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Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017

Chapter

Active Front End System Overview

This chapter describes AFE system main components. The chapter groups

components that are used in an IP20 2500 MCC Style enclosure, an

IP21Rittal enclosure, and main components for the AFE IP00 open chassis

configuration.

AFE in IP20 2500 MCC Style

Enclosure

Main Component Sections

Figure 1

shows a one-line diagram for an AFE system in an IP20 2500 MCC

Style enclosure. The main component sections consist of the following items:

• AC line switchgear consisting of the input circuit breaker (Q0), fuses

(F1.1…F1.3), and input contactor (K1)

• LCL filter (L1)
• Precharge circuit
• AFE power structure (U1) with AFE control assembly
• DC fuses (F2.1 and F2.2)

Figure 1 - Basic One-line Diagram for an AFE Frame 10 in IP20 2500 MCC Style Enclosure

DC Bus

Output

3 Phase

AC Input

L2
L3

PowerFlex

Active Front End System

Precharge

Circuit

R6.1

R6.2

AC Line Switchgear

LCL Filter (L1)

AFE

Power Structure (U1)

Fuses

U2
V2

V1
W1

DC+

DC-

F2.1

F2.2

Input

Contactor

Fuses

F1.1-F1.3

Input

Breaker

Precharge

Contactor

Precharge

Fuses

Factory-installed Common

Mode Core

Summary of Contents for 20Y

Page 1: ...PowerFlex Active Front End Frame 10 Catalog Number 20Y PowerFlex AFE PowerFlex 700AFE 400V 480V and 600V 690V Hardware Service Manual OriginalInstructions...

Page 2: ...nformation 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 T...

Page 3: ...in Bus Bar Cable Locations 21 AFE in IP21 Rittal Enclosure 22 Main Component Sections 22 Main Component Locations 23 Bus Bar Locations 24 AFE in IP00 Open Chassis Configuration 25 Chapter3 Component T...

Page 4: ...and Install the Power Structure Fan System 52 Remove the Power Structure from the Enclosure 52 Install the Power Structure in the Enclosure 55 Remove the Power Module from the Power Structure 55 Inst...

Page 5: ...ical Support 87 Before You Apply Power to the AFE 88 AppendixA Service Tools and Equipment Software Tools 89 Service Tools 89 AppendixB Schematic Diagrams Frame 10 Circuit Board Connections 91 Frame 1...

Page 6: ...6 Rockwell Automation Publication 20Y TG001C EN P April 2017 Table of Contents AppendixE AFE Power One line System Application Data Data to Collect 129 Typical Transformer Winding Types 130 Index 131...

Page 7: ...led common mode core at the DC bus output Figure 1 on page 19 Updated the system schematics for a Frame 10 AFE in IP20 2500 MCC style enclosure to include the factory installed commonmode core at the...

Page 8: ...tallationInstructions publication PFLEX IN029 Provides information fordrive fan system service and installation Drives in Common Bus Configurations Application Guidelines publication DRIVES AT002 Prov...

Page 9: ...t equipment The oscilloscope chassis can be at a potentiallyfatalvoltageifnotproperlygrounded Usehighvoltagedifferential voltageprobesforallvoltagemeasurementswiththeoscilloscopechassisthat is correct...

Page 10: ...10 Rockwell Automation Publication 20Y TG001C EN P April 2017 Preface Notes...

Page 11: ...ween 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 PowerFl...

Page 12: ...rds 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...

Page 13: ...xists in the power structure Reset the fault and restart Verify the fiber optic connections Verify ASIC board jumper connections from X9 to X15 see Figure 13 on page 91 Contact technical support If th...

Page 14: ...Config Correctthecauseandmanuallyclearthe fault 34 CAN Bus Flt A sent message was not acknowledged Cycle the power Replace the control board on the power structure See page 39 35 Application Problem i...

Page 15: ...rBrd Chksum The checksum read from the EEPROM does not match the checksum that is calculated from the EEPROM data Cycle the power Checkthe fiber opticsbetweenthefiber optic adapter board and the ASIC...

Page 16: ...closure MCCB Q1 Check digital input 4 on the control board of the power structure 133 DigInConflict Digital input functions are in conflict Check the parameter settings of parameters 221 226 138 DCRef...

