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PowerFlex 700AFE Frame 10 Hardware Service Manual

1. i o fa 6 E 2 9 e LI ib 1 ear 4 Le e Li l 3t eseeeeo Ne Fuse and Fuse Holder e Precharge Kit L e Control Transformer T4 e Control Transformer Primary Fuse and Fuse Holder Control Box located on front of enclosure door shown with control box cover removed Control Transformer T10 Secondary Fuse and Fuse Holder Table D G Precharge Assembly Part Numbers for AFE in IP20 2500 MCC Style Enclosure Part Name Precharge Fuse Part No SK Y1 MCCF5 F10 Precharge Fuse Holder SK Y1 MCCF5FUSEHOLDER F10 Precharge Kit 1 SK Y1 PRE2 F10 Control Transformer T4 1500VA SK R1 OFANXFMR Control Transformer Primary Fuse 400 480V SK Y1 MCCF6 D 600 690V SK Y1 MCCF6 F Control Transformer Primary Fuse Holder SK Y1 MCCF6FUSEHOLDER Control Transformer T10 Secondary Fuse Holder SK Y1 MCCF3F4 0 Kit includes diode bridge V6 two resistors R6 1 and R6 2 and a snubber capacitor C1 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P D 8 Disassemb
2. Position 1 8 4 5 7 8 9 10 11 12 13 14 15 16 g h i 7 1 58838858558 5 2222 252 2 Y gt e 22 S r ss oe 4 90 ae 5 L gt 1 5 z Som 5 4 52 8541 J e d eS 5 001 0205 _ 0 o 24585 l 14 SS 5 0 u n L0 oc o How e t 5 Ew 21755 ane c 12 E sv sEtSsSs Cm z 2 e 5 44 v vU gt BS 55 BE SL0CmO 2 2 o 800 m0 ks 5 5 0700 nr a vo BISS ll il E liis 021 a 1 e A 3 e L E E zi z LL Lx E S 2 9 28 5 98 E o iL gh 55 1 Ro 9298 l 67 IIA rn amp 8 s aja LH S zT 519 aS jot 2250 Pd 0 9 m T 7 5 5 lt 55855 58 rAR RR RRRRRRRARRRRRRRRSE PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 7 Schematic Diagrams A069 009 pue
3. 3 s S fi o f 1 o 8 e s Jd rij DC bus bars between AFE Power Structure U1 and DC bus AC power cables between Input Circuit Breaker 00 and AC input fuses F1 1 F1 3 Optional Bus Splice Kit shown input fuse bus link AC bus bars between AC fuses F1 1 F1 3 and Input Contactor K1 power cables between Input Contactor K1 and LCL Filter L1 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 2 4 Active Front End System Overview AFE in IP21 Rittal Enclosure Main Component Sections The following figure shows a basic one line diagram for an AFE system in a IP21 Rittal enclosure The main component sections consist of the following items e AC Line Switchgear consisting of the input disconnect 00 and MCCB motor controlled circuit breaker Q1 LCL Filter L1 Precharge Circuit AFE power structure U1 with AFE control assembly DC Fuses F2 1 and F2 2 Figure 2 4 Basic One line Diagram for AFE in IP21 Rittal Enclosure
4. zz DE 91 1 3p 12272 019 9 2 OL9 v 4 uc pud L9 2 1 8 Zk 48 01 IX ev 02 3 9 il 8 ek gay zc 91SX z 4829 LO vil A c SX 39 4 1207 ve N zz CON oes 9 0 9 a 65 TIX asjnd uedo 4 ml Mj i H i EY BEX 2 89 Is diy cd E CEA 3c 2 el 9 c L L g 4 N 95 9 4 0 2 2 x x Tavis 0 x olny 8 0 iss v 8 P ia 0 l X x OLAV 4 x NV X x 5 8 95 1 11 V8 0l LX uonisod NYIN Y UI SI YMS 95 ueun LS UoRNgysnd Y JUO ued GOIN SUL ois JS jo uonisod 925 8 y jo jjIM 9 103281009 eui I pue LO GOON uonisod 0 UI SI YOUMS 0 S ueuM 310N a m HOLOVINOO 330 ONIDHVHO 8 fi 9 Y 2 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 21 Schematic Diagrams 069 009 pue 21 12945 einsoj2u3 1241 01 128 AMBIJ 48 NMOHS LON SI 40109 NIHM 90 1
5. PowerFlex Active Front End System 44 G Enclosure The following figure shows a basic one line diagram for an AFE system in a IP20 2500 MCC Style enclosure The main component sections consist of the following items e ACLine Switchgear consisting of the input circuit breaker 00 fuses F1 1 F1 3 and input contactor K1 e LCL Hiter L1 e Precharge Circuit e AFE power structure U1 with AFE control assembly e DC Fuses F2 1 and F2 2 Figure 2 1 Basic One line Diagram for AFE IP20 2500 MCC Style Enclosure mnis __ ___ ligu tuere euge a AClineSwitehgear LCL Filter L1 i AFE DC Input E PowerStructure U1 Fuses Breaker Contactor l l 3Phse 00 Fuses K AC 1 1 E e 1 o oe i o U if WAAR vi gt cn mi ARA Ld ARA Ld am G6 DES e a Output 1 E E 5777 1 LIE ii Ioa BL 116 l l l i al DTT 3 Precharge Fuses contr Precharge Circuit 1 1 pets R6 gt pro PowerFlex Active Front End Frame 10 Hardware Service Manual P
6. Active Front End System dum MISSE CRI i e jd oce TA l ACLine LCL Filter L1 AFE DC Switchgear PowerStructure UT Fuses 3 Phase Q0 01 ACInput dr MI SEA s MM P3 deba meme Lu e T BN NE te Eu WAMA Amn DcBus DC of 1 4 Output o PE 1 T l p decur al 46 por MEE 8 M 6 Ty de le bi i m xS NY S COO Motor Protection Precharge Relay Precharge Precharge Fuses Contactor Circuit kal 1 F6 Q5 K6 pr Pi R61 o gt bd Di t 1 NE PowerFlex PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Main Component Locations Active Front End System Overview 2 5 The following figure shows the main components of the AFE Frame 10 system in a IP21 Rittal enclosure Figure 2 5 AFE Frame 10 Main Component Locations IP21 Rittal Enclosure Item FRONT VIEW shown with enclosure doors removed o CDD D Description INTI
7. W T3 Approx 0 5 ohms 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 2 If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 3 Remove the protective front cover and terminal cover from the power structure See Removing Protective Covers from the Power Structure on page 4 12 There is one Gate Driver board 4 Measure the gate interface resistance for each U V and W phase Output Power transistor The resistance from each ignition pin to the branch emitter pin connectors X28 and X29 is approximately 166 ohms The resistance from the X28 branch emitter pin to the same branch output power terminal U T1 V T2 and W T3 is approximately 0 5 ohms The resistance from the X29 branch emitter to the same branch DC bus terminal is approximately 0 5 ohms If any of the gate interfaces fails this test replace the power module See Removing the Power Module from the Power Structure on page 4 20 Gate Interface for U V or W Low L 5 5 Emitter Approx 166 ohms E Extinguishing X24 X23 X22 Emitter Approx 166 ohms 4 4 Extinguishing RC gt lt Gate Interface for U V or W High Note Connectors X22 and X23 are connected in parallel with connectors X28 and X29 respectively and therefore do not have to be tested Pow
8. 3 2 Inspecting the Power 3 2 Performing Forward and Reverse Biased Diode Tests for Power Structure 3 3 Checking Fiber Optic Connections sansa 0 0 0 0 cece cece eee 3 5 Performing Gate Driver Board Resistance 3 7 Checking the AFE Power Structure Fan Inverter 3 8 AFE Power Structure Component Section Understanding Torque Figures in Assembly Diagrams 4 2 Torque Specifications 25552 ep pe aequa c Rd ra s 4 2 Removing Power from the 4 3 Control Frame Access Procedures 4 4 Removing the DPI Interface 4 4 Installing the DPI Interface Assembly 4 5 Removing the I O Circuit Boards and Control 4 5 Installing the I O Circuit Boards and Control Board 4 6 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P ii Table of Contents Chapter 5 Chapter 6 Chapter 7 Removing the Fiber Optic Adapter Circuit 4 6 Installing the Fiber Optic Adapter Circuit Board 4 8 Rem
9. Position 4 5 7 8 9 10 11 12 13 14 15 16 b e d e f g h i j k l lt a gt lt lt BS ER ma e ww 3 Au al eS s SN gt aut 5 2 1 8 Hu ig Fi g 5 ug I zi 8 E o m E 88 o n EE 5 lo 6 o 4 5 E 20000 o gt TaS c re a a o o z LL lo B8 2 8 9 E 000000 m N o E G 1 LI LL 1 e s lt LA s o LI ir c R E 9 2 4 4 G amp EE SE A 1 2 5 irg o g 60076 RE IB RE E 1 wl Alo eus 9 T ao L p Als E o H u m 3 gs lt no 4 As 5 84 5 lt a e w PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 15 Schematic Diagrams A069 009 7 2 19945 1241 01 ewesy 91 8 6 4 318vN3 YSLYSANI 1 7 se 5 Ter 81015 104 202 TOYXLNOS 1282 WHOL 2 0 0282 oz Yale woo woo
10. T VH su SLX HAAG T sx vixiH3AHQ _ _ ox _ x 0 zx 30 90 m Kejsu afueyg VAJO Ave DISV 2 ex avoga uaravav O140 19 L VOS Sx TANVd 7TOHINOO 1015 zx TOHLINOO LINA TOHLNOO Publication 20Y TG001B EN P PowerFlex Active Front End Frame 10 Hardware Service Manual Schematic Diagrams B 2 ircuitry Frame 10 Power Module C ejnpojy JOMOd 01 4 c g anbi LLIN G vix x SX Y TERM V 1 87008A SIX7ELX L QSvVOS IN3A3SnSV3NN 4 H31H3ANOO AON3n03H4 30 peed ui p A 069 ui 9 YQ Q sees U sdeo z A 005 g 8 chy eH 1ISV Sx ex foisv 12 5 7TOHINOO PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P To ASIC Circuit Board X11 Schematic Diagrams B 3 Frame 10 Power Structure Main Fan Connections Fan Control 3 For more details see the PowerFlex 7005 700H and 700AFE Drive Fan Systems Installation Instructions publication P
11. Zinov an u AQv3u 34v bbdl 02 9 di 31 121 39031MON32 V jsanbal NO 899W jeuondo ine NO WMd LINN JOHLNOD 2 56 6 BS 6 140 az 9 1 32 9 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 16 PowerFlex Active Front End Frame 10 Hardware Service Manual Schematic Diagrams lt 5 a m u z x kol It OE 8 E ws QW 4 ja 09 ik 89 ow 0 5 10 R E T aN ge E a u Publication 20Y TG001B EN P Figure B 16 Frame 10 in IP21 Rittal Enclosure Sheet 8A only 400 480V Schematic Diagrams lt LL X HI IET 80 069 062 4 Tur 82 009 w TTA E Ses ka EJ HI o WU 5 LTT 5 E La 1 amp Se lt G B 17 Figure B 17 Frame 10 in IP21 Rittal Enclosure Sheet 8B only 600 690V PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Schematic Diagr
12. LX PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Schematic Diagrams B 13 Control Wiring Diagram for Frame 10 in IP21 Rittal Enclosure X1 S6 Remote Operation of N O Motor Controlled Circuit Breaker 60 3 tional N O Optional 8i 7 N O 5 6 e NOTE Unused terminals are not shown Not 8 e 9 N O 10 11 N O 12 H5 T4 H 230V AC F3 ti 2 Control Power N 510 1 5 Q1 ii 2 10 NO 3 ti Ut 4 95 98 511 96 13 d 6 K20 D1 A1 C2 A2 C1 11 N O C11 14 22 21 21 31 34 gt 4 1 H3 1 A2 1 11 2 o NO 14 21 n9 24 F10 10 L K6 N A1 2 ar Faut N O Reset 64 z Optional i Terminal 4 1 Block X52 4 1 Ailo o o o old dd 6 6 amp 606 05 1 2 3 4
13. Z 19945 ensojou3 ejas DOW 00652 0241 U 01 4 318VN YALYSANI UH LEE 994 ex E YOLIWINOD NIVW OEEZ UH us 3 s 62 A 2 e 4 UE E 88 l a r Y my H tiv 64 eu uu 1518 0716 0216 308100 130 19 9 M019V1N0 NIV mE S800 n 14 0 9 V 1vq 20 0997 q58v WO wo WO G 9 0 21 Linov GNDIOA jenol viv LVIV 0c 6L 8L a 9L tl 0L 6 8 L 9 5 v t 9 090 061 Cebu 0819 L L tif 09 Orem A ii 915 Q tl t 193 19 ur i 3 1 NV NV 3 99 em tl v9 997 IX m m X p E z B F 5282855 5 5 m 282822 5 28285 lt gt lt gt 5 83 8 FUS 2 2 108110 5 i i d ly 6E LE 9 st EE 43 le 0 6c 9c sc vc amp 6L 8L 9L SL tl EL 0L 10 so 0 70 10 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Schematic Diagrams B 8 A069 009 pue 08 007 8 19945 ensojoua els DOW 0092 U 01 ewesy 68 en6i4
14. 4 26 Removing the Power Structure DC Bus Capacitors 4 26 Installing the Power Structure DC Bus 4 27 Replacing the Existing Power Structure with a New Power Structure 4 27 AC Line Switchgear Component Section AFE in IP20 2500 MCC Style Enclosure 5 2 ABE in IP21 Rittal Enclosure 2 22 rete RO ee 5 2 Precharge Component Section Prechargimng FUNCHONS me E om eec GR Dees eee es 6 2 Replacing the Precharge 6 2 Testing the Control Transformer T4 and 24V DC Power Supply 10 6 3 For AFE in IP20 2500 MCC Style 6 3 For AFE in IP21 Rittal 6 4 Testing the Precharge Bridge Using Power Structure Terminals 6 6 Replacing the Precharge Bridge 6 6 Testing the Precharge 1 6 7 Replacing the Precharge Resistor 6 8 AFE in IP20 2500 MCC Style Enclosure 6 8 AFE1n Rittal EncloSUEe ert ette x ER etait ay re ARS ds 6 8 LCL Filter Component Section
15. 11 Schematic Diagrams A069 009 08 00 19945 e1nso ou3 45 DOW 0052 01 9ureJ4 en6i4 44 ly or 6 8t LE 9t st vt 43 Le 0 6 8c 4 9c sc ve EZ oz 61 8L at 9L SL tl L oL 60 80 40 90 50 v0 0 10 9 0 tl etl 620 619 9 s s 913 4 8 6L3 9 lt 6ld 9 z 8r m NL X TATI NL ozy X 9 m ozy z A 08211 x zezo 5 DS S iid B iz 2 4 ve ee z EE QE Ix 10J9EJU09 95019 Ww i xe iso ex i H fi rs 19 es EC 98 6 X x 18916 x L 0 CA gSi E 015 1075 YyO IMS 95 99 uonisod jo juepuedepui uedo gy JOJJEJU09 pue 015 Ly HOLOV INOO 94 uonisod 0 UI SI YMS OLS 8U ueuM t NV E MENI els i 9 9 l ti 8 1 h 148 4 1 9H 0U RT o 2 3 2582 2 28 4 Pes SLE 55 3 8 oo 5 am H 5 1 q 2 4 or 6 LE 9t SE EE 43 oE 67 8c a 9c sc H4 oz 6L 8L l 9L v L oL 60 80 10 90 50 v0 0 Publication 20Y TG001B EN P PowerFlex Acti
16. ATTENTION Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or implement the installation start up and subsequent maintenance of the system Failure to comply can result in personal injury and or equipment damage gt gt PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P P 4 Overview Notes PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Chapter 1 Troubleshooting and Error Codes gt gt PP ATTENTION avoid an electric shock hazard verify that all power to the PowerFlex Active Front End has been removed before performing any servicing or repairs ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing Check the DC bus voltage between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be Zero for all three measurements ATTENTION Hot surfaces can cause severe burns Do not touch the heatsink surface during operation of the PowerFlex Active Front End After disconnecting power allow time for cooling ATTENTION The PowerFlex Active Front End contains electrostatic discharge ESD sensitive parts and assemblies that can be damaged if you do not follow ESD control procedures Static control precautions are requir
17. See Removing Power from the AFE on page 4 3 2 If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 3 Remove the Air Flow Plate See Removing the AFE Air Flow Plate on page 4 11 4 Remove the protective front cover and terminal cover from the power structure See Removing Protective Covers from the Power Structure on page 4 12 the ASIC circuit board located on the power structure are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION The sheet metal cover and mounting screws on PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P AFE Power Structure Component Section 4 15 5 Remove the four screws that secure the ASIC cover to the ASIC assembly remove the DC bus connection from the ASIC cover and remove the ASIC cover Remove R Screws emove screws and cover a ASIC cover pele Remove DC assembly bus connection 6 Unplug the fan which mounts on the cover from connector X11 of the ASIC circuit board 7 Carefully unplug the fiber optic cables H1 through H7 from sockets on the ASIC board and carefully set them aside Important When mishandled the ability of fiber optic cables to transmit data is greatly diminished using optical transmission equipment This product emits intense light and
18. 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 2 If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 3 Foran AFE in a IP20 2500 MCC Style enclosure remove the four M6 x16 screws that secure the Air Flow Plate to the AFE For an AFE in a IP21 Rittal enclosure remove the four T8 Torx head screws that secure the Air Flow Plate to the AFE 4 Slide the Air Flow Plate from the AFE Removing Air Flow Plate for Removing Air Flow Plate for AFE in IP20 2500 MCC Style Enclosure AFE in IP21 Rittal Enclosure Remove screws Remove screws Remove screws Installing the AFE Air Flow Plate Install the Air Flow Plate in reverse order of removal PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 4 12 Power Structure Component Section Removing Protective Covers from the Power Structure You must remove the protective covers to access the internal components of the power structure 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 2 If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 3 Remove the four M5 POZIDRIV screws that secure the protective front cover and terminal cover to the power str
19. 18 Allen wrench 14 Wire cutter 15 Nose pliers 16 Crimping tools For cable terminals 1 5 240 17 Angle wrench 18 Flat nose screw driver 7x2mm 19 POZIDRIV screw driver 1 2 3 20 Phillips screw driver 1 2 3 21 Torx screw driver 25 22 Hexagonal wrench 4 5 6 23 ESD protected place of work Working surface floor covering seat and ground connections 24 ESD protective clothing Wrist wrap shoes overall clothing coat 25 Power supply service Capacity of three phase service 400 500 690V AC 30A 26 20 MAINSTND maintenance stand Maintenance stand for removing power structure from AFE enclosure 27 Fiber optic repair kit Agilent HFBR 4593 Polishing Kit consisting of a Polishing Fixture 600 grit abrasive paper and 3 mm pink lapping film 3M Company OC3 14 For Agilent HFBR 4532 latching connectors and HFBR RL cable See Agilent publications 5988 9777EN and 5988 3625EN PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 2 Service Tools and Equipment Notes PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Appendix B Schematic Diagrams Frame 10 Circuit Board Connections TOHLINOO suonoeuuo OL 4 b g anig Lee 8H H3ANHQ _ _ 8H H3AHI zH H 1I 9H H3AIHQ 7 SH
20. ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION The PowerFlex Active Front End contains electrostatic discharge ESD sensitive parts and assemblies that can be damaged if you do not follow ESD control procedures Static control precautions are required to install test service or repair this assembly If you are unfamiliar with static control procedures see Guarding Against Electrostatic Damage publication 8000 4 5 2 or any other applicable ESD protection handbook gt gt PP PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 7 2 LCL Filter Component Section Removing the LCL Filter 1 Remove power from the AFE Protective Barrier See Removing Power from the AFE on page 4 3 2 Remove the sixteen T25 Torx self tapping screws that secure the protective barrier 3 Remove the protective barrier from the LCL Filter enclosure Figure 71 Removing LCL Filter Protective Barrier FRONT VIEW AFE and LCL Filter in IP21 Rittal enclosures shown with doors removed LCL Filter DC Fan Fuses located on sidewall Front Bracket removal is required only when removing LCL Filter from enclosure bay Protective Barrier
21. U T1 DC VIT2 DC W T3 DC 0 The actual voltage reading can vary depending upon your equipment If your readings are not near 0 5V verify that the actual voltage measured is consistent for the power structure PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Checking Fiber Optic Connections Component Test Procedures 3 5 Table 3 C Reverse Biased Diode Tests on Power Structure Meter Leads Nominal meter reading U T1 DC V T2 DC W T3 DC Meter should display OL zero load DC U T1 DC V T2 DC W T3 If the AFE fails any of these measurements replace the Power Module in the power structure or the complete power structure using any of the following options Contact your local representative to schedule On site Services Contact your local representative to make arrangements to return the power structure to the factory for repair by Remanufacturing Services Foran AFE not covered under factory warranty a customer has the option of repairing the power structure using procedures described in this manual Damaged or improperly connected fiber optic cables can cause apparent Gate Driver board malfunctions For fiber optic cable connections see page C 1 page C 2 and page C 3 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 2 If present remove the protective barriers See Removing A
22. X8 X3 X1 X4 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P LCL Filter Component Section 7 5 5 Remove the six fasteners that secure the DC to DC power supply Installing the LCL Filter Fan Install the DC to DC power supply in reverse order of removal while DC Power Supply referring to Torque Specifications on page 4 2 Replacing the LCL Filter Fan 1 Remove the LCL Filter protective barrier See Removing the LCL Filter Protective Barrier on page 7 2 2 Disconnect terminal blocks X51 and X53 X51 X53 LCL FILTER Hexagonal O RIGHT SIDE VIEW bolt location TX PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 7 6 LCL Filter Component Section Removing the LCL Filter PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Lower the front fan sheet metal edge and slide it forward to remove the alignment studs from their respective holes in the fan frame sheet metal Slide out the fan assembly Remove the LCL Filter Fan DC Power supply See Removing the LCL Filter Fan DC Power Supply on page 7 3 Reinstall the LCL Filter Fan in reverse order of removal while referring to Torque Specifications on page 4 2 Note the following LCL Filter air flow cooling requirements LCL Filter Required Air
23. i Precharge Precharge Precharge Fuses Contactor Circuit K6 i R6 1 i 862 i o T PowerFlex Active Front End System BUCHEN EE CHEM LC CERE n 2 Ce Customer supplied Parts Customer supplied enclosure PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 2 8 Active Front End System Overview Notes PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Chapter 3 Component Test Procedures PPP PPP ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION To avoid an electric shock hazard verify that all power to the PowerFlex Active Front End has been removed before performing any servicing or repairs ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing Check the DC bus voltage between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be Zero for all three measurements ATTENTION Hot surfaces can cause severe burns Do not touch the heatsink surface during operat
24. SLIMY lt NMOHS LON SI NOLLO3S SSONOD NIHM __ 1 TETTE 485921 eio JBUJBJUJ i n a 10 02 IM u emi SHS SX LO viros SFIX 10 dure 10 SIXI BOCES V0CX 10 1009 U ISAP M 18648 290 veo 1 Publication 20Y TG001B EN P PowerFlex Active Front End Frame 10 Hardware Service Manual 22 Schematic Diagrams Notes PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Circuit Board Connections Connector Descriptions Appendix C The following tables detail the connection points for the Frame 10 PowerFlex Active Front End circuit boards and components Table C A Fiber Optic Adapter Board to ASIC Circuit Board Connections Fiber Optic Signal Description ASIC Board Fiber Adapter Connector Type Reference to ASIC Board Type Connector a H1 TX Gate Enable RX H1 H2 TX U Gate RX H2 H3 TX V Gate RX H3 H4 TX W Gate RX H4 H5 TX A D Convert RX H5 H6 TX VBUS RX RX H6 H7 RX VBUS TX TX H7 X2 From 24V DC Power To X10 X3 Erom itid 24V DC Power To supply Figure C 1 on page C 3 for ASIC board fiber optic connectors Important When
25. Secondary Transformer Type Input Volts Output Volts kVA 2 None Solid High Resistive Ground Cable Length Cable Type Line Reactor Mfgr Cat Num Impedance Isolation Xtmr Mfgr Cat Num Impedance Input Contactor AFE Cat Num SCR Cat Num Output Contactor Cable Length Cable Type Drive Cat Num Output Reactor Mfgr Cat Num Terminator Mfgr Cat Num Cable Length Cable Type Motor Mfgr Volts Amps RPM Hz Power Design No Encoder Brake Motor Heater PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 2 AFE Power One line System Application Data Typical Transformer The following diagrams show typical transformer winding types Winding Types Delta Wye with Grounded Wye Neutral A Delta Delta with Grounded Leg or Four Wire Connected Secondary Delta BA Ungrounded Secondarv ay A PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P AC line switchgear components AFE in IP20 2500 MCC Style enclosure D 9 AFE in IP21 Rittal enclosure D 10 overview 5 1 Active Front End system overview 2 1 additional resources publications P 2 website P 1 AFE power structure ASIC assembly parts D 4 checking fan inverter fuses 3 8 external componen
26. 12 10 Remove the X3 fan connector PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Power Structure Component Section 4 19 11 Remove the four 8 x 20 screws that secure the power structure to the enclosure back panel For clarity only the back panel of the enclosure is shown Remove screws M8 x 20 6 7 Nem 60 Ibein Remove screws 12 Partially pull the power structure forward from the enclosure to expose the lifting holes 13 Secure appropriate lifting apparatus to the power structure and completely remove the power structure approximately 220 1b 99 8 kg from the enclosure Installing the Power Structure in the Enclosure Install the power structure in reverse order of removal See the PowerFlex Active Front End User Manual publication 20Y UMO01 for tightening torques of AC supply DC bus input and ground connection terminations PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 4 20 AFE Power Structure Component Section Removing the Power Module from the Power Structure Important Do not attempt to disassemble the Power Module 1 Remove the power structure from the AFE enclosure See Removing the Power Structure from the Enclosure on page 4 17 Important Before the internal components Power Module DC bus capacitors balancing resistors and so forth of the power structure can be accessed the
27. 2 2200 0085 uv P 1802 1015 140902 aay dav TIS wo WO d PAL IIA JML nv a a fl u u 3 L 9 5 D 2 L 9 9 0 9 9 9 9 9 o o o o 0 o w l l l i i i t 1 99 ajqeuq 2 co 1 01 79 jeuondo T 9 19594 19 08 jeuondo JOpejuo JJMOd 9s Jo uone1ado ajoway LS 22 JIN 5 vl I JON T ev 19 TA id TIS ve tAre ve N oH 19 JN H ON 2 I 19 vM PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 6 Schematic Diagrams System Schematics for Frame 10 in IP20 2500 MCC Style Enclosure The following system schematics are for the AFE Frame 10 in a IP20 2500 MCC Style enclosure The PowerFlex AFE catalog number has an enclosure code of P for standard color or W for optional gray color as shown in the example catalog string below For other enclosure designs contact the supplier of the system for the system schematics
28. 3 Disconnect the cables from X2 and X3 of the Fiber Optic Adapter board Important Note polarity when removing X2 and X3 wires If polarity is not maintained when re installing these wires the ASIC board or fiber optic board can be damaged X1 disconnects from the Control board when you remove the board from the Control Frame Sockets for Fiber Optic cables Connects to 24V DC power x2 4 Carefully disconnect the fiber optic cables from the right side of the circuit board and carefully set them aside Important When mishandled the ability of fiber optic cables to transmit data is greatly diminished using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION Hazard of permanent eye damage exists when Important The minimum inside bend radius for fiber optic cable is 25 4 mm 1 in Any bends with a shorter inside radius can permanently damage the fiber optic cable Signal attenuation increases with decreased inside bend radii PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 4 8 Power Structure Component Section 5 Remove the four screws that secure the Fiber Optic Adapter board to the stand offs on the back of the Control box IP20 or Control Frame 21 and remove t
29. A signal loss has occurred Configure this fault with parameter 203 or 206 Anlg In x Loss A microprocessor watchdog timeout has occurred The AFE input current has exceeded the 1 minute overload rating Fan is not energized at start command This includes the power structure or LCL Filter fans 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 A sent message was not acknowledged Problem in application software with task overload The ambient temperature around the power structure heatsink is too low The new power unit or option board installed is a different type new option board was added There was an error reading parameters 019 Motoring MWh 020 Regen MWh and 021 Elapsed Run Time from Troubleshooting and Error Codes 1 Check all user supplied fuses 2 Check the AC input line voltage Check supply voltage fuses and cable 1 Verify parameter 203 or 206 Anlg In x Loss setting Input signal level should be greater than or equal to 1 5V or 3 mA 2 Check for broken loose connections at the inputs 1 Cycle the power 2 Replace the Control board See page 4 5 Check for an excess load If the LCL Filter fan is not operating check the fan DC power supply board located in front of the LCL Filter fan 2 I
30. Bloo o 19708 so Precharge Circuit and Precharge Resistors R6 1 and R6 2 LCL Filter L1 Active Front End Power Structure U1 AC Line Switchgear Motor controlled Circuit Breaker Q1 Input Disconnect Q0 AFE Control Assembly shown with user installed HIM olo olo oloo DC Fuses F2 1 and F2 2 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 2 6 Active Front End System Overview Bus Bar Locations There are several sets of bus bars in the AFE Frame 10 system that connect main system components e Bus bars between Input Disconnect Q0 and MCCB Q1 e Bus bars between MCCB 01 and the LCL Filter L1 e Bus bars between the LCL Filter L1 and AFE Power Structure U1 e Bus bars between the AFE Power Structure U1 and DC Bus Bars The following figure shows these bus bar locations Figure 2 6 AFE Frame 10 Bus Bar Locations in IP21 Rittal Enclosure AC bus bars between LCL Filter L1 and AFE Power Structure 01 AC bus bars between Motor Controlled Circuit Breaker Q1 and LCL Filter L1 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P FRONT VIEW shown with enclosure doors removed DC bus bar DC
31. Component Section Fuse Replacement DC bus fuses are required for short circuit protection The following tables Guidelines list the recommended DC bus fuses Table 400 480 Volt DC Fusing Frame AFE Fuse Size Enclosure Style Amps Bussman Type Ferraz Shawmut Type 20 2500 MCC 1100 170M6499 10 1100 PC73UD95V11CTF IP21 Rittal 1250 170M6566 Table 8 B 600 690 Volt DC Fusing Frame AFE Fuse Size Enclosure Style Amps Bussman Type Ferraz Shawmut Type IP20 2500 MCC 630 170M6454 10 630 PC73UD13C630TF IP21 Rittal 700 170M6305 To replace fuses use the following procedure 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 2 Open the power structure enclosure door 3 If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 Remove and discard the blown fuse Insert the fuse body between the bus bars Turn the threaded rod into the fuse body n Place the Belleville domed washer and hexagonal nut on the threaded rod and hand tighten 8 Hold the threaded rod with the hex key while tightening the nut to the specified torque Stud Tightening Nut Tightening Stud Type Torque max Torque max M8 x 30 10 Nem 13 5 Nem M8 x 35 88 5 Ibein 132 8 Ibein M10x30 15 26 M10x50 132 8 Ibein 230 1 Ibein M12x35 15Nem 46 Nem M12x50 13
32. Serial Port 4 o la c 5 X2 o D BH co co Slot A 2 12 9 m o PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 4 6 AFE Power Structure Component Section 5 Remove the three screws that secure the Control board to the Control box and remove the Control board NOTE Do not remove the enclosure cover from the Control Frame For clarity the enclosure is shown without the cover 3 Nem 27 Ibein 54 Wa Installing the I O Circuit Boards and Control Board Install the Control and I O circuit boards in reverse order of removal while referring to Torque Specifications on page 4 2 Removing the Fiber Optic Adapter Circuit Board 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 2 For an AFE in a IP20 2500 MCC Style enclosure open the control box on the enclosure door to access the Control assembly For an AFE in a IP21 Rittal enclosure do the following Open the enclosure door to access the Control Frame Loosen the T8 screws to open the Control Frame c Swing open the Control Frame which exposes the back of the Control box to access the fiber optic adapter board o 0 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Power Structure Component Section 4 7
33. Structure Access Follow these instructions to remove and install components on the power Procedures structure and to remove the Power Module from the power structure Important To access Power Modules for replacement requires the power structure to be completely removed from the AFE enclosure Removing AFE Protective Barriers 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 2 Remove the screws that secure the protective barriers to the AFE enclosure 3 Remove the protective barriers Removing Protective Barriers for Removing Protective Barriers for AFE in IP20 2500 MCC Style Enclosure AFE in IP21 Rittal Enclosure o o P 8 pn ri Remove Remove screws screws Remove Remove screws Screws ti 22292928 4 Installing the AFE Protective Barriers Install the protective barriers in reverse order of removal PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Power Structure Component Section 4 11 Removing the AFE Air Flow Plate You must remove the Air Flow Plate to remove the power structure from the AFE
