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Rockwell Automation Allen-Bradley PowerFlex 700AFE, Hardware Service Manual

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Rockwell Automation Allen-Bradley PowerFlex 700AFE Hardware Service Manual Download Page 36

36

Rockwell Automation Publication 20Y-TG002C-EN-P - April 2017

Chapter 4

AFE Power Structure Component Section

Understand the Torque 

Figures in Assembly 

Diagrams

Icons and numbers in the assembly diagrams indicate how to tighten hardware.

 

Torque Specifications

The following table lists fastener torque specifications for the circuit boards 

and main components of the Active Front End.

 

PZ2
4 N•m
(35 lb•in)

Tool Type and Size:
• PZ indicates Pozidriv screwdriver bit
• P indicates Phillips screwdriver bit

Tightening Torque

Fastener Type  

 Pozidriv 

screw

Phillips screw

Hexagonal bolt or 
standoff

 Hexagonal 

screw

Hexagonal nut

Torx head screw

Item

Hardware

Final Torque

AC input terminals

M10 nut

40 N•m (354 lb•in)

ASIC circuit board (mounting)

M4 x 8 Pozidriv screws

0.9 N•m (8 lb•in)

ASIC circuit board cover

M4 x 8 Pozidriv screws

0.9 N•m (8 lb•in)

ASIC fan

M4 x 16 Pozidriv screws

0.4 N•m (3.5 lb•in)

Capacitor

M4 x 8 self-tapping screws

1 N•m (9 lb•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 x 12 Pozidriv screws

4 N•m (35 lb•in)

DPI/HIM assembly door

M3 x 6 Phillips screws

0.9 N•m (8 lb•in)

DPI/HIM assembly (mounting)

M3 x 6 Phillips screws

0.9 N•m (8 lb•in)

Fan inverter assembly

M5 x 10 Pozidriv screws

4 N•m (35 lb•in)

Fan inverter fuse base

M4 x 8 Pozidriv screws

3 N•m (27 lb•in)

Fan inverter fuse holder

M4 x 8 Pozidriv screws

3 N•m (27 lb•in)

Gate driver circuit board (mounting)

M4 x 8 Pozidriv screws

1.35 N•m (12 lb•in)

Main cooling fan (mounting)

M5 x 10 Pozidriv screws

3 N•m (27 lb•in)

Precharge bridge assembly

Wire fasteners

M5 x 12 machine screws

4.5 N•m (40 lb•in)

Mounting

M5 nuts

3.9 N•m (35 lb•in)

Precharge bridge resistor assembly

M5 x 12 Torx self-tapping screws

4.5 N•m (40 lb•in)

LCL filter upper 
front bracket

In IP20 enclosure

M8 x 20 
M6 x 16 screws

6.7 N•m (60 lb•in)
4.5 N•m (40 lb•in)

In IP21 enclosure

M5 x 12 Torx self-tapping screws

4.5 N•m (40 lb•in)

Summary of Contents for Allen-Bradley PowerFlex 700AFE

Page 1: ...PowerFlex Active Front End Frame 13 Catalog Number 20Y PowerFlex AFE PowerFlex 700AFE 400V 480V and 600V 690V Hardware Service 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: ... 20 Main Bus Bar 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 Test Procedures View the Status Indicators 28 Perform Visual Inspections 28 Inspect the Cooling Tunnels 28 Inspect the Power Structure 29 Perform Forward and Reverse Biased Diode Tests for Power Struct...

Page 4: ...the Power Structure Fan System 53 Remove the Power Structure from the Enclosure 54 Install the Power Structure in the Enclosure 59 Remove the U V or W Phase Assembly from the Power Structure 59 Remove the Power Module from the U V or W Phase Assembly 62 Install the Power Module on the U V or W Phase Assembly 67 Remove the U V or W Phase Assembly DC Bus Capacitors 67 Install the U V or W Phase Asse...

Page 5: ...Component Section Overview 93 Fuse Replacement Guidelines 94 Chapter9 Startup After Repair Technical Support 97 Before Applying Power to the AFE 97 AppendixA Service Tools and Equipment Software Tools 99 Service Tools 99 AppendixB Schematic Diagrams Frame 13 Circuit Board Connections 101 Frame 13 Power Structure Power Circuitry Block Diagram 102 Frame 13 Power Module Circuitry 103 Frame 13 Power S...

Page 6: ...embly Assembly Diagrams and Spare Parts AFE Power Structure Assembly 130 LCL Filter Assembly used in IP20 and IP21 enclosures 133 Precharge Assembly 135 AC Line Switchgear 137 AppendixE AFE Power One line System Application Data Data to Collect 139 Typical Transformer Winding Types 140 Index 141 ...

Page 7: ... common mode core at the DC bus output Figure 1 on page 19 Updated the system schematics for a Frame 13 AFE in IP20 2500 MCC style enclosure to include the factory installed common mode core at the DC bus output Figure 21 on page 108 Cat No 20D J 500 N 0 NNNBNNNN UL OpenType IP00 540V 650V Normal Duty Power 250 kW 200 kW 450 kW 500 kW Heavy Duty Power DCVoltage Range 462 594 350 583 713 350 Amps I...

Page 8: ...stallationInstructions publication PFLEX IN029 Provides information fordrive fan system service and installation Drives in Common Bus Configurations Application Guidelines publication DRIVES AT002 Provides guidelines considerations and limitations for the proper application of PowerFlex drives used in common bus configurations Wiring and Grounding Guidelines for pulse Width Modulated AC Drives pub...

Page 9: ...ent The oscilloscope chassis can be at a potentially fatal voltage if not properly grounded Use high voltage differential voltage probes for all voltage measurements with the oscilloscope chassis that is correctly grounded to an earth ground ATTENTION The PowerFlex Active Front End contains electrostatic discharge ESD sensitive parts andassemblies that can be damagedif you do notfollow ESD control...

Page 10: ...10 Rockwell Automation Publication 20Y TG002C EN P April 2017 Preface Notes ...

Page 11: ...tween the DC terminal and the chassis The voltage must be zero for all three measurements ATTENTION Hot surfaces can cause severe burns Do not touch the heatsink surface during operation of the PowerFlex Active Front End After you disconnect power allow time for cooling ATTENTION The PowerFlex Active Front End contains electrostatic discharge ESD sensitive parts and assemblies that can be damaged ...

Page 12: ... drive components Record the size and type of main fuses Record any other important marks and damage Note grounding type solid high resistance or floating and source impedance of the power distribution system Addressing PowerFlex Active Front End Faults No Name Description Action if appropriate 1 PrechargeActv The AFE is still in precharge because the charging switch is open K20 K6 and K1 for AFE ...

Page 13: ... that is greater than the parameter 082 Ground I Lvl value The current must appear for 800 milliseconds before the unit will fault Use a digital voltmeter to check for low impedance to ground and verify the bus cables bars between the Disconnect and AC input lines Power structure and LCL filter For AFE in IP20 enclosure Q0 input breaker and K1 input contactor which includes the precharge disconnec...

