20Y-TG002B-EN-P
4-28
AFE Power Structure Component Section
11. Remove the screws that secure the Power Bus Bar and support
insulators to the power structure.
12. Remove the Power Bus Bar and insulators.
Tightening torque for reassembly is 14 N•m (124 lb•in).
Support insulator
Remove screws
13. Disconnect the Balancing Resistor wires from the DC bus bars.
Older Style Balancing Resistors
P2
4 N•m
(35 lb•in)
PZ2
3 N•m
(27 lb•in)
Balancing resistor assembly screws
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Remove wire
connections from
DC bus bar end
Newer Style Balancing Resistors
P2
4 N•m
(35 lb•in)
PZ2
3 N•m
(27 lb•in)
Balancing resistor assembly screws
AFE Power Structure Component Section
4-29
14. Remove the screws that secure the Balancing Resistor assemblies to the
U, V, or W Phase Assembly.
Remove screws
15. Remove the Balancing Resistor assemblies (see step 13 picture for
screw locations).
16. Remove the Connective DC Bus Bars and insulators.
Tightening torque for reassembly is 4 N•m (35 lb•in).
Bus bars (only
1 for 480V unit)
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
Input Power
Module shown
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Publication 20Y-TG002B-EN-P
4-30
AFE Power Structure Component Section
17. Remove the M4 x 8 screws that secure the Power Module to the U, V, or
W Phase Assembly.
18. Remove the Power Module.
Remove screws
Remove screws
19. Repeat steps 10 through 18 for each remaining Phase Assembly.
Installing the Power Module on the U, V, or W Phase Assembly
Install the Power Module in reverse order of removal, while referring to
Torque Specifications on page 4-2.
Removing the U, V, or W Phase Assembly DC Bus Capacitors
1. Remove the power structure from the AFE enclosure.
See Removing the Power Structure from the Enclosure on page 4-19.
2. Remove the U, V, or W Phase Assembly from the AFE.
See Removing the U, V, or W Phase Assembly from the Power
Structure on page 4-23.
3. Remove the power module from the U, V, or W Phase Assembly—but
do not perform the last three steps (20 through 22) in that procedure.
See Removing the Power Module from the U, V, or W Phase
Assembly on page 4-25.
4. Note the polarity of the capacitors.
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Publication 20Y-TG002B-EN-P
AFE Power Structure Component Section
4-31
5. Remove the four M4 x 8 screws that secure the capacitor to the power
structure.
Remove screws
Remove screws
6. Remove the capacitor.
Tightening torque for reassembly is 1.35 N•m (12 lb•in). We
recommend replacing all capacitors at the same time.
7. Repeat steps 5 and 6 for each remaining DC Bus Capacitor being
removed.
Installing the U, V, or W Phase Assembly DC Bus Capacitors
Install the capacitors in reverse order of removal. Make sure to observe the
polarity of the capacitors as noted in removal step 4 above.
Replacing the Existing Power Structure with a New Power Structure
When replacing the existing AFE Frame 13 power structure with a new one
(SK-Y1-PWRMOD-D1K3 for 400/480V or SK-Y1-PWRMOD-E1K0 for
600/690V), you must do the following before installing the new power
structure to avoid possible equipment malfunction:
• Remove the common mode capacitors in the new power structure.
• Remove the Power Supply Voltage Feedback board from the new power
structure.
Use the following procedure.
1. Remove the old power structure from the enclosure.
See Removing the Power Structure from the Enclosure on page 4-19.
2. Remove the common mode capacitors from the new Frame 13 power
structure that is replacing the old power structure.
For the procedure to remove the common mode capacitors, see the
PowerFlex Active Front End User Manual, publication 20Y-UM001.
Refer to Chapter 2, section ‘Disconnecting Common Mode Capacitors’,
and subsection ‘Frame 13 Power Structure’. These instructions apply to
an AFE in a IP20 2500MCC Style enclosure or an AFE in a IP21 Rittal
enclosure.
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Publication 20Y-TG002B-EN-P
4-32
AFE Power Structure Component Section
3. Use the following substeps to remove the Power Supply Voltage
Feedback board from the new Frame 13 power structure that is
replacing the old power structure.
a. Disconnect the DC bus connection cable from connector J2, and the
motor feedback connection cable from connector J1 at the top of the
Power Supply Voltage Feedback board.
Disconnect:
J2
J1
J8 (located
behind cover)
J4
J5
b. Carefully disconnect the fiber optic cables from sockets J4 and J5
on the side of the Power Supply Voltage Feedback board, and
secure these unused cables to the adjacent fan housing so that they
are out of the way.
!
ATTENTION: Hazard of permanent eye damage exists when
using optical transmission equipment. This product emits intense
light and invisible radiation. Do not look into fiber optic ports or
fiber optic cable connectors.
c. Remove the four screws that secure the Power Supply Voltage
Feedback board and cover to the V phase assembly module fan
housing.
d. Carefully remove the Power Supply Voltage Feedback board and
cover.
e. Disconnect the cable from connector J8 on the Power Supply
Voltage Feedback board, and secure this unused cable to the
adjacent fan housing so that it is out of the way.
4. Install the new (replacement) power structure.
See Installing the Power Structure in the Enclosure on page 4-23.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Chapter
5
AC Line Switchgear Component Section
!
!
ATTENTION: To avoid an electric shock hazard, verify that all
power to the PowerFlex Active Front End has been removed
before performing any servicing or repairs.
ATTENTION: To avoid an electric shock hazard, verify that the
voltage on the bus capacitors has discharged completely before
servicing. Check the DC bus voltage between the +DC and -DC
terminals, between the +DC terminal and the chassis, and
between the -DC terminal and the chassis. The voltage must be
zero for all three measurements.
!
ATTENTION: The sheet metal cover and mounting screws on
the ASIC Board located on the power structure are energized at
(-) DC bus potential high voltage. Risk of electrical shock, injury,
or death exists if someone comes into contact with the assembly.
!
ATTENTION: Hot surfaces can cause severe burns. Do not
touch the heatsink surface during operation of the PowerFlex
Active Front End. After disconnecting power allow time for
cooling.
!
ATTENTION: Hazard of permanent eye damage exists when
using optical transmission equipment. This product emits intense
light and invisible radiation. Do not look into fiber optic ports or
fiber optic cable connectors.
!
ATTENTION: The PowerFlex Active Front End contains
electrostatic discharge (ESD) sensitive parts and assemblies that
can be damaged if you do not follow ESD control procedures.
Static control precautions are required to install, test, service, or
repair this assembly. If you are unfamiliar with static control
procedures, see Guarding Against Electrostatic Damage,
publication 8000-4.5.2, or any other applicable ESD protection
handbook.
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Publication 20Y-TG002B-EN-P
5-2
AC Line Switchgear Component Section
AFE in IP20 2500 MCC Style For a PowerFlex AFE system in the IP20 2500 MCC Style enclosure, the
AC line switchgear components are the input circuit breaker (Q0), AC input
Enclosure
fuses (F1.1…F1.3), and input contactor (K1).
The input circuit breaker either connects or disconnects the AFE system to
the AC line. The input contactor connects the internal AFE system AC line
to the AFE power structure through the LCL filter. The AFE power
structure contains the control logic that opens or closes the input contactor.
See the PowerFlex Active Front End User Manual, publication
20Y-UM001, for the AC input fusing and circuit breaker protection
recommendations.
AFE in IP21 Rittal Enclosure For a PowerFlex AFE system in the IP21 Rittal enclosure, the AC line
switchgear components are the input disconnect (Q0) and MCCB (Q1).
The input disconnect either connects or disconnects the AFE system to the
AC line. The MCCB connects the internal AFE system AC line to the AFE
power structure through the LCL filter. The AFE power structure contains
the control logic that enables or disables the resettable trip mechanism that
is integrated into the MCCB. The trip mechanism controls the MCCB
functionality.
See the PowerFlex Active Front End User Manual, publication
20Y-UM001, for the AC input fusing and MCCB protection
recommendations.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Chapter
6
Precharge Component Section
!
!
ATTENTION: To avoid an electric shock hazard, verify that all
power to the PowerFlex Active Front End has been removed
before performing any servicing or repairs.
ATTENTION: To avoid an electric shock hazard, verify that the
voltage on the bus capacitors has discharged completely before
servicing. Check the DC bus voltage between the +DC and -DC
terminals, between the +DC terminal and the chassis, and
between the -DC terminal and the chassis. The voltage must be
zero for all three measurements.
!
ATTENTION: The sheet metal cover and mounting screws on
the ASIC Board located on the power structure are energized at
(-) DC bus potential high voltage. Risk of electrical shock, injury,
or death exists if someone comes into contact with the assembly.
!
ATTENTION: Hot surfaces can cause severe burns. Do not
touch the heatsink surface during operation of the PowerFlex
Active Front End. After disconnecting power allow time for
cooling.
!
ATTENTION: Hazard of permanent eye damage exists when
using optical transmission equipment. This product emits intense
light and invisible radiation. Do not look into fiber optic ports or
fiber optic cable connectors.
!
ATTENTION: The PowerFlex Active Front End contains
electrostatic discharge (ESD) sensitive parts and assemblies that
can be damaged if you do not follow ESD control procedures.
Static control precautions are required to install, test, service, or
repair this assembly. If you are unfamiliar with static control
procedures, see Guarding Against Electrostatic Damage,
publication 8000-4.5.2, or any other applicable ESD protection
handbook.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
6-2
Precharge Component Section
Precharging Functions
The precharge circuitry has two main functions:
• It provides AFE system enclosure control power.