34. The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION Hot surfaces can cause severe burns Do not touch the heatsink surface during operation of the PowerFlex Active Front End After disconnecting power allow time for cooling ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION The PowerFlex Active Front End contains electrostatic discharge ESD sensitive parts and assemblies that can be damaged if you do not follow ESD control procedures Static control precautions are required to install test service or repair this assembly If you are unfamiliar with static control procedures see Guarding Against Electrostatic Damage publication 8000 4 5 2 or any other applicable ESD protection handbook Use the instructions in this chapter to remove and install components from the Active Front End To remove and install components on the power structure and to remove the Power Module from the power structure see Power Structure Access Procedures on page 4 10 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 4 2 Power Struct
35. airflow channel 10 Remove the M5 POZIDRIV screws that secure the bus bar terminals to the power structure 11 Slide the bus bar terminals out of the frame 12 Remove the bus bar airflow channel from the frame PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 4 22 AFE Power Structure Component Section 13 Remove the M8 x 20 hexagonal screws that secure the input power cables to the input power bus bar Tightening torque for reassembly is 14 Nem 124 Ibein 14 Cut and remove the cable ties that secure the input power cables to the EMC cover plate and remove the cables Remove screws and input power cables Cut cable ties 15 Remove the M5 x 10 POZIDRIV and M4 x 8 POZIDRIV screws that secure the EMC cover to the AFE and remove the cover NL E n m Remove screws 2 72 4 Nem 35 E D TN 7 Remove EMC cover Remove screws Remove screw and 22 snubber capacitors 3 Nem 27 Ibein 16 Remove the screws that secure the snubber capacitors to the power structure and remove the snubber capacitors PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P AFE Power Structure Component Section 4 23 17 Remove the screws that secure the power bus bar and support insulators to the power structure 9 a Support insulators Power bus bar 18 Remove the power
36. and R6 2 LCL Filter L1 Active Front End Power Structure U1 AC Line Switchgear Input Circuit Breaker 00 Input Fuses F1 1 F1 3 Input Contactor K1 DC Fuses F2 1 and F2 2 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P AFE Control Assembly the door and shown with user installed DC bus bar Optional Bus Splice Kit shown DC bus bar AC power cables between LCL Filter L1 and AFE Power Structure U1 Active Front End System Overview 2 3 Main Bus Bar Cable Locations There are several sets of bus bar cables in the AFE Frame 10 system that connect main system components Bus cables between Input Breaker 00 and AC Fuses 1 1 1 3 Bus bars between AC Fuses 1 1 1 3 and Input Contactor K1 Bus cables between Input Contactor K1 and the LCL Filter L1 Bus bars between the AFE Power Structure U1 and DC Bus The following figure shows these bus bar cable locations Figure 2 3 AFE Frame 10 Bus Bar Cable Locations in IP20 2500 MCC Style Enclosure FRONT VIEW shown with enclosure doors removed e face v V m d 2 f o al ja 9 0
37. bus bar and insulators Tightening torque for reassembly is 14 Nem 124 Ibein 19 Disconnect the Balancing Resistor assembly wires from the DC bus bars Remove wire i tions from Older Style Balancing Resistor Assembly DC bus bar end P2 PZ2 4 Nem oe 3 Nem 35 Ibein 27 Ibein Assembly mounting screws Remove wire connections Newer Style Balancing Resistor Assembly fm 3 Nem 35 Ibein 27 Assembly mounting screws PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 4 24 AFE Power Structure Component Section 20 Remove the screws see step 19 picture for screw locations that secure the Balancing Resistor assemblies to the power structure Balancing resistor assembly Remove screws 21 Remove the Balancing Resistor assemblies 22 Remove the M6 x 12 screws that secure the Connective DC bus bars and insulators to the power structure bus bar DC bus bar Insulator PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P AFE Power Structure Component Section 4 25 Location Fasteners Torque o M10 x 25 hexagonal screws M10 spring washers and M10 washers 8 Nem 70 Ibein e M8 x 25 hexagonal screws 8 spring washers and M8 washers 8 Nem 70 e M6 x 12 screws 4 Nem 35 Ibein 23 Remove the Connective DC bus bars and insulators Tightening torque for re
38. enclosure 4 9 DPI HIM assembly 4 4 fiber optic adapter circuit board 4 6 gate driver circuit board 4 12 I O circuit boards and control board 4 5 LCL filter fan DC power supply 7 3 from 20 2500 MCC Style enclosure 7 6 from IP21 Rittal enclosure 7 8 protective cover 7 2 power from the AFE 4 3 power module from the power structure 4 20 power structure DC bus capacitors 4 26 power structure from the enclosure 4 17 power structure main cooling fan 4 17 protective covers from the power structure 4 12 replacing power structure with a new power structure 4 27 resources publications P 2 website P 1 reverse biased diode test 3 3 S schematic diagrams B 1 service tools A 1 software tools A 1 spare parts information D 1 website P 2 D 1 startup after repair 9 1 status indicators 3 2 System overview 2 1 Index 3 T testing control transformer and 24V DC power supply 6 3 forward biased diode 3 3 gate driver board resistance 3 7 precharge bridge 6 6 precharge resistor 6 7 reverse biased diode 3 3 torque specifications 4 2 troubleshooting and error codes 1 1 turning off the AFE 4 3 viewing the status indicators 3 2 visual inspections 3 2 W website additional resources P 1 spare parts P 2 D 1 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Index 4 PowerFlex Active Front End Frame 10 Hardware Service Manual Pu
39. secure the insulator to the metal frame and remove the insulator gt Remove insulator c Replace the insulator Remove fasteners PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P AFE Power Structure Component Section 4 17 Installing the ASIC Circuit Board Install the ASIC circuit board in reverse order of removal while referring to Torque Specifications on page 4 2 Reconnect cables and jumpers to the ASIC board while referring to Figure B 1 on page 1 the ASIC circuit board located on the power structure are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly Verify that the DC bus wire is properly connected to the ASIC chassis cover ATTENTION The sheet metal cover and mounting screws on Removing and Installing the Power Structure Fan System There is one Main Cooling Fan on the power structure For complete details on all fan system related information see the PowerFlex 700S 700H and 700AFE Drive Fan Systems Installation Instructions publication PFLEX INO29 including removal and installation of the following items AC fan inverters AC fan capacitors AC main cooling fans DC fan power supplies DC main cooling fans Fan fusing Removing the Power Structure from the Enclosure Important Power structure removal is required only when it or its internal componen
40. 12 WH WH H8 H11 VL VL H7 Fiber Optic Gate Signals H10 VH VH H6 connect UH to UH UL to UL and so forth H9 UL UL H5 H8 UH UH H4 DTR N 3 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 2 ETR Phase T ITR Phase Overcurrent ASIC Board Fiber Optic Adapter Board Figure C 1 Fiber Optic Cable Routing Gate Driver Board Six Fiber Optic Cables X5 X4 X3 X2 X15 9 c oo LL jsjejejzjejsjej 2 of Connector Descriptions C 3 For Gate Driver board part number information see Table D B on page D 3 For ASIC board part number information see Table D C on page D 4 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P C4 Connector Descriptions Hardware Connections Figure 2 AFE Power Structure Fan Inverter Circuit Board Connectors H X8 5 L I O L I le
41. 142 6E 8t LE 9t st ve EE 43 LE 0 6 8c Lu 9c st vc oc 6L 8L a 9L tl L oL 60 80 40 90 50 0 0 Lo z vev 6 NI lt Ajddns Arewud ay eBueuo peeu Z se A069 si uonoeuuoo Jeuuojsuej 9poo 069 009 104 se SI jeuuojsue 104 L 9JON 00 IX iemd wawo 1 0228 55 zegon vs A 0178 4 sv 6 1 lt 1518 ix 18 SH 2518 ZBL BION 118 0 18 tig Orie ZH L608 0608 1509 0509 4 21 2 9 9 4 1 249 9 4 or 6 8t LE 9 SE vt 43 oE 67 8z 4 92 52 vc EZ z oc 6L 8L D 9L tL 0L 60 80 10 90 50 v0 0 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 9 Schematic Diagrams A069 009 6 19945 ensojoua ejas DOW 0052 U 01 4 678 w w 12 Wy ov 0 8E 3 3 9 9 sE sE v L vt 0718 X NI 8 v
42. 2 8 Ibein 407 1 Ibein 15 Nem 46 Nem M12X40 55 8 407 1 bein Important Do not apply torque or twisting force to the fuse body as this can damage the fuse PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P DC Fuses Component Section 8 3 For more information about Bussmann fuses go online at http ww w cooperindustries com For more information about Ferraz Shawmut fuses go online at http www ferrazfuses com PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 8 4 DC Fuses Component Section Notes PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Chapter 9 Startup After Repair ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION Power must be applied to the PowerFlex Active Front End to perform the following start up procedure Some of the voltages present are at incoming line potential To avoid electric shock hazard or damage to equipment only qualified service personnel should perform the following procedure Thoroughly read and understand the procedure before beginning During startup if one of these pre powerup checks reveals a concern do not proceed Re
43. 4 4 Power Structure Component Section Control Frame Access Removing the DPI Interface Assembly Procedures 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 Important Before removing connections and wires mark them to avoid incorrect wiring during assembly 2 Foran AFE in a IP20 2500 MCC Style enclosure disregard this step For an AFE in a IP21 Rittal enclosure locate the control assembly item Figure 2 5 and remove the two screws from the front of the DPI hinged assembly For AFE in IP20 2500 For AFE in IP21 MCC Style Enclosure Rittal Enclosure Remove L screws P1 0 9 Nem 8 Ibein ne U 3 Foran AFE in a IP20 2500 MCC Stvle enclosure open the control box door to access the DPI interface board For an AFE in a IP21 Rittal enclosure open the hinged assembly that holds the DPI interface board 4 Unplug the DPI cable from the X2 connector on the DPI interface board Back view of the DPI X2 interface board which remains mounted on the X47 amp back of the Control Frame 29 Green Ground Wire Based on PCB ma 5 Remove the four screws and the assembly from the Control Frame For AFE in IP20 2500 For AFE in IP21 8 u
44. 5 6 7 8 9 10 11 2 13 15 6 17 18 19 20 MAt 1 2 2 10Vref PotGND 10Vref AOUTI AOUTC AOUT2 DINi DIN2 DIN3 DIN4 DINS DIN6 D COM D COM 24V 24VCOM A16 1 ABCD ABCD ABED F ABCD 20C DA1 4 A11 EEN seepi 9 8008 R1 MOControl R1 9 T oom p r 20C DO1 20C DPI1 121 0 093 SLOTB 13 SLOTE 1 66 Inverter Enable Figure B 13 Control Wiring Diagram for Frame 10 in IP21 Rittal Enclosure PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 14 Schematic Diagrams 1 3 20Y System Schematics for Frame 10 AFE in IP21 Rittal Enclosure The following system schematics are for the AFE Frame 10 in a IP21 Rittal enclosure The PowerFlex AFE catalog number has an enclosure code of A as shown in the example catalog string below For other enclosure designs contact the supplier of the system for the system schematics
45. EN COS P 2 Additional Support Available on Internet 3 General Precautions for Class 1 LED P 3 Troubleshooting and Error Codes Creating Fault Reports x per e bee s e 1 2 Addressing PowerFlex Active Front End 6 1 2 Common Symptoms and Corrective Actions 1 7 Active Front End System Overview AFE in IP20 2500 MCC Style 2 1 Main Component A OAS 2 1 Component eee algae aie RN es 2 2 Main Bus Bar Cable 2 3 AFE in IP21 Rittal Enclos re ed utet 0556 eb 2 4 Main Component Sections 2 4 Main Component Locations 2 5 Bus Bar Locations 435 eus Ce e ata dn 2 6 AFE in IP00 Open Chassis Configuration 2 7 Component Test Procedures Viewing the Status 3 2 Performing Visual Inspections 1 3 2 Inspecting the Cooling Tunnel
46. End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Chapter 5 AC Line Switchgear Component Section ATTENTION To avoid an electric shock hazard verify that all power to the PowerFlex Active Front End has been removed before performing any servicing or repairs ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing Check the DC bus voltage between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be Zero for all three measurements ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION Hot surfaces can cause severe burns Do not touch the heatsink surface during operation of the PowerFlex Active Front End After disconnecting power allow time for cooling ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION The PowerFlex Active Front End contains electrostatic discharge ESD sensitive parts and assemblies that can be damaged if you do not follow ESD control procedures Static con
47. End is available on the Allen Bradley website at http www ab com support abdrives powerflex 70 PF7ReleasedParts pdf PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P D 2 Disassembly Assembly Diagrams and Spare Parts AFE Power Structure Figure 0 1 AFE Power Structure Assembly External Components Assembly the ASIC Board located on the power structure are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION The sheet metal cover and mounting screws on Side Cover Front Cover T ASIC Assembly Terminal Cover Upgrade Kit Fuse Holder for Fan Inverter SESS 7 5 E Mounting Rack Table D A AFE Power Structure Assembly External Component Part Numbers Part Name Part No ASIC Assembly Upgrade Kit without ASIC Board 20 FR10850 Bus Bar Assembly n a Fuse Holder for Fan Inverter only AC fan system 20 PP20300 1 Fan Inverter Fuse only AC fan system 20 PP20202 1 Terminal Cover n a Front Cover n a Power Structure 400 480V 460A SK Y1 PWRMOD D460 600 690V 325A SK Y1 PWRMOD E325 Maintenance Stand 20 MAINSTD 0 For additional AC fan System information see publication PFLEX INO29 PowerFlex Active Front End Frame 10 Hardware Service Manual Publicat
48. FE Protective Barriers on page 4 10 3 Remove the protective front cover and terminal cover from the power structure See Removing Protective Covers from the Power Structure on page 4 12 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 3 6 Component Test Procedures PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Locate the Gate Driver board on the front of the power structure right side enclosure Gate Driver Board ASIC Board Verify that the fiber optic cables are properly connected between the Gate Driver board and the ASIC board Important The minimum inside bend radius for fiber optic cable is 25 4 mm 1 in Any bends with a shorter inside radius can permanently damage the fiber optic cable Signal attenuation increases with decreased inside bend radii Verify that the fiber optic cables are properly connected between the ASIC board and the Fiber Optic Adapter circuit board Disconnect the cables and inspect them for scratches and cracks and overall integrity Important When mishandled the ability of fiber optic cables to transmit data is greatly diminished Reconnect the cables replacing any damaged cables Performing Gate Driver Board Resistance Measurements Approx 0 5 ohms Component Test Procedures 3 7
49. FLEX INO29 To X51 on the LCL Filter Power Supply Circuit Board DC Main Fan 81 X8 X3 X82 Isolated 48V DC Power Fan Module Supply Circuit Board X2 DC o DC o Figure B 3 DC Fan Power Supply all AFEs in IP20 2500 MCC Style or IP21 Rittal enclosure January 2013 and later From Power From ASIC Switch Setting To indicate the following Board X10 Board X11 51 Off 50 Hz fan motor frequency For more details see the MN 2 PowerFlex 7005 700H and S2 Off 220 V AC motor voltage 7TOOAFE Drive Fan Systems S3 On 230 V AC motor voltage Installation Instructions publication PFLEX INO29 54 Off Not used mm Area Under Main Power Terminal Strip l Black 6 1 To d Blue Main Fan 25 0 2 Fan Frequency ix T M Off On Off Convener gt Black4 f i i S1 Setup Switch 22 10 x3 Black 3 E Area Under Fan Power Supply Plate pb gt J Fan Area Figure B 4 AC Fan Power Supply only AFE Power Structure in IP21 Rittal enclosure December 2012 and earlier PowerFlex Active Front End Frame 10 Hardware Service Ma
