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PowerFlex 700AFE Frame 13 Hardware Service Manual

1. Remove screws Remove Remove f screws Enclosure Bay for Input Switchgear PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Enclosure Bay for LCL Filter Enclosure Bay for AFE Power Structure AFE Power Structure Component Section 4 11 Removing Protective Barriers for AFE in 21 Rittal Enclosure DATA Remove Remove screws screws Remove Remove screws screws Installing AFE Protective Barriers Install the protective barriers in re
2. E AC Line LCL Filter L1 AFE DC Switchgear Power Structure U1 Fuses 3 Phase 00 01 I ACInput o PE BOTE T enne e Pun ul D i VANNI e al TF B WANA Pun MW pm DC Bus B3 Output 4 eE e _2 Q iS F2 4 G 6 R5 LEJH 1 256 1 1 1 ee Motor Protection Precharge Relay Precharge Precharge Fuses Contactor NES Circuit gt F6 Q5 K6 R6 1 T R6 2 l PowerFlex Active Front End System PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Main Component Locations Active Front End System Overview 2 5 The following figure shows the main components of the AFE Frame 13 system in a IP21 Rittal enclosure Figure 2 5 Frame 13 Main Component Locations in IP21 Rittal Enclosure SSS SS S555 FRONT VIEW shown with enclosure doors removed lo SS These components are located behind this Contr
3. F2 1 DC E M6 Phase Module 2 2 DC U Measure L R Gate Driver Bd 08 Fan F2 3 DC 22 4 DC Measure L R Gate Driver Bd x8 Fan F2 5 DC eet Phase Module F2 6 DC W Measure L R Gate Driver xe Fan 1X11 21 Charge 22 Xi5 Relay mE 404 0289 QEVA External Wiring ASIC Shown Dashed Board Figure 2 Frame 13 Power Structure Power Circuitry Block Diagram PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P U L1 Module W L3 B 3 Schematic Diagrams itry Frame 13 Power Module 2 ajnpoyy 4 5082 y seueg ul sde 10128082 A009 72 leed 5982 9 saues sde 2 uoneinByuo 0106082 00 1 SALON oueue si 9110 4 2 Jamo 3 gt gt gt gt gt vX piers 02 61 81080 uoqqiy 81 LX vH peog 9125 ix 1 pensi pix SX o qe
4. Table 38 Forward Biased Diode Tests on Power Structure Meter Leads Location see above Nominal meter reading DC DC V T2 9 DC W T3 Value should gradually rise to about 0 5V 1 U T1 DC V T2 DC W T3 DC The actual voltage reading can vary depending upon your equipment If your readings are not near 0 5V verify that the actual voltage measured is consistent for the power structure Table 3 C Reverse Biased Diode Tests on Power Structure Meter Leads L calion see above Nominal meter reading U T1 DC V T2 DC 9 W T3 DC Meter should display 0L zero load DC U T1 DC V T2 DC W T3 If the AFE fails any of these measurements replace all Power Modules for each line phase in the power structure or the complete power PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Checking Fiber Optic Connections Component Test Procedures 3 5 structure using any of the following options Contact your local representative to schedule On site Services Contact your local representative to make arrangements to return the power structure to the factory for repair by Remanufacturing Services Foran AFE not covered under factory warranty a customer has the option of repairing the power structure u
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6. 9 2 Service Tools and Equipment Software Tools eos chee REOR Up os Seda eed eb ee 1 Service Io0 s EE s Pes A 1 Schematic Diagrams Frame 13 Circuit Board Connections B 1 Frame 13 Power Structure Power Circuitry Block Diagram B 2 Frame 13 Power Module B 3 Frame 13 Power Structure Main Fan B 4 Frame 13 Power Structure Main Fan B 5 Control Wiring Diagram for Frame 13 IP20 2500 MCC Style Enclosure B 6 System Schematics for Frame 13 IP20 2500 MCC Style Enclosure B 8 Control Wiring Diagram for Frame 13 in IP21 Rittal Enclosure B 15 System Schematics for Frame 13 in IP21 Rittal Enclosure B 16 Connector Descriptions Circuit Board Connections C 1 Hardware Connections C 4 Disassembly Assembly Diagrams and Spare Parts AFE Power Structure Assembly 0 0 cece cece eee nee eens D 2 LCL Filter Assembly used in IP20 and IP21 D 5 Precharge Assembly AES APA ak wae
7. en P 2 Cross gt P 2 Additional Support Available on 3 General Precautions for Class 1 LED P 3 Troubleshooting and Error Codes Creating Fault Reports cee Re odd pe er RESI NUES 1 2 Addressing PowerFlex Active Front End 1 2 Common Symptoms and Corrective Actions 1 7 Active Front End System Overview AFE in IP20 2500 MCC Style 2 1 Main Component Sections 7 2 1 Main Component Locations 2 2 Main Bus Bar 2 3 AFE in P21 Rittal 2 4 Main Component Sections 7 7 2 4 Main Component Locations 20 2 5 Bus Bar Locations i ioo pel DER nb RICH PN HERE teases 2 6 AFE in 00 Open Chassis Configuration 2 7 Component Test Procedures Viewing the Status Indicators
8. 3 2 Performing Visual Inspections 3 2 Inspecting the Cooling 8 3 2 Inspecting the Power 3 2 Performing Forward and Reverse Biased Diode Tests for Power Structure 3 3 Checking Fiber Optic 3 5 Performing Gate Driver Board Resistance Measurements 3 7 Checking the AFE Power Structure Fan Inverter Fuses 3 8 AFE Power Structure Component Section Understanding Torque Figures in Assembly Diagrams 4 2 Torque Specifications 4 2 Removing Power from the 4 3 Control Frame Access Procedures 4 4 Removing the DPI Interface 4 4 Installing the DPI Interface Assembly 4 5 Removing the I O Circuit Boards and Control 4 5 Installing the I O Circuit Boards and Control 4 6 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P ii Table of Contents Chapter 5 Chapter 6 Chapter 7 Re
9. AFE Power Structure Pin 1 KLIXON Pin 4 KLIXON x Fuse X4 1 X53 3 pin DC Bus Fan DC Power DC supply Supply PCB Pin DC supply X3 X3 xg X81 4 pin 3 on AFE Power Structure Pin 1 16 5V Pin 3 fan control Pin 5 fan alarm Figure 7 3 LCL Filter Fan DC Power Supply Wiring Diagram newer version LCL Filter KLIXON X52 4 pin AFE Power Structure Pin 1 KLIXON Pin 4 KLIXON X81 Fuse x2 X53 3 pin 1 DC Bus Fan DC Power Pin DC supply Supply PCB Pin DC supply x3 X8 X51 4 pin on AFE Power Structure Pin 4 16 5V Pin1 Pin 3 fan control Pin 2 Pin 2 DC Pin 3 Pin 1 fan alarm lt Flying Lead to DC Bus Important Before doing any work disconnect the AFE power structure from the AC supply and wait until the fan stops and the indicators on the keypad turn off If a keypad is not attached see the indicator through the keypad base Wait 5 more minutes before doing any work on the DC to DC power supply to let it completely discharge Furthermore do not open the cover until after this time has expired X51 X53 PowerFlex Active Front End Frame 13 Hardware Service Ma