• It provides the precharge circuitry to charge the DC bus.
The AFE system is available in both 400/480V AC and 600/690V AC
system voltage configurations. Control logic voltages are as follows:
• For an AFE in a IP20 2500 MCC Style enclosure, it is 120V AC single
phase and also 24V DC power.
• For an AFE in a IP21 Rittal enclosure, it is 230V AC single phase and
also 24V DC power.
The precharge circuitry lets the DC capacitors, located in the AFE power
structure, to be properly charged with in-line current limiting resistors to
DC bus voltage magnitudes.
See the PowerFlex Active Front End User Manual, publication
20Y-UM001, for the minimum and maximum system capacitance
requirements.
Replacing the Precharge
Fuse
The precharge fuse assembly for an AFE in a IP20 enclosure is located in
the Input Power enclosure. For an AFE in a IP21 enclosure, the precharge
fuse assembly is located in the Power Structure enclosure.
1. Remove power from the AFE.
See Removing Power from the AFE on page 4-3.
2. Open the appropriate enclosure door.
3. If present, remove the protective barriers.
See Removing AFE Protective Barriers on page 4-10.
4. Slide the fuse sleeve out from the fuse holder.
5. Remove the fuse from the sleeve and appropriately discard the old fuse.
6. See the appropriate table below for the recommended new replacement
fuse, and install the fuse in reverse order of removal.
Table 6.A 400/480 Volt Precharge Fuse Rating
Frame
Size
Enclosure Style
13
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
IP20 2500 MCC
IP21 Rittal
Fuse Holder (3)
Fuse
Amps
50
32
Type
Type
Bussmann DFJ-50
(1)
Bussmann CH60J3
ABB OFAF000H32
(2)
ABB O540D12000
(1)
Precharge fuse designation is F5 for AFE in IP20 2500 MCC style enclosure.
(2)
Precharge fuse designation is F6 for AFE in IP 21 Rittal enclosure.
(3)
Precharge fuse holder holds a quantity of three fuses.
Precharge Component Section
6-3
Table 6.B 600/690 Volt Precharge Fuse Rating
Frame
Size
Enclosure Style
13
Testing the Control
Transformer (T4) and 24V
DC Power Supply (T10)
IP20 2500 MCC
IP21 Rittal
Fuse Holder (3)
Fuse
Amps
Type
50
Bussmann DFJ-50 (1)
32
Type
ABB OFAA000GG32
Bussmann CH60J3
(2)
ABB O540D12000
(1)
Precharge fuse designation is F5 for AFE in IP20 2500 MCC style enclosure.
(2)
Precharge fuse designation is F6 for AFE in IP 21 Rittal enclosure.
(3)
Fuse holder holds a quantity of three fuses.
For AFE in IP20 2500 MCC Style Enclosure
1. If present, remove the protective barriers.
See Removing AFE Protective Barriers on page 4-10.
!
ATTENTION: These tests must be performed by qualified
personnel. During these tests, the AFE is powered. Take proper
precautions to avoid injury from electrical shock.
2. Locate the control transformer (T4) and 24V DC power supply (T10).
The control transformer (T4) is located at the bottom of the left-most
enclosure (AC input switchgear). The 24V DC power supply (T10) is
located in the bottom of the control box.
FRONT VIEW
(shown with enclosure doors removed)
Control Box
(located on front of enclosure door;
shown with control box cover removed)
24V DC Power Supply (T10)
Control
Transformer
(T4)
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
6-4
Precharge Component Section
3. Use a digital voltmeter to test the control transformer (T4).
a. Measure the primary AC line voltage, which is at the 400…480V
AC or 600…690V AC system voltage.
b. Measure the control transformer (T4) output voltage, which is
approximately 120V AC.
If these measurements are not within ±10%, perform these other steps.
c. Power down the AFE.
d. Remove the output (secondary) wires.
e. Power up the AFE and retest by repeating steps a and b.
The control transformer (T4) may require replacement if these
measurements continue to be outside of the ±10% tolerance.
4. Use a digital voltmeter to test the 24V DC power supply (T10).
a. Measure the primary voltage, which is 120V AC.
b. Measure the power supply (T10) output voltage, which is
approximately 24V DC.
If these measurements are not within ±10%, perform these other steps.
c. Power down the AFE.
d. Remove the 24V DC output wires of the power supply (T10).
e. Power up the AFE and retest by repeating steps a and b.
The 24V DC power supply (T10) may require replacement if these
measurements continue to be outside of the ±10% tolerance.
For AFE in IP21 Rittal Enclosure
1. If present, remove the protective barriers.
See Removing AFE Protective Barriers on page 4-10.
!
ATTENTION: These tests must be performed by qualified
personnel. During these tests, the AFE is powered. Take proper
precautions to avoid injury from electrical shock.
2. Locate the control transformer (T4) and 24V DC power supply (T10).
The control transformer (T4) is located behind the Control Frame. The
24V DC power supply (T10) is located on a sub-panel in front of the
components shown in the front view.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Precharge Component Section
6-5
FRONT VIEW
(shown with enclosure doors removed)
Control Transformer (T4)
is mounted directly
behind Control Frame
assembly
24V DC Power Supply (T10) is
mounted on this DIN rail which is
on a sub-panel mounted behind
the Control Frame assembly
3. Use a digital voltmeter to test the control transformer (T4).
a. Measure the primary AC line voltage, which is at the 400…480V
AC or 600…690V AC system voltage.
b. Measure the control transformer (T4) output voltage, which is
approximately 230V AC.
If these measurements are not within ±10%, perform these other steps.
c. Power down the AFE.
d. Remove the output (secondary) wires.
e. Power up the AFE and retest by repeating steps a and b.
The control transformer (T4) may require replacement if these
measurements continue to be outside of the ±10% tolerance.
4. Use a digital voltmeter to test the 24V DC power supply (T10).
a. Measure the primary voltage, which is 230V AC.
b. Measure the power supply (T10) output voltage, which is
approximately 24V DC.
If these measurements are not within ±10%, perform these other steps.
c. Power down the AFE.
d. Remove the 24V DC output wires of the power supply (T10).
e. Power up the AFE and retest by repeating steps a and b.
The 24V DC power supply (T10) may require replacement if these
measurements continue to be outside of the ±10% tolerance.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
6-6
Precharge Component Section
Testing the Precharge
Bridge Using the Power
Structure Terminals
1. Remove power from the AFE.
See Removing Power from the AFE on page 4-3.
2. If present, remove the protective barriers.
See Removing AFE Protective Barriers on page 4-10.
3. To test the precharge bridge, measure the points on the power structure
listed in the table below.
Table 6.C Precharge Bridge Tests on Power Structure
Meter Leads
+
Nominal Meter Reading
Test Point Locations
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
-
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.
1. Remove power from the AFE.
See Removing Power from the AFE on page 4-3.
2. Open the power structure enclosure door.
3. If present, remove the protective barriers.
See Removing AFE Protective Barriers on page 4-10.
4. Remove the protective front covers and terminal covers from the power
structure.
See Removing Protective Covers from the Power Structure on
page 4-13.
5. Remove the four POZIDRIVE screws that secure the bridge protective
cover.
6. Remove the bridge protective cover.
7. Prior to removal, note the locations of the DC+, DC–, L1, L2, and L3
wires, and then disconnect these wires.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Precharge Component Section
6-7
8. Remove the precharge bridge mounting nuts.
9. Remove and appropriately discard the old precharge bridge.
10. Install the new precharge bridge in reverse order of removal, while
referring to Torque Specifications on page 4-2.
Testing the Precharge
Resistor
1. Remove power from the AFE.
See Removing Power from the AFE on page 4-3.
2. Open the LCL Filter enclosure door.
3. If present, remove the protective barriers.
See Removing AFE Protective Barriers on page 4-10.
4. Measure the resistance between the following two points with an
ohmmeter:
– Between the (+) side of the precharge resistor R6.1 and the (+)
terminal on the TB of the precharge circuit.
NOTE: This measurement applies to an AFE in either a IP20 2500
MCC Style enclosure or an AFE in a IP21 Rittal enclosure.
– Between the (–) side of the precharge resistor R6.2 and the (–)
terminal on the TB of the precharge circuit.
NOTE: This measurement only applies to an AFE in a IP21 Rittal
enclosure.
The precharge resistance is approximately 11 ohms for each
measurement for an AFE in a IP20 2500 MCC Style enclosure, or 20
ohms for each measurement for an AFE in a IP21 Rittal enclosure. If
the measured value is not correct, disconnect a resistor wire and
re-measure again. If the measured value is still not correct, replace the
precharge resistor.
Important: Verify that the precharge resistor has not been engineered
to a different value by the system engineer to accommodate
a larger system capacitance, as this may change the value of
the precharge resistor. See the PowerFlex Active Front End
User Manual, publication 20Y-UM001, for total DC bus
capacitance limits for the precharging circuit.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
6-8
Precharge Component Section
Replacing the Precharge
Resistor Assembly
AFE in IP20 2500 MCC Style Enclosure
1. Remove power from the AFE.
See Removing Power from the AFE on page 4-3.
2. Open the LCL Filter enclosure door.
3. If present, remove the protective barriers.
See Removing AFE Protective Barriers on page 4-10.
