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Rockwell Automation Allen-Bradley PowerFlex 700AFE, User Manual

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Rockwell Automation Allen-Bradley PowerFlex 700AFE User Manual Download Page 11

Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017

11

Preface

You can view or download publications at

http://www.rockwellautomation.com/global/literature-library/overview.page

. 

To order paper copies of technical documentation, contact your local 

Allen-Bradley distributor or Rockwell Automation sales representative.

Drive Information

The following publications provide detailed information for PowerFlex drives 

that are compatible with the PowerFlex Active Front End.

 

You can view or download publications at

http://www.rockwellautomation.com/global/literature-library/overview.page

. 

To order paper copies of technical documentation, contact your local 

Allen-Bradley distributor or Rockwell Automation sales representative.

To find your local Rockwell Automation distributor or sales representative, 

visit 

http://www.rockwellautomation.com/global/distributor-locator/sales-

locator.page

 

Drive

Resource

Description

PowerFlex 700 
Series A Drive

PowerFlex 700 
Series B Drive

PowerFlex 700 Series A User Manual, publication 

20B-UM001

 

PowerFlex 700 Series B User Manual, publication 

20B-UM002

 

PowerFlex 700 Frames 0…6 Installation Instructions, publication 

20B-IN019

 

PowerFlex 700 Frames 7…10 Installation Instructions, publication 

20B-IN014

 

PowerFlex 70/700 Reference Manual, publication 

PFLEX-RM001

 

PowerFlex 70 Installation Instructions, publication 

20A-IN009

 

PowerFlex 70EC/700VC Reference Manual, publication 

PFLEX-RM004

 

PowerFlex 700 Technical Data, publication 

20B-TD001

 

PowerFlex Dynamic Braking Resistor Calculator, publication 

PFLEX-AT001

 

Provides information for how to install, 
configure, and use PowerFlex 700 Series A 
and Series B drives.

PowerFlex 700H Drive

PowerFlex 700H Installation Manual, publication 

PFLEX-IN006

 

PowerFlex 700H Programming Manual, publication 

20C-PM001

 

PowerFlex 700H Technical Data, publication 

20C-TD001

 

Provides information for how to install, 
configure, and use PowerFlex 700H drives.

PowerFlex 700S Drive

PowerFlex 700S with Phase II Control Installation Manual (Frames 1…6), publication 

20D-IN024

 

PowerFlex 700S with Phase II Control Installation Manual (Frames 9…14), publication 

PFLEX-IN006

 

PowerFlex 700S with Phase II Control Programming Manual (All Frame Sizes), publication 

20D-PM001

 

PowerFlex 700S with Phase II Control Reference Manual, publication 

PFLEX-RM003

 

PowerFlex 700S with Phase II Control Technical Data, publication 

20D-TD002

 

Provides information for how to install, 
configure, and use PowerFlex 700S drives.

PowerFlex 750-Series 
Drive

PowerFlex 750-Series Drive Installation Instructions, publication 

750-IN001

 

PowerFlex 750-Series Drive Programming Manual, publication 

750-PM001

 

PowerFlex 750-Series Technical Data, publication 

750-TD001

 

Provides information for how to install, 
configure, and use PowerFlex 750-Series 
drives.

PowerFlex SCR Bus Supply PowerFlex SCR Bus Supply User Manual, publication 

20S-UM001

 

Provides information for SCR bus supplies.

Summary of Contents for Allen-Bradley PowerFlex 700AFE

Page 1: ...PowerFlex Active Front End Catalog Number 20Y PowerFlex AFE PowerFlex 700AFE Frames 10 and 13 Firmware Revision Number 1 xxx User Manual OriginalInstructions ...

Page 2: ...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 Labels may also be on or inside the equipment to provide specific precautions WARNING Identifies informati...

Page 3: ...ocations 22 Frame 10 22 Frame 13 23 Mounting Considerations 24 Operating Temperatures 24 Minimum Mounting Clearances 24 AC Supply Source Considerations 26 Unbalanced Ungrounded or Resistive Grounded Distribution Systems 26 Input Power Conditioning 27 Grounding Requirements 27 Recommended Grounding Scheme 27 Safety Ground PE and Shield Termination SHLD 29 Fuses and Circuit Breakers 29 Power Wiring ...

Page 4: ...rmity 49 Low Voltage Directive 2006 95 EC 49 EMC Directive 2004 108 EC 49 General Notes 49 Essential Requirements for CE Compliance 49 Chapter2 AFE in IP21 Rittal Enclosure Installation Wiring Main Component Sections 52 Frame 10 52 Frame 13 53 Main Component Locations 54 Frame 10 54 Frame 13 55 Mounting Considerations 56 Operating Temperatures 56 Minimum Mounting Clearances 56 AC Supply Source Con...

Page 5: ... I O Terminal Blocks 76 I O Cable Grounding 77 Typical I O Wiring 78 Analog I O Configuration 79 Hardware Enable Circuitry 80 Analog I O Wiring Examples for AFE in IP21 Rittal Enclosure 80 Precharging the AFE 81 Introduction 81 Important Guidelines 81 CE Conformity 82 Low Voltage Directive 2006 95 EC 82 EMC Directive 2004 108 EC 82 General Notes 82 Essential Requirements for CE Compliance 82 Chapt...

Page 6: ...Guidelines 139 Ambient Temperature Load 139 Altitude Load 400 480V AC Input 139 Altitude Load 600 690V AC Input 139 AFE Current Ratings and Watts Loss 140 400 Volt AC Input Ratings 140 480 Volt AC Input Ratings 140 600 Volt AC Input Ratings 140 690 Volt AC Input Ratings 140 Fusing and Circuit Breakers for AFE in IP20 2500 MCC Style Enclosure 141 AC Input Fuse and Circuit Breaker Ratings 141 DC Bus...

Page 7: ... Menu 162 Memory Storage Menu 162 Start up Menu 162 Preferences Menu 162 View and Edit Parameters 163 HIM 163 Numeric Keypad Shortcut 163 Remove Install the HIM 163 AppendixC Application Notes Sizing Guidelines 165 Basic Procedure to Size the AFE 165 Advanced Procedure to Size the AFE 166 Voltage Boost 167 Paralleling AFEs 168 Guidelines for AFEs in IP20 2500 MCC Style Enclosure 168 Guidelines for...

Page 8: ...8 Rockwell Automation Publication 20Y UM001F EN P April 2017 Table of Contents Notes ...

Page 9: ...Manual 9 Manual Conventions 10 Rockwell Automation Support 10 Additional Resources 10 General Precautions 12 Catalog Number Explanation 13 Description of Operation 14 Benefits of the AFE 16 AFE in IP00 Open Chassis Configuration 17 Topic Page Updated the basic one line diagram for a Frame 10 AFE in IP20 2500 MCC style enclosure to include the factory installed common mode core at the DC bus output...

Page 10: ... informationfor how to troubleshoot Frame10 AFE units PowerFlex Active Front End Frame 13 Hardware Service Manual publication20Y TG002 Provides informationfor how to troubleshoot Frame13 AFE units PowerFlex 700H 700S and 700AFE Drive Fan Systems Installation Instructions publication PFLEX IN029 Provides information for how to install drive fan systems Drives in Common Bus Configurations publicatio...

Page 11: ...lication20A IN009 PowerFlex 70EC 700VC Reference Manual publication PFLEX RM004 PowerFlex 700 Technical Data publication 20B TD001 PowerFlex Dynamic Braking Resistor Calculator publication PFLEX AT001 Provides information for how to install configure and use PowerFlex 700 Series A and Series B drives PowerFlex 700H Drive PowerFlex 700H Installation Manual publicationPFLEX IN006 PowerFlex 700H Prog...

Page 12: ...ed if you do not follow ESD control procedures Static control precautions are required when you 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 ...

Page 13: ... Rittal Enclosure NEMA UL Type 1 Yes N 2 2 Restricted to SSB Includes AFE power module LCL filter and control assembly Excludes circuit breaker or precharge circuit IP00 open chassis Yes P 3 3 Includes AFE power module LCL filter control assembly Incoming circuit breaker and precharge circuit in 2500 MCC Style enclosure Frame 10 has 1250 amp DC bus and Frame 13 has 3000 amp DC bus IP20 NEMA UL Typ...

Page 14: ...ormation and bus conditioning requirements see Drives in Common Bus Configurations publication DRIVES AT002 Figure 1 AFE Supplying a Lineup of Common Bus Drives Figure 2 AFE Supplying a Single Drive L1 L2 L3 3 Phase 400VAC DC DC DC DC BR1 BR2 M L1 L1 L2 L2 L3 L3 DC DC BR1 BR2 M PowerFlex 755 PowerFlex Active Front End PowerFlex 755 DC DC BR1 BR2 M L1 L1 L2 L2 L3 L3 DC DC BR1 BR2 M PowerFlex 755 Po...

Page 15: ... current reference indicates capacitive reactive power compensation The default value of the reactive current reference parameter is zero The set value of the reactive current reference is compared to its measured value and the error is fed to the PI regulator The PI regulator is also referred to as the synchronizing controller because its function is to keep the inverter synchronized with line su...

Page 16: ... input terminals Improved power factor the AFE actively controls the power factor regardless of motor speed and load In addition the PowerFlex AFE can be used for power factor correction on the power system Voltage boost the AFE boosts the DC voltage See Voltage Boost on page 167 for guidelines regarding voltage boost This voltage boost also helps protect critical processes from the potentially di...

Page 17: ... AFE Frame 10 in IP00 Open Chassis Configuration L1 L2 L3 R6 1 R6 2 U2 V2 W2 C1 C2 C3 C4 C5 C6 U1 U1 V1 W1 U DC DC V F2 1 F2 2 W PE PE K6 AC Line Switchgear LCL Filter L1 AFE Power Structure U1 DC Fuses Precharge Circuit 3 phase AC Input Input Breaker Q0 Input Contactor K1 Fuses F1 1 F1 3 DC Bus Output PowerFlex Active Front End System Precharge Fuses F5 Precharge Contactor Customer Supplies these...

Page 18: ... Configuration L1 L2 L3 R6 1 U2 V2 W2 C1 C2 C3 C4 C5 C6 U1 V1 W1 K6 F2 1 F2 2 F2 3 F2 4 F2 5 F2 6 DC DC W PE PE DC DC V PE DC DC U PE AC Line Switchgear LCL Filter L1 AFE Power Structure U1 DC Fuses Precharge Circuit 3 phase AC Input Input Breaker Q0 Input Contactor K1 Fuses F1 1 F1 3 DC Bus Output PowerFlex Active Front End System Precharge Fuses F5 Precharge Contactor Customer Supplies these Par...