50. Fan Inverter Fuse Base M4 x 8 POZIDRIV screws 3 Nem 27 Ibein Fan Inverter Fuse Holder M4 x 8 POZIDRIV screws 3 Nem 27 Ibein Gate Driver Circuit Board Mounting M4 x 8 POZIDRIV screws 1 35 Nem 12 Ibein Main Cooling Fan Mounting M5 x 10 POZIDRIV screws 3 Nem 27 Ibein Precharge Bridge Wire Fasteners M5 x 12 machine screws 4 5 Nem 40 Ibein Assembly Mounting M5 nuts 3 9 Nem 35 Ibein Precharge Bridge Resistor Assembly M5 x 12 Torx self tapping screws 4 5 Nem 40 Ibein LCL Filter Upper In IP20 Encl M8 x 20 M6 x 16 screws 6 7 Nem 60 Ibein 4 5 Nem 40 Ibein Front Bracket In IP21 Encl M5 x 12 Torx self tapping screws 4 5 Nem 40 Ibein LCL Filter Lower Front Bracket IP20 encl M8 x 20 screws 6 7 Nem 60 Ibein Motor Output Terminals on Power Structure M8 x 20 hexagonal screws 20 Nem 177 Ibein Power Structure Output Terminals U V W M8 x 20 hexagonal screws 14 Nem 124 Ibin Power Structure Block Mounting M10 x 12 hexagonal screws 20 Nem 177 Ibein Power Structure DC Bus Input Terminals M6 x 16 POZIDRIV screws 4 Nem 35 Ibein Protective Covers on Front M5 x 10 POZIDRIV screws 3 Nem 27 Ibein Power Structure Terminal M5 x 16 POZIDRIV screws 3 27 Ibein POZIDRIV is a registered trademark of the Phillips Screw Company Phillips is a registered trademark of Phillips Screw Company PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20
51. Flow LCL 460 1100 m hr LCL 1300 1300 m hr The procedures to remove the LCL Filter are slightly different depending on the enclosure in which it is installed From the IP20 2500 MCC Style Enclosure 1 Remove power from the See Removing Power from the AFE on page 4 3 Remove the LCL Filter protective barrier See Removing the LCL Filter Protective Barrier on page 7 2 Remove the X51 and X53 terminal blocks from the LCL fan assembly Remove the X52 terminal block from the LCL Filter assembly upper right side Remove the lower and upper front brackets that hold the LCL Filter in the enclosure see Figure 7 4 See Detail and remove the two M5 x 12 screws See Detail B and remove the three 8 x 20 screws See Detail and remove the six x 16 screws This bracket holds the LCL Filter in the enclosure LCL Filter Component Section 7 7 Figure 7 4 Removing LCL Filter from AFE in IP20 2500 MCC Style Enclosure Re ON NG o Sy EN UN DETAIL DETAIL 6 Disconnect the AC input power cables L1 L2 L3 between the input contactor and LCL Filter For cable locations see Figure 2 3 on page 2 3 7 Disconnect the output cables U V W between the LCL Filter and the AFE power structure F
52. Hardware Service Manual Allen Bradley PowerFlex Active Front End Frame 10 PowerFlex AFE PowerFlex 700AFE 400 480V and 600 690V 5 E T T1 d ES B 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 ass
53. LCL Filter Fan and DC Power Supply behind cover Installing the LCL Filter Reinstall the protective barrier in reverse order of removal while referring Protective Barrier to Torque Specifications on page 4 2 Replacing the LCL Filter DC The LCL Filter DC fan fuses are located on the interior sidewall above the Fan Fuses LCL Filter assembly Important Replace LCL Filter fan fuses with only 8 Ferraz Shawmut fuses For complete details on LCL fan system information see the PowerFlex 700 700S and 700AFE Drive Fan Systems Installation Instructions publication PFLEX INO29 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P LCL Filter Component Section 7 3 Removing the LCL Filter Fan The following figures show the LCL Filter fan DC Power Supply wiring diagram with the connections to the AFE power structure and DC bus DC Power Supply For complete details on LCL fan system information see the PowerFlex 700H 7005 and 700AFE Drive Fan Systems Installation Instructions publication PFLEX INO29 Figure 7 2 Filter Fan DC Power Supply Wiring Diagram older version LCL Filter 2 4 Fan DC Power Supply PCB X8 KLIXON X52 4 pin Pin 1 KLIXON Pin 4 KLIXON AFE Power Structure Fuse X53 3 pin Pin DC supply Pin DC suppl
54. Removing the LCL Filter Protective 7 2 Installing the LCL Filter Protective 7 2 Replacing the LCL Filter DC Fan 7 2 Removing the LCL Filter Fan DC Power 7 3 Installing the LCL Filter Fan DC Power 1 7 5 Replacing the LCL Filter Fan ees sete xe Red gare rte a rete 7 5 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Chapter 8 Chapter 9 Appendix Appendix Appendix Appendix D Appendix E Index Table of Contents iii Removing the ECL Filter 3523 ika Rer Ree E bii Ter aue a UO pps 7 6 From the IP20 2500 MCC Style 7 6 From the IP21 Rittal 2 7 8 Installing the LCL Filter in the 7 9 DC Fuses Component Section OVerVIeW 25455 8 1 Fuse Replacement Guidelines ed eee e Rep wasn RM e RR aee tus 8 2 Startup After Repair Before Applying Power to 9 2 Service Tools and Equipment Software Tools ip ee RS Iv Ups A 1 Service Tools tto Eo EC 4 A 1 Sch
55. SSPLICE F10 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P D 10 Disassembly Assembly Diagrams and Spare Parts Figure D 10 AC Line Switchgear Components for AFE in IP21 Rittal Enclosure FRONT VIEW shown with enclosure doors removed EI B o oT DAD Ns Motor Controlled Circuit Breaker 20000 Input Disconnect Switch Table D J AC Line Switchgear Part Numbers for AFE in IP21 Rittal Enclosure Part Name Part No Control Circuit Relay 230VAC SK Y1 K20 DF got shown 24VDC SK Y1 K4 DF Input Disconnect Switch SK Y1 Q0 F10 Motor Controlled Circuit Breaker SK Y1 Q1 F10 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Data to Collect Pere SCR Bus Supply AFE 9 Drive Drive Appendix E AFE Power One line System Application Data Collect the following AFE system data before contacting Allen Bradley Drives Technical Support Utility Transformer Delta Delta Delta Wye etc Type Input Volts Output Volts kVA 2 None Solid High Resistive Ground Cable Length Cable Type
56. TG001B EN P November 2014 Supersedes Publication 20Y TG001A EN P June 2011 Copyright 2014 Rockwell Automation Inc All rights reserved Printed in the U S A
57. TION The LCL Filter is heavy To avoid personal PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P the LCL Filter from the enclosure LCL Filter Component Section 7 9 8 Slide the LCL Filter out of the enclosure Note that ramps customer supplied shown below may be required due to enclosure floor mismatch LCL Filter Removed from Enclosure Installing the LCL Filter in Install the LCL Filter in reverse order of removal while referring to Torque the Enclosure Specifications on page 4 2 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 7 10 LCL Filter Component Section Notes PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Overview Chapter 8 DC Fuses Component Section PP ATTENTION avoid an electric shock hazard verify that all power to the PowerFlex Active Front End has been removed before performing any servicing or repairs ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing Check the DC bus voltage between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be Zero for all three measurements ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the powe
58. Y TG001B EN P Removing Power from the AFE AFE Power Structure Component Section 4 3 ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing Check the DC bus voltage between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be Zero for all three measurements Remove power before making or breaking cable connections When you remove or insert a cable connector with power applied an electrical arc can occur An electrical arc can cause personal injury or property damage by the following e Sending an erroneous signal to your system s field devices causing unintended machine motion e Causing an explosion in a hazardous environment Electrical arcing causes excessive wear to contacts on both the module and its mating connector Worn contacts can create electrical resistance 1 Turn off and lock out input power L1 L2 L3 2 Wait five minutes 3 Verify that there is no voltage at the AFE input power terminals 4 Check the DC bus voltage between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements before proceeding PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P
59. al Publication 20Y TG001B EN P Index 2 L LCL filter assembly parts D 5 fan DC power supply installation 7 5 removal 7 3 fan replacement 7 5 fuse replacement 7 2 removing from 20 2500 MCC Style enclosure 7 6 21 Rittal enclosure 7 8 removing protective cover 7 2 M main component locations AFE in IP20 2500 MCC Style enclosure 2 2 AFE in IP21 Rittal enclosure 2 5 main component sections AFE in IP20 2500 MCC Style enclosure 2 1 AFE in IP21 Rittal enclosure 2 4 measurement points for forward and reverse diode tests 3 4 motor controlled circuit breaker MCCB 5 2 0 one line diagram AFE in IP00 open chassis configuration 2 7 AFE in IP20 2500 MCC Style enclosure 2 1 AFE in IP21 Rittal enclosure 2 4 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P P performing forward biased diode test 3 3 gate driver board resistance measurements 3 7 reverse biased diode test 3 3 visual inspections 3 2 powering down 4 3 precharge assembly parts AFE in IP20 2500 MCC Style enclosure D 7 AFE in IP21 Rittal enclosure D 8 bridge replacement 6 6 bridge testing 6 6 fuse replacement 6 2 resistor replacement 6 8 testing control transformer and 24V DC power supply 6 3 testing resistor 6 7 precharging functions 6 2 R removing AFE air flow plate 4 11 AFE protective barriers 4 10 ASIC circuit board 4 14 control frame only AFE in IP21 Rittal
60. ame panel Control Transformer T4 is mounted directly behind Motor Controlled Circuit Breaker MCCB 3 Use a digital voltmeter to test the control transformer T4 a Measure the primary AC line voltage which is at the 400 480V AC or 600 690V AC system voltage b Measure the control transformer T4 output voltage which is approximately 230V AC If these measurements are not within 41090 perform these other steps c Power down the AFE d Remove the output secondary wires e Power up the AFE and retest by repeating steps a and b The control transformer T4 may require replacement if these measurements continue to be outside of the 10 tolerance 4 Use a digital voltmeter to test the 24 DC power supply T10 a Measure the primary voltage which is 230V AC b Measure the power supply T10 output voltage which is approximately 24V DC If these measurements are not within 10 perform these other steps c Power down the AFE d Remove the 24V DC output wires of the power supply T10 e Powerup the AFE and retest by repeating steps a and b The 24V DC power supply T10 may require replacement if these measurements continue to be outside of the 10 tolerance PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 6 6 Precharge Component Section Testing the Precharge 1 Bridge Using the Power Struc
61. ams B 18 A069 009 pue 6 12945 enso 2u3 1241 01 SWEJJ 81 8 nd 4 tl NL 48 8 IX 3 a o 3 4 4 pi 3 4 HOQAWZ a 4 i N v 1L 4 11 vea IX 90 t PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 19 Schematic Diagrams A069 009 pue A08t 00t 01 19945 eunsojou3 1241 U 01 SWEJJ 618 9M I4 d 9l s NE NI 48 6 08 TI x U 6 899X t 6EX zn tl z 3 3 a 2115 10 ey ID 95 VT 6EX 1 25 D 9 o 11 8 ol 996 964 96 42 9 96 LO 97 SX b be 99 9 8c9 4410 7 SX Tl t z m l i gi aug 5 82 LX 8 18 8 d eov 3 m Le 9 5 VEL IL 11 V8 6 IX V dIHL30VLIOAH3ONA i3s3u Suaxvaua Linoulo Linv4 g99N 8 S v PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Schematic Diagrams B 20 A069 009 pue 08 00 LL 12945 eunsopou3 1241 U 0 02 8 4
62. ansformer T4 and 24V DC Power Supply T10 1 If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 ATTENTION These tests must be performed by qualified A personnel During these tests the AFE is powered Take proper precautions to avoid injurv from electrical shock 2 Locate the control transformer 4 and 24V DC power supply T10 The control transformer T4 is located on the left side of the input circuit breaker QO The 24V DC power supplv T10 is located in the bottom of the control box FRONT VIEW shown with enclosure doors removed Control Transformer 4 Control Box located on front of enclosure door shown with control box cover removed 24V DC Power Supplv T10 Seeeeou 3 Use a digital voltmeter to test the control transformer T4 a Measure the primary AC line voltage which is at the 400 480V AC or 600 690V AC system voltage PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 6 4 Precharge Component Section b Measure the control transformer T4 output voltage which is approximately 120V AC If these measurements are not within 4109 perform these other steps c Power down the AFE d Remove the output secondary wires e Power up the AFE and retest by repeating steps a and b The control transformer T4 ma
63. arger system capacitance as this may change the value of the precharge resistance See the PowerFlex Active Front End User Manual publication 20Y UMOO0I for total DC bus capacitance limits for the precharging circuit PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 6 8 Precharge Component Section Replacing the Precharge Resistor Assembly PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P AFE in IP20 2500 MCC Style Enclosure 1 Remove power from the See Removing Power from the AFE on page 4 3 Open the LCL Filter enclosure door If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 Disconnect the R6 1 and R6 2 precharge resistor wires from the resistor terminals on the precharge resistor assembly Remove the two precharge resistor assembly mounting screws that secure the assembly to the bracket on the LCL enclosure bay Remove the mounting screws from the failed precharge resistor and appropriately discard the resistor Install the new precharge resistor in reverse order of removal while referring to Torque Specifications on page 4 2 AFE in IP21 Rittal Enclosure 1 Remove power from the See Removing Power from the AFE on page 4 3 Open the LCL Filter enclosure door If present remove the protective barriers See Removing AFE Protective Barriers on pa
64. art up and programming information This information is available in the PowerFlex Active Front End User Manual publication 20Y UMO001 Additional Resources You can view or download publications at http www rockwellautomation com literature To order paper copies of technical documentation contact your local Rockwell Automation distributor or sales representative PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 2 Overview Understanding Manual Conventions General Information The following publications provide general drive information Title Publication Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives DRIVES IN001 Safety Guidelines for the Application Installation and Maintenance of Solid State Control SGl 1 1 A Global Reference Guide for Reading Schematic Diagrams 100 2 10 Guarding Against Electrostatic Damage 8000 4 5 2 PowerFlex Active Front End Information The following publications provide specific AFE information Title Publication PowerFlex Active Front End User Manual 20V UMO01 PowerFlex 700H 700S 700AFE Drive Fan Systems Installation Instructions PFLEX INO29 Drives in Common Bus Configurations Application Guidelines DRIVES AT002 For spare parts information on PowerFlex 7 Class Architecture Class Low Voltage AC Drives including the PowerFlex Active Front End go online at http www ab com support abdr
65. assembly is 4 Nem 35 Ibein Bus bar Remove all screws holding bus Insulator am um bars and insulators to AFE frame Bus bar Metal plate SS SENE a Remove Insulator TA LU Bus bar Metal plate EN usseunsssumasezsosn Remove Insulator screws 690V AFE Power Structure shown PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 4 26 AFE Power Structure Component Section 24 Remove the x 8 screws that secure the Power Module to the power structure 25 Remove the Power Module Remove screws Remove screws Installing the Power Module on the Power Structure Install the Power module in reverse order of removal while referring to Torque Specifications on page 4 2 Removing the Power Structure DC Bus Capacitors 1 See Removing the Power Module from the Power Structure on page 4 20 and perform steps 1 through 21 Do not perform steps 24 and 25 removal of the Power Module is not necessary to replace the DC bus capacitors 2 Note the polarity of the capacitors 3 Remove the four 4 x 8 screws that secure the capacitor to the power structure Remove screws Remove screws PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P AFE Power Structure Component Section 4 27 4 Remove the capacitor Tightening torque for reassembly is 1 35 Nem 12 Ibein We recommend replacing a