4. Disconnect the R6.1 precharge resistor wires from the resistor terminals
on the precharge resistor assembly.
5. Remove the two precharge resistor assembly mounting screws that
secure the assembly to the bracket on the LCL enclosure bay.
6. Remove the mounting screws from the failed precharge resistor, and
appropriately discard the resistor.
7. Install the new precharge resistor in reverse order of removal, while
referring to Torque Specifications on page 4-2.
AFE in IP21 Rittal Enclosure
1. Remove power from the AFE.
See Removing Power from the AFE on page 4-3.
2. Open the LCL Filter enclosure door.
3. If present, remove the protective barriers.
See Removing AFE Protective Barriers on page 4-10.
4. Disconnect the wires from the (+) and (-) terminals on the precharge
resistor assembly.
5. Verify that the capacitor on the bridge (+) and (-) terminals is still in the
circuit.
6. Disconnect the white wires from the terminal block by the bridge.
7. Remove the mounting screws from the failed precharge resistor, and
appropriately discard the resistor.
8. Install the new precharge resistor in reverse order of removal, while
referring to Torque Specifications on page 4-2.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Chapter
7
LCL Filter Component Section
!
!
ATTENTION: To avoid an electric shock hazard, verify that all
power to the PowerFlex Active Front End has been removed
before performing any servicing or repairs.
ATTENTION: To avoid an electric shock hazard, verify that the
voltage on the bus capacitors has discharged completely before
servicing. Check the DC bus voltage between the +DC and -DC
terminals, between the +DC terminal and the chassis, and
between the -DC terminal and the chassis. The voltage must be
zero for all three measurements.
!
ATTENTION: The sheet metal cover and mounting screws on
the ASIC Board located on the power structure are energized at
(-) DC bus potential high voltage. Risk of electrical shock, injury,
or death exists if someone comes into contact with the assembly.
!
ATTENTION: Hot surfaces can cause severe burns. Do not
touch the heatsink surface during operation of the PowerFlex
Active Front End. After disconnecting power allow time for
cooling.
!
ATTENTION: Hazard of permanent eye damage exists when
using optical transmission equipment. This product emits intense
light and invisible radiation. Do not look into fiber optic ports or
fiber optic cable connectors.
!
ATTENTION: The PowerFlex Active Front End contains
electrostatic discharge (ESD) sensitive parts and assemblies that
can be damaged if you do not follow ESD control procedures.
Static control precautions are required to install, test, service, or
repair this assembly. If you are unfamiliar with static control
procedures, see Guarding Against Electrostatic Damage,
publication 8000-4.5.2, or any other applicable ESD protection
handbook.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
7-2
LCL Filter Component Section
Removing the LCL Filter
Protective Barriers and
Vented Cover
1. Remove power from the AFE.
See Removing Power from the AFE on page 4-3.
2. Remove the protective barriers from the LCL Filter enclosure.
For an AFE in a IP20 MCC Style enclosure, see Removing AFE
Protective Barriers on page 4-10. For an AFE in a IP21 Rittal enclosure,
see Figure 7.1 below.
3. Remove the four T25 Torx self-tapping screws that secure the front
bracket shown in the figure below.
This bracket holds the LCL Filter in the enclosure.
4. Remove the vented cover from the bottom of the LCL Filter to access
the DC fan fuses, fan, and DC power supply.
Figure 7.1 Removing Protective Barriers and Vented Cover from LCL Filter
FRONT VIEW
LCL Filter in IP21 Rittal Enclosure
(shown with enclosure door and protective barriers removed)
Remove Protective Barriers
The following components
are located behind the
vented cover:
• LCL Filter DC Fan Fuses
• LCL Filter Fan
• DC Power Supply
Front Bracket
Installing the LCL Filter
Protective Barriers and
Vented Cover
Reinstall the protective barriers and vented cover in reverse order of
removal, while referring to Torque Specifications on page 4-2.
Replacing the LCL Filter DC The LCL Filter DC fan fuses are located behind the vented cover at the
bottom of the LCL Filter.
Fan Fuses
Important: Replace LCL Filter fan fuses with only ATQ8 (Ferraz
Shawmut) fuses.
For complete details on LCL fan system information, see PowerFlex 700H,
700S, and 700AFE Drive Fan Systems Installation Instructions, publication
PFLEX-IN029.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
LCL Filter Component Section
7-3
Removing the LCL Filter Fan The following figures show the LCL Filter fan DC Power Supply wiring
diagram with the connections to the AFE power structure and DC bus.
DC Power Supply
For complete details on LCL fan system information, see the PowerFlex
700H, 700S, and 700AFE Drive Fan Systems Installation Instructions,
publication PFLEX-IN029.
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)
LCL Filter
X1
KLIXON
Fan
X81
X2
Fan DC Power
Supply PCB
X3
X8
AFE Power Structure
X52 (4-pin)
Pin 1 = KLIXON
Pin 4 = KLIXON
Fuse
X53 (3-pin)
+ Pin = DC+ (supply)
– Pin = DC– (supply)
DC Bus
X51 (4-pin)
Pin 4 = +16.5V
Pin 3 = (fan control)
Pin 2 = –DC
Pin 1 = (fan alarm)
X3 on AFE Power Structure
Pin 1
Pin 2
Pin 3
Flying Lead to –DC Bus
Important: Before doing any work, disconnect the AFE power structure
from the AC supply, and wait until the fan stops and the
indicators on the keypad turn off. (If a keypad is not attached,
see the indicator through the keypad base.) Wait 5 more
minutes before doing any work on the DC-to-DC power supply
to let it completely discharge. Furthermore, do not open the
cover until after this time has expired.
X51
X53
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
7-4
LCL Filter Component Section
1. Remove the LCL Filter protective barriers.
See Removing the LCL Filter Protective Barriers and Vented Cover on
page 7-2.
2. Remove the two M4 x 10 mm POZIDRIVE screws that secure the cover.
3. Remove the cover.
4. Remove the connectors X1, X3, X4, and X8.
X8
X3
X1
X4
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
LCL Filter Component Section
7-5
5. Remove the six fasteners that secure the DC-to-DC power supply.
Installing the LCL Filter Fan
DC Power Supply
Install the DC-to-DC power supply in reverse order of removal, while
referring to Torque Specifications on page 4-2.
Replacing the LCL Filter Fan 1. Remove the LCL Filter protective barriers.
See Removing the LCL Filter Protective Barriers and Vented Cover on
page 7-2.
2. Disconnect terminal blocks X51 and X53.
X51
X53
3. Lower the front fan sheet metal edge and slide it forward to remove the
alignment studs from their respective holes in the fan frame sheet metal.
4. Slide out the fan assembly.
5. Remove the LCL Filter Fan DC Power supply.
See Removing the LCL Filter Fan DC Power Supply on page 7-3.
6. Reinstall the LCL Filter Fan in reverse order of removal, while referring
to Torque Specifications on page 4-2.
Note the following LCL Filter air flow cooling requirements.
LCL FIlter
Required Air Flow
LCL 460
1100 m3/hr
LCL 1300
1300 m3/hr
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
7-6
LCL Filter Component Section
Removing the LCL Filter
The procedures to remove the LCL Filter are slightly different depending on
the enclosure in which it is installed.
From the IP20 2500 MCC Style Enclosure
1. Remove power from the AFE.
See Removing Power from the AFE on page 4-3.
2. Remove the LCL Filter protective barriers.
See Removing the LCL Filter Protective Barriers and Vented Cover on
page 7-2.
3. Remove the Air Flow Plate.
See Removing the AFE Air Flow Plate on page 4-12.
4. Remove the X51 and X53 terminal blocks from the LCL fan assembly.
5. Remove the X52 terminal block from the LCL filter assembly (upper
right side).
6. Remove the top and bottom brackets that hold the LCL Filter in the
enclosure (see Figure 7.4).
a. See Detail A and remove the six M8 x 20 screws.
b. See Detail B and remove the six M8 x 20 screws.
Figure 7.4 Removing LCL Filter from AFE in IP20 2500 MCC Style Enclosure
DETAIL A
DETAIL B
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
LCL Filter Component Section
7-7
7. See Figure 7.5, Detail C and remove the six M10 x 10 washer hex nuts
and associated hardware that secure the input bus bars to the LCL Filter.
Figure 7.5 Removing Input Bus Bar Connections
DETAIL C
DETAIL D
8. See Figure 7.5, Detail D and remove the twelve M6 x16 screws that
secure the LCL Filter output bus bars to the AFE power structure.
9. See Figure 7.5 and slide the LCL Filter out of the enclosure.
!
ATTENTION: The LCL Filter is heavy. To avoid personal
injury or damage to the equipment, use caution when removing
the LCL Filter from the enclosure.
Note that ramps may be required due to enclosure floor mismatch.
From the IP21 Rittal Enclosure
1. Remove power from the AFE.
See Removing Power from the AFE on page 4-3.
2. Remove the LCL Filter protective barriers.
See Removing the LCL Filter Protective Barriers and Vented Cover on
page 7-2.
3. Remove the X51 and X53 terminal blocks from the LCL fan assembly.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
7-8
LCL Filter Component Section
4. Remove the X52 terminal block from the LCL filter assembly (upper
right side).
5. Remove the four T25 Torx self-tapping screws that secure the front
bracket shown in Figure 7.1.
This bracket holds the LCL Filter in the enclosure.