Page 19: ...llation the AFE Topic Page Main Component Sections 20 Main Component Locations 22 Mounting Considerations 24 AC Supply Source Considerations 26 Grounding Requirements 27 Fuses and Circuit Breakers 29 Power Wiring 29 Disconnect the Common Mode Capacitors 37 Use the AFE with PowerFlex Drives 39 Control Wiring 40 Precharging the AFE 47 CE Conformity 49 ATTENTION The following information is a guide f...

Page 20: ...ine 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 6 Basic One line Diagram for a Frame 10 AFE in IP20 2500 MCC Style Enclosure L1 L2 L3 R6 1 R6 2 U2 V2 W2 C1 C2 C3 C4 C5 C6 U1 U1 V1 W1 U DC DC V F2 1 F2 2 W PE PE K6 AC Line Switchgear LCL Fil...

Page 21: ...tactor K1 LCL filter L1 Precharge circuit AFE power structure U1 with AFE control assembly DC fuses F2 1 F2 6 Figure 7 Basic One line Diagram for a Frame 13 AFE in IP20 2500 MCC Style Enclosure L1 L2 L3 R6 1 U2 V2 W2 C1 C2 C3 C4 C5 C6 U1 V1 W1 F2 1 F2 2 F2 3 F2 4 F2 5 F2 6 K6 DC DC W PE PE DC DC V PE DC DC U PE AC Line Switchgear LCL Filter L1 AFE Power Structure U1 DC Fuses Precharge Circuit 3 ph...

Page 22: ...ame 10 system in an IP20 2500 MCC Style enclosure Figure 8 AFE Frame 10 Main Component Locations in IP20 2500 MCC Style Enclosure Front View shown with enclosure doors removed 1 1 2 3 4 5 6 7 8 Front View shown with enclosure doors closed Item Description 1 Precharge circuit and precharge resistor 2 LCL filter L1 3 Active Front End power structure U1 4 AC line switchgear Input circuit breaker 5 In...

Page 23: ...e 13 Main Component Locations in IP20 2500 MCC Style Enclosure 1 7 6 5 9 2 8 4 3 Front View shown with enclosure doors removed Front View reduced size shown with enclosure doors closed Item Description 1 Precharge circuit 2 Precharge resistor 3 LCL filter L1 4 Active Front End power structure U1 5 AC line switchgear Input circuit breaker 6 Input fuses 7 Input contactor 8 DC fuses 9 AFE control ass...

Page 24: ...re 2 2 For an AFE in the IP20 2500 MCC Style enclosure this air means surrounding the outside of the enclosure Minimum Airflow Normal Duty Heavy Duty Power Module LCL Filter 10 0 40 C 32 104 F 0 40 C 32 104 F 1400 m3 hr 824 cfm 1100 m3 hr 647 cfm 13 1 1 The Frame 13 690V AFE has only normal duty operation at nominal rated power and maximum ambient temperature at 35 C 95 F 4200 m3 hr 2472 cfm 1300 ...

Page 25: ...nstallation Wiring Chapter 1 Figure 11 Frame 13 in IP20 2500 MCC Style Enclosure 73 mm 2 9 in 27 mm 1 0 in 591 5 mm 23 in 790 2 mm 31 in 990 2 mm 39 in 200 mm 7 87 in Top View Front View Clearance to Wall Clearance to Wall Height Clearance Door Swing Clearance Door Swing Clearance Door Swing Clearance ...

Page 26: ...t monitor use only Type B adjustable devices to avoid nuisance tripping Unbalanced Ungrounded or Resistive Grounded Distribution Systems If phase to ground voltage exceeds 125 of normal or the supply system is ungrounded see Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives publication DRIVES IN001 for more information ATTENTION To guard against personal injury and equipment ...

Page 27: ...used by other equipment on the line or by events such as lightning strikes The power source has frequent interruptions Grounding Requirements The Active Front End safety ground PE must be connected to system ground Ground impedance must conform to the requirements of national and local industrial safety regulations and electrical codes Periodically check the integrity of all ground connections Rec...

Page 28: ...Series Drive or PowerFlex 7 Class Drive can be on the right or left side of the AFE PowerFlex 755 Frame 8 drive is shown on the right side Customer wiring or DC bus bar splice is required to connect the AFE to the drive To Line PE PowerFlex AFE Frame 10 PE SHLD DC DC DC DC PE PE R L1 S L2 T L3 U T1 V T2 W T3 PowerFlex 750 Series Drive or PowerFlex 7 Class Drive can be on the right or left side of ...

Page 29: ...ons Power Wiring Most start up difficulties are the result of incorrect wiring Verify that the wiring is done as instructed Read and understand the instructions before you begin to installation the AFE Power Cable Types Acceptable for 400 690 Volt Installations Various cable types are acceptable for PowerFlex Active Front End installations For many installations unshielded cable is adequate provid...

Page 30: ...posed EMC regulations or a high degree of communication and networking are also good candidates for shielded cable Consider the general specifications that are dictated by the environment of the installation including temperature flexibility moisture characteristics and chemical resistance Also include a braided shield that is specified by the manufacturer as having coverage of at least 75 An addi...

Page 31: ...V and 120V control voltage Location Rating Type Description Standard option 1 1000V 90 C 194 F XHHW2 RHW 2 Anixter B29528 B29532 Belden 29528 29532 Or equivalent Four tinned copper conductors with XLPE insulation Copper braid aluminum foil combination shield and tinned copper drain wire PVC jacket Standard option 2 Tray rated 1000V 90 C 194 F RHH RHW 2 Anixter OLFLEX 76xxx03 Or equivalent Three ti...

Page 32: ...re to change the control voltage 1 Locate the X3 terminal block Figure 14 Figure 14 X3 Terminal Block Location for AFE in IP20 2500 MCC Style Enclosure 2 To match the AC line voltage move the wire that is shown in Figure 15 to the appropriate X3 terminal X3 Terminal Block Location Frame 10 shown with enclosure doors removed Front View Front View Frame 13 shown with enclosure doors removed X3 Termi...

Page 33: ...C Style Enclosure Installation Wiring Chapter 1 Figure 15 Input Voltage Setting for Control Voltage on Frames 10 and 13 in IP20 2500 MCC Style Enclosure 400 480 600 690 For 400 480V or 600 690VAC Input Move this wire to the terminal that matches the AC line voltage X3 Terminal Block ...

Page 34: ... 4 Max Min Recommended 1 Input power terminals L1 L2 L3 1 10 Input power 240 mm2 500 MCM 95 mm2 3 O AWG 40 N m 354 lb in N A 2 SHLD terminal line PE ground 3 10 Terminating point for wiring shields 300 mm2 600 MCM 2 1 mm2 14 AWG 40 N m 354 lb in M5 M10 3 SHLD terminal motor PE ground 3 4 DC bus 3 DC DC 10 DC output using cable 240 mm2 500 MCM 2 1 mm2 14 AWG 70 N m 620 lb in M12 DC output using spl...

Page 35: ...minal line PE ground 3 13 Terminating point for wiring shields 300 mm2 600 MCM 2 1 mm2 14 AWG 40 N m 354 lb in M5 M10 3 SHLD terminal motor PE ground 3 4 DC bus 3 DC DC 13 DC output using cable 380 mm2 750 MCM 2 1 mm2 14 AWG 70 N m 620 lb in M12 DC output using right side splice kit SK Y1 BUSSPLICE F13R 40 N m 354 lb in M10 DC output using left side splice kit SK Y1 BUSSPLICE F13L 1 Maximum minimu...

Page 36: ...of the enclosure ATTENTION Tominimizedisruptionofairflowthroughtheenclosureand avoidoverheatingwithintheAFEenclosure removeonlytheminimumarea thatisneededtoroutethepowercables When you remove any of the five side cover plates shaded areas that are shown in Figure 18 for routing the AC input ground PE and DC bus output wiring always use the barrier kit catalog number SK Y1 MCCBARRIER to maintain ai...

Page 37: ...ne voltage To access the common mode capacitors the LCL filter must be removed from the enclosure To remove the Frame 10 AFE LCL filter from the IP20 2500 MCC Style enclosure see the instructions in the PowerFlex Active Front End Frame 10 Hardware Service Manual publication 20Y TG001 Area for routing AC input and ground PE connections Shaded areas for routing DC bus output connections on either th...

Page 38: ...s installed in either of these systems A high resistance grounded distribution system An ungrounded distribution system where the line to ground voltages on any phase exceed 125 of the nominal line to line voltage To remove the AFE Frame 13 LCL filter from the IP20 2500 MCC Style enclosure see the instructions in the PowerFlex Active Front End Frame 13 Hardware Service Manual publication 20Y TG002...

Page 39: ...owerFlex 7 Class or PowerFlex 750 Series drives the common mode capacitors of these drives must be disconnected See the documentation for the respective drives When supplying power to PowerFlex drives of different frame sizes on the same DC bus additional bus capacitance can be needed For details see Drives in Common Bus Configurations publication DRIVES AT002 Remove Three Jumpers Remove Three Jum...

Page 40: ...nd They are designed to reduce common mode interference Grounding these terminals can cause signal noise ATTENTION Inputs must be configured with software and jumpers see Analog I O Configuration on page 46 If you configure an analog input for 0 20 mA operation and drive it from a voltage source you can cause component damage Verify proper configuration before you apply input signals ATTENTION It ...

Page 41: ...age 49 for details Type Wire Types Description Minimum Insulation Rating Unshielded PerUS NECor applicable national or local code 300V 60 C 140 F Shielded Multi conductor shieldedcable suchas Belden 8770 or equivalent 0 5 mm2 22 AWG 3 conductor shielded J1 J2 J3 J4 J5 Components thatare mountedoninsideofAFE enclosure see Figure 14 for location See Table 6for door control box item number descriptio...

Page 42: ...terminal block canaccept These sizes are not recommendations Torque Max Min Max Recommended 1 Analog I O Analog I O signals 2 5 mm2 14 AWG 0 5 mm2 22 AWG 0 2 N m 1 8 lb in 0 2 N m 1 8 lb in 2 Digital inputs Digital input signals 2 5 mm2 14 AWG 0 5 mm2 22 AWG 0 2 N m 1 8 lb n 0 2 N m 1 8 lb in 3 Digital outputs Digital out relays 2 5 mm2 14 AWG 0 5 mm2 22 AWG 0 5 N m 4 5 lb in 0 5 N m 4 5 lb in 4 C...

