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PowerFlex 700AFE User Manual

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1. Shown with O enclosure doors removed O O PEE O AA AA E FRONT VIEW RIGHT SIDE VIEW Table 13 AFE Frame 13 Power Terminal Specifications in IP21 Rittal Enclosure Wire Size Range 2 Torque 1 Item Name Frame Description 3 Terminal Bolt Maximum Minimum Recommended gt Z o Input Power Terminals 13 Input power 300mm 2 1mm 70 Nem M12 11 12 13 0 600 MCM 14AWG 620 Ib in 2 SHLD Terminal PE 13 Terminating point for wiring shields 300 mm 2 1mm 40 Nem M10 Ground 600 MCM I4 AWG 354 Ib in dcBus 9 bc D 13 DC output 300mm 21mm 70N m M12 600 MCM 14 AWG 620 Ib in Maximum minimum sizes that the terminals will accept these are not recommendations Do not exceed maximum wire size Parallel connections may be required These connections are bus bar type termination
2. s ql MES a X3 Terminal Block Location J 3 SS 1 FRONT VIEW FRONT VIEW Rockwell Automation Publication 20Y UMOOTE EN P July 2014 33 Chapter1 AFE in IP20 2500 MCC Style Enclosure Installation Wiring 2 Move the wire shown in Figure 13 to the appropriate X3 terminal to match the AC line voltage Figure 13 Input Voltage Setting for Control Voltage on Frames 10 and 13 in IP20 2500 MCC Style Enclosure For 400 480V or 600 690VAC Input 400 480 600 690 OIOJOJO X3 Terminal Block OOO h Move this wire to the terminal that matches the AC line voltage 34 Rockwell Automation Publication 20Y UM001E EN P July 2014 AFE in IP20 2500 MCC Style Enclosure Installation Wiring Chapter 1 Power Terminals for AFE in IP20 2500 MCC Style Enclosure The following figures and tables show the power terminal locations and specifications for AFE Frames 10 and 13 in an IP20 2500 MCC Style enclosure Figure 14 A
3. go i ene Sine cani I A eg ee Se ee gt ee E eee l I Vy s i AC Line N LCL Filter L1 i l AFE DC Switchgear Pg Fuses 3 Phase 00 u i i AC Input po l Lj BAAN ARAL 21 E 71 e TF t XE pa TOR IH ADM Hn x Ti Ss hd WANA DAMMI i DC Bus i T i4 23 Output it a a ag AA IA E I Ld EHE 24 I I G j6 x 25 I C x E I I I i m E 26 I A A r I Motor Protection Precharge Relay Precharge Precharge uses Contactor A Circuit P F6 Q5 K6 V e Y y I I I Ld EN I I PowerFlex i Active Front End System Rockwell Automation Publication 20Y UMOOTE EN P July 2014 53 Chapter2 AFE in IP21 Rittal Enclosure tnstallation Wiring Main Component Locations Frame 10 This section shows the main component locations for AFE Frame 10 and Frame 13 systems in a IP21 Rittal enclosure The following figure shows the main components of the AFE Frame 10 system in a IP21 Rittal enclosure Figure 24 AFE Frame 10 Main Component Locations in IP21 Rittal Enclosure FRONT VIEW shown with enclosure doors removed o 9o MO oo o e AIA o o o oo
4. FRONT VIEW OF LCL FILTER Rockwell Automation Publication 20Y UMOOTE EN P July 2014 69 Chapter 2 70 Close up View of Common Mode Capacitor Assembly AFE in IP21 Rittal Enclosure Installation Wiring Frame 10 Power Structure The AFE Frame 10 power structure in the IP21 Rittal enclosure contains common mode capacitors that must be removed Use the following procedure to remove these capacitors from the AFE Frame 10 power structure 1 Locate the common mode capacitors on the Frame 10 power structure Location of Common Mode Capacitors on Frame 10 Power Structure 2 Remove the common mode capacitors a Disconnect the two black wires b Unscrew and remove the capacitor assembly consisting of two capacitors on a small metal bracket Close up View of Common Mode Capacitor Assembly Rockwell Automation Publication 20Y UMOOTE EN P July 2014 AFE in IP21 Rittal Enclosure lInstallation Wiring Chapter 2 Frame 13 Power Structure The AFE Frame 13 power structure in the IP21 Rittal enclosure contains common mode capacitors that must be removed These capacitors are located on the Phase V center module of the power structure Use the following procedure to remove these capacitors from the AFE Frame 13 power structure 1 Locate the common mode capacitors on t
5. Description Precharge Circuit LCL Filter L1 Active Front End Power Structure U1 Switchgear Motor controlled Circuit Breaker Input Disconnect AFE Control Assembly shown with user installed HIM Item o e e 9 ACLine e 6 O DC Fuses 54 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 AFE in IP21 Rittal Enclosure lInstallation Wiring Chapter 2 Frame 13 The following figure shows the main components of the AFE Frame 13 system in a IP21 Rittal enclosure Figure 25 AFE Frame 13 Main Component Locations in IP21 Rittal Enclosure FRONT VIEW shown with enclosure doors removed mei SSS 555 25 E EE 5555 5555 SSS 52 46 SS S526 S65 555 2 4 SS SSS SS These components are located on a sub panel mounted in front of the bus bars shown above Item Description o Precharge Circuit O LC Filter L1 e Active Front End Power Structure U1 4 AC Line Motor controlled Circuit Breaker e Switchgear Input Disconnect 6 AFE Control Assembly shown with user installed HIM 7 DC Fuses Rockwell Automation Publication 20Y UM001E EN P July 2014 55 Chapter2 AFE in IP21 Rittal Enclosure Installation Wiring Mounting Considera
6. Logix to 20 COMM x 20 COMM x to Logix Word Output1 0 Word Input 1 0 1 LogicCommand 1 Logic Status 2 Reference bus voltage 2 Feedback bus voltage 3 Datalink In A1 3 Datalink Out A1 4 Datalink In A2 4 Datalink Out A2 5 Datalink In B1 5 Datalink Out B1 6 Datalink In B2 6 Datalink Out B2 7 Datalink In C1 7 Datalink Out C1 8 Datalink In C2 8 Datalink Out C2 9 Datalink In D1 9 Datalink Out D1 10 Datalink In D2 10 Datalink Out D2 142 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Supplemental Information Appendix A Logic Command Word for PowerFlex 750 Series Drives Logic Bits 31 13 12 11 10 9 8 7 Command Description Normal Stop 0 Not Normal Stop Normal Stop Start 0 Not Start Start Jog 17 0 Not Jog 1 Par 556 Jog1 Clear Fault 9 0 Not Clear Fault Clear Fault Unipolar Direction 00 No Command 01 Forward Command 0 Reverse Command 1 Hold Direction Control Manual 0 Not Manual Manual x Reserved x x Accel Time 00 No Command 01 Use Accel Time 1 Par 535 0 Use Accel Time 2 Par 536 Use Present Time x x Decel Time 00 No Command 01 Use Decel Time 1 Par 537 0 Use Decel Time 2 Par 538 Use Present Time X Ref Select 1 0
7. FRONT VIEW OF LCL FILTER Frame 10 or Frame 13 Power Structure IMPORTANT The Frame 10 or Frame 13 AFE in a IP20 2500 MCC Style enclosure is shipped from the factory with the common mode capacitors removed so the user need not do this However when a power structure is replaced the common mode capacitors in the new power structure must be removed by the user prior to installation For instructions to do this see Frame 10 Power Structure on page 70 or Frame 13 Power Structure on page 71 Using the AFE with When the Active Front End is used with drives that have common mode capacitors for example PowerFlex 7 Class or PowerFlex 750 Series drives the PowerFlex Drives common mode capacitors of these drives must be disconnected See the documentation for the respective drives When supplying power to PowerFlex drives of different frame sizes on the same DC bus additional bus capacitance may be needed For details see Drives in Common Bus Configurations publication DRIVES AT002 Control Wiring The AFE in a IP20 2500 MCC Style enclosure is factory wired and programmed to operate from the operator switches on the front of the enclosure See Table 7 and Figure 21 for I O terminal designations Only when customized or remote 40 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 AFE in IP20 2500 MCC Style Enclosure Installation Wiring Chapter 1 control is required will
8. Imensions Dimensions are in millimeters and inches 45 AFEFrame 13 in IP21 Rittal Endosure D 1264 7 49 8 Figure Supplemental Information Appendix A e gt pm LL ia au won e d lt 2 cc o Oo a O Y E 2 J S vy gt ry N co a e nn co ol A y N o ol f EL ER B s 5 090209020009090 090000090 090000000000090 Q808586865 gt d 00200002090909 808086808 un co a 8020002000000000 9096999990 in e 0505056 000000009 OS0S0S050 ce uy e OSOS OSO SOSOSONOS OLOPOLO SS 0202020902020909 0809090909 als 090900000009090 9096999090 8969098989090989 OZ0ZOZOZO8 000000000000000 000000000 o o H me ua A e ol EL 3 d eS io n o o A 20920202090909208 909202020 o 2090909090909090 090909090 Kt 8080808080805059 8080803080 4 i i el 080208090209090 862086805 S eo 0909090809000809 0209090209 old 2908080900080909 peee E 090900080000090 090000090 QBOLOLG20808680 OLOPOLO lt olo 9862995839995998 8020802020 020200000000090 090009090 sic 8090909020909020 Bo8o858086 ss 090200000000090 Q808586865 sis 080909
9. This is the safety ground for the AFE that is required by code This point must be connected to adjacent building steel girder or joist a floor ground rod or bus bar see above Grounding points must comply with national and local industrial safety regulations and or electrical codes Shield Termination SHLD The Shield terminal Figure 30 or Figure 31 provides a grounding point for the AFE cable shield It must be connected to an earth ground by a separate continuous lead The drive cable shield must be connected to this terminal on the AFE end and the drive frame on the drive end Use a shield terminating or EMI clamp to connect the shield to this terminal 60 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Fuses and Circuit Breakers Power Wiring AFE in IP21 Rittal Enclosure Installation Wiring Chapter 2 The IP21 Rittal enclosure for the AFE includes a motor controlled circuit breaker MCCB and DC bus output fusing The MCCB is used for precharge operation For details on MCCB and precharge operation see page 78 For fuse and circuit breaker information see Appendix A Local national electrical codes can determine additional requirements for the installations Because most start up difficulties are the result of incorrect wiring take every precaution to verify the wiring is correct Read and understand all items in this section before beginning installation Rockwell Automation cannot assume
10. q 142 6 LI 5 6 76 192 6 242 6 9 6 RIGHT SIDE VIEW Overall Dimensions mm inches Weight kg bs Height 1032 40 6 Width 708 27 9 Depth 553 21 8 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 306 675 Supplemental Information Appendix A Figure 50 Control Box Dimensions only for AFE in IP21 Rittal Enclosure Dimensions are in millimeters and inches a A 190 7 7 5 A En o po x q 213 36 8 4 La d H LI 1 _ Frame Overall Dimensions mm inches Size A B C 10 532 24 20 6 446 17 6 135 96 5 4 13 733 67 28 9 448 17 6 135 96 5 4 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 139 AppendixA Supplemental Information DPI Communication This section contains information about using DPI communication with the Con figu rations PowerFlex Active Front End Typical Programmable Controller Configurations IMPORTANT Ifprograms are written that continuousl
11. To Drive Control DPI Interface Board Description HIM connection when installed in AFE Cable connection for handheld and remote options Splitter cable connected to DPI Port 2 which provides an additional port No Connector O DPIPort1 O DPIPort2 DPIPort3or2 O DPIPort5 Cable connection for communications adapter 1 There is no Port 4 on PowerFlex 7 Class products Port 4 only exists on legacy SCANport products Rockwell Automation Publication 20Y UMOOTE EN P July 2014 145 AppendixB HIM Overview LCD Display Elements ALT Functions 146 Display Description Fe PowerLoss Auto Direction Drive Status Alarm Auto Man Information Commanded or Output Volts Main Menu Diagnostics Parameter Device Select Programming Monitoring Troubleshooting To use an ALT function press the ALT key and release it and then press the programming key associated with the desired function listed in the following table Table 23 ALT Key Functions ALT Key plus Function View Selects how parameters are viewed or shows detailed information O about a parameter or component O Lang Displays the language selection screen 2 Auto Man Switches between Auto and Manual Modes Remove Lets the HIM be removed without causing a fault if the HIM is not the ES last controlling device and does not have manual control of the AFE e
12. Thermal Switch 1 Thermal Switch 9 To Digital 5 Input 5 Yop Frame 10 LCL Filter O The input of the acknowledge signal from the main contactor is missing Digital input functions are in conflict DC voltage reference is less than the limit in parameter 080 DC Ref Lo Lmt DC voltage reference exceeds the limit in parameter 081 DC Ref Hi Lmt O DC voltage is less than the value set by parameter 078 DC Bus Lo Alarm DC voltage exceeds the value set by parameter 079 DC Bus Hi Alarm Rockwell Automation Publication 20Y UMOOTE EN P July 2014 B X52 is located on the LCL Filter X52 approximate location 0 O 0 0 0 Frame 13 LCL Filter Check ifthe main contactor is closed Check the wiring of the feedback signal Check the parameter settings to correct the problem Check the parameter setting Check the parameter setting Check the parameter setting Check the parameter setting Table 22 Fault Alarm Cross Reference By Name Troubleshooting Chapter 5 Fa
13. Default Bit X X X x 15 14 13 12 x X x 11 10 9 Values Default Min Max Units Default Options 0 Control Permitted 1 1 Control Masked x Reserved Based on Unit Rating Based on Unit Rating 1V AC 0 Normal 0 Normal 1 Auto No Description File Lists the major parameter file category Group Lists the parameter group within a file No Parameter number 8 Parameter value cannot be changed until the AFE is stopped Vy 32 hit parameter Parameter Name amp Description Parameter name as it appears on an LCD HIM with a brief description of the parameter function Values Defines the various operating characteristics of the parameter Three parameter types exist ENUM Default Lists the value assigned at the factory Read Only no default Options Displays the available programming selections Bit Bit Lists the bit place holder and definition for each bit Numeric Default Lists the value assigned at the factory Read Only no default Min Max The range lowest and highest setting possible for the parameter Units Unit of measure and resolution as shown on the LCD HIM How AFE Parameters are The LCD HIM displays parameters in a File Group Parameter or Or gan ized Numbered List view order To switch display mode access the Main Menu press the qu key and release it and while the cursor is on the pa
14. D 2 Ba nf na F r c M en Se a A E sem Y o O T 0929992929202 09292580 OSOS OSOS OS SOSOS Q8o8o8o808 A Q8OSO8o808056805 080800000 Bakoko8a8o80 680 030909090 090900209090809 0209000209 O808086852080808 802080868 E oseseessese sees 808680808 x OR OSOS OSOS OS SO 000000000 ORO OSO SO SOLOS 80808080 S 000200000200090 000000000 ni ORO SOS OSOS OS OSOS 0808080809 S OSOS OS OSOS OSOSOS 080808090 n Ro BORO SOS OSOS oSOSO 2095999090 2 000000000000000 000000000 e eur OZOZIZIZIZOZIZOI a808080808 Cs rr Ss SZOZIZIZIGIZORO 980505089 mo OLSLSLSLSLSLqL09 0909099909 eo gt ss QBo8oRa8o20858o8 808080808 gt ca OBS OS OSOS OSOS 80898080 e az 0000000000000009 00000600000 eS E Nm 0000000009009000 0000000900 Sa 2 i SQ e m n me e e Lo o A F ce 7 D e e LE fo o ca 2920292026252 250595962 8 P tr OSOS OSOS OSO SOLOS 0202090209 A e OOOO OS OSOS OS OSOS 080808090 gt a G909095909090909 0909080809 oo eo Kee ees esee 9030909090 n 80200900809000 3090309030 yo un 8080000000600000 6080808099 Ne Co H 090000090909090 000000000 x als 8080208080208080 8090902090 vi R 70 0 59696PS S O 000000000 n gt w N i i A S ila M mo Y i alle ol Wu Les 23 ci gt e SS 133 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 1 0 2242 5 88 3 25 Height to Lifting Lug Y 536 21 1
15. DC Bus lc cdm aes Arctic I a N ACLine II LCL Filter L1 AFE i DC I Switchgear i i Power Structure U1 Fuses 3 Phase I 00 Q i AC Input 1 E I VI I a Sy y Ta nnn e Pun y oU I I l IRTE vi 12 se y La e s AU rr dE RE 2 1 R B HHHH C NNN AS oW 22 I i i I o PE DC HA oy I a a l I I Leese esa Lr I PE jp J I I Q C5 I mu I I a l Si I I B 6 F I F3 I Hc PUR ipod Clodio I Motor Protection l Precharge Relay Precharge Precharge I Fuses Contactor A I l Circuit I I t l I I E I I l I F6 Q5 K6 I b 6 1 I CH t l l R2 l l I o l l I L PowerFlex Active Front End System 52 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Output L1 D B AFE in IP21 Rittal Enclosure lInstallation Wiring Chapter 2 Frame 13 The following figure shows a basic one line diagram for an AFE Frame 13 in a IP21 Rittal enclosure The main component sections consist of the following items e AC Line Switchgear consisting of the input disconnect Q0 and MCCB motor controlled circuit breaker Q1 e LCL Filter L1 e Precharge Circuit e AFE power structure U1 with AFE control assembly e DC fuses F2 1 F2 6 Figure 23 Basic One line Diagram for an AFE Frame 13 in IP21 Rittal Enclosure
16. PowerFlex Customer supplied Parts Customer supplied Parts Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Customer supplied enclosure 19 Preface The following figure shows a basic one line diagram for an AFE Frame 13 ina IP00 NEMA UL Open Chassis configuration and the parts the customer must supply Figure 5 Basic One line Diagram for an AFE Frame 13 in IP00 Open Chassis Configuration e I I 1 r q n 1 i AC Line Switchgear LCL Filter L1 AFE DC I Input Input i I l Fuses Breaker Contactor I I I Pad Q0 Fuses K1 l nput l H I I put pai F1 1 F1 3 i M 11 HT o j T E DC Bus D ESA SS l r1 TA Output B e Me i l l i B3 l C L E H mE Customer C5 I B4 1 supplied I I Parts ee 105 I i i o I R6 NENNEN E I e Customer supplied I Precharge Precharge Precharge Parts Fuses Contactor Hon FS Circuit K6 I I ae DI R6 1 o gt E DI e DI o gt PowerFlex E l I Active Front End System ZA AZZ eS hee L M wenn Cu
17. 111 Alarm 2 Fault Read Only Captures and displays the bit pattern of parameter 098 Cnvrtr Alarm 2 at the time ofthe last fault Bit z g Definition TE s S D 212 1 Condition True Default x x x x x x x 0 0 0 Condition False Bit 15 14 13 12411 10 9 1 0 x Reserved 112 Testpoint 1 Sel Default 499 Selects the function whose value is displayed in parameter 113 Testpoint 1 Data These are internal values Min Max 0 65535 that are not accessible through parameters Units None 113 Testpoint 1 Data Default Read Only Displays the present value of the function selected in parameter 112 Testpoint 1 Sel Min Max 32767 Units None 114 Testpoint 2 Sel Default 499 Selects the function whose value is displayed in parameter 115 Testpoint 2 Data These are internal values Min Max 0 65535 that are not accessible through parameters Units None 115 Testpoint 2 Data Default Read Only Displays the present value of the function selected in parameter 114 Testpoint 2 Sel Min Max 32767 Units None 116 Cnvrtr OL Count Default Read Only Displays the accumulated percentage of AFE overload Continuously operating the AFE over the set level will Min Max 0 196 4 100 096 increase this value to 100 and cause an AFE fault Units 0 1 104 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 E 120 124 126 128 130 125 127 129 131 Programming and Parameters Chapter 4
18. I K6 I l I I l ies E A I amp o E PowerFlex I DI Ad l I 700AFE System o r 1 Tm mp E 1 l AC Line Switchgear LCL Filter L1 AFE DC i E Input Input I Power Structure U1 Fuses I p Breaker Contactor I Q0 Fuses K1 I F1 1 F1 I Fo 4 I I I sa iud F21 xi I ig e I Fi H T Le E ly I i I F2 3 I I i I 7 I am ial ae I aa ft I I I l i I 1 B5 I I PE EE 3 ie Fg lop 9 I L J I l Precharge Precharge Precharge l I Fuses Contactor FE l FS Circuit I T I I I I I I l I K6 I I I ued DI 6 1 o gt e DHe PowerFlex l pi gt l I I 700AFE System 9 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 157 AppendixC Application Notes Guidelines for AFEs in IP21 Rittal Enclosure e AFE units of different power sizes can be connected in parallel e For AFEs in IP21 Rittal enclosures a maximum of six AFEs can be paralleled However this can be limited by the capacity of the DC bus bar e Each AFE must have its own LCL filter e Each AFE must have its own short circuit protection on A
19. b Turn the 0 1 START switch to START and let it automatically return to 1 The precharging takes about 5 10 seconds depending on the connected DC bus capacitance When the DC bus voltage has reached its nominal value the AFE control automatically closes the circuit breaker The precharging can be aborted by turning the switch to 0 off To stop the AFE turn the 0 1 START switch to 0 off NOTE Pressing the Stop key on the HIM only stops the AFE output it does not open the MCCB to stop the AFE When a voltage drop or a blackout occurs in the supplying network the under voltage release coil opens the circuit breaker To turn on the AFE turn the 0 1 START switch to START and let it automatically return to 1 on 3 REM Remote operation with signals to the control terminals a Set the MCCB CONTROL switch to REM b Connect a normally closed NC contact to terminals X1 58 and X1 61 This contact has to be in the NC state for the AFE to precharge and run A remote pulse of 0 4 1 0 second duration connected to terminals X1 57 and X1 60 starts the precharging of the AFE When the DC voltage has reached its nominal value the AFE unit automatically closes the circuit breakers To stop the AFE turn the 0 1 START switch to 0 off NOTE Pressing the Stop key on the HIM only stops the AFE output it does not open the MCCB to stop the AFE When a voltage drop or a blackout occurs in the supplying network the undervolt
20. 1 0 239 552 LEFT SIDE VIEW BM 94 217 566 FRONT VIEW gt 223 T RIGHT SIDE VIEW ad 140 5 5 75 A Be die o OG Sines Se l B s o O BOTTOM VIEW Overall Dimensions mm inches Weight kg bs Height Width Depth 1050 41 3 239 9 4 556 22 3 100 221 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 137 Appendix A Supplemental Information Figure 49 AFE Frame 13 Power Structure Dimensions Dimensions are in millimeters and inches 147 58 lt Tp qi 3 3 lt 22 3 j 5 al la ip la al O OL i A I I 4 I 1012 5 39 9 mM O or O 373 i 14 7 E 107 o ol lo ol lo ol ul I 4 Y 514 8 lt 20 3 FRONT VIEW 0 26 1 0 LEFT SIDE VIEW Both Sides 620 5 ie 24 4 388 5 15 3 156 5 62 lt lt l l 1 O FT IT CA CA CA BOTTOM VIEW CARO DECO Chica J 43 6 L3 D O O a 708 gt 27 9 138 N I n I In yl Wo NS ES uu
21. 9 0 S Shown with endosure doors E o removed e fs E p 7 y fell o H i 0 TIO IES Ano E E El i EE E eS E E El EE ba FRONT VIEW RIGHT SIDE VIEW Table 12 AFE Frame 10 Power Terminal Specifications in IP21 Rittal Enclosure Wire Size Range Torque Item Name Frame Description 7 Terminal Bolt Maximum Minimum Recommended Ze O Input Power Terminals 10 Input power 300mm 2 1mm 40 Nem M10 L1 12 13 600 MCM 14AWG 354 Ibsin 2 SHLD Terminal PE 10 Terminating point for wiring shields 300 mm 21mm 40Nem M10 Ground 9 600 MCM 14AWG 354 bein DCBus P bc D 10 DC output 300mm 21mm 70N m M12 600 MCM 14AWG 620 Ib in 1 Maximum minimum sizes that the terminals will accept these are not recommendations 2 Do not exceed maximum wire size Parallel connections may be required 3 These connections are bus bar type terminations and require the use of lug type connectors 4 Apply counter torque to the nut on the other side of terminations when tightening or loosening the terminal bolt to avoid damage to the terminal Rockwell Automation Publication 20Y UMOOTE EN P July 2014 65 Chapter2 AFE in IP21 Rittal Enclosure Installation Wiring Figure 31 AFE Frame 13 Power Terminal Locations in IP21 Rittal Enclosure
22. Anlg In Config Selects the mode for the analog inputs Bit Definition V 1 mA 1 Current Default X X X x Tx x x 0 0 Voltage Bit 15 14 13 12 11 10 9 0 x Reserved 201 Analog In 1 Hi Default 10 000V Sets the highest input value to the Analog Input 1 scaling block Min Max 4 000 20 000 mA Parameter 200 Anlg In Config defines if this input will be 10V or 4 20 mA 10 000V Units 0 001 mA 0 001V 202 Analog In 1 Lo Default 0 000V Sets the lowest input value to the Analog Input 1 scaling block Min Max 4 000 20 000 mA Parameter 200 Anlg In Config defines if this input will be 10V or 4 20 mA 10 000V 5A Units 0 001 mA 5 0 001V 203 Analog In 1 Loss Default 0 Disabled Selects the AFE action when an analog signal loss is detected Signal loss is defined as an analog signal Options 0 Disabled A a lt less than 1V or 2 mA The signal loss event ends and normal operation resumes when the input signal 1 Fault level is greater than or equal to 1 5V or 3 mA 2 Hold Input A 3 Set Input Lo 5 4 Set Input Hi 5 204 Analog In 2 Hi Default 10 000V o ha Sets the highest input value to the Analog Input 2 scaling block Min Max 4 000 20 000 mA 5 Parameter 200 Anlg In Config defines if this input is 10V or 4 20 mA 10 000V Units 0 001 mA 0 001V 205 Analog In 2 Lo Default 0 000V Sets the lowest input value to the Analog Input 2 scaling block Min Max 4
23. Bit7 Faulted indicates the AFE has detected a fault Bit 8 At Reference indicates the DC bus voltage is at the command value Bit 9 Mot CurLim indicates the AFE exceeds the current limit in motoring mode Bit 10 Regen CurLim indicates the AFE exceeds the current limit in regenerative mode Bit 11 Cmd Delayed indicates pending start command e Bits 12 14 indicate the DC bus voltage reference selection Rockwell Automation Publication 20Y UMOOTE EN P July 2014 101 Chapter 4 102 Group Diagnostics Programming and Parameters No 096 097 098 099 Parameter Name amp Description Values Cnvrtr Status 2 Displays the present operating condition of the AFE and active source Bit Definition DPI at 500k g lt c 2 zx 5 1 Condition True gt AutoRst Ctdn gt ModindexLim Default x x 0 x x x 0 Condition False Bit 15 14 13 12111 10 9 x Reserved Bit 0 Ready indicates all inhibits are cleared Bit 1 Active indicates the AFE is modulating e Bit 2 ModIndexLim indicates the AFE reached the modulation index limitation Bit 8 AutoRst Ctdn indicates the auto restart timer is counting down e Bit 9 AutoRst Act indicates the auto restart function is activated Bit 13 DPI at 500k indicates DPI communication with 500k of baud rate Cnvrtr Alarm 1 Displays alarm conditions that present
24. Four tinned copper conductors with XLPE insulation Option 1 RHW 2 Anixter B29528 B29532 TM Copper braid aluminum foil combination shield and tinned Belden 29528 29532 or copper drain wire equivalent e PVCjacket Standard Tray rated 1000V 90 C 194 F Three tinned copper conductors with XLPE insulation Option 2 RHH RHW 2 Anixter OLFLEX e corrugated copper tape with three bare copper grounds in 76xxx03 or equivalent eA with Hen p pperg e PVCjacket Class amp Il Tray rated 1000V 90 C 194 F Three bare copper conductors with XLPE insulation and Division amp II RHH RHW 2 Anixter 7VFD xxxx impervious corrugated continuously welded aluminum or equivalent Cable Trays and Conduit A armor Black sunlight resistant PVC jacket overall Three copper grounds ATTENTION To avoid a possible shock hazard caused by induced voltages unused wires in the conduit must be grounded at both ends For the same reason if a drive sharing a conduit is being serviced or installed all drives using this conduit must be disabled This helps minimize the possible shock hazard from cross coupled motor leads If cable trays or large conduits are to be used refer to guidelines presented in Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives publication DRIVES IN001 Selecting and Verifying Control Transformer Voltage The control transformer in the AFE is used to match the
25. July 2014 11 AppendixA Supplemental Information The AFE supports 16 bit and 32 bit datalinks which can be selected on the Logix module definition screen for details see the communication adapter documentation The example screen below shows a 20 COMM E Ethernet IP adapter using a 32 bit parameter Datalink A on the input and two 16 bit parameters on the output Module Definition O x Revision fi y Datalink input Data Output Data e Eee ro LogicCommend Electronic Keying Compatible Module Feedback Reterence i we VA 3 TotslCurrent 2 75 MctorPowerL imt i Diva Humo soov 4604 Ri ScTotCurent TT 76 RegenPowerLm sf re Irc roe 7 I Connection Parameters via Detalinks Yi tant Data Format Parameters i Sort Input Output selection lists by Parameter Name q DANGER Unexpected hazardous motion of machinery may occur when improperly using software to configure a drive Parameter names selected for the Input and Output Data appear as member names in the dive Module Defined Data Types and defines necessary Datalink parameters in the RSLogix 5000 project Actual data transfer between controller and drive is determined by Datalink parameters You must download configuration to the drive to ensure that the controller drive and communication module configurations are consistent with each other Co I EE Hap i The data is used as shown below
26. No Signal Factory Default Description 1 Analog In 1 1 2 Isolated 9 bipolar differential 9 bit amp sign 88k ohm input impedance A jumper see 1 2 Analog In 1 4 Table 8 selects 0 10V 10V or 4 20 mA 3 Analog In 2 0 Default 0 10V Ri 200k ohm 4 20 mA MAO Ri 100 ohm 4 Analog In 2 1 5 10V Pot Reference 2k ohm min 10 mA max load 1 accuracy 6 Pot Common GND For and 10V pot references 7 10V Pot Reference 2k ohm min 10 mA max load 1 accuracy 8 Analog Out 1 2 Bipolar current out is not bipolar 9 bit and sign 2k ohm min load A jumper see 9 Analog Out Common Table 8 selects 0 10V 10V or 4 20 mA 10 Analog Out 2 11 Digital In 1 RunCmd 24V DC Opto isolated 250V Low State less than 5V DC 12 Digital In 2 Ext Reset High State greater than 20V DC 11 2 mA 13 Digital In 3 Enable Mcont DC Enable Digital Input 6 is jumper selectable 14 Digital In 4 Contactor Ack for HW Enable 15 DigitalIn5 LCL Temp On Time lt 16 7 ms Off Time lt 1 ms 16 Digital In 6 Hardware Enable see page 46 17 Digital In Common Allows source or sink operation 18 19 24v 0c Unit supplied logic input power 20 24V Common Common for internal power supply 21 Digital Out 1 nc Contact Ctrl Max Resistive Load 240V AC 30V DC 1200VA 150W 22 Digital Out 1 Common Max Current 5A Min Load 10 mA 23 Digital Out 1 N 0 Max Inductive Load
27. ON START REM MAN AUTO O d i D i The AFE READY status indicator lights up when precharge is completed the input contactor K1 is closed AC power is connected to the AFE and no faults are active The AFE READY status indicator operates independent of the control method The AFE FAULT status indicator lights to indicate that the AFE is in a fault state In an over current situation the fault that caused the input circuit breaker Q0 to trip must be identified and fixed before resetting the breaker Modes of Operation There are three different modes in which the contactor and precharge can be controlled The desired control is selected with the REM AUTO MAN selector switch 1 AUTO Automatic operation that automatically precharges and closes the contactor when the supply voltage is energized a Set the REM AUTO MAN switch to AUTO b Set the OFF ON START switch to ON Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Startup Chapter 3 The precharging of the units automatically starts when input power is present When the DC Bus Voltage reaches its nominal value the contactor closes To stop the AFE turn the OFF ON START switch to OFF NOTE Pressing the O Stop key on the HIM only stops the AFE output it does not open the input contactor to stop the AFE When a voltage drop or a blackout occurs in the supplying network the unit precharges automatically and closes the input
28. and 20 is required when using the 24V DC internal supply Incorrect digital input programming There is some other start inhibit Indication Flashing red status light None None Check status bits of parameter 100 Start Inhibits Corrective Action Clear fault Press the HIM O Stop key Cycle power to the AFE e Set parameter 121 Fault Clear to T Clear Faults see page 105 Clear Faults by using the HIM Diagnostic menu Wire inputs correctly and or install jumper Program Digital Inx Sel for correct inputs see page 111 Run programming may be missing Correct the source of the inhibit Instability in the AC Line Input Current and DC Bus Voltage Cause s ACline voltage more than 596 above normal Negative reactive Ref on parameter 065 Reactive Ref with a soft high impedance AC line Indication Instability in AC line current and DC bus voltage May trip on fault F7 Overload Instability in AC line current and DC bus voltage May trip an F7 overload Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Corrective Action Increase parameter 060 DC Volt Ref proportional to the percentage of the ACline voltage above nominal Change parameter 065 Reactive Ref value to zero Verify if the AFE is running on a soft line per AC line source considerations Figure 40 AFE Start Sequence Troubleshooting Diagram Sof
29. o o o gt n 700 Pe FRONT VIEW Rockwell Automation Publication 20Y UMOOTE EN P July 2014 27 Chapter1 AFE in IP20 2500 MCC Style Enclosure Installation Wiring AC Supply Source Considerations 28 The AFE Frame 10 or Frame 13 in a IP20 2500 MCC Style enclosure is suitable for use on a circuit capable of delivering 100 000 rms symmetrical amperes at 400 480V and 65 000 rms symmetrical amperes at 600 690V The AFE must not be used on undersized or high impedance supply systems The supply system kVA must be equal to or greater than the drive related kW and the system impedance must be less than 10 Operation outside these limits can cause instability resulting in AFE shutdown System Impedance PowerFlex 700AFE kVA Transformer kVA x Transformer Impedance You must take into account the kVA of all PowerFlex AFEs on the distribution system and the system impedance of upstream transformers by improper fusing or circuit breaker selection use only the recommended line ATTENTION To guard against personal injury and or equipment damage caused fuses or circuit breakers specified in Appendix A If a Residual Current Detector RCD is used as a system ground fault monitor use only Type