10. J DETAIL D 8 See Figure 7 5 Detail D and remove the twelve x16 screws that secure the LCL Filter output bus bars to the AFE power structure 9 SeeFigure 7 5 and slide the LCL Filter out of the enclosure injury or damage to the equipment use caution when removing ATTENTION The LCL Filter is heavy To avoid personal the LCL Filter from the enclosure Note that ramps may be required due to enclosure floor mismatch From the IP21 Rittal Enclosure 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 2 Remove the LCL Filter protective barriers See Removing the LCL Filter Protective Barriers and Vented Cover on page 7 2 3 Remove the X51 and X53 terminal blocks from the LCL fan assembly PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 7 8 LCL Filter Component Section 4 Remove the X52 terminal block from the LCL filter assembly upper right side 5 Remove the four T25 Torx self tapping screws that secure the front bracket shown in Figure 7 1 This bracket holds the LCL Filter in the enclosure 6 Remove the MCCB to LCL Filter bus bars L1 L2 L3 For bus bar locations see Figure 2 6 on page 2 6 7 Remove the LCL Filter to AFE power structure bus bars U V W For bus bar locations see Figure 2 6 on page 2 6 8 Disconnect the ground wire from the LCL Filter chassis
11. Figure C 2 AFE Power Structure Fan Inverter Circuit Board Connectors X3 X8 C e Table C C ASIC Board AFE Power Structure V Phase Fan Inverter Board Connections ASIC Board Connector 1 X11 Pin Signal Description Pin From 2 ASIC_ 15V To 2 From FAN_CONTROL To To FAN_ALARM From See Figure C 1 on page C 3 for ASIC board connectors Phase V Fan Inverter Board Connector X8 Table C D Phase V Fan Inverter Board W Phase Fan Inverter Board Connections Phase V Fan Inverter Board Connector X3 Pin Signal Description Pin From 2 15V To 2 From FAN_CONTROL NEXT To 3 To 4 FAN_ALARM From 7 Phase W Fan Inverter Board Connector X8 Table C E Phase W Fan Inverter Board U Phase Fan Inverter Board Connections Phase W Fan Inverter Board Connector X3 Pin Signal Description Pin From 2 15V To 2 From FAN_CONTROL NEXT To 3 To 4 FAN_ALARM From 7 Phase U Fan Inverter Board Connector X8 For part number information see the PowerFlex 700H 7005 and 700AFE Drive Fan Systems Installation Instructions publication PFLEX IN029
12. 1 These components are located a sub panel mounted behind the Control Frame assembly Precharge Fuse Precharge Kit Precharge Motor Protection Relay Fuse Disconnect Switch Table D H Precharge Assembly Part Numbers for AFE IP21 Rittal Enclosure 1 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 SK Y1 PRE1 F13DF Control Transformer T4 750VA 400 480V SK Y1 T4 D 600 690V SK Y1 T4 F Control Transformer Motor Protection Relay SK Y1 Q4 DF Control Transformer Circuit 400 480V SK Y1 F3 D LA 600 690V SK Y1 F3 F 24V DC Power Supply T10 SK Y1 T10 DF 24V DC Power Supply Circuit Breaker 2A SK Y1 F10 DF Precharge Motor Protection Relay SK Y1 Q5 F13 snubber capacitor C1 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Kit includes diode bridge V6 contactor K6 two resistors R6 1 and R6 2 and a AC Line Switchgear Input Circuit Breaker AC Input Fuses Input Contactor Disassembly Assembly Diagrams and Spare Parts D 9 Figure D 9 AC Line Switchgear Components for AFE in IP20 2500 MCC Style Enclosure F
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14. SI 20 pueog eDeyoA OL 9 JO ELH 3 A eSeud 10 LLH 8 OLH 9 10 6H 8H p1eog DISV jouog Ue oL 001 pieius p1eog 018 uo 9X J0j9euuo 01 M 9SEUd 10 GX 10 YX 9 104 5ISV Wol4 Publication 20Y TG002B EN P PowerFlex Active Front End Frame 13 Hardware Service Manual B 4 Schematic Diagrams Frame 13 Power Structure Main Fan Connections To ASIC Circuit Board X11 Fan Control 3 DC DC DC Main Fan X81 8 X82 Isolated 48V DC W Phase Fan Module Power Supply Circuit Board X2 e Ay 777 DC Main Fan X81 X8 X3 X82 Isolated 48V DC ase Fan Module Power Supply Circuit Board X2 4 V DC Main Fan ZEN X81 X8 X3 x82 Te TT Isolated 48V DC Power Supply Circuit Board X2 esee PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Figure B 4 Frame 13 Power S
15. 4 23 Removing the U V or W Phase Assembly from the Power Structure 4 23 Removing the Power Module from the U V or W Phase Assembly 4 25 Installing the Power Module on the U W Phase Assembly 4 30 Removing the U or W Phase Assembly DC Bus Capacitors 4 30 Installing the U V or W Phase Assembly DC Bus Capacitors 4 31 Replacing the Existing Power Structure with a New Power Structure 4 31 AC Line Switchgear Component Section AFE in IP20 2500 MCC Style Enclosure 5 2 AFE in IP21 Rittal Enclosure 5 2 Precharge Component Section Precharegmg Functions Rt Nga AE Eri ERE 6 2 Replacing the Precharge 6 2 Testing the Control Transformer T4 and 24V DC Power Supply 10 6 3 For AFE in IP20 2500 MCC Style 6 3 For AFE IP21 Rittal Enclosure 6 4 Testing the Precharge Bridge Using the Power Structure Terminals 6 6 Replacing the Precharge Bridge 6 6 Testing the Precharge 6 7 Replacing the Precharge Resistor 6 8 AFE in
16. 9 S y 19 09 euondo 8c Jopejuo j2M0d Jo uonesado ajoway 45 12 S gw t ev 19 Di ON 115 v2 r v E3 N 4 v2 01 12 DN 2 ET 19 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P B 8 Schematic Diagrams System Schematics for Frame 13 in IP20 2500 MCC Style Enclosure The following system schematics are for the AFE Frame 13 in a IP20 2500 MCC Style enclosure The PowerFlex AFE catalog number has an enclosure code of P for standard color or W for optional gray color as shown in the example catalog string below For other enclosure designs contact the supplier of the system for the system schematics Position 1 3 4 5 7 8 9 10 11 12 13 14 15 16 20 1K3 P 0 A N N A N A 0 ab MM f g h i j k 1 538853885882 sree Shee RayR AR ARTS RR RRA RR RRR RASS e S NU A
17. Di pi 9 Pi s i pi e i PowerFlex i Active Front End System i SSS Customer supplied Parts Customer supplied enclosure PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 2 8 Active Front End System Overview Notes PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Chapter 3 Component Test Procedures gt gt ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION To avoid an electric shock hazard verify that all power to the PowerFlex Active Front End has been removed before performing any servicing or repairs ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing Check the DC bus voltage between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements ATTENTION Hot surfaces can cause severe burns Do not touch the heatsink surface during operation of the PowerFlex Active Front End After disconnecting power allow time for cooling ATTENTION Hazard of permanent eye damage exists whe