Page 43: ... grounding ATTENTION For the AFE in the IP20 2500 MCC Style enclosure digital inputs 1 3 4 and 5 and digital outputs 1 and 2 are wired at the factory andprogrammedtooperatefromthecontrolsonthefrontoftheenclosure Digital output 3 is programmable and factory wired for 24V DC only Do not change the wiring and programming for those digital inputs and outputs or it results in malfunction of the system ...

Page 44: ...ter than 20V DC 11 2 mA DC Enable digital input 6 is jumper selectable for HW Enable On time 16 7 ms Off Time 1 ms 12 Digital In 2 Ext Reset 13 Digital In 3 Enable Mcont 14 Digital In 4 Contactor Ack 15 Digital In 5 LCL Temp 16 Digital In 6 Hardware Enable see page 46 17 18 Digital In Common Allows source or sink operation 19 24V DC 4 4 150 mA maximum load Can be used to provide control power from...

Page 45: ... for AFE in IP20 2500 MCC Style Enclosure 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 14 K1 K20 S11 11 14 13 K4 X3 64 X3 63 H5 FAULT 2 1 16 17 18 19 20 20C DPI1 Slot E A13 20C DO1 Slot B A12 20C DA1 A Slot A A11 AIA1 AIA2 AIA1 AIA2 10Vref PotGND 10Vref AOUT1 AOUTC AOUT2 DIN1 DIN2 DIN3 DIN4 DIN5 DIN6 D_COM D_COM 24V 24VCOM 26 25 24 21 22 23 R1 R2 K4 24V R3 R1 K4 H3 1 READY 2 1 X3 66 X3 65 3 4 See Analog I ...

Page 46: ...nclosure IMPORTANT Analog I O must be configured through programming and the jumpers shown in Table 8 See Figure 22 for jumper locations andTable 8 for I O jumper configurations Signal Jumper Setting Analog inputs J1 analog in 1 J2 analog in 2 0 20 mA 0 10V 10V Analog outputs J3 analog out 1 J4 analog out 2 0 20 mA 0 10V 10V ATTENTION For the AFE in the IP20 2500 MCC Style enclosure digital inputs...

Page 47: ... IP20 2500 MCC Style Enclosure Input Output Connection Example Required Parameter Changes Potentiometer unipolar DC volt reference 10k Ω Pot recommended 2k Ω Min Configure input for voltage Parameter 200 and set appropriate jumper per Table 8 Adjust scaling Parameters 80 81 and 204 205 View results Parameter 018 Analog voltage input unipolar DC volt reference 0 10V input Configure input for voltag...

Page 48: ... the common bus you must connect an auxiliary contact on the disconnect to a digital input of the drive The corresponding input must be set to the Precharge Enable option This option provides the proper precharge interlock guarding against possible damage to the drive when connected to a common DC bus The precharge status of the AFE must be interlocked with the connected drives such that the drive...

Page 49: ...al and energy EMC Directive 2004 108 EC EN61800 3 Adjustable speed electrical power drive systems Part 3 EMC product standard including specific test methods General Notes The AFE can cause radio frequency interference if used in a residential or domestic environment You are required to take measures to help prevent interference and follow the essential requirements for CE compliance that is liste...

Page 50: ...ielded cable with a coverage of 75 or better metal conduit or have shielding cover with equivalent attenuation 5 All shielded cables must terminate with proper shielded connector 6 Motor cables of DC input drives that are used with the AFE must be shielded cable wire with a coverage of 75 or more or must be inside metal conduit or have shielding cover with equivalent attenuation ...

Page 51: ...omponent locations of AFE Frame 10 and Frame 13 systems in an IP21 Rittal enclosure Topic Page Main Component Sections 52 Main Component Locations 54 Mounting Considerations 56 AC Supply Source Considerations 58 Grounding Requirements 59 Fuses and Circuit Breakers 62 Power Wiring 62 Disconnect the Common Mode Capacitors 69 Using the AFE with PowerFlex Drives 74 Control Wiring 74 Precharging the AF...

Page 52: ...llowing items AC line switchgear consisting of the input disconnect Q0 and MCCB motor controlled circuit breaker Q1 LCL filter L1 Precharge circuit AFE power structure U1 with AFE control assembly DC fuses F2 1 and F2 2 Figure 24 Basic One line Diagram for an AFE Frame 10 in IP21 Rittal Enclosure L1 L2 L3 R6 1 R6 2 U2 V2 W2 C1 C2 C3 C4 C5 C6 U1 U1 V1 W1 U DC DC V F2 1 F2 2 W PE PE Q1 Q0 Q5 K6 F6 A...

Page 53: ... controlled circuit breaker Q1 LCL filter L1 Precharge circuit AFE power structure U1 with AFE control assembly DC fuses F2 1 F2 6 Figure 25 Basic One line Diagram for an AFE Frame 13 in IP21 Rittal Enclosure L1 L2 L3 R6 1 R6 2 U2 V2 W2 C1 C2 C3 C4 C5 C6 U1 V1 W1 Q1 Q0 Q5 K6 F6 F2 1 F2 2 F2 3 F2 4 F2 5 F2 6 DC DC W PE PE DC DC V PE DC DC U PE AC Line Switchgear LCL Filter L1 AFE Power Structure U1...

Page 54: ... Frame 10 Figure 26 shows the main components of the AFE Frame 10 system in an IP21 Rittal enclosure Figure 26 AFE Frame 10 Main Component Locations in IP21 Rittal Enclosure Item Description 1 Precharge circuit 2 LCL filter L1 3 Active Front End power structure U1 4 AC line switchgear Motor controlled circuit breaker 5 Input disconnect 6 AFE control assembly shown with user installed HIM 7 DC fuse...

Page 55: ...E Frame 13 Main Component Locations in IP21 Rittal Enclosure 1 2 3 7 5 4 6 FrontView shown with enclosure doors removed These components are on a subpanel that is mounted in front of the bus bars shown here Item Description 1 Precharge circuit 2 LCL filter L1 3 Active Front End power structure U1 4 AC line switchgear Motor controlled circuit breaker 5 Input disconnect 6 AFE control assembly shown ...

Page 56: ... AFE in the IP21 Rittal enclosure this means air surrounding the module Minimum Airflow Normal Duty Heavy Duty Power Module LCL Filter 10 0 40 C 32 104 F 0 40 C 32 104 F 1400 m3 hr 824 cfm 1100 m3 hr 647 cfm 13 1 1 The Frame 13 690V AFE has only normal duty operation at nominal rated power and maximum ambient temperature at 35 C 95 F 4200 m3 hr 2472 cfm 1300 m3 hr 765 cfm 200 mm 7 87 in 400 mm 15 ...

Page 57: ...17 57 AFE in IP21 Rittal Enclosure Installation Wiring Chapter 2 Figure 29 Frame 13 in IP21 Rittal Enclosure 200 mm 7 87 in 50 mm 2 0 in 50 mm 2 0 in 800 mm 31 5 in Top View Clearance to Wall Clearance to Wall Height Clearance Door Swing Clearance Front View ...

Page 58: ...e supply system is ungrounded see Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives publication DRIVES IN001 for more information ATTENTION To guard against personal injury and equipment damage that is caused by improper fusing or circuit breaker selection use only the recommended line fuses or circuit breakers that are specified in Appendix A ATTENTION The PowerFlex Active F...

Page 59: ...y other equipment on the line or by events such as lightning strikes The power source has frequent interruptions Grounding Requirements The Active Front End Safety Ground PE must be connected to system ground Ground impedance must conform to the requirements of national and local industrial safety regulations and or electrical codes Check the integrity of all ground connections periodically Recomm...

Page 60: ... PE R L1 S L2 T L3 U T1 V T2 W T3 PE SHLD PowerFlex 700AFE Frame 10 shown in IP21 Rittal enclosure PowerFlex 750 Series Drive or PowerFlex 7 Class Drive PowerFlex 700S Frame 10 drive shown Customer wiring required to connect the AFE to the drive To Line PE PE SHLD DC DC DC DC PE PE R L1 S L2 T L3 U T1 V T2 W T3 PowerFlex AFE Frame 13 PowerFlex 750 Series Drive or PowerFlex 7 Class Drive PowerFlex ...

Page 61: ... bar see Figure 31 Grounding points must comply with national and local industrial safety regulations and or electrical codes Shield Termination SHLD The Shield terminal Figure 34 or Figure 35 provides a grounding point for the AFE cable shield It must be connected to an earth ground by a separate continuous lead The drive cable shield must be connected to this terminal on the AFE end and the driv...

Page 62: ...nsulation thickness less than or equal to 15 mils 0 4mm 0 015 in Use only copper wire Wire gauge requirements and recommendations are based on 75 C 167 F Do not reduce wire gauge when using higher temperature wire Unshielded Cable THHN THWN or similar wire is acceptable for PowerFlex Active Front End installation in dry environments provided adequate free air space and or conduit fill rates limits...

Page 63: ...d example of recommended cable is Belden 29528 29532 AWG 1 through AWG 410 This cable has three XLPE insulated conductors plus ground with a spiral copper shield that is surrounded by a PVC jacket Armored Cable Cable with continuous aluminum armor is often recommended in drive system applications or specific industries It offers most of the advantages of standard shielded cable and also combines c...

Page 64: ...n 29528 29532 Or equivalent Four tinned copper conductors with XLPE insulation Copper braid aluminum foil combination shield and tinned copper drain wire PVC jacket Standard option 2 Tray rated 1000V 90 C 194 F RHH RHW 2 Anixter OLFLEX 76xxx03 Or equivalent Three tinned copper conductors with XLPE insulation Corrugated copper tape withthree bare copper grounds in contact with shield PVC jacket Cla...

Page 65: ... appropriate X3 terminal Figure33 InputVoltageSettingforControlVoltageonFrames10and13inIP21Rittal Enclosure Frame 10 shown with enclosure doors removed Frame 13 shown with enclosure doors removed X3 Terminal Block Location X3 Terminal Block Location Front View Front View 400 440 460 480 500 525 600 690 For 400 480V AC Input For 600 690V AC Input Move this wire to the terminal that matches the AC l...