Page 14: ...ar the fault 47 NvsReadChksum Therewasanerrorreadingparameters 019 Motoring MWh 020 Regen MWh and 021 Elapsed Run Time from EEPROM Cycle the power Replace thecontrol board See page 39 58 Start Prevent Startup has been prevented Cancel prevention of startup if cancellation can be done safely Remove Run Request 65 I O Removed An I O option board has been removed Clear the fault 70 Power Unit Incorre...

Page 15: ... on the power board is incompatible with the control board Reset the fault Cycle the power Replace the control board on the power structure See page 39 Contact technical support 107 New IO Option A new option board was added to the control board Clear the fault and verify the correct parameters for the new option board Reprogram parameters as necessary 113 Fatal App A Fatal Application error has o...

Page 16: ...nConflict Digital input functions are in conflict Check the parameter settings of parameters 221 226 138 DCRefLowLim DC voltage reference is less than the limitinparameter080 DCRefLoLmt Check the parameter setting Verify the bus voltage to be above the parameter value Troubleshoot the cause of the low voltage condition 139 DCRefHighLim DC voltage reference exceeds the limit in parameter 081 DC Ref...

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 missing There is some other start inhibit Check status bits of parameter 100 Start Inhibits Correct the source of the inhibit Cause Indication Corrective Action AC line voltage more than 5 above normal I...

Page 18: ...18 Rockwell Automation Publication 20Y TG002C EN P April 2017 Chapter 1 Troubleshooting and Error Codes Notes ...

Page 19: ...onsist of the following items AC line switchgear consisting of the input circuit breaker Q0 fuses F1 1 F1 3 and input contactor K1 LCL filter L1 Precharge circuit AFE power structure U1 with AFE control assembly DC fuses F2 1 F2 6 Figure 1 Basic One line Diagram for an AFE Frame 13 in IP20 2500 MCC Style Enclosure DC Bus Output L1 3 Phase AC Input L2 L3 PowerFlex Active Front End System Precharge ...

Page 20: ...ocations in IP20 2500 MCC Style Enclosure 7 6 5 9 2 8 4 3 1 Front View shown with enclosuredoors removed Front View reduced size shown with enclosure doors closed Item Description 1 Precharge circuit 2 Precharge resistor R6 1 3 LCL filter L1 4 Active Front End power structure U1 5 AC line switchgear Input circuit breaker Q0 6 Input fuses F1 1 F1 3 7 Input contactor K1 8 DC fuses F2 1 F2 6 9 AFE co...

Page 21: ... between the AFE power structure U1 and DC bus Figure 3 shows these bus bar locations Figure 3 AFE Frame 13 Bus Bar Locations in IP20 2500 MCC Style Enclosure Front View shown with enclosure doors removed DC Bus Bar DC Bus Bar DC Bus Bars between AFE Power Structure U1 and DC Bus Optional Bus Splice Kit not shown Optional Bus Splice Kit not shown AC Power Bus Bars between Input Contactor K1 and LC...

Page 22: ...t Q0 and MCCB motor controlled circuit breaker Q1 LCL filter L1 Precharge circuit AFE power structure U1 with AFE control assembly DC fuses F2 1 F2 6 Figure 4 Basic One line Diagram for AFE in IP21 Rittal Enclosure DC Bus Output L1 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 DC Fuses U2 V2 W2 C1 C2 C3 ...

Page 23: ...omponent Locations in IP21 Rittal Enclosure These components are located behind this Control Frame assembly 2 1 6 5 4 3 7 Front View shown with enclosure doors removed Item Description 1 Precharge circuit and precharge resistors R6 1 and R6 2 2 LCL filter L1 3 Active Front End power structure U1 4 AC line switchgear Motor controlled circuit breaker Q1 5 Input disconnect Q0 6 AFE control assembly s...

Page 24: ... L1 and AFE power structure U1 Bus bars between the AFE power structure U1 and DC bus bars Figure 6 shows these bus bar locations Figure 6 AFE Frame 13 Bus Bar Locations in IP21 Rittal Enclosure AC bus bars between Main Disconnect Q0 and Motor Controlled Circuit Breaker Q1 DC bus bar DC bus bar DC bus bars between AFE Power Structure U1 and DC fuses AC Input bus bars AC bus bars between Motor Cont...

Page 25: ...e 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 L2 L3 PowerFlex Active Front End System Precharge Circuit R6 1 LCL Filter L1 AFE Power Structure U1 DC Fuses U2 V2 W2 C1 C2 C3 C4 C5 C6 U1 V1 W1 Input Contactor K1 Fuses F1 1 F1 3 Input Breaker Q0 AC Line Switchge...

Page 26: ...26 Rockwell Automation Publication 20Y TG002C 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 the PowerFlex Active Front End After you disconnect power allow time for cooling ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense li...

Page 28: ...he heatsinks and tunnels if necessary Item Name Color State Description 1 PWR Power Green Steady Lights 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 on the connected network See to the Communication Adapter User Manual publication 20COMM UMxxx Status of DPI port internal communication if prese...

Page 29: ...ard 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 the test finds a short the meter displays 000 If the test finds an open circuit or reversed polarity the meter displays 0L zero load A reverse biased diode test finds an open circuit and the meter display...

Page 30: ...orward and Reverse Diode Tests Table 2 Forward Biased Diode Tests on Power Structure FrontView AFE in IP21 Rittal Enclosure shown with doors removed FrontView AFE in IP20 2500 MCC Style Enclosure shown with doors removed 1 1 2 2 Meter Leads Location see Figure 8 Nominal Meter Reading DC U T1 1 Value gradually rises to about 0 5V 1 1 The actual voltage reading can vary depending upon your equipment...

Page 31: ...es that are described in this manual Check the Fiber optic Connections Damaged or improperly connected fiber optic cables can cause apparent gate driver board malfunctions For fiber optic cable connections see Table 9 on page 123 Table 10 on page 124 and Figure 36 on page 125 The check the fiber optic connection follow these steps 1 Remove power from the AFE See Remove Power from the AFE on page 3...

Page 32: ...ic adapter circuit board 7 Disconnect the cables and inspect them for scratches and cracks and overall integrity 8 Reconnect the cables replacing any damaged cables IMPORTANT The minimum inside bend radius for fiber optic cable is 25 4 mm 1 in Anybendswithashorterinsideradiuscanpermanentlydamage the fiber optic cable Signal attenuation increases with decreased inside bend radii IMPORTANT When mish...

Page 33: ... W The resistance from each ignition pin to the branch emitter pin connectors X10 and X11 is approximately 166 Ω The resistance from the X10 branch emitter pin to the same branch power terminal U T1 V T2 and W T3 is approximately 0 5 Ω The resistance from the X11 branch emitter to the same branch DC bus terminal is approximately 0 5 Ω If any of the gate interfaces fails this test replace the appro...

Page 34: ...move the protective barriers See Remove AFE Protective Barriers on page 44 3 Remove the protective front covers and terminal covers from the power structure for each phase U V and W See Remove Protective Covers from the Power Structure on page 47 4 A pair of fuses F1 and F2 feed DC bus power to each fan inverter a Locate these fuses shown below and remove them b Use a multi meter to verify that th...