Page 17: ...4V DC internal supply None Wire inputs correctly and or install jumper Incorrect digital input programming None Program parameters 221 226 Digital Inx Sel for correct inputs Run programming can be mis...

Page 18: ...18 Rockwell Automation Publication 20Y TG001C EN P April 2017 Chapter 1 Troubleshooting and Error Codes Notes...

Page 19: ...ections consist of the following items AC line switchgear consisting of the input circuit breaker Q0 fuses F1 1 F1 3 and input contactor K1 LCL filter L1 Precharge circuit AFE power structure U1 with...

Page 20: ...tions in IP20 2500 MCC Style Enclosure 1 1 2 8 3 5 6 4 7 Front View shown with enclosure doors removed Front View shown with enclosure doors closed Item Description 1 Precharge circuit and precharge r...

Page 21: ...he AFE power structure U1 and DC bus Figure 3 shows the bus bar and cable locations Figure 3 AFE Frame 10 Bus Bar and Cable Locations in IP20 2500 MCC Style Enclosure DC bus bar DC bus bar DC bus bars...

Page 22: ...nput disconnect Q0 and MCCB motor controlled circuit breaker Q1 LCL filter L1 Precharge circuit AFE power structure U1 with AFE control assembly DC fuses F2 1 and F2 2 Figure 4 Basic One line Diagram...

Page 23: ...e Figure 5 AFE Frame 10 Main Component Locations in IP21 Rittal Enclosure 1 2 3 7 4 5 6 Front View shown with enclosuredoors removed Item Description 1 Precharge circuit and precharge resistors R6 1 a...

Page 24: ...L1 and AFE power structure U1 Bus bars between the AFE power structure U1 and DC bus bars Figure 6 shows the bus bar locations Figure 6 AFE Frame 10 Bus Bar Locations in IP21 Rittal Enclosure DC bus...

Page 25: ...Basic One line Diagram for AFE in IP00 Open Chassis Configuration Customer supplied Parts Customer supplied Parts Customer supplied Parts Customer supplied enclosure DC Bus Output L1 3 Phase AC Input...

Page 26: ...26 Rockwell Automation Publication 20Y TG001C EN P April 2017 Chapter 2 Active Front End System Overview Notes...

Page 27: ...sis 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...

Page 28: ...e heatsink and tunnel if necessary Item Name Color State Description 1 PWR power Green Steady Illuminates when power is applied to the AFE 2 PORT 1 1 These indicators operate only when a 20 COMM X com...

Page 29: ...orward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each test the meter must display a voltage near 0 5V If t...

Page 30: ...and reverse biased diode tests on the power structure Figure 8 Measurement Points for Forward and Reverse Diode Tests Table 2 Forward Biased Diode Tests on Power Structure Meter Leads Nominal Meter Re...

Page 31: ...g procedures that are described in this manual Check Fiber optic Connections Damaged or improperly connected fiber optic cables can cause apparent gate driver board malfunctions For fiber optic cable...

Page 32: ...apter circuit board 7 Disconnect the cables and inspect them for scratches and cracks and overall integrity 8 Reconnect the cables replacing any damaged cables Gate Driver Board ASIC Board IMPORTANT T...

Page 33: ...r The resistance from each ignition pin to the branch emitter pin connectors X28 and X29 is approximately 166 The resistance from the X28 branch emitter pin to the same branch output power terminal U...

Page 34: ...37 2 If present remove the protective barriers See Remove AFE Protective Barriers on page 44 3 Remove the protective front cover and terminal cover from the power structure See Remove Protective Cove...

Page 35: ...ENTION The sheet metal cover and mounting screws on the ASIC Board that is on the power structure are energized at DC bus potential high voltage Risk ofelectricalshock injury or deathexistsifsomeoneco...

Page 36: ...in DC DC terminals M6 x 20 Pozidriv screws 5 N m 44 lb in DC connective bus bars M10 x 20 hexagonal screws 8 N m 71 lb in M8 x 25 hexagonal socket head screws 8 N m 71 lb in M6 x12 Pozidriv screws 4...

Page 37: ...crews 4 N m 35 lb in Protective covers on power structure Front M5 x 10 Pozidriv screws 3 N m 27 lb in Terminal M5 x 16 Pozidriv screws 3 N m 27 lb in Item Hardware Final Torque ATTENTION To avoid an...