66. blication 20Y TG001B EN P Rockwell Automation Support Rockwell Automation provides technical information 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 fu
67. bus bar DC bus bars between AFE Power Structure U1 and DC fuses AC bus bars between Input Disconnect 00 and Motor Controlled Circuit Breaker Q1 AC Input bus bars Active Front End System Overview 2 7 AFE in 00 Open Chassis The following figure shows a basic one line diagram for an AFE system in a Configuration IP00 NEMA UL Open Chassis configuration and the parts the customer must supply Figure 2 7 Basic One line Diagram for AFE in IP00 Open Chassis Configuration arm X o pages ENS TM 277777222 11 aa ACLineSwitchgear i LCL Filter L1 iE AFE w g Power Structure U1 Fuses Breaker Contactor NN 3 Phase 00 Fuses Fg ACInput 11 13 Lg 2 yl ul 1 u I o U x V2 TX 12 j i sm E M T W AAA Wi V x DG o l e DCB B 1 SEIL JEJE m NANNAN i l oW 2 5 DC oH E Output di T L L Customer Q C5 PE L supplied MEC 13 Parts G 6 E T iii EE Customer p supplied RR Me Parts
68. e 53 tE 1 le 0 og 4 4 st t 9t st st vc vc 24 u u A Iz oz 6L 8L aL a 91 91 2 vL 622 4 NOQvZ 406 N tl fl fl E B 1 622 0 70716 3d u LL aw 60 60 90 90 10 0 90 Y E 90 98 01 1L 118 x 4 1 99 8 vo 0 0 0 AlddNS 43MOd vZ zw zw 10 10 4 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Schematic Diagrams B 10 A069 009 01 19945 ensopou3 45 DOW 0052 U 01 4 08 12 6 15 9 43 le oE 6 14 9c vc 4 4 oc 6L 8L a 9L SL tl fl 0L 10 50 0 10 6287 4 z vn L8 9 9 9 L89 lt I8 9 z CC8 9 lt 5 5 zz 920 4 iz st SEV LI NET 6ZQ 1 gt 5 hee ex es 01201 923 10 gt 64 117 015 L a 0 18 8z OLX NI v 9 6 MLIT 1518 4 1 s9 6 4 or 6 8t LE 9t St vt 43 0 67 8z 44 92 52 ve tt oz 6L 8L at 9L tl L 0L 60 80 10 90 50 v0 0 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P
69. e Record any other important marks and damage e Note grounding type solid high resistance or floating and source impedance of the power distribution system Addressing PowerFlex No Name Description Action if appropriate Active Front End Faults 1 PrechargeActv The AFE is still in precharge Reset the fault and restart because the charging switch K20 K6 and Kt for AFE in IP20 2 ocur contact 2500 MCC Style enclosure or K20 K6 and Q1 for AFE in IP21 Rittal enclosure is open e faulty operation e component failure 2 Auxiliary In The AFE control digital input Verify wiring to the digital inputs on interlock is open the AFE control board are correct 4 DC UnderVolt The DC bus voltage fell below Monitor the incoming AC line for low the minimum value of 333V for voltage or power interruption 400 480V units or 461V for 600 690V units You can enable disable this fault with parameter 120 Fault Config PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Troubleshooting and Error Codes 1 3 Action if appropriate 10 12 13 14 DC OverVolt Overload HeatsinkOvrTp IGBT OverTemp System Fault AC OverCurr Ground Fault Power Structure Fault Description the maximum value of 911V for 400 480V units or 1200V for 600 690V units When input current exceeds 125 for 60 seconds or 150 for 30 seconds The o
70. e checksum calculated The checksum read from the EEPROM does not match the checksum calculated from the EEPROM data Action if appropriate 1 Cycle the power 2 Replace the Control board See page 4 5 1 Cancel prevention of startup if this can be done safely 2 Remove Run Request Clear the fault 1 Check the power structure for damaged components Replace if defective 2 Replace the power structure Check the DPI device event queue and corresponding fault information for the device 1 Check the HIM connection 2 adapter was not intentionally disconnected check the wiring to the port Replace the wiring port expander adapters Control board or complete AFE as required 3 If an adapter was intentionally disconnected and the Logic Mask bit for that adapter is set to 47 this fault will occur To disable this fault set the bit in parameter 154 Logic Mask to 0 for the port in which the adapter is connected 1 Check the control wiring 2 Check the position of the J5 hardware enable jumper 3 Check the digital input programming 1 Restore the AFE to the factory defaults 2 Cycle the power 3 Replace the Control board in the power structure See page 4 5 1 Cycle the power 2 Check the fiber optics between the Fiber Optic Adapter board and the ASIC board See page C 1 page C 2 and page C 3 for connections 3 Replace the Fiber Optic Adapter board s
71. e injury or death Wear proper Personal Protective Equipment PPE Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment PPE PPP Allen Bradley Rockwell Software and Rockwell Automation are trademarks of Rockwell Automation Inc Irademarks not belonging to Rockwell Automation are property of their respective companies Summary of Changes The information below summarizes the changes to this manual since its last release June 2011 Added information for Frame 10 AFE in IP20 2500 MCC Style enclosure Throughout manual PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P soc ii Summary of Changes PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Chapter 1 Chapter 2 Chapter 3 Chapter 4 Table of Contents Overview Who Should Use this 12 P 1 Whats in this Manual ded ceu ER eR Re ea eh dE oe EE Ea P 1 Whatis Notanthis Manual eu pe eR i E E E CER Gale P 1 Additional Besoutces coe Ned RR E ae ee d P 1 General Information P 2 PowerFlex Active Front End P 2 Understanding Manual eee 2 TEMS P 2 Cross IR ELCL
72. e on the following devices For AFE in IP20 enclosure input contactor K1 For AFE in IP21 enclosure MCCB Q1 2 Check digital input 4 on the Control board of the power structure Check the parameter settings of parameters 221 226 1 Check the parameter setting 2 Verify the bus voltage to be above the parameter value 3 Troubleshoot the cause of the low voltage condition 1 Check the parameter setting 2 Verify the bus voltage to be below the parameter value 3 Troubleshoot the cause of the high voltage condition Check the parameter setting Check the parameter setting AFE does not Start from Start or Run Inputs wired to the terminal block Cause AFE is faulted Incorrect input wiring See the Control Wiring section in the PowerFlex Active Front End User Manual publication 20Y UM001 for information NOTE Jumper from terminal 17 to 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 the fault Press Stop Cycle the power e Set parameter 121 Fault Clear to 1 e Clear Faults on the HIM Diagnostic menu Wire inputs correctly and or install jumper Program parameters 221 226 Digital Inx Sel for correct inputs Run program
73. ed using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION Hazard of permanent eye damage exists when Important The minimum inside bend radius for fiber optic cable is 25 4 mm 1 in Any bends with a shorter inside radius can permanently damage the fiber optic cable Signal attenuation increases with decreased inside bend radii 7 Disconnect the X13 X14 and X15 cables from sockets of the Gate Driver board and set them aside 8 Remove the five screws that secure the Gate Driver board and support bracket to the power structure ___ Remove screws 7 4875 Remove Gate Driver circuit board support bracket Remove screws 9 Carefully remove the Gate Driver board and the board support bracket PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 4 14 AFE Power Structure Component Section 10 Carefully remove the two plastic screws that secure the Gate Driver board screening plate to the power structure and remove the screening plate 11 Remove the two stand offs that support the Gate Driver board Remove plastic screws Remove screening plate Remove stand offs Installing the Gate Driver Circuit Board Install the Gate Driver circuit board in the reverse order of removal Removing the ASIC Circuit Board 1 Remove power from the AFE
74. ed to install test service or repair this assembly If you are unfamiliar with static control procedures see Guarding Against Electrostatic Damage publication 8000 4 5 2 or any other applicable ESD protection handbook PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 1 2 Troubleshooting and Error Codes Creating Fault Reports Complete fault reports are critical for analysis and repair of modules returned to the factory At a minimum do the following e Using an Allen Bradley drive configuration tool such as Connected Components Workbench software DriveExplorer U software or DriveExecutive software do the following Upload all parameters from the PowerFlex Active Front End Run the Technical Support Wizard Collect the AFE system application data shown in Appendix E e If possible record the contents of the fault queue faults and times of OCcurrence e Make record of the following Any burn marks on the rectifying module DC capacitors inverter bridge charging resistors balancing precharging resistors printed circuit boards bus bars cabling and fiber optic cabling Any liquid and condensation marks on printed circuit boards components and mechanical parts Amount of dust and other additional particles on drive and drive components Any mechanical damage to the drive and drive components Record the size and type of main fuses
75. ee page 4 6 and or the ASIC board see page 4 14 in the power structure 4 Contact Technical Support PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 1 6 Troubleshooting and Error Codes No 106 107 113 120 121 125 126 Name MCB PB Config New IO Option Fatal App Change O Comm Loss LCL OverTemp LCL Fan Stop Description The AFE rating information stored on the power board is incompatible with the Control board A new option board was added to the Control board A Fatal Application error has occurred An option board has been replaced A defective option board or I O board slot The LCL Filter has been overheated or the signal is not connected to input Action if appropriate 1 Reset the fault 2 Cycle the power 3 Replace the Control board on the power structure See page 4 5 4 Contact Technical Support 1 Clear the fault and verify the correct parameters for the new option board 2 Reprogram parameters as necessary 1 Cycle the power 2 Replace the Control board on the power structure See page 4 5 Reset the fault 1 Check the Control board to 1 O option board connection 2 Verify the ground integrity from the Control board to the option board 3 Replace the Control board and or I O board See page 4 5 Check the LCL Filter and signal connection or verify that digi
76. ematic Diagrams Frame 10 Circuit Board Connections 1 B 1 Frame 10 Power Module 2 B 2 Frame 10 Power Structure Main Fan B 3 Control Wiring Diagram for Frame 10 in IP20 2500 MCC Style Enclosure B 4 System Schematics for Frame 10 in IP20 2500 MCC Style Enclosure B 6 Control Wiring Diagram for Frame 10 in IP21 Rittal Enclosure B 13 System Schematics for Frame 10 AFE in IP21 Rittal Enclosure B 14 Connector Descriptions Circuit Board Connections kk peti E ER ele dele ur EFT aU EX E C 1 Hardware Connections uds ete loe t ere RD oh ere RO OR CLARA C 4 Disassembly Assembly Diagrams and Spare Parts AFE Power Structure 1 1 D 2 LCL Filter Assembly used in IP20 and IP21 D 5 Precharge Assembly s s i sce p be ed Rep RR d odere Ere PE RS D 7 AC SCAT ts rentes dte drca dh anatase SA et D 9 AFE Power One line System Application Data Data to Collect eie g E 1 Typical Transformer Winding E 2 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P iv Table of Contents PowerFlex Active Front End Fra
77. erFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 3 8 Component Test Procedures Checking the AFE Power Structure Fan Inverter Fuses PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 1 5 Remove power from the AFE See Removing Power from the AFE on page 4 3 If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 Remove the protective front cover and terminal cover from the power structure See Removing Protective Covers from the Power Structure on page 4 12 A pair of fuses F1 and F2 feed DC Bus power to the fan inverter a Locate these fuses shown below and remove them b Using a multi meter verify that they not open Reinstall the good fuses and replace any open fuse with an equivalent rated fuse Chapter 4 AFE Power Structure Component Section gt gt bo PP ATTENTION To avoid an electric shock hazard verify that all power to the PowerFlex Active Front End has been removed before performing any servicing or repairs ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing Check the DC bus voltage between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements ATTENTION
78. ervice Manual Publication 20Y TG001B EN P AC Line Switchgear Disassembly Assembly Diagrams and Spare Parts D 9 Figure D 9 AC Line Switchgear Components for AFE in IP20 2500 MCC Style Enclosure FRONT VIEW shown with enclosure doors removed e D o0 e amp eeeesseu Fan Blower Kit Input Circuit Breaker DC Bus Fuses Bus Link between Input Circuit Breaker and AC Input Fuses AC Input Fuses Bus Bars between Input Contactor and AC Input Fuses Input Contactor Table 01 AC Line Switchgear Part Numbers for AFE in IP20 2500 MCC Style Enclosure Part Name Part No AC Input Fuses 400 480V SK Y1 MCCF1 F10D 600 690V SK Y1 MCCF1 F10F DC Bus Fuses 400 480V SK Y1 MCCF2 D 600 690V SK Y1 MCCF2 F Input Circuit Breaker 400 480V SK Y1 MCCQ0 F10D 600 690V SK Y1 MCCQ0 F10F Input Contactor 100 D420ED11 Input Circuit Breaker Handle Mechanism SK Y1 HANDLE F10 Bus Link between Input Circuit Breaker and AC Input Fuses SK Y1 BUSCB F10 Bus Bars between Input Contactor and AC Input Fuses SK Y1 BUSCNTCT F10 Fan Blower Kit SK R1 OFAN12 F8 LCL Filter Bay Door Fan Kit two at top of door not shown 20 750 FAN3 F8 Bus Splice Kit not shown optional SK Y1 BUSSPLICE F10 MCC Bus Splice Barrier Kit not shown optional 1 SK Y1 MCCBARRIER The MCC Bus Splice Barrier kit must be used when installing a Bus Splice kit SK Y1 BU
79. f secondary network if connected These indicators operate only when a 20 COMM X communication adapter is installed in the AFE and operating on the connected network Performing Visual Inspections Important Always remove power from the Active Front End before performing visual inspections See Removing Power from the AFE on page 4 3 Inspecting the Cooling Tunnel 1 Remove the main cooling fan from the bottom of the power structure See Removing and Installing the Power Structure Fan System on page 4 17 2 Inspect the tunnel Clean the heatsink and tunnel if necessary Inspecting the Power Structure 1 Remove the protective barriers See Removing AFE Protective Barriers on page 4 10 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Performing Forward and Reverse Biased Diode Tests for Power Structure Component Test Procedures 3 3 2 Remove the protective front cover and terminal cover from the power structure See Removing Protective Covers from the Power Structure on page 4 12 3 Check components for burn marks breakage or foil delamination on circuit boards Check all the boards on the power structure Replace any of these components if they show evidence of burn marks breakage or foil delamination A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across th
80. f the power structure fan is not operating check the fan inverter board located behind the fan For additional information see PowerFlex 700H 700S and 700AFE Drive Fan Systems Installation Instructions publication PFLEX IN029 Correct the cause and manually clear the fault 1 Cycle the power 2 Replace the Control board on the power structure See page 4 5 Contact Technical Support Raise the ambient temperature Clear the fault and verify the correct parameters for the new option board Clear the fault 1 Cycle the power 2 Replace the Control board See page 4 5 EEPROM 54 58 65 70 71 81 94 100 104 Zero Divide Start Prevent 1 0 Removed Power Unit Periph Loss Port DPI Loss Hardware Enbl Param Chksum PwrBrd Chksum Troubleshooting and Error Codes 1 5 Description This event occurred because a mathematical function had a dividend of zero Startup has been prevented An option board has been removed Incorrect output power device operation 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 500 baud An enable signal is missing from the control terminal block only when jumper J5 is removed on the digital I O board The checksum read from the Control board does not match th