Page 35: ...N 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 of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION Hot surfaces can cause severe burns Do not touch the heatsink surface during operation of the PowerFlex Active Front End After you disconnect power allow ...

Page 36: ...Capacitor M4 x 8 self tapping screws 1 N m 9 lb 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 x 12 Pozidriv screws 4 N m 35 lb in DPI HIM assembly door M3 x 6 Phillips screws 0 9 N m 8 lb in DPI HIM assembly mounting M3 x 6 Phillips screws 0 9 N m 8 lb in Fan inverter ...

Page 37: ...M6 x 16 Pozidriv Protective covers on power structure Front M5 x 10 Pozidriv 3 N m 27 lb in Terminal M5 x 16 Pozidriv 3 N m 27 lb in Item Hardware Final Torque ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing Check the DC bus voltagebetweenthe DCand DCterminals betweenthe DCterminaland the chassis and between the D...

Page 38: ... two screws from the front of the 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 holds the DPI interface board 4 Unplug the DPI cable from the X2 connector on the DPI interface board IMPORTANT Before you remove the connections and wires mark them to...

Page 39: ...0 MCC Style enclosure open the control box 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 and any I O cables 3 Remove the I O boards from the control board and enclosure Note the order of the boards and the keys that help prevent placement of boards i...

Page 40: ...e 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 AFE See Remove Power from the AFE on page 37 2 For an AFE in an IP20 2500 MCC Style enclosure open the control box on the enclosure door to access the control assembly X2 Slot A X7 Serial Port X3 Slot B X4 Sl...

Page 41: ...the right side of the 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 be damaged ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber ...

Page 42: ... Install 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 insidebend radius for fiber optic cable is25 4 mm 1 in Any bends with a shorter inside radius can permanently damage the fiber optic cable Signal attenuation increases with decreased inside bend radii PZ2 0 9 N m 8 lb in...

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 away from the power structure 4 Lift the control frame from the hinges and remove it Replace the Control Frame Replace the control frame in reverse order of removal See Torque Specifications on page ...

Page 44: ... 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 enclosure 3 Remove the protective barriers IMPORTANT To replace power modules you must remove the power structure from the AFE enclosure Remove Screws Remove Screws Remove Screws Remove Screws Removing Protective Barriers for AFE in IP20 2500 M...

Page 45: ...45 AFE Power Structure Component Section Chapter 4 Install AFE Protective Barriers Install the protective barriers in reverse order of removal Remove Screws Remove Screws Remove Screws Remove Screws Removing Protective Barriers for AFE in IP21 Rittal Enclosure ...

Page 46: ...ers on page 44 3 For an AFE in an IP20 2500 MCC Style enclosure remove the four M6 x 16 screws that secure the airflow plate to the AFE and remove the two M6 x 16 screws that secure the airflow plate to the LCL filter For an AFE in an IP21 Rittal enclosure remove the four T8 Torx head screws that secure the airflow plate to the AFE 4 Slide the airflow plate from the AFE Install the AFE Airflow Pla...

Page 47: ...ctive barriers See Remove AFE Protective Barriers on page 44 3 Remove the four M5 Pozidriv screws that secure the protective front covers and terminal covers to the power structure 4 Remove the covers Install Protective Covers on the Power Structure Install the protective covers on the power structure in reverse order of removal See Torque Specifications on page 36 for torque specifications Remove...

Page 48: ...er board Observe polarity when removing 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 sockets of the gate driver board and set them aside ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits inten...

Page 49: ... plastic screws that secure the gate driver board screening plate to the power structure and remove the screening plate 11 Remove the two stand offs that support the gate driver board 12 Repeat step 5 through step 11 for each of the remaining gate driver boards Install the Gate Driver Circuit Boards Install the gate driver circuit boards in the reverse order of removal Remove Screws Remove Gate Dr...

Page 50: ...vers and terminal covers from the power structure See Remove Protective Covers from the Power Structure on page 47 5 Remove the four screws that secure the ASIC cover to the ASIC assembly remove the DC bus connection from the ACSIC cover and remove the ASIC cover 6 Unplug the fan which mounts on the cover from connector X11 of the ASIC circuit board ATTENTION Thesheetmetalcoverandmountingscrewsont...

Page 51: ...when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors IMPORTANT When mishandled the ability of fiber optic cables to transmit data is greatly diminished IMPORTANT The minimum insidebend radius for fiber optic cable is25 4 mm 1 in Any bends with a shorter inside radius can permanently dam...

Page 52: ... and detach the four plastic standoffs that secure the ASIC board to the ASIC chassis and remove the ASIC board If the plastic insulator requires replacement follow these steps a Remove the four screws that secure the board holder to the metal frame and remove the metal frame and insulator Remove Screws Remove ASIC Assembly Removes Screws Remove Screw Remove ASIC Circuit Board from Chassis Remove ...

Page 53: ...ain cooling fans on the power structure For complete details on all fan system related information see the PowerFlex 700S 700H and 700AFE Drive Fan Systems Installation Instructions publication PFLEX IN029 including removal and installation of the following items AC fan inverters AC fan capacitors AC main cooling fans DC fan power supplies DC main cooling fans Fan fusing ATTENTION The sheet metal ...

Page 54: ...he fiber optic adapter board located behind the control assembly for AFE in IP20 2500 MCC Style enclosure or the control frame for AFE inIP21 Rittal enclosure For location of connections see Remove the Fiber optic Adapter Circuit Board on page 40 6 Depending on the enclosure in which the AFE is installed follow the appropriate procedure to remove the power structure from the enclosure AFE in IP20 ...

Page 55: ...wer structure to the MCC bus b Remove the U T1 V T2 and W T3 connections from the power structure at the bottom front of the power structure c Remove the ground connections of the power structure from the enclosure PE terminals AFE in IP20 2500 MCC Style Enclosure shown with enclosure doors removed DC Bus Connections U T1 V T2 and W T3 Connections Ground Connections M10 x 50 11 3 N m 100 lb in M10...

Page 56: ...ower Structure on page 59 f Secure appropriate cables or chains to the recommended lift points on the power structure and tighten the cables or chains For details see Lifting and Mounting the PowerFlex Active Front End AFE Frames 10 and 13 publication 20Y IN001 g To detach the power structure from its cart assembly remove the six hexagonal bolts from the upper portion of the chassis backside ATTEN...

Page 57: ...wo per phase from the power structure bus bars For DC fuse removal instructions see Fuse Replacement Guidelines on page 94 k Separate the power structure from its cart assembly and remove the power structure by using appropriate lifting equipment AFEinIP21RittalEnclosure If your AFE is in an IP21 Rittal enclosure continue to remove the power structure with these steps Back of Cart Assembly Remove ...

Page 58: ...the ground connections of the power structure from the enclosure PE terminals d Remove the output cable screws and the two hexagonal screws that secure the power structure to the AFE frame e Install the maintenance stand catalog number 20 MAINSTD onto the power structure rails SideView FrontView U T1 V T2 W T3 Input Power Terminals DC Bus Fuse Terminal Connections U T1 V T2 and W T3 Connections Gr...