Page 38: ...he DPI hinged assembly 3 For an AFE in an IP20 2500 MCC Style enclosure open the control box door to access the DPI interface board For an AFE in an IP21 Rittal enclosure open the hinged assembly that...

Page 39: ...ox and carefully unplug the DPI cable and any I O cables For an AFE in an IP21 Rittal enclosure open the enclosure that contains the control and I O circuit boards and carefully unplug the DPI cable a...

Page 40: ...reverse order of removal See Torque Specifications on page 36 Remove the Fiber optic Adapter Circuit Board To remove the fiber optic adapter circuit board follow these steps 1 Remove power from the AF...

Page 41: ...e circuit board and carefully set them aside IMPORTANT Note polarity when removing X2 and X3 wires If polarity is not maintained when reinstalling these wires the ASIC board or fiber optic board can b...

Page 42: ...stall the Fiber optic Adapter Circuit Board Install the fiber optic adapter circuit board in reverse order of removal See Torque Specifications on page 36 IMPORTANT The minimum inside bend radius for...

Page 43: ...these steps 1 Remove power from the AFE See Remove Power from the AFE on page 37 2 Loosen the T8 Torx head screws which secure the control frame to the AFE enclosure 3 Swing the control frame out and...

Page 44: ...iers To remove AFE protective barriers follow these steps 1 Remove power from the AFE See Remove Power from the AFE on page 37 2 Remove the screws that secure the protective barriers to the AFE enclos...

Page 45: ...E on page 37 2 If present remove the protective barriers See Remove AFE Protective Barriers on page 44 3 For an AFE in an IP20 2500 MCC Style enclosure remove the four M6 x16 screws that secure the ai...

Page 46: ...ers See Remove AFE Protective Barriers on page 44 3 Remove the four M5 Pozidriv screws that secure the protective front cover and terminal cover to the power structure 4 Remove the covers Install Prot...

Page 47: ...ing for later reattachment 6 Carefully unplug the fiber optic cables from sockets along the bottom of the gate driver board and carefully set them aside 7 Disconnect the X13 X14 and X15 cables from so...

Page 48: ...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 Install the Gate Driver Circuit Board Install the ga...

Page 49: ...the ASIC cover to the ASIC assembly remove the DC bus connection from the ASIC cover and remove the ASIC cover 6 Unplug the fan which mounts on the cover from connector X11 of the ASIC circuit board 7...

Page 50: ...d 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 I...

Page 51: ...he insulator Install the ASIC Circuit Board Install the ASIC circuit board in reverse order of removal See Torque Specifications on page 36 Reconnect cables and jumpers to the ASIC board See Figure 13...

Page 52: ...ors AC main cooling fans DC fan power supplies DC main cooling fans Fan fusing Remove the Power Structure from the Enclosure To remove the power structure from the enclosure follow these steps 1 Remov...

Page 53: ...nnect the seven fiber optic cables that are 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...

Page 54: ...re to the enclosure back panel 12 To expose the lifting holes partially pull the power structure forward from the enclosure 13 Secure an appropriate lifting apparatus to the power structure and remove...

Page 55: ...r structure from the AFE enclosure See Remove the Power Structure from the Enclosure on page 52 2 Place the power structure on a flat surface for stability 3 To facilitate power structure removal from...

Page 56: ...access the internal components remove the power structure 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...

Page 57: ...agonal screws that secure the input power cables to the input power bus bar Tightening torque for reassembly is 14 N m 124 lb in 14 Cut and remove the cable ties that secure the input power cables to...

Page 58: ...power structure 18 Remove the power bus bar and insulators Tightening torque for reassembly is 14 N m 124 lb in 19 Disconnect the balancing resistor assembly wires from the DC bus bars Remove Screws...

Page 59: ...ee step 19 picture for screw locations that secure the balancing resistor assemblies to the power structure 21 Remove the balancing resistor assemblies 22 Remove the M6 x 12 screws that secure the con...

Page 60: ...cation Fasteners Torque 1 M10 x 25 hexagonal screws M10 spring washers and M10 washers 8 N m 70 lb in 2 M8 x 25 hexagonal screws M8 spring washers and M8 washers 8 N m 70 lb in 3 M6 x 12 screws 4 N m...