Page 66: ...Range 1 2 Torque TerminalBolt Size 3 4 Max Min Recommended 1 Input power terminals L1 L2 L3 1 10 Input power 300 mm2 600 MCM 2 1 mm2 14 AWG 40 N m 354 lb in M10 2 SHLD terminal PE ground 3 10 Terminating point for wiring shields 300 mm2 600 MCM 2 1 mm2 14 AWG 40 N m 354 lb in M10 3 DC bus 3 DC DC 10 DC output 300 mm2 600 MCM 2 1 mm2 14 AWG 70 N m 620 lb in M12 1 Maximum minimum sizes that the term...

Page 67: ...Item Name Frame Description Wire Size Range 1 2 Torque TerminalBolt Size 3 4 Maximum Minimum Recommended 1 Input power terminals L1 L2 L3 1 13 Input power 300 mm2 600 MCM 2 1 mm2 14 AWG 70 N m 620 lb in M12 2 SHLD terminal PE ground 3 13 Terminating point for wiring shields 300 mm2 600 MCM 2 1 mm2 14 AWG 40 N m 354 lb in M10 3 DC bus 3 DC DC 13 DC output 300 mm2 600 MCM 2 1 mm2 14 AWG 70 N m 620 l...

Page 68: ...us Output Wiring for AFE Frame 10 in IP21 Rittal Enclosure Frame13 The AC input ground PE and DC bus output are located in the right most bay see front view of Figure 35 The AC input ground and DC bus output ATTENTION Tominimizedisruptionofairflowthroughtheenclosureand avoidoverheatingwithintheAFEenclosure removeonlytheminimumarea thatisneededtoroutethepowercables In addition remove only the minim...

Page 69: ... mode capacitors the LCL filter must be removed from the enclosure To remove the Frame 10 AFE LCL filter from the IP21 Rittal enclosure see the instructions in the PowerFlex Active Front End Frame 10 Hardware Service Manual publication 20Y TG001 To disconnect the common mode capacitors remove the jumpers that are shown in Figure 37 For more information on ungrounded system installation see Wiring ...

Page 70: ...s in the PowerFlex Active Front End Frame 13 Hardware Service Manual publication 20Y TG002 To disconnect the common mode capacitors remove the upper guard and then remove the jumpers that are shown in Figure 38 For more information on ungrounded system installation see Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives publication DRIVES AT001 Figure 38 AFE Frame 13 LCL Filter...

Page 71: ...Rockwell Automation Publication 20Y UM001F EN P April 2017 71 AFE in IP21 Rittal Enclosure Installation Wiring Chapter 2 Remove Three Jumpers Remove Three Jumpers Front View of LCL Filter ...

Page 72: ...ve these capacitors from the AFE Frame 10 power structure follow these steps 1 Locate the common mode capacitors on the Frame 10 power structure 2 Remove the common mode capacitors a Disconnect the two black wires b Unscrew and remove the capacitor assembly consisting of two capacitors on a small metal bracket Location of Common Mode Capacitors on Frame 10 Power Structure Close up View of Common M...

Page 73: ...e removed These capacitors are on the Phase V center module of the power structure To remove these capacitors from the AFE Frame 13 power structure follow these steps 1 Locate the common mode capacitors on the Phase V module of the Frame 13 power structure 2 Remove the common mode capacitors a Disconnect the two black wires Location of Common Mode Capacitors on Phase V Module of Frame 13 AFE Power...

Page 74: ...etails see Drives in Common Bus Configurations publication DRIVES AT002 Control Wiring The AFE in an IP21 Rittal enclosure is wired at the factory and programmed to operate from the operator switches on the front of the enclosure See Table 17 and Figure 40 for I O terminal designations If customized or remote control is required then you must change the control wiring and correspondent digital I O...

Page 75: ...ble output of the AFE to each variable frequency drive enable input or enable parameter 132 Contact Off Cnfg to force off the main contactor if there is a fault This action makes sure that once the AFE stops modulating there is no motoring current flowing through the AFE IGBT diodes FailuretodisabletheAFEoutputcanresultincomponentdamageorareduction in product life When you enable parameter 132 see...

Page 76: ...nge 1 1 Maximum minimum that the terminal block canaccept These sizes are not recommendations Torque Max Min Max Recommended 1 Analog I O Analog I O signals 2 5 mm2 14 AWG 0 5 mm2 22 AWG 0 2 N m 1 8 lb in 0 2 N m 1 8 lb in 2 Digital inputs Digital input signals 2 5 mm2 14 AWG 0 5 mm2 22 AWG 0 2 N m 1 8 lb n 0 2 N m 1 8 lb in 3 Digital outputs Digital out relays 2 5 mm2 14 AWG 0 5 mm2 22 AWG 0 5 N ...

Page 77: ...ding ATTENTION For the AFE in the IP21 Rittal enclosure digital inputs 1 3 4 and 5 and digital outputs 1 and 2 are wired at the factory and programmed to operate from the controls on the front of the enclosure Digital output 3 is programmable and factory wired for 24V DC only Do not change the wiring and programming for those digital inputs and outputs or it results in malfunction of the system Po...

Page 78: ...e 18 selects 0 10V 10V or 4 20 mA 9 Analog Out Common 10 Analog Out 2 11 Digital In 1 RunCmd 24V DC Opto isolated 250V Low state less than 5V DC Highstate greaterthan20VDC 11 2 mA DC Enable Digital Input 6 is jumper selectable for HW Enable On time 16 7 ms Off Time 1 ms 12 Digital In 2 Ext Reset 13 Digital In 3 Enable Mcont 14 Digital In 4 Contactor Ack 15 Digital In 5 LCL Temp 16 Digital In 6 Har...

Page 79: ...COM 24V 24VCOM 26 25 24 21 22 23 R1 R2 K4 24V R3 R1 Com 24V DC See Analog I O Configuration on page 79 for jumper settings AFE Run MCCB On Request MCCB Acknowledge LCL OverTemp 24V to LCL AFE Ready HIM Cradle A14 MCCB Close Fault Relay 4 Charging 1 Interlocker 2 To User supplied Drive Inverter Enable Input Input Contactor Control MCCB Supply MCCB Open IMPORTANT Analog I O must be configured throug...

Page 80: ... digital inputs and outputs or it results in malfunction of the system Signal Jumper Setting Hardware Enable J5 Hardware Enable Input Programmable no hardware enable Input Output Connection Example Required Parameter Changes Potentiometer unipolar DC volt reference 10k Ω Pot recommended 2k Ωm min Configure input for voltage Parameter 200 and set appropriate jumper per Table 18 Adjust scaling Param...

Page 81: ...out internal precharge are used and a disconnect is installed between the input of the drive and the DC bus you must use an external precharge circuit between the disconnect and the DC input of the drive If drives with internal precharge are used with a disconnect switch to the common bus you must connect an auxiliary contact on the disconnect to a digital input of the drive The corresponding inpu...

Page 82: ...nd energy EMC Directive 2004 108 EC EN61800 3 Adjustable speed electrical power drive systems Part 3 EMC product standard including specific test methods General Notes The AFE can cause radio frequency interference if used in a residential or domestic environment You are required to take measures to help prevent interference and follow the essential requirements for CE compliance listed here if ne...

Page 83: ...ed cable with a coverage of 75 or better metal conduit or have shielding cover with equivalent attenuation 5 All shielded cables must terminate with proper shielded connector 6 Motor cables of DC input drives that are used with the AFE must be shielded cable wire with a coverage of 75 or more or must be inside metal conduit or have shielding cover with equivalent attenuation ...

Page 84: ...84 Rockwell Automation Publication 20Y UM001F EN P April 2017 Chapter 2 AFE in IP21 Rittal Enclosure Installation Wiring Notes ...

Page 85: ...foreApplyingPowertotheAFE 1 Verify that the input circuit breaker is off 2 Confirm that all wiring to the AFE AC Input ground DC bus and I O is connected to the correct AFE terminals and is secure 3 Verify that AC line power at the disconnect device is within the rated value of the AFE Topic Page AFE in IP20 2500 MCC Style Enclosure 85 AFE in IP21 Rittal Enclosure 90 ATTENTION Power must be applie...

Page 86: ...eters to default configurations 2 low voltage Resets parameters to default configurations and configures parameters for a 400 480V AFE unit for 400V operation 600 690V AFE unit for 600V operation 3 high voltage Resets parameters to default configurations and configures parameters for a 400 480V AFE unit for 480V operation 600 690V AFE unit for 690V operation IMPORTANT The DC bus voltage must be pr...

Page 87: ... To accept eachdefaultsetting press Enter 8 Enter the Start Stop IO section Parameters 221 225 Digital In 1 5 Sel and parameters 228 229 and 233 Digital Out 1 3 Sel are set to run the AFE from the operator switches on the AFE door see Figure 23 on page 45 for the typical I O wiring diagram To run the AFE through a network communication adapter change digital input 1 from Run to Not Used and send a...

Page 88: ...The AFE READY status indicator operates independent of the control method The AFE FAULT status indicator lights to indicate that the AFE is in a fault state In an overcurrent situation the fault that caused the input circuit breaker Q0 to trip must be identified and fixed before resetting the breaker Modes of Operation There are three different modes in which the contactor and precharge can be con...

Page 89: ...onds duration connected to terminals X3 57 and X3 60 starts the precharging of the AFE When the DC voltage has reached its nominal value the AFE unit automatically closes the input contactor To stop the AFE turn the OFF ON START switch to OFF IMPORTANT Pressing the Stop key on the HIM only stops the AFE output it does not open the input contactor to stop the AFE When a voltage drop or a blackout o...

Page 90: ...the AFE disconnect lever to on 2 Set parameter 091 Reset To Defaults to the appropriate setting for your installation 3 Use the HIM to enter the Assisted Start up procedure 091 Reset to Defaults Resets parameters to default configurations except parameters 093 Language and 090 Param Access Lvl 0 ready A new value can be entered 1 factory Resets parameters to default configurations 2 low voltage Re...

Page 91: ...DC bus voltage referenceis sufficient To accept eachdefaultsetting press Enter 8 Enter the Start Stop IO section Parameters 221 225 Digital In 1 5 Sel and parameters 228 229 and 233 Digital Out 1 3 Sel are set to run the AFE from the operator switches on the AFE door see Figure 40 on page 79 for the typical I O wiring diagram To run the AFE through a network communication adapter change digital in...