Page 59: ...20Y UM001 for fastener torques of AC supply DC bus input and ground connection terminations Remove the U V or W Phase Assembly from the Power Structure To remove the U V or W phase assembly from the power structure follow these steps 1 Remove the power structure from the AFE enclosure See Remove the Power Structure from the Enclosure on page 54 2 Remove the ASIC Circuit board See Remove the ASIC C...

Page 60: ... 4 AFE Power Structure Component Section 3 Remove the M10 x 25 hexagonal screws that secure the input power cables to the input power terminals on the power structure 4 Remove the insulators from between the DC and DC bus bars Remove Screws and Washers Remove Insulators ...

Page 61: ... hexagonal screws from the top section of each phase assembly U V or W that you want to remove DC Bus Bar DC Bus Bar Insulator Location Fasteners Qty Torque 1 M10 x 20 hexagonal screws M10 spring washers and M10 washers 6 8 N m 70 lb in 2 M8 x 25 hexagonal screws M8 spring washers and M8 washers 6 8 N m 70 lb in 3 M6 x 12 screws 2 4 N m 35 lb in IMPORTANT Only two screws are shown for each phase a...

Page 62: ...om the U V or W Phase Assembly The following procedure describes removing the power module from one phase assembly Repeat this procedure for each phase assembly To remove the power module from the U V or W phase assembly follow these steps IMPORTANT Only one screw is shown for each phase assembly in the bottom section of the drawing IMPORTANT Do not attempt to disassemble the power module within t...

Page 63: ...ove the insulator holding plate from between the bus bar terminals 4 Remove the M5 Pozidriv screws that secure the bus bar terminals to the power structure 5 Slide the bus bar terminals out of the phase assembly 6 If the bus bar airflow channel is damaged remove and replace it 7 Remove the M8 x 20 hexagonal screws that secure the input power cables to the input power bus bar Tightening torque for ...

Page 64: ... cables 9 Remove the M5 x 10 Pozidriv and M4 x 8 Pozidriv screws that secure the EMC cover to the AFE and remove the cover 10 Remove the screws that secure the snubber capacitors to the U V or W phase assembly and remove the snubber capacitors Remove Screws and Output Power Cables Cut Cable Ties Remove Screws Remove Screw and Snubber Capacitors PZ2 4 N m 35 lb in Remove Screws Remove EMC Cover PZ2...

Page 65: ...r bus bar and insulators Tightening torque for reassembly is 14 N m 124 lb in 13 Disconnect the balancing resistor wires from the DC bus bars Remove Screws Support Insulator P2 4 N m 35 lb in PZ2 3 N m 27 lb in Balancing Resistor Assembly Screws Older Style Balancing Resistors Newer Style Balancing Resistors P2 4 N m 35 lb in PZ2 3 N m 27 lb in Balancing Resistor Assembly Screws Remove the wire co...

Page 66: ...e the balancing resistor assemblies see step 13 picture for screw locations 16 Remove the connective DC bus bars and insulators Tightening torque for reassembly is 4 N m 35 lb in Remove Screws 690V AFE Input Power Module Shown Remove Screws Remove Screws Metal Plate Metal Plate Remove all screws holding bus bars and insulators to AFE frame Bus Bars only 1 for 480V unit Insulator Bus Bar Insulator ...

Page 67: ...move the U V or W Phase Assembly DC Bus Capacitors To remove the U V or W phase assembly DC bus capacitors follow these steps 1 Remove the power structure from the AFE enclosure See Remove the Power Structure from the Enclosure on page 54 2 Remove the U V or W phase assembly from the AFE See Remove the U V or W Phase Assembly from the Power Structure on page 59 3 Remove the power module from the U...

Page 68: ... 4 above Replace the Existing Power Structure with a New Power Structure To replace the existing power structure with a new power structure follow these steps 1 Remove the old power structure from the enclosure See Remove the Power Structure from the Enclosure on page 4 54 2 Remove the common mode capacitors from the new Frame 13 power structure that is replacing the old power structure IMPORTANT ...

Page 69: ...he motor feedback connection cable from connector J1 at the top of the power supply voltage feedback board b Carefully disconnect the fiber optic cables from sockets J4 and J5 on the side of the power supply voltage feedback board c Secure the cables to the adjacent fan housing so that they are out of the way d Remove the four screws that secure the power supply voltage feedback board and cover to...

Page 70: ... EN P April 2017 Chapter 4 AFE Power Structure Component Section g Secure the cable to the adjacent fan housing so that it is out of the way 4 Install the new replacement power structure See Install the Power Structure in the Enclosure on page 59 ...

Page 71: ... voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION Hot surfaces can cause severe burns Do not touch the heatsink surface during operation of the PowerFlex Active Front End After you disconnect power allow time for cooling ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits inten...

Page 72: ...ontactor See the PowerFlex Active Front End User Manual publication 20Y UM001 for the AC input fusing and circuit breaker protection recommendations AFE in IP21 Rittal Enclosure For a PowerFlex AFE system in the IP21 Rittal enclosure the AC line switchgear components are the input disconnect Q0 and MCCB Q1 The input disconnect either connects or disconnects the AFE system to the AC line The MCCB c...

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 of the PowerFlex Active Front End After you disconnect power allow time for cooling ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense...

Page 74: ...the Precharge Fuse The precharge fuse assembly for an AFE in an IP20 enclosure is located in the Input Power enclosure For an AFE in an IP21 enclosure the precharge fuse assembly is located in the power structure enclosure To replace the precharge fuse follow these steps 1 Remove power from the AFE See Remove Power from the AFE on page 37 2 Open the appropriate enclosure door 3 If present remove t...

Page 75: ...FE Protective Barriers on page 44 2 Locate the control transformer T4 and 24V DC power supply T10 Frame Size Enclosure Style Fuse Fuse Holder 3 3 Fuse holder holds a quantity of three fuses Amps Type Type 13 IP20 2500 MCC 50 Bussmann DFJ 50 1 1 Precharge fuse designation is F5 for AFE in IP20 2500 MCC style enclosure Bussmann CH60J3 IP21 Rittal 32 ABB OFAA000GG32 2 2 Precharge fuse designation is ...

Page 76: ...wn the AFE d Remove the output secondary wires e Power up the AFE and retest by repeating step a and step b The control transformer T4 can require replacement if these measurements continue to be outside of the 10 tolerance 4 Use a digital voltmeter to test the 24V DC power supply T10 a Measure the primary voltage which is 120V AC b Measure the power supply T10 output voltage which is approximatel...

Page 77: ...nd the control frame The 24V DC power supply T10 is on a subpanel in front of the components that are shown in the front view 3 Use a digital voltmeter to test the control transformer T4 a Measure the primary AC line voltage which is at the 400 480V AC or 600 690V AC system voltage b Measure the control transformer T4 output voltage which is approximately 230V AC ATTENTION Perform these tests only...

Page 78: ...e AFE and retest by repeating step a and step b The 24V DC power supply T10 can require replacement if these measurements continue to be outside of the 10 tolerance Test the Precharge Bridge Using the Power Structure Terminals 1 Remove power from the AFE See Remove Power from the AFE on page 37 2 If present remove the protective barriers See Remove AFE Protective Barriers on page 44 3 To test the ...