18. V 1075 70 002 WOOAve APZ WOO sD s vr 80 Ear agy qoav OLNOV ZVIV 130 37 9 37 9 Z 9 S H 0 8 1 9 S t 2 Ola Aor nma u pn 0 LX 5 9 ip 4 m ix A o 8 oF T BO 0 Sa BB 2 x nz 28 m 58 T Aavad 34v LINN TOHLNOO 8 9 6 Y Publication 20Y TG002B EN P PowerFlex Active Front End Frame 13 Hardware Service Manual B 18 Schematic Diagrams T y we S 21 a x i N i i o i Te 8 05 gt oz Tur g or ge 1 tals 09 80 0 9 007 9 H HIE 2 10 20 ia 5 zn amp m lt E PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Figure B 17 Frame 13 in IP21 Rittal Enclosure Sheet 8A only 400 480V B 19 Schematic Diagrams A069 009 Ajuo gg 19945 ensojou3 1241
19. 069 009 104 se oi 028 51 1euuojsue epoo eDeyoA 08 00 104 210 60 60 80 80 10 94 10 90 z 90 50 sv6 n 1518 1x 1509 0509 5 v0 0 lt 21 219 9 B 1 219 9 10 10 9 3 3 4 2 8 V PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P B 11 Schematic Diagrams A069 009 pue 6 19945 ensojou3 ejus DOW 0052 4 0 78 en614 4 i or 6 8t LE 9E SE 43 LE 0t 6c 8z 14 St 14 r4 6 8 at 9L SL vL L oL 60 80 10 90 50 v0 0 10 Y i ov 6E 8t LE 9 SE SC8 01 Sz 2 4 NL 9 8 LE 0 6 8c Lt Sc vc EZ 0 8 at 9 620 4 ADM Sg A L 629 4 NOQve lt 016134 e OLL oL 60 80 L0 90 9801 11 isis 5 17 59 9 70 0 Kiddns 90 10 3 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Schematic Diagrams B 12 A069 009 pue 01 12945 15 220 0052 Lig 4 19 9 s s 612 0 ii 618 9 c M 2208 89
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22. 5 Unscrew the terminals for the DC supply from X1 of the first Gate Driver board Observe polarity when removing for later re attachment 6 Carefully unplug the fiber optic cables from sockets along the bottom of the Gate Driver board and carefully set them aside Important When mishandled the ability of fiber optic cables to transmit data is greatly diminished using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION Hazard of permanent eye damage exists when Important The minimum inside bend radius for fiber optic cable is 25 4 mm 1 in Any bends with a shorter inside radius can permanently damage the fiber optic cable Signal attenuation increases with decreased inside bend radii 7 Disconnect the X13 X14 and X15 cables from sockets of the Gate Driver board and set them aside 8 Remove the five screws that secure the Gate Driver board and support bracket to the power structure Remove screws Remove Gate Driver circuit board support bracket Remove screws 9 Carefully remove the Gate Driver board and the board support bracket PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P AFE Power Structure Component Section 4 15 10 Carefully remove the two plastic screws that secure the Gate Driver board screening plate to the power structure an
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24. Whenever possible isolate the AFE from the rest of the DC bus system to enable the AFE to be powered separately Appendix A Service Tools and Equipment Software Tools Connected Components Workbench software DriveExecutive software or DriveExplorer software are tools that can be used for uploading downloading and monitoring system parameters Service Tools The following list contains the basic service tools needed for repair and maintenance measurements Item Description Details 1 Oscilloscope Portable digitizing dual channel scope with isolation 2 Current clamp 1000A ac rms signal output 3 High voltage differential probe P5210 or equivalent 4 Soldering station Soldering de soldering 5 Flash light 6 Multi meter Digital multimeter capable of AC and DC voltage continuity resistance capacitance measurements and forward diode bias tests Fluke Model 87 IIl or equivalent 7 Insulation tester 1000V DC Torque wrench 1 12 Nem Torque wrench 6 50 Nem 10 box wrench 7 mm 8 mm 10 mm 13 mm 17 mm 19 mm 22 mm 11 Socket extension 230 mm 12 Wrench 7 mm 8 mm 10 mm 13 mm 17 mm 19 mm 22 mm 13 Allen wrench 14 Wire cutter 15 Nose pliers 16 Crimping tools For cable terminals 1 5 240 17 Angle wrench 18 Flat nose screw driver 7x2 mm 19 POZIDRIV screw driver 1 2 3 20 Phillips screw driver 1 2
25. e Install the Maintenance Stand catalog number 20 MAINSTD onto the power structure rails For details see Installation Instructions PowerFlex 700S 700H High Power Maintenance Stand publication PFLEX INO14 personal injury or damage to the equipment use caution when ATTENTION The power structure is heavy To avoid removing the power structure from the enclosure f Slide the power structure outward onto the rails of the optional Maintenance Stand Installing the Power Structure in the Enclosure Install the power structure in reverse order of removal See the PowerFlex Active Front End User Manual publication 20Y UMO01 for tightening torques of AC supply DC bus input and ground connection terminations Removing the U V or W Phase Assembly from the Power Structure Important Do not attempt to disassemble the Power Module within the U V or W Phase Assembly 1 Remove the power structure from the AFE enclosure See Removing the Power Structure from the Enclosure on page 4 19 2 Remove the ASIC Circuit board See Removing the ASIC Circuit Board on page 4 15 3 Remove the M10 x 25 hexagonal screws that secure the input power cables to the Input Power terminals on the power structure Remove screws and washers PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 4 24 AFE Power Structure Component Section 4 Remove the insulators from between the DC and DC bus ba
26. 0 z0 10 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Schematic Diagrams B 15 Control Wiring Diagram for Frame 13 21 Rittal Enclosure x1 Remote Operation of Motor Controlled Circuit Breaker 60 Optional 61 NOTE Unused terminals are not shown T4 230V AC L1 Control Power N Q1 4 34 02 t U1 95 98 96 511 R2 13 48 45 9 02 K20 D1 1 a A2 C1 11 ch NO t C12 21 22 1 21 31 34 K4 1 H3 1 A2 1 11 2 4 21 N O F10 T10 2 L K6 N A1 2 24 Fault 13 L4 PE Reset 2 NO 14 Optional L1 1 E Terminal 7 1 52 1 T A1 1 5 5 9 5 1 2 3 4 5 6 7 8 9 10 12 14 15 16 17 18 19 20 1 AIA1 AIA2 AIA2 10Vref PotGND 10Vref AOUT1 AOUTC AOUT2 DIN1 DIN2 DIN3 DIN5 06 D COM D COM 24V 24VCOM ABCD ABCD ABCD ABCD A16 1 gt