Page 92: ...or lights to indicate that the circuit breakers are in a tripped state In an overcurrent situation the fault that caused the circuit breaker to trip must be identified and fixed before resetting the circuit breakers The MCCB can be reset only by pressing the MCCB RESET push button when the MCCB CONTROL switch is in MAN MCCB Motor controlled Circuit Breaker and Modes of Operation There are three di...

Page 93: ...als to the control terminals a Set the MCCB CONTROL switch to REM b Connect a normally closed NC contact to terminals X1 58 and X1 61 This contact has to be in the NC state for the AFE to precharge and run A remote pulse of 0 4 1 0 seconds duration connected to terminals X1 57 and X1 60 starts the precharging of the AFE When the DC voltage has reached its nominal value the AFE unit automatically c...

Page 94: ...e HIM only stops the AFE output it does not open the MCCB to stop the AFE When a voltage drop or a blackout occurs in the supplyingnetwork the undervoltage release coil opens the circuit breaker When the supply is restored the precharging and MCCB closing must be reinitiated To turn on the AFE turn the 0 1 START switch to START and let it automatically return to 1 on ...

Page 95: ...ely There are three types of parameters Numeric Parameters These parameters have a numeric value such as 1V AC ENUM Parameters These parameters allow a selection from two or more items The HIM displays a text message for each item Bit Parameters These parameters have individual bits associated with features or conditions If the bit is 0 the feature is off or the condition is false If the bit is 1 ...

Page 96: ...heDCvoltage reference andstopswhenthere is no regeneration The converter starts by a Run or Start command To avoid starting a digital input can be configured to enable Auto mode selection is allowed only if an external motoring bus supply is installed Default Options 0 0 1 Normal Normal Auto COMMUNICATION Masks and Owners 154 Logic Mask Determines which communication adapters can control the unit ...

Page 97: ...nt Lmt Val 077 DC Bus Lo Alarm 078 DC Bus Hi Alarm 079 Utility Converter Memory Param Access Lvl 090 Reset to Defaults 091 Language 093 Voltage Class 094 Diagnostics Start Inhibits 100 Dig In Status 102 Dig Out Status 103 Faults Fault Config 120 Alarms Alarm Config 135 Inputs and Outputs Analog Inputs Anlg In Config 200 Analog In 1 Hi 201 Analog In 1 Lo 202 Analog In 2 Hi 204 Analog In 2 Lo 205 An...

Page 98: ... 102 Dig Out Status 103 Fault Frequency 104 Fault Total Curr 105 Fault Bus Volts 106 Fault Temp 107 Status 1 Fault 108 Status 2 Fault 109 Alarm 1 Fault 110 Alarm 2 Fault 111 Testpoint 1 Sel 112 Testpoint 1 Data 113 Testpoint 2 Sel 114 Testpoint 2 Data 115 Cnvrtr OL Count 116 Faults Fault Config 120 Fault Clear 121 Fault Clear Mode 122 Power Up Marker 123 Fault 1 Code 124 Fault 2 Code 125 Fault 3 C...

Page 99: ...nt squared as sampled at the PWM peak and valley and then taking the square root of the sum every AC line cycle The imbalance is then evaluated every AC line cycle by first finding the largest smallest and average phase current Two equations are then used to calculate the value displayed Based_on_Largest Largest Average x 100 Average Based_on_Largest Largest Average x 100 Average The equation that...

Page 100: ...un This parameter can be reset with parameter 092 Reset Meters Default Min Max Units Read Only 0 0 214748364 0 Hr 0 1 Hr 022 023 Analog In1 Value Analog In2 Value Displays the value of the signal at the analog inputs Default Min Max Units Read Only 0 000 20 000 mA or 10 000V 0 001 mA or 0 001V Converter Data 030 Rated kW Displays the nominal power rating of the AFE Default Min Max Units Read Only ...

Page 101: ...0 However this adjustment affects the modulated output voltage and current waveform THD during overload operation Default Min Max Units 100 20 200 1 045 RatedLineCurrent Sets the rated current of the supply transformer This parameter can be set if the AFE is oversized compared to the supply or feedingtransformer capacity Default Min Max Units Unit Current 0 0 6553 5 Amps 1 0 Amps 046 Start Stop Mo...

Page 102: ...arameter 053 Auto Rstrt Tries is set to a value other than zero Default Min Max Units 1 0 sec 0 5 30 0 sec 0 1 sec Voltage Loop 060 DC Volt Ref Sel Selects the source of the DC bus voltage reference to the AFE Default Options 0 0 1 2 3 4 5 6 7 DC Volt Ref DC Volt Ref Analog In1 Analog In2 DPI Port 1 DPI Port 2 DPI Port 3 DPI Port 4 DPI Port 5 061 DC Volt Ref Sets the DC voltage reference Used when...

Page 103: ...egen Power Lmt Sets the limit for regenerative power allowed to the AC line Default Min Max Units 300 0 0 1 300 0 0 1 077 Current Lmt Val Sets the current limit value Default Min Max Units 1 5 x Rated Amps 0 0 Based on Unit Rating 0 1 Amps 078 DC Bus Lo Alarm Sets the lowest acceptable DC bus voltage for the application A warning is indicated if the DC bus voltage falls below the value of this par...

Page 104: ...SetssynchronizationtoreducethecirculatingcurrentbetweenparallelconnectedAFEswhentheyare connectedto thesame DCbusandare fed fromthe sameincomingpowersourcewithoutanisolation transformer Inthiscase parameter085 Droop mustbesetto5 inallAFEs andthisparameter086 PWM Synch must be set to 1 Enabled Default Options 0 0 1 Disabled Disabled Enabled 087 Start Up Delay Sets a starting delay when Run command ...

Page 105: ... Reset To Defaults operation Default Options Read Only 0 Low Voltage 1 High Voltage Diagnostics 095 Cnvrtr Status 1 Displays the present operating condition of the AFE Bit 0 Ready indicates all inhibits are cleared Bit 1 Active indicates that the AFE is modulating Bit 2 Motoring indicates that the AFE is running in Motoring mode Bit 3 Regenerating indicates that the AFE is regenerating power to th...

Page 106: ...er 081 DC Ref Hi Lmt Bit 8 DCBusLo Alarm indicates that the DC voltage is less than the value set by parameter 078 DC Bus Lo Alarm Bit 9 DCBusHi Alarm indicates that the DC voltage exceeds the value set by parameter 079 DC Bus Hi Alarm Bit 10 Overload indicates that parameter 003 Total Current exceeds the rated current Read Only 098 Cnvrtr Alarm 2 Displays alarm conditions that presently exist in ...

Page 107: ...4 Fault Frequency Captures and displays the AC line frequency at the time of the last fault Default Min Max Units Read Only 63 0 63 0 Hz 0 1 Hz 105 Fault Total Curr Captures and displays the DC bus amps at the time of the last fault Default Min Max Units Read Only 0 0 Rated Amps x 2 0 1 Amps 106 Fault Bus Volts Captures and displays the DC bus voltage at the time of the last fault Default Min Max ...

Page 108: ...oint 2 Sel Default Min Max Units Read Only 32767 None 116 Cnvrtr OL Count Displays the accumulated percentage of AFE overload Continuously operating the AFE over the set level increases this value to 100 and cause an AFE fault Default Min Max Units Read Only 0 1 100 0 0 1 File Group No Parameter Name and Description Values Bit Definition DCVoltRefD2 DCVoltRefD1 DCVoltRefD0 Cmd Delayed Regen CurLim...

Page 109: ...by these parameters can be compared to parameter 123 Power Up Marker for the time from the most recent power up Therefore Fault x Time Power Up Marker Time difference to the most recent power up A negative value indicates that the fault occurred before the most recent power up A positive value indicates that the fault occurredafter the most recent power up Default Min Max Units Read Only 0 0000 42...

Page 110: ...hen the DC voltage reference exceeds the limit in parameter 081 DC Ref Hi Lmt Bit 8 DCBusLoAlarm sets an alarm when the DC voltage isless than the value set by parameter 078 DC Bus Lo Alarm Bit 9 DCBusHiAlarm sets an alarm when the DC voltage exceeds the value set by parameter 079 DC Bus Hi Alarm 136 Alarm Clear Resets all Alarm 1 4 Code parameters to 0 Default Options 0 0 1 Ready Ready Clr Alarm ...

Page 111: ... 0 1V DC Masks and Owners 154 Logic Mask Sets which adapters can control the AFE If the bit for an adapter is set to 0 the adapter has no control functions except for stop 155 Fault Clr Mask Sets which adapters can clear a fault See Logic Mask 156 Stop Owner Displays the adapters that are presently issuing a valid stop command Read Only 157 Start Owner Displays the adapters that are presently issu...

Page 112: ... In A2 Link A Word 2 174 175 Data In C1 Link C Word 1 Data In C2 Link C Word 2 See Data In A1 Link A Word 1 Data In A2 Link A Word 2 176 177 Data In D1 Link D Word 1 Data In D2 Link D Word 2 See Data In A1 Link A Word 1 Data In A2 Link A Word 2 180 181 Data Out A1 Link A Word 1 Data Out A2 Link A Word 2 Sets the parameter number whose value is written to a communication device data table Default M...

Page 113: ...og Input 2 scaling block Parameter 200 Anlg In Config defines if this input is 10V or 4 20 mA Default Min Max Units 10 000V 4 000 20 000 mA 10 000V 0 001 mA 0 001V 205 Analog In 2 Lo Sets the lowest input value to the Analog Input 2 scaling block Parameter 200 Anlg In Config defines if this input is 10V or 4 20 mA Default Min Max Units 0 000V 4 000 20 000 mA 10 000V 0 001 mA 0 001V 206 Analog In 2...

Page 114: ... 000 mA 0 000V 4 000 20 000 mA 10 000V 0 001 mA 0 001V File Group No Parameter Name and Description Values Bit Definition Analog Out2 Analog Out1 Default x x x x x x x x x x x x x x 1 1 Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 Absolute 0 Signed x Reserved Options Analog Out1 Lo Value AnalogOut1Hi Value Parameter Anlg Out Absolut Signed Absolute 0 Input Volt 0V AC 0V AC 200 Rated 2 2 100 corresp...

Page 115: ... fixed and non configurable Digital In6 Sel Selects the function for the digital inputs 1 Run Selects the digitalinputtocommand the AFE to start modulating as longas the stopinput is not on It is selectable for other functions if the Run is controlled over DPI 2 Clear Fault Selects the digital input if a fault is pending to clear it if the condition is no longer present It is also selectable if th...