Page 61: ...removal See Torque Specifications on page 36 Remove the Power Structure DC Bus Capacitors 1 See Remove the Power Module from the Power Structure on page 55 and perform step 1 through step 21 Do not p...

Page 62: ...cture from the enclosure See Remove the Power Structure from the Enclosure on page 52 2 Remove the common mode capacitors from the new Frame 10 power structure that is replacing the old power structur...

Page 63: ...al high voltage Risk ofelectricalshock injury or deathexistsifsomeonecomesinto contact with the assembly ATTENTION Hot surfaces can cause severe burns Do not touch the heatsink surface during operatio...

Page 64: ...ntactor See the PowerFlex Active Front End User Manual publication 20Y UM001 for the AC input fusing and circuit breaker protection recommendations AFE in IP21 Rittal Enclosure For a PowerFlex AFE sys...

Page 65: ...voltage Risk ofelectrical shock injury or death exists if someonecomes into contact with the assembly ATTENTION Hot surfaces can cause severe burns Do not touch the heatsink surface during operation o...

Page 66: ...for the minimum and maximum system capacitance requirements Replace the Precharge Fuse The precharge fuse assembly for an AFE in an IP20 enclosure is located in the power structure enclosure For an A...

Page 67: ...ply T10 The control transformer T4 is on the left side of the input circuit breaker Q0 The 24V DC power supply T10 is located in the bottom of the control box Frame Size Enclosure Style Fuse Fuse Hold...

Page 68: ...output voltage which is approximately 24V DC If these measurements are not within 10 perform these steps c Power down the AFE d Remove the 24V DC output wires of the power supply T10 e Power up the A...

Page 69: ...placement if these measurements continue to be outside of the 10 tolerance 4 Use a digital voltmeter to test the 24V DC power supply T10 a Measure the primary voltage which is 230V AC b Measure the po...

Page 70: ...power from the AFE See Remove Power from the AFE on page 37 2 Open the power structure enclosure door 3 If present remove the protective barriers See Remove AFE Protective Barriers on page 44 4 Remove...

Page 71: ...he side of the precharge resistor R6 2 and the terminal on the TB of the precharge circuit The precharge resistance is approximately 12 5 for each measurement for an AFE in an IP20 2500 MCC Style encl...

Page 72: ...removal See Torque Specifications on page 4 36 AFE in IP21 Rittal Enclosure To replace the precharge resistor assembly in an IP221 Rittal enclosure follow these steps 1 Remove power from the AFE See R...

Page 73: ...oltage 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...

Page 74: ...LCL Filter Protective Barrier Install the LCL Filter Protective Barrier Reinstall the protective barrier in reverse order of removal See Torque Specifications on page 36 Replace the LCL Filter DC Fan...

Page 75: ...ersion X3 X3 LCL Filter X8 X53 3 pin Pin DC supply Pin DC supply X4 X51 4 pin Pin 1 16 5V Pin 3 fan control Pin 5 fan alarm Fuse X52 4 pin Pin 1 KLIXON Pin 4 KLIXON X1 Fan KLIXON X1 Fan DC Power Suppl...

Page 76: ...ter 7 LCL Filter Component Section 1 Remove the LCL filter protective barrier See Remove the LCL Filter Protective Barrier on page 74 2 Remove the two M4 x 10 mm Pozidriv screws that secure the cover...

Page 77: ...7 LCL Filter Component Section Chapter 7 5 Remove the six fasteners that secure the DC to DC power supply Install the LCL Filter Fan DC Power Supply Install the DC to DC power supply in reverse order...

Page 78: ...emove the alignment studs from their respective holes in the fan frame sheet metal 5 Slide out the fan assembly 6 Remove the LCL filter fan DC power supply See Remove the LCL Filter Fan DC Power Suppl...

Page 79: ...Barrier on page 74 3 Remove the X51 and X53 terminal blocks from the LCL fan assembly 4 Remove the X52 terminal block from the LCL filter assembly upper right side 5 Remove the lower and upper front...

Page 80: ...out of the enclosure From the IP21 Rittal Enclosure To remove the LCL filter from the IP21 Rittal enclosure follow these steps 1 Remove power from the AFE See Remove Power from the AFE on page 37 2 R...