27. Enclosure The following figure shows a basic one line diagram for an AFE system in a IP20 2500 MCC Style enclosure The main component sections consist of the following items AC Line Switchgear consisting of the input circuit breaker QO 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 2 1 Basic One line Diagram for AFE in IP20 2500 MCC Style Enclosure AC Line Switchgear LCL Filter 11 Input Input Power Structure U1 Breaker Contactor 00 Fuses K1 F1 1 F1 3 Ua M DC Bus ML VARAA le e ARR Output le WANA ANAM oe Q i al 116 25 L E l pada ath Mea east vee pats Precharge Precharge Precharge uses Contactor reni Circuit K6 gt Pi o gt e pl 42 Pi 4 PowerFlex 1 Active Front End System SS SS PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN
28. No Name DC OverVolt Overload HeatsinkOvrTp IGBT OverTemp System Fault AC OverCurr Ground Fault Power Structure Fault Description The DC bus voltage exceeded the maximum value of 911V for 400 480V units or 1200V for 600 690V units When input current exceeds 125 for 60 seconds or 150 for 30 seconds The overload is a linear type in counting up The power structure heatsink temperature has exceeded the maximum allowable value 85 C Alarm 90 C Fault The output transistors have exceeded their maximum operating temperature due to an excessive load A hardware problem exists in the power structure The AC line current has exceeded the hardware current limit A current path to earth ground exists that is greater than the parameter 082 Ground Lvl value The current must appear for 800 milliseconds before the unit will fault A hardware problem exists in the power structure PowerFlex Active Front End Frame 13 Hardware Service Manual Troubleshooting and Error Codes 1 3 Action if appropriate 1 Check if the AFE was ina regenerative current limit condition which may indicate an excess regenerative load Adjust parameter 076 Regen Power Lmt Monitor incoming AC line for high voltage or voltage transients Reduce the current consumption of the AFE or increase parameter 133 Cnvrtr OL Factor 1 Verify that the maximum ambient tempera
29. PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Connector Descriptions C 5 Figure C 3 LCL Filter Fan Inverter Circuit Board Connectors Sg gt WY 2 x3 u X4 E e 8 255 P ane co 8 L geseh oo E ne 40 FO ET 5 05 4 20 of Xi 095 Lr 30 Table C F LCL Filter Fan Inverter Circuit Board Connections LCL Filter DC Fan LCL Filter DC Inverter Board Fan Assembly X1 X1 X3 X3 X8 X51 4 53 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P C 6 Connector Descriptions Notes PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Appendix D Disassembly Assembly Diagrams and Spare Parts Diagram Page AFE Power Structure Assembly External Components D 2 AFE Power Structure Internal Components U V or W Phase Assembly D 3 AFE Power Structure ASIC Assembly D 4 LCL Filter Assembly D
30. PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 4 22 AFE Power Structure Component Section AFE in IP21 Rittal Enclosure a PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P shown with enclosure doors removed Remove the six DC bus fuses from the terminal connections at the top of the power structure DC Bus Fuse Terminal Connections RG AFE in 21 Rittal Enclosure Front View Input Power Terminals Side View U T1 V T2 and W T3 Connections Ground 2 Connection Remove the U T1 V T2 and W T3 connections from the power structure at the front of the power structure Remove the ground connections of the power structure from the enclosure PE terminals Remove the output cable fastening screws and the two hexagonal screws that secure the power structure to the AFE frame Remove screws p each side of enclosure AFE Power Structure Component Section 4 23
31. Remove DC bus connection Unplug the fan which mounts on the cover from connector X11 of the ASIC circuit board Carefully unplug the fiber optic cables H1 through H7 from sockets on the ASIC board and carefully set them aside Important When mishandled the ability of fiber optic cables to transmit data is greatly diminished using optical transmission equipment This product emits intense ATTENTION Hazard of permanent eye damage exists when PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors Important The minimum inside bend radius for fiber optic cable is 25 4 mm 1 in Any bends with a shorter inside radius can permanently damage the fiber optic cable Signal attenuation increases with decreased inside bend radii Disconnect the X9 terminal block and the X15 terminal connectors Note When replacing the existing ASIC board with a new board the X9 and X15 connectors must be transferred and connected to the new board before installation Disconnect the X3 X4 X5 X6 and X10 cables from sockets on the front of the ASIC board and set them aside AFE Power Structure Component Section 4 17 10 Remove the four screws that secure the ASIC assembly to the power structure and remove the ASIC assembly Remove screws Remove ASIC assembly Removes screws 11 Remove the s
32. To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing Check the DC bus voltage between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION Hot surfaces can cause severe burns Do not touch the heatsink surface during operation of the PowerFlex Active Front End After disconnecting power allow time for cooling ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION The PowerFlex Active Front End contains electrostatic discharge ESD sensitive parts and assemblies that can be damaged if you do not follow ESD control procedures Static control precautions are required to install test service or repair this assembly If you are unfamiliar with static control procedures see Guarding Against Electrostatic Damage publication 8000 4 5 2 or any other applicable ESD protection handbook Use the instructions in this chapter to r
33. injury or damage to the equipment use caution when removing ATTENTION The LCL Filter is heavy To avoid personal the LCL Filter from the enclosure 9 Slide the LCL Filter out of the enclosure Note that ramps may be required due to enclosure floor mismatch Installing the LCL Filter in Install the LCL Filter in reverse order of removal while referring to Torque the Enclosure Specifications on page 4 2 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Overview Chapter 8 DC Fuses Component Section gt ATTENTION To avoid an electric shock hazard verify that all power to the PowerFlex Active Front End has been removed before performing any servicing or repairs ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing Check the DC bus voltage between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION Hot surfaces can cause severe burns Do not touch the heatsink surface during operation of the PowerFl