30. 0 Normal The AFE starts only with the Run request by a RUN or START command 1 Auto The AFE starts regenerative operation automatically whenever the DC bus voltage is higher than the DC voltage reference and stops when there is no regeneration To avoid starting a digital input can be configured to Enable and turning off the digital input stops the automatic starting Restart Delay Sets the minimum time between a previous stop command and the next start request to start the AFE This parameter takes effect only if parameter 46 Start Stop Mode is set to 0 Normal Stop Delay Sets the off time delay between the removal of a Run request and stopping the modulation This parameter takes effect only if parameter 046 Start Stop Mode is set to 1 Auto The converter stops modulating after Stop Delay when the converter changes from regenerative to motoring mode and the DC bus voltage is at least 3 below the DC voltage reference Auto Stop Level Sets the active current level for the Auto operation mode when parameter 046 Start Stop Mode is set to 1 Auto When the active current value is higher than this value the regeneration stops Contact On Delay Sets the Main contactor on delay time the delay from Main contactor acknowledge to modulation start Values Default Min Max Units Default Min Max Units Default Options Default Min Max Units Default Min
31. 1 Factory Resets parameters to factory defaults 2 Low Voltage Resets parameters to factory defaults and configures parameters for a 400 480V AFE unit for 400V operation e 600 690V AFE unit for 600V operation 3 High Voltage Resets parameters to factory defaults and configures parameters for a 400 480V AFE unit for 480V operation e 600 690V AFE unit for 690V operation NOTE The DC bus voltage must be present to set the voltage class 3 Use the HIM to enter the Assisted Start up procedure Step Example LCD Display a Inthe Main Menu use the Y or Key to scroll to Start Up b Press the Enter key F gt Stopped Main Menu Memory Storage Preferences Volt Default 0 Ready Option 0 Ready 1 Factory 2 Low Voltage 3 High Voltage Auto Figure 37 Active Front End Start up Procedure Menu Main Menu DE gt Alarm Fit Cnfg gt Limits gt DC Bus Ctrl Done gt Start Stop l 0 IE Exit Y Y Y Y Sets Input Defines Sets Current Sets the Voltage Configurable and DC Bus Voltage Alarms and Faults Power Limits Reference Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Y Configures Digital Inputs including Run Digital Outputs and Analog Outputs Startup Chapter3 4 Enter the Input Voltage Selection in the Start up Routine Select the appropriate AC input voltage for your installation 48
32. Alarm 1 4 Code parameters to 0 Options 0 Ready 1 Clr Alarm Que 137 Alarm 1 Code Default Read Only 138 Alarm2 Code Min Max 0 65535 139 Alarm3 Code 140 Alarm 4 Code Displays a code that represents a converter alarm The codes appear in the order they occur Alarm 1 Code the most recent alarm A time stamp is not available with alarms Units None 106 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Programming and Parameters Chapter 4 Communication File File COMMUNICATION Comm Control Masks amp Owners 152 153 154 155 156 157 158 Parameter Name amp Description DPI Baud Rate Default Read Only Displays the 500 kbps baud rate that DPI uses for peripherals attached to the AFE Cnvrtr Logic Rslt Read Only Captures and displays the final Logic Command resulting from the combination of all DPI and discrete inputs This parameter has the same structure as the product specific Logic Command received via DPI and is used in peer to peer communications Bit 3 Definition gt El E E 1 Condition True Default X x ix x x 0 x x JO x x x 10 0 Condition False Bit 15 14 13 12 11 10 9 8 7 6 5 4 43 x Reserved DPI Port Sel Default 1 DPI Port 1 Selects which DPI port reference value appears in parameter 153 DPI Port Value Options 1 DPI Port 1 2 DPI Port
33. gt 3 240V AC 30V DC 840VA 105W 24 Digital Out 2 N C Fault Max Current 3 5A Min Load 10 mA 25 Digital Out 2 3 Com NOTE See the Attention above this table for more details 26 Digital Out3 N 0 Active 1 Important Input must be configured with a jumper AFE damage can occur if jumper is not installed properly See Analog 1 0 Configuration on page 45 2 These inputs outputs are dependant on a number of parameters 3 Differential Isolation External source must be maintained at less than 160V with respect to PE Input provides high common mode immunity 4 150 mA maximum load Can be used to provide control power from an external 24V source when main power is not applied 5 Contacts in un powered state Any relay programmed as Fault or Alarm energizes pick up when power is applied to the AFE and de energizes drop out when a fault or alarm exists Relays selected for other functions energize only when that condition exists and de energizes when the condition is removed 6 When this output is configured as active it can be wired to the Enable input of the connected drives to prevent the AFE from supplying power when the AFE is not running Rockwell Automation Publication 20Y UM001E EN P July 2014 AFE in IP20 2500 MCC Style Enclosure Installation Wiring Chapter 1 Typical 1 0 Wiring The IP20 2500 MCC Style enclosure for the AFE is factory wired and programmed to operate from t
34. remove jumper J5 Figure 20 and wire the enable input to Digital In 6 see below Verify that Digital In6 Sel parameter 226 is set to 1 Enable Table 9 Hardware Enable Configuration for AFE in IP20 2500 MCC Style Enclosure Signal Jumper Setting Hardware J5 Hardware Enable Input Programmable No Hardware Enable Enable Analog 1 0 Wiring Examples for AFE in IP20 2500 MCC Style Enclosure Input Output Connection Example Required Parameter Changes Potentiometer Unipolar e Configure Input for Voltage DCVolt Reference Parameter 200 and set appropriate jumper 10k Ohm Pot per Table 8 Recommended Adjust Scaling 2k Ohm Minimum Parameters 80 81 and 204 205 e View Results Parameter 018 Analog Voltage Input e Configure Input for Voltage Unipolar DC Volt alm Parameter 200 and set appropriate jumper Reference per Table 8 0 10V Input 1E Adjust Scaling Parameters 80 81 and 204 205 View results Parameter 018 Analog Current Input zm e Configure Input for Current Unipolar DC Volt GM Parameter 200 and set appropriate jumper Reference per Table 8 4 20 mA Input 118 Adjust Scaling M Parameters 80 81 and 204 205 ET Ey e View results E Parameter 018 Analog Output e Configure with Parameter 207 and set 10V 4 20
35. see Drives in Common Bus Configurations publication DRIVES AT002 162 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 A AC Line Freq parameter 95 AC Line kVA parameter 95 AC Line kVar parameter 95 AC Line kW parameter 95 AC supply source unbalanced 28 58 ungrounded 28 58 Active Current parameter 95 Active Ki parameter 99 Active Kp parameter 99 Active Ref parameter 99 AFE dimensions 131 fault descriptions 117 Frame 10 main component locations in IP20 2500 MCC Style enclosure 24 in IP21 Rittal enclosure 54 Frame 13 main component locations in IP20 2500 MCC Style enclosure 25 in IP21 Rittal enclosure 55 main component sections in IP20 2500 MCC Style enclosure 22 in IP21 Rittal enclosure 52 parameters 91 Alarm 1 Fault parameter 104 Alarm 1 Code parameter 106 Alarm 2 Fault parameter 104 Alarm 2 Code parameter 106 Alarm 3 Code parameter 106 Alarm 4 Code parameter 106 Alarm Clear parameter 106 alarm dearing 121 Alarm Config parameter 106 Alarms Parameter Group 106 Analog In 1 Hi parameter 109 Analog In 1 Lo parameter 109 Analog In 1 Loss parameter 109 Analog In 2 Hi parameter 109 Analog In 2 Lo parameter 109 Analog In 2 Loss parameter 109 Analog In1 Value parameter 96 Analog In2 Value parameter 96 Analog Inputs Parameter Group 109 Analog Out1 Hi parameter 110 Analog Out1 Lo parameter 110 Analog Out1 Sel parameter 110 Analog Out2 Hi parameter 110 Analog Out2 Lo parameter 110 Analog Ou
36. 000 20 000 mA Parameter 200 Anlg In Config defines if this input is 10V or 4 20 mA 10 000V Units 0 001 mA 0 001V 206 Analog In 2 Loss Default 0 Disabled Selects the AFE action when an analog signal loss is detected Signal loss is defined as an analog signal Options 0 Disabled less than 1V or 2 mA The signal loss event ends and normal operation resumes when the input signal 1 Fault level is greater than or equal to 1 5V or 3 mA 2 Hold Input 3 Set Input Lo 4 Set Input Hi 207 Anlg Out Config Selects the mode for the analog outputs Bit Definition Ea Ss 2 Il 5 e E S 1 Current E Default x x x x x x x 0 0 Voltage Bit 15 14 13 12 11 10 9 0 x Reserved Important Make sure the jumpers are in the correct position or the output will be wrong J3 Analog Output 1 J4 Analog Output 2 Position AB Current Position BC Voltage 0 10V default Position CD Voltage 10V Rockwell Automation Publication 20Y UMOOTE EN P July 2014 109 Chapter4 Programming and Parameters Rockwell Automation Publication 20Y UMOOTE EN P July 2014 3 No Parameter Name amp Description Values oS 208 Anlg Out Absolute Selects whether the signed value or absolute value of a parameter is used before being scaled to drive the analog output Bit SIs Definition
37. 082 Ground Lvl value 1000 m 3300 ft max without derating Max Surrounding Air Temperature without De rating 0 40 C 32 104 F Frame 13 600 690V AFE is rated at 35 C See Derating Guidelines on page 127 for derating above 35 C Storage Temperature all constructions 40 60 C 40 140 F Atmosphere Important The AFE must not be installed in an area where the ambient atmosphere contains volatile or corrosive gas vapors or dust If the AFE is not going to be installed for a period of time it must be stored in an area where it is not exposed to a corrosive atmosphere Relative Humidity 5 95 non condensing Shock Non operational 15G peak for 11 ms duration EN50178 EN60068 2 27 Vibration 1mm 0 039 in displacement 1G peak EN50178 EN60068 2 6 Sound Frame 10 71dBat1m 3 28ft Frame 13 80 dB at 1 m 3 28 ft AC Input Voltage Tolerance 10 Frequency Tolerance 48 63 Hz Input Phases Three phase input provides full rating for all AFEs The AFE cannot be operated with single phase input Displacement Power Factor 1 0 default across entire range Efficiency 97 5 at rated amps nominal line volts Short Circuit Rating AFE Frame 10 in IP20 AFE Frame 13 in IP20 AFE in IP21 or AFE IP00 100 kA for 400 480V unit 65 kA for 600 690V unit 100 kA for 400 480V unit 100 kA for 600 690V unit Determined by AIC rating of installed fuse circuit brea
38. 2 3 DPI Port 3 4 DPI Port 4 5 DPI Port 5 DPI Port Value Default Read Only Displays the value of the DPI reference selected in parameter 152 DPI Port Sel Min Max 0 0 1500 0V DC Units 0 1V DC Logic Mask Sets which adapters can control the AFE If the bit for an adapter is set to 0 the adapter has no control functions except for stop Definition 2 2 2 T 1 Control Permitted Default x x x x x x x 1 0 Control Masked Bit 15 14 13 12 1 10 9 x Reserved Fault Clr Mask See Logic Mask Sets which adapters can clear a fault Stop Owner Read Only Displays the adapters that are presently issuing a valid stop command Bi ese o E Definition Eleje eleg zlaja zagaa LIBRE 1 Issuing Command Default X x ix x x x x ix x x 0 0 0 0 0 0 No Command Bit 1 14 13 12 11 109 8 7 6 5 4 3 2 1 0 x Reserved Start Owner See Stop Owner Displays the adapters that are presently issuing a valid start command Fault Clr Owner See Stop Owner Displays the adapters that are presently clearing a fault Rockwell Automation Publication 20Y UMOOTE EN P July 2014 107 Chapter 4 5 S a 108 Programming and Parameters Parameter Name amp Description Data In A1 Link A Word 1 Data In A2 Link A Word 2 Sets the parameter number whose value is written from a communication device data table If paramete
39. 20Y PowerFlex 700AFE b Voltage Rating Code Input Voltage Phase D 400 480V AC 3 F 600 690V AC 3 cl 400 480V Input Input kW at HPat Code Amps 40 asov Frame ND HD ND HD ND HD 460 309 497 460 eS 259 41 P 1300 873 1404 8 quo gm qm P a 600 690V Input Input HP at kW at Code Amps 600V 69gov Frame Size Position 9 10 11 12 0 A N N e f g h d Enclosure Conformal Code Type Coating A IP21 Rittal Enclosure Yes NEMA UL Type 1 N IP00 Open Chassis Yes IP20 NEMA UL Type 1 2500 MCC Style Endosure p with Power Bus Yes 800 mm 31 5 in Deep Standard Cabinet Color RAL7032 IP20 NEMA UL Type 1 2500 MCC Style Endosure with Power Bus W 800 mm 31 5 in Deep Yes CenterLine 2100 Gray ASA49 Includes AFE power module LCL Filter Control Assembly motor controlled circuit breaker and precharge circuit in a Rittal enclosure Restricted to SSB Includes AFE power module LCL Filter and Control Assembly Does not include circuit breaker or precharge circuit Includes AFE power module LCL Filter Control Assembly Incoming circuit breaker and precharge circuit in 2500 MCC Style enclosure Frame 10 has 1250 Amp DC bus and Frame 13 has 3000 Amp DC bus Preface 13 14 15 16 A N A 0 i j k l g Brake Code w Brake IGBT N No h Brake Resistor Code w Resistor N No i Equipment Type Code Description A AFE with Power Line Filter j C
40. 63 0 Hz 0 1 Hz Read Only 0 0 Rated Amps x 2 0 1 Amps Read Only Rated Amps 0 1 Amps Read Only Rated Amps x 2 0 1 Amps Read Only 0 0 6553 5 Amps 0 1 Amps 2 gt Read Only 0 0 100 0 0 1 Read Only 0 0 Rated Amps x 2 0 1 Amps Read Only 0 0 Based on Unit Rating 0 1V DC Read Only Based on Unit Rating 0 1 Amps Read Only Based on Unit Rating 0 1 kW Read Only Based on Unit Rating 0 1 kVar Read Only 0 0 Based on Unit Rating 0 1 KVA Read Only 1 00 0 01 Read Only 0 200 C 1 C 95 Chapter 4 96 Group Metering Converter Data Programming and Parameters No 018 022 023 030 031 032 033 Parameter Name amp Description Cmd DC Volt Displays the commanded DC bus voltage reference Motoring MWh Displays the accumulated motoring MWh This parameter may be reset with parameter 092 Reset Meters Regen MWh Displays the accumulated regenerative MWh fed back to the AC line This parameter may be reset with parameter 092 Reset Meters Elapsed Run Time Displays the accumulated amount oftime that the AFE has been in Run This parameter may be reset with parameter 092 Reset Meters Analog In1 Value Analog In2 Value Displays the value of the signal at the analog inputs Rated kW Displays the nominal power rating of the AFE Rated Volts Displays the nominal
41. AFE is faulted e An AFE can be connected while other parallel AFE units are running When connecting the AFE to the DC bus follow these steps in the order shown a Precharged the isolated AFE When completed the AFE control closes the MCCB b Close the DC disconnect to connect the AFE to the DC bus 158 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Application Notes Appendix C When disconnecting the AFE from the DC bus follow these steps in the order shown a Stop the inverters and AFEs connected to the same DC bus from modulating The AFE load must be zero before being disconnected to reduce the load on the MCCB b Open the MCCB of the AFE c Open the DC disconnect switch d Restart the other AFE units e When AFEs are paralleled the DC bus voltage at regeneration is 5 higher than with a single AFE due to the 596 droop See Drives in Common Bus Configurations publication DRIVES AT002 for supported drives that can be used in the various AFE configurations e Figure 54 on page 160 shows an example of paralleling two AFEs in their IP21 Rittal enclosures where each AFE has its own precharging circuit precharging control and fusing on the DC bus output and input contactor In this case turn the disconnects Q0 ofall AFEs to ON and set all of the MCCB CONTROL selector switches on the door to AUTO to enable automatic operation When turning on the main power the two AFEs precharge automatic
42. Active Front End Power Structure U1 AC Line Switchgear Input Circuit Breaker Input Fuses Input Contactor DC Fuses ol o ol olo ooe AFE Control Assembly on the AFE door and shown with user installed HIM 24 Rockwell Automation Publication 20Y UM001E EN P July 2014 AFE in IP20 2500 MCC Style Enclosure Installation Wiring Chapter 1 Frame 13 The following figure shows the main components of the AFE Frame 13 system in a IP20 2500 MCC Style enclosure Figure 9 AFE Frame 13 Main Component Locations in IP20 2500 MCC Style Enclosure FRONT VIEW shown with enclosure doors removed FRONT VIEW 2 reduced size shown with enclosure doors closed i OJo 00 oe ger cz SSL SSL SISI o o Item Description o Precharge Circuit e Precharge Resistor LCL Filter L1 4 Active Front End Power Structure U1 e Input Circuit Breaker AC Line Switchgear Input Fuses Input Contactor e DC Fuses AFE Control Assembly on the AFE door and shown with user installed HIM Rockwell Automation Publication 20Y UMOOTE EN P July 2014 25 Chapter1 AFE in IP20 2500 MCC Style Enclosure Installation Wiring Mounting Considerations When mounting the Active Front End consider the following information Operating Temperatures Frame Surrounding Air Temperature 2 Minimum Air Flow Size Normal Duty Heavy Duty Power Module LCL Fi
43. Cl Sw Door I con iring Wir tallation Ins 57 e losur NC 21 Rittal E in IP In AFE TRI Amm T oi all oW Fee a Cle ure ndlos in 13 in e Fram W FRONT VIE lo 385983 Si p a i a bp Eu 5909 cs 9o 9o 8989 8080 d 1 a p v b C a a b p E p b b CO E SRG b 9283 i oot 9o b 8080 a 983583 b i a Li vU a i a B E RESI c e 8263 95 _ 1 lol o lo fol 8289 385988 x p a E UO p i a a p a el b B p a y SE Eds 2089 e 835389 gun A i E i 8388 IT 1 o p b p SRL 8268 NL e E 2 a pl g S gt Es z Es E E s Cu 4 201 July p N EE 001 UM ion 20 blication Pu ation tom Il Au kwe Roc Chapter2 AFE in IP21 Rittal Enclosure Installation Wiring AC Supply Source Considerations 58 The AFE Frame 10 or Frame 13 in a IP21 Rittal enclosure is suitable for use on a circuit capable of delivering up to a maximum of 100 000 rms symmetrical amperes 600 690 volts with recommended fuses or circuit breakers The AFE must not be used on undersized or high impedance supply systems The supply system kVA must be
44. DC Fusing Frame Fuse Rating Si ze Amps Bussman Type 10 630A 170M6454 13 630 A 2 per phase 170M6454 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 129 AppendixA Supplemental Information Fusing and Circuit Breakers for AFE in IP21 Rittal Enclosure AC Input Fuse and Circuit Breaker Ratings The tables in this section provide the recommended AC input line fuses and circuit breakers The AFE in a IP21 Rittal enclosure includes the recommended MCCB Motor Controlled Circuit Breaker 400 480 Volt AC Fusing and MCCB Ratings Frame Fuse Ratings MCCB Ratings s Amps Bussman Type Ferraz Shawmut Type Amps ABB Type 10 800 NH3UD69V800PV 630 T5H630FF3LS 1000 1706277 13 2200 PC44UD75V22CTQ 1600 T7516FF3PR231LS 1000 3 per phase 170M6277 1 Suitable for replacement fuse 600 690 Volt AC Fusing and MCCB Ratings Frame Fuse MCCB Ratings ids Amps Bussman Type Ferraz Shawmut Type Amps ABB Type 10 700 PC73UD13C630PA 400 T5H400LS 700 170M6305 13 1800 PC84UD12C18CTQ 1600 T7516FF3PR231LS 700 3 per phase 170M6305 1 Suitable for replacement fuse DC Bus Output Fuse Ratings DC Bus Output fusing must be used for short circuit protection The tables in this section provide the ratings of the DC Bus Output fuses used for the AFE in a IP21 Rittal enclosure 465 800 Volt DC Fusing F
45. DC disconnect to connect the AFE to the DC bus When disconnecting the AFE from the DC bus follow these steps in the order shown a Stop the inverters and AFEs connected to the same DC bus from modulating The AFE load must be zero before being disconnected to reduce the load on the contactor b Open the contactor ofthe AFE c Open the DC disconnect switch d Restart the other AFE units e When AFEs are paralleled the DC bus voltage at regeneration is 5 higher than with a single AFE due to the 596 droop See Drives in Common Bus Configurations publication DRIVES AT002 for supported drives that can be used in various AFE configurations e Figure 52 on page 156 shows an example of paralleling two AFEs in their IP20 2500 MCC Style enclosures where each AFE has its own precharging circuit precharging control and fusing on the DC bus output and main contactor In this case turn the disconnects Q0 ofall AFEs to ON and set all of the REM AUTO MAN selector switches on the door to AUTO to enable automatic operation When turning on the main power the two AFEs precharge automatically After charging the contactors K1 are closed and the AFEs start the modulation The control signal Inverter Enable shown in Figure 21 on page 45 can be used to interlock the drives connected to the DC bus Rockwell Automation Publication 20Y UMOOTE EN P July 2014 155 AppendixC Application Notes Figure 52 Connecting Parallel Fra
46. E l I DE l R6 E L l J sera I Precharge Precharge Precharge uses Contactor SE I FS Circuit i l I I I I LL l I I K6 I I I l pt DI R6 l I PowerFlex l I Active Front End System SNE ZE 0 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 23 Chapter1 AFE in IP20 2500 MCC Style Enclosure Installation Wiring Main Component Locations This section shows the main component locations for AFE Frame 10 and Frame 13 systems in a IP20 2500 MCC Style enclosure Frame 10 The following figure shows the main components of the AFE Frame 10 system in a IP20 2500 MCC Style enclosure Figure 8 AFE Frame 10 Main Component Locations in IP20 2500 MCC Style Enclosure FRONT VIEW shown with enclosure doors closed O O Item Description FRONT VIEW shown with enclosure doors removed SUE T Jy 8860 Precharge Circuit and Precharge Resistor LCL Filter L1
47. Enclosure Installation Wiring Chapter 1 5 All shielded cables must terminate with proper shielded connector 6 Motor cables of DC input drives used with the AFE must be shielded cable wire with a coverage of 75 or more or must be inside metal conduit or have shielding cover with equivalent attenuation Rockwell Automation Publication 20Y UMOOTE EN P July 2014 49 Chapter1 AFE in IP20 2500 MCC Style Enclosure Installation Wiring Notes 50 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Chapter 2 AFE in IP21 Rittal Enclosure Installation Wiring This chapter provides information on installing and wiring the PowerFlex Active Front End in a IP21 Rittal enclosure For information on installing and wiring the AFE in a IP20 2500 MCC Style enclosure see Chapter 1 Topic Main Component Sections Page 52 Main Component Locations 54 Mounting Considerations 56 AC Supply Source Considerations 58 Grounding Requirements 59 Fuses and Circuit Breakers 61 Power Wiring 61 Disconnecting Common Mode Capacitors 68 Using the AFE with PowerFlex Drives 72 Control Wiring 72 Precharging the AFE 78 CE Conformity 79 Most start up difficulties are the result of incorrect wiring Every precaution must be taken to verify that the wiring is done as instructed All items must be read and understood before the actual instal
48. Failure to disable the AFE output can result in component damage or a reduction in product life When enabling parameter 132 see page 105 for details The AFE is shipped with parameter 132 disabled This will not stop or shut down DC output when a fault occurs Rockwell Automation Publication 20Y UMOOTE EN P July 2014 AFE in IP21 Rittal Enclosure lInstallation Wiring Chapter 2 Signal and Control Wire Types Table 14 Recommended Signal Wire for AFE in IP21 Rittal Enclosure Signal Type Wire Type s Description Minimum Insulation Rating Belden 8760 9460 0 5 mm 22 AWG twisted pair or equivalent 10096 shield with drain 300V 75 90 C Analog 1 0 AR Belden 8770 0 5 mm 22 AWG 3 conductor 167 194 F or equivalent shielded for remote pot only EMC Compliance See CE Conformity on page 79 for details 1 Ifthe wires are short and contained within an enclosure that has no sensitive circuits the use of shielded wire may not be necessary but is always recommended Table 15 Recommended Control Wire for Digital 1 0 Type Wire Type s Description Minimum Insulation Rating Unshielded Per US NEC or applicable national or local code 300V 60 C Shielded Multi conductor shielded cable such 0 5 mm 22 AWG 140 F as Belden 8770 or equivalent 3 conductor shielded Figure 35 AFE 1 0 Terminal Blocks and Jumpers eS 2 Peri VZD y ADD f 1 0 Terminal Blocks Tabl
49. I DC Input Input PowerStructure U1 Fuses I I Breaker Contactor I I 00 uses Ko yy l I l F1 1 F13 a I M QA Le e Pun EE d WAAR AAR 1 F I ie Yu Anal le s Ann V i 21 MENA Sy tal M ARA ARAM AE m l I i l l PE DC o 2 a a Lg l E E JEMEN Q C5 m im I I a l I I Gl T I l I I I em as nas jaa De I ie Precharge Precharge Precharge Fuses Contactor NATA I FS Circuit I I l l D7 I I I I I I I K6 I 4 x 3 86 1 I 9 3 bd o PowerFlex Dt py R62 I I 700AFE System o 156 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Application Notes Appendix C Figure 53 Connecting Parallel Frame 13 AFEs in IP20 2500 MCC Style Enclosures AC Line Switchgear LCL Filter L1 1 AFE DC Input Input 1 Power Structure U1 Breaker Contactor I 3 Phase 00 Fuses KI l AC Input Ld Par poa d L1 o y E IS DC Bus 12 e T PI e Output L3 De i I eq NT I I I I ty E I Pai ty bi BEL I gt I T l _ E Jb aum B x e I Precharge Precharge Precharge uses Contactor PM F5 Circuit I l l I I l l 4 l
50. Lmt 3 Monitor incoming AC line for high voltage or voltage transients Reduce the current consumption of the AFE or increase parameter 133 Cnvrtr OL Factor 1 Verify that the maximum ambient temperature has not been exceeded 2 Check the fans including the ASIC board on frame 10 and higher converters 3 Check for an excess load 1 Verify that the maximum ambient temperature has not been exceeded Check the fan or fans wn Check for an excess load Cycle the power Verify the fiber optic connections Contact Technical Support see page 124 dA 0 N If the problem persists replace the converter unit Check programming for an excess load or other causes of excess current 117 Chapter5 Troubleshooting Table 21 Fault Alarm Types Descriptions and Actions Continued No 13 21 29 30 31 32 33 34 35 37 44 45 47 54 58 65 118 Name Ground Fault Converter Flt LineSync Fail Unbalanced PU Phase Loss Anlg In Loss MicroWatchdog IGBT Temp Hw Fan Cooling AutoReset Lim CAN Bus Flt Application HeatsinkUndTp Device Change Device Add NvsReadChksum Zero Divide Start Prevent 1 0 Removed Fault eG eo 010 0 OJO Alarm Description A current path to earth ground exists that is greater than the parameter 082 Ground Lvl value The current must appear for 800 milliseconds
51. Logic Rslt 151 Comm Control 107 Fault Clr Owner 158 Masks amp Owners 107 Cnvrtr OL Count 116 Diagnostics 104 Fault Config 120 Faults 105 Cnvrtr OL Factor 133 Faults 105 Fault Frequency 104 Diagnostics 103 Cnvrtr Status 1 095 Diagnostics 101 Fault Temp 107 Diagnostics 103 Cnvrtr Status 2 096 Diagnostics 102 Fault Total Curr 105 Diagnostics 103 Contact Off Cnfg 132 Faults 105 Ground Current 010 Metering 95 Contact On Delay 050 Control Modes 9 Ground Lvl 082 Limits 99 Control Options 051 Control Modes 98 Heatsink Temp 017 Metering 95 Control SW Ver 033 Converter Data 96 Imbalance 009 Metering 95 Current Lmt Val 077 Limits 99 input Current R 006 Metering 95 Data In AX 170 171 Datalinks 108 nput Current S 007 Metering 95 Data In BX 172 173 Datalinks 108 nput Current T 008 Metering 95 Data In CX 174 175 Datalinks 108 nput Voltage 001 Metering 95 Data In DX 176 177 Datalinks 108 Language 093 Converter Memory 101 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Chapter4 Programming and Parameters Pa ra meter Cross Reference Parameter Name Group Parameter Name Group Page DC Bus Lo Alarm Limits 99 Start Owner Masks amp Owners 107 m by Number DC Bus Hi Alarm imits 9
52. Max Units Default Options Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Programming and Parameters Chapter 4 Based on Unit Rating Based on Unit Rating WAC 3 6 kHz 3 0 16 0 kHz 0 1 kHz 2 Software 2 HW Modulator Software 1 Software 2 Software 3 WN O 100 20 200 1 Unit Current 0 0 6553 5 Amps 1 0 Amps 0 Normal 0 Normal 1 Auto 220 ms 0 32000 ms 1 ms 100 ms 0 32000 ms 1 ms 3 0 100 0 100 0 1 0 0 40 secs 0 00 10 00 secs 0 01 secs 97 Chapter4 Programming and Parameters Control Modes 052 Restart Modes 053 l e be lt gt c 054 1060 062 063 98 Parameter Name amp Description Control Options A set of bits to select AFE control options to disable different harmonic compensation Bit Definition DC Ref Follow 1 Condition True X 0 Condition False x Reserved Default x x X Xx 11 10 9 x X x 15 14 13 12 e Bit 5 5th Comp Off Disables 5th harmonic elimination when Bit 5 1 Bit 12 DC Ref Follow Allows the DC Voltage Reference to follow the AC Input Voltage if the input voltage is rising when Bit 12 1 In this case the DC Bus Voltage Ref P1 Input Voltage x P61 DC Volt Ref P40 Nom Input V
53. PVC jacket See Chapter 2 Wire Types in Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives publication DRIVES IN001 Interlocked armor is acceptable for shorter cable runs but continuous welded armor is preferred Best performance is achieved with three spaced ground conductors but acceptable performance below 200 HP is provided by use of a single ground conductor Recommended shielded armored wire is listed in Table 1 Table 1 Recommended Shielded Armored Wire for AFE in IP20 2500 MCC Style Enclosure Location Standard Option 1 Rating Type 1000V 90 C 194 F XHHW2 RHW 2 Anixter B29528 B29532 Belden 29528 29532 or equivalent Description Four tinned copper conductors with XLPE insulation e Copper braid aluminum foil combination shield and tinned copper drain wire PVC jacket Standard Option 2 Tray rated 1000V 90 C 194 F RHH RHW 2 Anixter OLFLEX 76xxx03 or equivalent Three tinned copper conductors with XLPE insulation corrugated copper tape with three bare copper grounds in contact with shield PVC jacket Class amp Il Division amp 11 Tray rated 1000V 90 C 194 F RHH RHW 2 Anixter 7VFD xxxx or equivalent Three bare copper conductors with XLPE insulation and impervious corrugated continuously welded aluminum armor Black sunlight resistant PVC jacket overall Three copper grounds Rockwell Automation Public
54. Parameter 85 Droop to 5 for current sharing of the AFEs Set Parameter 86 PWM Synch to 1 to reduce circulating currents between AFEs connected to the same DC bus and fed from the same power source e Ifone of the paralleled AFEs is to be isolated from the AC and DC voltages you must isolate the AC input and DC output The AC input can be isolated with a circuit breaker or a disconnect switch Contactors are not suitable for isolating the AC input because they cannot be locked in the safe position The DC output can be isolated with a disconnect A load isolation switch or safety isolation switch can be used to isolate the precharging circuit from the AC input e Each AFE must use a separate precharging circuit precharging control switch DC bus output fusing and main contactor Each AFE controls its own precharging and main contactor Therefore it is possible to disconnect the AFE when other parallel AFEs are powered up but not modulating e The fault relay of both AFEs must be interlocked with each other such that both AFEs are disabled not running when either AFE is faulted Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Application Notes Appendix C e An AFE can be connected while other parallel AFE units are running When connecting the AFE to the DC bus follow these steps in the order shown a Precharged the isolated AFE When completed the AFE control closes the contactor b Close the
55. Parameter Name amp Description Values Fault Config Enables disables annunciation of the listed faults Bit E an Definition ARME z553 a 1 Enabled Default X x x x x x x x x ix JO 0 JO 0 0 Disabled Bit 15 14 13 12 11 10 9 5 4 43 1 x Reserved Fault Clear Default 0 Ready Resets a fault and clears the fault queue Options 0 Ready 0 Ready A new value may be entered 1 Clear Faults 1 Clear Faults A fault is reset 2 Clr Fault Que 2 Clr Fault Que The fault queue is cleared Fault Clear Mode Default 1 Enabled Enables disables a fault reset clear faults attempt from any source This does not apply to fault codes which Options 0 Disabled are cleared indirectly through other actions 1 Enabled Power Up Marker Default Read Only Displays the elapsed hours since initial AFE power up This value rolls over to 0 after the AFE has been powered Min Max 0 0000 429496 7295 Hr on for more than the maximum value shown For relevance to most recent power up see parameters Units 0 0001 Hr 128 131 Fault x Time Fault 1 Code Default Read Only Fault 2 Code Min Max 0 65535 Fault 3 Code Units None Fault 4 Code Displays a code that represents the fault that tripped the AFE The codes appear in these parameters in the order they occur parameter 124 Fault 1 Code the most recent fault Fault 1 Time Default Read Only Fault 2 Time Min Max 0 0000 429496 7295 Hr Fau
56. Rockwell Automation Publication 20Y UMOOTE EN P July 2014 21 Chapter1 AFE in IP20 2500 MCC Style Enclosure Installation Wiring Main Component Sections This section describes the main component sections of AFE Frame 10 and Frame 13 systems in a IP20 2500 MCC Style enclosure Frame 10 The following figure shows a basic one line diagram for an AFE Frame 10 ina IP20 2500 MCC Style enclosure The main component sections consist of the following items e AC Line Switchgear consisting of the input circuit breaker Q0 fuses F1 1 F1 3 and input contactor K1 e LCL Filter L1 e Precharge Circuit e AFE power structure U1 with AFE control assembly e DC fuses F2 1 and F2 2 Figure 6 Basic One line Diagram for an AFE Frame 10 in IP20 2500 MCC Style Enclosure I e O 1 x A jr c ie a A O FEA AC Line Switchgear LCL Filter L1 AFE DC Input Input I Power Structure U1 Fuses Breaker Contactor l I 3 Phase 00 Fuses Kl l AC Input F1 1 F1 3 I VI u i I B M Iv T o He ANN e oV PA F2 1 B vole Si WAAR ow E ro F DCBus I i o PE DC o es Output i a 4 I c sii te l Q 6 PEL i G 6 I I I I I I Ue tens Seite
57. a2 S 3 1 Absolute Default X x X x x x X 1 0 Signed Bit 15 14 13 12 11 10 9 0 x Reserved 209 Analog Out Sel Default 0 Input Volt Selects the source for Analog Output 1 Options See Table Options Analog Out1 Lo Value Analog Out1 Hi Parameter Anlg Out Absolut Value Signed Absolute 0 Input Volt OVAC OVAC 200 Rated 2 1 AC Line Freq 63 0 Hz 0Hz 63 0 Hz 2 Total Curr 0 Amps 0 Amps 200 Rated Y 3 Active Curr 200 Rated 0 Amps 200 Rated 4 ReactiveCurr 200 Rated 0 Amps 200 Rated 93 5 nput Curr R 0 Amps 0 Amps 200 Rated 6 nput Curr S 0 Amps 0 Amps 200 Rated 7 input CurrT 0 Amps 0 Amps 200 Rated 9 8 DCBusVolt ov DC ov DC 300 Rated 9 DC Bus Curr 200 Rated 0 Amps 200 Rated P 10 ACLine kW 20096 Rated OKW 200 Rated 7 11 AClinekVar 20096 Rated 0 kVar 200 Rated 7 2 12 AC Line kVA OKVA OKVA 200 Rated 2 13 Power Factor 1 00 0 1 00 5 14 DC Bus V Ref P080 V DC P080 V DC P081 V DC ME 15 Param Cnt 3 A aram Cntl e 16 TestPtDatal 32767 0 32767 gt c 1 Parameter controlled analog output allows PLC to control analog outputs through datalinks Set in parameter 217 Anlg Out1 Setpt and parameter 218 Anlg Out2 Setpt 2 100 corresponds to parameter 031 Rated Volts 3 100 corresponds to parameter 032 Rated Amps 4 100 corresponds to parameter 030 Rated kW 210 Analog Out1 Hi Default 20 000 mA 10 000V Sets the Analog Ou