Page 79: ...mounting nuts 9 Remove and appropriately discard the old precharge bridge 10 Install the new precharge bridge in reverse order of removal See Torque Specifications on page 36 Test the Precharge Resistor To test the precharge resistor follow these steps 1 Remove power from the AFE See Remove Power from the AFE on page 4 37 2 Open the LCL filter enclosure door 3 If present remove the protective barr...

Page 80: ...red value is not correct disconnect a resistor wire and remeasure again If the measured value is still not correct replace the precharge resistor IMPORTANT Verify that the precharge resistor has not been engineered to another value by the system engineer to accommodate a larger system capacitance The engineered value can change the value of the precharge resistance See the PowerFlex Active Front E...

Page 81: ...ews from the failed precharge resistor and appropriately discard the resistor 7 Install the new precharge resistor in reverse order of removal See Torque Specifications on page 36 AFE in IP21 Rittal Enclosure To replace the precharge resistor assembly in an IP21 Rittal enclosure follow these steps 1 Remove power from the AFE See Remove Power from the AFE on page 37 2 Open the LCL filter enclosure ...

Page 82: ...82 Rockwell Automation Publication 20Y TG002C EN P April 2017 Chapter 6 Precharge Component Section Notes ...

Page 83: ...voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION Hot surfaces can cause severe burns Do not touch the heatsink surface during operation of the PowerFlex Active Front End After you disconnect power allow time for cooling ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intens...

Page 84: ...f the LCL filter Figure 9 Removing Protective Barriers and Vented Cover from LCL Filter Install the LCL Filter Protective Barriers and Vented Cover Reinstall the protective barriers and vented cover in reverse order of removal See Torque Specifications on page 36 Replace the LCL Filter DC Fan Fuses The LCL filter DC fan fuses are located behind the vented cover at the bottom of the LCL filter For ...

Page 85: ... 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 Supply PCB AFE Power Structure X3 on AFE Power Structure DC Bus X3 LCL Filter X8 X53 3 pin Pin DC supply Pin DC supply X2 X51 4 pin Pin 4 16 5V Pin 3 fan control Pin 2 DC Pin 1 fan alarm Fuse X52 4 pin Pin 1 KLIXON Pin 4 KLIXON X1 Fan KLIXON X81 Fan DC Power Supply PCB AFE Powe...

Page 86: ...nent Section To remove the LCL filter fan DC power supply follow these steps 1 Remove the LCL filter protective barriers See Remove the LCL Filter Protective Barriers and Vented Cover on page 7 84 2 Remove the two M4 x 10 mm Pozidriv screws that secure the cover 3 Remove the cover X51 X53 ...

Page 87: ...ure the DC to DC power supply Install the LCL Filter Fan DC Power Supply Install the DC to DC power supply in reverse order of removal See Torque Specifications on page 36 Replace the LCL Filter Fan To replace the LCL filter fan follow these steps 1 Remove the LCL filter protective barriers See Remove the LCL Filter Protective Barriers and Vented Cover on page 84 X8 X3 X1 X4 ...

Page 88: ...page 36 Note the following LCL filter airflow cooling requirements Remove the LCL Filter The procedures to remove the LCL filter are different depending on the enclosure in which it is installed From the IP20 2500 MCC Style Enclosure To remove the LCL filter from an IP20 2500 MCC enclosure follow these steps 1 Remove power from the AFE See Remove Power from the AFE on page 37 2 Remove the LCL filt...

Page 89: ...om brackets that hold the LCL filter in the enclosure see Figure 12 a See Detail A and remove the six M8 x 20 screws a See Detail B and remove the six M8 x 20 screws Figure 12 Remove LCL Filter from AFE in IP20 2500 MCC Style Enclosure 7 See Figure 13 on page 90 Detail C and remove the six M10 x 10 washer hex nuts and associated hardware that secure the input bus bars to the LCL filter DETAIL A DE...

Page 90: ...sure To remove the LCL filter from an IP21 Rittal enclosure follow these steps 1 Remove power from the AFE See Remove Power from the AFE on page 37 2 Remove the LCL filter protective barriers See Remove the LCL Filter Protective Barriers and Vented Cover on page 84 3 Remove the X51 and X53 terminal blocks from the LCL fan assembly ATTENTION The LCL filter is heavy To avoid personal injury or damag...

Page 91: ...3 For bus bar locations see Figure 6 on page 24 7 Remove the LCL filter to AFE power structure bus bars U V W For bus bar locations see Figure 6 on page 24 8 Disconnect the ground wire from the LCL filter chassis 9 Slide the LCL filter out of the enclosure Install the LCL Filter in the Enclosure Install the LCL filter in reverse order of removal See Torque Specifications on page 36 ATTENTION The L...

Page 92: ...92 Rockwell Automation Publication 20Y TG002C EN P April 2017 Chapter 7 LCL Filter Component Section Notes ...

Page 93: ...at 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 severe burns Do not touch the heatsink surface during operation of the PowerFlex Active Front End After you disconnect power allow time for cooling ATTENTION Hazard of permanent eye damage exists w...

Page 94: ...e bus bars 6 Turn the threaded rod into the fuse body 7 Place the Belleville domed washer and hexagonal nut on the threaded rod and hand tighten 8 Hold the threaded rod with the hex key while tightening the nut to the specified torque Frame Size AFE Enclosure Style Fuse Amps Bussman Type Ferraz Shawmut Type 13 IP20 2500 MCC 1100 170M6499 IP21 Rittal 1100 PC73UD95V11CTF 1250 170M6566 Frame Size AFE...

Page 95: ...ection Chapter 8 For information about Bussmann fuses click this link http www cooperindustries com For information about Ferraz Shawmut fuses click this link http www ferrazfuses com IMPORTANT Do not apply torque or twisting force to the fuse body Too much force can damage the fuse ...

Page 96: ...96 Rockwell Automation Publication 20Y TG002C EN P April 2017 Chapter 8 DC Fuses Component Section Notes ...

Page 97: ...t ground DC bus and I O is connected to the correct AFE terminals and is secure ATTENTION 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 of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION Power must be applied to the PowerFlex Active Front End to perform...

Page 98: ...tartup After Repair 6 Verify that AC line power at the disconnect device is within the rated value of the AFE 7 Verify that the control power voltage is correct 8 Whenever possible isolate the AFE from the rest of the DC bus system to enable the AFE to be powered separately ...

Page 99: ...C 8 Torque wrench 1 12 N m 9 Torque wrench 6 50 N m 10 Box wrench 7 mm 8 mm 10 mm 13 mm 17 mm 19 mm 22 mm 11 Socket extension 230 mm 12 Wrench 7 mm 8 mm 10 mm 13 mm 17 mm 19 mm 22 mm 13 Allen wrench 14 Wire cutter 15 Needle nose pliers 16 Crimping tools For cable terminals 1 5 240 17 Angle wrench 18 Screwdriver 7 x 2 mm 19 Pozidriv screwdriver 1 2 3 20 Phillips screwdriver 1 2 3 21 Torx screwdrive...