34. 1 ous LX SOVIIOA H3QNn 13599 Su3xv3ug LINDYIO NY 8298 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Schematic Diagrams B 22 A069 009 LL 19945 ensojoua EHH Lzdi 78 eJnDi4 zl DE ds iz v OL 9 9 7 s uj at 019 291 1 ILY 2 1 98 98 lt Ni 48 01 4 ozy E 2i 17 gc 9 4 45 vo zz 5 sii SX 39 ju 14 3r I ozy r4 i r vo 74 z9 199 LX 09 6891X x n J qi D 1 vz SX j esnd 4 829 IN M i E eb ey 1S x s v Y 9 Y 8 Hu L 5 8 2 9 21 x x vs o 1 8 X 0 ES L fiar org ies NA 015 24018 9v 2 BEX X x t 4 x x n 61216 e t v6 3 es 14 95 e lt 11 v8 0L 4 usn uoniisod NYIN OU ul S 9S eui LS uonnqusnd 1969 UBD SUL 9S jo uonisod 5 3 jo uedo IIM 9y 101260402 T pue LO GOON uonisod 0 ui S uos OLS ueuM
35. 44 45 47 LineSync Fail Phase Loss Anlg In Loss MicroWatchdog IGBT Temp Hw Fan Cooling AutoReset Lim CAN Bus Fit Application HeatsinkUndTp Device Change Device Add NvsReadChksum Description One input of the known phase rotation is missing There is zero current in one of the three phases An analog input is configured to fault on a signal loss A signal loss has occurred Configure this fault with parameter 203 or 206 Anlg In x Loss A microprocessor watchdog timeout has occurred The AFE input current has exceeded the 1 minute overload rating Fan is not energized at start command This includes the power structure or LCL Filter fans The AFE unsuccessfully attempted to reset a fault and resumed running for the programmed number in parameter 053 Auto Rstrt Tries You can enable disable this fault with parameter 120 Fault Config A sent message was not acknowledged Problem in application software with task overload The ambient temperature around the power structure heatsink is too low The new power unit or option board installed is a different type A new option board was added There was an error reading parameters 019 Motoring MWh 020 Regen MWh and 021 Elapsed Run Time from EEPROM Action if appropriate 1 Check all user supplied fuses 2 Check the AC input line voltage Check supply voltage fuses and cable 1 V
36. 5 LCL Filter Power Supply Assembly D 6 LCL Filter Fan Assembly D 6 Precharge Assembly for AFE in IP20 2500 MCC Style Enclosure D 7 Precharge Assembly for AFE in IP21 Rittal Enclosure D 8 AC Line Switchgear Components for AFE in IP20 2500 MCC Style Enclosure D 9 AC Line Switchgear Components for AFE in 21 Rittal Enclosure D 10 Diagrams on the following pages illustrate disassembly and assembly of the AFE and its sub systems and are followed by a list of spare part numbers where applicable When ordering spare parts you must provide the serial number of the PowerFlex Active Front End The serial number is located on the data nameplate on the Control Frame just above the bar code Data Nameplate on AFE Data Nameplate on AFE in IP20 2500 MCC Style Enclosure in IP21 Rittal Enclosure 13 Frame 13 A complete list of spare parts for the Frame 13 PowerFlex Active Front End is available on the Allen Bradley website at http www ab com support abdrives powerflex70 PF7ReleasedParts pdf PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P D 2 Disassembly Assembly Diagrams and Spare Parts AFE Power Structure Figure 0 1 AFE Power Structure Assembly External Components Assembly the ASIC Board located on the powe
37. AC line voltage which is at the 400 480V AC or 600 690V AC system voltage b Measure the control transformer T4 output voltage which is approximately 230V AC If these measurements are not within 10 perform these other steps c Power down the AFE d Remove the output secondary wires e Power up the AFE and retest by repeating steps a and b The control transformer T4 may require replacement if these measurements continue to be outside of the 10 tolerance 4 Use a digital voltmeter to test the 24V DC power supply 10 a Measure the primary voltage which is 230V AC b Measure the power supply T10 output voltage which is approximately 24V DC If these measurements are not within 10 perform these other steps Power down the AFE d Remove the 24V DC output wires of the power supply T10 e Power up the AFE and retest by repeating steps a and b The 24V DC power supply T10 may require replacement if these measurements continue to be outside of the 10 tolerance PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 6 6 Precharge Component Section Testing the Precharge 1 Bridge Using the Power Structure Terminals Replacing the Precharge 1 Bridge PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Remove power from the AFE See Removing Power from the AFE on page 4 3 If present remove the protec
38. ALON a YOLOVLNOO 330 NO 8 2 9 6 Y 6 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Circuit Board Connections Connector Descriptions Appendix C The following tables detail the connection points for the Frame 13 PowerFlex Active Front End circuit boards and components Table C A Fiber Optic Adapter Board to ASIC Circuit Board Connections Fiber Optic Signal Description ASIC Board Fiber Adapter Connector Type Reference to ASIC Board Type Connector H1 TX Gate_Enable RX H1 H2 TX 0 Gate RX H2 H3 TX V Gate RX H3 H4 TX W Gate RX H4 H5 TX A D Convert RX H5 H6 TX VBUS RX RX H6 H7 RX VBUS TX TX H7 X2 From 24V DC Power To X10 X3 From Auxiliary 24V DC Power To T10 power supply on Supply control panel 1 See Figure C 1 on page C 3 for ASIC board fiber optic connectors Important When mishandled the ability of fiber optic cables to transmit data is greatly diminished ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors Important The minimum inside bend radius for fiber optic cable is 25 4 mm 1 in Any bends with a shorter inside radius can permanently damage the fiber optic cable Signal attenuation increases with decr
39. Hardware Service Manual Publication 20Y TG002B EN P 7 6 LCL Filter Component Section Removing the LCL Filter PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P The procedures to remove the LCL Filter are slightly different depending on the enclosure in which it is installed From the IP20 2500 MCC Style Enclosure 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 Remove the LCL Filter protective barriers See Removing the LCL Filter Protective Barriers and Vented Cover on page 7 2 Remove the Air Flow Plate See Removing the AFE Air Flow Plate on page 4 12 Remove the X51 and X53 terminal blocks from the LCL fan assembly Remove the X52 terminal block from the LCL filter assembly upper right side Remove the top and bottom brackets that hold the LCL Filter in the enclosure see Figure 7 4 a See Detail A and remove the six M8 x 20 screws b See Detail B and remove the six M8 x 20 screws Figure 74 Removing LCL Filter from in IP20 2500 MCC Style Enclosure LCL Filter Component Section 7 7 7 See Figure 7 5 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 Figure 7 5 Removing Input Bus Bar Connections DETAIL C