58. and Options 0 Ready 090 Param Access Lvl 1 Factory 0 Ready A new value may be entered 2 Low Voltage 1 Factory Resets parameters to factory defaults 3 High Voltage 2 Low Voltage Resets parameters to factory defaults and configures parameters for a 400 480V AFE unit for 400V operation 600 690V AFE unit for 600V operation 3 High Voltage Resets parameters to factory defaults and configures parameters for a 400 480V AFE unit for 480V operation e 600 690V AFE unit for 690V operation NOTE The DC bus voltage must be present to set the voltage class 3 Use the HIM to enter the Assisted Start up procedure Step Example LCD Display a Inthe Main Menu use the 99 or Key to scroll to Start Up stop OG b Pressthe Enter key Volt Main Menu Memory Storage Preferences See Figure 37 for the Active Front End start up procedure Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Startup Chapter 3 4 Enter the Input Voltage Selection in the start up routine Select the appropriate AC input voltage for your installation 480 for example To accept each default setting press Enter 5 Enter the Alarm Flt Cnfg selection The Alarm Flt Cnfg sets parameters 120 Fault Config and 135 Alarm Config For basic applications the default settings can be used To accept each default setting press Enter 6 Enter the Limits section For basic applications
59. areas shown in Figure 16 for routing the AC input ground PE and DC bus output wiring always use the Barrier Kit SK Y1 MCCBARRIER to maintain air flow integrity through the enclosure Removing sections for routing in other areas disrupts the air flow throughout the enclosure causing overheating ATTENTION To minimize disruption of air flow through the enclosure and avoid Frame 10 The AC input and ground PE wiring for the IP20 2500 MCC Style enclosure must be routed through the top of the enclosure The DC bus output can be routed through either the left or right side of the enclosure see shaded areas in figure below Figure 16 Routing Areas for AC Input Ground and DC Bus Output Wiring for AFE Frame 10 in IP20 2500 MCC Style Enclosure Area for routing AC input and ground PE connections Shaded areas for routing DC bus output connections on either the left or right side of the enclosure When the side cover plate is removed for DC bus routing always use the Barrier Kit SK Y1 MCCBARRIER to maintain proper air flow in the AFE enclosure and prevent overheating Frame 13 The AC Input and Ground PE wiring for the IP20 2500 MCC Style enclosure must be routed through the top of the enclosure The DC bus output can be routed through either the left or right side of che enclosure see shaded area in figure below Rockwell Automation Publication 20Y UMOOTE EN P July 2014 37 Chapter
60. display 010 Ground Current Displays the ground current measured by summing the three input phase currents 011 DC Bus Volt Displays the filtered DC bus voltage The filter time constant is 32 milliseconds 012 DC Bus Current NY Displays the DC bus current Positive value indicates motoring negative value indicates regeneration 013 AC Line kW 7 Displays the real power on the AC side Positive value indicates motoring negative value indicates regeneration 014 ACLine kVar Xy Displays the reactive power on the AC line 015 AC Line kVA NY Displays the apparent power on the ACline 016 Power Factor Displays the power factor Positive value indicates motoring power negative sign indicates regenerative power 017 Heatsink Temp Displays the measured heatsink temperature Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Values Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Programming and Parameters Chapter 4 Read Only 0 0 1000 0V AC 0 1V AC Read Only 63 0
61. ee eee tet AS 4 I I Precharge Precharge Precharge Fuses Contactor reni FS Circuit I K6 I I PS DI R6 1 o gt gt Peo pi pi R62 PowerFlex l I Active Front End System EE L irse 22 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Frame 13 AFE in IP20 2500 MCC Style Enclosure Installation Wiring Chapter 1 The following figure shows a basic one line diagram for an AFE Frame 13 ina IP20 2500 MCC Style enclosure The main component sections consist of the following items e AC Line Switchgear consisting of the input circuit breaker Q0 fuses F1 1 F1 3 and input contactor K1 e LCL Filter L1 e Precharge Circuit e AFE power structure U1 with AFE control assembly e DC fuses F2 1 F2 6 Figure 7 Basic One line Diagram for an AFE Frame 13 in IP20 2500 MCC Style Enclosure a n 3 I AC Line Switchgear LCL Filter L1 l AFE y DC Input Input i Fuses Breaker Contactor I I 3 Phase Q0 Fuses K1 I l ACInput F1 1 F13 l D u M s E1 1 e nnl ANAU LES L p el 2 CO Le Le Ann l Ee ig M Eg WARA ARAM a I I I B3 a a I gt FH R al 1 6 l F24 I G C6 T F25 l I
62. if the AFE is installed on a resistive grounded distribution system or an ungrounded distribution system See Figure 33 on page 68 or Figure 34 on page 69 for jumper locations gt gt ATTENTION The power structure of the PowerFlex Active Front End in the IP21 Rittal enclosure contains common mode capacitors that must be disconnected regardless of the application in which the AFE is used For locations of the common mode capacitors and instructions to remove them see Frame 10 Power Structure on page 70 or Frame 13 Power Structure on page 71 gt Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Grounding Requirements AFE in IP21 Rittal Enclosure lInstallation Wiring Chapter 2 Input Power Conditioning Certain events on the power system supplying an AFE can cause component damage or shortened product life This includes the following events e The power system has power factor correction capacitors switched in and out of the system either by the user or by the power company e The power source has intermittent voltage spikes in excess of 6000 volts These spikes can be caused by other equipment on the line or by events such as lightning strikes e The power source has frequent interruptions The Active Front End Safety Ground PE must be connected to system ground Ground impedance must conform to the requirements of national and local industrial safety regulations and or electrical codes Check the integr
63. input voltage class 400V 480V 600V or 690V of the AFE Rated Amps Displays the nominal AC input current rating of the AFE Control SW Ver Displays the Main Control Board software version of the AFE Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Values Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Read Only 0 0 1500 0V DC 0 1V DC Read Only 0 0 429496729 5 MWh 0 1 MWh Read Only 0 0 429496729 5 MWh 0 1 MWh Read Only 0 0 214748364 0 Hr 0 1 Hr Read Only 0 000 20 000 mA or 10 000V 0 001 mA or 0 001V Read Only 0 00 3000 00 kW 0 01 kW Read Only 0 0 1000 0V AC 0 1V AC Read Only 0 0 6553 5 Amps 0 1 Amps Read Only 0 000 255 255 0 001 Dynamic Control File No File Group 040 041 042 043 045 DYNAMIC CONTROL Control Modes 046 047 048 049 050 Parameter Name amp Description Nom Input Volt Sets the incoming supply voltage level It is used to calculate the DC voltage level for charging control PWM Frequency Sets the carrier frequency for the PWM output This frequency is fixed to 3 6 kHz and cannot be changed due to the LCL filter Modulation Type Selects the modulation
64. mA Bipolar E appropriate jumper per Table 8 10V Unipolar shown c Select Source Value AND i Parameter 209 Analog Out Sel Lo ug Adjust Scaling i Parameters 210 211 46 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Precharging the AFE AFE in IP20 2500 MCC Style Enclosure Installation Wiring Chapter 1 This section contains important information about AFE precharging Introduction An AFE in the IP20 2500 MCC Style enclosure contains an internal precharging circuit The precharging unit is used to charge the DC bus capacitors The charging time depends on the capacitance of the intermediate circuit and the resistance of the charging resistors Table 10 shows the technical specifications for the precharge in the AFE enclosure For correct operation of the precharging circuit verify that the input circuit breaker QO is on and the input contactor K1 and precharging circuit contactor are controlled by the AFE Table 10 Total DC Bus Capacitance Limits for Precharging Circuit of AFE in IP20 2500 MCC Style Enclosure Frame Size Capacitance min q Capacitance max Q 10 2x25 ohms 9900 uF 70 000 pF 13 1x11 ohms 3 x 3 67 ohms 29 700 pF 128 000 pF 1 The minimum capacitance is built into the AFE 2 The maximum capacitance is the capacitance of the AFE plus the external capacitance ATTENTION If the maximum capacitance is exceeded component damage in AFE occurs
65. number if applicable e Product serial number e Firmware revision level verified using parameter 033 Control SW Ver e Most recent fault code e Your application The data contained in the following parameters helps in initial troubleshooting of a faulted drive You can use the table below to record the data provided for each listed parameter Parameter Name Description Recorded Parameter Data 104 Fault Frequency Captures and displays the AC line frequency at time of last fault 105 Fault Total Curr Captures and displays the DC bus amps at time of last fault 106 Fault Bus Volts Captures and displays the DC bus voltage at time of last fault 107 Fault Temp Captures and displays the heatsink temperature at time of last fault 108 Status 1 Fault Captures and displays Cnvrtr Status 1 bit pattern at time of last fault 109 Status 2 Fault Captures and displays Cnvrtr Status 2 bit pattern at time of last fault 110 Alarm 1 Fault Captures and displays Cnvrtr Alarm 1 bit pattern at time of last fault 111 Alarm 2 Fault Captures and displays Cnvrtr Alarm 2 bit pattern at time of last fault 124 Fault 1 Code Displays a code that represents the fault that tripped the AFE The codes will appear in these parameters in the order they occur Fault 1 Code equals the most recent fault 126 Fault 2 Code 128 Fault 3 Code 130 Fault 4 Code 125 Fault 1 Time Di
66. of secondary network if connected 1 These indicators operate only when a 20 COMM X communication adapter is installed in the AFE and operating on the connected network Rockwell Automation Publication 20Y UMOOTE EN P July 2014 115 Chapter5 Troubleshooting Faults and Alarms 116 HIM Indication The LCD HIM also provides visual notification of a fault or alarm condition Condition Display AFE is indicating a fault The LCD HIM immediately reports the fault condition by displaying the following e Faulted appears in the status line Rai Fault number Time Since Fault Fault name 0000 23 52 e Time that has passed since fault occurred Press Esc to regain HIM control Fault F AFE is indicating an alarm The LCD HIM immediately reports the alarm condition F gt Power Loss AUD by displaying the following Volt Alarm name Type 2 alarms only Main Menu Alarm bell graphic Diagnostics Parameter Device Select A fault is a condition that stops the AFE There are three fault types Fault Type Fault Description O Auto Reset Run When this type of fault occurs and Auto Rstrt Tries page 98 is set to a value greater than 0 a user configurable timer Auto Rstrt Delay page 98 begins When the timer reaches zero the AFE attempts to automatically reset the fault If the condition that caused the fault is no longer present the fault is reset and t
67. of the enclosure see shaded area in figure below Figure 32 Routing Areas for AC Input Ground and DC Bus Output Wiring for AFE Frame 10 in IP21 Rittal Enclosure Area for routing DC bus output connections Area for routing AC input Do not allow hot and ground PE connections air to enter the bottom of the enclosure Frame 13 The AC input ground PE and DC bus output are located in the right most bay see front view of Figure 31 The AC input ground and DC bus output wiring can be routed through the top bottom or right side of the right most bay Rockwell Automation Publication 20Y UMOOTE EN P July 2014 67 Chapter 2 Disconnecting Common AFE in IP21 Rittal Enclosure Installation Wiring Mode Capacitors 68 RIGHT SIDE VIEW OF LCL FILTER Frame 10 LCL Filter The Frame 10 AFE LCL Filter contains common mode capacitors that are referenced to ground To guard against AFE damage these devices must be disconnected if the AFE is installed on a high resistance grounded distribution system or an ungrounded distribution system where the line to ground voltages on any phase exceed 12596 of the nominal line to line voltage To access the common mode capacitors the LCL Filter must be removed from the enclosure To remove the Frame 10 A
68. the ACline voltage 64 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 AFE in IP21 Rittal Enclosure lInstallation Wiring Chapter 2 Power Terminals for AFE in IP21 Rittal Enclosure The following figures and tables show the power terminal locations and specifications for AFE Frames 10 and 13 in an IP21 Rittal enclosure Figure 30 AFE Frame 10 Power Terminal Locations in IP21 Rittal Enclosure KIMONO ENCON Na oO erum Ar d Minoc o of iH E A Al 90 I 5 E S
69. the control wiring and correspondent digital I O parameter setting need to be changed Here are some important points to remember about I O wiring e Always use copper wire e Wire with an insulation rating of 600V or greater is recommended e Control and signal wires must be separated from power wires by at least 0 3 meters 1 foot e When it is unavoidable to cross control and signal wires with power wires always cross power wires at a 90 angle IMPORTANT 1 Oterminals labeled or Common are not referenced to earth ground They are designed to greatly reduce common mode interference Grounding these terminals can cause signal noise 1 0 Configuration on page 45 Also configuring an analog input for 0 20 mA operation and driving it from a voltage source can cause component damage Verify proper configuration before applying input signals i ATTENTION Inputs must be configured with software and jumpers see Analog connected to the AFE output when the AFE is not active not modulating This can be done by either connecting the Inverter Enable output of the AFE to each variable frequency drive s enable input or by enabling parameter 132 Contact Off Cnfg to force the main contactor off in case of a fault This ensures that once the AFE stops modulating there is no motoring current flowing through the AFE IGBT diodes Failure to disable the AFE output can result in component damage or a reduction in product li
70. the default settings for the parameters 75 Motor Power Lmt 76 Regen Power Lmt and 77 Current Lmt Val can be used By default Regen Power Lmt and Current Lmt Val are set to let maximum peak power flow from the DC bus to the AC line and prevent DC bus overvoltage faults on the inverters To accept each default setting press Enter 7 Enter the DC Bus Ctrl section of the Start up routine By default the DC bus voltage reference is set to come from parameter 61 DC Volt Ref With this setting the DC Volt Ref is calculated based on the selected AC input voltage For basic applications this setting for the DC bus voltage reference is sufficient To accept each default setting press Enter 8 Enter the Start Stop IO section Parameters 221 225 Digital In 1 5 Sel and parameters 228 229 and 233 Digital Out 1 3 Sel are set to run the AFE from the operator switches on the AFE door see Figure 36 on page 76 for the typical I O wiring diagram The AFE can also be run through a network communication adapter by changing Digital Input 1 from Run to Not Used and sending a Start command through the communication adapter For DPI communication details see DPI Communication Configurations on page 140 To accept each default setting press Enter Analog Outputs can also be programmed through this procedure if desired 9 Disable the AFE output when the AFE is not active not modulating This can be done by eithe
71. through the communication adapter For DPI communication details see DPI Communication Configurations on page 140 To accept each default setting press Enter Analog Outputs can also be programmed through this procedure if desired 9 Disable the AFE output when the AFE is not active not modulating This can be done by either connecting the Inverter Enable output of the AFE to the variable frequency drive s enable input or by enabling parameter 132 Contact Off Cnfg to force the main contactor off in case of a fault This ensures that once the AFE stops modulating there is no motoring current flowing through the AFE IGBT diodes Failure to disable the AFE output can result in component damage or a reduction in product life When enabling parameter 132 see page 105 for details The AFE is shipped with parameter 132 disabled This will not stop or shut down DC output when a fault occurs 10 Select Done Exit to complete the Assisted Start up procedure Rockwell Automation Publication 20Y UMOOTE EN P July 2014 83 Chapter 3 84 Startup Status Indicators For information on AFE status indicators see AFE Status on page 115 Control Devices The following figure shows the operators or control devices switches pushbuttons and status indicators on a IP20 2500 MCC Style enclosure Figure 38 Control Devices for AFE in IP20 2500 MCC Style Enclosure AFE FAULT AFE READY AFE RESET OFF
72. type 0 HW Modulator ASIC modulator with the classical third harmonic injection The current distortion is lower and spectrum is slightly better compared to the Software Modulator 1 Software 1 Symmetric vector modulator with symmetrical zero vectors Current distortion is less than with software modulator 2 if boosting is used 2 Software 2 Symmetric BusClamp in which one switch always conducts 60 degrees either to negative or positive DC rail Switching losses are reduced compared to the modulation type 0 and 1 and spectrum is narrow 3 Software 3 Unsymmetrical BusClamp in which one switch always conducts 120 degrees to negative DC rail to reduce switching losses Drawback is that upper and lower switches are unevenly loaded and spectrum is wide We recommend using the Software 2 setting For AFE parallel operation the Software 3 setting in all AFEs must be used Modulation Index Sets the modulation index limit The default setting of modulation index is 100 To get the maximum 1 minute overload current ND HD the modulation index needs to be adjusted from 100 to 120 However this effects the modulated output voltage and current waveform THD during overload operation RatedLineCurrent Sets the rated current of the supply transformer This parameter may need to be set if the AFE is oversized compared to the supply or feeding transformer capacity Start Stop Mode Selects the operating mode for the AFE
73. unit Input Ppecel x1000 N 3xViLx 1 1 where P pece is in KW and Vj RMS line to line AC input voltage Compare the absolute values of the input current required for the regenerative unit during acceleration deceleration and steady state Select the regenerative unit with the input current rating that meets or exceeds the worst case input current 1 Pmotoris the motor power required for the application The Pyotor could be positive if that section of the machine is motoring or negative ifthat section ofthe machine is regenerating 152 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Voltage Boost Application Notes Appendix C the DC bus voltage The minimum DC bus voltage is limited by the rectified diode 1 ATTENTION The AFE can be used for voltage boost but cannot be used to lower bridge voltage AFE parameter 61 DC Volt Ref can be adjusted to boost the DC voltage The maximum value of parameter 61 DC Volt Ref is Rated Volts x 1 35 x 1 3 for 400 480V units Rated Volts x 1 35 x 1 15 for 600 690V units where Rated Volts is the AC input voltage for the AFE The maximum AC output to the motor DC Volt Ref V 2x 1 1 Example AC line voltage 400V AC Motor 460V AC Max DC Volt Ref 2 400 x 1 35 x 1 3 2 702V DC Maximum AC output to motor 702V DC V 2 x 1 1 451V AC In addition the AC input current required by the AFE increases when using voltage boost Both the continuo
74. 0 for example To accept each default setting press Enter 5 Enter the Alarm Flt Cnfg selection The Alarm Flt Cnfg sets parameters 120 Fault Config and 135 Alarm Config For basic applications the default settings can be used To accept each default setting press Enter 6 Enter the Limits section For basic applications the default settings for the parameters 75 Motor Power Lmt 76 Regen Power Lmt and 77 Current Lmt Val can be used By default Regen Power Lmt and Current Lmt Val are set to let maximum peak power flow from the DC bus to the AC line and prevent DC bus overvoltage faults on the inverters To accept each default setting press Enter 7 Enter the DC Bus Ctrl section of the Start up routine By default the DC bus voltage reference is set to come from parameter 61 DC Volt Ref With this setting the DC Volt Ref is calculated based on the selected AC input voltage For basic applications this setting for the DC bus voltage reference is sufficient To accept each default setting press Enter 8 Enter the Start Stop IO section Parameters 221 225 Digital In 1 5 Sel and parameters 228 229 and 233 Digital Out 1 3 Sel are set to run the AFE from the operator switches on the AFE door see Figure 21 on page 45 for the typical I O wiring diagram The AFE can also be run through a network communication adapter by changing Digital Input 1 from Run to Not Used and sending a Start command
75. 00 No Command x Ref Select 2 001 Ref A Select Par 545 Ref Select 3 010 Ref B Select Par 550 011 Preset 3 Par 573 00 Preset 4 Par 574 01 Preset 5 Par 575 0 Preset 6 Par 576 1 Preset 7 Par 577 Reserved Coast Stop 0 Not Coast to Stop Coast to Stop Current Limit Stop 0 Not Current Limit Stop Current Limit Stop un 9 0 Not Run Run jog 27 0 Not Jog 2 Par 557 Jog2 eserve eserve eserve eserve eserve eserve eserve eserve eserve eserve eserve X eserve 1 ANot Stop condition logic bit 0 0 must first be present before a 1 Start condition will start the drive 2 A Not Stop condition logic bit 0 0 must first be present before a 1 Jog 1 Jog 2 condition will jog the drive A transition to a 0 will stop the drive 3 To perform this command the value must switch from 0 to 1 4 ANot Stop condition logic bit 0 0 must first be present before a 1 Run condition will run the drive A transition to a 0 wil Rockwell Automation Publication 20Y UMOOTE EN P July 2014 143 AppendixA X Supplemental Information Logic Status Word for PowerFlex 750 Series Drives Logic Bits 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Command Description x RunReady 0 Not Ready to Run Ready to Run x Active 0 Not Active Active Hm Reverse orward x Command Directio
76. 00H 7005 and 700AFE Drive Fan Systems Installation Instructions PFLEX IN029 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Preface General Information The following publications are recommended for general information Title Publication Drives in Common Bus Configurations DRIVES AT002 Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives DRIVES IN001 Preventive Maintenance of Industrial Control and Drive System Equipment DRIVES TD001 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 Drive Information The following publications provide detailed information for PowerFlex drives that are compatible with the PowerFlex Active Front End Drive Description Publication PowerFlex 700 PowerFlex 700 Series A User Manual 20B UM001 Series A Drive PowerFlex 700 Series B User Manual 20B UM002 PowerFlex 700 PowerFlex 700 Frames 0 6 Installation Instructions 20B IN019 Series B Drive PowerFlex 700 Frames 7 10 Installation Instructions 20B IN014 PowerFlex 70 700 Reference Manual PFLEX RM001 PowerFlex 70 Installation Instructions 20A IN009 PowerFlex 70EC 700VC Reference Manual PFLEX RM004 PowerFlex 700 Technical Data 20B TD001 PowerFlex Dynamic Braking Resistor Calculator PFLEX ATOO1 PowerFlex 700H Drive PowerFlex 700H Installat
77. 00S Drives 141 Logic Command Word for PowerFlex 750 Series Drives 143 Logic Status Word for PowerFlex 750 Series Drives 144 Appendix B External and Internal Connections eese 145 LOD Display Elementi T rn eode etel 146 ALT Padoa ees seca A eae di uo ota etr ur dtd 146 Mense decret O deu 147 Diagnostics Mende ta Aeque una epit dep tl 147 Parameter Meno a kal dintel Ge ache tu 148 Device Select Mente es Meet A IES 148 Memory Storage Meith uius anes uus Rp NS tas cede Seo eaten 148 Start up Mein ise ved er cR Cb ia Rode 148 Preferences Menorca ETE TEC oko nO er s 148 Viewing and Editing Parameters eee ec oerte 149 DEDE EIDMS at DRE bUPe Ia Ie 149 Numeric Keypad Shortcut mece asepe le oeey hse denise 149 Remoying Installing the HIM uri 149 Appendix C Sizing Guidelines eco aay dee ote venga v Eu edv ee e deed 151 Basic Procedure to Size the AFE Lt 151 Advanced Procedure to Size che AFE 152 Voltage Bods iscsi Legea lei 153 Paralleling AFE oin an ina ee Rae ta pe Eta ATEA 154 Guidelines for AFEs in IP20 2500 MCC Style Enclosure 154 Guidelines for AFEs in IP21 Rittal Enclosure 158 Paralleling an AFE with One or More PowerFlex SCR Bus Supplies ir ii o rH IS 162 Index O ot ea EIN E E 163 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 9 Table of Contents 10 Rockwell Automation Publication 20Y UMOOTE E
78. 0809090809 0909090909 GC ceo 0909000909000909 0909000209 no g 2 OSO SOS OSOSOS SOS O808626268 Ss 5 9596969096909090 9605268596 Lu N LLI 2626262626262626 2626262086 gt wu 8080909080909090 8080209090 os e 8000890080000909 8890895988 S2 E ana 9 090200020202090 000000000 S ca 090909090009090 O80868080 eo A 090909090009090 000006000 r i e QBORSLG808085205 O80858680 ch S 8 8080808080808000 8020202080 x E 0000000090000000 0000000009 cc a cai 0900020900020909 0209090909 ca e e 3889828939898989 3339393333 Y a Elo O O O O O O O O O O O O O t o o alo d Cem e Sh E oI B a o o eo mic o o 2626222026202 92209590 020909090909090 090909090 8090900000009000 030309090 A 7 3 0909090809090809 0209090809 83533802502802 832398099 0802090902090909 0909090809 020200000009090 090909090 T 0202090000000909 Q808696968 n OSO SOSOSOSOS SOS O808686808 Bod 9595959393950 050505050 s 020200000009090 090909090 QRO8525902686005 osos 090000000202090 000000090 9090909090809090 8090909090 QBOLSLSLG2085868 09039990 8080808080005909 8909090909 A 2090909090909090 3090909090 0800000000000000 0805050000 y m LI tl Y 2 Si A eo gt PM a F T eo H H wo n 9 ci gt on a Boo gt aw sot TT Tre 2 oF n E a E AS ca Rockwell Automation Publication 20Y UMOOTE EN P July 2014 134 Supplemental Information Appendix A Figure 46 AFE Frame 10 LCL Filter Dimensions
79. 1 AFE in IP20 2500 MCC Style Enclosure Installation Wiring Figure 17 Routing Areas for AC Input Ground and DC Bus Output Wiring for AFE Frame 13 in IP20 2500 MCC Style Enclosure Area for routing AC input and ground PE connections Shaded areas for routing DC bus output connections on either the left or right side of the enclosure When the side cover plate is removed for DC bus routing always use the Barrier Kit SK Y1 MCCBARRIER to maintain proper air flow in the AFE enclosure and prevent overheating Disconnecting Common Frame 10 LCL Filter Mode Capacitors The Frame 10 AFE LCL Filter contains common mode capacitors that are referenced to ground To guard against AFE damage these devices must be disconnected if the AFF is installed on a high resistance grounded distribution system or an ungrounded distribution system where the line to ground voltages on any phase exceed 125 of the nominal line to line voltage To access the common mode capacitors the LCL Filter must be removed from the enclosure To remove the Frame 10 AFE LCL Filter from the IP20 2500 MCC Style enclosure see the instructions in the PowerFlex Active Front End Frame 10 Hardware Service Manual publication 20Y TG001 capacitors has discharged completely before removing or installing jumpers Check the DC bus voltage between the DC and DC terminals between the DC terminal and the chassis and b
80. 1 Ib in 7 1 Ibein 1 Maximum minimum that the terminal block will accept these are not recommendations 42 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 AFE in IP20 2500 MCC Style Enclosure Installation Wiring Chapter 1 1 0 Cable Grounding When installing shielded multi conductor cable for analog and digital I O strip the cable at a distance from the terminal plug so you can fix it to the cable clamp for grounding JL d 4 D JE p aC Position the exposed shield so the clamp grips it NOTE This clamp is not designed for strain relief Rockwell Automation Publication 20Y UMOOTE EN P July 2014 43 Chapter 1 AFE in IP20 2500 MCC Style Enclosure Installation Wiring ATTENTION For the AFE in the IP20 2500 MCC Style enclosure Digital Inputs 1 3 4 and 5 and Digital Outputs 1 and 2 are factory wired and programmed to operate from the controls on the front of the enclosure Digital Output 3 is programmable and factory wired for 24V DC only Do not change the wiring and programming for those digital inputs and outputs or it will result in malfunction of the system Table 7 Door Control Box 1 0 Terminal Designations for AFE in IP20 2500 MCC Style Enclosure
81. 103 RatedLineCurrent 045 Control Modes 97 Alarm X Code 137 140 Alarms 106 Dig Out Setpt 227 Digital Outputs 112 Reactive Current 005 Metering 95 Analog In 1 Hi 201 Analog Inputs 109 Dig Out Status 103 Diagnostics 103 Reactive Ki 069 Current Loop 99 Analog In 1 Lo 202 Analog Inputs 109 ig Out2 Invert 230 Digital Outputs 112 Reactive Kp 068 Current Loop 99 Analog In 1 Loss 203 Analog Inputs 109 ig Out2 OffTime 232 Digital Outputs 112 Reactive Ref 065 Current Loop 99 Analog In 2 Hi 204 Analog Inputs 109 ig Out2 OnTime 231 Digital Outputs 112 Reactive Sel 070 Current Loop 9 Analog In 2 Lo 205 Analog Inputs 109 ig Out3 Invert 234 Digital Outputs 112 Regen MWh 020 Metering 96 Analog In 2 Loss 206 Analog Inputs 109 ig Out3 OffTime 236 Digital Outputs 112 Regen Power Lmt 076 Limits 9 Analog In1 Value 022 Metering 96 ig Out3 OnTime 235 Digital Outputs 112 Reset Meters 092 Converter Memory 101 Analog In2 Value 023 Metering 96 Digital InX Sel 221 226 Digital Inputs 111 Reset To Defaults 091 Converter Memory 101 Analog Out1 Hi 210 Analog Outputs 110 Digital Out1 Sel 228 Digital Outputs 112 Restart Delay 047 Control Modes 97 Analog Out1 Lo 211 Analog Outputs 110 Digital Out2 Sel 229 Digital Outputs 112 Start Inhibits 100 Diagnostics 103 Analog Out Sel 209 Analog Outputs 110 Digital Out3 Sel 233 Digital Outputs 112 Start Owner 157 Masks amp Owners 107 Analog Out2 Hi 213 Analog Outputs 110 DPI Baud Rate 150 Comm Control 107 Start Up Delay 087 Parallel Mode 100 A
82. 147 Diagnostics Parameter Group 101 Dig In Status parameter 103 Dig Out Setpt parameter 112 Dig Out Status parameter 103 Dig Out2 Invert parameter 112 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Dig Out2 OffTime parameter 112 Dig Out2 OnTime parameter 112 Dig Out3 Invert parameter 112 Dig Out3 OffTime parameter 112 Dig Out3 OnTime parameter 112 Digital In1 Sel parameter 111 Digital In2 Sel parameter 111 Digital In3 Sel parameter 111 Digital In4 Sel parameter 111 Digital In5 Sel parameter 111 Digital In6 Sel parameter 111 Digital Inputs Parameter Group 111 Digital Out1 Sel parameter 112 Digital Out2 Sel parameter 112 Digital Out3 Sel parameter 112 Digital Outputs Parameter Group 112 discharging bus capacitors 14 distribution systems 38 68 unbalanced 28 58 ungrounded 28 58 DPI Baud Rate parameter 107 DPI communication configurations 140 DPI Port Sel parameter 107 DPI Port Value parameter 107 Droop parameter 100 Dynamic Control File 97 editing parameters 91 Elapsed Run Time parameter 96 electrostatic discharge ESD 14 EMC Directive 48 79 F factory defaults resetting to 148 fault descriptions 117 queue 147 Fault 1 Code parameter 105 Fault 1 Time parameter 105 Fault 2 Code parameter 105 Fault 2 Time parameter 105 Fault 3 Code parameter 105 Fault 3 Time parameter 105 Fault 4 Code parameter 105 Fault 4 Time parameter 105 Fault Bus Volts parameter 103 Fault Clear Mode parameter 105 Fault
83. 2014 105 Chapter4 Programming and Parameters No Parameter Name amp Description Values 135 Alarm Config Enables disables alarm conditions that will initiate an AFE alarm Bit E Els e a ns ss 2 Sie zilsa2as5g Definition 3 5 2 S i Slajlala s E 53 3 23 5joe e L 2 98 lal 5S SIS IS Sig flslelole AJAS ls Saal 1 Enabled Default x x x x x 1 0 Disabled 15 14 13 12111 10 9 0 x Reserved Bit 0 Prechrg Actv sets an alarm when the precharging is not completed Bit 1 DC UnderVolt sets an alarm when the DC link voltage exceeded the limit Bit 2 Anlg In Loss sets an alarm when the analog input is lost Bit 3 LineSyncFail sets an alarm when the AC input line phase is missing Bit 4 HeatsinkOvTp sets an alarm when the heatsink temperature is over temperature 90 C Bit 5 LCL Fan Stop sets an alarm when the LCL fan has been stopped Bit 6 DCRefLowLim sets an alarm when the DC voltage reference is less than the limit in parameter 080 DC Ref Lo Lmt Bit 7 DCRefHighLim sets an alarm when the DC voltage reference exceeds the limit in parameter 081 DC Ref Hi Lmt Bit 8 DCBusLoAlarm sets an alarm when the DC voltage is less than the value set by parameter 078 DC Bus Lo Alarm Bit 9 DCBusHiAlarm sets an alarm when the DC voltage exceeds the value set by parameter 079 DC Bus Hi Alarm 136 Alarm Clear Default 0 Ready Resets all
84. 325 10 376 3 6 325A 358A 367A 8000 W 278 3 6 240A 360A 272A 20YF1KO 130 193 3 6 1030A 1133A 1164 A 26 000 W 1 Heavy duty rating does not apply to Frame 13 600 690V AFE 128 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Fusing and Circuit Breakers for AFE in IP20 2500 MCC Style Enclosure Supplemental Information Appendix A AC Input Fuse and Circuit Breaker Ratings The tables in this section provide the recommended AC input line fuses and circuit breakers The AFE in a IP20 2500 MCC Style enclosure includes the recommended AC input fusing and circuit breaker 400 480 Volt AC Fusing and Circuit Breaker Ratings Frame Fuse Rating Main Circuit Breaker Rating Si T Amps Bussman Type Amps ABB Type 10 800A 170M6696 600A T5L600BW 13 2200A 17047090 1600 A T8VBC3FCO00000xx 600 690 Volt AC Fusing and Circuit Breaker Ratings Frame Fuse Rating Main Circuit Breaker Rating si i Amps Bussman Type Amps ABB Type 10 630A 170M6694 400A T5L400BW 13 1800 A 170M7532 1600A T8VBC3FCO00000xx DC Bus Output Fuse Ratings DC Bus Output fusing must be used for short circuit protection The tables in this section provide the ratings of the DC Bus Output fuses used for the AFE ina IP20 2500 MCC Style enclosure 465 800 Volt DC Fusing Frame FuseRating si s Amps Bussman Type 10 1100A 170M6499 13 1100 A 2 per phase 170M6499 640 1100 Volt