6. Remove the MCCB-to-LCL Filter bus bars (L1, L2, L3).
For bus bar locations, see Figure 2.6 on page 2-6.
7. Remove the LCL Filter-to-AFE power structure bus bars (U, V, W).
For bus bar locations, see Figure 2.6 on page 2-6.
8. Disconnect the ground wire from the LCL Filter chassis.
!
ATTENTION: The LCL Filter is heavy. To avoid personal
injury or damage to the equipment, use caution when removing
the LCL Filter from the enclosure.
9. Slide the LCL Filter out of the enclosure.
Note that ramps may be required due to enclosure floor mismatch.
Installing the LCL Filter in
the Enclosure
Install the LCL Filter in reverse order of removal, while referring to Torque
Specifications on page 4-2.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Chapter
8
DC Fuses Component Section
!
!
ATTENTION: To avoid an electric shock hazard, verify that the
voltage on the bus capacitors has discharged completely before
servicing. Check the DC bus voltage between the +DC and -DC
terminals, between the +DC terminal and the chassis, and
between the -DC terminal and the chassis. The voltage must be
zero for all three measurements.
!
ATTENTION: The sheet metal cover and mounting screws on
the ASIC Board located on the power structure are energized at
(-) DC bus potential high voltage. Risk of electrical shock, injury,
or death exists if someone comes into contact with the assembly.
!
ATTENTION: Hot surfaces can cause severe burns. Do not
touch the heatsink surface during operation of the PowerFlex
Active Front End. After disconnecting power allow time for
cooling.
!
ATTENTION: Hazard of permanent eye damage exists when
using optical transmission equipment. This product emits intense
light and invisible radiation. Do not look into fiber optic ports or
fiber optic cable connectors.
!
Overview
ATTENTION: To avoid an electric shock hazard, verify that all
power to the PowerFlex Active Front End has been removed
before performing any servicing or repairs.
ATTENTION: The PowerFlex Active Front End contains
electrostatic discharge (ESD) sensitive parts and assemblies that
can be damaged if you do not follow ESD control procedures.
Static control precautions are required to install, test, service, or
repair this assembly. If you are unfamiliar with static control
procedures, see Guarding Against Electrostatic Damage,
publication 8000-4.5.2, or any other applicable ESD protection
handbook.
An AFE system in a IP20 2500 MCC Style enclosure or IP21 Rittal
enclosure contains the protective DC bus fuses.
Important: For PowerFlex AFE systems in the IP00 Open Chassis
configuration, output fuses must be supplied by the user.
See the PowerFlex Active Front End User Manual, publication
20Y-UM001, for the DC bus output fusing recommendations.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
8-2
DC Fuses Component Section
Fuse Replacement
Guidelines
DC bus fuses are required for short circuit protection. The following tables
list the recommended DC bus fuses.
Table 8.A 400/480 Volt DC Fusing
Frame AFE
Size
Enclosure Style
IP20 2500 MCC
13
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
13
IP21 Rittal
Fuse
To replace fuses, use the following procedure.
1. Remove power from the AFE.
See Removing Power from the AFE on page 4-3.
2. Open the power structure enclosure door.
3. If present, remove the protective barriers.
See Removing AFE Protective Barriers on page 4-10.
4. Remove and discard the blown fuse.
5. Insert the fuse body between the bus bars.
6. Turn the threaded rod into the fuse body.
7. Place the Belleville (domed) washer and hexagonal nut on the threaded
rod and hand tighten.
8. Hold the threaded rod with the hex key while tightening the nut to the
specified torque.
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)
Important: Do not apply torque or twisting force to the fuse body, as
this can damage the fuse.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
DC Fuses Component Section
8-3
For more information about Bussmann fuses, go online at
http://www.cooperindustries.com.
For more information about Ferraz Shawmut fuses, go online at
http://www.ferrazfuses.com.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
8-4
DC Fuses Component Section
Notes:
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Chapter
9
Startup After Repair
!
!
Phone
ATTENTION: The sheet metal cover and mounting screws on
the ASIC Board located on the power structure are energized at
(-) DC bus potential high voltage. Risk of electrical shock, injury,
or death exists if someone comes into contact with the assembly.
ATTENTION: Power must be applied to the PowerFlex Active
Front End to perform the following start-up procedure. Some of
the voltages present are at incoming line potential. To avoid
electric shock hazard or damage to equipment, only qualified
service personnel should perform the following procedure.
Thoroughly read and understand the procedure before beginning.
During startup, if one of these pre-powerup checks reveals a
concern, do not proceed. Remove power including user-supplied
control voltages. User-supplied voltages can exist even when
main AC power is not applied to the PowerFlex Active Front
End. Correct the malfunction before continuing.
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 on Support (http://support.rockwellautomation.com/)
• Under Contact Customer Support, click on Phone Support
Internet
⇒
Go to http://www.ab.com/support/abdrives/
E-mail
⇒
[email protected]
Be prepared to provide the following information when you contact
Allen-Bradley Drives Technical Support:
• Product Catalog Number
• Product Serial Number
• Firmware Revision Level
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
9-2
Startup After Repair
Before Applying Power to
the AFE
1. Open the power structure enclosure door.
2. If present, remove the protective barriers.
See Removing AFE Protective Barriers on page 4-10.
3. Check for zero volts between DC+ and DC-.
4. Perform forward and reverse biased diode tests, using a digital
multimeter.
See Performing Forward and Reverse Biased Diode Tests for Power
Structure on page 3-3.
5. Confirm that all wiring to the AFE (AC input, ground, DC bus, and I/O)
is connected to the correct AFE terminals, and is secure.
6. Verify that AC line power at the disconnect device is within the rated
value of the AFE.
7. Verify that the control power voltage is correct.
8. Whenever possible, isolate the AFE from the rest of the DC bus system
to enable the AFE to be powered separately.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Appendix
A
Service Tools and Equipment
Software Tools
Connected Components Workbench software, DriveExecutive software, or
DriveExplorer software are tools that can be used for uploading,
downloading, and monitoring system parameters.
Service Tools
The following list contains the basic service tools needed for repair and
maintenance measurements.
Item Description
Details
1
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
—
6
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
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
22
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).
For Agilent HFBR-4532 latching connectors and HFBR-RL cable. See Agilent
publications 5988-9777EN and 5988-3625EN.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
A-2
Service Tools and Equipment
Notes:
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Appendix
B
Schematic Diagrams
Frame 13 Circuit Board Connections
ASIC
Circuit
Board
25
26
21
22
23
X9
X6
+24V
0EVA
DC+
DC-
1
2
3
To X6 on Phase U
Gate Driver Board
To H15 on Phase U
Gate Driver Board
To H16 on Phase U
Gate Driver Board
X3
H8
X15
Charge
Relay
From DC Bus
H9
X600
X11 (Fan Control)
3
To Fan Inverter X8
X26
ASIC Board Fan
M4
X4
To X6 on Phase V
Gate Driver Board
H10
To H15 on Phase V
Gate Driver Board
H11
To H16 on Phase V
Gate Driver Board
X5
To X6 on Phase W
Gate Driver Board
H12
To H15 on Phase W
Gate Driver Board
H13
To H16 on Phase W
Gate Driver Board
2
X1
X10
H1
H2
H3
H4
H5
H6
H7
X2
Fiber Optic Cables
2
+24V
Fiber Optic
Adapter Board
X29
X2
H1 H2 H3 H4 H5 H6 H7
X3
+24V 1
Gnd 2
20-VB00601
DPI Interface
Board
X1
37
X1
700AFE Control Board
X2
(slot A)
20C-DA1-A
(24V DC Digital
Input with
Analog I/O)
X3
(slot B)
20C-D01
(Digital Output
Option)
Analog Digital
I/O Inputs
(10) (8/10)
3
X4
(slot C)
Option
Board
Option
Board
X1
20C-DPI1
(DPI Comm.
Option) X2
X3
HIM
Bezel
X2
RS-232
Programming
Port
X5
X6
(slot D)
(slot E)
X1
X4
J2
X3
X7
J1
20
PWR
9
PORT
MOD
NET A
NET B
9
DPI Assembly
20C-DPI1
DPI Comm.
Option Board
3
9
HIM
J3
Door
Example:
20-HIM-A3
HIM
External DPI
Figure B.1 Frame 13 Circuit Board Connections
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
B-2
Schematic Diagrams
Frame 13 Power Structure Power Circuitry Block Diagram
F2.1
F2.2
DC+
Phase
Module
U
DC-
Measure L/R
Gate Driver Bd.
X8
X3
DC+
F2.3
DC+
Phase
Module
V
DC Bus Output
F2.4
Fan
DC-
DCMeasure L/R
Gate Driver Bd.
X8
X3
PE
F2.5
F2.6
Fan
DC+
Phase
Module
W
DC-
Measure L/R
Gate Driver Bd.