40. Replace the control frame in reverse order of removal while referring to Torque Specifications on page 4 2 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 4 10 AFE Power Structure Component Section Power Structure Access Procedures Remove Screws lt Remove Follow these instructions to remove and install components on the power structure and to remove Power Modules from the power structure Important To access Power Modules for replacement requires the power Removing AFE Protective Barriers 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 structure to be completely removed from the AFE enclosure 2 Remove the screws that secure the protective barriers to the AFE enclosure 3 Remove the protective barriers Removing Protective Barriers for AFE in IP20 2500 MCC Sty Enclosure 1 screws Remove screws 7 Screws
41. U er 81 8 enDi4 el di 6 NI LX 2 vl X 9 7 c Mm ay H z S I Vi 6 LX 21 9 9 1 829 Publication 20Y TG002B EN P PowerFlex Active Front End Frame 13 Hardware Service Manual Schematic Diagrams B 20 A069 009 pue 6 19945 ensojou3 1241 4 enbi4 SL NI 364 20 0 3 1 20 72 2 062 L OLL lt NL 48 8 VEOL IX H3MOd 20 Ave 11 Y8 8 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P B 21 Schematic Diagrams A069 009 pue 01 19945 ensojoua 1241 4 0c g anfia 8 4 NL 29 i 67 895X 2426 24 Z 6EX eu zio 5 v 69 SH i aus nA OK OK LO 0 zc 95 4 LP Z 6EX 7 in Ho og 1 6 SX z eb zb SX 92 9 Sy 10 Js 8v 97 SX 96 186 42 9 ud b sey 10 9 9 SX e bsx NAE 829 amp a D E bh 10 2 5 g g SX Op qe gi Q o 8 5 L TE
42. Wire inputs correctly and or install jumper None Program parameters 221 226 Digital Inx Sel for correct inputs Run programming may be missing Check status bits of Correct the source of the inhibit parameter 100 Start Inhibits PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 1 8 Troubleshooting and Error Codes Instability in the AC Line Input Current and DC Bus Voltage Cause AC line voltage more than 5 above normal Negative reactive Ref on parameter 065 Reactive Ref with a soft high impedance AC line PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Indication Instability in AC line current and DC bus voltage May trip on fault F7 Overload Instability in AC line current and DC bus voltage May trip an F7 overload Corrective Action Increase parameter 060 DC Volt Ref proportional to the percentage of the AC line voltage above nominal Change parameter 065 Reactive Ref value to zero Verify if the AFE is running on a soft line per the AC line source considerations Chapter 2 Active Front End System Overview This chapter describes AFE system main components and is grouped by those used in a IP20 2500 MCC Style enclosure a IP21 Rittal enclosure and main components for the AFE 00 open chassis configuration AFE IP20 2500 MCC Style Main Component Sections
43. board connection 2 Verify the ground integrity from the Control board to the option board 3 Replace the Control board and or board See page 4 5 Check the LCL Filter and signal connection or verify that digital input 5 is closed See Chapter 7 There are nine total thermal switches connected in series to monitor temperature inside the coil of each filter inductor X52 Thermal Switch 1 t Thermal Switch 9 t To Digital gt Input 5 X52 is located on the LCL Filter X52 approximate location Frame 13 LCL Filter The LCL fan has been stopped Check the LCL fan See Chapter 7 NOTE This fault occurs only when the user has manually programmed a digital input as option 5 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Common Symptoms and Corrective Actions No Name Description 128 Contact Fdbk missing 133 DigInConflict conflict 138 DCRefLowLim DC Ref Lo Lmt 139 DCRefHighLim Ref Hi Lmt 140 DCBusLoAlarm Lo Alarm 141 DCBusHiAlarm Hi Alarm The input of the acknowledge signal from the main contactor is Digital input functions are in DC voltage reference is less than the limit in parameter 080 DC voltage reference exceeds the limit in parameter 081 DC DC voltag
44. gt back of the Control Frame 7 Green Ground Wire 9 Se eS 5 Remove the four screws and the assembly from the Control Frame For AFE in 20 2500 For AFE in 21 MCC Style Enclosure Rittal Enclosure T Door with DPI interface Mounting screws Mounting screws board and B F HIM in open osition 0 9 Nem 0 9 Nem 8 Ibsin 8 Ibein ne e n PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P AFE Power Structure Component Section 4 5 Installing the DPI Interface Assembly Install the DPI interface assembly in the reverse order of removal while referring to Torque Specifications on page 4 2 Removing the I O Circuit Boards and Control Box 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 2 For an AFE a IP20 2500 MCC Style enclosure open the control box and carefully unplug the DPI cable and any I O cables For an AFE in a IP21 Rittal enclosure open the enclosure that contains the control and I O circuit boards and carefully unplug the DPI cable and any I O cables 3 Remove the I O boards from the Control board and enclosure Note the order of the boards and the keys which prevent placement of boards in incorrect slots NOTE Do not remove the enclosure cover from the Control Frame For clarity the enclosure is
45. not within 10 perform these other steps c Power down the AFE d Remove the 24V DC output wires of the power supply T10 e Power up the AFE and retest by repeating steps a and b The 24V DC power supply T10 may require replacement if these measurements continue to be outside of the 10 tolerance For AFE in IP21 Rittal Enclosure 1 If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 personnel During these tests the AFE is powered Take proper ATTENTION These tests must be performed by qualified 2 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P precautions to avoid injury from electrical shock Locate the control transformer T4 and 24V DC power supply T10 The control transformer T4 is located behind the Control Frame The 24V DC power supply T10 is located on a sub panel in front of the components shown in the front view Precharge Component Section 6 5 FRONT VIEW shown with enclosure doors removed Control Transformer T4 is mounted directly behind Control Frame assembly 24V DC Power Supply T10 is mounted on this DIN rail which is on a sub panel mounted behind the Control Frame assembly 3 Use a digital voltmeter to test the control transformer T4 a Measure the primary