Page 100: ...100 Rockwell Automation Publication 20Y TG002C EN P April 2017 Appendix A Service Tools and Equipment Notes ...

Page 101: ... X1 H2 H1 H3 H5 H4 H6 H7 X4 J3 DPI Assembly 20C DPI1 DPI Comm Option Board X3 PORT NET A NET B MOD 20 PWR Example 20 HIM A3 External DPI HIM 9 Door HIM 20 VB00601 DPI Interface Board X2 X1 J2 J1 9 X5 X29 Fiber Optic Cables 24V 0EVA 3 DC DC Gnd 24V X3 2 1 X1 X26 700AFE Control Board Fiber Optic Adapter Board M4 ASIC Board Fan 2 2 24V X2 Option Board 20C DA1 A 24V DC Digital Input with Analog I O HI...

Page 102: ...er Structure Power Circuitry Block Diagram ExternalWiring Shown Dashed DC Bus Output X9 26 25 24V 0EVA X15 21 22 23 Charge Relay DC PE DC DC DC DC DC DC DC W L3 U L1 V L2 X11 F2 1 F2 2 F2 3 F2 4 F2 5 F2 6 ASIC Board Gate Driver Bd Fan Measure L R Phase Module V Phase Module U Phase Module W Gate Driver Bd Fan Measure L R Gate Driver Bd Fan Measure L R X8 X3 X8 X3 X8 X3 ...

Page 103: ...9 X17 X18 X14 X5 X3 X4 Shield Shield Shield Gate Driver Board Power Board 1 AC Input Phase either U T1 or V T2 or W T3 Diagram is generic To J2 on Voltage Feedback Board DC feedback is wired from 1 Phase Module only NOTES 1 400V Capacitor Configuration 2 Caps in Series 6 Caps in Parallel 2 600V Capacitor Configuration 3 Caps in Series 4 caps in Parallel See Note 1 From ASIC Board X3 for Phase U X4...

Page 104: ...n Control DC Main Fan DC DC 3 4 4 4 X81 W Phase Fan Module Isolated 48V DC Power Supply Circuit Board X8 X3 X2 X82 DC Main Fan X81 V Phase Fan Module X8 X3 X2 X82 DC Main Fan X81 U Phase Fan Module X8 X3 X2 X82 Isolated 48V DC Power Supply Circuit Board Isolated 48V DC Power Supply Circuit Board Figure 17 Frame 13 Power Structure Main DC Fan Connections newer version ...

Page 105: ...rcuit Board X11 2 4 BLK X2 3 X2 1 6A F1 Fan Frequency Converter DC AC X3 V1 U1 X8 BLK 1 X5 1 BLK 2 X4 1 Brown 6 3 BLK 2 2 μf 300V AC 5 BLK 4 BLK 1 3 10 Meg 2 2 μf 300V AC 7 μf 10 Meg 2 Blue M2 Black Yellow Green 4 F2 S1 1 S1 2 S1 3 S1 4 Off On S1 Setup Switch Off Off Phase V Module Main Fan 230V AC 50 Hz 2 4 BLK X2 3 X2 1 6A F1 Fan Frequency Converter DC AC X3 V1 U1 X8 BLK 1 X5 1 BLK 2 X4 1 Brown ...

Page 106: ...tomation Publication 20Y TG002C EN P April 2017 Appendix B Schematic Diagrams ControlWiringDiagramfor Frame13inIP202500MCC StyleEnclosure Figure 19 Control Wiring Diagram for Frame 13 in IP20 2500 MCC Style Enclosure ...

Page 107: ...0Y TG002C EN P April 2017 107 Schematic Diagrams Appendix B Figure 20 Control Wiring Diagram for Frame 13 in IP20 2500 MCC Style Enclosure continued Fault Reset optional To Indicator Enable Remote Operation of Power Contactor optional ...

Page 108: ...ase connection Fan control from the unit 16 5V from the unit Fan alarm to the unit 7 C29 FIBER OPTIC CABLE F2 1 F2 2 F2 3 F2 4 F2 5 F2 6 L I i 7 6 5 4 3 2 1 24VDC PE PE PE 3 2 W V U B B B B B B U1 X70 DC Bus 1 X3 A B C D E F G H 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 41 42 01 02 03 04 05 06 07 08 09 10 11 12 13 14 15 ...

Page 109: ... 29 30 31 32 33 34 35 36 37 38 39 40 41 42 AFE ON FAULT RESET OPTIONAL FAULT RESET MAIN CONTACTOR ON REQUEST MAIN CONTACTOR ACKNOWLEDGE LCL OVER TEMP AFE FAULT AFE READY CONTROL UNIT 6 C18 TF11 TF 1 6 C16 7070 7121 7170 7120 6180 7140 7160 7130 6 C30 AP1 6 C31 OF1 9 D13 24VDC 6 B36 9 D14 24VDC 10 F8 K1 1CL K1 1CC 10 F15 MAIN CONTACTOR CONTROL TO USER SUPPLIED DRIVE INVERTER ENABLE INTPUT FIBER OPT...

Page 110: ... 29 30 31 32 33 34 35 36 37 38 39 40 41 42 6 G12 L1 6 G12 L2 6050 8090 8170 8171 8210 8220 8091 Note 1 2 6051 10 E32 8151 L1 9 A5 Note 1 For 400 480 Voltage code D primary control transformer connection is factory wired to 480V as default For 600 690 Volatge code F primary control transformer connection is factory wired to 690V as default 2 Customer may need to change the primary voltage tap accor...

Page 111: ...1 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 41 42 8 G5 L1 8 G34 1N 9120 8151 9140 8170 24V DC POWER SUPPLY 24DCV 7 C29 24DCV 7 C29 L1 10 B6 1N 10 B35 Figure 24 Frame 13 in IP20 2500 MCC Style Enclosure Sheet 9 400 480V and 600 690V ...

Page 112: ...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 41 42 9 G5 1L 9 G34 1N 8151 7271 8170 11140 10310 S10 11 D9 K1 11 E25 K1 1CL 7 D29 7 D29 K1 1CC 7 F13 E29 6 B13 6 C13 6 C13 8 B22 11 D26 1L 11 A6 1N 11 A35 Figure 25 Frame 13 in IP20 2500 MCC Style Enclosure Sheet 10 400 480V and 600 690V ...

Page 113: ... 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 10 H6 1L 8151 10 H35 1N 7 E31 6 G19 6 G19 6 G19 C16 10 E32 F31 10 D25 S10 K1 10 D25 8170 11280 11240 11160 11120 8151 11140 11140 11141 11142 11270 1L Note When the S10 switch is in 0 position the MAIN CONTACTOR K1 and charging contactor K6 will open independent of the position of the S6 switch 1N Figure 26 ...

Page 114: ...NECTION INTERNAL CONNECTION X1 Jumper and Numbering Details X3 Customer Connection and Numbering Details X1 X3 FAN TB1 FAN TB2 Fan TB3 Door Three Jumper and Numbering Details INTERNAL CONNECTION INTERNAL CONNECTION FAN TB3 Component Circuit Breaker Fuse F1 1 to F1 3 Q0 F2 1 to F2 6 F3 F4 F5 F6 F11 Tag Name Current Rating 400 480V 2200A 1100A 6A 6A 50A 6A 8A 1600A 1800A 630A 6A 6A 50A 8A 8A 1 3 6 1...