Page 116: ...s enough to charge Use this feature only if the control board is supplied from an external 24V DC power supply Default 1 Options 1 0 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 23 24 25 Fault Not Used Fault 1 Alarm 1 Ready Active Motoring Regenerating In Precharge Current Limit At Reference Contact Ctrl ContactorAck Charge Cntrl 6 Anlg In Loss 2 DC UnderVolt 2 DCRefLowLim 2 DCRefHighLim 2 Reserve...

Page 117: ...ring 100 Analog Out1 Hi 210 Analog Outputs 114 Analog Out1 Lo 211 Analog Outputs 114 Analog Out1 Sel 209 Analog Outputs 114 Analog Out2 Hi 213 Analog Outputs 114 Analog Out2 Lo 214 Analog Outputs 114 Analog Out2 Sel 212 Analog Outputs 114 Anlg In Config 200 Analog Inputs 113 Anlg Out Absolute 208 Analog Outputs 114 Anlg Out Config 207 Analog Outputs 113 Anlg Out1 Scale 215 Analog Outputs 115 Anlg ...

Page 118: ...stics 107 Dig Out Setpt 227 Digital Outputs 116 Dig Out Status 103 Diagnostics 107 Dig Out2 Invert 230 Digital Outputs 116 Dig Out2 OffTime 232 Digital Outputs 116 Dig Out2 OnTime 231 Digital Outputs 116 Dig Out3 Invert 234 Digital Outputs 116 Dig Out3 OffTime 236 Digital Outputs 116 Dig Out3 OnTime 235 Digital Outputs 116 Digital InX Sel 221 226 Digital Inputs 115 Digital Out1 Sel 228 Digital Out...

Page 119: ...ol Modes 101 Param Access Lvl 090 Converter Memory 105 Power Factor 016 Metering 99 Power Up Marker 123 Faults 109 PWM Frequency 041 Control Modes 101 PWM Synch 086 Parallel Mode 104 Rated Amps 032 Converter Data 100 Rated kW 030 Converter Data 100 Rated Volts 031 Converter Data 100 RatedLineCurrent 045 Control Modes 101 Reactive Current 005 Metering 99 Reactive I Ki 069 CurrentLoop 103 Reactive I...

Page 120: ...C Line kW Metering 99 014 AC Line kVar Metering 99 015 AC Line kVA Metering 99 016 Power Factor Metering 99 017 Heatsink Temp Metering 99 018 Cmd DC Volt Metering 100 019 Motoring MWh Metering 100 020 Regen MWh Metering 100 021 Elapsed Run Time Metering 100 022 Analog In1 Value Metering 100 023 Analog In2 Value Metering 100 030 Rated kW Converter Data 100 031 Rated Volts Converter Data 100 032 Rat...

Page 121: ... Delay Parallel Mode 104 090 Param Access Lvl Converter Memory 105 091 Reset To Defaults Converter Memory 105 092 Reset Meters Converter Memory 105 093 Language Converter Memory 105 094 Voltage Class Converter Memory 105 095 Cnvrtr Status 1 Diagnostics 105 096 Cnvrtr Status 2 Diagnostics 106 097 Cnvrtr Alarm 1 Diagnostics 106 098 Cnvrtr Alarm 2 Diagnostics 106 099 DC Ref Source Diagnostics 106 100...

Page 122: ...op Owner Masks and Owners 111 157 Start Owner Masks and Owners 111 158 Fault Clr Owner Masks and Owners 111 170 171 Data In AX Datalinks 112 172 173 Data In BX Datalinks 112 174 175 Data In CX Datalinks 112 176 177 Data In DX Datalinks 112 180 181 Data Out AX Datalinks 112 182 183 Data Out BX Datalinks 112 184 185 Data Out CX Datalinks 112 186 187 Data Out DX Datalinks 112 200 Anlg In Config Analo...

Page 123: ...l Inputs 115 227 Dig Out Setpt Digital Outputs 116 228 Digital Out1 Sel Digital Outputs 116 229 Digital Out2 Sel Digital Outputs 116 230 Dig Out2 Invert Digital Outputs 116 231 Dig Out2 OnTime Digital Outputs 116 232 Dig Out2 OffTime Digital Outputs 116 233 Digital Out3 Sel Digital Outputs 116 234 Dig Out3 Invert Digital Outputs 116 235 Dig Out3 OnTime Digital Outputs 116 236 Dig Out3 OffTime Digi...

Page 124: ...124 Rockwell Automation Publication 20Y UM001F EN P April 2017 Chapter 4 Programming and Parameters Notes ...

Page 125: ...5 Faults and Alarms 126 Manually Clearing Faults 127 Fault and Alarm Descriptions 127 Clear the Alarms 131 Common Symptoms and Corrective Actions 131 Technical Support 135 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 communication adapter is installed in the AFE and operating onthe ...

Page 126: ...olt Main Menu Diagnostics Parameter Fault F 5 DC OverVolt Time Since Fault 0000 23 52 F Power Loss Auto 0 0 Volt Main Menu Diagnostics Parameter Device Select Fault Type Fault Description 1 Auto reset run When this type of fault occurs and Auto Rstrt Tries page 102 is set to a value greater than 0 a user configurable timer Auto Rstrt Delay page 102 begins When the timer reaches zero the AFE attemp...

Page 127: ...ich can indicate an excess regenerative load 2 Adjust parameter Regen Power Lmt 3 Monitor incoming AC line for high voltage or voltage transients 7 Overload 3 When input current exceeds 125 for 60 seconds or 150 for 30 seconds The overload is a linear type in counting up Reduce the current consumption of the AFE or increase parameter 133 Cnvrtr OL Factor 8 HeatsinkOvrTp 2 1 The heatsink temperatur...

Page 128: ...Rstrt Tries You can enable disable this fault with parameter 120 Fault Config Correct the cause and manually clear the fault 34 CAN Bus Flt 2 A sent message was not acknowledged 1 Cycle the power 2 Replace the main control board 35 Application 1 Problem in application software with task overload Contact technical support seepage 135 37 HeatsinkUndTp 1 The ambient temperature is too low Raise the a...

Page 129: ...ted 1 Restore the AFE to the default configurations 2 Cycle the power 3 Reload User Set if used 104 PwrBrd Chksum 2 ThechecksumreadfromtheEEPROMdoesnotmatch the checksum calculated from the EEPROM data 1 Cycle the power 2 Contact technical support seepage 135 3 If the problem persists replace the AFE 106 MCB PB Config 2 The AFE rating information that is stored on the power board is incompatible w...

Page 130: ...al input functions are in conflict Check the parameter settings to correct the problem 138 DCRefLowLim 1 DC voltage reference is less than the limit in parameter 080 DC Ref Lo Lmt Check the parameter setting 139 DCRefHighLim 1 DC voltage reference exceeds the limit in parameter 081 DC Ref Hi Lmt Check the parameter setting 140 DCBusLoAlarm 1 DC voltage is less than the value set by parameter 078 D...

Page 131: ...x New IO Option 107 x DCBusHiAlarm 141 x NvsReadChksum 47 x DCBusLoAlarm 140 x Overload 7 x DCRefHighLim 139 x ParamChksum 100 x DCRefLowLim 138 x Periph Loss 71 x Device Add 45 x Phase Loss 21 x Device Change 44 x Port DPI Loss 81 x DigIn Cnflct 133 x Power Unit 70 x Fan Cooling 32 x PrechargeActv 1 x Fatal App 113 x PwrBrd Chksum 104 x Ground Fault 13 x Start Prevent 58 x Hardware Enbl 94 x Syst...

Page 132: ...inhibit Causes Indication Corrective Action AC line voltage more than 5 above normal Instability in AC line current and DC bus voltage Can trip on fault F7 Overload Increase parameter 060 DC Volt Ref proportional to the percentage of the AC line voltage above nominal Negative reactive I Ref on parameter 065 Reactive I Ref with a soft high impedance AC line Instability in AC line current and DC bus...

Page 133: ... the selected control Ready to switch on DC link voltage 0 8 DC nominal Request to close input contactor on Digital In3 Input Contactor Close through Digital Out1 should be set Contact Ctrl Input Contactor Ack Digital Input 4 shouldbe set Contactor Ack see P102 Dig In Status for digital input status Ready to Run see P95 Cnvrtr Status1 Ready bit 1 Startup delay elapsed see P087 Start Up Delay defau...

Page 134: ...igure 45 AFE Fault Handling Sequence Troubleshooting Diagram No Yes Yes No Fault Active Fault Acknowledge Fault Acknowledge AFE Running Stop the AFE New Run Command Edge IsInputContactor or Circuit Breaker Open Input Contactor or Circuit Breaker Open Input Contactor or CircuitBreaker Closed ...

Page 135: ...t time of last fault 109 Status 2 Fault Captures and displays Cnvrtr Status 2 bit pattern at time of last fault 110 Alarm 1 Fault Captures and displays Cnvrtr Alarm 1 bit pattern at time of last fault 111 Alarm 2 Fault Captures and displays Cnvrtr Alarm 2 bit pattern at time of last fault 124 Fault 1 Code Displays a code that represents the fault that tripped the AFE The codes appear in these para...

Page 136: ...136 Rockwell Automation Publication 20Y UM001F EN P April 2017 Chapter 5 Troubleshooting Notes ...

Page 137: ...methods Low Voltage Directive 2014 30 EU EN 61800 5 1 Adjustable speed electrical power drive systems Part 5 1 Safety requirements Electrical thermal and energy 1 Applied noise impulses can be counted with the standard pulse train These applied noise impulses can cause erroneously high Pulse Freq readings KCC Korean KC registration 2 2 Registration KCC REM RAA 20A See the certificate of registrati...

Page 138: ...ors ordust IftheAFEisnotgoingtobeinstalledforsometime storetheAFEinan area where it is not exposed to a corrosive atmosphere Relative humidity 5 95 noncondensing Shock non operational 15G peak for 11 ms duration EN50178 EN60068 2 27 Vibration 1 mm 0 039 in displacement 1G peak EN50178 EN60068 2 6 Sound Frame 10 Frame 13 71 dB at 1 m 3 28 ft 80 dB at 1 m 3 28 ft Electrical AC input voltage toleranc...