Page 81: ...r For bus bar locations see Figure 6 on page 24 7 Disconnect the output bus bars U V W between the LCL filter and the AFE power structure For bus bar locations see Figure 6 on page 24 8 Slide the LCL...

Page 82: ...82 Rockwell Automation Publication 20Y TG001C EN P April 2017 Chapter 7 LCL Filter Component Section Notes...

Page 83: ...is on the power structure are energized at DC bus potential high voltage Risk ofelectrical shock injury or death exists if someonecomes into contact with the assembly ATTENTION Hot surfaces can cause...

Page 84: ...bus bars 6 Turn the threaded rod into the fuse body 7 Place the belleville domed washer and hexagonal nut on the threaded rod and hand tighten 8 Hold the threaded rod with the hex key while tightenin...

Page 85: ...ection Chapter 8 For information about Bussman fuses click this link http www cooperindustries com For information about Ferraz Shawmut fuses click this link http www ferrazfuses com IMPORTANT Do not...

Page 86: ...86 Rockwell Automation Publication 20Y TG001C EN P April 2017 Chapter 8 DC Fuses Component Section Notes...

Page 87: ...ctrical 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 performthefollowingstart upprocedure Someofthe...

Page 88: ...DC and DC 4 To perform forward and reverse biased diode tests use a digital multimeter See Perform Forward and Reverse Biased Diode Tests for Power Structure on page 29 5 Confirm that wiring to the AF...

Page 89: ...0V DC 8 Torque wrench 1 12 N m 9 Torque wrench 6 50 N m 10 Box wrench 7 mm 8 mm 10 mm 13 mm 17 mm 19 mm 22 mm 11 Socket extension 230 mm 12 Wrench 7 mm 8 mm 10 mm 13 mm 17 mm 19 mm 22 mm 13 Allen wren...

Page 90: ...90 Rockwell Automation Publication 20Y TG001C EN P April 2017 Appendix A Service Tools and Equipment Notes...

Page 91: ...ll Automation Publication 20Y TG001C EN P April 2017 91 Appendix B Schematic Diagrams Frame 10 Circuit Board Connections This section provides schematic diagrams Figure 13 Frame 10 Circuit Board Conne...

Page 92: ...92 Rockwell Automation Publication 20Y TG001C EN P April 2017 Appendix B Schematic Diagrams Frame 10 Power Module Circuitry Figure 14 Frame 10 Power Module Circuitry...

Page 93: ...Module For more details see the PowerFlex 700S 700H and 700AFE Drive Fan Systems Installation Instructions publication PFLEX IN029 X8 F2 X2 4 FanFrequency Converter Off S1 1 Off S1 2 On S1 3 Off S1 4...

Page 94: ...Publication 20Y TG001C EN P April 2017 Appendix B Schematic Diagrams ControlWiringDiagramfor Frame10inIP202500MCC StyleEnclosure Figure 17 Control Wiring Diagram for Frame 10 in IP20 2500 MCC Style E...

Page 95: ...4 10Vref 5 PotGND 6 22 R1 23 10Vref 7 AOUT1 8 AOUTC 9 AOUT2 10 R2 24 X1 A B C D 25 X2 R3 26 FAULT DIN1 11 DIN2 12 DIN3 13 DIN4 14 X3 X6 A B C D DIN5 15 DIN6 16 D_COM 17 D_COM 18 24V 19 24VCOM 20 A14 A...

Page 96: ...6201 6202 6241 6242 L1 8 A2 L2 8 A2 7 G7 TF 1 TF11 7 G15 X70 Wire Connected to DC secondary side of fan inverter fuses in power structure CAUTION High Voltage DC bus potential CABLE 6251 6250 6252 BU...

Page 97: ...X3 X6 A BC D LCL OVER TEMP DIN5 15 6 C18 TF11 DIN6 16 D_COM 17 D_COM 18 TF 1 6 C16 65 64 X1 K4 E31 12 11 14 24V 19 H3 1 2 1 24VCOM 20 A14 9 A BC D A B A11 20C DA1 A Basic I O SLOT A NXOPTA2 20C D01 S...

Page 98: ...16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40...

Page 99: ...09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 3...

Page 100: ...10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 3...

Page 101: ...17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 4...