85. 39 Alarm Clear 136 Alarm2 Code 138 Alarm4Code 140 Communication Comm Control DPI Baud Rate 150 DPI Port Sel 152 Cnvrtr LogicRslt 151 DPI Port Value 153 Masks amp Owners Logic Mask 154 Stop Owner 156 Fault Clr Owner 158 Fault Clr Mask 155 StartOwner 157 Datalinks Data In A1 170 DatalnD1 176 Data 0utC1 184 Data In A2 171 DatalnD2 17 Data 0utC2 185 Data In B1 172 Data Out Al 180 Data Out DI 186 Data In B2 173 Data Out A2 181 Data0utD2 187 Data In C1 174 Data0utB1 182 Data In 2 175 DataOutB2 183 Inputs amp Analog Inputs Anlg In Config 200 Analog In 1 Loss 203 Analog In 2 Loss 206 Outputs Analog In 1 Hi 201 Analog In 2 Hi 204 Analog In 1 Lo 202 Analog In 2 Lo 205 Analog Outputs Anlg Out Config 207 Analog Out1 Lo 211 Anlg Out Scale 215 Anlg Out Absolut 208 Analog Out2 Sel 212 Anlg Out2 Scale 216 Analog Out Sel 209 Analog Out2 Hi 213 AnlgOut1 Setpt 217 Analog Out Hi 210 Analog Out2 Lo 214 Anlg Out2 Setpt 218 Digital Inputs Digital In1 Sel 221 DigitalIn3Sel 223 DigitalIn5 Sel 225 Digital In2 Sel 222 DigitalIn4 Sel 224 Digital In6 Sel 226 Digital Outputs Dig Out Setpt 227 Dig Out2 OnTime 231 DigOut3 OnTime 235 Digital Out1 Sel 228 DigOut20fffime 232 DigOut30fffime 236 Digital Out2 Sel 229 Digital Out3 Sel 233 Dig Out2 Invert 230 DigOut3 Invert 234 94 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Monitor File S No Parameter Name amp Description io 001 Input Voltage Displays the incoming supply voltage only whe
86. 4 Rockwell Automation Inc All rights reserved Printed in the U S A
87. 4VDC Com Charging 1 Interlocker 2 To User supplied Drive Inverter Enable Input Analog 1 0 Configuration Important Analog I O must be configured through programming and the jumpers shown below See Figure 35 for jumper locations and Table 18 for I O jumper configurations Table 18 1 0 Configuration for AFE in IP21 Rittal Enclosure Signal Jumper Setting Analog J1 Analog In 1 0 20 mA 0 10V x 10V Inputs J2 Analog In 2 n n n p n n ABCD ABCD A BC D ABCD ABCD ABCD Goo poo 0000 00006 ool coms ololo o algo o ooldia oodo ooog oodo Analog J3 Analog Out 1 0 20 mA 0 10V 10V Outputs J4 Analog Out 2 3 4 n 4 ABCD ABCD ABCD ABCD Ooo ooo ogo olo blelo o alaoo oblio oboo Rockwell Automation Publication 20Y UMOOTE EN P July 2014 AFE in IP21 Rittal Enclosure lInstallation Wiring Chapter 2 Hardware Enable Circuitry 5 and Digital Outputs 1 and 2 are factory wired and programmed to operate from the controls on the front of the enclosure Do not change the wiring and programming for those digital inputs and outputs or it will result in malfunction of the system ATTENTION For the AFE in the IP21 Rittal enclosure Digital Inputs 1 3 4 and You can program a digital input as an Enable input The status of this inp
88. 5 3 J1 9 o O Door Control Box Components Components mounted on inside of AFE enclosure see Figure 12 for location X3 Term No Default Description 57 and 60 Remote momentary pulse of 0 4 1 0 sec across these terminals starts precharge in REM mode when terminals 58 and 61 are remotely closed 58 and 61 These terminals must be remotely closed to start precharge Opening these terminals opens the main contactor K1 63 and 64 Remotely dosing these terminals resets an AFE fault 65 and 66 AFE run signal to the inverter enable input 29 X3 Terminals 400 and 480 480 Control input voltage setting 600and690 690 See Table 6 below for door control box item number descriptions and specifications 1 0 Terminal Blocks Table 6 Door Control Box 1 0 Terminal Block Specifications for AFE in IP20 2500 MCC Style Enclosure No Name Description Wire Size Range 1 Torque Maximum Minimum Maximum Recommended O Analog 0 Analog 1 0 Signals 2 5 mm 0 5 mm 0 2 Nem 0 2 Nem 14 AWG 22 AWG 1 8 Ib in 1 8 Ib in Digital Inputs Digital Input Signals 2 5 mm 0 5 mm 0 2 Nem 0 2 Nem 14 AWG 22 AWG 1 8 Iben 1 8 Ib in Digital Outputs Digital Out Relays 2 5 mm 0 5 mm 0 5 Nem 0 5 Nem 14 AWG 22 AWG 4 5 Ibein 4 5 Ibein Control Terminal Customer input and 2 5 mm 0 5 mm 0 8 Nem 0 8 Nem output control 14 AWG 22 AWG 7
89. 9 Grounding Requirements soda Le pe ken E CHAR zaia 59 Recommended Grounding Scheme LLL cece ee eees 59 Safety Ground PES bdsm Et EP EBEN eve ed iuis 60 Shield Termination SHLD iude pad 60 Fuses and Circuit Breaker o oCoeeeee d ete ETE Ori e 61 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Startup Table of Contents Power WINS A eis Power Cable Types Acceptable for 400 690 Volt Installations Unshielded Gable sous alba th so de eheu eeu ShieldedC able estet usos trao ea oe eae A lai Gable Trays and Conduit iiic EHE Eo e EAR Selecting and Verifying Control Transformer Voltage Power Terminals for AFE in IP21 Rittal Enclosure DC Bus Output Waring cack ama ter in Routing the AC Input Ground PE and DC Bus Output Wiring for AFE in IP21 Rittal Enclosure ivi Disconnecting Common Mode Capacitors Frae TO LGL bere ae Frame 15 LGE Filter ene anehe Frame 10 Power Structure cece eee Frame 13 Power Structure eee eee Using the AFE with PowerFlex Drives pila eat Control Wiring AA A RA Signal and Control Wire IPs Et 1 O Verinitial Blocks o a VO Cable Ground iS IPOD A DAS qo RR RS Analog I O Configuration s cule a roneEE Hardware Enable Ciria coe ayia tena EE Ted Analog I O Wiring Examples for AFE in IP21 Rittal Enclosure Precharging the AFE elia laine o ee test dedans Eee i cole dial i cle Important Guidelin
90. 9 Fault Clr Owner Masks amp Owners 107 DC Ref Lo Lmt Limits 99 ata In AX Datalinks 108 Number Parameter Name Group Page DC Ref Hi Lmt Limits 99 ata In BX Datalinks 108 001 Input Voltage Metering 95 Ground Lvl Limits 99 ata In CX Datalinks 108 002 AC Line Freq Metering 95 Droop arallel Mode 100 ata In DX Datalinks 108 003 Total Current Metering 95 PWM Synch arallel Mode 100 ata Out AX Datalinks 108 004 Active Current Metering 95 Start Up Delay arallel Mode 100 ata Out BX Datalinks 108 005 eactive Current Metering 95 Param Access Lvl Converter Memory 101 ata Out CX Datalinks 108 006 input Current R Metering 95 Reset To Defaults Converter Memory 101 ata Out DX Datalinks 108 007 input Current S Metering 95 Reset Meters Converter Memory 101 Anlg In Config Analog Inputs 109 008 input Current T Metering 95 Language Converter Memory 101 Analog In 1 Hi Analog Inputs 109 009 Imbalance Metering 95 Voltage Class Converter Memory 101 Analog In 1 Lo Analog Inputs 109 010 Ground Current Metering 95 Cnvrtr Status 1 iagnosti 101 Analog In 1 Loss Analog Inputs 109 011 DC Bus Volt Metering 95 Cnvrtr Status 2 jagnosti 102 Analog In 2 Hi Analog Inputs 109 012 DC Bus Current Metering 95 Cnvrtr Alarm 1 iagnosti 102 Analog In 2 Lo Analog Inputs 109 013 AC Line kW Metering 95 Cnvrtr Alarm 2 iagnosti 102 Analog In 2 Loss Analog Inputs 109 014 AC Line kVar Metering 95 DC Ref Source iagnosti 102 Anlg Out Config Analog Outputs 109 015 AC Line kVA Metering 95 Start
91. AFE output it does not open the input contactor to stop the AFE When a voltage drop or a blackout occurs in the supplying network the input contactor opens When the supply is restored the precharging must be re initiated To turn the AFE on turn the OFF ON START switch to START and let it automatically return to ON Rockwell Automation Publication 20Y UMOOTE EN P July 2014 85 Chapter 3 AFE in IP21 Rittal Enclosure 86 Startup This procedure requires that a HIM be installed If an operator interface is not available remote devices must be used to start up the AFE Startup Procedure Before Applying Power to the AFE 6 7 Verify that the disconnect lever is pushed to off 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 Verify that AC line power at the disconnect device is within the rated value of the AFE Verify that the control power voltage is correct When DC disconnects are used for each inverter verify that the disconnect levers for all inverters are set to off Set the MCCB CONTROL switch to MAN Set the 0 1 START switch to 0 off Programming the AFE 1 2 Push the AFE disconnect lever to on Set parameter 091 Reset To Defaults to the appropriate setting for your installation 091 Reset to Defaults Default 0 Ready Resets parameters to factory defaults except parameters 093 Language
92. Alarm Descriptions 252224 poe esses tutae 117 C canne Alarms EA 121 Common Symptoms and Corrective Actions lesse esse 122 Technical Support ec suere rer bee SERIE EE e MA Ou 124 Appendix A Specifications cui ud rile ibis deb PEE id lies 125 Derabing GUI illa Roster otv ipei 127 Ambient T emperature Load ue RU ec ERU 127 Altitude Load 400 480V AC Input oocoooccoccccnccnnccn ooo 127 Altitude Load 600 690V AC Input lesse 127 AFE Current Ratings and Watts Loss lore iii 128 400 Volt AC Input Ratings satira pa iti 128 480 Volt AC Input Ratings eee 128 600 Volt AG Input Ratings soe sevby se rari 128 690 Volt AC Input Rates is dann SR RSEN NAE 128 Fusing and Circuit Breakers for AFE in IP20 2500 MCC Style Enclosure atte sits dans icu A ae Ae dl 129 AC Input Fuse and Circuit Breaker Ratings 129 DC Bus Output Fuse Ratings ici iii 129 Fusing and Circuit Breakers for AFE in IP21 Rittal Enclosure 130 AC Input Fuse and Circuit Breaker Ratings 130 DC Bus Output Fuse Ratings casilla 130 DERIO ubi ucripeioet i cua ier dapi LE 131 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 HIM Overview Application Notes Table of Contents DPI Communication Configurations LL 140 Typical Programmable Controller Configurations 140 Logic Command Word for PowerFlex 700 700H 700S Drives 140 Logic Status Word for PowerFlex 700 700H 7
93. Appendix A Logic Status Word for PowerFlex 700 700H 700S Drives Logic Bits 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Status Description X Ready 0 Not Ready 1 Ready X Active 0 Not Active 1 Active X Motoring 0 Not Motoring 1 Motoring X Regenerating 0 Not Regenerating 1 Regenerating X In Precharge 0 Not In Precharge 1 In Precharge X Droop Active 0 Not Droop Active for AFE Paralleling 1 Droop Active for AFE Paralleling X Alarm 0 No Alarm 1 Alarm X Faulted 0 Not Faulted 1 Faulted X At Reference 0 Not At Reference 1 At Reference X Mot CurLim 0 Not Exceeding Current Limit in Motoring Mode 1 Exceeding Current Limit in Motoring Mode X Regen CurLim 0 Not Exceeding Current Limit in Regenerative Mode 1 Exceeding Current Limit in Regenerative Mode X Cmd Delayed 0 Condition False 1 Condition True X DCVoltReflDO Bits x DCVoltReflD1 Description 1 13 12 X DCVoltReflD2 0 0 0 DCVolt Ref 0 0 1 Analog In 1 0 J1 0 AnalogIn2 0 1 1 DPI Port 1 1 0 0 DPI Port 2 1 0 1 DPI Port 3 1 1 0 DPI Port 4 1 1 1 DPI Port 5 X Reserved The AFE reference is the commanded bus voltage for example a value of 6000 represents 600 0V DC The feedback value is the bus voltage measured in the AFE Rockwell Automation Publication 20Y UMOOTE EN P
94. B adjustable devices to avoid nuisance tripping Unbalanced Ungrounded or Resistive Grounded Distribution Systems If phase to ground voltage will exceed 125 of normal or the supply system is ungrounded see Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives publication DRIVES IN001 for more information ATTENTION The PowerFlex Active Front End has not been designed to be used N on IT insulated tera or corner grounded power networks above 600V phase to phase voltage Operation on such a network can cause a hazardous failure of the insulation system of the AFE ATTENTION The LCL Filter of the PowerFlex Active Front End contains common mode capacitors that are referenced to ground These devices must be disconnected if the AFE is installed on a resistive grounded distribution system or an ungrounded distribution system See Figure 18 on page 39 or Figure 19 on page 40 for jumper locations Input Power Conditioning Certain events on the power system supplying an AFE can cause component damage or shortened product life This includes the following events e The power system has power factor correction capacitors switched in and out of the system either by the user or by the power company Rockwell Automation Publication 20Y UMOOTE EN P July 2014 AFE in IP20 2500 MCC Style Enclosure Installation Wiring Chapter 1 e The power source has intermittent voltage spikes in excess of 6000 volts These
95. C and DC sides See Appendix A for fusing information When paralleling you must check the sufficient short circuit capacity of the system e The AFE units must be derated by 5 of their power rating e Configure the following parameters for parallel operation Set Parameter 42 Modulation Type to 3 Set Parameter 82 Ground I Lvl to 100 Set Parameter 85 Droop to 5 for current sharing of the AFEs Set Parameter 86 PWM Synch to 1 to reduce circulating currents between AFEs connected to the same DC bus and fed from the same power source e Ifone of the paralleled AFEs is to be isolated from the AC and DC voltages you must isolate the AC input and DC output The AC input can be isolated with a circuit breaker or a disconnect switch Contactors are not suitable for isolating the AC input because they cannot be locked in the safe position The DC output can be isolated with a disconnect A load isolation switch or safety isolation switch can be used to isolate the precharging circuit from the AC input e Each AFE must use a separate precharging circuit precharging control switch DC bus output fusing and main contactor Each AFE controls its own precharging and main contactor Therefore it is possible to disconnect the AFE when other parallel AFEs are powered up but not modulating e The fault relay of both AFEs must be interlocked with each other such that both AFEs are disabled not running when either
96. Chapter1 AFE in IP20 2500 MCC Style Enclosure Installation Wiring 22 Figure 11 Typical Grounding Example for AFE Frame 13 in IP20 2500 MCC Style Enclosure L1 S L2 T L3 FEEL A PowerFlex 750 Series Drive or PowerFlex 7 Class Drive bar Line PE can be located on the right or left side of the AFE PowerFlex 755 Frame 8 drive shown on right side p ae Customer wiring or DC bus S bar splice required to connect the AFE to the drive Fuses and Circuit Breakers 30 PowerFlex AFE Frame 13 Safety Ground PE and Shield Termination SHLD This is the safety ground for the AFE that is required by code This point must be connected to adjacent building steel girder or joist a floor ground rod or bus bar see above Grounding points must comply with national and local industrial safety regulations and or electrical codes The Shield terminal Figure 14 or Figure 15 provides a grounding point for the AFE cable shield It must be connected to an earth ground by a separate continuous lead The drive cable shield must be connected to this terminal on the AFE end and the drive frame on the drive end Use a shield terminating or EMI clamp to connect the shield to this terminal The IP20 2500 MCC Style enclosure for t
97. Clear parameter 105 Fault Clr Mask parameter 107 Fault Clr Owner parameter 107 Fault Config parameter 105 Fault Frequency parameter 103 Fault Temp parameter 103 Fault Total Curr parameter 103 Faults Parameter Group 105 File Communication 107 Dynamic Control 97 Inputs amp Outputs 109 Monitor 95 Utility 101 File Group Parameter 92 fuse and circuit breaker ratings 129 130 G general precautions 14 Ground Current parameter 95 Ground Lvl parameter 99 grounding recommended scheme 29 59 requirements 29 59 shields 30 60 Group Parameter Alarms 106 Analog Inputs 109 Analog Outputs 109 Comm Control 107 Control Modes 97 Converter Data 96 Converter Memory 101 Current Loop 99 Datalinks 108 Diagnostics 101 Digital Inputs 111 Digital Outputs 112 Faults 105 Limits 99 Masks amp Owners 107 Metering 95 Parallel Mode 100 Restart Modes 98 Voltage Loop 98 hardware enable 46 77 Heatsink Temp parameter 95 HIM 145 ALT functions 146 Diagnostics menu 147 external and internal connections 145 LCD display elements 146 Memory Storage menu 148 menu structure 147 Preferences menu 148 removing 149 I Imbalance parameter 95 Input Current R parameter 95 Input Current S parameter 95 Input Current T parameter 95 input potentiometer 46 77 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Index input power conditioning 28 59 Input Voltage parameter 95 Inputs amp Outputs File 109 L Language paramete
98. Data iagnosti 104 ig Out2 Invert Digital Outputs 112 043 Modulation Index Control Modes 97 Cnvrtr OL Count iagnosti 104 ig Out2 OnTime Digital Outputs 112 045 RatedLineCurrent Control Modes 97 Fault Config aults 105 ig Out2 OffTime Digital Outputs 112 046 Start Stop Mode Control Modes 97 Fault Clear aults 105 igital Out3 Sel Digital Outputs 112 047 Restart Delay Control Modes 97 Fault Clear Mode aults 105 ig Out3 Invert Digital Outputs T 048 Stop Delay Control Modes 97 Power Up Marker aults 105 ig Out3 OnTime Digital Outputs 112 049 Auto Stop Level Control Modes 9 Fault 1 Code aults 105 ig Out3 OffTime Digital Outputs 112 050 Contact On Delay Control Modes 9 Fault 1 Time aults 105 051 Control Options Control Modes 98 Fault 2 Code aults 105 052 AutoRstrt Config Restart Modes 98 Fault 2 Time aults 105 053 Auto Rstrt Tries Restart Modes 98 Fault 3 Code aults 105 054 Auto Rstrt Delay Restart Modes 98 Fault 3 Time aults 105 060 DC Volt Ref Sel Voltage Loop 98 Fault 4 Code aults 105 061 DC Volt Ref Voltage Loop 98 Fault 4 Time aults 105 062 DC Volt Kp Voltage Loop 98 Contact Off Cnfg aults 105 063 DC Volt Ki Voltage Loop 98 Cnvrtr OL Factor Faults 105 064 Active Ref Current Loop 99 Alarm Config Alarms 106 065 Reactive Ref Current Loop 99 Alarm Clear Alarms 106 066 Active Kp Current Loop 99 Alarm X Code Alarms 106 067 Active Ki Current Loop 99 DPI Baud Rate Comm Control 107 068 Reactive Kp Current Loop 99 Cnvrtr Logic Rslt Comm Contr
99. Dimensions are in millimeters and inches 420 1 16 5 340 94 ma 298 1 214 mn gt By A 9 7 A mid a 4 5 D x j le PR LH E 210 1 Els 8 3 pe en in ij i du 1645 41 1761 5 65 9 4 1 69 4 1404 5 66 26 55 3 949 53 S Y 37 4 m 1056 5 ELE NL sg 9 o o Wb DI Dis mar E o AE 429 5 r i O 7 0 poy ry tv ty Zt ud 4 437 87 gt 1 17 gm 183 9 0 4 288 5 169 1 e A P n l A n r y FRONT VIEW RIGHT SIDE VIEW 478 1 18 8 496 94 19 6 LEFT SIDE VIEW AFE Overall Dimensions mm inches Weight kg lbs Input Volt nput otage Height Width Depth 400 480V 263 580 1761 5 69 4 288 5 11 4 496 9 19 6 600 690V 304 670 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 135 AppendixA Supplemental Information Figure 47 AFE Frame 13 LCL Filter Dimensions Dimensions are in millimeters and inches 1477 A 58 2 Heigh
100. Exp Lets the value to be entered as an exponent Param Enters a parameter number for viewing or editing Rockwell Automation Publication 20Y UMOOTE EN P July 2014 HIM Overview Appendix B Menu Structure Figure 51 HIM Menu Structure User Display 9 e View Alarm Queue i Alarms Cir Alarm Queue Diagnostics ED Faults gt Fault Info Status Info gt Cnvrtr Status 1 View Fault Queue eo Device Items Cnvrtr Status 2 Clear Faults Device Version gt PowerFlex 700AFE Cnvrtr Alarm 1 Clr Fault Queue HIM Version Product Data Cnvrtr Alarm 2 Reset Device Control Board DC Ref Source Power Board Slot A E Start Inhibits Last Stop Source LCD HIM Product Data Dig In Status LCD HIM Control Board Dig Out Status Keyboard Numeric Heatsink Temp View selected through qc M M RG Y Param Access Lvl Basic euo File Group Par FGP File Advanced Numbered List File 1 Name FGP Group __ Changed Params File 2 Name Group 1 Name FGP Parameter File3 Name Group2Name Parameter Name Group3 Name parameter Name Parameter Name A PowerFlex 700AFE Y Device Select Connected DPI Devices Value Screen Him CopyCat gt Device gt HIM Memory Storage ES Reset To Defaults Device lt HIM Delete HIM Set Start U e Continue H Up Introduction gt Complete Steps Start
101. FE Frame 10 Power Terminal Locations in IP20 2500 MCC Style Enclosure i e SBSSO0O FRON T VIEW Shown with o enclosure doors and side removed qa a RIGHT SIDE VIEW Table 2 AFE Frame 10 Power Terminal Specifications in IP20 2500 MCC Style Enclosure Wire Size Range 2 Torque Item Name Frame Description 3 Terminal Bolt Maximum Minimum Recommended 3128 o Input Power Terminals 10 Input power 240mm 95mm 40 N m N A L1 12 130 500 MCM 3 0 AWG 354 Ibsin SHLD Terminal line PE Ground Aa TER 300mm 21mm 40N m SHLD Terminal motor 10 Terminating point for wiring shields 600 MCM 14AWG 354 Ibsin M5 M10 PE Ground 8 o DC Bus DC DC 10 DC output using cab
102. FE LCL Filter from the IP21 Rittal enclosure see the instructions in the PowerFlex Active Front End Frame 10 Hardware Service Manual publication 20Y TG001 capacitors has discharged completely before removing or installing jum pers 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 To avoid an electric shock hazard verify that the voltage on the bus To disconnect the common mode capacitors remove the jumpers shown in Figure 33 For more information on ungrounded system installation see Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives publication DRIVES IN001 Figure 33 AFE Frame 10 LCL Filter Common Mode Capacitor Jumper Locations Remove Three Jumpers 9g 8 ol T E 8 ans A n of i to is Remove z E o 9 o E A Il O Il DI n Three Jumpers 8 8 8 Sh 0 8 8 lt I IT TEL T IT e T I T I T o 6 of Oo OHO o 6 O O Q A97 N97 A97 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 AFE in IP21 Rittal Enclosure lInstallation Wiring Chapter 2 Frame 13 LCL Filter The Frame 13 AFE LCL Filter contains comm
103. Figure 43 AFE Frame 13 in IP20 2500 MCC Style Enclosure Dimensions nonce n 2400 1 e 95 gt FRONT VIEW 43 1 43 1 an gt a 0 gt 557 757 957 219 m 29 8 377 E E i D 4 4 2356 9 92 8 mi BOTTOM VIEW 132 699 1 27 5 d Dimensions are in millimeters and inches L d i j a 2379 8 93 7 2265 5 89 2 Y Y 803 4 32 958 38 RIGHT SIDE VIEW Overall Dimensions mm inches Weight kg bs Height 2379 8 93 7 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Width 2400 1 95 Depth 958 38 2200 4850 Appendix A 42 498 7 196 Mar Supplemental Information Dimensions are in millimeters and inches 935 36 8 Dm Figure 44 AFE Frame 10 in IP21 Rittal Enclosure Dimensions ST e mea N co ta gt Wu ne a SoH xo Sa a 2 cc Em a DS
104. HIM displays a text message for each item Bit Parameters These parameters have individual bits associated with features or conditions If the bit is 0 the feature is off or the condition is false If the bit is 1 the feature is on or the condition is true The following example table shows how each parameter type is presented in this manual Rockwell Automation Publication 20Y UMOOTE EN P July 2014 91 Chapter4 Programming and Parameters 0000 3 Parameter Name amp Description S Nom Input Volt O Sets the incoming supply voltage level used to calculate the DC voltage level for charging control 046 Start Stop Mode Fa 3 z S Q9 Selects the operating mode for the regenerative unit E 0 Normal The converter starts only with a Run request La 5 r gt La c 1 Auto The converter starts regenerative operation automatically whenever the DC Voltage is a higher than the DC Voltage reference and stops when there is no regeneration The converter starts by a Run or Start command To avoid starting a digital input can be configured to enable Auto mode selection is allowed only if an external motoring bus supply is installed to not damage the unit 154 Logic Mask Q9 Determines which communication adapters can control the unit If the bit for an adapter is set COMMUNICATION Masks amp Owners to 0 the adapter has no control functions except for stop Bit Definition
105. Important Guidelines The following guidelines must be read and understood 1 If drives without internal precharge are used and a disconnect is installed between the input of the drive and the DC bus you must use an external precharge circuit between the disconnect and the DC input of the drive 2 If drives with internal precharge are used with a disconnect switch to the common bus you must connect an auxiliary contact on the disconnect toa digital input of the drive The corresponding input must be set to the Precharge Enable option This provides the proper precharge interlock guarding against possible damage to the drive when connected to a common DC bus 3 The precharge status of the AFE must be interlocked with the connected drives such that the drives are disabled not running when the AFE is in a precharge state Rockwell Automation Publication 20Y UMOOTE EN P July 2014 47 Chapter1 AFE in IP20 2500 MCC Style Enclosure Installation Wiring CE Conformity 48 Conformity with the Low Voltage LV Directive and Electromagnetic Compatibility EMC Directive has been demonstrated by using harmonized European Norm EN standards published in the Official Journal of the European Communities PowerFlex Active Front End units comply with the EN standards listed below when installed according to this User Manual and the PowerFlex drive Reference Manual Declarations of Conformity are available online at http www ab c
106. 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 PP 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 ARCFLASH 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 pro
107. Inhibits iagnosti 103 Anlg Out Absolute Analog Outputs 110 016 Power Factor Metering 95 Last Stop Source iagnostics 103 Analog Out Sel Analog Outputs 110 017 Heatsink Temp Metering 95 Dig In Status jagnosti 103 Analog Out1 Hi Analog Outputs 110 018 Cmd DC Volt Metering 96 Dig Out Status jagnosti 103 Analog Out1 Lo Analog Outputs 110 019 Motoring MWh Metering 96 Fault Frequency iagnosti 103 Analog Out2 Sel Analog Outputs 110 020 Regen MWh Metering 96 Fault Total Curr iagnostics 103 Analog Out2 Hi Analog Outputs 110 021 Elapsed Run Time Metering 96 6 Fault Bus Volts iagnosti 103 Analog Out2 Lo Analog Outputs 110 022 Analog In1 Value Metering 96 7 Fault Temp iagnosti 103 Anlg Out1 Scale Analog Outputs 111 023 Analog In2 Value Metering 96 8 Status 1 Fault iagnostics 104 Anlg Out2 Scale Analog Outputs 111 030 Rated kW Converter Data 96 9 Status 2 Fault iagnostics 104 Anlg Out1 Setpt Analog Outputs 111 031 Rated Volts Converter Data 96 0 Alarm 1 Fault iagnosti 104 Anlg Out2 Setpt Analog Outputs 111 032 Rated Amps Converter Data 96 1 Alarm 2 Fault iagnosti 104 igital InX Sel Digital Inputs 111 033 Control SW Ver Converter Data 96 2 Testpoint 1 Sel iagnosti 104 ig Out Setpt Digital Outputs 112 040 Nom Input Volt Control Modes 97 3 Testpoint 1 Data iagnosti 104 igital Out1 Sel Digital Outputs 112 041 PWM Frequency Control Modes 97 4 Testpoint 2 Sel iagnosti 104 igital Out2 Sel Digital Outputs 112 042 Modulation Type Control Modes 97 5 Testpoint 2
108. N P July 2014 Who Should Use this Manual What Is Not in this Manual Manual Conventions Preface The purpose of this manual is to provide you with the basic information needed to install start up and troubleshoot the PowerFlex Active Front End AFE Topic Who Should Use this Manual Page 11 What Is Not in this Manual 11 Manual Conventions 11 Rockwell Automation Support 12 Additional Resources 12 General Precautions 14 Catalog Number Explanation 15 Description of Operation 16 Benefits of the AFE 18 AFE in IP00 Open Chassis Configuration 19 This manual is intended for qualified personnel You must be able to program and operate an Active Front End unit and adjustable frequency AC drives In addition you must have an understanding of the parameter settings and functions This manual is designed to provide only installation start up and programming information for the PowerFlex Active Front End For detailed drive information see Drive Information on page 13 The following conventions are used throughout this manual e In this manual we may also refer to the PowerFlex Active Front End as AFE Active Front End or unit e To differentiate parameter names and LCD display text from other text the following conventions are used Parameter Names appear in brackets For example DC Bus Voltage Display Text app
109. OTE EN P July 2014 151 AppendixC Application Notes Advanced Procedure to Size the AFE 1 2 6 Convert all motor powers to kW kW HP x 0 746 Determine the total power and input current required during acceleration For Motoring Loads Pprive PMotor Motor Efficiency For Regenerating Loads Pprive PMotor Motor Efficiency P accel ri Pre PDrivez Calculate the input current required on the regenerative unit during acceleration taking advantage of the 110 for 1 minute overload rating of the regenerative unit Limput Paca x 1000 V 3x Vr x 1 1 where P4 is in kW and V RMS line to line AC input voltage Determine the total power and input current required during steady state run operation For Motoring Loads Pprive PMotor Motor Efficiency For Regenerating Loads Pp ive PMotor Motor Efficiency Prun 7 Ppriver PDrive2 Calculate the steady state input current required on the regenerative unit Limput PRun x 1000 V 3 x Vj where Pp is in KW and Vj RMS line to line AC input voltage Determine the total power and input current required during deceleration For Motoring Loads Pprive PMotor Motor Efficiency For Regenerating Loads Pp ive PMotor Motor Efficiency Poe F PDrive1 PDrive2 Calculate the input current required on the regenerative unit during deceleration taking advantage of the 110 for 1 minute overload rating of the regenerative
110. Out3 Invert Default Selects if the Digital Output 3 is inverted or not Min Max Units Dig Out3 OnTime Default Sets the ON Delay time for Digital Output 3 This is the time between the occurrence of a condition Min Max and activation of the relay Units Dig Out3 OffTime Default Sets the OFF Delay time for Digital Output 3 This is the time between the disappearance of a Min Max condition and de activation of the relay Units Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Read Only Fault 1 0 Not Used 1 Fault 2 Alarm 3 Ready 4 Active 5 Motoring 6 Regenerating 7 In Precharge 8 Current Limit 9 At Reference 10 Contact Ctrl 11 ContactorAck 12 Charge Cntrl 6 13 Anlg In Loss 9 14 DCUnderVolt 2 15 DCRefLowLim Y 16 DCRefHighlim 17 Reserved 18 23 Input 1 6 Link 24 LogicCmdBit 25 Param Cntrl 6 1 True 0 False 1 True 0 00 sec 0 00 163 00 sec 0 01 sec 0 00 sec 0 00 163 00 sec 0 01 sec 4 Active See Digital Out2 Sel 0 False 0 False 1 True 0 00 sec 0 00 163 00 sec 0 01 sec 0 00 sec 0 00 163 00 sec 0 01 sec SS e Programming and Parameters Chapter 4 Pa ra meter Cross Reference Parameter Nam
111. Over nica I amp Input Voltage DE ly available if power 2 Alarm FIt Cnfg cycled during startup 3 Limits 4 DC Bus Ctrl Make a selection A a 5 Strt Stop I O Abort Device Identi i Preferences Change sale 6 Done Exit Backup Resume User Dspy Lines oo User Dspy Time Start Up Menu User Dspy Video Reset User Dspy Contrast Press ED to move between menu items Press e to select a menu item Press ED to move 1 level back in the menu structure Press to select how to view parameters Diagnostics Menu When a fault trips the Active Front End use this menu to access detailed data about the AFE Option Description Faults View fault queue or fault information clear faults or reset the AFE Status Info View parameters that display status information about the AFE Device Version View the firmware revision and hardware series of components HIM Version View the firmware revision and hardware series of the HIM Rockwell Automation Publication 20Y UMOOTE EN P July 2014 147 Appendix B 148 HIM Overview Parameter Menu See Viewing and Editing Parameters on page 149 Device Select Menu Use this menu to access parameters in connected peripheral devices Memory Storage Menu AFE data can be saved to or recalled from HIM sets HIM sets are files stored in permanent nonvolatile HIM memory Description HIM Copycat Save data to a HIM set load data from a HIM set to active AFE Device gt HIM
112. User Manual Allen Bradley PowerFlex Active Front End PowerFlex AFE PowerFlex 700AFE Frames 10 and 13 Firmware Revision Number 1 xxx Allen Bradley Rockwell Software Automation 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
113. acitors 38 Frame lO DEL Pla pto 38 Frame T3 GL AA vol ou sei hi a Ab lano 39 Frame 10 or Frame 13 Power Structure eere to res 40 Using the AFE with PowerElex Dives sais in tases eue ees paren es 40 Control Wii ia 40 Signal and Control Wire Types oss wiyewnuds voter e eto ated 41 I O Terminal Blocks ici sado vad tela 42 I O Cable Grounding ria 43 BESIDE BA UTC ET m 45 Analog I O Configuration Jc lai E PPS 45 Hardware Enable CIECHIEBR el oa 46 Analog I O Wiring Examples for AFE in IP20 2500 MCC Style E closure si tuc eee E eek ecb cda 46 Precharemgthe ABE oiii quaa sas Pese tus Xu RS EPA 47 os PER 47 Important Guidelines fuit ici E LEVE eo kc 47 CE Conformity ar us om eue tia 48 Low Voltage Ditecuive 2006 95 BC vittorio 48 EMC Directive 2004 108 EG iocus coe ee ESI YS 48 General Notes eta 48 Essential Requirements for CE Compliance 48 Chapter2 Main Component Sections rai 32 Piinie 10 275 dic koi a dV ER RS EDEN RISE deux et HN 32 Franco 53 Main Component Locations cese utes vere tates diel gee eons ered 54 Frame bizze tea teen erases ya du esa 54 Frame Licodia EEEE ira 55 Mounting Considefati fis ari td 56 Operating Temper 56 Minimum Mounting Clearances LL 56 AC Supply Source Considerations 00 ccc eee eee eee neces 58 Unbalanced Ungrounded or Resistive Grounded Distribution Siete 58 Input Power Conditioning co eese etr o rer eer e tn Rad 5
114. age release coil opens the circuit breaker When the supply is restored the precharging and MCCB closing must be re initiated To turn the AFE on turn the 0 1 START switch to START and let it automatically return to 1 on Rockwell Automation Publication 20Y UMOOTE EN P July 2014 89 Chapter3 Startup Notes 90 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Chapter 4 Programming and Parameters This chapter provides a complete listing and description of the PowerFlex Active Front End parameters The parameters can be programmed viewed or edited using an LCD HIM Human Interface Module Alternatively programming can be performed using a personal computer with a configuration tool such as Connected Components Workbench software DriveExecutive software or DriveExplorer software Topic Page About Parameters 91 How AFE Parameters are Organized 92 Monitor File 95 Dynamic Control File 97 Utility File 101 Communication File 107 Inputs amp Outputs File 109 Parameter Cross Reference by Name 113 Parameter Cross Reference by Number 114 About Pa rameters To configure the AFE to operate in a specific way certain AFE parameters may have to be configured appropriately Three types of parameters exist Numeric Parameters These parameters have a single numeric value such as 1V AC ENUM Parameters These parameters allow a selection from 2 or more items The LCD