46. on page 4 23 3 Remove the power module from the U V or W Phase Assembly but do not perform the last three steps 20 through 22 in that procedure See Removing the Power Module from the Phase Assembly on page 4 25 4 Note the polarity of the capacitors PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P AFE Power Structure Component Section 4 31 5 Remove the four M4 x 8 screws that secure the capacitor to the power structure Remove screws Remove screws 6 Remove the capacitor Tightening torque for reassembly is 1 35 Nem 12 Ibein We recommend replacing all capacitors at the same time 7 Repeat steps 5 and 6 for each remaining DC Bus Capacitor being removed Installing the U V or W Phase Assembly DC Bus Capacitors Install the capacitors in reverse order of removal Make sure to observe the polarity of the capacitors as noted in removal step 4 above Replacing the Existing Power Structure with a New Power Structure When replacing the existing AFE Frame 13 power structure with a new one SK Y1 PWRMOD D1K3 for 400 480V or SK Y 1 PWRMOD E1KO for 600 690V you must do the following before installing the new power structure to avoid possible equipment malfunction Remove the common mode capacitors in the new power structure Remove the Power Supply Voltage Feedback board from the new power structure Use the following procedure
47. optic cable Signal attenuation increases with decreased inside bend radii Verify that the fiber optic cables are properly connected between the ASIC board and the Fiber Optic Adapter circuit board Disconnect the cables and inspect them for scratches and cracks and overall integrity Important When mishandled the ability of fiber optic cables to transmit data is greatly diminished Reconnect the cables replacing any damaged cables Performing Gate Driver Board Resistance Measurements Approx 0 5 ohms 61 W T3 Component Test Procedures 3 7 Remove power from the AFE See Removing Power from the AFE on page 4 3 If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 Remove the protective front covers and terminal covers from the power structure for each phase U V and W See Removing Protective Covers from the Power Structure on page 4 13 There are three Gate Driver boards on the power structure one for each phase U V and W Measure the power transistor gate interface resistance for each phase U V and W The resistance from each ignition pin to the branch emitter pin connectors X10 and X11 is approximately 166 ohms The resistance
48. remove the power structure from the enclosure AFE in IP20 2500 MCC Style Enclosure a Disassemble the four M10 x 50 bolts and associated hardware that secure the DC and DC bus bars of the AFE power structure to the MCC bus AFE 20 2500 MCC Style Enclosure shown with enclosure doors removed DC Bus Connections M10 x 50 11 3 Nem 100 Ibein U T1 V T2 and W T3 Connections M10 x 40 40 Nem 354 Ibein Ground Connections PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 4 20 AFE Power Structure Component Section 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 d Remove eight M6 x 16 screws that secure the cart assembly to the enclosure i EN Remove screws Cart Assembly ES M6 x 16 Ca 4 5 Nem 4 40 Ibsin Remove screws ATTENTION The cart assembly is heavy To avoid A personal injury or damage to the equipment use caution when removing the cart assembly from the enclosure e Roll the cart assembly which contains the power structure outward from the enclosure Note that ramps may be required due to floor mismatch When replacing the complete power structure continue with the follow
49. shown without the cover H Keys 4 Unplug the serial connection from X7 of the Control board 7 558205 l N 3 Serial Port X2 Slot A Slot B X4 Slot C X5 Slot D X6 Slot E 9999999999 9199994199998 99999941999 9999994999 9199994199998 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 4 6 AFE Power Structure Component Section 5 To remove the Control box remove the three screws that secure it to the Control Frame NOTE Do not remove the enclosure cover from the Control Frame For clarity the enclosure is shown without the cover 3 Nem 27 Ibein 2 Installing the I O Circuit Boards and Control Box Install the control box and I O circuit boards in reverse order of removal while referring to Torque Specifications on page 4 2 Removing the Fiber Optic Adapter Circuit Board 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 2 Foran AFE in a IP20 2500 MCC Style enclosure open the control box on the enclosure door to access the Control assembly For an AFE in a IP21 Rittal enclosure see the following drawing and do perform these substeps Loosen T8 Torx head screws Open the enclosure door to access the Contr
50. tee d 0911 8L fin c fra aj 9 9L Ot LLL 9L vS 42 EMEN E vL vL Z x x 1uvis 81 1075 in ud 2 u m 1 1075 211 0L U21IMS 95 y uonisod y u do 1012e1u00 Hulbieyd ois 60 pue L4 HOLDVINOO NIVW 9t uonisod 0 51 YDYMS OLS 94 ueuM ION X x SI 2 5 XL x NV E T x x a 80 at le s e M co N 1018 15 191 90 95 IL Puy 1518 TL 9 0 2 o 3 5255 83 w 425 5 22 9599 36 59 DOM y z 5 g a 10 10 H 9 1 1 A q 2 Y PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Schematic Diagrams B 14 5 pue Jayeasg pue 99018 21 199 6 ejas DOW 0052 0241 U 61 8 nd 4 52 6t 8t LE 9E SE 43 LE 0t 6c 82 4 9c 14 r4 oz 6L 8L at 9L SL vL L oL 60 80 10 90 50 v0 0 10 NOLD3NNOO TVNH31NI SISISISISIS LL OL 6 8 L 9 5 t E L 0 0 0 0 tel 10 0 01 le oT o 921 egi yy NOLDINNOD
51. terminal and the chassis The voltage must be zero for all three measurements before proceeding PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 4 4 AFE Power Structure Component Section Control Frame Access Removing the DPI Interface Assembly Procedures 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 Important Before removing connections and wires mark them to avoid incorrect wiring during assembly 2 For an AFE in a IP20 2500 MCC Style enclosure disregard this step For an AFE in a IP21 Rittal enclosure locate the control assembly item 6 in Figure 2 5 and remove the two screws from the front of the DPI hinged assembly For AFE 20 2500 21 MCC Style Enclosure Rittal Enclosure Remove Screws zo 1 e 0 9 Nem o o 8 Ibein o mne re U U 3 For an AFE in IP20 2500 MCC Style enclosure open the control box door to access the DPI interface board For an AFE in a IP21 Rittal enclosure open the hinged assembly that holds the DPI interface board 4 Unplug the DPI cable from the X2 connector on the DPI interface board _ Back view of the DPI X2 interface board which pee remains mounted on the X4