Page 102: ...ee User Manual for more details INTERNAL CONNECTION INTERNAL CONNECTION X1 Jumper and Numbering Details X3 External Connection and Numbering Details X1 X3 FAN TB Component Circuit Breaker Fuse F1 Q0 F...

Page 103: ...DIN2 DIN3 DIN4 DIN5 DIN6 D_COM D_COM 24VCOM 20C DA1 4 SLOT A 20C DPI1 SLOT E 20C DO1 SLOT B 24V PE AOUTC AOUT2 X3 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 A13 H3 1 13 14 S11 1 2 H5 L1 N T4 F3 T1...

Page 104: ...j k l 1 2 I I I 3 4 5 12 14 96 98 11 95 1 3 2 4 Q 1 SY 6 1 2 3 4 5 6 L1 L2 L3 1 2 1 2 L1 L2 L3 X52 Older Version Newer Version X53 X51 U V W M 1 2 3 4 1 3 4 PE U V W B B PE 1 2 1 2 3 L1 L2 L3 PE B B...

Page 105: ...Rockwell Automation Publication 20Y TG001C EN P April 2017 105 Schematic Diagrams Appendix B Figure 28 Frame 10 in IP21 Rittal Enclosure Sheet 7 400 480V and 600 690V...

Page 106: ...ndix B Schematic Diagrams 1 2 3 4 5 6 230 02 500 480 460 440 400 01 PE 1 2 6 7B L1 6 7B L2 Q4 T4 F3 1 X1 11 X1 2 12 1L 9 1A 1N 9 1F 400 X3 440 460 480 500 1 2 3 4 5 6 7 8 A B C D E F A B C D E F I I I...

Page 107: ...107 Schematic Diagrams Appendix B PE 1 2 3 4 5 6 230 02 690 600 525 01 1 2 6 7B L1 6 7B L2 1 X1 11 X1 2 12 1L 9 1A 1N 9 1F 525 X3 600 690 Q4 T4 F3 1 2 3 4 5 6 7 8 A B C D E F A B C D E F I I I Figure...

Page 108: ...endix B Schematic Diagrams 1 2 L N PE F10 T10 230V AC 24V DC 24VDC 7 3E 24VDC 7 3E 8 8A 1L 8 8F 1N 3 X1 24V DC POWER SUPPLY 13 X1 4 14 1L 10 1A 1N 10 1F 1 2 3 4 5 6 7 8 A B C D E F A B C D E F Figure...

Page 109: ...Q1 30 X1 5 X5 4 UV 11 3B UV1 11 5D CBR 5C 3F CBR 7 3E CBCO Q1 7 X5 10 Q1 M 11 8 X5 9 CBCL 7 3E 7 4E CBCC 12 13 9 8A 1L 9 8F 1N 5 X1 15 X1 6 16 1L 11 1A 1N 11 1F 27 28 X1 S6 S11 21 X5 20 RO2 X5 A12 1 2...

Page 110: ...Q1 and the charging contactor K6 will open independent of the position of the S6 switch The MCCB can only be reset with pushbutton S11 when the S6 switch is in the MAN position SWITCH S6 REMOTE MANUAL...

Page 111: ...Rockwell Automation Publication 20Y TG001C EN P April 2017 111 Schematic Diagrams Appendix B Figure 34 Frame 10 in IP21 Rittal Enclosure Sheet 12 400 480V and 600 690V...

Page 112: ...112 Rockwell Automation Publication 20Y TG001C EN P April 2017 Appendix B Schematic Diagrams Notes...

Page 113: ...X 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 24VDC Power To X10 X3 From Auxiliary 24V DC power supply To T10 power supply connecto...

Page 114: ...Fiber optic gate signals connect UH to UH UL to UL and so forth Ribbon Cable Signal Description Pin 1 Pin 2 U_Feedback U_Power_OK Pin 3 Pin 4 U_DTR 1 U_ETR 2 Pin 5 Pin 6 U_ITR 3 U_DC Pin 7 Pin 8 UI U...

Page 115: ...ng H11 H12 H13 H8 H9 H10 X9 X15 X3 X4 X5 H4 H5 H6 H1 H2 H3 H7 X2 X11 H1 H2 H3 H4 H5 H6 H7 X2 X3 Seven Fiber optic Cables Six Fiber optic Cables Fiber optic Adapter Board ASIC Board Gate Driver Board F...