Page 115: ...ontrol AIA2 AIA2 ABCD J2 ABCD J3 ABCD J4 ABCD 10Vref PotGND 10VrefAOUT1 DIN1 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 T10 1 2 3 4 S10 57 58 60 61 X1 K6 69 Fault Reset Optional 70 X1 A1 72 Inverter Enable X1 A1 A2 13 14 K4 A1 A2 N O N O N O N O...

Page 116: ...1 3 5 12 14 96 98 11 95 Q 1 SY 2 4 6 2 4 6 I I I 1 2 2200A 2200A 2200A 2 2 1 1 1 2 3 4 1 3 4 F1 1 F1 2 F1 3 Q1 L1 F11 8A F6 Q5 V6 X6 DC DC C1 K6 11 2E 32A 1 3 2 4 U1 L1 L2 L3 U U B B B B B B V V W W PE PE PE PE X52 X53 M X51 X2 X3 X10 7 6A TF 1 AP1 7 1D OF1 7 1D TF11 7 5C 16 5V from the unit Fan control from the unit Fan alarm to the unit 1100A F2 1 1100A F2 2 1100A F2 3 1100A F2 4 1100A F2 5 1100...

Page 117: ...1 19 70 12 14 11 X1 A1 1 AIA1 AIA2 AIA2 10Vref 10Vref AOUT1 AOUT2 DIN1 DIN2 DIN3 DIN4 DIN5 DIN6 D_COM D_COM 24V 24VCOM AOUTC PotGND AIA1 A11 A1 A2 14 11 21 72 12 24 22 K4 X1 7B FAULT R1 R2 R2 R3 MC Control A16 1 A12 1 MCCB CONTROL INVERTER ENABLE K20 20C DO1 SLOT B 20C DPI1 SLOT E 20C DA1 A SLOT A 4E 12 14 11 1 1 2 2 K4 PE A13 A14 H3 1 X2 X3 1 2 2 7 21 22 23 24 25 26 6 4E AP1 6 4E OF1 9 5B 24VDC 9...

Page 118: ...17 Appendix B Schematic Diagrams 6 7B L1 6 7B L2 Q4 X3 F3 T4 PE 1 3 5 2 1 X1 11 2 400440460480500 I I I 4 6 01 400 440 460 480 500 02 230 X1 1 2 1L 9 1A 1N 9 1F 12 1 A B C D E F H 2 3 4 5 6 7 8 G Figure 31 Frame 13 in IP21 Rittal Enclosure Sheet 8A only 400 480V ...

Page 119: ... 2017 119 Schematic Diagrams Appendix B 6 7B L1 6 7B L2 Q4 1 3 5 2 I I I 4 6 X1 1 X3 T4 01 525 600 690 02 230 525600690 F3 1 2 PE X1 11 2 1L 9 1A 1N 9 1F 12 1 A B C D E F H 2 3 4 5 6 7 8 G Figure 32 Frame 13 in IP21 Rittal Enclosure Sheet 8B only 600 690V ...

Page 120: ...17 Appendix B Schematic Diagrams 24V DC POWER SUPPLY 8 8A 1L 8 8F 1N X1 5 6 F10 T10 1 2 230VAC 24VDC 24VDC 7 2E 24VDC 7 2E L PE N 1L 10 1A 16 1N 10 1F X1 15 1 A B C D E F H 2 3 4 5 6 7 8 G Figure 33 Frame 13 in IP21 Rittal Enclosure Sheet 9 400 480V and 600 690V ...

Page 121: ... 8 9 8F 1N X1 H5 S6 S11 17 18 X39 2 A12 1 2 X39 2 X39 2 CBR 6C 1 4 3 X5 Q1 Q1 6 X5 7 X5 11 X5 20 X5 X5 1 2 3 48 45 46 12 13 21 X5 8 9 10 D1 C11 C12 D2 U2 C2 R2 U1 C1 R1 YU Q1 M YO YC YR 6 2B Q1 6 2B 12 14 11 Q1 6 2B UV 11 3B 7 3E CBCO 7 3E CBCC 4F CBR CBCL 7 3E UV1 11 5D 4 5 95 96 98 13 14 1 2 2 2 1L 11 1A 1N 11 1F Figure 34 Frame 13 in IP21 Rittal Enclosure Sheet 10 400 480V and 600 690V ...

Page 122: ...C OFF 10 8A 1L 53 X1 10 4D UV 0 0 3 1 1 4 2 1 START START S10 2 1 4 3 X38 X38 S10 10 9 2 1 S6 REM MAN AUTO 2 1 6 5 6 X38 57 X1 8 7 12 11 4 5 58 S6 REM MAN AUTO 3 5 7 9 11 1 4 6 8 10 12 2 MCCB Close charging pulse MCCB Open 3 59 X1 X1 X38 60 61 62 13 14 K6 2E 22 21 24 K4 7 4E A1 A2 10 8F 1N K6 55 X1 1 3 5 13 2 4 6 14 6 7C 6 7C 6 7C 3C 22 21 24 K20 6E 22 24 21 14 X5 15 Q1 16 X5 6 2B UV1 10 4D 54 1L ...

Page 123: ...H2 H3 TX V_Gate RX H3 H4 TX W_Gate RX H4 H5 TX A D Convert RX H5 H6 TX VBUS_RX RX H6 H7 RX VBUS_TX TX H7 X2 From 24V DC Power To X10 X3 From Auxiliary 24V DC Power Supply To T10 power supply on control panel ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber o...

Page 124: ...2 Fiber optic gate signals connect UHto UH UL to UL andso 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_DC _I Pin 9 Pin 10 U_TEMP U_DC T Ribbon Cable Signal Description Pin 1 Pin 2 V_Feedback V_Power_OK Pin 3 Pin 4 V_DTR 1 V_ETR 2 Pin 5 Pin 6 V_ITR 3 V_DC Pin 7 Pin 8 VI V_DC _I Pin 9 Pin 10 V_TEMP V_DC ...

Page 125: ... H3 H4 H5 H6 H7 X2 X3 H2 X11 X12 H4 X10 X8 X9 X7 X1 H2 X11 X12 H4 X10 X8 X9 X7 X1 H2 X11 X12 H4 X10 X8 X9 X7 X1 Seven Fiber optic Cables Six Fiber optic Cables Fiber optic Adapter Board ASIC Board W Phase Gate Driver Board For ASIC board part number information see Table 17 on page 132 For Gate Driver board part number information see Table on page 131 V Phase Gate Driver Board U Phase Gate Driver...

Page 126: ...x 700H 700S and 700AFE Drive Fan Systems Installation Instructions publication PFLEX IN029 X3 X8 ASIC Board Connector 1 1 See Figure 36 on page 125 for ASIC board connectors Pin Signal Description Pin Phase V Fan Inverter Board Connector X11 From 2 ASIC_ 15V To 2 X8 From 3 FAN_CONTROL To 3 To 4 FAN_ALARM From 7 Phase V Fan Inverter Board Connector Pin Signal Description Pin Phase W Fan Inverter Bo...