X8
X3
Fan
X11
21
22
23
25
26
External Wiring
Shown Dashed
X15
X9
Charge
Relay
+24V
0EVA
ASIC
Board
Figure B.2 Frame 13 Power Structure Power Circuitry Block Diagram
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
U / L1
V / L2
W / L3
X19
X20
X1
5
5
Power Board #1
V_LO
V_HI
TERM V
I_U
Power Board #2
I_V
Shield
X4
U_LO
U_HI
TERM U
Ribbon Cable
X3
5
TERM W
3
5
W_LO
W_HI
X18
X17
3
X1
X4
X3
5
5
I_W
From ASIC Board
H8 & H9 for Phase U
H10 & H11 for Phase V
H12 & H13 for Phase W
H2, H4
Gate Driver
Board
Shield
Ribbon Cable
3
3
I_U
To
Main Fan
Control
X21
X1
X5
X14
X3
X4
V_LO
V_HI
TERM V
Shield
10
From ASIC Board
X3 for Phase U
X4 for Phase V
X5 for Phase W
X13
DC-
DC-
See
Note 1
6
4
I_V
To
Connector X6
on ASIC Board
PE
DC+
DC+
I_W
Figure B.3 Frame 13 Power Module Circuitry
2. 600V Capacitor Configuration:
3 Caps in Series
4 caps in Parallel
1. 400V Capacitor Configuration:
2 Caps in Series
6 Caps in Parallel
NOTES:
To J2 on Voltage
Feedback Board
(DC feedback is
wired from 1 Phase
Module only.)
AC Input Phase, either
U/T1 or
V/T2 or
W/T3
(Diagram is generic)
W/T3
V/T2
U/T1
DC-
DC+
Schematic Diagrams
B-3
Frame 13 Power Module Circuitry
W_LO
W_HI
TERM W
U_LO
U_HI
TERM U
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
B-4
Schematic Diagrams
To ASIC Circuit Board
X11 (Fan Control)
3
4
DC- DC+
DC Main Fan
X8 X3
X81
Isolated 48V DC
Power Supply
Circuit Board
W Phase Fan Module
X82
X2
4
DC Main Fan
X81
X8 X3
Isolated 48V DC
Power Supply
Circuit Board
V Phase Fan Module
X82
X2
4
DC Main Fan
X81
U Phase Fan Module
X8 X3
Isolated 48V DC
Power Supply
Circuit Board
X2
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
X82
Figure B.4 Frame 13 Power Structure Main DC Fan Connections – newer version
Frame 13 Power Structure Main Fan Connections
DC+ DC-
From DC Bus
F2
6A
F1
F2
6A
F1
F2
6A
F1
(-)
(+)
(-)
(+)
(-)
(+)
S1 Setup Switch
Off Off On Off
S1-1 S1-2 S1-3 S1-4
X2-1
X2-3
S1 Setup Switch
Off Off On Off
S1-1 S1-2 S1-3 S1-4
X2-1
X2-3
S1 Setup Switch
Off Off On Off
S1-1 S1-2 S1-3 S1-4
X2-1
X2-3
Fan Frequency Converter
DC/AC
Fan Frequency Converter
DC/AC
Fan Frequency Converter
DC/AC
2
X3
4
X5-1 BLK 1
X4-1 BLK 2
2
2
4
4
X5-1 BLK 1
X4-1 BLK 2
4
X3
X8
4
X3
X5-1 BLK 1
X4-1 BLK 2
2.2 µf
300V AC
2.2 µf
300V AC
7 µf
10 Meg
10 Meg
3
BLK
5
BLK
4
BLK
6
BLK
3
BLK
5
BLK
4
BLK
6
BLK
2.2 µf
300V AC
2.2 µf
300V AC
2.2 µf
300V AC
2.2 µf
300V AC
7 µf
10 Meg
10 Meg
7 µf
10 Meg
10 Meg
From ASIC Circuit Board X11
3
BLK
5
BLK
4
BLK
6
BLK
Blue
4
Blue
Brown
Black
4
Blue
Brown
Black
1
3
Brown
Black
4
Yellow/Green
2
1
3
Yellow/Green
2
1
3
Yellow/Green
2
M3
M2
M1
Phase W Module
Main Fan
230V AC, 50 Hz
Phase V Module
Main Fan
230V AC, 50 Hz
Phase U Module
Main Fan
230V AC, 50 Hz
Figure B.5 Frame 13 Power Structure Main AC Fan Connections – older version
V1
U1
V1
U1
X8
3
Jumper
V1
U1
X8
4
Schematic Diagrams
B-5
Frame 13 Power Structure Main Fan Connections
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
B-6
Schematic Diagrams
Control Wiring Diagram for Frame 13 in IP20 2500 MCC Style Enclosure
Figure B.6 Control Wiring Diagram for Frame 13 in IP20 2500 MCC Style Enclosure
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
B-7
Fault Reset
(optional)
To Indicator
Enable
Remote Operation of
Power Contactor
(optional)
Schematic Diagrams
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
U1
L1
F2.2
X51
1
V
4
3
2
1
-
2
TF11 /7-G15
/7-G7 TF+1
3
4
5
7 B+ B-
F2.3
6
PE
F2.4
Fan alarm to the unit
DC- fuse base connection
Fan control from the unit
16.5V from the unit
6180
7070
W
F2.5
B+
B-
+
24VDC
-
PE
6182
6181
F2.6
2
1
4
3
BUS BAR
OF1 /7-C24
AP1 /7-C23
F11
G
In=1600A
xIn
Switch Key:
7
6
8
3
9
4
10
5
xIn
i
TEXT
11 12 13 14 15
2
off 1.5
I3=
Switch handle
48 72 108 144s
3 12 24 36
0.4 0.5 0.6 0.7 0.8 0.9 1
+
0 0.025 0.05 0.075
t1
I=3xI1
+
I
60Hz
50Hz
In=1600A
OFF
50%
100%
200%
xin
InN=
+
xIn
48 72 108 144s
3 12 24 36
I
DC-
DC+
0.4 0.5 0.6 0.7 0.8 0.9 1
+
0 0.025 0.05 0.075
t1
I=3xI1
L
I1=
7
2
8
3
9
4
10
5
xIn
i
TEXT
11 12 13 14 15
6
off 1.5
I3=
FACTORY DEFAULT TRIP SETTING FOR 600/690V AC
60Hz
50Hz
OFF
50%
100%
200%
xin
InN=
L
I1=
2
1
4
3
3
4
R6.1
6241
V6
L1
3
2
1
+
C1
L2
L3
6200 6201 6202
K6 1
/11-C31 2
6172 6173 6174
F5
-
5
6
6
5
H
DC+
DC-
L1 /8-A2
L2 /8-A2
39
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
05
04
03
02
01
Figure B.7 Frame 13 in IP20 2500 MCC Style Enclosure – Sheet 6 (400/480V and 600/690V)
42
PE
4
3
2
1
X53 +
X52
F
FACTORY DEFAULT TRIP SETTING FOR 400/480V AC
E
41
F2.1
B+ B-
PE
W
L3
5
6
2
6050
6051
6052
PE
D
42
U
V
L2
3
4
2
1
6
I>
5
C
40
-DC Bus
3
2
X3
1
BUS BAR
U
L1
BUS BAR
BUS BAR
K1 1
/10-E32 2
2
1
4
2
1
I>
I>
3
BUS BAR
F1.1 F1.2 F1.3
Q0
1
B
MAIN CIRCUIT
L1 L2 L3
41
FIBER
OPTIC CABLE
/7-C29
X70
A
40
39
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
05
04
03
02
01
Freq
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Freq
B-8
Schematic Diagrams
System Schematics for Frame 13 in IP20 2500 MCC Style Enclosure
The following system schematics are for the AFE Frame 13 in a IP20 2500
MCC Style enclosure. The PowerFlex AFE catalog number has an
enclosure code of P for standard color (or W for optional gray color) as
shown in the example catalog string below. For other enclosure designs,
contact the supplier of the system for the system schematics.
1-3
4
5-7
8
9
Position
10
11
12
13
14
15
16
20Y
D
1K3
P
0
A
N
N
A
N
A
0
a
b
c
d
e
f
g
h
i
j
k
l
8151
7272
7273
F
AFE ON
7130 7160
7140
6180
FAULT RESET
(OPTIONAL)
MAIN CONTACTOR
ON REQUEST
MAIN CONTACTOR
ACKNOWLEDGE
K1.1CC /10-F15
/6-B36
7330
7070
G
7120
7170
7121
H
18
17
16
15
14
13
12
11
10
09
08
07
06
05
04
03
02
01
39
40
41
42
40
41
42
Figure B.8 Frame 13 in IP20 2500 MCC Style Enclosure – Sheet 7 (400/480V and 600/690V)
38
37
36
35
39
MAIN CONTACTOR
CONTROL
34
33
32
31
30
29
38
37
36
35
34
33
32
31
30
29
FIBER OPTIC
CABLE
27
TO USER SUPPLIED
DRIVE INVERTER
ENABLE INTPUT
26
27
28
25
26
28
24
22
21
25
/9-D14 24VDC-
23
/9-D13 24VDC+
24
/10-F8 K1.1CL
23
22
21
20
9140
CONTROL UNIT
E
TF+1 /6-C16
19
9120
D
AFE READY
20
/6-C30 AP1
/6-C31 OF1
C
AFE FAULT
19
18
17
16
15
14
13
12
11
10
09
08
07
06
05
04
03
B
FAULT RESET
02
A
LCL OVER TEMP
/6-C18 TF11
01
Schematic Diagrams
B-9
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
A
L1 /9-A5
H
05
04
03
02
01
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
17
18
18
1N /9-A34
16
17
8170
15
16
27
28
29
30
31
32
33
28
29
30
31
32
33
36
37
38
39
40
41
42
36
37
38
39
40
41
42
Figure B.9 Frame 13 in IP20 2500 MCC Style Enclosure – Sheet 8 (400/480V and 600/690V)
35
35
34
26
27
34
25
24
23
26
8220
25
24
23
22
21
21
/10-E32
20
20
22
19
19
8210
14
15
12
11
10
13
Note: 1 & 2
8091
14
8170 8171
8090
13
12
11
10
Note: 1) For 400/480 (Voltage code “D”) primary control transformer connection is factory wired to 480V as default.