Page 116: ...werFlex 700H 700S and 700AFE Drive Fan Systems Installation Instructions publication PFLEX IN029 Figure 37 LCL Filter Fan Inverter Circuit Board Connectors Table 12 LCL Filter Fan Inverter Circuit Boa...

Page 117: ...re 45 on page 125 AC Line Switchgear Components for AFE in IP20 2500 MCC Style Enclosure Figure 46 on page 126 AC Line Switchgear Components for AFE in IP21 Rittal Enclosure Figure 47 on page 127 Cat...

Page 118: ...DC bus potential highvoltage Riskofelectricalshock injury ordeathexistsifsomeonecomes into contact with the assembly Terminal Cover Front Cover Mounting Rack Side Cover ASIC Assembly Upgrade Kit Fuse...

Page 119: ...nubber Capacitor Assembly Airflow Channel Power Module IGBTs Electrolytic Capacitors Balancing Resistors DC Bus Bar Terminal Assembly Screening Plate AC Fan Inverter Assembly or DC Fan Power Supply se...

Page 120: ...SK Y1 QOUT E325 Power bus bar N A Screening plate for gate driver board N A Snubber capacitor assembly N A ATTENTION The sheet metal cover and mounting screws on the ASIC Board that is located on the...

Page 121: ...le 15 AFE Power Structure ASIC Assembly Part Numbers Part Name Cat No ASIC assembly bracket Included in 20 FR10850 ASIC assembly cover ASIC assembly insulator ASIC board 1 1 The ASIC board is unprogra...

Page 122: ...Assembly Part Numbers Part Name Cat No LCL filter assembly 400 480V SK Y1 LCL1 D460 600 690V SK Y1 LCL1 E325 LCL high frequency capacitor assembly 20 F 400 480V SK Y1 CAPHF2 DF 10 F 600 690V SK Y1 CA...

Page 123: ...LCL Filter Fan Assembly Table 18 LCL Filter Fan Assembly Part Number Part Name Cat No Universal Kit Discontinued July 2014 2 2 These discontinued kits are no longer available but spares inventory is a...

Page 124: ...Transformer Primary Fuse and Fuse Holder Control Transformer T10 Secondary Fuse and Fuse Holder Control Box on front of enclosure door shown with control box cover removed Part Name Cat No Precharge...

Page 125: ...mounted directly behind Motor Controlled Circuit Breaker MCCB 24V DC Power Supply T10 and CircuitBreaker Part Name Cat No Precharge fuse 400 480V SK Y1 F6 D 600 690V SK Y1 F6 F Fuse disconnect switch...

Page 126: ...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...

Page 127: ...IP21 Rittal Enclosure Table 22 AC Line Switchgear Part Numbers for AFE in IP21 Rittal Enclosure Part Name Cat No Control circuit relay not shown 230V AC SK Y1 K20 DF 24V DC SK Y1 K4 DF Input disconnec...

Page 128: ...128 Rockwell Automation Publication 20Y TG001C EN P April 2017 Appendix D Disassembly Assembly Diagrams and Spare Parts Notes...

Page 129: ...Input Contactor AFE Cat No ____________________________SCR Cat No _____________________________ Output Contactor Cable Length ___________________________Cable Type ______________________________ Drive...

Page 130: ...ine System Application Data Typical Transformer Winding Types The diagrams in this section show typical transformer winding types Figure 48 Delta Wye with Grounded Wye Neutral Figure 49 Delta Delta wi...

Page 131: ...IP21 Rittal enclosure 103 creating fault reports 12 D DC bus fuses 84 DC fuses overview 83 replacement guidelines 84 de energizing the AFE 37 diagnostic status indicators 28 diode test forward biased...

Page 132: ...4 ASIC circuit board 48 control frame only AFE in IP21 Rittal enclosure 43 DPI HIM assembly 38 fiber optic adapter circuit board 40 gate driver circuit board 46 I O circuit boards and control board 39...

Page 133: ......

Page 134: ...roduct Use the code to route your call directly to a technical support engineer http www rockwellautomation com global support direct dial page Literature Library Installation Instructions Manuals Bro...

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