115. alent attenuation Rockwell Automation Publication 20Y UMOOTE EN P July 2014 79 Chapter 2 80 AFE in IP21 Rittal Enclosure Installation Wiring 5 All shielded cables must terminate with proper shielded connector 6 Motor cables of DC input drives used with the AFE must be shielded cable wire with a coverage of 75 or more or must be inside metal conduit or have shielding cover with equivalent attenuation Rockwell Automation Publication 20Y UMOOTE EN P July 2014 AFE in IP20 2500 MCC Style Enclosure Chapter 3 Startup This chapter describes how to start up the Active Front End For a brief description of the HIM Human Interface Module see Appendix B Topic Page AFE in 1P20 2500 MCC Style Enclosure 81 AFE in IP21 Rittal Enclosure 86 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 must perform the following procedure Thoroughly read and understand the procedure before beginning If an event does not occur while performing this procedure 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 AFE Correct the malfunction before continuing ATTENTION Power must be applied to the Active Front End to perform the The basic start up procedure must be performed when starting a n
116. ally After charging the MCCB motor controlled circuit breakers Q1 are closed and the AFEs start the modulation The control signal Inverter Enable shown in Figure 36 on page 76 can be used to interlock the drives connected to the DC bus Rockwell Automation Publication 20Y UMOOTE EN P July 2014 159 AppendixC Application Notes Figure 54 Connecting Parallel Frame 10 AFEs in IP21 Rittal Enclosure E I 1 T TT m li l AC Line Switchgear LCL Filter L1 AFE DC Power Structure U1 Fuses 3 Phase Q0 01 I I AC Input I EN VI i LI ac y A eU onn ANN oU D pe Tr VANA e ANNA oV P A 21 j D B te WANA ADAM ow _ ER a DC Bus I Lo PE DC o Leste Output I i a e a SE STORTA ee sl Q ej PE Bl 6 T I E L I I Motor Protection I Precharge Relay Precharge Precharge Fuses Contactor SOME Circuit NL I I I TT F6 05 K6 I PowerFlex 700AFE1 L seen mu gt ee nr
117. and specific test methods Low Voltage Directive 2006 95 EC EN 61800 5 1 Adjustable speed electrical power drive systems Part 5 1 Safety requirements Electrical thermal and energy The AFE is also designed to meet the following specifications NFPA 70 US National Electrical Code NFPA 79 Electrical Standard for Industrial Machinery 2002 Edition NEMA ICS 7 0 Safety standards for Construction and Guide for Selection Installation and Operation of Adjustable Speed Drive Systems 1 Applied noise impulses may be counted in addition to the standard pulse train causing erroneously high Pulse Freq readings Rockwell Automation Publication 20Y UMOOTE EN P July 2014 125 Appendix A 126 Supplemental Information Category Protection Environment Electrical Control Specification AFE Voltage Class 380 400V 480V 600V 690V Bus Overvoltage Trip 911V DC 911V DC 1200V DC 1200V DC Bus Undervoltage Shutoff Fault 333VDC 333V DC 461V DC 461V DC Heat Sink Thermistor Monitored by microprocessor overtemp trip Ground Fault Protection Yes Input Phase Loss Protection Yes Input Overcurrent Protection Yes Overtemperature Protection Yes LCL Filter Overtemperature Protection Yes Line Transients Up to 6000 volts peak per IEEE C62 41 1991 Control Logic Noise Immunity Showering arc transients up to 1500V peak Ground Fault Trip Altitude DC bus to ground current exceeds par
118. ation 20Y UMOOTE EN P July 2014 AFE in IP20 2500 MCC Style Enclosure Installation Wiring Chapter 1 Cable Trays and Conduit unused wires in the conduit must be grounded at both ends For the same reason if a drive sharing a conduit is being serviced or installed all drives using this conduit must be disabled This helps minimize the possible shock hazard from cross coupled motor leads ATTENTION To avoid a possible shock hazard caused by induced voltages If cable trays or large conduits are to be used refer to guidelines presented in Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives publication DRIVES IN001 Selecting and Verifying Control Transformer Voltage The control transformer in the AFE is used to match the input AC line voltage of the AFE in an IP20 2500 MCC Style enclosure to the 230V and 120V control voltage Verify that the control voltage is set appropriately for the supplied AC line voltage If necessary change the control voltage using this procedure 1 Locate the X3 terminal block Figure 12 Figure 12 X3 Terminal Block Location for AFE in IP20 2500 MCC Style Enclosure Frame 10 Frame 13 shown with enclosure shown with enclosure doors removed doors removed X3 Terminal 2 Block Location dele 9 gelee ler gt 99e 00 Pelee e SS SSL Apa gy
119. ay 050 Modulation Type 042 Restart Delay 047 Control Options 051 Modulation Index 043 Stop Delay 048 Restart Modes AutoRstrt Config 052 AutoRstrtTries 053 AutoRstrtDelay 054 Voltage Loop DC Volt Ref Sel 060 DCVoltKp 062 DC Volt Ref 061 DCVoltki 063 Current Loop Active Ref 064 Active I Ki 067 Reactive I Sel 070 Reactive Ref 065 Reactive Kp 068 Active Kp 066 Reactive Ki 069 Limits Motor PowerLmt 075 DC Bus Lo Alarm 078 DCRefHilmt 081 Regen PowerLmt 076 DC Bus Hi Alarm 079 Ground Lvl 082 Current Lmt Val 077 DCReflolmt 080 Parallel Mode Droop 085 PWM Synch 086 StartUp Delay 087 Utility Converter Memory Param Access Lvl 090 Reset Meters 092 Voltage Class 094 Reset To Defaults 091 Language 093 ae er Diagnostics Cnvrtr Status 1 095 Dig Out Status 103 Alarm 2 Fault 111 Cnvrtr Status 2 096 Fault Frequency 104 Testpoint 1 Sel 112 Cnvrtr Alarm 1 097 Fault Total Curr 105 Testpoint1Data 113 Cnvrtr Alarm 2 098 Fault Bus Volts 106 Testpoint2Sel 114 DC Ref Source 099 Fault Temp 107 Testpoint2Data 115 Start Inhibits 100 Status 1 Fault 108 Cnvrtr OL Count 116 Last Stop Source 101 X Status 2 Fault 109 Dig In Status 102 Alarm 1 Fault 110 Faults Fault Config 120 Fault 2 Code 125 Fault3Time 130 Fault Clear 121 Fault3Code 126 Fault4Time 131 Fault Clear Mode 122 Fault4Code 127 Contact Off Cnfg 132 Power Up Marker 123 Fault 1 Time 128 CnvrtrOLFactor 133 Fault 1 Code 124 Fault2 Time 129 Alarms Alarm Config 135 Alarm 1 Code 137 Alarm 3 Code 1
120. before the unit will fault A hardware problem exists in the power structure One input line phase is missing An imbalance between the power modules exists paralleled units only Frame 13 There is zero current in one of the three phases An analog input is configured to fault on a signal loss Asignal loss has occurred Configure this fault with parameter Anlg In x Loss A microprocessor watchdog timeout has occurred The drive output current has exceeded the instantaneous current limit Fan is not energized at start command 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 Asent message was not acknowledged Problem in application software with task overload The ambient temperature is too low The new power unit or option board installed is a different type Anew option board was added There was an error reading parameters 019 Motoring MWh 020 Regen MWh and 021 Elapsed Run Time from EEPROM This event occurred because a mathematical function had a dividend of zero Startup has been prevented An 1 0 option board has been removed Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Action ifappropriate Check the cables 1 Cycle the power 2 Contact Technical Support see page 124 3 If the problem persists repla
121. ce the converter unit 1 Check all user supplied fuses 2 Check the AC input line voltage 1 Check for DC voltage imbalance between the power modules 2 Check for current input imbalance between the power modules Check supply voltage fuses and cable 1 Check parameter settings 2 Check for broken loose connections at the inputs 1 Cycle the power 2 Replace the Main Control board 1 Check for an excess load 2 Contact Technical Support see page 124 1 Check the status of parameter 097 Cnvrtr Alarm 1 bit 5 LCL Fan Stop If set to 1 check the fan on the LCL Filter If set to 0 check the fan on the converter 2 If the LCL Filter fan is not operating check its DC power supply Correct the cause and manually clear the fault 1 Cycle the power 2 Replace the Main Control board Contact Technical Support see page 124 Raise the ambient temperature Clear the fault and reset the AFE to the factory defaults Clear the fault 1 Cycle the power 2 Replace the Main Control board 1 Cycle the power 2 Replace the Main Control board 1 Cancel prevention of startup if this can be done safely 2 Remove Run Request Clear the fault Table 21 Fault Alarm Types Descriptions and Actions Continued No 70 71 81 94 100 104 106 107 113 120 121 Name Power Unit Periph Loss Port DPI Loss Hardware Enbl Param Chksum PwrBrd Chk
122. contactor when the main supply voltage returns 2 MAN Manual operation by the OFF ON START switch on the enclosure door a Set the REM AUTO MAN switch to MAN b Turn the OFF ON START switch to START and let it automatically return to ON The precharging takes about 5 10 seconds depending on the connected DC bus capacitance When the DC bus voltage has reached its nominal value the AFE control automatically closes the contactor The precharging can be aborted by turning the switch to OFF To stop the AFE turn the OFF ON START switch to OFF NOTE Pressing the Stop key on the HIM only stops the AFE output it does not open the input contactor to stop the AFE When a voltage drop or a blackout occurs in the supplying network the input contactor opens To turn on the AFE turn the OFF ON START switch to START and let it automatically return to ON 3 REM Remote operation with signals to the control terminals a Set the REM AUTO MAN switch to REM b Connect a normally closed NC contact to terminals X3 58 and X3 61 This contact has to be in the NC state for the AFE to precharge and run A remote pulse of 0 4 1 0 second duration connected to terminals X3 57 and X3 60 starts the precharging ofthe AFE When the DC voltage has reached its nominal value the AFE unit automatically closes the input contactor To stop the AFE turn the OFF ON START switch to OFF NOTE Pressing the o Stop key on the HIM only stops the
123. dicate the AFE start is inhibited by the respective DPI port Last Stop Source Default Read Only Displays the source that initiated the most recent stop sequence It will be cleared set to zero during the next Options 0 Pwr Removed start sequence 1 5 DPIPort 1 5 6 Reserved 7 Digital In 8 Fault 9 Not Enabled Dig In Status Read Only Displays the status of the digital inputs Bit e 2 zE27 z Definition 5 3 gt S S 5a Qaa Aaaa 1 InputPresent Default X x ix x x x x x x ix JO 0 JO 0 0 0 0 Input Not Present Bit 15 14 13 12 11 109 817 6 5 43 2 1 0 x Reserved Dig Out Status Read Only Displays the status of the digital outputs Bit Definition 1 Output Present 0 Output Not Present Default X x x x x x x DigitalQut 3 gt DigitalOut 2 gt DigitalOut 1 Bit 15 14 13 12 11 10 9 x Reserved Fault Frequency Default Read Only Captures and displays the AC line frequency at the time of the last fault Min Max 63 0 63 0 Hz Units 0 1 Hz Fault Total Curr Default Read Only Captures and displays the DC bus amps at the time of the last fault Min Max 0 0 Rated Amps x2 Units 0 1 Amps Fault Bus Volts Default Read Only Captures and displays the DC bus voltage at the time of the last fault Min Max 0 Max Bus Volts Units WDC Fault Temp Default Read Only Captures and displays the heatsink temperature a
124. ds NEC VDE CSA BSI and so forth and A variety of cable types are acceptable for PowerFlex Active Front End installations For many installations unshielded cable is adequate provided it can be separated from sensitive circuits As an approximate guide use a spacing of 0 3 meters 1 ft for every 10 meters 32 8 ft of length In all cases avoid long parallel runs Do not use cable with an insulation thickness less than or equal to 15 mils 0 4mm 0 015 in Use only copper wire Wire gauge requirements and recommendations are based on 75 C Do not reduce wire gauge when using higher temperature wire Unshielded Cable THHN THWN or similar wire is acceptable for PowerFlex Active Front End installation in dry environments provided adequate free air space and or conduit fill rates limits are provided Do not use THHN or similarly coated wire in wet areas Any wire chosen must have a minimum insulation thickness of 15 mils and cannot have large variations in insulation concentricity Shielded Cable Shielded cable contains all of the general benefits of multi conductor cable with the added benefit of a copper braided shield that can contain much of the noise generated by a typical AC drive Strongly consider shielded cable in installations with sensitive equipment such as weigh scales capacitive proximity switches and other devices that can be affected by electrical noise in the distribution system Applications with large numbers of dr
125. e Number Group Page Parameter Name Number Group Page Data Out AX 180 181 Datalinks 108 Last Stop Source 101 Diagnostics 103 by N a m e Data Out BX 182 183 Datalinks 108 Logic Mask 154 Masks amp Owners 107 Data Out CX 184 185 Datalinks 108 Modulation Index 043 Control Modes OF Parameter Name Number Group Page Data Out DX 186 187 Datalinks 108 Modulation Type 042 Control Modes 97 AC Line Freq 002 Metering 65 DC Bus Current 012 Metering 95 Motor Power Lmt 075 Limits 99 ACLine kVA 015 Metering 95 C Bus Hi Alarm 079 Limits 99 Motoring MWh 019 Metering 96 ACLine kVar 014 Metering 95 C Bus Lo Alarm 078 Limits 99 Nom Input Volt 040 Control Modes 97 ACLine kW 013 Metering 95 C Bus Volt 011 Metering 95 Param Access Lvl 090 Converter Memory 101 Active Current 004 Metering 95 C Ref Hi Lmt 081 Limits 99 Power Factor 016 Metering 95 Active Ki 067 Current Loop 99 C Ref Lo Lmt 080 Limits 99 Power Up Marker 123 Faults 105 Active Kp 066 Current Loop 99 C Ref Source 099 Diagnostics 102 PWM Frequency 041 Control Modes 97 Active Ref 064 Current Loop 99 C Volt Ki 063 Voltage Loop 98 PWM Synch 086 Parallel Mode 100 Alarm 1 Fault 110 Diagnostics 104 DC Volt Kp 062 Voltage Loop 98 Rated Amps 032 Converter Data 96 Alarm 2 Fault 111 Diagnostics 104 DC Volt Re 061 Voltage Loop 98 Rated kW 030 Converter Data 96 Alarm Clear 136 Alarms 106 DC Volt Ref Sel 060 Voltage Loop 98 Rated Volts 031 Converter Data 96 Alarm Config 135 Alarms 106 Dig In Status 102 Diagnostics
126. e 16 1 0 Terminal Block Specifications for AFE in IP21 Rittal Enclosure No Name Description Wire Size Range Torque Maximum Minimum Maximum Recommended Analogl O Analog 1 0 Signals 2 5 mm 0 5 mm 0 2 Nem 0 2 Nem 14 AWG 22 AWG 1 8 Ib in 1 8 Ib in Digital Inputs Digital Input Signals 2 5 mm 0 5 mm 0 2 N m 0 2 N m 14 AWG 22 AWG 1 8 Iben 1 8 Ib in Digital Outputs Digital Out Relays 2 5 mm 0 5 mm 0 5 Nem 0 5 Nem 14 AWG 22 AWG 4 5 b in 4 5 b in 1 Maximum minimum that the terminal block will accept these are not recommendations Rockwell Automation Publication 20Y UMOOTE EN P July 2014 73 Chapter2 AFE in IP21 Rittal Enclosure tnstallation Wiring 1 0 Cable Grounding When installing shielded multi conductor cable for analog and digital I O strip the cable at a distance from the terminal plug so you can fix it to the cable clamp for grounding Position the exposed shield so the clamp grips it NOTE This clamp is not designed for strain relief 74 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 AFE in IP21 Rittal Enclosure lInstallation Wiring Chapter 2 ATTENTION For the AFE in the IP21 Rittal enclosure Digital Inputs 1 3 4 and 5 and Digital Outputs 1 and 2 are factory wired and programmed to operate from the contro
127. e 22 AFE in 1P21 Rittal enclosure 52 configuring parameters 91 Conformity CE 48 79 Contact Off Cnfg parameter 105 Contact On Delay parameter 97 163 Index 164 control 1 0 terminal block in 1P20 2500 MCC Style enclosure 44 1 0 terminal block in IP21 Rittal enclosure 75 wire 42 73 Control Modes Parameter Group 97 Control Options parameter 98 Control SW Ver parameter 96 conventions used in this manual 11 Converter Data Parameter Group 96 Converter Memory Parameter Group 101 CopyCat HIM function 148 cross reference of parameters by name 113 by number 114 Current Lmt Val parameter 99 Current Loop Parameter Group 99 D Data In A1 parameter 108 Data In A2 parameter 108 Data In B1parameter 108 Data In B2 parameter 108 Data In C1 parameter 108 Data In C2 parameter 108 Data In D1 parameter 108 Data In D2 parameter 108 Data Out A1 parameter 108 Data Out A2 parameter 108 Data Out B1 parameter 108 Data Out B2 parameter 108 Data Out C1 parameter 108 Data Out C2 parameter 108 Data Out D1 parameter 108 Data Out D2 parameter 108 data saving 148 Datalinks Parameter Group 108 DC Bus Current parameter 95 DC Bus Hi Alarm parameter 99 DC Bus Lo Alarm parameter 99 DC Bus Volt parameter 95 DCRef Hi Lmt parameter 99 DCRef Lo Lmt parameter 99 DC Ref Source parameter 102 DC Volt Ki parameter 98 DCVolt Kp parameter 98 DCVolt Ref parameter 98 DC Volt Ref Sel parameter 98 defaults resetting to 148 diagnostic data viewing
128. e has three XLPE insulated conductors plus ground with a spiral copper shield surrounded by a PVC jacket Armored Cable Cable with continuous aluminum armor is often recommended in drive system applications or specific industries It offers most of the advantages of standard shielded cable and also combines considerable mechanical strength and resistance to moisture It can be installed in concealed and exposed manners and removes the requirement for conduit EMT in the installation It can also be directly buried or embedded in concrete Because noise containment can be affected by incidental grounding of the armor to building steel when the cable is mounted we recommend the armor cable have an overall PVC jacket See Chapter 2 Wire Types in Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives publication DRIVES INOOI Interlocked armor is acceptable for shorter cable runs but continuous welded armor is preferred Best performance is achieved with three spaced ground conductors but acceptable performance below 200 HP is provided by use of a single ground conductor Recommended shielded armored wire is listed in Table 11 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 AFE in 1P21 Rittal Enclosure Installation Wiring Chapter 2 Table 11 Recommended Shielded Armored Wire for AFE in IP21 Rittal Enclosure Location Rating Type Description Standard 1000V 90 C 194 F XHHW2
129. e line to ground voltages on any phase exceed 125 of the nominal line to line voltage To remove the AFE Frame 13 LCL Filter from the IP20 2500 MCC Style enclosure see the instructions in the PowerFlex Active Front End Frame 13 Hardware Service Manual publication 20Y TG002 capacitors has discharged completely before removing or installing jumpers 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 To avoid an electric shock hazard verify that the voltage on the bus To disconnect the common mode capacitors remove the upper guard and then remove the jumpers shown in Figure 19 For more information on ungrounded system installation see Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives publication DRIVES IN001 Rockwell Automation Publication 20Y UM001E EN P July 2014 39 Chapter1 AFE in IP20 2500 MCC Style Enclosure Installation Wiring Figure 19 AFE Frame 13 LCL Filter Common Mode Capacitor Jumper Locations sa Remove Three Jumpers Remove Three Jumpers
130. ears in quotes For example Enabled Rockwell Automation Publication 20Y UMOOTE EN P July 2014 11 Preface Rockwell Automation Support Additional Resources 12 Rockwell Automation offers support services worldwide with over 75 sales and support offices over 500 authorized distributors and over 250 authorized systems integrators located throughout the United States alone In addition Rockwell Automation representatives are in every major country in the world Local Product Support Contact your local Rockwell Automation representative for the following e Sales and order support e Product technical training e Warranty support e Support service agreements Technical Product Assistance For technical assistance please review the information in Chapter 5 Troubleshooting first If you still have problems then access the Allen Bradley Technical Support website at http www ab com support abdrives or contact Rockwell Automation When you contact Technical Support be prepared to provide the information listed on page 124 These documents contain additional information concerning related products from Rockwell Automation AFE Information The following publications are recommended for troubleshooting the PowerFlex Active Front End Title Publication PowerFlex Active Front End Frame 10 Hardware Service Manual 20Y TG001 PowerFlex Active Front End Frame 13 Hardware Service Manual 20Y TG002 PowerFlex 7
131. el connected AFEs when they Options 0 Disabled E are connected to the same DC bus and are fed from the same incoming power source without an 1 Enabled 5 isolation transformer In this case parameter 085 Droop must be set to 5 in all AFEs and this parameter 086 PWM Synch must be set to 1 Enabled a 087 Start Up Delay Default 0 00 sec Sets a starting delay when Run command is given When programming different delay to parallel Min Max 0 00 300 00 sec AFEs the AFEs start in sequence Units 0 01 sec 100 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Programming and Parameters Chapter 4 Utility File o No Parameter Name amp Description Values pra 2 090 Param Access Lvl Default 0 Basic Selects the parameter display level Options 0 Basic 0 Basic Reduced parameter set 1 Advanced 1 Advanced Full parameter set 091 Reset to Defaults Default 0 Ready Resets parameters to factory defaults except parameters 093 Language and Options 0 Ready 090 Param Access Lvl 1 Factory 0 Ready A new value may be entered 2 Low Voltage 1 Factory Resets parameters to factory defaults 3 High Voltage 2 Low Voltage Resets parameters to factory defaults and configures parameters for a it 400 480V AFE unit for 400V operation S 600 690V AFE unit for 600V operation 3 3 High Voltage Resets parameters to fact
132. elow See Figure 20 for jumper locations and Table 8 for I O jumper configurations Table 8 1 0 Configuration for AFE in IP20 2500 MCC Style Enclosure Signal Jumper Setting Analog J1 Analog In 1 0 20 mA 0 10V x 10V Inputs J2 Analog In 2 n n n p n n ABCD ABCD ABCD ABCD ABCD ABCD odoo joo 0000 0000 oolplg 0006 ololo o lago o oobla lo oogla oodo Analog J3 Analog Out 1 0 10V 10V Outputs J4 Analog Out 2 3 4 3 4 ABCD ABCD ABCD ABCD ogo ooo oodo 0000 ofalao oboo ool oodo Rockwell Automation Publication 20Y UMOOTE EN P July 2014 45 Chapter1 AFE in IP20 2500 MCC Style Enclosure Installation Wiring Hardware Enable Circuitry 1 3 4 and 5 and Digital Outputs 1 and 2 are factory wired and programmed to operate from the controls on the front of the enclosure Do not change the wiring and programming for those digital inputs and outputs or it will result in malfunction of the system ATTENTION For the AFE in the IP20 2500 MCC Style enclosure Digital Inputs You can program a digital input as an Enable input The status of this input is interpreted by the AFE software If the application requires the AFE to be disabled without software interpretation a dedicated hardware enable configuration can be used To do this
133. equal to or greater than the drive related kW and the system impedance must be less than 10 Operation outside these limits can cause instability resulting in AFE shutdown System Impedance PowerFlex 700AFE kVA Transformer kVA x Transformer Impedance You must take into account the kVA of all PowerFlex AFEs on the distribution system and the system impedance of upstream transformers by improper fusing or circuit breaker selection use only the recommended line ATTENTION To guard against personal injury and or equipment damage caused fuses or circuit breakers specified in Appendix A If a Residual Current Detector RCD is used as a system ground fault monitor use only Type B adjustable devices to avoid nuisance tripping Unbalanced Ungrounded or Resistive Grounded Distribution Systems If phase to ground voltage will exceed 125 of normal or the supply system is ungrounded see Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives publication DRIVES IN001 for more information ATTENTION The PowerFlex Active Front End has not been designed to be used on IT insulated tera or corner grounded power networks above 600V phase to phase voltage Operation on such a network can cause a hazardous failure of the insulation system of the AFE ATTENTION The LCL Filter of the PowerFlex Active Front End contains common mode capacitors that are referenced to ground These devices must be disconnected
134. es esie ionica ule Ede CE Canton dears vid rallo M fas eo qus Low Voltage Directive 2006 95 EC 000 EMG Directive 2004 108 EC is o chelsea EC hie General Notes A A d Essential Requirements for CE Compliance Chapter 3 AFE in IP20 2500 MCC Style Enclosures 2 es Startup Procedure tus ved ose terran an eatin sno pua edd erga Control Devices a ato do el cu sh or o eR Modesor OBerition cies cies um ode Dex UM eris AFE in IP21 Rittal Enclosure scanio Startup Procedufe cornnlr bi Control Devices aliene MCCB Motor Controlled Circuit Breaker and Modesof Oper ti hi qaos cina Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Table of Contents Programming and Parameters Troubleshooting Supplemental Information Chapter 4 About Parameters nds 91 How AFE Parameters ate Organized oi isso tania 92 File Group Parameter Order 3353352335310 ia0 dettate 92 Basic Parameter VIP 93 Advanced Parameter Nievo elena 94 Monitor Plesso p 95 Dynaniic Control File o petali tiva 97 Utility File atra e at a ici col rara A o ENE 101 Communication File Scorpa 107 Inputs amp Outputs lella ra 109 Parameter Cross Reference by Name 113 Parameter Cross Reference by Number 0 000s eee 114 Chapter 5 ARES pa IA 115 Front Panel Indicators 115 HIM Indication s rece toena SSH I E 116 Pauls ando aris tetonas Tone laren die oio d 116 Manually Clearing Faults a 117 Fault and
135. etween the DC terminal and the chassis The voltage must be zero for all three measurements ATTENTION To avoid an electric shock hazard verify that the voltage on the bus To disconnect the common mode capacitors remove the jumpers shown in Figure 18 For more information on ungrounded system installation see Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives publication DRIVES IN001 38 Rockwell Automation Publication 20Y UM001E EN P July 2014 RIGHT SIDE VIEW OF LCL FILTER AFE in IP20 2500 MCC Style Enclosure Installation Wiring Chapter 1 Figure 18 AFE Frame 10 LCL Filter Common Mode Capacitor Jumper Locations Remove Three Jumpers O 0 0 8 O T t E a N Ge a a o AA fer Remove s E 2 sa o Three Jumpers o 6 HO OHO Ao 6 o O O S e ny NS NS Frame 13 LCL Filter The Frame 13 AFE LCL Filter contains common mode capacitors that are referenced to ground To guard against AFE damage these devices must be disconnected if the AFE is installed on a high resistance grounded distribution system or an ungrounded distribution system where th
136. ew AFE to verify the condition of the unit and to configure essential parameters for operating the AFE Because the names of the switches pushbuttons and status indicators are different for an AFE in a IP20 2500 MCC Style enclosure than an AFE in a IP21 Rittal enclosure see the appropriate subsection This procedure requires that a HIM be installed If an operator interface is not available remote devices must be used to start up the AFE Startup Procedure Before Applying Power to the AFE 1 Verify that the input circuit breaker is off 2 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 3 Verify that AC line power at the disconnect device is within the rated value ofthe AFE Rockwell Automation Publication 20Y UMOOTE EN P July 2014 81 Chapter3 Startup 091 82 4 Verify that the control power voltage is correct 5 When DC disconnects are used for each inverter verify that the disconnect levers for all inverters are set to off 6 Set the REM MAN AUTO switch to MAN 7 Set the OFF ON START switch to OFF Programming the AFE 1 Turn the AFE circuit breaker handle to on 2 Set parameter 091 Reset To Defaults to the appropriate setting for your installation Reset to Defaults Resets parameters to factory defaults except parameters 093 Language and 090 Param Access Lvl 0 Ready A new value may be entered
137. fe f ATTENTION It is important to disable the variable frequency drives that are When enabling parameter 132 see page 105 for details The AFE is shipped with parameter 132 disabled This will not stop or shut down DC output when a fault occurs Signal and Control Wire Types Table 4 Recommended Signal Wire for AFE in IP20 2500 MCC Style Enclosure Signal Type Wire Type s Description Minimum Insulation Rating Belden 8760 9460 0 5 mm 22 AWG twisted pair or equivalent 100 shield with drain 300V 75 90 C Analog 1 0 2 167 194 F Belden 8770 0 5 mm 22 AWG 3 conductor 167 or equivalent shielded for remote pot only EMC Compliance See CE Conformity on page 48 for details 1 Ifthe wires are short and contained within an enclosure that has no sensitive circuits the use of shielded wire may not be necessary but is always recommended Rockwell Automation Publication 20Y UMOOTE EN P July 2014 41 Chapter1 AFE in IP20 2500 MCC Style Enclosure Installation Wiring Table 5 Recommended Control Wire for Digital 1 0 Type Wire Type s Description Minimum Insulation Rating Unshielded Per US NEC or applicable national or local code 3 300V 60 C Shielded Multi conductor shielded cable such as Belden 0 5 mm 22 AWG 140 F 8770 or equivalent 3 conductor shielded Figure 20 Door Control Box 1 0 Terminal Blocks and Jumpers For jumper configurations see Table 8 on page 4
138. ff Selects the digital input when closed to command the main contactor to open This is to force the main contactor open and discharge the DC bus We recommend not to change the factory default wiring and setting except that Digital In6 Sel can be configured for any other function Rockwell Automation Publication 20Y UMOOTE EN P July 2014 111 Chapter 4 Programming and Parameters Val E 2 a E gt o n k gt a 172 Parameter Name amp Description Values Dig Out Setpt Sets the digital output from a communication device Example Set parameter 172 Data In B1 to 227 and parameter 229 Digital Out2 Sel to Param Cntl Digital Output 2 can be controlled by controlling Bit 1 of this parameter over Datalink B1 Bit eg Definition 2 2 amp 1 Output Energized Default X X X X x xXx x 0 10 0 Output Deenergized Bit 15 14 13 12 11 10 9 2 1 x Reserved Digital Out1 Sel Default Digital Output 1 is specified for controlling the main contactor This cannot be configured by the user It is read only as 10 Contact Ctrl Digital Out2 Sel Default 1 Selects the AFE status that energizes a CRx output relay Options 1 Any relay programmed as Fault or Alarm energizes pick up when power is applied to the AFE and de energizes drop out when a fault or alarm exists Relays selected for other functions energize only when that conditio
139. fig 106 Analog In 1 Hi 109 Analog In 1 Lo 109 Analog In 1 Loss 109 Analog In 2 Hi 109 Analog In 2 Lo 109 Analog In 2 Loss 109 Analog In1 Value 96 Analog In2 Value 96 Analog Out1 Hi 110 Analog Out1 Lo 110 Analog Out1 Sel 110 Analog Out2 Hi 110 Analog Out2 Lo 110 Analog Out2 Sel 110 Anlg In Config 109 Anlg Out Absolute 110 Anlg Out Config 109 Anlg Out1 Scale 111 Anlg Out1 Setpt 111 Anlg Out2 Scale 111 Anlg Out2 Setpt 111 Auto Rstrt Delay 98 Auto Rstrt Tries 98 Auto Stop Level 97 AutoRstrt Config 98 Cmd DC Volt 96 Cnvrtr Alarm 1 102 Cnvrtr Alarm 2 102 Cnvrtr Logic Rslt 107 Cnvrtr OL Count 104 Cnvrtr OL Factor 105 Cnvrtr Status 1 101 Cnvrtr Status 2 102 Contact Off Cnfg 105 Contact On Delay 97 Control Options 98 Control SW Ver 96 Current Lmt Val 99 Data In A1 108 Data In A2 108 Data In B1 108 Data In B2 108 Data In C1 108 Data In C2 108 Data In D1 108 Data In D2 108 Data Out A1 108 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Data Out A2 108 Data Out B1 108 Data Out B2 108 Data Out C1 108 Data Out C2 108 Data Out D1 108 Data Out D2 108 DC Bus Current 95 DC Bus Hi Alarm 99 DC Bus Lo Alarm 99 DC Bus Volt 95 DC Ref Hi Lmt 99 DC Ref Lo Lmt 99 DC Ref Source 102 DC Volt Ki 98 DC Volt Kp 98 DC Volt Ref 98 DC Volt Ref Sel 98 Dig In Status 103 Dig Out Setpt 112 Dig Out Status 103 Dig Out2 Invert 112 Dig Out2 OffTime 112 Dig Out2 OnTime 112 Dig Out3 Invert 112 Dig Out3 OffTime 112 Di
140. formation AFE Current Ratings and Watts Loss 400 Volt AC Input Ratings The following tables provide PowerFlex Active Front End current ratings including continuous and 1 minute and typical watts loss AFE Catalog Frame kW Rating PWM ACInput Amps DCOutput Typical Number Size Freq Amps Watts Loss ND HD kHz Cont 1Min Cont 20YD460 10 309 3 6 460A 506A 520A 8000 W 258 3 6 385A 578A 435A 20YD1K3 13 873 3 6 1300 A 1430 A 1469 A 23 000 W 772 3 6 1150A 1725A 1299 A 480 Volt AC Input Ratings AFE Catalog Frame HP Rating PWM ACInput Amps DC Output Typical Number Size Freq Amps Watts Loss ND HD kHz Cont 1 Min Cont 20YD460 10 497 3 6 460A 506A 520A 8000 W 416 3 6 385A 578A 435A 20YD1K3 13 1404 3 6 1300 A 1430 A 1469 A 23 000 W 1242 3 6 1150A 1725A 1299 A 600 Volt AC Input Ratings AFE Catalog Frame HP Rating PWM ACInput Amps DCOutput Typical Number Size Freq Amps Watts Loss ND HD kHz Cont 1Min Cont 20YF325 10 439 3 6 325A 358A 367A 8000 W 324 3 6 240A 360A 272A 20YF1KO BM 1390 3 6 1030 A 1133A 1164 A 26 000 W 1 Heavy duty rating does not apply to Frame 13 600 690V AFE 690 Volt AC Input Ratings AFE Catalog Frame kW Rating PWM ACInput Amps DCOutput Typical Number Size Freq Amps Watts Loss ND HD kHz Cont 1Min Cont 20YF