81. g to the AFE AC input ground DC bus and I O 1s 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 Whenever possible isolate the AFE from the rest of the DC bus system to enable the AFE to be powered separately Appendix A Service Tools and Equipment Software Tools Connected Components Workbench software DriveExecutive software or DriveExplorer software are tools that can be used for uploading downloading and monitoring system parameters Service Tools The following list contains the basic service tools needed for repair and maintenance measurements Item Description Details 1 Oscilloscope Portable digitizing dual channel scope with isolation 2 Current clamp 1000A ac rms signal output 3 High voltage differential probe P5210 or equivalent 4 Soldering station Soldering de soldering 5 Flash light 6 Multi meter Digital multimeter capable of AC and DC voltage continuity resistance capacitance measurements and forward diode bias tests Fluke Model 87 IIl or equivalent 7 Insulation tester 1000V DC Torque wrench 1 12 Nem Torque wrench 6 50 Nem 10 box wrench 7 mm 8 mm 10 mm 13 mm 17 mm 19 mm 22 mm 11 Socket extension 230 mm 12 Wrench 7 mm 8 mm 10 mm 13 mm 17 mm 19 mm 22 mm
82. ge 4 10 Disconnect the wires from the and terminals on the precharge resistor assembly Verify that the capacitor on the bridge and terminals is still in the circuit Disconnect the white wires from the terminal block by the bridge Remove the mounting screws from the failed precharge resistor and appropriately discard the resistor Install the new precharge resistor in reverse order of removal while referring to Torque Specifications on page 4 2 Chapter LCL Filter Component Section ATTENTION To avoid an electric shock hazard verify that all power to the PowerFlex Active Front End has been removed before performing any servicing or repairs ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing Check the DC bus voltage between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be Zero for all three measurements ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION Hot surfaces can cause severe burns Do not touch the heatsink surface during operation of the PowerFlex Active Front End After disconnecting power allow time for cooling
83. he Fiber Optic Adapter board For AFE in IP20 2500 MCC Style Enclosure PZ2 0 9 Nem 8 Ibein Installing the Fiber Optic Adapter Circuit Board For AFE in IP21 Rittal Enclosure PZ2 0 9 Nem 8 Ibein Install the Fiber Optic Adapter circuit board in reverse order of removal while referring to Torque Specifications on page 4 2 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P AFE Power Structure Component Section 4 9 Removing the Control Frame only for AFE in IP21 Rittal enclosure 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 X50 terminal block 2 Loosenthe T8 Torx head screws which secure the Control Frame to the AFE enclosure 3 Swing the Control Frame out and away from the power structure 4 Liftthe Control Frame from the hinges and remove it Loosen T8 Torx head Screws 4 Replacing the Control Frame Replace the control frame in reverse order of removal while referring to Torque Specifications on page 4 2 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 4 10 Power Structure Component Section Power
84. he control logic that enables or disables the resettable trip mechanism that is integrated into the MCCB The trip mechanism controls the MCCB functionality See the PowerFlex Active Front End User Manual publication 20Y UMO001 for the AC input fusing and MCCB protection recommendations PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Chapter 6 Precharge Component Section PP ATTENTION avoid an electric shock hazard verify that all power to the PowerFlex Active Front End has been removed before performing any servicing or repairs ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing Check the DC bus voltage between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be Zero for all three measurements ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION Hot surfaces can cause severe burns Do not touch the heatsink surface during operation of the PowerFlex Active Front End After disconnecting power allow time for cooling ATTENTION Hazard of permanent eye damage exists when using optical transmissi
85. i MCC Style Enclosure Rittal Enclosure E 77 Door with DPlinterface Mounting screws Mounting screws board and 7 Bi HIM in open osition 0 9 Nem 0 9 Nem 8 Ibein 8 Ibein oo nd 6 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P AFE Power Structure Component Section 4 5 Installing the DPI Interface Assembly Install the DPI interface assembly in the reverse order of removal while referring to Torque Specifications on page 4 2 Removing the Circuit Boards and Control Board 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 For an AFE in a IP20 2500 MCC Style enclosure open the control box and carefully unplug the DPI cable and any I O cables For an AFE in a IP21 Rittal enclosure open the enclosure that contains the control and I O circuit boards and carefully unplug the DPI cable and any I O cables Remove the I O boards from the Control board and enclosure Note the order of the boards and the keys which prevent placement of boards in incorrect slots NOTE Do not remove the enclosure cover from the Control Frame For clarity the enclosure is shown without the cover Keys Unplug the serial connection from X7 of the Control board V4 G 3
86. invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION Hazard of permanent eye damage exists when Important The minimum inside bend radius for fiber optic cable is 25 4 mm 1 in Any bends with a shorter inside radius can permanently damage the fiber optic cable Signal attenuation increases with decreased inside bend radii 8 Disconnect the X9 terminal block and the X15 terminal connectors Note When replacing the existing ASIC board with a new board the X9 and X15 connectors must be transferred and connected to the new board before installation 9 Disconnect the X3 X4 X5 X6 and X10 cables from sockets on the front of the ASIC board and set them aside PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 4 16 AFE Power Structure Component Section 10 Remove the four screws that secure the ASIC assembly to the power structure and remove the ASIC assembly 11 Remove the screw and detach the four plastic standoffs that secure the ASIC board to the ASIC chassis and remove the ASIC board S S Remove screw Remove ASIC circuit board from chassis If the plastic insulator requires replacement do the following a Remove the four screws that secure the board holder to the metal frame and remove the metal frame and insulator Remove screws 1 T i Remove metal frame and insulator b Carefullv remove the four fasteners that
87. ion 20Y TG001B EN P Disassembly Assembly Diagrams and Spare Parts D 3 Figure D 2 AFE Power Structure Assembly Internal Components __ 7 EMC Cover DC Bus Bar Assembly Si Ot Power Bus Bar Electrolytic Capacitors Balancing Resistors Power Module IGBTs DC Bus Bar Terminal Assembly AC Fan Inverter Assembly or DC Fan Power Supply see publication PFLEX INO29 for complete details Main Cooling Fan Assembly see publication PFLEX INO29 for complete details Gate Drive Board Table D B AFE Power Structure Assembly Internal Component Part Numbers Part Name Part No Air Flow Channel n a Balancing Resistors n a DC Bus Bar Assembly n a DC Bus Bar Terminal Assembly n a Electrolytic Capacitors ELKO 3300 uF 420V for 400 480V AFE 20 PP01005 ELKO 5600 420V for 600 690V AFE 20 PP01099 EMC Cover n a Gate Driver Board 400 480V SK Y1 GDB1 F10D 600 690V SK Y1 GDB1 F10E Power Module 400 480V SK Y1 QOUT D460 600 690V SK Y1 QOUT E325 Power Bus Bar n a Screening Plate for Gate Driver Board n a Snubber Capacitor Assembly n a PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 4 Disassembly Assembly Diagrams and Spare Parts the ASIC Board located on the power structure are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact w
88. ion of the PowerFlex Active Front End After disconnecting power allow time for cooling ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION The PowerFlex Active Front End contains electrostatic discharge ESD sensitive parts and assemblies that can be damaged if you do not follow ESD control procedures Static control precautions are required to install test service or repair this assembly If you are unfamiliar with static control procedures see Guarding Against Electrostatic Damage publication 8000 4 5 2 or any other applicable ESD protection handbook PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 3 2 Component Test Procedures Viewing the Status Indicators 1 OOOOO 25 OOOOO 22298 Table AFE Status Indicator Descriptions Item Color State Description o PWR Power Green Steady Illuminates when power is applied to the e PORT 1 Status of DPI port internal communication if present MOD 1 See the Communication Status of communication adapter when installed 8 Adapter User Manual publication 20COMM UMxxx Status of network if connected NET B Status o
89. ith the assembly ATTENTION The sheet metal cover and mounting screws on Figure D 3 AFE Power Structure ASIC Assembly ASIC Assembly Cover ASIC Board ae ASIC Insulator ASIC Assembly Bracket s Table D C AFE Power Structure ASIC Assembly Part Numbers Part Name Part No ASIC Assembly Bracket ASIC Assembly Cover Included in 20 FR10850 ASIC Assembly Insulator ASIC Board 1 400 480V AFE SK H1 ASICBD D460 600 690V AFE SK H1 ASICBD E325 Fiber Optic Cable Set 20 PP09017 The ASIC board is unprogrammed PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Disassembly Assembly Diagrams and Spare Parts D 5 LCL Filter Assembly used FigureD 4 LCL Filter Assembly in IP20 and IP21 enclosures LCL Filter Assembly sek LCL Capacitor 4 Sa Assembly NV LCL High Frequency Capacitor Assembly Table D D LCL Filter Assembly Part Numbers Part Name Part No LCL Filter Assembly 400 480V SK Y1 LCL1 D460 600 690V SK Y1 LCL1 E325 LCL High Frequency 20 uF 400 480V SK Y1 CAPHF2 DF Capacitor Assembly 10 600 690V SK Y1 CAPHF1 DF LCL Capacitor Assembly 120 uF 400 480V SK Y1 CAPLCL1 D425 53 uF 600 690V SK Y1 CAPLCL1 F325 LCL Filter Inverter Fan Fuse SK Y1 F11 F10 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P D 6 Disassembly A
90. ives powerflex70 PF7ReleasedParts pdf Become familiar with the following conventions used in this manual Terms The following words are used throughout the manual to describe an action Word Meaning Can Possible able to do something Cannot Not possible not able to do something May Permitted allowed Must Unavoidable you must do this Shall Required and necessary Should Recommended Should Not Not recommended Cross References Figure 3 1 on page 3 4 is a cross reference to Figure 3 1 on page 4 of Chapter 3 Figure 1 on page C 3 is a cross reference to Figure C 1 on page 3 of Appendix C PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Overview P 3 Additional Support Additional troubleshooting information and software tools are available on Available on Internet the Allen Bradley Drives Technical Support website at http ww w ab com support abdrives General Precautions for Class 1 LED Product using optical transmission equipment This product emits intense light and invisible radiation Do not look into module ports or fiber optic cable connectors ATTENTION Hazard of permanent eye damage exists when ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone come
91. jjejjej fei ej el 9 je iei e le je Table ASIC Board AFE Power Structure Fan Inverter Board Connections AFE Power Structure Fan Inverter Board ASIC Board Connector Pin Signal Description Pin Connector X11 From 2 ASIC_ 15V To 2 X8 From 3 FAN CONTROL To To 4 FAN ALARM From See Figure C 1 on page C 3 for ASIC board connectors For part number information see the PowerFlex 700H 700S and 700AFE Drive Fan Systems Installation Instructions publication PFLEX INO29 Figure C 3 LCL Filter Fan Inverter Circuit Board Connectors Bl X4 L I N esci LEES _ pi Wo Pre cr 55 3000 o oO a a a 202105 on Table C D LCL Filter Fan Inverter Circuit Board Connections LCL Filter DC Fan LCL FilterDC Inverter Board Fan Assembly 1 1 X3 X3 X8 X51 X4 X53 PowerFlex Active Front End Frame 10 Ha
92. ll capacitors at the same time 5 Repeat steps 3 and 4 for each remaining DC bus capacitor being removed Installing the Power Structure DC Bus Capacitors Install the capacitors in reverse order of removal Make sure to observe the polarity of the capacitors as noted in removal step 2 above Replacing the Existing Power Structure with a New Power Structure When replacing the power structure with a new one it is important to note that the common mode capacitors in the new power structure must be removed Use the following procedure to replace the power structure 1 Remove the old power structure from the enclosure See Removing the Power Structure from the Enclosure on page 4 17 2 Remove the common mode capacitors from the new Frame 10 power structure that is replacing the old power structure For the procedure to remove the common mode capacitors see the PowerFlex Active Front End User Manual publication 20Y UMOOI Refer to Chapter 2 section Disconnecting Common Mode Capacitors and subsection Frame 10 Power Structure These instructions apply to an AFE in IP20 2500 MCC Style enclosure or an AFE in a IP21 Rittal enclosure 3 Install the new replacement power structure See Installing the Power Structure in the Enclosure on page 4 19 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 4 28 Power Structure Component Section Notes PowerFlex Active Front
93. ly Assembly Diagrams and Spare Parts Figure D 8 Precharge Assembly for AFE in IP21 Rittal Enclosure FRONT VIEW shown with enclosure doors removed e Precharge Fuse Precharge Kit o 0566 e Precharge Motor o Protection Relay 5 e Fuse Disconnect Switch 0 E EE ER EE g o 20 e Control Transformer Motor Protection Relav e Control Transformer Circuit Breaker 24V DC Power Supply T10 and Circuit Breaker Control Transformer T4 mounted directly behind Motor Controlled Circuit Breaker MCCB Table D H Precharge Assembly Part Numbers for AFE in IP21 Rittal Enclosure Part Name Part No Precharge Fuse 400 480V SK Y1 F6 D 600 690V SK Y1 F6 F Fuse Disconnect Switch SK Y1 F6DISC DF Precharge Kit 1 SK Y1 PRE1 F10DF Control Transformer T4 750VA 400 480V SK Y1 T4 D 600 690V SK Y1 T4 F Control Transformer Motor Protection Relay SK Y1 Q4 DF Control Transformer Circuit 400 480V SK Y1 F3 D Breaker 4A 600 690V SK Y1 F3 F 24V DC Power Supply T10 SK Y1 T10 DF 24V DC Power Supply Circuit Breaker 2A SK Y1 F10 DF Precharge Motor Protection Relay SK Y1 Q5 F10 0 Kit includes diode bridge V6 contactor K6 two resistors R6 1 and R6 2 and a snubber capacitor C1 PowerFlex Active Front End Frame 10 Hardware S
94. me 10 Hardware Service Manual Publication 20Y TG001B EN P Overview Who Should Use this This manual is intended for qualified service personnel responsible for Manual troubleshooting and repairing the PowerFlex Active Front End AFE You should have previous experience with and basic understanding of electrical terminology procedures required troubleshooting equipment equipment protection procedures and methods and safety precautions See safety related practices contained in Standard for Electrical Safety in the Work Place publication NFPA 70E What is in this Manual This manual contains hardware service information for the Frame 10 PowerFlex Active Front End Verify that you are working on a Frame 10 by checking the data nameplate on the AFE The frame number is printed just above the serial number Data Nameplate on AFE Data Nameplate on AFE IP20 2500 MCC Style Enclosure in IP21 Rittal Enclosure Serial Number 12345678 7 0 460 60 Hz 420 500 630 550 840 630 Frame 10 Serial Number 2622381652 I l I 1 1 1 l l l I 1 1 1 1 hj o l l l 1 1 1 1 What is Not in this Manual This manual does not contain installation st