Page 139: ...400 480V AC Input Altitude Load 600 690V AC Input 0 20 40 60 80 0 20 30 10 40 50 60 70 80 100 Frame 10 400 480V Frame 10 600 690V Frame 13 400 480V Frame 13 600 690V 120 Ambient Temperature C of Rated Power 0 20 40 60 80 0 1000 1500 500 2000 2500 3000 3500 4000 100 120 of Rated Power Installation Altitude Above Sea Level m 0 20 40 60 80 0 1000 1500 500 2000 2500 3000 100 120 ofRated Power Installa...

Page 140: ...rame Size Hp Rating PWM Freq AC Input Amps DC Output Amps Typical Watts Loss ND HD kHz Cont 1 Min Cont 20YD460 10 497 3 6 460 A 506 A 520 A 8000 W 416 3 6 385 A 578 A 435 A 20YD1K3 13 1404 3 6 1300 A 1430 A 1469 A 23 000 W 1242 3 6 1150 A 1725 A 1299 A AFE Catalog Number Frame Size Hp Rating PWM Freq AC Input Amps DC Output Amps Typical Watts Loss ND HD kHz Cont 1 Min Cont 20YF325 10 439 3 6 325 A...

Page 141: ... Bus Output fuses must be used for short circuit protection The tables in this section provide the ratings of the DC Bus Output fuses used for the AFE in an IP20 2500 MCC Style enclosure 465 800VoltDCFusing 640 1100VoltDCFusing Frame Size Fuse Rating Main Circuit Breaker Rating Amps Bussman Type Amps ABB Type 10 800 A 170M6696 600 A T5L600BW 13 2200 A 170M7090 1600 A T8VBC3FC000000xx Frame Size Fu...

Page 142: ...ure 465 800VoltDCFusing 640 1100VoltDCFusing Frame Size Fuse Ratings MCCB Ratings Amps Bussman Type 1 Ferraz Shawmut Type Amps ABB Type 10 800 NH3UD69V800PV 630 T5H630FF3LS 1000 170M6277 13 2200 PC44UD75V22CTQ 1600 T7516FF3PR231LS 1000 3 per phase 170M6277 1 Suitable for replacement fuse Frame Size Fuse MCCB Ratings Amps Bussman Type 1 Ferraz Shawmut Type Amps ABB Type 10 700 PC73UD13C630PA 400 T5...

Page 143: ... 10 in IP20 2500 MCC Style Enclosure Dimensions 640 25 1754 6 69 1 2265 5 89 2 2380 1 94 1204 1 47 800 7 31 5 955 1 38 1061 4 42 138 6 5 461 4 18 699 1 28 Dimensions are in millimeters and inches Front View Right Side View Bottom View Overall Dimensions mm in Weight kg lb Height Width Depth 2380 1 94 1204 1 47 955 1 38 1035 2282 ...

Page 144: ...tyleEnclosure Dimensions 878 1 35 1747 4 69 2265 5 89 2 2379 8 93 7 803 4 32 958 38 2400 1 95 699 1 27 5 2356 9 92 8 43 1 1 7 43 1 1 7 757 29 8 557 21 9 957 37 7 Dimensions are in millimeters and inches Front View Right Side View Bottom View Overall Dimensions mm in Weight kg lb Height Width Depth 2379 8 93 7 2400 1 95 958 38 2200 4850 ...

Page 145: ...l Enclosure Dimensions 935 36 8 1090 25 42 9 1000 39 4 498 19 6 42 1 7 2270 5 89 4 670 7 26 4 475 18 7 95 5 3 8 6 43 0 3 862 08 33 9 275 10 8 475 18 7 125 4 9 Dimensions are in millimeters and inches Front View Right Side View Bottom View Overall Dimensions mm in Weight kg lb Height Width Depth 2270 5 89 4 1000 39 4 670 7 26 4 600 1323 ...

Page 146: ...264 7 49 8 1800 70 9 475 18 7 125 4 9 61 2 4 61 2 4 475 18 7 95 3 7 275 10 8 675 26 6 125 4 9 1088 8 42 9 2270 89 4 2242 5 88 3 Height to Lifting Lug 536 21 1 25 1 0 653 25 7 37 1 5 Dimensions are in millimeters and inches Front View Right Side View Bottom View Overall Dimensions mm in Weight kg lb Height Width Depth 2270 5 89 4 1800 70 9 690 27 2 1280 2821 9 ...

Page 147: ... 7 1 7 87 3 4 288 5 11 4 183 9 7 496 94 19 6 368 1 14 5 478 1 18 8 340 94 13 4 298 1 11 7 429 5 16 9 66 2 6 214 8 4 113 1 4 5 1056 5 41 6 1404 5 55 3 1674 5 65 9 1761 5 69 4 169 1 6 7 Dimensions are in millimeters and inches Front View Right Side View Left Side View AFE Input Voltage Overall Dimensions mm in Weight kg lb Height Width Depth 400 480V 1761 5 69 4 288 5 11 4 496 9 19 6 263 580 600 690...

Page 148: ... 1477 58 2 559 9 22 0 592 5 23 3 280 11 0 26 1 0 32 1 3 34 1 3 403 5 15 9 37 1 5 553 5 21 8 703 5 27 7 1421 55 9 140 5 5 Dimensions are in millimeters and inches Front View Left Side View Height with Wheel Guide Trays Height from Bottom Surface of Unit AFE Input Voltage Overall Dimensions mm in Weight kg lb Height Width Depth 400 480V 1442 56 8 494 19 4 525 20 7 477 1052 600 690V 473 1043 ...

Page 149: ... 5 1 0 77 3 0 85 3 3 190 7 5 75 3 0 237 9 0 113 5 4 5 520 8 20 5 566 22 3 552 21 7 239 9 4 495 8 19 5 205 8 1 108 4 3 75 3 0 140 5 5 Ø 26 1 0 Both Sides Dimensions are in millimeters and inches Front View Right Side View Left Side View Bottom View Minimum to Enclosure Wall Minimum to Enclosure Roof Overall Dimensions mm in Weight kg lb Height Width Depth 1050 41 3 239 9 4 556 22 3 100 221 ...

Page 150: ...566 22 3 373 14 7 1012 5 39 9 107 4 2 Ø 26 1 0 Both Sides 514 8 20 3 156 5 6 2 708 27 9 388 5 15 3 620 5 24 4 147 5 8 Typ 85 3 3 Typ 142 6 5 6 192 6 7 6 242 6 9 6 Dimensions are in millimeters and inches Front View Right Side View Left Side View Bottom View Overall Dimensions mm in Weight kg lb Height Width Depth 1032 40 6 708 27 9 553 21 8 306 675 ...

Page 151: ...l Information Appendix A Figure 54 Control Box Dimensions only for AFE in IP21 Rittal Enclosure A B C 190 7 7 5 213 36 8 4 Dimensions are in millimeters and inches Frame Size Overall Dimensions mm in A B C 10 532 24 20 6 446 17 6 135 96 5 4 13 733 67 28 9 448 17 6 135 96 5 4 ...

Page 152: ...es a write to the drives nonvolatilememory EEPROM Because theEEPROMaccommodatesonlya fixed number of writes excessive continuous block transfers can quickly damage the EEPROM Therefore do not assign attribute 9 to continuous block transfers See the individual communication adapter user manual for details Logic Bits 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Command Description x Stop 0 Not Stop 1 Norma...

Page 153: ...recharge 0 Notin precharge 1 In precharge x Droop Active 0 Not droop active for AFE paralleling 1 Droop active for AFE paralleling x Alarm 0 No alarm 1 Alarm x Faulted 0 Not faulted 1 Faulted x At Reference 0 Not at reference 1 At reference x Mot CurLim 0 Not exceeding current limit in Motoring Mode 1 Exceeding current limit in Motoring Mode x Regen CurLim 0 Not exceeding current limit in Regenera...

Page 154: ...rameter Datalink A on the input and two 16 bit parameters on the output The data is used as shown in the table Logix to 20 COMM x 20 COMM x to Logix Word Output I O Word Input I O 1 Logic Command 1 Logic Status 2 Reference bus voltage 2 Feedback bus voltage 3 Datalink In A1 3 Datalink Out A1 4 Datalink In A2 4 Datalink Out A2 5 Datalink In B1 5 Datalink Out B1 6 Datalink In B2 6 Datalink Out B2 7 ...

Page 155: ...ime x Ref Select 1 000 No command 001 Ref A Select Par 545 010 Ref B Select Par 550 011 Preset 3 Par 573 100 Preset 4 Par 574 101 Preset 5 Par 575 110 Preset 6 Par 576 111 Preset 7 Par 577 x Ref Select 2 x Ref Select 3 x Reserved x Coast Stop 0 Not coast to stop 1 Coast to stop x Current Limit Stop 0 Notcurrent limit stop 1 Current limit stop x Run 4 0 Not run 1 Run x Jog 2 2 0 Not Jog 2 Par 557 1...

Page 156: ...11 Auto Preset Speed 7 Par 577 01000 Reserved 01001 Reserved 01010 Reserved 01011 Reserved 01100 Reserved 01101 Reserved 01110 Reserved 01111 Reserved 10000 Man Port 0 10001 Man Port 1 10010 Man Port 2 10011 Man Port 3 10100 Man Port 4 10101 Man Port 5 10110 Man Port 6 10111 Reserved 11000 Reserved 11001 Reserved 11010 Reserved 11011 Reserved 11100 Reserved 11101 Man Port 13 embedded EtherNet IP 1...

Page 157: ...emental Information Appendix A x Enable On 0 Not enable on 1 Enable on x Motor Overload 0 Not motor overload 1 Motor overload x Regen 0 Not regen 1 Regen Logic Bits 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Command Description ...

Page 158: ...158 Rockwell Automation Publication 20Y UM001F EN P April 2017 Appendix A Supplemental Information Notes ...

Page 159: ... Connector 1 1 There is no port 4 on PowerFlex 7 Class products Port 4 only exists on legacy SCANport products Description 1 DPI port 1 HIM connection when installed in AFE 2 DPI port 2 Cable connection for handheld and remote options 3 DPI port 3 or 2 Splitter cable that is connected toDPI Port 2 which provides an additional port 4 DPI port 5 Cable connection for communications adapter X1 X2 HIM ...

Page 160: ...ded or Output Volts Programming Monitoring Troubleshooting F Power Loss Auto 0 0 Volt Main Menu Diagnostics Parameter Device Select ALT Key plus Function View Selects how parameters are viewed or shows detailed information about a parameter or component Lang Displays the language selection screen Auto Man Switches between Auto and Manual Modes Remove Lets the HIM be removed without causing a fault...