141. g Out3 OnTime 112 Digital In1 Sel 111 Digital In2 Sel 111 Digital In3 Sel 111 Digital In4 Sel 111 Digital In5 Sel 111 Digital In6 Sel 111 Digital Out1 Sel 112 Digital Out2 Sel 112 Digital Out3 Sel 112 DPI Baud Rate 107 DPI Port Sel 107 DPI Port Value 107 Droop 100 Elapsed Run Time 96 Fault 1 Code 105 Fault 1 Time 105 Fault 2 Code 105 Fault 2 Time 105 Fault 3 Code 105 Fault 3 Time 105 Fault 4 Code 105 Fault 4 Time 105 Fault Bus Volts 103 Fault Clear 105 Fault Clear Mode 105 Fault Clr Mask 107 Fault Clr Owner 107 Fault Config 105 Fault Frequency 103 Fault Temp 103 Fault Total Curr 103 Ground Current 95 Ground Lvl 99 Heatsink Temp 95 Imbalance 95 Input Current R 95 Input Current S 95 Input Current T 95 Input Voltage 95 Language 101 Last Stop Source 103 Logic Mask 107 Modulation Index 97 Modulation Type 97 Motor Power Lmt 99 Motoring MWh 96 Nom Input Volt 97 Param Access Lvl 101 Power Factor 95 Power Up Marker 105 PWM Frequency 97 PWM Synch 100 Rated Amps 96 Rated kW 96 Rated Volts 96 RatedLineCurrent 97 Reactive Current 95 Reactive Ki 99 Reactive Kp 99 Reactive Ref 99 Reactive Sel 99 Regen MWh 96 Regen Power Lmt 99 Reset Meters 101 Reset to Defaults 82 86 101 Restart Delay 97 Start Inhibits 103 Start Owner 107 Start Up Delay 100 Start Stop Mode 97 Status 1 Fault 104 Status 2 Fault 104 Stop Delay 97 Stop Owner 107 Testpoint 1 Data 104 Testpoint 1 Sel 104 Testpoint 2 Data 104 Testp
142. ge reference Used when parameter 060 DC Volt Ref Sel is set to 0 DC Volt Ref Min Rated Volts x 1 35 x 1 05 Max Rated Volts x 1 35 x 1 3 for 400 480V units Rated Volts x 1 35 x 1 15 for 600 690V Units units 0 1V DC DC Volt Kp Default 200 Sets the proportional gain for the bus regulator to adjust regulator response Min Max 0 10000 Units None DC Volt Ki Default 0 0040 sec Sets the voltage loop integral gain for responsiveness of the bus regulator Min Max 0 0000 6 0000 sec Units 0 0001 sec Rockwell Automation Publication 20Y UMOOTE EN P July 2014 DYNAMIC CONTROL Limits 066 067 068 069 070 075 076 077 078 079 080 081 082 Parameter Name amp Description Active Ref Displays the active current reference Reactive Ref If selected by Reactive Sel this parameter sets the reference for the reactive current This can be used for power factor correction of the power system Positive value gives inductive current negative value gives capacitive current The maximum reactive current is limited by the following formula Maximum Reactive Ref P032 Rated Amps 2 P004 Active Current 2 Active Kp Sets the active current controller gain Active Ki Sets the integral gain of the active current controller Reactive I Kp Sets the synchronization controller gain Reactive I Ki Sets the integral of the synchronization c
143. he PowerFlex drive Reference Manual Declarations of Conformity are available online at http www ab com certification ce docs Low Voltage Directive 2006 95 EC EN61800 5 1 Adjustable speed electrical power drive systems Part 5 1 Safety requirements Electrical thermal and energy EMC Directive 2004 108 EC EN61800 3 Adjustable speed electrical power drive systems Part 3 EMC product standard including specific test methods General Notes e The AFE can cause radio frequency interference if used in a residential or domestic environment The user is required to take measures to prevent interference in addition to the essential requirements for CE compliance listed below if necessary e Conformity of the AFE with CE EMC requirements does not guarantee an entire machine or installation complies with CE EMC requirements Many factors can influence total machine installation compliance Essential Requirements for CE Compliance Conditions 1 6 listed below must be satisfied for the PowerFlex Active Front End to meet the requirements of EN61800 3 1 Use a standard PowerFlex Active Front End CE compatible unit 2 Review important precautions and attention statements throughout this document before installing the Active Front End 3 Grounding as described on page 59 4 Control 1 0 and signal wiring must be braided shielded cable with a coverage of 75 or better metal conduit or have shielding cover with equiv
144. he AFE includes AC input fusing input circuit breaker Q0 an input contactor K1 and DC bus output fusing The contactor is used for precharge operation For details on precharge operation see page 47 For fuse and circuit breaker information see Appendix A Local national electrical codes can determine additional requirements for the installations Rockwell Automation Publication 20Y UMOOTE EN P July 2014 AFE in IP20 2500 MCC Style Enclosure Installation Wiring Chapter 1 Power Wiring Because most start up difficulties are the result of incorrect wiring take every precaution to verify the wiring is correct Read and understand all items in this section before beginning installation Rockwell Automation cannot assume responsibility for the compliance or noncompliance to any code national local or otherwise for the proper installation of this unit or associated equipment A risk of personal injury and or equipment damage exists if codes are ignored during installation ATTENTION The following information is merely a guide for proper installation Power Cable Types Acceptable for 400 690 Volt Installations local codes outline provisions for safely installing electrical equipment Installation must comply with specifications regarding wire types conductor sizes branch circuit protection and disconnect devices Failure to do so may result in personal injury and or equipment damage f ATTENTION National Codes and standar
145. he AFE is restarted Non Resettable This type of fault normally requires AFE or motor repair The cause ofthe fault must be corrected before the fault can be cleared After repair the fault is reset on power up User Configurable These faults can be enabled and disabled to annunciate or ignore a fault condition by using Fault Config page 105 An alarm is a condition that if left untreated may stop the AFE There are two alarms types Alarm Type Alarm Description o User Configurable These alarms can be enabled or disabled by using Alarm Config page 106 27 Non Configurable These alarms are always enabled See Fault and Alarm Descriptions on page 117 Rockwell Automation Publication 20Y UM001E EN P July 2014 Manually Clearing Faults Fault and Alarm Descriptions Table 21 Fault Alarm Types Descriptions and Actions No Name PrechargeActv Auxiliary In DC UnderVolt DC OverVolt Overload HeatsinkOvrTp IGBT OverTemp System Fault AC OverCurr Steps 1 Press the HIM E Escape key to acknowledge the fault The fault information is removed so that you can use the HIM 2 Address the condition that caused the fault The cause must be corrected before the fault can be cleared Troubleshooting Chapter 5 3 After corrective action has been taken clear the fault with one of these methods e Press the HIM O Stop key Cycle power to the AFE Set AFE para
146. he AFE plus the external capacitance ATTENTION If the maximum capacitance is exceeded component damage in AFE occurs Important Guidelines The following guidelines must be read and understood 1 Ifdrives without internal precharge are used and a disconnect is installed between the input of the drive and the DC bus you must use an external precharge circuit between the disconnect and the DC input of the drive 2 If drives with internal precharge are used with a disconnect switch to the common bus you must connect an auxiliary contact on the disconnect toa digital input of the drive The corresponding input must be set to the Precharge Enable option This provides the proper precharge interlock guarding against possible damage to the drive when connected to a common DC bus 3 The precharge status of the AFE must be interlocked with the connected drives such that the drives are disabled not running when the AFE is ina precharge state Rockwell Automation Publication 20Y UMOOTE EN P July 2014 CE Conformity AFE in IP21 Rittal Enclosure lInstallation Wiring Chapter 2 Conformity with the Low Voltage LV Directive and Electromagnetic Compatibility EMC Directive has been demonstrated by using harmonized European Norm EN standards published in the Official Journal of the European Communities PowerFlex Active Front End units comply with the EN standards listed below when installed according to this User Manual and t
147. he Phase V module of the Frame 13 power structure Location of Common Mode Capacitors on Phase V Module of Frame 13 AFE Power Structure Phase V Module of Frame 13 Power Structure 2 Remove the common mode capacitors a Disconnect the two black wires b Unscrew and remove the capacitor assembly consisting of two capacitors on a small metal bracket Close up View of Common Mode Capacitors on Phase V Module of Frame 13 AFE Power Structure Disconnect Wires and Unscrew Capacitor Assembly Close up View of Common Mode Capacitor Assembly Rockwell Automation Publication 20Y UMOOTE EN P July 2014 71 Chapter2 AFE in IP21 Rittal Enclosure tnstallation Wiring Using the AFE with PowerFlex Drives Control Wiring 72 When the Active Front End is used with drives that have common mode capacitors for example PowerFlex 7 Class or PowerFlex 750 Series drives the common mode capacitors of these drives must be disconnected See the documentation of the respective drives When supplying power to PowerFlex drives of different frame sizes on the same DC bus additional bus capacitance may be needed For details see Drives in Common Bus Configurations publication DRIVES AT002 The AFE in a IP21 Rittal enclosure is factory wired and programmed to operate from the operator switches on the front of the enclosure See Table 17 and Figure 36 for I O terminal designations Only when a customized or remote control is requ
148. he high value for the range of Analog Output 2 scale Entering 0 0 disables this scale and max Min Max Based on Analog Out2 Sel scale will be used Units Based on Analog Out2 Sel 3 Example If parameter 212 Analog Out2 Sel DC Bus Volt the maximum value is 3 2 parameter 031 Rated Volts 800V DC By setting parameter 216 Anlg Out2 Scale 600V DC 2 then 600V DC instead of 800V DC is used for the parameter 213 Analog Out2 Hi value at the analog 2 output 217 Anlg Out1 Setpt Default 0 000 mA 0 000V Sets the Analog Output 1 value from a communication device Min Max 4 000 20 000 mA Example Set parameter 170 Data In A1 to 217 value from communication device Then set 10 000V parameter 209 Analog Out1 Sel to Param Cntl Units 0 001 mA 0 001V Anlg Out2 Setpt Default 0 000 mA 0 000V Sets the Analog Output 2 value from a communication device Min Max 4 000 20 000 mA Example Set parameter 171 Data In A2 to 218 value from communication device Then set unit 10 000V parameter 212 Analog Out2 Sel to Param Cntl Units 0 001 mA E 0 001V Digital In1 Sel DefaultIn1 1 Run Digital In2 Sel Default In2 2 Clear Fault a Digital In3 Sel Default In3 3 Enable Mcont Digital In4 Sel Default In4 6 ContactorAck Digital In5 Sel Only this parameter is fixed and non configurable Default In5 4 LCL OverTemp Digital In6 Sel Default In6 5 Not Used Selects the funct
149. he operator switches on the front of the enclosure The AFE in the IP20 2500 MCC Style enclosure has an input contactor K1 The AFE is configured to run when precharge is complete the contactor is closed and no faults are present The following figure shows the factory installed wiring Figure 21 Factory installed Wiring Diagram for AFE in IP20 2500 MCC Style Enclosure Remote Fault Reset optional nput Contactor On Request nput Contactor Acknowledge ault Reset AFE On LCL OverTemp AFE Ready 24V to LCL AFE Fault x3 64 4 3 a K4 K4 SHE M 4 I u la H3 1 2 H5 DD See Analog 1 0 Configuration on 13 63 READY BUE a 2 IQ0N Ki NAS page 45 for jumper settings n u c A a 0 05 50 0 0 0 0 010 O 0O O 00 ae 1 2 3 4 5 6 7 8 9 1 1 2 B MW 15 6 7 18 19 200 3 AIAI AIA1 AIA2 AlA2 10Vref PotGND 10Vref AOUTI AOUTC AOUT2 DINI DIN2 DIN3 DIN4 DINS DING D COM D COM 24V 24VCOM ES e t bd CS e f npu BE Ez N MA dr R 7 ub 22 23 Ox O72 Pza Control 24 O25 O26 a L_ Input Contactor Close Fault HIM Cradle 414 Input Contactor Supply Relay 4 M Oo Y pw ba 4 X3 66 X3 65 Charging 1 24V DC Interior 2 To User supplied Drive Inverter Enable Input Analog 1 0 Configuration Important Analog I O must be configured through programming and the jumpers shown b
150. indicator lights to indicate that the circuit breakers are in a tripped state In an over current situation the fault that caused the circuit breaker to trip must be identified and fixed before resetting the circuit breakers The MCCB can be reset only by pressing the MCCB RESET pushbutton when the MCCB CONTROL switch is in MAN MCCB Motor Controlled Circuit Breaker and Modes of Operation There are three different modes in which the MCCB and precharge can be controlled The desired control is selected with the MCCB CONTROL selector switch 1 AUTO Automatic operation that automatically precharges and closes the MCCB when the supply voltage is energized a Set the MCCB CONTROL switch to AUTO b Set the 0 1 START switch to 1 on Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Startup Chapter 3 The precharging of the unit automatically starts when input power is present When the DC Bus Voltage reaches its nominal value the circuit breaker automatically closes To stop the AFE turn the 0 1 START switch to 0 off NOTE Pressing the O Stop key on the HIM only stops the AFE output it does not open the MCCB to stop the AFE When a voltage drop or a blackout occurs in the supplying network the unit precharges automatically and closes the circuit breakers when the main supply voltage returns 2 MAN Manual operation by the 0 1 START switch on the enclosure door a Set the MCCB CONTROL switch to MAN
151. input AC line voltage of the AFE in an IP21 Rittal enclosure to the 230V control voltage Verify that the control voltage is set appropriately for the supplied AC line voltage If necessary change the control voltage using this procedure 1 Locate the X3 terminal block Figure 28 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 63 Chapter2 AFE in IP21 Rittal Enclosure tnstallation Wiring Figure 28 X3 Terminal Block Location for AFE in IP21 Rittal Enclosure Frame 10 Frame 13 Shown with enclosure doors removed Shown with enclosure doors removed E ID mn TIBIA X3 Terminal Block Location Mi X3 Terminal Block Location FRONT VIEW FRONT VIEW 2 Move the wire shown in Figure 29 to the appropriate X3 terminal to match the AC line voltage Figure 29 Input Voltage Setting for Control Voltage on Frames 10 and 13 in IP21 Rittal Endosure For 400 480V AC Input For 600 690V AC Input 400 440 460 480 500 525 600 690 OJO OJOJIO OJOJO X3 Terminal Block X3 Terminal Block OIO OIOIO ONO ho Move this wire to the bo this wire to the terminal that matches terminal that matches the ACline voltage
152. insert it into the AFE or connect its cable to the AFE Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Example Displays Remove HIM Do you wish to continue Press Enter 149 AppendixB HIM Overview Notes 150 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Appendix C Application Notes opc Page Voltage Boost 153 Paralleling AFEs 154 Sizing Guidelines Use the following guidelines to properly size the AFE Basic Procedure to Size the AFE 1 Sum the DC Input current rating of the connected drives See the respective drive documentation specifications or Drives in Common Bus Configurations publication DRIVES AT002 2 Multiply the total DC current by 0 9 This compensates for the boosted DC bus voltage that is provided by the AFE 3 Select the AFE with the DC current rating that meets or exceeds the value calculated in step 2 Examples e Normal Duty ND 110 1 minute DC Input Rating of Connected Drives AFE DC ND ND Current ND Cont DC Voltage Power Currents Sum x 0 9 Output Amps 5x 60 HP 5x 84 5 422 5 A 457 5A 520A 1x30 HP 1x85 8A e Heavy Duty HD 150 1 minute AC Input Voltage DC Input Rating of Connected Drives AFE DC HD HD Current HD Cont DC AC Input Voltage Currents Sum x 0 9 Output Amps Voltage 650V 5x60 HP 5x 84 5 422 5 A 480V 1x30 HP 1x55 7 55 7A Rockwell Automation Publication 20Y UMO
153. ion Manual PFLEX IN006 PowerFlex 700H Programming Manual 20C PM001 PowerFlex 700H Technical Data 20C TD001 PowerFlex 7005 Drive PowerFlex 7005 with Phase II Control Installation Manual Frames 1 6 20D IN024 PowerFlex 700S with Phase I Control Installation Manual Frames 9 14 PFLEX IN006 PowerFlex 7005 with Phase Il Control Programming Manual All Frame Sizes 20D PM001 PowerFlex 700S with Phase Il Control Reference Manual PFLEX RM003 PowerFlex 7005 with Phase Il Control Technical Data 20D TD002 PowerFlex 750 Series PowerFlex 750 Series Drive Installation Instructions 750 IN001 Drive PowerFlex 750 Series Drive Programming Manual 750 PM001 PowerFlex 750 Series Technical Data 750 TD001 PowerFlex SCR Bus PowerFlex SCR Bus Supply User Manual 20S UM001 Supply 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 To find your local Rockwell Automation distributor or sales representative visit http www rockwellautomation com locations Rockwell Automation Publication 20Y UMOOTE EN P July 2014 13 Preface General Precautions bb bb D 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 ter
154. ion for the digital inputs Options 0 Not Used 1 Run Selects the digital input to command the AFE to start modulating as long as the stop input is 1 Run not on It is selectable for other functions if the Run is controlled over DPI 2 Clear Fault 2 Clear Fault Selects the digital input if a fault is pending to clear it if the condition is no longer 3 Aux Fault present It is also selectable if this is controlled by Comm Bus 4 LCL OverTemp 3 Aux Fault Selects the digital input to be a customer supplied external signal wired into the AFE 5 LLFanStop unit Opening this contact issues an external fault command disabling the converter 6 ContactorAck 4 LCL OverTemp Selects the digital input to be used as temperature protection to the LCL filter dire i Di Stop Selects the digital input to be used as an acknowledge signal from the LCL filter fan 9 Enable Mcont P TR 10 Mcontoff 6 ContactorAck Selects the digital input to be used as an acknowledge signal from the main contactor 7 Excl Link Selects the digital input to control a digital output 8 Enable Selects the digital input to allow a Run command If J5 jumper on the digital input card is removed the enable function is assigned to Digital Input 6 enable input and creates a fault if opened 9 Enable Mcont Selects the digital input when opened to command the main contactor to open This is to force the main contactor open and discharge the DC bus 10 Mcont O
155. ion on the Web to assist you in using its products At http www rockwellautomation com support you can find technical and application notes sample code and links to software service packs You can also visit our Support Center at https rockwellautomation custhelp com for software updates support chats and forums technical information FAQs and to sign up for product notification updates In addition we offer multiple support programs for installation configuration and troubleshooting For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com services online phone Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwellautomation com rockwellautomation support overview page or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor Yo
156. ired will the control wiring and correspondent digital I O parameter setting need to be changed Here are some important points to remember about I O wiring e Always use copper wire e Wire with an insulation rating of 600V or greater is recommended e Control and signal wires must be separated from power wires by at least 0 3 meters 1 foot e When it is unavoidable to cross control and signal wires with power wires always cross power wires at a 90 angle IMPORTANT 1 0 terminals labeled or Common are not referenced to earth ground They are designed to greatly reduce common mode interference Grounding these terminals can cause signal noise 1 0 Configuration on page 76 Also configuring an analog input for 0 20 mA operation and driving it from a voltage source can cause component damage ATTENTION Inputs must be configured with software and jumpers see Analog Verify proper configuration before applying input signals f ATTENTION It is important to disable the variable frequency drives that are connected to the AFE output when the AFE is not active not modulating This can be done by either connecting the Inverter Enable output of the AFE to each variable frequency drive s enable input or by enabling parameter 132 Contact Off Cnfg to force the main contactor off in case of a fault This ensures that once the AFE stops modulating there is no motoring current flowing through the AFE IGBT diodes
157. it 0 DigInConflict indicates there is a conflict with the digital input settings Bit Contact Fdbk indicates there is no feedback from the main contact DC Ref Source Default Displays the source of the DC bus voltage reference to the unit Options Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Y O Un fa W NN O Read Only Read Only Read Only Read Only DC Volt Ref Analog In1 Analog In2 DPI Port 1 DPI Port 2 DPI Port 3 DPI Port 4 DPI Port 5 Group Diagnostic No 100 101 102 103 104 105 106 107 Programming and Parameters Chapter 4 Parameter Name amp Description Values Start Inhibits Read Only Displays the inputs presently preventing the AFE from starting Dit e geles E Definition 2 3 2 E SEIS Za EE 5285 68 za DITO ELE 1 Inhibit True Default x x 0 0 o 0 O x x 0 10 0 JO 0 0 0 Inhibit False Bit 15 14 13 2 11 109 8 7 6 5 4 43 2 1 x Reserved Bit0 Bitl Bit2 Bit3 Fault is set when the AFE is faulted Type 2 Alarm is set when the AFE has an alarm of type 2 Enable is set when the AFE is not enabled DC Bus Pchrg is set when the AFE is in precharging Bit 4 Stop Assertd is set when a stop command is asserted Bit 5 Params Reset is set when parameter 091 Reset To Defaults is reset to defaults Bit 6 Startup Actv is set when the AFE is in startup sequencing Bits 9 13 in
158. ity of all ground connections periodically Recommended Grounding Scheme For installations in which the AFE is within an enclosure use a single safety ground point or ground bus bar connected directly to building steel All circuits including the AC input ground conductor must be grounded independently and directly to this point or ground bus bar Figure 26 Typical Grounding Example for AFE Frame 10 in IP21 Rittal Enclosure PowerFlex 700AFE Frame 10 PowerFlex 750 Series Drive or PowerFlex 7 Class Drive shown in IP21 Rittal enclosure PowerFlex 700S Frame 10 drive shown EDIDI NII COM Customer wiring required to DC DC connect the AFE to the drive De DG U T1 V T2 W T3 T To Line PE Rockwell Automation Publication 20Y UMOOTE EN P July 2014 59 Chapter2 AFE in IP21 Rittal Enclosure Installation Wiring Figure 27 Typical Grounding Example for AFE Frame 13 in IP21 Rittal Enclosure PowerFlex 750 Series Drive or PowerFlex 7 Class Drive PowerFlex AFE Frame 13 PowerFlex 7005 Frame 10 drive shown Customer wiring required to connect the AFE to the drive R L1 S L2 7 13 7 CC li Safety Ground PE
159. ives in a similar location imposed EMC regulations or a high degree of communication and networking are also good candidates for shielded cable Rockwell Automation Publication 20Y UMOOTE EN P July 2014 31 Chapter 1 32 AFE in IP20 2500 MCC Style Enclosure Installation Wiring Consider all of the general specifications dictated by the environment of the installation including temperature flexibility moisture characteristics and chemical resistance In addition include a braided shield specified by the cable manufacturer as having coverage of at least 75 An additional foil shield can be greatly improve noise containment A good example of recommended cable is Belden 29528 29532 AWG 1 through AWG 410 This cable has three XLPE insulated conductors plus ground with a spiral copper shield surrounded by a PVC jacket Armored Cable Cable with continuous aluminum armor is often recommended in drive system applications or specific industries It offers most of the advantages of standard shielded cable and also combines considerable mechanical strength and resistance to moisture It can be installed in concealed and exposed manners and removes the requirement for conduit EMT in the installation It can also be directly buried or embedded in concrete Because noise containment can be affected by incidental grounding of the armor to building steel when the cable is mounted we recommend the armor cable have an overall
160. ker AFE Voltage Class 380 400V 480V 600V 690V DC Output Voltage Range 462 702 583 842 700 932 802 1071 Method Sine coded PWM Carrier Frequency 3 6 kHz Intermittent Overload Normal Duty 110 Overload capability for up to 1 minute Heavy Duty 150 Overload capability for up to 1 minute this heavy duty rating does not apply to Frame 13 600 690V AFEs Current Limit Capability Current Limit programmable from 20 150 of rated input current Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Derating Guidelines Supplemental Information Appendix A The following charts illustrate derating guidelines based on conditions Ambient Temperature Load 120 Frame 10 mm 100 EN Frame 10 m N Frame 13 400 480V 80 S s of Rated 60 A Power 40 n Frame 13 600 690 20 s MS 0 0 10 20 30 40 50 60 70 80 Ambient Temperature C Altitude Load 400 480V AC Input 120 100 80 60 of Rated Power 40 20 0 0 500 1000 1500 2000 2500 3000 3500 4000 Installation Altitude Above Sea Level m Altitude Load 600 690V AC Input 120 100 ER NAE 9 ret 40 20 0 0 500 1000 1500 2000 2500 3000 Installation Altitude Above Sea Level m Rockwell Automation Publication 20Y UMOOTE EN P July 2014 127 AppendixA Supplemental In
161. lation begins Rockwell Automation cannot assume responsibility for the compliance or the f ATTENTION The following information is merely a guide for proper installation noncompliance to any code national local or otherwise for the proper installation of this 700AFE or associated equipment A hazard of personal injury and or equipment damage exists if codes are ignored during installation This section describes the main component sections and main component locations of AFE Frame 10 and Frame 13 systems in a IP21 Rittal enclosure Rockwell Automation Publication 20Y UMOOTE EN P July 2014 51 Chapter2 AFE in IP21 Rittal Enclosure Installation Wiring Main Component Sections 13 systems in a IP21 Rittal enclosure Frame 10 This section describes the main component sections of AFE Frame 10 and Frame The following figure shows a basic one line diagram for an AFE Frame 10 in a IP21 Rittal enclosure The main component sections consist of the following items e AC Line Switchgear consisting of the input disconnect Q0 and MCCB motor controlled circuit breaker Q1 e LCL Filter L1 e Precharge Circuit e AFE power structure U1 with AFE control assembly e DC fuses F2 1 and F2 2 Figure 22 Basic One line Diagram for an AFE Frame 10 in IP21 Rittal Enclosure
162. le 240mm 2 1 mm2 70 Nem M12 500 MCM 14AWG 620 Ib in DC output using Splice Kit 40 N m M10 SK Y1 BUSSPLICE F10 354 Ib in 1 Maximum minimum sizes that the terminals will accept these are not recommendations 2 Do not exceed maximum wire size Parallel connections may be required 3 These connections are bus bar type terminations and require the use of lug type connectors 4 Apply counter torque to the nut on the other side of terminations when tightening or loosening the terminal bolt to avoid damage to the terminal Rockwell Automation Publication 20Y UMOOTE EN P July 2014 35 Chapter1 AFE in IP20 2500 MCC Style Enclosure Installation Wiring Figure 15 AFE Frame 13 Power Terminal Locations in IP20 2500 MCC Style Enclosure FRONT VIEW Shown with enclosure doors and side removed Jee gt FO A ar 1 2 T 1 D o n a oH F4 l a RIGHT SIDE VIEW Table 3 AFE Frame 13 Power Terminal Specifications in IP20 2500 MCC Style Enclosure Wire Size Range 2 Torque I
163. le 18 aremm 4 20 mA Input 1 Adjust Scaling i DI Parameters 80 81 and 204 205 E View results Eu Parameter 018 Analog Output e Configure with Parameter 207 and set 10V 4 20 mA Bipolar appropriate jumper per Table 18 10V Unipolar shown c Select Source Value AN i Parameter 209 Analog Out Sel ste Adjust Scaling LE Parameters 210 211 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 77 Chapter2 AFE in IP21 Rittal Enclosure tnstallation Wiring Precharging the AFE 78 This section contains important information about AFE precharging Introduction An ATE in the IP21 Rittal enclosure contains an internal precharging circuit The precharging unit is used to charge the DC bus capacitors The charging time depends on the capacitance of the intermediate circuit and the resistance of the charging resistors Table 20 shows the technical specifications for the precharge in the AFE enclosure For correct operation of the precharging circuit the input circuit breaker and the precharging circuit contactor must be controlled by the AFE Table 20 Total DC Bus Capacitance Limits for Precharging Circuit of AFE in IP21 Rittal Enclosure Frame Size Resistance Capacitance min 1 Capacitance max 2 10 2x 20 ohms 9900 pF 70 000 pF 13 2x11 ohms 29 700 pF 128 000 pF 1 The minimum capacitance is built into the AFE 2 The maximum capacitance is the capacitance of t
164. ls on the front of the enclosure Digital Output 3 is programmable and factory wired for 24V DC only Do not change the wiring and programming for those digital inputs and outputs or it will result in malfunction of the system Table 17 1 0 Terminal Designations for AFE in IP21 Rittal Enclosure No Signal Factory Default Description 1 Analog In 1 1 2 Isolated 8 bipolar differential 9 bit amp sign 88k ohm input impedance A jumper see 1 2 Analog In 1 Table 18 selects 0 10V 10V or 4 20 mA 3 Analog In 2 Default 0 10V Ri 200k ohm 4 20 mA pets Ri 100 ohm 4 Analog In 2 1 5 10V Pot Reference 2k ohm min 10 mA max load 1 accuracy 6 Pot Common GND For and 10V pot references 7 10V Pot Reference 2k ohm min 10 mA max load 196 accuracy 8 Analog Out 1 2 Bipolar current out is not bipolar 9 bit and sign 2k ohm min load A jumper see 9 Analog Out Common Table 18 selects 0 10V 10V or 4 20 mA 10 Analog Out 2 11 Digital In 1 RunCmd 24V DC Opto isolated 250V Low State less than 5V DC 12 Digital In 2 Ext Reset High State greater than 20V DC 11 2 mA 13 Digital In 3 Enable Mcont DC Enable Digital Input 6 is jumper selectable 14 Digital In 4 Contactor Ack for HW Enable 15 Digitalin 5 LCL Temp On Time lt 16 7 ms Off Time lt 1 ms 16 Digital In 6 Hard
165. lt 3 Time Units 0 0001 Hr Fault 4 Time Displays the time between initial AFE power up and the occurrence of the associated trip fault The time shown by these parameters can be compared to parameter 123 Power Up Marker for the time from the most recent power up Therefore Fault x Time Power Up Marker Time difference to the most recent power up A negative value indicates the fault occurred before the most recent power up A positive value indicates the fault occurred after the most recent power up Contact Off Cnfg Configures faults that will force the main contactor off in case of fault This is only possible if the precharge contactor is off or controlled over the network Digital output selection and the AFE is supplied by an external 24V DC power supply This provides an option to protect the AFE when the AFE is faulted modulating is stopped and the motoring current can still flow through the IGBT diode di ele B Definition 21S 3 s 5 3 E 29 E ae x 3 2 83 Y 3 Mii al e acl Sl Default x x x xh Ix to to lo to x o 0 Disabled Contactor Off command from fault x Reserved Bit BUBRI aj 5 3 10 If enabled the auto restart function will be disabled Cnvrtr OL Factor Default 1 00 Sets the operating level for the AFE overload Min Max 0 50 1 50 AFE rated current x AFE OL Factor Operating Level Units None Rockwell Automation Publication 20Y UMOOTE EN P July
166. lter 0 40 C 1400 m hr 824 cfm 1100 m hr 647 cfm 32 104 F 4200 m3 hr 2472 cfm 1300 m3 hr 765 cfm 10 0 40 C 30 32 104 F 1 The Frame 13 690V AFE has only Normal Duty operation at nominal rated power and maximum ambient temperature at 35 C 2 Foran AFE in the IP20 2500 MCC Style enclosure this air means surrounding the outside of the enclosure Minimum Mounting Clearances Frame 10 in IP20 2500 MCC Style Enclosure 50mm 50mm Q 0 in TOP VIEW 20 in Clearance to Wall 4 ana t 5659 mm i J 22 in 1 Door Swing Clearance id SLI a 200 mm 7 87 in Height Clearance o o d FRONTVIEW 26 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 AFE in IP20 2500 MCC Style Enclosure Installation Wiring Chapter 1 Frame 13 in IP20 2500 MCC Style Enclosure 73 mm TOP VIEW 27 mm 29 n y 4 D oi Clearance to Wall Clearance to Wall E EN CO Be EN a amp Re CON aa CON a 591 5 mm 790 2 mm 23 in E 990 2 mm 31 in Door Swing Clearance 39 in Door Swing Clearance o J wee E Pa Door Swing Clearance J F 200 mm 7 87 in Height Clearance
167. ly exist in the unit Bit EPEIE Sl Gel alaiz Definition gt s 8 3 s 3 2 8 3 2 2l 52252 23 8 S S Si gis 2 S 2 A IEZZO 1 Condition True Default X iX X Xx 1 0 Condition False 15 14 13 12 11 10 9 0 x Reserved Bit 0 Prechrg Actv indicates that precharging is not completed Bit 1 DC UnderVolt indicates the DC link voltage exceeded the limit Bit 2 Anlg In Loss indicates the analog input loss Bit 3 LineSync Fail indicates the AC input line phase is missing Bit 4 HeatsinkOv Tp indicates the heatsink temperature is over temperature 90 C e Bit 5 LCL Fan Stop indicates the LCL fan has been stopped Bit 6 DCRefLowLim indicates the DC voltage reference is less than the limit in parameter 080 DC Ref Lo Lmt Bit 7 DCRefHighLim indicates the DC voltage reference exceeds the limit in parameter 081 DC Ref Hi Lmt Bit 8 DCBusLo Alarm indicates the DC voltage is less than the value set by parameter 078 DC Bus Lo Alarm Bit 9 DCBusHi Alarm indicates the DC voltage exceeds the value set by parameter 079 DC Bus Hi Alarm Bit 10 Overload indicates that parameter 003 Total Current exceeds the rated current Cnvrtr Alarm 2 Displays alarm conditions that presently exist in the unit Bit Definition 1 Condition True 0 Condition False Default X X X X X X X gt Contact Fdbk gt 2 DigInConflict Bit 15 14 13 12 11 10 9 x Reserved B