95. ming may be missing Correct the source of the inhibit PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 1 8 Troubleshooting and Error Codes Instability in the AC Line Input Current and DC Bus Voltage Cause AC line voltage more than 5 above normal Negative reactive Ref on parameter 065 Reactive Ref with a soft high impedance AC line PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 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 Corrective Action Increase parameter 060 DC Volt Ref proportional to the percentage of the AC line voltage above nominal Change parameter 065 Reactive Ref value to zero Verify if the AFE is running on a soft line per the AC line source considerations Chapter 2 Active Front End System Overview This chapter describes AFE system main components and is grouped by those used in a IP20 2500 MCC Style enclosure a IP21 Rittal enclosure and main components for the AFE IPOO open chassis configuration AFE in IP20 2500 MCC Style Main Component Sections
96. mishandled the ability of fiber optic cables to transmit data is greatly diminished ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors Important The minimum inside bend radius for fiber optic cable is 25 4 mm 1 in Any bends with a shorter inside radius can permanently damage the fiber optic cable Signal attenuation increases with decreased inside bend radii PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 2 Connector Descriptions Table C B ASIC Board to Gate Driver Board Connections ASIC Board Gate Driver Board Signal Description X3 X13 4 phase Ribbon Cable Signal Description Pin 1 U Feedback Pin2 U Power OK Pin 3 U 0 Pin 4 U Pin 5 U ITR 9 Pin 6 U DC Pin7 UI Pin 8 U DC I Pin 9 U TEMP Pin 10 U DC T XA X14 V phase Ribbon Cable Signal Description Pin 1 V Feedback Pin2 V Power OK Pin 3 v DTR 1 Pin 4 V 2 Pin 5 VITRO Pin 6 V DC Pin 7 VI Pin 8 V DC I Pin 9 V TEMP Pin 10 V DCT X5 X15 W phase Ribbon Cable Signal Description Pin 1 W Feedback Pin 2 W Power OK Pin 3 W DTR 1 4 W_ETR 2 Pin 5 WTR 3 Pin 6 DC Pin 7 WI Pin 8 W DC Pin 9 W TEMP Pin 10 W DC T H13 WL WL H9 H
97. move power including user supplied control voltages User supplied voltages can exist even when main AC power is not applied to the PowerFlex Active Front End Correct the malfunction before continuing Phone United States 1 262 512 8176 7 AM 6 PM CST Canada 1 440 646 5800 24 hour support Outside United You can access the phone number for your country via the States Canada Internet Go to http www ab com e Click on Support http support rockwellautomation com e Under Contact Customer Support click on Phone Support Internet Go to http www ab com support abdrives E mail gt support drives ra rockwell com Be prepared to provide the following information when you contact Allen Bradley Drives Technical Support e Product Catalog Number e Product Serial Number e Firmware Revision Level PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 9 2 Startup After Repair Before Applying Power to 1 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Open the power structure enclosure door If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 Check for zero volts between DC and DC Perform forward and reverse biased diode tests using a digital multimeter See Performing Forward and Reverse Biased Diode Tests for Power Structure on page 3 3 Confirm that all wirin
98. nctioning and needs to be returned follow these procedures United States Contact your distributor You 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
99. nual Publication 20Y TG001B EN P 4 Schematic Diagrams Control Wiring Diagram for Frame 10 in IP20 2500 MCC Style Enclosure 4 ole ely EE 219141 8 2 1 S i 725 5 5 FORAS 82 4 12 Falga sal a a a 1 z z z no u XD g 8 e z z a2 gj ze 31 49 gj gaj zz g 21 x l u Figure B 5 Control Wiring Diagram for Frame 10 in IP20 2500 MCC Style Enclosure PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 5 Schematic Diagrams viv 11075 st vu 2 10 wa l Uu TWLAOXN i i gt 1 gt 1 7 69 eed E unc uis LI LI O a O Yos 8800
100. on equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION The PowerFlex Active Front End contains electrostatic discharge ESD sensitive parts and assemblies that can be damaged if you do not follow ESD control procedures Static control precautions are required to install test service or repair this assembly If you are unfamiliar with static control procedures see Guarding Against Electrostatic Damage publication 8000 4 5 2 or any other applicable ESD protection handbook PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 6 2 Precharge Component Section Precharging Functions Replacing the Precharge Fuse The precharge circuitry has two main functions e t provides AFE system control power e It provides the precharge circuitry to charge the DC bus The AFE system is available in both 400 480V AC and 600 690V AC system voltage configurations Control logic voltages are as follows e For an AFE in a IP20 2500 MCC Style enclosure it is 120V AC single phase and also 24V DC power e Foran AFE ina IP21 Rittal enclosure it is 220V AC single phase and also 24V DC power The precharge circuitry lets the DC capacitors located in the AFE power structure to be properly charged with in line current limiting resistors to DC bus voltage magnitudes See the PowerFlex Active Front End User Manual
101. or cable locations see Figure 2 3 on page 2 3 injury or damage to the equipment use caution when removing ATTENTION The LCL Filter is heavy To avoid personal the LCL Filter from the enclosure PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 7 8 LCL Filter Component Section Slide the LCL Filter out of the enclosure Note that ramps customer supplied shown below may be required due to enclosure floor mismatch Cp ETUR ur 4 Ma Zy From the IP21 Rittal Enclosure 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 Remove the LCL Filter protective barrier See Removing the LCL Filter Protective Barrier on page 7 2 Remove the X51 and X53 terminal blocks from the LCL fan assembly Remove the X52 terminal block from the LCL Filter assembly upper right side Remove the four T25 Torx self tapping screws that secure the front bracket shown in Figure 7 1 This bracket holds the LCL Filter in the enclosure Disconnect the AC input bus bars L1 L2 L3 between the MCCB and LCL Filter For bus bar locations see Figure 2 6 on page 2 6 Disconnect the output bus bars U V W between the LCL Filter and the AFE power structure For bus bar locations see Figure 2 6 on page 2 6 injury or damage to the equipment use caution when removing ATTEN
102. ose junctions To pass each test the meter must display a voltage near 0 5 V If the test finds a short the meter displays 000 If the test finds an open circuit or reversed polarity the meter displays OL zero load Important The actual voltage readings can vary depending upon your equipment If your readings are not near the indicated values in the following tables verify that the actual voltage measured is consistent for the Power module A reverse biased diode test finds an open circuit and the meter displays OL zero load 4 Forward biased test Reverse biased test on PN junction on PN junction 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 2 Remove the protective barriers See Removing AFE Protective Barriers on page 4 10 3 Disconnect any drives connected to the DC bus from the DC bus or remove the DC bus fuses from the AFE PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 3 4 Component Test Procedures 4 Conduct forward and reverse biased diode tests on the power structure Figure 3 1 Measurement Points for Forward and Reverse Diode Tests B DC Liza B DC Table 3 B Forward Biased Diode Tests on Power Structure Meter Leads Nominal meter reading DC U T1 DC VIT2 DC WIT3 Value should gradually rise to about 0 5V 1
103. oving the Control Frame only for AFE IP21 Rittal enclosure 4 9 Replacing the Control 4 9 Power Structure Access Procedures 4 10 Removing AFE Protective 4 10 Installing the AFE Protective 4 10 Removing the AFE Air Flow 4 11 Installing the AFE Air Flow 4 11 Removing Protective Covers from the Power Structure 4 12 Installing Protective Covers on the Power 5 4 12 Removing the Gate Driver Circuit Board 4 12 Installing the Gate Driver Circuit Board 4 14 Removing the ASIC Circuit Board 4 14 Installing the ASIC Circuit 4 17 Removing and Installing the Power Structure Fan 4 17 Removing the Power Structure from the Enclosure 4 17 Installing the Power Structure in the 4 19 Removing the Power Module from the Power 4 20 Installing the Power Module on the Power Structure
104. power structure must be removed from its mounting chassis 2 Place the power structure on a flat surface for stability 3 Place the power structure on its backside to facilitate power structure removal from its mounting chassis Backside of Remove screws Power Structure M8 x 20 20 Nem 177 Ibein Power Structure Mounting Chassis E ON ds Output cable Remove screws fastening screws M8 x 20 M10 x 20 20 Nem 40 Nem 177 Ibein 354 Ibein 4 Toremove the power structure from its mounting chassis do the following a Remove the four 8 x 20 hexagonal screws b Remove the three 10 x 20 output cable fastening screws Separate the power structure from its mounting chassis PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P AFE Power Structure Component Section 4 21 5 Remove the power structure side panel to access the internal components MILL Side Panel 6 Place the power structure on its heatsink side for easy access to the internal components 7 Remove the Gate Driver Circuit board See Removing the Gate Driver Circuit Board on page 4 12 8 Remove the capacitor leads from the DC input bus bars at the top of the power structure 9 Remove the insulator holding plate from between the bus bar terminals Remove screws PZ2 m sal 4 Nem 85 Ibein T T sy Remove insulator holding plate Remove bus bar terminals Remove
105. publication 20Y UM001 for the minimum and maximum system capacitance requirements The precharge fuse assembly for an AFE in a IP20 enclosure is located in the power structure enclosure For an AFE in a IP21 enclosure the precharge fuse assembly is located in the LCL Filter enclosure 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 2 Open the appropriate enclosure door 3 If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 4 Slide the fuse sleeve out from the fuse holder 5 Remove the fuse from the sleeve and appropriately discard the old fuse 6 Seethe appropriate table below for the recommended new replacement fuse and install the fuse in reverse order of removal Table 6 A 400 480 Volt Precharge Fuse Rating Fuse Holder 1 Enclosure Style Type 1 20 2500 MCC 30 Bussmann DFJ 30 Bussmann CH30J3 IP21 Rittal 32 ABB OFAF000H32 ABB 0540012000 Fuse holder holds a quantity of three fuses PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Precharge Component Section 6 3 Table 6 B 600 690 Volt Precharge Fuse Rating Fuse Holder 1 Enclosure Style Type IP20 2500 MCC 30 Bussmann DFJ 30 Bussmann CH30J3 IP21 Rittal 32 ABB OFAA000GG32 ABB O540D12000 0 Fuse holder holds a quantity of three fuses Testing the Control For AFE in IP20 2500 MCC Style Enclosure Tr
106. r structure are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION Hot surfaces can cause severe burns Do not touch the heatsink surface during operation of the PowerFlex Active Front End After disconnecting power allow time for cooling ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION The PowerFlex Active Front End contains electrostatic discharge ESD sensitive parts and assemblies that can be damaged if you do not follow ESD control procedures Static control precautions are required to install test service or repair this assembly If you are unfamiliar with static control procedures see Guarding Against Electrostatic Damage publication 8000 4 5 2 or any other applicable ESD protection handbook An AFE system in a IP20 2500 MCC Style enclosure or IP21 Rittal enclosure contains protective DC bus fuses Important For PowerFlex AFE systems in the Open Chassis configuration output fuses must be supplied by the user See the PowerFlex Active Front End User Manual publication 20Y UMO01 for the DC bus output fusing recommendations PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 8 2 DC Fuses
107. rdware Service Manual Publication 20Y TG001B EN P Appendix D Disassembly Assembly Diagrams and Spare Parts Diagram Page AFE Power Structure Assembly External Components D 2 AFE Power Structure Assembly Internal Components D 3 AFE Power Structure ASIC Assembly D 4 LCL Filter Assembly D 5 LCL Filter Power Supply Assembly D 6 LCL Filter Fan Assembly D 6 Precharge Assembly for AFE in IP20 2500 MCC Style Enclosure D 7 Precharge Assembly for AFE in 21 Rittal Enclosure D 8 AC Line Switchgear Components for AFE in IP20 2500 MCC Style Enclosure D 9 AC Line Switchgear Components for AFE in IP21 Rittal Enclosure D 10 Diagrams on the following pages illustrate disassembly and assembly of the AFE and its sub systems and are followed by a list of spare part numbers where applicable When ordering spare parts you must provide the serial number of the PowerFlex Active Front End The serial number is located on the data nameplate on the Control Frame just above the bar code Data Nameplate on AFE Data Nameplate on AFE in IP20 2500 MCC Style Enclosure in IP21 Rittal Enclosure CE ri Frame 10 0 460 60 Hz 420 500 630 550 840 630 Frame 10 A complete list of spare parts for the Frame 10 PowerFlex Active Front
108. s into contact with the assembly ATTENTION avoid an electric shock hazard verify that the A voltage on the bus capacitors has discharged completelv before servicing Check the DC bus voltage between the and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements ATTENTION Potentially fatal voltages can result from improper usage of an oscilloscope and other test equipment The oscilloscope chassis can be at a potentially fatal voltage if not properly grounded Use high voltage differential voltage probes for all voltage measurements with the oscilloscope chassis correctly grounded to an earth ground ATTENTION The PowerFlex Active Front End contains electrostatic discharge ESD sensitive parts and assemblies that can be damaged if you do not follow ESD control procedures Static control precautions are required to install test service or repair this unit If you are unfamiliar with static control procedures see Guarding Against Electrostatic Damage publication 8000 4 5 2 or any other applicable ESD protection handbook ATTENTION An incorrectly applied or installed PowerFlex Active Front End can result in component damage or a reduction in product life Wiring or application errors such as undersizing the motor incorrect or inadequate AC supply or excessive ambient temperatures can result in malfunction of the system
109. ssembly Diagrams and Spare Parts Figure D 5 LCL Filter Power Supply Assembly Table D E LCL Filter Power Supply Assembly Part Numbers Part Name LCL Filter Power Supply Part No Universal Kit Discontinued July 2014 2 400 480V 4 SK Y1 DCPS1 D460 SK Y1 DCPS2 F10 0 600 690V SK Y1 DCPS1 F325 LCL Fan Wire Kit 1 This kit can be used for either voltage class 2 These discontinued kits are no longer available but spares inventory is applicable Figure 0 6 LCL Filter Fan Assembly Table D F LCL Filter Fan Assembly Part Number Part Name Main Fan 48V DC PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Part No SK Y1 DCFAN1 SK Y1 HF1 DF Precharge Assembly Precharge Resistors Disassembly Assembly Diagrams and Spare Parts D 7 Figure D 7 Precharge Assembly for in IP20 2500 MCC Style Enclosure FRONT VIEW shown with enclosure doors removed 2 4 e 5 1 5 9