For 600/690 (Volatge code “F”) primary control transformer connection is factory wired to 690V as default.
2) Customer may need to change the primary voltage tap according to incoming supply.
09
G
08
F
09
E
07
8151
D
08
C
06
6051
B
07
6050
/6-G12 L1
/6-G12 L2
06
05
04
03
02
01
B-10
Schematic Diagrams
D
8151
E
F
G
L1 /10-B6
H
12
12
17
18
19
20
21
22
23
24
25
26
27
28
18
19
20
21
22
23
24
25
26
27
28
31
32
33
31
32
33
36
37
38
39
40
41
42
36
37
38
39
40
41
42
Figure B.10 Frame 13 in IP20 2500 MCC Style Enclosure – Sheet 9 (400/480V and 600/690V)
35
35
34
30
30
34
29
29
8170
16
17
14
15
24DCV- /7-C29
16
9140
15
14
1N /10-B35
11
11
/8-G34 1N
10
10
13
09
09
13
08
08
24DCV+ /7-C29
07
07
9120
06
06
05
04
/8-G5 L1
04
05
03
03
24V DC POWER SUPPLY
02
C
01
B
02
A
01
Schematic Diagrams
B-11
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
D
8151
11140
/7-F13
/11-D26
E
7271
/-E29
F
G
1N /11-A35
1L /11-A6
H
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
42
41
40
39
38
37
36
42
41
40
39
38
Figure B.11 Frame 13 in IP20 2500 MCC Style Enclosure – Sheet 10 (400/480V and 600/690V)
/8-B22
/6-B13
/6-C13
/6-C13
37
36
35
34
8170
33
34
35
32
31
33
10310
32
31
30
C
29
/9-G34 1N
/9-G5 1L
B
K1.1CL /7-D29
30
A
/7-D29 K1.1CC
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
S10 /11-D9
K1 /11-E25
B-12
Schematic Diagrams
8170
/6-G19
/6-G19
/6-G19
-C16
11270
11141
11140
11142
E
G
H
1L
1N
Note: When the S10 switch is in 0 position, the MAIN CONTACTOR K1 and
charging contactor K6 will open independent of the position of the S6 switch.
F
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
40
41
42
41
42
Figure B.12 Frame 13 in IP20 2500 MCC Style Enclosure – Sheet 11 (400/480V and 600/690V)
39
40
38
37
36
39
38
37
36
35
34
35
33
34
32
33
32
31
/-F31
/10-E32
11140
11120
8151
D
30
11280
/7-E31
11240
11160
C
31
/10-H35 1N
/10-H6 1L
8151
B
/10-D25 S10
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
A
K1 /10-D25
01
Schematic Diagrams
B-13
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
X1
3
1
3
4
5
INTERNAL CONNECTION
2
6
6
7
8
10
11
12
37
36
35
34
33
32
31
Figure B.13 Frame 13 in IP20 2500 MCC Style Enclosure – Sheet 12 (Terminal Block Layout, and Circuit Breaker and Fuse Ratings
42
9
41
INTERNAL CONNECTION
5
30
29
28
27
26
25
24
23
22
21
20
19
18
17
16
15
14
13
12
11
10
09
08
42
4
1
3
6
1
1
3
2
2
Quantity
40
3
Current Rating
600-690V
400-480V
1600A
1600A
1800A
2200A
630A
1100A
6A
6A
6A
6A
50A
50A
8A
6A
8A
8A
07
06
05
04
03
02
01
41
2
INTERNAL CONNECTION
Fan TB3 Door Three (Jumper and Numbering Details)
FAN TB2
INTERNAL CONNECTION
Fan TB2 Door Two (Jumper and Numbering Details)
Q0
F1.1 to F1.3
F2.1 to F2.6
F3
F4
F5
F6
F11
Circuit Breaker
Fuse
Tag Name
H
39
1
2
G
CIRCUIT BREAKER AND FUSE RATINGS
Component
F
40
FAN TB3
INTERNAL CONNECTION
For 400/480V or
600/690V AC Input
1
INTERNAL CONNECTION
FAN TB1
INTERNAL CONNECTION
Fan TB1 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)
Customer Connection (see User Manual for more details)
X3 (Customer 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
05
Remote Stop
04
Remote Start
03
INTERNAL CONNECTION
B
Fault Reset
(optional)
Inverter
Enable Input
02
A
Move this wire
to the terminal
that matches the
AC line voltage
01
INTERNAL CONNECTION
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
57
58
60
61
63
64
65
66
400
480
600
690
B-14
Schematic Diagrams
B-15
Schematic Diagrams
Control Wiring Diagram for Frame 13 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.
F3
230V AC
Control Power
1
2
3
4
5
6
7
8
9
10
11
12
T4
H5
L1
N
1
2
S10
Q1
1
2
3
N.O.
4
N.O.
U2
U1
95
98
96
R2
R1
48
45
D2
D1
C2
C1
C11
C12
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
A1
A2
13
N.O.
14
X1
Fault
69
Reset
70
(Optional)
1
4
(Terminal
Block X52)
A1
K6
L
N
24V+
24VPE
L1
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
X3
1
2
-A12.1
21
22
R2
23
19
20
DIN6 D_COM D_COM +24V 24VCOM
20C-DA1-4
SLOT A
PE
R3
24
25
X1
20C-DO1
SLOT B
26
-A13
20C-DPI1
SLOT E
72 Inverter Enable
Figure B.14 Control Wiring Diagram for Frame 13 in IP21 Rittal Enclosure
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
H
G
F
E
D
C
B
A
1
-L1
-U1
-Q1
4
3
2
1
5
6
5
2
X3
X2
U
PE
B+ B-
PE
B+ B-
PE
X10
PE
2
1
4
3
1100A
-F2.6
OF1 /7-1D
AP1 /7-1D
8A
-F11
4
5
Newer Version
6
16.5V from the unit
Fan control from the unit
DC- fuse base connection
Fan alarm to the unit
TF11 /7-5C
/7-6A TF+1
-Q5
-K6
/11-2E
I>
4
2
3
5
-X6
-R6.1
1
4
3
4
3
6
5
6
5
+
2
1
+
-R6.2
-C1
-
2
1
-
L1 L2 L3
2
1
2
-V6 3
6
I>
32A
-F6
I>
1
7
8
DC+
DC-
L1 /8-1A
L2 /8-1A
L3 /8-1A
Figure B.15 Frame 13 in IP21 Rittal Enclosure – Sheet 6 (400/480V and 600/690V)
1100A 1100A
-F2.4 -F2.5
W
Fan alarm to the unit
Fan control from the unit
-F2.2 -F2.3
V
4
TF11 /7-5C
/7-6A TF+1
16.5V from the unit
1100A 1100A
X51
3
1
-
X53 +
4
3
2
X52 1
M
3
Older Version
-F2.1
B+ B-
PE
W
2
12 14 96 98
Q/1 SY
11 95
1100A
U
V
L1 L2 L3
2200A 2200A 2200A
2
2
4 6
-F1.1 -F1.2 -F1.3
1 1 1
I >> I >> I >>
3
1
MAIN CIRCUIT
L1 L2 L3
2
B-16
Schematic Diagrams
System Schematics for Frame 13 in IP21 Rittal Enclosure
The following system schematics are for the Frame 13 AFE in a IP21 Rittal
enclosure. The PowerFlex AFE catalog number has an enclosure code of A
as shown in the example catalog string below. For other enclosure designs,
contact the supplier of the system for the system schematics.