168. me 10 AFEs in IP20 2500 MCC Style Enclosures pv aS 1 qn Ende At n m Us so m 1 por 1 ACLine Switchgear LCL Filter L1 AFE 1 DC 4 Input Input i PowerStructure U1 Fuses I p Breaker Contactor I 3 Phase 0 Fuses KI l I AC Input FII FI3_L_ 1 E ni T l ANA ANN LI eo S11 eo a i o U 2 e H1 T 78 7 ET n l OV of RE Po e l3 e sul A WARN ANAMI y oW ae I F22 rT iT gt DC Bus I o PE DC of 4 He eS Output NE a a l I i m E J ee el Q 6 mi um i I i L I Gl vi l a I I I l I En NU a li E i I Prechage Precharge Precharge I Fuses Contactor ent F5 Circuit I l l l K6 l l I l DI i DI R6 1 o PowerFlex pi pi E t pes I 700AFE System l o l TORTE ME cac DG MCI SII ago ia ene E EAT DE RYE A vil i ACLine Switchgear l LCL Filter L1 jf AFE
169. memory or delete a HIM set Device lt HIM Reset To Defaults Restore the AFE to its factory default settings Start up Menu See Chapter 3 Preferences Menu The HIM and AFE have features that you can customize Option Description AFE Identity Add text to identify the AFE Change Password Enable disable or modify the password User Dspy Lines Select the display parameter scale and text for the User Display The User Display is two lines of user defined data that appears when the HIM is not being used for programming User Dspy Time Set the wait time for the User Display or enable disable it User Dspy Video Select Reverse or Normal video for the Frequency and User Display lines Reset User Dspy Return all the options for the User Display to factory default values The AFE is initially set to Basic Parameter View To view all parameters set parameter 196 ParamAccessLvl to option 1 Advanced Parameter 196 is not affected by the Reset to Defaults function Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Viewing and Editing Parameters LCD HIM Step 1 Inthe Main Menu press the or key to scroll to Parameter 2 Press the ES Enter key FGP File appears on the top line and the first three files appear below it 3 Press the or GD key to scroll through the files 4 Press the Enter key to select a file The groups in the file are displayed under it 5 Repeat ste
170. meter 121 Fault Clear to 1 Clear Faults Clear Faults by using the HIM Diagnostic menu Fault eo Alarm Description The charging switch is open when the START command has been given Faulty operation e Component failure The auxiliary input interlock is open The DC bus voltage fell below the minimum value of 333V for 400 480V AFEs or 461V for 600 690V AFEs You can enable disable this fault with parameter 120 Fault Config The DC bus voltage exceeded the maximum value of 911V for 400 480V AFEs or 1200V for 600 690V AFEs When input current exceeds 125 for 60 seconds or 150 for 30 seconds The overload is a linear type in counting up The heatsink temperature has exceeded the maximum allowable value 85 C Alarm 90 C Fault The output transistors have exceeded their maximum operating temperature due to an excessive load A hardware problem exists in the power structure The AC line current has exceeded the hardware current limit Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Action ifappropriate Reset the fault and restart Should the fault re occur contact Technical Support see page 124 Check all remote wiring Monitor the incoming AC line for low voltage or power interruption 1 Check if the AFE was in a regenerative current limit condition which may indicate an excess regenerative load 2 Adjust parameter Regen Power
171. minal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements ATTENTION To guard against personal injury and or equipment damage caused by an ARC Flash the user needs to identify the ARC Flash requirements per NFPA 70E 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 when installing testing servicing or repairing 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 startup and subsequent maintenance of the system Failure to comply can result in personal injury and or equipment damage Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Catalog Number Explanation 1 3 4 5 7 20Y D 460 a b c a Drive PowerFlex AFE
172. n 0 000 cece a ee 19 Chapter 1 Main Component Sections urlare 22 Frame lO n Lngd e bid bas a ia 22 Frame Eo tot Vari EL ella i t EE 23 Main Component Locations zitella 24 Prise 1022 eu oad eae tee cea teens enw oe 24 Frame 13 c cubre lee eee Sok eee eG Saw dk ws Sete du ut 25 Mounting Considerations nullita 26 Operating Temperatures ra n eremi aa eo 26 Minimum Mounting Clearances i i iii 26 AG Supply Source Considerations ainsi ariani 28 Unbalanced Ungrounded or Resistive Grounded Distribution Sitia oleole dei 28 Input Power Conditions eee 28 Grounding Requitementsa vos lello 29 Recommended Gro ndingScheme s ce oer eer een 29 Safety Ground PE and Shield Termination SHLD 30 Fuses and Circuit Breakers ss AS 30 Power WI ARA E UD DUE 31 Power Cable Types Acceptable for 400 690 Volt Installations 31 Unshielded ables exces oet tbc ie da 31 Sbiclded Cables So sh eet Sx pitas cat d ROO ES RS PR i p 31 Armored Cable epatiti E ek eet itus bine 32 Cable Trays and Conductas cab dde Bog beet 33 Selecting and Verifying Control Transformer Voltage 33 Power Terminals for AFE in IP20 2500 MCC Style Enclosure 35 Routing the AC Input Ground PE and DC Bus Output Wiring for AFE in IP20 2500 MCC Style Enclosure 37 Rockwell Automation Publication 20Y UM001E EN P July 2014 5 Table of Contents AFE in IP21 Rittal Enclosure Installation Wiring Disconnecting Common Mode Cap
173. n 0 Reverse orward x Actual Direction 0 uod x Accelerating 0 Not Accelerating Accelerating x Decelerating 0 Not Decelerating ecelerating ol x Alarm 0 No Alarm Par 959 and 960 Alarm Il x Fault 0 No Fault Par 952 and 953 Fault x At Setpt Spd 0 Not at Setpoint Speed At Setpoint Speed X Manual 0 Manual Mode Not Active Manual Mode Active X Spd Ref ID 0 00000 Reserved x Spd Ref ID 1 00001 Auto Ref A Par 545 x Spd Ref ID 2 00010 Auto Ref B Par 550 00011 Auto Preset Speed 3 Par 573 x w ae 00100 Auto Preset Speed 4 Par 574 di Doe 00101 Auto Preset Speed 5 Par 575 00110 Auto Preset Speed 6 Par 576 00111 Auto Preset Speed 7 Par 577 01000 Reserved 01001 Reserved 01010 Reserved 01011 Reserved 01100 Reserved 01101 Reserved 01110 Reserved 01111 Reserved 0000 Man Port 0 0001 Man Port 1 0010 Man Port 2 0011 Man Port 3 0100 Man Port 4 0101 Man Port 5 0110 Man Port 6 0111 Reserved 1000 Reserved 1001 Reserved 1010 Reserved 1011 Reserved 1100 Reserved 1101 Man Port 13 embedded ENET 1110 Man Port 14 Drive Logix 1111 Alternate Man Ref Sel X eserved x unning 0 Not Running Running x logging 0 Not Jogging Par 556 and 557 logging x Stopping 0 Not Stopping Stopping X C Brake 0 N
174. n jr 7 I AC Line Switchgear LCL Filter L1 AFE DC i i Power Structure U1 Fuses E u I I ie Tg aan ARAL ELT IE eH iis WARN enn NA 5 F2 1 A Le OS WARN ANAM oW T i e o se ti 1 4 A c ARH Fl rica Q G PEE 7 I G 6 E i J L J gt l I Motor Protection I I Precharge Relay Precharge Precharge I Fuses Contactor E Circuit N i I o I I l I F6 05 K6 I l l I i d 6 1 4 hall i bi 6 2 PowerFlex l o 700AFE 2 l L Lo eo e w ge e r l 160 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Application Notes Figure 55 Connecting Parallel Frame 13 AFEs in IP21 Rittal Enclosure Appendix C _ I a Y re Tob m poen I I ACLine Switchgear LCL Filte
175. n Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Programming and Parameters Chapter 4 Read Only 3200 0 Amp 0 1 Amp 0 0 Amp Based on parameter 032 Rated Amps 0 1 Amp 400 0 4000 None 0 0266 sec 0 0000 6 0000 sec 0 0001 sec 2000 0 32000 None 0 040 sec 0 000 20 000 sec 0 001 sec 0 React Ref 0 React Ref 1 Analog In1 2 Analog In2 300 0 0 1 300 0 0 1 300 0 0 1 300 0 0 1 1 5 x Rated Amps 0 0 Based on Unit Rating 0 1 Amps Based on Unit Rating 0 0 2000 0V DC 0 1V DC Based on Unit Rating 0 0 2000 0V DC 0 1V DC Read Only 0 0 1500 0V DC 0 1V DC Read Only 0 0 1500 0V DC 0 1V DC 50 0 0 0 100 0 0 1 Based on unit rating 99 Chapter4 Programming and Parameters 3 No Parameter Name amp Description Values i 085 Droop Default 0 00 Sets the droop as of active current reference for current balancing when AFEs are used in parallel Min Max 0 00 100 00 independent mode It affects DC bus voltage if enabled Recommended value for parallel AFEs is 5 Units 0 01 mad g 086 PWM Synch Default 0 Disabled gt o wn Y Sets synchronization to reduce the circulating current between parall
176. n exists and de energizes when the condition is removed 2 These selections correspond to bits in parameter 097 Cnvrtr Alarm Therefore these selections work only if the corresponding alarm is configured in parameter 135 Alarm Config 3 When a Digital Output is set to one of these for example Input 3 Link in conjunction with Digital Input 3 set to Excel Link the Digital Input 3 state on off is echoed in the Digital Output 4 Bit 7 of parameter 151 Cnvrtr LogicRslt controls the digital output 5 Parameter controlled digital output lets the PLC control digital outputs through data links Set in parameter 227 Dig Out Setpt 6 Charging contactor control over the network by Bit 7 of parameter 151 Cnvrtr LogicRslt and as soon as the main contactor is on the output is switched off An impulse over the network is enough to charge Use this feature only if the control board is supplied from an external 24V DC power supply Dig Out2 Invert Default Selects if the Digital Output 2 is inverted or not Options Dig Out2 OnTime Default Sets the ON Delay time for Digital Output 2 This is the time between the occurrence of a condition Min Max and activation of the relay Units Dig Out2 OffTime Default Sets the OFF Delay time for Digital Output 2 This is the time between the disappearance of a Min Max condition and de activation of the relay Units Digital Out3 Sel Default See Digital Out2 Sel Options Dig
177. n the AFE is in the Run state 002 AC Line Freq Displays the supply frequency The sign indicates the phase order only when the AFE is in the Run state 003 Total Current NW Displays the total AC input current present at L1 L2 and L3 inputs 004 Active Current YY Displays the amount of AC input current that is in phase with the AC input fundamental voltage component Positive value indicates motoring negative value indicates regeneration 005 Reactive Current YY Displays the amount of AC input current that is out of phase with the AC input fundamental voltage component Positive value indicates inductive current negative value indicates capacitive current 006 Input Current R 007 Input Current S 008 Input Current T Displays the RMS value of the L1 L2 and L3 phase AC input current 009 I Imbalance Displays the current imbalance calculated between phases L1 L2 and L3 The RMS current for each phase is calculated by summing the instantaneous current squared as sampled at the PWM peak and valley and then taking the square root of the sum every AC line cycle The imbalance is then evaluated every AC line cycle by first finding the largest smallest and average phase current Two equations are then used to calculate the value displayed 2 Based_on_Largest Largest Average x 100 Average E Z 2 Based_on_Largest Largest Average x 100 Average a The equation that gives the higher value is used for the
178. nalog Out2 Lo 214 Analog Outputs 110 DPI Port Sel 152 Comm Control 107 Start Stop Mode 046 Control Modes oF Analog Out2 Sel 212 Analog Outputs 110 PI Port Value 153 Comm Control 107 Status 1 Fault 108 Diagnostics 104 Anlg In Config 200 Analog Inputs 109 roop 085 Parallel Mode 100 Status 2 Fault 109 Diagnostics 104 Anlg Out Absolute 208 Analog Outputs 110 Elapsed Run Time 021 Metering 96 Stop Delay 048 Control Modes 97 Anlg Out Config 207 Analog Outputs 109 Fault 1 Code 124 Faults 105 Stop Owner 156 Masks amp Owners 107 Anlg Out1 Scale 215 Analog Outputs 111 Fault 1 Time 125 Faults 105 Testpoint 1 Data 113 Diagnostics 104 Anlg Out1 Setpt 217 Analog Outputs 111 Fault 2 Code 126 Faults 105 Testpoint 1 Sel 112 Diagnostics 104 Anlg Out2 Scale 216 Analog Outputs 111 Fault 2 Time 127 Faults 105 Testpoint 2 Data 115 Diagnostics 104 Anlg Out2 Setpt 218 Analog Outputs 111 Fault 3 Code 128 Faults 105 Testpoint 2 Sel 114 Diagnostics 104 Auto Rstrt Delay 054 Restart Modes 98 ault 3 Time 129 Faults 105 Total Current 003 Metering 95 Auto Rstrt Tries 053 Restart Modes 98 ault 4 Code 130 Faults 105 Voltage Class 094 Converter Memory 101 Auto Stop Level 049 Control Modes 97 ault 4 Time 131 Faults 105 AutoRstrt Config 052 Restart Modes 98 ault Bus Volts 106 Diagnostics 103 Cmd DC Volt 018 Metering 96 ault Clear 121 Faults 105 Cnvrtr Alarm 1 097 Diagnostics 102 ault Clear Mode 122 Faults 105 Cnvrtr Alarm 2 098 Diagnostics 102 Fault Clr Mask 155 Masks amp Owners 107 Cnvrtr
179. nection 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 Logic Mask for the adapter to 0 1 Check the control wiring 2 Check the position of the hardware enable jumper 3 Check the digital input programming Restore the AFE to the factory defaults Cycle the power Reload User Set if used wn Cycle the power Contact Technical Support see page 124 wn Ifthe problem persists replace the AFE 1 Reset the fault or cycle the power 2 Replace the Main Control board 1 Restore the AFE to factory defaults 2 Reprogram parameters as necessary Replace the Main Control board Reset the fault 1 Check the connector 2 Check for induced noise 3 Replace 1 0 board or Main Control board 119 Chapter5 Troubleshooting Table 21 Fault Alarm Types Descriptions and Actions Continued LCL OverTemp 128 Contact Fdbk 133 DiglnConflict 138 DCRefLowLim 139 DCRefHighLim 140 DCBusLoAlarm 141 DCBusHiAlarm 120 Description The LCL Filter has been overheated or the signal is not connected to input Action if appropriate Check the LCL Filter sensor connections the fan and fan power supply There are nine total thermal switches connected in series to monitor temperature inside the coil of each filter inductor X52
180. ntroller output Normally the active current Kp active current Ki reactive current Kp and reactive current Ki default values of the two current controllers are satisfactory with the standard LCL filter and should not be changed Figure 3 AFE Block Diagram i Park Transform u I 3 Alpha Cartesian Reactive Current D 2 l Beta Active Current B Polar Modulator Voltage Angle DC Volt Measured PI Active Current Ref PI Modulation Index DC Volt Reference Gi Fer Active Current jf r DC Volt Kp Active Curr Kp DC Volt Ki Active Curr Ki Reactive Current Ref PI PD Freq Reference Reactive Current E peu Reactive Curr Kp Reactive Curr Ki Rockwell Automation Publication 20Y UMOOTE EN P July 2014 17 Preface Benefits of the AFE The PowerFlex Active Front End provides the following benefits e Energy Savings with Regenerative Braking instead of wasting energy with resistor braking technology regenerative braking actually puts the energy back into the system to be used by other equipment e Low AC Input Harmonics the active front end provides low harmonics to meet IEEE 519 and CE at its input terminals e Improved Power Factor the AFE actively controls the power factor regardless of motor speed and load In addition the PowerFlex AFE can be used for power factor correction on the power system e Voltage Boost the AFE provides the ability to boost the DC
181. o the Enable input of the connected drives to prevent the AFE from supplying power when the AFE is not running Rockwell Automation Publication 20Y UM001E EN P July 2014 75 Chapter 2 76 AFE in 1P21 Rittal Enclosure Installation Wiring Typical 1 0 Wiring The IP21 Rittal enclosure for the AFE is factory wired and programmed to operate from the operator switches on the front of the enclosure The AFE in the IP21 Rittal enclosure has a motor controlled circuit breaker MCCB The AFE is configured to run when precharge is complete the MCCB is closed and no faults are present The following figure shows the factory installed wiring Figure 36 Factory installed Wiring Diagram for AFE in IP21 Rittal Enclosure AFE Run Fault Reset optional MCCB On Request MCCB Acknowledge LCL OverTemp 24V to LCL AFE Ready K4 H3 1 I s READY See Analog 1 0 Configuration on Da i 12 page 76 for jumper settings Y 31 CO OO OO OO 6 0 0 0 0 0 0 0 0 0 Olas 1 2 3 4 5 6 7 8 9 OJN D B 4 75 6 7 18 19 205 INi AIN2 AIN24 10VRef PotGND 10VRef AOUT1 AOUTC AOUT2 DINI DIN2 DIN3 DIN4 DINS DING D COM D COM 24V 24VCOM ES zx o e a 2 LL Input T 23 35 Ri el b Contactor R2 RN 2 Sa 21 Qn 933 Control O24 O25 O26 SZ MCCB Close HIM Cradle A14 Fault MCCB Supply Relay 4 Day A Mow MCCE Open f P 2
182. oint 2 Sel 104 Total Current 95 Voltage Class 101 PE 29 59 potentiometer wiring 46 77 power cables wiring AFE in IP20 2500 MCC Style enclosure 31 AFE in IP21 Rittal enclosure 61 terminal locations specifications Frame 10 in IP20 2500 MCC Style enclosure 35 Frame 10 in IP21 Rittal enclosure 65 Frame 13 in IP20 2500 MCC Style enclosure 36 Frame 13 in IP21 Rittal enclosure 66 power conditioning input 28 59 Power Factor parameter 95 Power Up Marker parameter 105 precautions general 14 preferences setting 148 programmable controller configurations 140 PWM Frequency parameter 97 PWM Synch parameter 100 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Index Rated Amps parameter 96 Rated kW parameter 96 Rated Volts parameter 96 RatedLineCurrent parameter 97 Reactive Current parameter 95 Reactive Ki parameter 99 Reactive Kp parameter 99 Reactive Ref parameter 99 Reactive Sel parameter 99 reference literature 13 Regen MWh parameter 96 Regen Power Lmt parameter 99 Reset Meters parameter 101 Reset to Defaults 148 Reset to Defaults parameter 82 86 101 Residual Current Detector RCD 28 58 Restart Delay parameter 97 Restart Modes Parameter Group 98 S saving data 148 setting preferences 148 shielded cables power 31 62 SHLD termination 30 60 signal wire 41 73 specifications 125 control 126 electrical 126 environment 126 protection 126 Start Inhibits parameter 103 Start Owne
183. ol 107 069 Reactive Ki Current Loop 99 DPI Port Sel Comm Control 107 070 Reactive Sel Current Loop 99 DPI Port Value Comm Control 107 075 Motor Power Lmt Limits 99 Logic Mask Masks amp Owners 107 076 Regen Power Lmt Limits 99 Fault Clr Mask Masks amp Owners 107 077 Current Lmt Val Limits 99 Stop Owner Masks amp Owners 107 114 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Chapter 5 Troubleshooting This chapter provides information to guide you in troubleshooting the PowerFlex Active Front End Included is a listing and description of AFE faults with possible solutions when applicable and alarms Topic Page AFE Status 115 Faults and Alarms 116 Manually Clearing Faults 117 Fault and Alarm Descriptions 117 Clearing Alarms 121 Common Symptoms and Corrective Actions 122 Technical Support 124 AFE Status The condition or state of the AFE is constantly monitored Any changes are indicated by the status indicators and or the HIM if present Front Panel Indications Description o PWR Power Green Steady Illuminates when power is applied to the AFE 2 PORTO Status of DPI port internal communication if present Mop See the Communication Adapter Status of communication adapter when installed i User Manual publication NETA 20COMM UMxxx Status of network if connected NET p Status
184. oltage However the following limits apply to tracking the DC voltage Reference Low Limit Parameter 1 Input Voltage x 1 35 x 1 05 for all units High Limit Parameter 40 Nom Input Voltage x 1 35 x 1 30 for 400V 480V units Parameter 40 Nom Input Voltage x 1 35 x 1 15 for 600V 690V units AutoRstrt Config Selects the faults that are automatically cleared by the auto restart function The attempt numbers are set by parameter 053 AutoRstrt Tries Bit Definition LCL OverTemp gt HeatsinkUndTp Anlg In Loss gt Ground Fault AC OverCurr DC OverVolt DCUnderVolt Auxiliary In 1 Condition True 0 Condition False Default X X x x x X x 0 8 Bit 15 14 13 12 11 10 9 x Reserved Auto Rstrt Tries Default 0 Sets the maximum number of times the AFE attempts to reset a configured fault and restart Min Max 0 10 0 No automatic restarting after fault trip Units None Auto Rstrt Delay Default 1 0 sec Sets the time between restart attempts when parameter 053 Auto Rstrt Tries is setto a value other Min Max 0 5 30 0sec than zero Units 0 1 sec DC Volt Ref Sel Default 0 DC Volt Ref Selects the source of the DC bus voltage reference to the AFE Options 0 DC Volt Ref 1 Analog In1 2 Analog In2 3 DPI Port 1 4 DPI Port 2 5 DPI Port 3 6 DPI Port 4 7 DPI Port 5 DC Volt Ref Default Parameter 031 Rated Volts x 1 35 x 1 1 Sets the DC volta
185. om certification ce docs Low Voltage Directive 2006 95 EC EN61800 5 1 Adjustable speed electrical power drive systems Part 5 1 Safety requirements Electrical thermal and energy EMC Directive 2004 108 EC EN61800 3 Adjustable speed electrical power drive systems Part 3 EMC product standard including specific test methods General Notes e The AFE can cause radio frequency interference if used in a residential or domestic environment The user is required to take measures to prevent interference in addition to the essential requirements for CE compliance listed below if necessary e Conformity of the AFE with CE EMC requirements does not guarantee an entire machine or installation complies with CE EMC requirements Many factors can influence total machine installation compliance Essential Requirements for CE Compliance Conditions 1 6 listed below must be satisfied for the PowerFlex Active Front End to meet the requirements of EN61800 3 1 Use a standard PowerFlex Active Front End CE compatible unit 2 Review important precautions and attention statements throughout this document before installing the Active Front End 3 Grounding as described on page 29 4 Control 1 0 and signal wiring must be braided shielded cable with a coverage of 75 or better metal conduit or have shielding cover with equivalent attenuation Rockwell Automation Publication 20Y UMOOTE EN P July 2014 AFE in IP20 2500 MCC Style
186. omm Slot Code Communication Option N None k 1 0 Option Code Uovo A Standard with Outputs 24V DC ND HD ND HD ND HD e N120V ACI O option is not available 325 439 376 HIM BE o0 co 09 T a ioni I 1KO 1030 1390 1193 13 0 NoHIM AFE Feedback Thereis no heavy duty rating for Frame 13 600 690V Code Installed On f o toe MA Documentation Code Documents Ship Carton A User Manual Yes Rockwell Automation Publication 20Y UMOOTE EN P July 2014 15 Preface Description of Operation The PowerFlex Active Front End is a regenerative DC bus supply that is used to supply DC power to a lineup of common DC bus drives or a single common bus drive The AFE uses a PWM Pulse Width Modulated controlled IGBT converter to allow bi directional power flow to the AC line The following figures show examples of the AFE powering a lineup of PowerFlex 755 drives and the AFE powering a single PowerFlex 755 drive For additional information and bus conditioning requirements see Drives in Common Bus Configurations publication DRIVES AT002 Figure 1 AFE Supplying a Lineup of Common Bus Drives PowerFlex Active Front End Il Il DC BRI BR2 DC LI X See publication DRIVES AT002 i for bus conditioning requirements O7L2 NG 0713 PowerFlex 755 3 Phase PowerFlex 400VAC Active Front End PowerFlex 755 X See
187. on mode capacitors that are referenced to ground To guard against AFE damage these devices must be disconnected if the AFE is installed on a high resistance grounded distribution system or an ungrounded distribution system where the line to ground voltages on any phase exceed 125 of the nominal line to line voltage To remove the AFE Frame 13 LCL Filter from the IP21 Rittal enclosure see the instructions in the PowerFlex Active Front End Frame 13 Hardware Service Manual publication 20Y TG002 capacitors has discharged completely before removing or installing jumpers 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 To avoid an electric shock hazard verify that the voltage on the bus To disconnect the common mode capacitors remove the upper guard and then remove the jumpers shown in Figure 34 For more information on ungrounded system installation see Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives publication DRIVES IN001 Figure 34 AFE Frame 13 LCL Filter Common Mode Capacitor Jumper Locations Remove Three Jumpers Remove Three Jumpers
188. ontroller Reactive Sel Selects the source from which the reactive current is taken Motor Power Lmt Sets the limit for motoring power on the AC line Regen Power Lmt Sets the limit for regenerative power allowed to the AC line Current Lmt Val Sets the current limit value DC Bus Lo Alarm Sets the lowest acceptable DC bus voltage for the application A warning is indicated if the DC bus voltage falls below the value of this parameter DC Bus Hi Alarm Sets the highest acceptable DC bus voltage for the application A warning is indicated if the DC bus voltage exceeds the value of this parameter DC Ref Lo Lmt Displays the limit value of the DC bus reference low limitation which is calculated based on the voltage class x 1 35 x 1 05 DC Ref Hi Lmt Displays the limit value of the DC bus reference high limitation which is calculated based on the voltage class x 1 35 x 1 3 for 400 480V units or voltage class x 1 35 x 1 15 for 600 690V units Ground I Lvl Sets the limit value of ground current in 96 of the unit rating before a ground current alarm or fault is activated For AFE parallel operation the values in all AFEs must be set to 10096 Values Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Min Max Units Default Options Default Min Max Units Default Mi
189. ory defaults and configures parameters for a E 400 480V AFE unit for 480V operation 600 690V AFE unit for 690V operation S NOTE The DC bus voltage must be present to set the voltage class 092 Reset Meters Default 0 Ready Resets these selected meters Motoring MWh Regen MWh and Elapsed Time to zero Options 0 Ready 1 Motoring MWh 2 Regen MWh 3 Elapsed Time 093 Language Default 0 Not Selected Limited to English language only Options 0 Not Selected 1 English z 094 Voltage Class Default Read Only Displays the last Reset To Defaults operation Options 0 Low Voltage 1 High Voltage 095 Cnvrtr Status 1 Read Only Displays the present operating condition of the AFE bit adele elele Bits Description Definition 8 s s a 14 13 12 EIEEE ggZ o Jo 0 DCVoltRef 3 BIRIS E 1 Condition True 0 0 1 Analogini Default 0 0 0 0 j0 0 Condition False Gc C I 7 5433 X Peserved 0 1 1 DPIPort1 1 0 0 DPIPort2 2 Bit 0 Ready indicates all inhibits are cleared eel 2 Bit 1 Active indicates the AFE is modulating 1 1 1 DPrPort5 S Bit2 Motoring indicates the AFE is running in motoring mode e Bit3 Regenerating indicates the AFE is regenerating power to the AC line Bit 4 In Precharge indicates the AFE is in precharging status Bit 5 Droop Active indicates that the droop function for AFE paralleling is activated Bit 6 Alarm indicates the AFE has detected an alarm
190. ot DC Brake DC Brake x B Active 0 Not Dynamic Brake Active Dynamic Brake Active x Speed Mode 0 Not Speed Mode Par 309 Speed Mode x osition Mode 0 Not Position Mode Par 309 Position Mode x forque Mode 0 Not Torque Mode Par 309 Torque Mode x AtZero Speed 0 Not at Zero Speed At Zero Speed x AtHome 0 Not at Home AtHome x At Limit 0 Not at Limit At Limit X Current Limit 0 Not at Current Limit At Current Limit x Bus Freq Reg 0 Not Bus Freq Reg Bus Freq Reg X Enable On 0 Not Enable On Enable On x Motor Overload 0 Not Motor Overload Motor Overload x Regen 0 Not Regen Regen 14 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Appendix B HIM Overview Topic Page External and Internal Connections 145 LCD Display Elements 146 ALT Functions 146 Menu Structure 147 Viewing and Editing Parameters 149 Removing Installing the HIM 149 External and Internal Connections HIM panel opens to allow access to DPI interface To open panel remove screws on left side of HIM panel and swing open The PowerFlex Active Front End provides a number of cable connection points
191. per Personal Protective Equipment PPE Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment PPE gt gt gt 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 This manual contains new and updated information New and Updated This table contains the changes made to this revision Information Topic Page Added information for the Frame 13 AFE in an IP20 2500 MCC Style enclosure Throughout manual Rockwell Automation Publication 20Y UM001E EN P July 2014 3 Summary of Changes Notes 4 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Preface AFE in IP20 2500 MCC Style Enclosure Installation Wiring Table of Contents Who Should Use this Manual oi ii ada 11 What Is Not in this Manta iena 11 Manual C onventlolisasessis liaison 11 Rockwell Automation Supporti iena 12 Local Product Support ooa sd dl oil ti cee tae Moon 12 Technical Product Assistance 12 Additional Resources anc rode ette rove tati tete bat SiS 12 AFE Ooformati n rs a Pete TE ated Ob ERE II 12 General Information ssh rail AS 13 Drive A Ea 13 General Pr ap a 14 Catalog Number Explanation dora sein en 15 Description of Operation lia 16 Benefits of the ARES La eid rer wet ard bate a 18 AFE in IP00 Open Chassis Configuratio
192. ps 3 and 4 to select a group and then a parameter The parameter value screen will appear 6 Press the Enter key to edit the parameter 7 Press the or ED key to change the value If desired press the key to move from digit to digit letter to letter or bit to bit The digit or bit that can be changed is highlighted 8 Press the Enter key to save the value To cancel a change press the ES key to escape 9 Press the or key to scroll through the parameters in the group or press the key to return to the group list Numeric Keypad Shortcut HIM Overview Appendix B Example Screen Main Menu Diagnostics Parameter Device Select IGP File Monitor Dynamic Control Utility FP Group Control Modes Voltage Loop Limits FGQg Parameter DC Volt Ref Sel DC Volt Ref FGP Par 61 DC Volt Ref RAE VOC 583 lt gt 842 FGP Par 61 DC Volt Ref 700 0 VDC 583 lt gt 842 When using a HIM with a numeric keypad press the ALT key and ec key to access the parameter by typing its number Removing Installing the HIM The HIM can be removed or installed while the AFE is powered Step To remove the HIM do the following 1 Press the GE key and then the ES Enter key The Remove HIM configuration screen appears 2 Press the Enter key to confirm that you want to remove the HIM 3 Remove the HIM from the AFE To install the HIM
193. publication DRIVES AT002 for bus conditioning requirements Active current and reactive currents are calculated from the three input phase current measurements I 1 Ij and Ij 3 as shown in Figure 3 The DC voltage controller is a PI type regulator A DC voltage reference sets the value ofthe DC link voltage to be maintained It is compared to measured DC voltage to obtain a DC voltage error as the input for the DC voltage controller 16 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Preface The output of the DC voltage controller is the active current reference which is compared to the measured active current The error between them is the input for the active current controller The output of the active current controller changes the modulation index and controls the inverter voltage The reactive current reference can be used for reactive power compensation A positive reactive current reference indicates inductive and a negative reactive current reference indicates capacitive reactive power compensation The default value of the reactive current reference parameter is zero The set value of the reactive current reference is compared to its measured value and the error is fed to the PI regulator The PI regulator is also referred to as the synchronizing controller because its function is to keep the inverter synchronized with line supply The frequency reference to the AFE is derived from the reactive current co
194. r L1 i AFE y DC 1 Fuses l I 3 Phase Q0 01 l I l AC Input I B i F21 u T m el AAA Le e AAR LES gh H fell c e V ARA 4 AnA i T b le tv WARN ANAW l I DC Bus ii p I B3 Output I i a 4 I oV 7 Do Dico EN RET I Dc Ld l l RHE 1 i F24 L_ c I B 6 I I i I ee I ri L E F26 x I oca e _ _ I Motor Protection I Precharge Relay Precharge Precharge uses Contactor FUIS Circuit I l F6 Q5 K6 I pre DI R6 1 oD DI ro CH R6 2 PowerFlex DI EA 4 I 700AFE1 i ee ewe ul L q q A A A ii IAEA AO ATTE E AE ee ee I DI pl AC Line Switchgear LCL Filter L1 na AFE bi DE j IREA DI x l Fuses i Q0 Q1 DI I Fg DI Licia Anne ARAL pp Lia H AMARA PA or E Ho x Ww Ann ANAM I I LI I DI I R3 I ms a pg A LI 1 din E Esc LI pa RA Q 6 DI I DI I I G C6 i i LI Li F2 5 I DI l LI l DI ji RS P E ere ili I Motor Protection l l Precharge Relay Precharge Precharge I uses Contactor UK I Circuit i Za SL I l I I DT I I F6 05 K6 i l I DI R6 1 Pl Po t PI R6 2 l PowerFlex DI o l i 700AFE 2 A aal L Rom y esce oc Rockwell Automation Publication 20Y UMOOTE EN P July 2014 161 AppendixC Application Notes Paralleling an AFE with One or More PowerFlex SCR Bus Supplies For information about paralleling an AFE with one or more PowerFlex SCR Bus Supplies
195. r 101 Last Stop Source parameter 103 Limits Parameter Group 99 linear list of parameters 114 Logic Command Word PowerFlex 700 700H 700S drives 140 PowerFlex 750 Series drives 143 Logic Mask parameter 107 Logic Status Word PowerFlex 700 700H 700S drives 141 PowerFlex 750 Series drives 144 Low Voltage Directive 48 79 M main component locations Frame 10 AFE in IP20 2500 MCC Style enclosure 24 Frame 10 AFE in IP21 Rittal enclosure 54 Frame 13 AFE in IP20 2500 MCC Style enclosure 25 Frame 13 AFE in IP21 Rittal enclosure 55 main component sections AFE in IP20 2500 MCC Style enclosure 22 AFE in IP21 Rittal enclosure 52 manual conventions 11 Masks amp Owners Parameter Group 107 Metering Parameter Group 95 mode capacitors 38 68 Modulation Index parameter 97 Modulation Type parameter 97 Monitor File 95 Motor Power Lmt parameter 99 Motoring MWh parameter 96 Nom Input Volt parameter 97 non resettable faults 116 0 operator interface 149 P Parallel Mode Parameter Group 100 Param Access Lvl parameter 101 parameter changing editing 149 cross reference by name 113 by number 114 165 Index 166 linear list 114 viewing 149 Parameters AC Line Freq 95 ACLine kVA 95 ACLine kVar 95 AC Line kW 95 Active Current 95 Active Ki 99 Active Kp 99 Active Ref 99 Alarm 1 Fault 104 Alarm 1 Code 106 Alarm 2 Fault 104 Alarm 2 Code 106 Alarm 3 Code 106 Alarm 4 Code 106 Alarm Clear 106 Alarm Con