Page 127: ...017 127 Connector Descriptions Appendix C Figure 38 LCL Filter Fan Inverter Circuit Board Connectors Table 14 LCL Filter Fan Inverter Circuit Board Connections X8 X1 X3 X4 LCL Filter DC Fan Inverter Board LCL Filter DC Fan Assembly X1 X1 X3 X3 X8 X51 X4 X53 ...

Page 128: ...128 Rockwell Automation Publication 20Y TG002C EN P April 2017 Appendix C Connector Descriptions Notes ...

Page 129: ... Rittal Enclosure Figure 46 on page 136 AC Line Switchgear Components for AFE in IP20 2500 MCC Style Enclosure Figure 47 on page 137 AC Line Switchgear Components for AFE in IP21 Rittal Enclosure Figure 48 on page 138 Cat No 20D J 500 N 0 NNNBNNNN UL OpenType IP00 540V Normal Duty Power 250 kW 200 kW 450 kW 500 kW Heavy Duty Power DCVoltage Range 462 594 350 583 713 350 Amps Input DC ACVoltage Ran...

Page 130: ...Risk of electrical shock injury or death exists if someone comes into contact with the assembly Terminal Covers Front Covers Bus Bar Assembly Fuse Holders for Fan Inverters ASIC Assembly Upgrade Kit Part Name Part No ASIC assembly upgrade kit without ASIC board 20 FR10850 Bus bar assembly N A Fuse holders for fan inverters only AC fan system 20 PP01094 1 1 For additional AC fan system information ...

Page 131: ...Assembly or DC Fan Power Supply see publication PFLEX IN029for complete details Main Cooling Fan Assembly see publication PFLEX IN029for complete details Table 16 AFE Power Structure Internal Component Part Numbers for U V or W Phase Assembly Part Name Cat No Airflow channel N A Balancing resistors N A DC bus bar assembly N A DC bus bar terminal assembly N A Electrolytic capacitors ELKO 3300 μF 42...

Page 132: ... on the power structure are energized at DC bus potential high voltage Riskofelectricalshock injury ordeathexistsifsomeonecomesinto contact with the assembly 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 unprogrammed 400 480V AFE SK H1 ASICBD D1300 600 690V AFE SK H1 ASICBD E1030 Fiber optic cable set 20 P...

Page 133: ...Catalog Numbers Part Name Cat No LCL filter assembly 400 480V SK Y1 LCL1 D1K3 600 690V SK Y1 LCL1 E1K0 LCL high frequency capacitor assembly 25 μF 400 480V SK Y1 CAPHF3 DF 20 μF 600 690V SK Y1 CAPHF2 DF LCL capacitor assembly 120 μF 400 480V SK Y1 CAPLCL1 D1K3 53 μF 600 690V SK Y1 CAPLCL1 F1K0 LCL filter inverter fan fuse SK Y1 F11 F10 LCL Filter Assembly LCL Capacitor Assembly LCL High Frequency ...

Page 134: ... LCL Filter Fan Assembly Table 20 LCL Filter Fan Assembly Catalog Number Part Name Cat No Universal Kit Discontinued July 2014 2 2 These discontinued kits are no longer available but spares inventory is applicable LCL filter power supply 400 480V SK Y1 DCPS2 F10 1 1 This kit can be used for either voltage class SK Y1 DCPS1 D460 600 690V SK Y1 DCPS1 F325 LCL fan wire kit SK Y1 HF1 DF Part Name Cat ...

Page 135: ...echarge Kit Control Transformer T4 Control Transformer Primary Fuse and Fuse Holder Control Transformer T10 Secondary Fuse and Fuse Holder Part Name Part No Precharge fuse SK Y1 MCCF5 F13 Precharge fuse holder SK Y1 MCCF5FUSEHOLDER F13 Precharge kit 1 1 Kit includes diode bridge V6 one resistor R6 1 and a snubber capacitor C1 SK Y1 PRE2 F13 Control transformer T4 1500VA SK R1 OFANXFMR F13 Control ...

Page 136: ...bpanel that is mounted behind the control frame assembly Precharge Fuse Precharge Kit Precharge Motor Protection Relay Fuse Disconnect Switch Part Name Part No Precharge fuse 400 480V SK Y1 F6 D 600 690V SK Y1 F6 F Fuse disconnect switch SK Y1 F6 DISC DF Precharge kit 1 1 Kit includes diode bridge V6 contactor K6 tworesistors R6 1 and R6 2 and a snubber capacitor C1 SK Y1 PRE1 F13DF Control transf...

Page 137: ... AC input fuses 400 480V SK Y1 MCCF1 F13D 600 690V SK Y1 MCCF1 F13F DC bus fuses 400 480V SK Y1 MCCF2 D 600 690V SK Y1 MCCF2 F Input circuit breaker 400 480V SK Y1 MCCQ0 F13 600 690V Input contactor SK Y1 MCCK1 F13 LCL filter bay door fan kit two at top of door not shown 20 750 FAN3 F8 Right side bus splice kit not shown optional SK Y1 BUSSPLICE F13R Left side bus splice kit not shown optional SK ...

Page 138: ...FE in IP21 Rittal Enclosure Table 24 AC Line Switchgear Part Numbers for AFE in IP21 Rittal Enclosure Front View shown with enclosure doors removed Input Disconnect Switch Motor Controlled CircuitBreaker Part Name Part No Control circuit relay 230V AC SK Y1 K20 DF 24V DC SK Y1 K4 DF Input disconnect switch SK Y1 Q0 F13 Motor controlled circuit breaker SK Y1 Q1 F13 ...

Page 139: ...ut Contactor AFE Cat No ____________________________SCR Cat No _____________________________ Output Contactor Cable Length ___________________________Cable Type ______________________________ Drive Cat No ________________________________________________________________ Output Reactor Mfgr Cat No _________________________________________________ Terminator Mfgr Cat No ______________________________...

Page 140: ...ne line System Application Data Typical Transformer Winding Types The following diagrams show typical transformer winding types Figure 49 Delta Wye with Grounded Wye Neutral Figure 50 Delta Delta with Grounded Leg or Four Wire Connected Secondary Delta Figure 51 Ungrounded Secondary or ...

Page 141: ...e AFE 37 diagnostic status indicators 28 diode tests forward biased 29 reverse biased 29 disassembly assembly diagrams 129 E externalcomponentsofAFEpowerstructure 130 F fan inverter fuse checking 34 faults creating reports 12 list 12 fiber optic cable routing connections 125 connection checking 31 forward biased diode test 29 G gate driver board resistance measurements 33 general precautions 9 H h...

Page 142: ...circuit boards and control board 39 LCL filter fan DC power supply 85 from IP20 2500 MCC Style enclosure 88 from IP21 Rittal enclosure 90 protective covers 84 power from AFE 37 power modules from U V or W phase assembly 62 powerstructureDCbuscapacitorsfromU V or W phase assembly 67 power structure from enclosure 54 power structure main cooling fans 53 protective covers from the power structure 47 ...

Page 143: ......

Page 144: ...uct 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 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 ...

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