1-3
4
5-7
8
9
Position
10
11
12
13
14
15
16
20Y
D
1K3
A
0
A
N
N
A
N
A
0
a
b
c
d
e
f
g
h
i
j
k
l
H
G
F
E
D
/6-4E OF1
/6-4E AP1
7
2
1
X3
2
-A12.1
3
AIA2-
4
21
22
5
3
6
7
8
CONTROL UNIT
9
4
10
PWM ON
11
Fault Reset
(Optional)
12
13
MCCB
CONTROL
23
14
12
24
22
FAULT
-K4
21
11
A2
A1
24
R2
15
20C-DO1
SLOT B -A13
DIN5
17
18
2
1
19
20
-X39.1 2
-H3.1
-A14
20C-DPI1
SLOT E
20C-DA1-A
SLOT A
DIN6 D_COM D_COM +24V 24VCOM
16
11
-X39.1 1
-4E
-K4
12
-X1 71
14
AFE READY
6
9
PE
7
8
Figure B.16 Frame 13 in IP21 Rittal Enclosure – Sheet 7 (400/480V and 600/690V)
INVERTER
ENABLE
-7B
26
/11-2D -X1 72
25
R3
DIN4
14
-X5 19
/6-2B
34
31
17 18
-Q1
32
14
5
MCCB
ACKNOWLEDGE
-X5
/11-6E 11
-K20
12
-X1 70
-X1 69
MCCB ON request
AIA2+ -10Vref PotGND +10Vref AOUT1 AOUTC AOUT2 DIN1 DIN2 DIN3
ABCD
ABCD
ABCD
ABCD
J1
J2
J3
J4
R1 MC Control R2
2
AIA1+
1
AIA1-
-A16.1
X2 A11
A1.1
/9-5B 24VDC-
C
/9-5B 24VDC+
B
CBCO /10-5C
LCL OVER TEMP
/6-2C TF11
TF+1 /6-3C
A
/10-6A CBCL
2
CBCC /10-6C
1
Schematic Diagrams
B-17
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
H
G
F
E
D
C
B
A
-Q4
/6-7B L1
/6-7B L2
-X3
6
4
2
-T4
PE
-F3 2
1
400 440 460 480 500
I>
I>
I>
5
3
1
02
1
01
400
440
460
480
500
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
230
2
11
-X1
1
-X1
3
4
6
12
2
7
1N /9-1F
1L /9-1A
8
Figure B.17 Frame 13 in IP21 Rittal Enclosure – Sheet 8A (only 400/480V)
5
B-18
Schematic Diagrams
-Q4
C
H
G
F
E
D
/6-7B L1
/6-7B L2
B
-X3
I>
4
I>
2
-T4
1
-F3 2
PE
5
6
I>
525 600 690
3
1
02
A
01
525
600
690
230
1
2
11
-X1
1
-X1
3
4
6
12
2
7
1N /9-1F
1L /9-1A
8
Figure B.18 Frame 13 in IP21 Rittal Enclosure – Sheet 8B (only 600/690V)
5
Schematic Diagrams
B-19
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
H
G
F
E
D
C
B
A
/8-8F 1N
/8-8A 1L
1
2
15
-X1
5
-X1
3
-F10
1
2
N
24VDC- /7-2E
24VDC+ /7-2E
5
6
16
6
7
1N /10-1F
1L /10-1A
8
Figure B.19 Frame 13 in IP21 Rittal Enclosure – Sheet 9 (400/480V and 600/690V)
24VDC
230VAC PE
+
L
-T10
24V DC POWER SUPPLY
4
B-20
Schematic Diagrams
H
G
F
E
D
C
B
/9-8F 1N
/9-8A L1
17
-X1
7
-X1
2
1 -S11
3
-S6
4
14
13
5 4
96
YU
-X5 8
D2
-Q1
D1
-X5 7
A12.1/2
5
YO
C12
-Q1
C11
9
-X5 11
M
U2
46
-Q1
45
13
48
C2
10
YC
C1
/6-2B
12
CBCL /7-3E
U1
/7-3E CBCC
-X5 20
6
R2
8
18
21
YR
R1
-4F CBR
7
11
14
1N /11-1F
-X5 3
/6-2B
-Q1
12
-X5 1 2
1L /11-1A
8
Figure B.20 Frame 13 in IP21 Rittal Enclosure – Sheet 10 (400/480V and 600/690V)
CBR -6C
/6-2B 98
CIRCUIT BREAKERS
UNDER VOLTAGE TRIP
4
-X5 6
95
-Q1
-X39.2 2 -X39.2 2
-H5
-X39.2 1
MCCB FAULT
RESET
3
UV /11-3B
UV1 /11-5D
A
2
/7-3E CBCO
1
Schematic Diagrams
B-21
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
H
G
F
E
D
C
B
/10-8F 1N
/10-8A 1L
2
1
3
5
13
2
4
6
14
A2
A1
21
-K6
24
-K4
/7-4E
4 2
3 1
22
0
1
START
-S10
0
/6-7C
/6-7C
/6-7C
-3C
CHARGING
CONTACTOR
55
-K6 13
-2E 14
START
-X1
1
53
-X1
3
-X38
2
3
1
22
24
-Q1
21
/6-2B
-X5 16
24
57
-X1
-S6
60
OFF
5
4
-X1 61
MCCB Open
6
14
12
24
22
-K20
A1
21 -3D
11 /7-5C
A2
56
54
42
41
44
-X5 24
/6-2B
-Q1
-X5 22 23
7
1N
1L
8
Figure B.21 Frame 13 in IP21 Rittal Enclosure – Sheet 11 (400/480V and 600/690V)
62
11
7
58
12
8
2 4 6 8 10 12
1 3 5 7 9 11
AUTO
5
NOTE: When the -S10 switch is in the “0” position, the MCCB -Q1 and
the charging contactor -K6 will open independent of the
position of the -S6 switch. The MCCB can only be reset with
pushbutton -S11 when the -S6 switch is in the “MAN” position.
MCCB Close
(charging) pulse
6
-X38
1
5
2
2
6
REM
MAN
REM
MAN
AUTO
9
-K20 21
-6E
-X5 14 15
22
4
SWITCH - S6
- REMOTE
- MANUAL
- AUTOMATIC
10
3
1
4
-X1 59
-X38
-S6
-S10
-X38
ON
/10-4D UV
A
1
UV1 /10-4D
B-22
Schematic Diagrams
Appendix
C
Connector Descriptions
Circuit Board Connections
The following tables detail the connection points for the Frame 13
PowerFlex Active Front End circuit boards and components.
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 on
control panel
(1)
See Figure C.1 on page C-3 for ASIC board fiber-optic connectors.
Important: When mishandled, the ability of fiber optic cables to transmit
data is greatly diminished.
!
ATTENTION: Hazard of permanent eye damage exists when
using optical transmission equipment. This product emits intense
light and invisible radiation. Do not look into fiber optic ports or
fiber optic cable connectors.
Important: The minimum inside bend radius for fiber optic cable is 25.4
mm (1 in.). Any bends with a shorter inside radius can
permanently damage the fiber optic cable. Signal attenuation
increases with decreased inside bend radii.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
C-2
Connector Descriptions
Table C.B ASIC Board-to-Gate Driver Board Connections
ASIC Board
Gate Driver Board
Signal Description
X3
X1
‘U’ phase
X4
X1
X5
X1
H13 (WL)
H12 (WH)
H11 (VL)
H10 (VH)
H9 (UL)
H8 (UH)
(WL) H4
(WH) H2
(VL) H4
(VH) H2
(UL) H4
(UH) H2
(1)
DTR = N Desat
(2)
ETR = Phase I2T
(3)
ITR = Phase Overcurrent
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
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
‘V’ phase
‘W’
phase
Fiber Optic Gate Signals
(connect UH to UH, UL to UL, and so forth)
H5
H4
H3
H4
H3
Seven
Fiber Optic
Cables
H7 H6
H5
Six
Fiber Optic
Cables
X1
H2
X3
H13 H12 H11 H10 H9
X11
X2
H2
H1
X15
For ASIC board part number
information, see Table D.C on page D-4.
X4
H1
H4
H2
X5
H6
H2
H7
X1
X2
X3
H4
ASIC Board
X10
Fiber Optic
Adapter Board
X1
X12
X9
X12
X9
X12
X9
X11
X8
X11
X8
X11
X8
X7
X10
X7
X10
H4
H2
X7
For Gate Driver board part number
information, see Table D.B on page D-3.
U Phase
Gate Driver
Board
V Phase
Gate Driver
Board
W Phase
Gate Driver
Board
Connector Descriptions
C-3
Figure C.1 Fiber Optic Cable Routing
H8
X9
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-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 V Phase Fan Inverter Board Connections
ASIC Board Connector (1)
X11
(1)
Pin
Signal Description
Pin
Phase V 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.
Table C.D Phase V Fan Inverter Board - W Phase Fan Inverter Board Connections
Pin
Signal Description
Pin
Phase W Fan
Inverter Board
Connector
From
2
+15V
To
2
X8
From
3
FAN_CONTROL NEXT
To
3
To
4
FAN_ALARM
From
7
Phase V Fan Inverter
Board Connector
X3
Table C.E Phase W Fan Inverter Board - U Phase Fan Inverter Board Connections
Pin
Phase U Fan
Inverter Board
Connector
To
2
X8
FAN_CONTROL NEXT
To
3
FAN_ALARM
From
7
Phase W Fan Inverter
Board Connector
Pin
Signal Description
X3
From
2
+15V
From
3
To
4
For part number information, see the PowerFlex 700H, 700S, and 700AFE
Drive Fan Systems Installation Instructions, publication PFLEX-IN029.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Connector Descriptions
C-5
Figure C.3 LCL Filter Fan Inverter Circuit Board Connectors
X3
X4
X8
X1
Table C.F LCL Filter Fan Inverter Circuit Board Connections
LCL Filter DC Fan
Inverter Board
LCL Filter DC
Fan Assembly
X1
X1
X3
X3
X8
X51
X4
X53
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
C-6
Connector Descriptions
Notes:
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Appendix
D
Disassembly/Assembly Diagrams and Spare Parts
Diagram
Page
AFE Power Structure Assembly External Components
D-2
AFE Power Structure Internal Components (U, V or W Phase Assembly)
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
Diagrams on the following pages illustrate disassembly and assembly of the
AFE and its sub-systems and are followed by a list of spare part numbers
where applicable.
When ordering spare parts, you must provide the serial number of the
PowerFlex Active Front End. The serial number is located on the data
nameplate on the Control Frame just above the bar code.
Data Nameplate on AFE
in IP20 2500 MCC Style Enclosure
0035
-842
0/435
Data Nameplate on AFE
in IP21 Rittal Enclosure
Cat No.