196. r connecting the Inverter Enable output of the AFE to the variable frequency drive s enable input or by enabling parameter 132 Contact Off Cnfg to force the main contactor off in case of a fault This ensures that once the AFE stops modulating there is no motoring current flowing through the AFE IGBT diodes Failure to disable the AFE output can result in component damage or a reduction in product life When enabling parameter 132 see page 105 for details The AFE is shipped with parameter 132 disabled This will not stop or shut down DC output when a fault occurs 10 Select Done Exit to complete the Assisted Start up procedure Rockwell Automation Publication 20Y UMOOTE EN P July 2014 87 Chapter 3 88 Startup Status Indicators For information on AFE status indicators see AFE Status on page 115 Control Devices The following figure shows the operators or control devices switches g P pushbuttons and status indicators on a IP21 Rittal enclosure Figure 39 Control Devices for AFE in IP21 Rittal Enclosure MCCB FAULT AFE READY O MCCB CONTROL MCCB RESET 0 1 START REM MAN AUTO 1 MAN START i Q 0 REM AUTO The AFE READY status indicator lights up when precharge is completed the MCCB is closed AC power is connected to the AFE and no faults are active The AFE READY status indicator operates independent of the control method i Or The MCCB FAULT status
197. r parameter 107 Start Up Delay parameter 100 Start Stop Mode parameter 97 start up 81 static discharge ESD 14 Status 1 Fault parameter 104 Status 2 Fault parameter 104 Stop Delay parameter 97 Stop Owner parameter 107 supplemental information 125 supply source AC 28 58 T technical support 12 124 terminal block 1 0 in IP20 2500 MCC Style enclosure 44 1 0 in IP21 Rittal enclosure 75 wire size 42 73 terminals power Frame 10 in IP20 2500 MCC Style enclosure 35 Frame 10 in IP21 Rittal enclosure 65 Frame 13 in IP20 2500 MCC Style enclosure 36 Frame 13 in IP21 Rittal enclosure 66 167 Index 168 Testpoint 1 Data parameter 104 Testpoint 1 Sel parameter 104 Testpoint 2 Data parameter 104 Testpoint 2 Sel parameter 104 Total Current parameter 95 troubleshooting 115 U unbalanced ungrounded AC supply source 28 58 ungrounded distribution systems 38 68 unshielded power cables 31 61 user configurable alarms 116 Utility File 101 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 V viewing and changing parameters 149 Voltage Class parameter 101 Voltage Loop Parameter Group 98 Ww website reference literature 13 technical support 12 wire control 42 73 signal 41 73 wiring hardware enable 46 77 potentiometer 46 77 power for AFE in IP20 2500 MCC Style enclosure 31 power for AFE in IP21 Rittal enclosure 61 Rockwell Automation Support Rockwell Automation provides technical informat
198. rame Fuse Sue Amps Bussman Type Ferraz Shawmut Type 10 1100 PC73UD95V11CTF 1250 170M6566 13 2400 PC84UD11C24CTO 1250 2 per phase 170M6566 1 Suitable for replacement fuse 640 1100 Volt DC Fusing Frame Fuse Size Amps Bussman Type Ferraz Shawmut Type 10 630 PC73UD13C630TF 700 170M6305 13 2000 PC84UD11C20CTQ 1000 2 per phase 170M8510 1 Suitable for replacement fuse 130 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Supplemental Information Appendix A Dimensions Figure 42 AFE Frame 10 in IP20 2500 MCC Style Enclosure Dimensions Dimensions are in millimeters and inches 640 RENE eal 6 LJ 4 I i d 2380 1 2265 5 94 89 2 i 1754 6 69 1 Y Y Y 1204 1 800 7 47 m 31 5 955 1 FRONT VIEW G8 RIGHT SIDE VIEW 461 4 138 6 8 TTT 5 Pato d A i E 699 1 28 1061 4 2 x BOTTOM VIEW Overall Dimensions mm inches Weight kg Ibs Height Width Depth 2380 1 94 1204 1 47 955 1 38 1035 2282 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 131 Appendix A Supplemental Information
199. rameter selection press the key In addition parameter 090 Param Access Lvl can be set to display basic parameters Basic view or all parameters Advanced view File Group Parameter Order This simplifies programming by grouping parameters that are used for similar functions The parameters are organized into files Each file is divided into groups and each group contains a set of parameters related to a specific purpose By default the LCD HIM displays parameters by File Group Parameter view 92 Rockwell Automation Publication 20Y UM001E EN P July 2014 Programming and Parameters Chapter 4 Basic Parameter View Parameter 090 Param Access Lvl set to option 0 Basic File Group Parameters Monitor Metering Input Voltage 001 Active Current 004 Input Current S 007 ACLine Freq 002 Reactive Current 005 Input Current T 008 Total Current 003 Input Current R 006 DCBusVolt 011 Converter Data Rated kW 030 Rated Amps 032 Rated Volts 031 Control SW Ver 033 Dynamic Control Modes Nom Input Volt 040 Control Start Stop Mode 046 Voltage Loop DC Volt Ref Sel 060 DC Volt Ref 061 Limits Motor PowerLmt 075 Current Lmt Val 077 DC Bus Hi Alarm 079 Regen PowerLmt 076 DC Bus Lo Alarm 078 Utility Converter Memory Param Access Lvl 090 Voltage Class 094 uU Reset to Defaults 091 CM Language 093 Diagnostics Start Inhibits 100 Dig In Status 102 Dig Out Status 103 Faults Fault Config 120 Alarms Alarm Config 135 Inp
200. responsibility for the compliance or noncompliance to any code national local or otherwise for the proper installation of this unit or associated equipment A risk of personal injury and or equipment damage exists if codes are ignored during installation f ATTENTION The following information is merely a guide for proper installation Power Cable Types Acceptable for 400 690 Volt Installations local codes outline provisions for safely installing electrical equipment Installation must comply with specifications regarding wire types conductor sizes branch circuit protection and disconnect devices Failure to do so may result in personal injury and or equipment damage ATTENTION National Codes and standards NEC VDE CSA BSI and so forth and A variety of cable types are acceptable for PowerFlex Active Front End installations For many installations unshielded cable is adequate provided it can be separated from sensitive circuits As an approximate guide use a spacing of 0 3 meters 1 ft for every 10 meters 32 8 ft of length In all cases avoid long parallel runs Do not use cable with an insulation thickness less than or equal to 15 mils 0 4mm 0 015 in Use only copper wire Wire gauge requirements and recommendations are based on 75 C Do not reduce wire gauge when using higher temperature wire Unshielded Cable THHN THWN or similar wire is acceptable for PowerFlex Active Front End installation in dry environmen
201. rs that can only be changed while the unit is stopped are used as datalink inputs they are not updated until the unit is stopped See the communication adapter User Manual for datalink information Data In B1 Link B Word 1 Data In B2 Link B Word 2 Data In C1 Link C Word 1 Data In C2 Link C Word 2 Data In D1 Link D Word 1 Data In D2 Link D Word 2 Data Out A1 Link A Word 1 Data Out A2 Link A Word 2 Sets the parameter number whose value is written to a communication device data table Data Out B1 Link B Word 1 Data Out B2 Link B Word 2 Data Out C1 Link C Word 1 Data Out C2 Link C Word 2 Data Out D1 Link D Word 1 Data Out D2 Link D Word 2 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Values Default 0 0 Disabled Min Max 0 236 Units None See Data In A1 Link A Word 1 Data In A2 Link A Word 2 See Data In A1 Link A Word 1 Data In A2 Link A Word 2 See Data In A1 Link A Word 1 Data In A2 Link A Word 2 Default 0 0 Disabled Min Max 0 236 Units None See Data Out A1 Link A Word 1 Data Out A2 Link A Word 2 See Data Out A1 Link A Word 1 Data Out A2 Link A Word 2 See Data Out A1 Link A Word 1 Data Out A2 Link A Word 2 Programming and Parameters Chapter 4 Inputs amp Outputs File No Parameter Name amp Description Values Group 200
202. s and require the use of lug type connectors Apply counter torque to the nut on the other side of terminations when tightening or loosening the terminal bolt to avoid damage to the terminal DC Bus Output Wiring The length of the DC bus connections between the AFE and the drive or drives must be minimized to keep the bus inductance low for reliable system operation For more information see Drives in Common Bus Configurations publication DRIVES AT002 66 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 AFE in IP21 Rittal Enclosure Installation Wiring Chapter 2 Routing the AC Input Ground PE and DC Bus Output Wiring for AFE in IP21 Rittal Enclosure ATTENTION To minimize disruption of air flow through the enclosure and A avoid overheating within the AFE enclosure remove only the minimum area needed to route the power cables In addition remove only the minimum area from the enclosure within the shaded areas shown in Figure 32 for routing the ACinput ground PE and DC bus output wiring Removing sections for routing in other areas disrupts the air flow throughout the enclosure causing overheating Frame 10 The AC input and ground PE wiring for the IP21 Rittal enclosure can be routed through either the bottom of the enclosure or through the bottom right side of the enclosure see shaded area in figure below The DC bus output wiring for the IP21 Rittal enclosure must be routed through the top right side
203. spikes can be caused by other equipment on the line or by events such as lightning strikes e The power source has frequent interruptions Grounding Requirements The Active Front End Safety Ground PE must be connected to system ground Ground impedance must conform to the requirements of national and local industrial safety regulations and or electrical codes Check the integrity of all ground connections periodically Recommended Grounding Scheme For installations in which the AFE is within an enclosure use a single safety ground point or ground bus bar connected directly to building steel All circuits including the AC input ground conductor must be grounded independently and directly to this point or ground bus bar Figure 10 Typical Grounding Example for AFE Frame 10 in IP20 2500 MCC Style Enclosure R L1 S L2 T L3 A PowerFlex 750 Series Drive or PowerFlex 7 Class Drive can be located on the right or left side of the AFE PowerFlex 755 Frame 8 drive shown on right side To Line PET L o da o Mia Customer wiring or DC bus Sa bar splice required to connect Li LI _ the AFE to the drive O U T1 V T2 W T3 PE ee m SHLD PowerFlex AFE Frame 10 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 29
204. splays the time between initial unit power up and the occurrence of the associated trip fault Can be compared to Power Up Marker for the time from the most recent power up 127 Fault 2 Time Fault x Time Power Up Marker Time difference to the most recent power up A 129 Fault 3 Time negative value indicates fault occurred before most recent power up A positive value indicates fault occurred after most recent power up Time stamp of the fault occurrence 131 Fault 4 Time 137 140 Alarm Code 1 4 Displays a code that represents a converter alarm The codes will appear in the order they occur Alarm 1 Code the most recent alarm A time stamp is not available with alarms 124 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Appendix A Supplemental Information dope sd ange Derating Guidelines 127 AFE Current Ratings and Watts Loss 128 Fusing and Circuit Breakers for AFE in IP20 2500 MCC Style Enclosure 129 Fusing and Circuit Breakers for AFE in IP21 Rittal Enclosure 130 DC Bus Output Fuse Ratings 130 Dimensions 131 DPI Communication Configurations 140 Specifications Category Specification Agency UL and cUL Listed to UL508C and CAN CSA 22 2 No 14 05 UL Listing is Certification c US applicable up to 600V AC Marked for all applicable European Directives m C EMC Directive 2004 108 EC EN 61800 3 Adjustable speed electrical power drive systems Part 3 EMC requirements
205. stomer supplied Parts Customer supplied enclosure 20 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Chapter 1 AFE in IP20 2500 MCC Style Enclosure Installation Wiring This chapter provides information on installing and wiring the PowerFlex Active Front End in a IP20 2500 MCC Style enclosure For information on installing and wiring the AFE in a IP21 Rittal enclosure see Chapter 2 Topic Main Component Sections Page 22 Main Component Locations 24 Mounting Considerations 26 AC Supply Source Considerations 28 Grounding Requirements 29 Fuses and Circuit Breakers 30 Power Wiring 31 Disconnecting Common Mode Capacitors 38 Using the AFE with PowerFlex Drives 40 Control Wiring 40 Precharging the AFE 47 CE Conformity 48 Most start up difficulties are the result of incorrect wiring Every precaution must be taken to verify that the wiring is done as instructed All items must be read and understood before the actual installation begins Rockwell Automation cannot assume responsibility for the compliance or the ATTENTION The following information is merely a guide for proper installation noncompliance to any code national local or otherwise for the proper installation of this 700AFE or associated equipment A hazard of personal injury and or equipment damage exists if codes are ignored during installation
206. sum MCB PB Config New IO Option Fatal App 1 0 Change 1 0 Comm Loss C Fault Alarm Description One or more of the IGBTs were operating in the active region instead of desaturation This can be caused by excessive transistor current or insufficient base drive voltage The 20 COMM x communication adapter has a fault on the network side The DPI port has stopped communicating A SCANport device was connected to a drive operating DPI devices at 500k baud An enable signal is missing from the control terminal block The checksum read from the Main Control board does not match the checksum calculated The checksum read from the EEPROM does not match the checksum calculated from the EEPROM data The AFE rating information stored on the power board is incompatible with the Main Control board Anew option board was added to the Main Control board A Fatal Application error has occurred An option board has been replaced An 1 0 Board lost communications with the Main Control board Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Troubleshooting Chapter 5 Action if appropriate Clear the fault Check the DPI device event queue and corresponding fault information for the device 1 Ifthe adapter was not intentionally disconnected check the wiring to the port Replace the wiring port expander adapters Main Control board or complete AFE as required 2 Check the HIM con
207. t the time of the last fault Min Max 0 200 C Units 1 C Rockwell Automation Publication 20Y UMOOTE EN P July 2014 103 Chapter4 Programming and Parameters 3 No Parameter Name amp Description Values fc 108 Status 1 Fault Read Only Captures and displays the bit pattern of parameter 095 Cnvrtr Status 1 at the time of the last fault Bits TDescription Description Bit a i nlol e Sio ge 14 13 12 it 2 S 2 2 2 sz la Definition 952 Zll g o 0 0 DCVolt Ref SS Sje 532 JBHPE 0 fo 1 Analogin1 e amp amBjjemix xa sex mm 0 1 0 Analogln2 1 Condition True Default x 0 0 0 o 0 0 0 0 0 0 0 0 si 0 1 1 DPIPort1 0 Condition False 1 lo 0 DPiPort2 Bit 15 14 13 12 11 10 9 8 6 5 4 3 2 x Reserved 1 lo 1 pi Port3 1 1 0 DPIPort4 1 1 1 DPIPort5 109 Status 2 Fault Read Only Captures and displays the bit pattern of parameter 096 Cnvrtr Status 2 at the time of the last fault Bit Definition s bj 2 E 3 1 Condition True Default 0 0 Condition False Bit 2 x Reserved 110 Alarm1 Fault Read Only Captures and displays the bit pattern of parameter 097 Cnvrtr Alarm 1 at the time of the last fault Bit ee ea Definition 28 gt s s 8 gt gt 5 5 SAHABE 1 Condition True Defautt o jo jo jo 0 Condition False E Bit 3 210 x Reserved
208. t with Wheel Guide Trays 136 525 20 7 559 9 22 0 592 5 23 3 LEFT SIDE VIEW AFE Input Voltage 400 480V 600 690V Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Overall Dimensions mm inches Height Width 1442 56 8 494 19 4 280 11 0 140 5 5 Rer 26 1 0 t n e 8 o i 32 1 3 34 D geo PT 89 A 703 5 27 7 1 553 5 21 8 403 5 15 9 1 Y Y Y Height from Bottom Surface of Unit Weight kg lbs Depth 477 1052 525 20 7 473 1043 Supplemental Information Appendix A Figure 48 AFE Frame 10 Power Structure Dimensions Dimensions are in millimeters and inches 190 7 5 85 63 a n A a os 245 i n 9 0 1 0 FT Minimum to a Endosure Roof i i i S e OL RI 5 A de 5 9 FA a 7 Endosure Wall i S Z S N 1050 41 3 1032 40 6 1009 39 7 o 373 147 i 7 108 el E b id iii HH Dy 4958 1135 la 520 8 m 19 5 026 gt 45 A 20 5 g
209. t2 Sel parameter 110 Analog Outputs Parameter Group 109 Anlg In Config parameter 109 Anlg Out Absolute parameter 110 Anlg Out Config parameter 109 Anlg Out Scale parameter 111 Anlg Out Setpt parameter 111 Rockwell Automation Publication 20Y UM001E EN P July 2014 Index Anlg Out2 Scale parameter 111 Anlg Out2 Setpt parameter 111 armored cable 32 62 Auto Rstrt Delay parameter 98 Auto Rstrt Tries parameter 98 Auto Stop Level parameter 97 Auto Reset Start 116 AutoRstrt Config parameter 98 bus capacitors discharging 14 C cables power armored 32 62 insulation 31 61 separation 31 61 shielded 31 61 62 unshielded 31 61 capacitors 38 68 capacitors bus discharging 14 catalog number explanation 15 CE Conformity 48 79 clearing alarms 121 faults 117 Cmd DC Volt parameter 96 Cnvrtr Alarm 1 parameter 102 Cnvrtr Alarm 2 parameter 102 Cnvrtr Logic Rslt parameter 107 Cnvrtr OL Count parameter 104 Cnvrtr OL Factor parameter 105 Cnvrtr Status 1 parameter 101 Cnvrtr Status 2 parameter 102 Comm Control Parameter Group 107 Common Mode capacitors 38 68 interference 41 72 Communication File 107 communications programmable controller configurations 140 component locations Frame 10 AFE in IP20 2500 MCC Style enclosure 24 Frame 10 AFE in IP21 Rittal enclosure 54 Frame 13 AFE in IP20 2500 MCC Style enclosure 25 Frame 13 AFE in IP21 Rittal enclosure 55 component sections AFE in IP20 2500 MCC Style enclosur
210. tem Name Frame Description Termina Balt Maximum Minimum Recommended gt Z o Input Power Terminals 13 Input power 380mm 53 mm 50 N m N A 11 12 13 0 750 MCM 1 0 AWG 442 Ib in SHLD Terminal line PE Ground TEN 300mm 21mm 40N m SHLD Terminal motor 13 Terminating point for wiring shields 600 MCM 14AWG 354 Ibsin M5 M10 PE Ground 6 o DC Bus DC DC 13 DC output using cable 380mm 2 1 mm2 70 Nem M12 750 MCM 14AWG 620 Ib in DC output using Right Side Splice Kit SK Y1 BUSSPLICE F13R 40 Nem T DC output using Left Side Splice Kit 354 Ibin SK Y1 BUSSPLICE F13L 36 Maximum minimum sizes that the terminals will accept these are not recommendations Do not exceed maximum wire size Parallel connections may be required These connections are bus bar type terminations and require the use of lug type connectors Apply counter torque to the nut on the other side of terminations when tightening or loosening the terminal bolt to avoid damage to the terminal Rockwell Automation Publication 20Y UMOOTE EN P July 2014 AFE in IP20 2500 MCC Style Enclosure Installation Wiring Chapter 1 Routing the AC Input Ground PE and DC Bus Output Wiring for AFE in IP20 2500 MCC Style Enclosure overheating within the AFE enclosure remove only the minimum area needed to route the power cables When removing any of the five side cover plates shaded
211. tions When mounting the Active Front End consider the following information Operating Temperatures Frame Surrounding Air Temperature 2 Minimum Air Flow Size Normal Duty Heavy Duty Power Module LCL Filter 0 40 C 1400 m hr 824 cfm 1100 m hr 647 cfm 32 104 F 4200 m3 hr 2472 cfm 1300 m3 hr 765 cfm 10 0 40 C 30 32 104 F 1 The Frame 13 690V AFE has only Normal Duty operation at nominal rated power and maximum ambient temperature at 35 C 2 Foran AFE in the IP21 Rittal enclosure this means air surrounding the module Minimum Mounting Clearances Frame 10 in IP21 Rittal Enclosure 50mm TOP VIEW 50mm 2 0in B de D 006 Clearance to Wall s re Clearance to Wall gl Ova Lo Y gl o lg 400 mm 1 157 in N x 600 mm Door Swing Clearance x Se 23 6 in i EJ EN Door Swing Clearance M 1 y 200 mm 7 87 in Height Clearance A c oot KERO Rana 000000000 00000000000000000 Sao GI 25009555 SIE Ro w 2500255 8500935550000 o p MENS S To nno 090000000 G9000000000000000 SI DE SIR RISI p EE s 56 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 2 er pt Cha ll Wa rance to Clea 3mm ain ce A ng
212. tput 1 value when the source value is at maximum Min Max 4 000 20 000 mA 10 000V Units 0 001 mA 0 001V 211 Analog Out1 Lo Default 0 000 mA 0 000V Sets the Analog Output 1 value when the source value is at minimum Min Max 4 000 20 000 mA 10 000V Units 0 001 mA 0 001V 212 Analog Out2 Sel Default 0 AC Line Freq Selects the source for Analog Output 2 Options See Analog Out Sel Table 213 Analog Out2 Hi Default 20 000 mA 10 000V Sets the Analog Output 2 value when the source value is at maximum Min Max 4 000 20 000 mA 10 000V Units 0 001 mA 0 001V 214 Analog Out2 Lo Default 0 000 mA 0 000V Sets the Analog Output 2 value when the source value is at minimum Min Max 4 000 20 000 mA 10 000V Units 0 001 mA 0 001V Programming and Parameters Chapter 4 3 No Parameter Name amp Description Values oc 215 Anlg Out1 Scale Default 0 0 Wy Sets the high value for the range of Analog Output 1 scale Entering 0 0 disables this scale andthe Min Max Based on Analog Out Sel maximum scale will be used Units Based on Analog Out Sel Example If parameter 209 Analog Out1 Sel DC Bus Volt the maximum value is 2 parameter 031 Rated Volts 800V DC By setting parameter 215 Anlg Out1 Scale 600V DC then 600V DC instead of 800V DC is used for the parameter 210 Analog Out1 Hi value at the analog output 216 Anlg Out2 Scale Default 0 0 Ur Sets t
213. ts provided adequate free air space and or conduit fill rates limits are provided Do not use THHN or similarly coated wire in wet areas Any wire chosen must have a minimum insulation thickness of 15 mils and cannot have large variations in insulation concentricity Rockwell Automation Publication 20Y UMOOTE EN P July 2014 61 Chapter 2 62 AFE in 1P21 Rittal Enclosure Installation Wiring Shielded Cable Shielded cable contains all of the general benefits of multi conductor cable with the added benefit of a copper braided shield that can contain much of the noise generated by a typical AC drive Strongly consider shielded cable in installations with sensitive equipment such as weigh scales capacitive proximity switches and other devices that can be affected by electrical noise in the distribution system Applications with large numbers of drives in a similar location imposed EMC regulations or a high degree of communication and networking are also good candidates for shielded cable Consider all of the general specifications dictated by the environment of the installation including temperature flexibility moisture characteristics and chemical resistance In addition include a braided shield specified by the cable manufacturer as having coverage of at least 75 An additional foil shield can be greatly improve noise containment A good example of recommended cable is Belden 29528 29532 AWG 1 through AWG 410 This cabl
214. tware initialize complete Ready to switch on Charging the DC link with external charging circuit DC link voltage gt 0 8 DC nominal No Request to close input contactor on Digital In3 Input Contactor Close through Digital Out1 should be set Contact Ctrl Input Contactor Ack Digital Input 4 should be set Contactor Ack see P102 Dig In Status for digital input status Ready to Run see P95 Cnvrtr Status1 Ready bit 1 Run command from 1 0 keypad or Fieldbus depends on the selected control Startup delay elapsed see P087 Start Up Delay default 0 secs Synchronize with input Sychronizing OK Sychronizing tries 2 5 Fault F10 LineSyncFail AFE Running Run LED is on Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Troubleshooting Chapter 5 123 Chapter 5 Technical Support Troubleshooting Figure 41 AFE Fault Handling Sequence Troubleshooting Diagram AFE Running Yes Fault active New Run Command Edge Stop the AFE Is Input Contactor or circuit breaker open Input Contactor or circuit breaker open Fault acknowledge Input Contactor or circuit breaker closed No Fault acknowledge When contacting Technical Support be prepared to provide this information e Order number e Product catalog number and drives series
215. u must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature Rockwell Automation maintains current product environmental information on its website at http www rockwellautomation com rockwellautomation about us sustainability ethics product environmental compliance page Rockwell Otomasyon Ticaret A S Kar Plaza Is Merkezi E Blok Kat 6 34752 erenk y stanbul Tel 90 216 5698400 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 20Y UM001E EN P July 2014 PN 252341 Supersedes Publication 20Y UM001D EN P March 2014 Copyright 201
216. ult Alarm S Name No E 3 AC OverCurr 12 v Anlg In Loss 29 V wv Application 35 v AutoReset Lim 33 v Auxiliary In 2 v CAN Bus Fit 34 v Contact Fdbk 128 v Converter Fit 14 v DC OverVolt 5 v DC UnderVolt 4 viv DCBusHiAlarm 141 v DCBusLoAlarm 140 v DCRefHighLim 139 v DCRefLowLim 138 v Device Add 45 v Device Change 44 v Digln Cnflct 133 v Fan Cooling 32 v Fatal App 13 v Ground Fault 13 v Hardware Enbl 94 v HeatsinkOvrTp 8 Viiv HeatsinkUndTp 37 v Clearing Alarms longer present Fault Alarm aE Name No S 3 1 0 Change 120 wv 1 0 Comm Loss 121 Y 1 0 Removed 65 v IGBT OverTemp 9 v IGBT Temp Hw 31 v LCL OverTemp 125 v LineSync Fail 17 vv MCB PB Config 1066 Y MicroWatchdog 30 v New IO Option 1077 v NvsReadChksum 47 v Overload 7 v Param Chksum 100 Y Periph Loss 7 v Phase Loss 21 v Port DPI Loss 81 v Power Unit 70 v PrechargeActv 1 v PwrBrd Chksum 104 Y Start Prevent 58 v System Fault 10 v Unbalanced PU 19 v Zero Divide 54 v Rockwell Automation Publication 20Y UMOOTE EN P July 2014 Alarms are automatically cleared when the condition that caused the alarm is no 121 Chapter5 Troubleshooting Common Symptoms and Corrective Actions 122 AFE does not Start from Start or Run Inputs wired to the terminal block Cause s AFE is faulted Incorrect input wiring see Control Wiring on page 40 or Control Wiring on page 72 for wiring examples NOTE Jumper between terminals 17 18
217. us and overload AC input current ratings must not be exceeded or the AFE will trip on overload See the Advanced Procedure to Size the AFE on page 152 for sizing guidelines Rockwell Automation Publication 20Y UMOOTE EN P July 2014 153 AppendixC Application Notes Paralleling AFEs 154 The power of the AFE input group can be increased by connecting several groups in parallel Paralleling refers to AFE units connected on the same input transformer and the same DC bus No communication between the units is required they work independently Paralleling is typically used when the power range of a single frame size is not enough or when redundancy is needed For additional information see Drives in Common Bus Configurations publication DRIVES AT002 Guidelines for AFEs in IP20 2500 MCC Style Enclosure e For AFEs in IP20 2500 MCC Style enclosures a maximum of two AFEs of the same power size for example two Frame 10 AFEs and same voltage class can be paralleled e Each AFE must have its own LCL filter e Each AFE must have its own short circuit protection on AC and DC sides See Appendix A for fusing information When paralleling you must check the sufficient short circuit capacity of the system e The AFE units must be derated by 5 of their power rating e Configure the following parameters for parallel operation Set Parameter 42 Modulation Type to 3 Set Parameter 82 Ground I Lvl to 100 Set
218. ut is interpreted by the AFE software If the application requires the AFE to be disabled without software interpretation a dedicated hardware enable configuration can be used To do this remove jumper J5 Figure 35 and wire the enable input to Digital In 6 see below Verify that Digital In6 Sel parameter 226 is set to 1 Enable Table 19 Hardware Enable Configuration for AFE in IP21 Rittal Enclosure Signal Jumper Setting Hardware J5 Hardware Enable Input Programmable No Hardware Enable Enable Analog 1 0 Wiring Examples for AFE in IP21 Rittal Enclosure Input Output Connection Example Required Parameter Changes Potentiometer Unipolar e Configure Input for Voltage DCVolt Reference Parameter 200 and set appropriate jumper 10k Ohm Pot per Table 18 Recommended Adjust Scaling 2k Ohm Minimum Parameters 80 81 and 204 205 View Results Parameter 018 Analog Voltage Input e Configure Input for Voltage Unipolar DC Volt GE Parameter 200 and set appropriate jumper Reference my per Table 18 0 10V Input T E Adjust Scaling Parameters 80 81 and 204 205 View results Parameter 018 Analog Current Input e Configure Input for Current Unipolar DC Volt GM Parameter 200 and set appropriate jumper Reference per Tab
219. uts amp Analog Inputs Anlg In Config 200 Analog In 2 Hi 204 Outputs Analog In 1 Hi 201 Analog In 2 Lo 205 E Analog In 1 Lo 202 P T Analog Outputs Analog Out Sel 209 Analog Out2 Sel 212 Analog Out Hi 210 Analog Out2 Hi 213 Analog Out1 Lo 211 Analog Out2 Lo 214 Digital Inputs Digital In1 Sel 221 DigitalIn4 Sel 224 Digital In2 Sel 222 DigitalIn5 Sel 225 Digital In3 Sel 223 Digital In6 Sel 226 Digital Outputs Digital Out1 Sel 228 DigitalOut3 Sel 233 Digital Out2 Sel 229 Dig Out3 Invert 234 Dig Out2 Invert 230 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 93 Chapter4 Programming and Parameters Advanced Parameter View Parameter 090 Param Access Lvl set to option 1 Advanced File Group Parameters Monitor Metering Input Voltage 001 lImbalance 009 Heatsink Temp 017 ACLine Freq 002 Ground Current 010 Cmd DC Volt 018 Total Current 003 DCBusVolt 011 Motoring MWh 019 Active Current 004 DC Bus Current 012 Regen MWh 020 Reactive Current 005 ACLinekW 013 Elapsed Run Time 021 Input Current R 006 ACLinekVar 014 Analog In1 Value 022 Input Current S 007 ACLine KVA 015 Analog In2 Value 023 Input Current T 008 Power Factor 016 Converter Data Rated kW 030 Rated Amps 032 Rated Volts 031 Control SW Ver 033 Dynamic Control Modes Nom Input Volt 040 RatedlineCurrent 045 Auto Stop Level 049 Control PWM Frequency 041 Start Stop Mode 046 Contact On Del
220. voltage See Voltage Boost on page 153 for guidelines regarding voltage boost This voltage boost also helps protect critical processes from the potentially disruptive effects of input voltage dips and sags cannot be used to lower the DC bus voltage The minimum DC bus voltage is ATTENTION The PowerFlex Active Front End can be used for voltage boost but limited by the rectified diode bridge voltage 18 Rockwell Automation Publication 20Y UMOOTE EN P July 2014 AFE in IP00 Open Chassis Configuration Preface The following figure shows a basic one line diagram for an AFE Frame 10 ina IP00 NEMA UL Open Chassis configuration and the parts the customer must supply Figure 4 Basic One line Diagram for an AFE Frame 10 in IP00 Open Chassis Configuration 1 A 4 I AC Line Switchgear LCL Filter L1 I AFE Iis ime d Power Structure U1 Breaker Contactor I 3 Phase 00 Fuses Kl I ACInput FLAG 1 a WAAR RARA Vv ul L1 BE e j i e NANI e ANNAN oU V2 AA ARAN 12 Sp o A e e e t o V EJ 5 B SU MANN ANAM ow I I o PE DC o d a a Eos m Customer Q l G I PED supplied I Parts B l C6 I l I I I I Precharge Precharge Precharge I Fuses Contactor SILE E5 Circuit Active Front End System BM
221. ware Enable see page 77 17 Digital In Common Allows source or sink operation 18 19 24v Dc Unit supplied logic input power 20 24V Common Common for internal power supply 21 Digital Out 1 nic Contact Ctrl Max Resistive Load 240V AC 30V DC 1200VA 150W 22 Digital Out 1 Common Max Current 5A Min Load 10 mA 23 Digital Out 1 N 0 Max Inductive Load 3 240V AC 30V DC 840VA 105W 24 Digital Out 2 N C Fault Max Current 3 5A Min Load 10 mA 25 Digital Out 2 3 Com NOTE See the Attention above this table for more details 26 Digital Out3 N 0 Active Important Input must be configured with a jumper AFE damage can occur if jumper is not installed properly See Analog 1 0 Configuration on page 76 These inputs outputs are dependant on a number of parameters Differential Isolation External source must be maintained at less than 160V with respect to PE Input provides high common mode immunity 150 mA maximum load Can be used to provide control power from an external 24V source when main power is not applied Contacts in un powered state Any relay programmed as Fault or Alarm energizes pick up when power is applied to the AFE and de energizes drop out when a fault or alarm exists Relays selected for other functions energize only when that condition exists and de energizes when the condition is removed When this output is configured as active it can be wired t
222. y write information to the AFE control take care to properly format the block transfer If attribute 10 is selected for the block transfer values are written to only RAM and are not saved by the drive This is the preferred attribute for continuous transfers If attribute 9 is selected each program scan completes a write to the drives nonvolatile memory EEPROM Because the EEPROM accommodates only a fixed number of writes excessive continuous block transfers can quickly damage the EEPROM Therefore do not assign attribute 9 to continuous block transfers See the individual communication adapter User Manual for additional details Logic Command Word for PowerFlex 700 700H 700S Drives Logic Bits 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Command Description X Stop 0 Not Stop 1 Normal Stop X Start 0 Not Start 1 Start X Reserved X Clear Fault 2 0 Not Clear Fault 1 Clear Fault X Reserved X Reserved X Reserved X Cmd LogicOut 0 Network controlled Digital Output off 1 Network controlled Digital Output on X Reserved X Reserved X Reserved X Reserved X Reserved X Reserved x Reserved x Reserved 1 A Not Stop condition logic bit 0 0 logic bit 8 0 and logic bit 9 0 must first be present before a 1 Start condition starts the AFE 2 To perform this command the value must switch from 0 to 1 140 Ro ckwell Automation Publication 20Y UM001E EN P July 2014 Supplemental Information

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