Page 161: ... In Status Dig Out Status HeatsinkTemp LCD HIM Product Data LCD HIM Control Board Keyboard Numeric Continue Start Over Press Press Press to move between menu items Press to select how to view parameters to select a menu item to move 1 level back in the menu structure Memory Storage Him CopyCat ResetTo Defaults Device HIM Device HIM Delete HIM Set Introduction PowerFlex 700AFE Connected DPI Devices...

Page 162: ... Defaults function does not affect Parameter 196 Option Description HIM Copycat Device HIM Device HIM Save data to a HIM set load data from a HIM set to active AFE memory or delete a HIM set Reset To Defaults Restore the AFE to its default configuration settings Option Description AFE Identity Add text to identify the AFE Change Password Enable disable or modify the password User Dspy Lines Select...

Page 163: ...change the value press the or key If desired press the key to move from digit to digit letter to letter or bit to bit The digit or bit that can be changed is highlighted 8 To save the value press the Enter key To cancel a change press the key to escape 9 Toscrollthroughtheparametersinthegroup pressthe or key or press the key to return to the group list Main Menu Diagnostics Parameter Device Select...

Page 164: ...164 Rockwell Automation Publication 20Y UM001F EN P April 2017 Appendix B HIM Overview Notes ...

Page 165: ...provided by the AFE 3 Select the AFE with the DC current rating that meets or exceeds the value calculated in step 2 Examples Normal duty ND 110 1 minute Heavy duty HD 150 1 minute Topic Page Sizing Guidelines 165 Voltage Boost 167 Paralleling AFEs 168 DC Input Rating of Connected Drives AFE DC Voltage ND Power ND Currents ND Current Sum x 0 9 ND Cont DC Output Amps AC Input Voltage 650V 5 x 60 Hp...

Page 166: ...2 Calculate the steady state input current required on the regenerative unit IInput PRun x 1000 3 x VLL where PRun is in kW and VLL RMS line to line AC input voltage 4 Determine the total power and input current required during deceleration 1 For Motoring Loads PDrive PMotor Motor Efficiency For Regenerating Loads PDrive PMotor Motor Efficiency PDecel PDrive1 PDrive2 Calculate the input current re...

Page 167: ...tor DC Volt Ref 2 x 1 1 Example AC line voltage 400V AC Motor 460V AC Max DC Volt Ref 400 x 1 35 x 1 3 702V DC Maximum AC output to motor 702V DC 2 x 1 1 451V AC In addition the AC input current required by the AFE increases when using voltage boost The continuous and overload AC input current ratings must not be exceeded or the AFE trips on overload See the Advanced Procedure to Size the AFE on p...

Page 168: ...n When paralleling you must check the sufficient short circuit capacity of the system Derate the AFE units by 5 of their power rating Configure the following parameters for parallel operation Set Parameter 42 Modulation Type to 3 Set Parameter 82 Ground I Lvl to 100 Set Parameter 85 Droop to 5 for current sharing of the AFEs Set Parameter 86 PWM Synch to 1 to reduce circulating currents between AF...

Page 169: ...he contactor of the AFE c Open the DC disconnect switch d Restart the other AFE units When AFEs are paralleled the DC bus voltage at regeneration is 5 higher than with one AFE due to the 5 droop See Drives in Common Bus Configurations publication DRIVES AT002 for supported drives that can be used in various AFE configurations Figure 56 on page 170 shows an example of paralleling two AFEs in their ...

Page 170: ... V F2 1 F2 2 W PE PE K6 AC Line Switchgear LCL Filter L1 AFE Power Structure U1 DC Fuses Precharge Circuit 3 phase AC Input Input Breaker Q0 Input Contactor K1 Fuses F1 1 F1 3 DC Bus Output PowerFlex 700 AFE System Precharge Fuses F5 Precharge Contactor AC Line Switchgear LCL Filter L1 AFE Power Structure U1 DC Fuses Precharge Circuit Input Breaker Q0 Input Contactor K1 Fuses F1 1 F1 3 PowerFlex 7...

Page 171: ... 3 F2 4 F2 5 F2 6 DC DC W PE PE DC DC V PE DC DC U PE AC Line Switchgear LCL Filter L1 AFE Power Structure U1 DC Fuses Precharge Circuit 3 phase AC Input Input Breaker Q0 Input Contactor K1 Fuses F1 1 F1 3 DC Bus Output PowerFlex 700 AFE System Precharge Fuses F5 Precharge Contactor AC Line Switchgear LCL Filter L1 AFE Power Structure U1 DC Fuses Precharge Circuit Input Breaker Q0 Input Contactor ...

Page 172: ...ting currents between AFEs connected to the same DC bus and fed from the same power source If one of the paralleled AFEs is isolated from the AC and DC voltages you must isolate the AC input and DC output The AC input can be isolated with a circuit breaker or a disconnect switch Contactors are not suitable for isolating the AC input because they cannot be locked in the safe position The DC output ...

Page 173: ... due to the 5 droop See Drives in Common Bus Configurations publication DRIVES AT002 for supported drives that can be used in the various AFE configurations Figure 58 on page 174 shows an example of paralleling two AFEs in their IP21 Rittal enclosures where each AFE has its own precharging circuit precharging control and fusing on the DC bus output and input contactor In this case turn the disconn...

Page 174: ...K6 F6 R6 1 R6 2 U2 V2 W2 C1 C2 C3 C4 C5 C6 U1 U1 V1 W1 U DC DC V F2 1 F2 2 W PE PE Q1 Q0 Q5 K6 F6 DC DC AC Line Switchgear LCL Filter L1 AFE Power Structure U1 DC Fuses Precharge Circuit 3 phase AC Input DC Bus Output PowerFlex 700 AFE 1 Precharge Fuses Precharge Contactor Motor Protection Relay AC Line Switchgear LCL Filter L1 AFE Power Structure U1 DC Fuses Precharge Circuit PowerFlex 700 AFE 2 ...

Page 175: ... DC DC F2 1 F2 2 F2 3 F2 4 F2 5 F2 6 DC DC W PE PE DC DC V PE DC DC U PE F2 1 F2 2 F2 3 F2 4 F2 5 F2 6 DC DC W PE PE DC DC V PE DC DC U PE AC Line Switchgear LCL Filter L1 AFE Power Structure U1 DC Fuses Precharge Circuit 3 phase AC Input DC Bus Output PowerFlex 700 AFE 1 Precharge Fuses Precharge Contactor Motor Protection Relay AC Line Switchgear LCL Filter L1 AFE Power Structure U1 DC Fuses Pre...

Page 176: ... April 2017 Appendix C Application Notes Paralleling an AFE with One or More PowerFlex SCR Bus Supplies For information about paralleling an AFE with one or more PowerFlex SCR Bus Supplies see Drives in Common Bus Configurations publication DRIVES AT002 ...

Page 177: ...alog Out2 Lo parameter 114 Analog Out2 Sel parameter 114 Analog Outputs Parameter Group 113 Anlg In Config parameter 113 Anlg Out Absolute parameter 114 Anlg Out Config parameter 113 Anlg Out1 Scale parameter 115 Anlg Out1 Setpt parameter 115 Anlg Out2 Scale parameter 115 Anlg Out2 Setpt parameter 115 armored cable 30 63 Auto Rstrt Delay parameter 102 Auto Rstrt Tries parameter 102 Auto Stop Level...

Page 178: ...viewing 161 Diagnostics Parameter Group 105 Dig In Status parameter 107 Dig Out Setpt parameter 116 Dig Out Status parameter 107 Dig Out2 Invert parameter 116 Dig Out2 OffTime parameter 116 Dig Out2 OnTime parameter 116 Dig Out3 Invert parameter 116 Dig Out3 OffTime parameter 116 Dig Out3 OnTime parameter 116 Digital In1 Sel parameter 115 Digital In2 Sel parameter 115 Digital In3 Sel parameter 115...

Page 179: ...nput Current S parameter 99 Input Current T parameter 99 input potentiometer 47 80 input power conditioning 27 59 Input Voltage parameter 99 Inputs Outputs File 113 L Language parameter 105 Last Stop Source parameter 107 Limits Parameter Group 103 linear list of parameters 120 Logic Command Word PowerFlex 700 700H 700S drives 152 PowerFlex 750 Series drives 155 Logic Mask parameter 111 Logic Statu...

Page 180: ...180 Rockwell Automation Publication 20Y UM001F EN P April 2017 Index by number 120 linear list 120 viewing 163 ...

Page 181: ...Data In B1 112 Data In B2 112 Data In C1 112 Data In C2 112 Data In D1 112 Data In D2 112 Data Out A1 112 Data Out A2 112 Data Out B1 112 Data Out B2 112 Data Out C1 112 Data Out C2 112 Data Out D1 112 Data Out D2 112 DC Bus Current 99 DC Bus Hi Alarm 103 DC Bus Lo Alarm 103 DC Bus Volt 99 DC Ref Hi Lmt 103 DC Ref Lo Lmt 103 DC Ref Source 106 DC Volt Ki 102 DC Volt Kp 102 DC Volt Ref 102 DC Volt R...

Page 182: ...ing input 27 59 Power Factor parameter 99 Power Up Marker parameter 109 precautions general 12 preferences setting 162 programmablecontrollerconfigurations 152 PWM Frequency parameter 101 PWM Synch parameter 104 R Rated Amps parameter 100 Rated kW parameter 100 Rated Volts parameter 100 RatedLineCurrent parameter 101 Reactive Current parameter 99 Reactive I Ki parameter 103 Reactive I Kp parameter...

Page 183: ... Testpoint 2 Sel parameter 108 Total Current parameter 99 troubleshooting 125 U unbalanced ungrounded AC supply source 26 58 ungrounded distribution systems 37 69 unshielded power cables 30 62 user configurable alarms 126 Utility File 105 V viewing and changing parameters 163 Voltage Class parameter 105 Voltage Loop Parameter Group 102 W website technical support 10 wire control 41 75 signal 41 75...

Page 184: ...184 Rockwell Automation Publication 20Y UM001F EN P April 2017 Index Notes ...

Page 185: ......

Page 186: ... 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 Brochures and Technical Data http www rockwellautomation com global literature library overview page Product Compatibility and Download Center PCDC Get help determining how products interact check features and cap...

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