110. tal input 5 is closed See Chapter 7 There are nine total thermal switches connected in series to monitor temperature inside the coil of each filter inductor X52 Thermal Switch 1 Thermal Switch 9 To Digital gt Input 5 X52 is located on the LCL Fllter X52approximate location Frame 10 LCL Filter The LCL fan has been stopped Check the LCL fan See Chapter 7 NOTE This fault occurs only when the user has manually programmed a digital input as option 5 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Common Symptoms and Corrective Actions No Name Description 128 Contact Fdbk missing 133 DiginConflict conflict 138 DCRefLowLim DC Ref Lo Lmt 139 DCRefHighLim Ref Hi Lmt 140 DCBusLoAlarm Lo Alarm 141 DCBusHiAlarm Hi Alarm The input of the acknowledge signal from the main contactor is Digital input functions are in DC voltage reference is less than the limit in parameter 080 DC voltage reference exceeds the limit in parameter 081 DC DC voltage is less than the value set by parameter 078 DC Bus DC voltage exceeds the value set by parameter 079 DC Bus Troubleshooting and Error Codes 1 7 Action if appropriate 1 Check for closur
111. tions from X9 to X15 see Figure B 1 on page B 1 Contact Technical Support If the problem persists replace or repair the power structure Check for an excessive load or other causes of excess current Using a digital voltmeter to check for low impedance to ground verify the bus cables bars between the Disconnect and AC input lines Power structure and LCL Filter For AFE in IP20 enclosure 00 input breaker and K1 input contactor which includes the precharge disconnect LCL Filter and K1 input cont For AFE in IP21 enclosure Q1 MCCB and Q0 disconnect Switch which includes the precharge disconnect LCL Filter and Q1 MCCB Cycle the power Contact Technical Support If the problem persists replace the converter unit PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 1 4 Action if appropriate 21 29 30 31 32 33 34 35 37 44 45 47 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Name LineSync Fail Phase Loss Anlg In Loss MicroWatchdog IGBT Temp Hw Fan Cooling AutoReset Lim CAN Bus Application HeatsinkUndTp Device Change Device Add NvsReadChksum Description One input of the known phase rotation is missing There is zero current in one of the three phases An analog input is configured to fault on a signal loss
112. trol precautions are required to install test service or repair this assembly If you are unfamiliar with static control procedures see Guarding Against Electrostatic Damage publication 8000 4 5 2 or any other applicable ESD protection handbook gt gt PP PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 5 2 AC Line Switchgear Component Section AFE in IP20 2500 MCC Style Enclosure AFE in IP21 Rittal Enclosure For a PowerFlex AFE system in the IP20 2500 MCC Style enclosure the AC line switchgear components are the input circuit breaker 00 AC input fuses F1 1 F1 3 and input contactor K1 The input circuit breaker either connects or disconnects the AFE system to the AC line The input contactor connects the internal AFE system AC line to the AFE power structure through the LCL filter The AFE power structure contains the control logic that opens or closes the input contactor See the PowerFlex Active Front End User Manual publication 20Y UMO001 for the AC input fusing and circuit breaker protection recommendations For a PowerFlex AFE system in the IP21 Rittal enclosure the AC line switchgear components are the input disconnect Q0 and MCCB Q1 The input disconnect either connects or disconnects the AFE system to the AC line The MCCB connects the internal AFE system AC line to the AFE power structure through the LCL filter The AFE power structure contains t
113. ts D 2 internal components D 3 assembly disassembly diagrams D 1 bus bar locations AFE in IP20 2500 MCC Style enclosure 2 3 AFE in IP21 Rittal enclosure 2 6 C checking fan inverter fuses 3 8 fiber optic connections 3 5 circuit board connections C 1 common symptoms and corrective actions 1 7 component test procedures 3 1 connections for circuit boards C 1 fiber optic cable routing C 3 control transformer and 24V DC power supply testing 6 3 control wiring diagram AFE in IP20 2500 MCC Style enclosure 4 AFE in IP21 Rittal enclosure B 13 creating fault reports 1 2 Index D DC fuses overview 8 1 replacement guidelines 8 2 de energizing the AFE 4 3 diagnostic status indicators 3 2 diode test forward biased 3 3 reverse biased 3 3 disassembly assembly diagrams D 1 E external components of AFE power structure D 2 F fan inverter fuse checking 3 8 faults creating reports 1 2 list 1 2 fiber optic cable routing connections C 3 connection checking 3 5 forward biased diode test 3 3 G gate driver board resistance measurements 3 7 general precautions P 3 H hardware connections C 4 hardware faults 1 2 input disconnect AFE in IP20 2500 MCC Style enclosure 5 2 AFE in IP21 Rittal enclosure 5 2 inspecting cooling tunnel 3 2 power structure 3 2 internal components of AFE power structure D 3 PowerFlex Active Front End Frame 10 Hardware Service Manu
114. ts Power Module DC bus capacitors balancing resistors and so forth needs to be replaced 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 2 If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 3 Remove the Air Flow Plate See Removing the AFE Air Flow Plate on page 4 11 4 Remove the DC and DC wires from the Fan Inverter Fuse assembly PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 4 18 Power Structure Component Section 5 Remove the connections from the DC bus terminals at the top of the power structure DC Bus Terminals ON U T1 V T2 and W T3 Connections Ground Connection PE 6 Remove the U T1 V T2 and W T3 connections from the power structure at the bottom front of the power structure 7 Remove the ground connection from the rear of the power structure 8 Disconnect the seven fiber optic cables connected to the fiber optic adapter board located behind the control assembly for AFE in IP20 2500 MCC Style enclosure or the Control Frame for AFE in IP21 Rittal enclosure For location of connections see Removing the Fiber Optic Adapter Circuit Board on page 4 6 9 Remove the protective front cover and terminal cover from the power structure to access the X3 fan connector See Removing Protective Covers from the Power Structure on page 4
115. ture Terminals Replacing the Precharge 1 Bridge PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P Remove power from the AFE See Removing Power from the AFE on page 4 3 If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 To test the precharge bridge measure the points on the power structure listed in the table below Table 6 C Precharge Bridge Tests on Power Structure Meter Leads Nominal Meter Reading Test Point Locations DC L1 DC L2 DC 13 Value should gradually rise to about 0 48V 1 L1 DC L2 DC DC l n L1 DC T L3 L2 DC La BO depay eter should display charging voltage DC L1 ny DC L2 DC 13 0 The actual voltage reading can vary depending upon your equipment If your readings are not near 0 48V verify that the actual voltage measured is consistent for the power structure Remove power from the AFE See Removing Power from the AFE on page 4 3 Open the power structure enclosure door If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 Remove the protective front cover and terminal cover from the power structure See Removing Protective Covers from the Power Structure on page 4 12 Remove the four POZIDRIVE screws that secure the bridge protecti
116. ublication 20Y TG001B EN P 2 2 Active Front End System Overview Main Component Locations The following figure shows the main components of the AFE Frame 10 system in a IP20 2500 MCC Style enclosure Figure 2 2 AFE Frame 10 Main Component Locations in IP20 2500 MCC Style FRONT VIEW Enclosure shown with enclosure doors closed Item Description FRONT VIEW shown with enclosure doors removed O U D q 5 4 gt B f 3g ol oso ellejje 29595 i i ir 7 E oo D joo Pa Ho Vu 1 l Precharge Circuit and Precharge Resistor R6 1
117. ucture 4 Remove the covers NOTE You need to remove only the terminal cover to gain access to the cooling fan connections P dd Front Cover E d Terminal Cover Installing Protective Covers on the Power Structure Install the protective covers on the power structure in reverse order of removal while referring to Torque Specifications on page 4 2 Removing the Gate Driver Circuit Board There is one Gate Driver circuit board on the front of the power structure 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 2 If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P AFE Power Structure Component Section 4 13 3 Remove the Air Flow Plate See Removing the AFE Air Flow Plate on page 4 11 4 Remove the protective front cover and terminal cover from the power structure See Removing Protective Covers from the Power Structure on page 4 12 5 Unscrew the terminals for the DC supply from X1 of the Gate Driver board Observe polarity when removing for later re attachment 6 Carefully unplug the fiber optic cables from sockets along the bottom of the Gate Driver board and carefully set them aside Important When mishandled the ability of fiber optic cables to transmit data is greatly diminish
118. umed by Rockwell Automation Inc with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequence 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 sever
119. ure Component Section Understanding Torque Icons and numbers in the assembly diagrams indicate how to tighten Figures in Assembly hardware ool Type and Size Diagrams Fastener Type PZ indicates POZIDRIV screwdriver bit POZIDRIV P indicates Phillips screwdriver bit Screw Phillips Screw Hexagonal Bolt or Standoff 22 gt 4Nem oe 35 Ibein Tightening Torque crew Hexagonal Nut Torx Head Screw Torque Specifications The following table lists fastener torque specifications for the circuit boards and main components of the Active Front End Item Hardware Final Torque AC Input Terminals M10 nut 40 Nem 354 Ibein ASIC Circuit Board Mounting M4 x 8 POZIDRIV screws 0 9 Nem 8 Ibein ASIC Circuit Board Cover M4 x 8 POZIDRIV screws 0 9 Nem 8 Ibein ASIC Fan M4 x 16 POZIDRIV screws 0 4 Nem 3 5 Ibein Capacitor 4 x 8 self tapping screws 1 Nem 9 Ibein DC DC Terminals M6 x 20 POZIDRIV screws 5 Nem 44 Ibein DC Connective Bus Bars M10 x 20 hexagonal screws M8 x 25 hexagonal socket head screws 8 Nem 71 M6 x 12 POZIDRIV screws 8 Nem 71 Ibein 4 Nem 35 DPI HIM Assembly Door M3 x 6 Phillips screws 0 9 Nem 8 Ibein DPI HIM Assembly Mounting M3 x 6 Phillips screws 0 9 Nem 8 Ibein Fan Inverter Assembly M5 x 10 POZIDRIV screws 4 Nem 35 Ibein
120. ve cover Remove the bridge protective cover Prior to removal note the locations of the DC DC L1 L2 and L3 wires and then disconnect these wires Testing the Precharge Resistor 10 Precharge Component Section 6 7 Remove the precharge bridge mounting nuts Remove and appropriately discard the old precharge bridge Install the new precharge bridge in reverse order of removal while referring to Torque Specifications on page 4 2 Remove power from the AFE See Removing Power from the AFE on page 4 3 Open the LCL Filter enclosure door If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 Measure the resistance between the following two points with an ohmmeter Between the side of the precharge resistor R6 1 and the terminal on the TB of the precharge circuit Between the side of the precharge resistor R6 2 and the terminal on the TB of the precharge circuit The precharge resistance is approximately 12 5 ohms for each measurement for an AFE in a IP20 2500 MCC Style enclosure or 20 ohms for each measurement for an AFE in a IP21 Rittal enclosure If the measured value is not correct disconnect a resistor wire and re measure again If the measured value is still not correct replace the precharge resistor Important Verify that the precharge resistor has not been engineered to a different value by the system engineer to accommodate a l
121. ve Front End Frame 10 Hardware Service Manual Schematic Diagrams B 12 pue jexyeejg jeuruue Z 12945 enso ou3 5 DOW 0052 0241 01 LE 9t SE ve amp 43 LE 0 6c 8c Lu 9c st 74 44 oc 6L 8L l 9L tl fl oL 60 80 40 90 50 0 Lo L v9 v9 amp 4 09 VOOLL a t VO 9 V008 H asn4 1 wor 009 00 19919 311010 A069 009 08 00 SONILVY 3503 ONY 8377388 juauodwio NOLD3NNO2 IVNEJLNI NOLDANNO TV NH2LNI sjiejaq aug 1000 g 04 NOLD3NNO2 TVNHLNI andul A069 009 10 A08b 00p 104 NOILDINNOD TVNH31N 21 9 2 09 2 e 009 7 e 0 47 4 or 99 59 4 9 JUAU 5 Ei indujajqeuq jeuondo Jasay ues owy dos ajoway G A s Fis 5 3gSZ ae 558 155 5 2 5 104 JENUEJA Jas 995 uorpauuo paljddns sasp 0 5 Buuaquiny pue uon auuo eura ex 100AV159 2018 SSS SSS SSS SS SS SS SS Se SS SEES SSS SISISISIS AIR IS NOILDINNOD TVNH31N sjiejaq pue 1
122. verload is linear type in counting up The power structure heatsink temperature has exceeded the maximum allowable value 85 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 A current path to earth ground exists that is greater than the parameter 082 Ground I Lvl value The current must appear for 800 milliseconds before the unit will fault A hardware problem exists in the power structure The DC bus voltage exceeded 1 Check if the AFE was in a regenerative current limit condition which may indicate an excess regenerative load Adjust parameter 076 Regen Power Lmt 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 Verifv that the maximum ambient temperature has not been exceeded Check the fans including ASIC board on the power structure 3 Check for an excess load Verify that the airflow plate is installed See page 4 11 Verify that the maximum ambient temperature has not been exceeded Check the fan s Check for an excess load Reset the fault and restart Verify the fiber optic connections Verify ASIC Board jumper connec
123. y DC Bus X51 4 pin Pin 1 16 5 Pin 3 fan control Pin 5 fan alarm on AFE Power Structure Figure 7 3 LCL Filter Fan DC Power Supply Wiring Diagram newer version LCL Filter xi KLIXON X81 X2 Fan DC Power sd xe EE ries Rees ied X52 4 pin AFE Power Structure Pin 1 KLIXON Pin 4 KLIXON Fuse X53 3 pin DC Bus Pin DC supply Pin DC supply X51 4 pin on AFE Power Structure Pin 4 16 5V Pin 1 Pin 3 fan control Pin 2 Pin 2 DC Pin 3 Pin 1 fan alarm L Flying Lead to DC Bus Important Before doing any work disconnect the AFE power structure from the AC supply and wait until the fan stops and the indicators on the keypad turn off If a keypad is not attached see the indicator through the keypad base Wait 5 more minutes before doing any work on the DC to DC power supply to let it completely discharge Furthermore do not open the cover until after this time has expired X51 X53 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P 7 4 LCL Filter Component Section 1 Remove the LCL Filter protective barrier See Removing the LCL Filter Protective Barrier on page 7 2 2 Remove the two x 10 mm POZIDRIVE screws that secure the cover 3 Remove the cover
124. y require replacement if these measurements continue to be outside of the 10 tolerance Use a digital voltmeter to test the 24V DC power supply T10 a Measure the primary voltage which is 120V AC b Measure the power supply T10 output voltage which is approximately 24V DC If these measurements are not within 4109 perform these other steps c Power down the AFE d Remove the 24V DC output wires of the power supply T10 e Power up the AFE and retest by repeating steps a and b The 24V DC power supply T10 may require replacement if these measurements continue to be outside of the 10 tolerance For AFE in IP21 Rittal Enclosure 1 If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 ATTENTION These tests must be performed by qualified 2 PowerFlex Active Front End Frame 10 Hardware Service Manual Publication 20Y TG001B EN P personnel During these tests the AFE is powered Take proper precautions to avoid injury from electrical shock Locate the control transformer T4 and 24V DC power supply T10 The control transformer T4 1s located behind the Control Frame The 24V DC power supply T10 is located on a sub panel in front of the components shown in the front view Precharge Component Section 6 5 FRONT VIEW shown with enclosure doors removed o 24V DC Power Supply T10 behind Control Fr

PowerFlex 700AFE Frame 10 Hardware Service Manual

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