J
20D
500 N 0 NNNBNNNN
UL Open Type/IP00
Frame: 13
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)
Continuous Amps
420/500
630/550
1 Min Overload Amps
AFE
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,
462 - 594 583 - 713
DC Voltage Range
Amps
350
350
Output: 3 Phase, 0 - 320Hz
AC Voltage Range
0 - 400
0 - 460
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
MFD. in 2005 on Feb 29
MADE IN THE USA (FAC 1B)
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 #: 13
Serial Number: 2622381987
Serial Number: 2622381652
2622381652
MADE IN THE USA (FAC 1B)
26223816
A complete list of spare parts for the Frame 13 PowerFlex Active Front End
is available on the Allen-Bradley website at
http://www.ab.com/support/abdrives/powerflex70/PF7ReleasedParts.pdf.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
D-2
Disassembly/Assembly Diagrams and Spare Parts
AFE Power Structure
Assembly
Figure D.1 AFE Power Structure Assembly External Components
!
ATTENTION: The sheet metal cover and mounting screws on
the ASIC Board located on the power structure are energized at
(-) DC bus potential high voltage. Risk of electrical shock, injury,
or death exists if someone comes into contact with the assembly.
Front Covers
ASIC Assembly
Upgrade Kit
Terminal Covers
Bus Bar Assembly
Fuse Holders for Fan Inverters
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 Holders for Fan Inverters (only AC fan system)
20-PP01094 (1)
Fan Inverter Fuse (only AC fan system)
20-PP20202 (1)
Terminal Covers
n/a
Front Covers
n/a
Power Structure
Maintenance Stand
(1)
400/480V (1300A)
SK-Y1-PWRMOD-D1K3
600/690V (1030A)
SK-Y1-PWRMOD-E1K0
20-MAINSTD
For additional AC fan system information, see publication PFLEX-IN029.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Disassembly/Assembly Diagrams and Spare Parts
D-3
Figure D.2 AFE Power Structure Internal Components (U, V or W Phase Assembly)
EMC Cover
DC Bus Bar Assembly
Snubber Capacitor Assembly
Power Bus Bar
Balancing Resistors
Electrolytic Capacitors
Power Module (IGBTs)
DC Bus Bar Terminal Assembly
AC Fan Inverter Assembly or
DC Fan Power Supply
(see publication PFLEX-IN029
for complete details)
Main Cooling Fan Assembly
(see publication PFLEX-IN029
for complete details)
Air Flow Channel
Screening Plate
Gate Driver Board
Table D.B AFE Power Structure Internal Component Part Numbers for
U, V, or W Phase Assembly
Part Name
Part No.
Air Flow Channel
n/a
Balancing Resistors
n/a
DC Bus Bar Assembly
n/a
DC Bus Bar Terminal Assembly
Electrolytic Capacitors
n/a
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-H1-GDB1-F1314D
600/690V
SK-H1-GDB1-F1314E
400/480V
SK-H1-QOUT-D1K3
600/690V
SK-H1-QOUT-E1K0
Power Bus Bar
n/a
Screening Plate (for Gate Driver Board)
n/a
Snubber Capacitor Assembly
n/a
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
D-4
Disassembly/Assembly Diagrams and Spare Parts
!
ATTENTION: The sheet metal cover and mounting screws on
the ASIC Board located on the power structure are energized at
(-) DC bus potential high voltage. Risk of electrical shock, injury,
or death exists if someone comes into contact with the assembly.
Figure D.3 AFE Power Structure ASIC Assembly
ASIC Assembly Cover
ASIC Board
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
600/690V AFE
Fiber Optic Cable Set
(1)
The ASIC board is unprogrammed.
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
SK-H1-ASICBD-D1300
SK-H1-ASICBD-E1030
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 High Frequency
Capacitor Assembly
(located behind)
LCL Capacitor
Assembly
Table D.D LCL Filter Assembly Part Numbers
Part Name
LCL Filter Assembly
Part No.
400/480V
SK-Y1-LCL1-D1K3
600/690V
SK-Y1-LCL1-E1K0
LCL High Frequency
Capacitor Assembly
25 µF 400/480V
SK-Y1-CAPHF3-DF
20 µF 600/690V
SK-Y1-CAPHF2-DF
LCL Capacitor Assembly
120 µF 400/480V
SK-Y1-CAPLCL1-D1K3
53 µF 600/690V
SK-Y1-CAPLCL1-F1K0
LCL Filter Inverter Fan Fuse
SK-Y1-F11-F10
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
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 Name
Part No.
Main Fan, 48V DC
SK-Y1-DCFAN1
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-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 Resistors
• Precharge Fuse and Fuse
Holder
• Precharge Kit
• Control Transformer (T4)
• Control Transformer Primary
Fuse and Fuse Holder
• 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-F13
Precharge Fuse Holder
SK-Y1-MCCF5FUSEHOLDER-F13
Precharge Kit
(1)
SK-Y1-PRE2-F13
Control Transformer (T4), 1500VA
Control Transformer Primary
Fuse
SK-R1-OFANXFMR-F13
400/480V
SK-Y1-MCCF6-D
600/690V
SK-Y1-MCCF6-F
Control Transformer Primary Fuse Holder
SK-Y1-MCCF6FUSEHOLDER
Control Transformer (T10) Secondary Fuse/Holder
SK-Y1-MCCF3F4
(1)
Kit includes diode bridge (V6), one resistor (R6.1), and a snubber capacitor (C1).
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
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)
Control Transformer (T4);
mounted on back wall
behind Control Frame
assembly
• 24V DC Power Supply
(T10) and Circuit
Breaker
• Control Transformer
Motor Protection Relay
• Control Transformer
Circuit Breaker
•
•
•
•
Precharge Fuse
Precharge Kit
Precharge Motor Protection Relay
Fuse Disconnect Switch
These components are located on a sub-panel
mounted behind the Control Frame assembly.
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-F6-DISC-DF
Precharge Kit (1)
SK-Y1-PRE1-F13DF
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-F13
(1)
Kit includes diode bridge (V6), contactor (K6), two resistors (R6.1 and R6.2), and a
snubber capacitor (C1).
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-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)
DC Bus
Fuses
Input Circuit Breaker
AC Input Fuses
Input Contactor
Table D.I AC Line Switchgear Part Numbers for AFE in IP20 2500 MCC Style
Enclosure
Part Name
AC Input Fuses
Part No.
400/480V
SK-Y1-MCCF1-F13D
600/690V
SK-Y1-MCCF1-F13F
DC Bus Fuses
400/480V
SK-Y1-MCCF2-D
600/690V
SK-Y1-MCCF2-F
Input Circuit Breaker
400/480V
SK-Y1-MCCQ0-F13
600/690V
Input Contactor
SK-Y1-MCCK1-F13
LCL Filter Bay Door Fan Kit (two at top of door; not shown)
20-750-FAN3-F8
Right-side Bus Splice Kit (not shown; optional)
SK-Y1-BUSSPLICE-F13R
Left-side Bus Splice Kit (not shown; optional)
MCC Bus Splice Barrier Kit (not shown; optional)
(1)
SK-Y1-BUSSPLICE-F13L
(1)
SK-Y1-MCCBARRIER
The MCC Bus Splice Barrier kit must be used when installing a Right-side Bus Splice kit
(SK-Y1-BUSSPLICE-F13R) or a Left-side Bus Splice kit (SK-Y1-BUSSPLICE-F13R).
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-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)
Input Disconnect Switch
Motor Controlled
Circuit Breaker
Table D.J AC Line Switchgear Part Numbers for AFE in IP21 Rittal Enclosure
Part Name
Control Circuit Relay
Part No.
230V AC
SK-Y1-K20-DF
24V DC
SK-Y1-K4-DF
Input Disconnect Switch
SK-Y1-Q0-F13
Motor Controlled Circuit Breaker
SK-Y1-Q1-F13
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Appendix
E
AFE Power One-line System Application Data
Data to Collect
Collect the following AFE system data before contacting Allen-Bradley
Technical Support.
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
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
E-2
AFE Power One-line System Application Data
Typical Transformer
Winding Types
The following diagrams show typical transformer winding types.
Delta-Wye with Grounded Wye Neutral
Delta-Delta with Grounded Leg
or
Four-Wire Connected Secondary Delta
or
Ungrounded Secondary
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Index
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 for U, V, or W
phase assembly, 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
C
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-6
AFE in IP21 Rittal enclosure, B-15
creating fault reports, 1-2
D
DC fuses
overview, 8-1
replacement guidelines, 8-2
de-energizing the AFE, 4-3
diagnostic status indicators, 3-2
diode tests
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
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 tunnels, 3-2
power structure, 3-2
internal components of AFE power structure
for U, V, or W phase assembly, D-3
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-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, 7-7
removing protective covers, 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
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
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, 4-12
AFE protective barriers, 4-10
ASIC circuit board, 4-15
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 boards, 4-13
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, 7-7
protective covers, 7-2
power from AFE, 4-3
power modules from U, V, or W phase
assembly, 4-25
power structure DC bus capacitors from
U, V, or W phase assembly, 4-30
power structure from enclosure, 4-19
power structure main cooling fans, 4-18
protective covers from the power
structure, 4-13
U, V, or W phase assembly from AFE
power structure, 4-23
replacing power structure with a new power
structure, 4-31
resources
publications, P-2
website, P-1
reverse biased diode tests, 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
S
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
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
Index-4
PowerFlex Active Front End—Frame 13 Hardware Service Manual
Publication 20Y-TG002B-EN-P
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If you experience a problem within the first 24 hours of installation, review the information that is contained in this
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Publication 20Y-TG002B-EN-P - February 2015
Supersedes Publication 20Y-TG002A-EN-P - January 2010
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