52. the Balancing Resistor assemblies to the U V or W Phase Assembly Remove screws 15 Remove 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 Nem 35 Ibein Bus bars only 1 for 480V unit A uum Remove all screws holding bus Insulator bars and insulators to AFE frame Bus bar Metal plate c SENE NS Remove Insulator 5 screws FA Bus bar E a Metal plate ERES Remove nsutator Screws 690V AFE Input Power Module shown PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 4 30 AFE Power Structure Component Section 17 Remove the M4 x 8 screws that secure the Power Module to the U V or W Phase Assembly 18 Remove the Power Module Remove screws Remove screws 19 Repeat steps 10 through 18 for each remaining Phase Assembly Installing the Power Module on the U V or W Phase Assembly Install the Power Module in reverse order of removal while referring to Torque Specifications on page 4 2 Removing the U V or W Phase Assembly DC Bus Capacitors 1 Remove the power structure from the AFE enclosure See Removing the Power Structure from the Enclosure on page 4 19 2 Remove the U V or W Phase Assembly from the AFE See Removing the U V or W Phase Assembly from the Power Structure
53. the control transformer T4 and 24V DC power supply T10 The control transformer T4 is located at the bottom of the left most enclosure AC input switchgear The 24V DC power supply T10 is located in the bottom of the control box FRONT VIEW shown with enclosure doors removed 57 6555 Control Box 76178 eoo located on front of enclosure door shown with control box cover removed SS RRL ALB 24V DC Power Supply T10 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 6 4 Precharge Component Section 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 120V AC If these measurements are not within 10 perform these other steps c Power down the AFE d Remove the output secondary wires e Power up the AFE and retest by repeating steps a and b The control transformer T4 may require replacement if these measurements continue to be outside of the 10 tolerance Use a digital voltmeter to test the 24V DC power supply T10 a Measure the primary voltage which is 120V AC b Measure the power supply T10 output voltage which is approximately 24V DC If these measurements are
54. transformer and 24V DC power supply testing 6 3 control wiring diagram AFE IP20 2500 MCC Style enclosure B 6 AFE in 21 Rittal enclosure B 15 creating fault reports 1 2 Index D DC fuses overview 8 1 replacement guidelines 8 2 de energizing the AFE 4 3 diagnostic status indicators 3 2 diode tests forward biased 3 3 reverse biased 3 3 disassembly assembly diagrams D 1 E external components of AFE power structure D 2 F fan inverter fuse checking 3 8 faults creating reports 1 2 list 1 2 fiber optic cable routing connections C 3 connection checking 3 5 forward biased diode test 3 3 G gate driver board resistance measurements 3 7 general precautions P 3 H hardware connections C 4 hardware faults 1 2 input disconnect AFE in IP20 2500 MCC Style enclosure 5 2 AFE in IP21 Rittal enclosure 5 2 inspecting cooling tunnels 3 2 power structure 3 2 internal components of AFE power structure for U V or W phase assembly D 3 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Index 2 L LCL filter assembly parts D 5 fan DC power supply installation 7 5 removal 7 3 fan replacement 7 5 fuse replacement 7 2 removing from 20 2500 MCC Style enclosure 7 6 21 Rittal enclosure 7 7 removing protective covers 7 2 M main component locations AFE IP20 2500 MCC Style enclosure 2 2 AFE 21
55. with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequence gt gt IMPORTANT Identifies information that is critical for successful application and understanding of the product Labels may also be on or inside the equipment to provide specific precautions SHOCK HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present BURN HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures ARCFLASH HAZARD Labels may be on or inside the equipment for example a motor control center to alert people to potential Arc Flash Arc Flash will cause severe injury or death Wear
56. 1 Remove the old power structure from the enclosure See Removing the Power Structure from the Enclosure on page 4 19 2 Remove the common mode capacitors from the new Frame 13 power structure that is replacing the old power structure For the procedure to remove the common mode capacitors see the PowerFlex Active Front End User Manual publication 20 001 Refer to Chapter 2 section Disconnecting Common Mode Capacitors and subsection Frame 13 Power Structure These instructions apply to an AFE in a IP20 2500MCC Style enclosure or an AFE in a IP21 Rittal enclosure PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 4 32 AFE Power Structure Component Section 3 Use the following substeps to remove the Power Supply Voltage Feedback board from the new Frame 13 power structure that is replacing the old power structure a Disconnect the DC bus connection cable from connector J2 and the motor feedback connection cable from connector J1 at the top of the Power Supply Voltage Feedback board J8 located behind cover b Carefully disconnect the fiber optic cables from sockets J4 and J5 on the side of the Power Supply Voltage Feedback board and secure these unused cables to the adjacent fan housing so that they are out of the way using optical transmission equipment This product emits intense light and invisib
57. 19599 Linv4 LINN TOH LNOO 1 0 9 bdV 0 9 9 Publication 20Y TG002B EN P PowerFlex Active Front End Frame 13 Hardware Service Manual Schematic Diagrams B 10 A069 009 pue 8 19945 ensojou3 46 DOIN 0052 Ul 6 g e Ww ly Ov Ov 6E 6E 8t 8t LE LE 9t 9t SE SE vev 6 NI 3 3 3 5 3 5 v 0 18 ca m 8l NV 81 NV 81 zal wi LX 281 181 8 4 9 D 2 EE 43 43 Le 81 81 81 81 281 zal 181 Nv3 Le oe th N N N N N N 8 N 8 N N N N 0 a 5 wm BW a 8c 6NV4 8Nv4 1 I 9 1 1 vNV i 14 44 eal eal Nv3 81 81 zal zal 181 Nv3 st e b g V s 0 8 EZ 1063 0 Pl u gt 0128 ra r4 Zw 4 bT 2 27 oc 6L 6L 14180418 a hs P LL aL 6 5 z E 4 an z lais z si 5 si si ex L EL L 910N i iddns Buipioooe de ay peau Aew 6 i608 0709 i jnejep Se A069 0106 51 uoroeuuoo 1 jouoo 4 epoo
58. 2B EN P DC Fuses Component Section 8 3 For more information about Bussmann fuses go online at http www cooperindustries com For more information about Ferraz Shawmut fuses go online at http www ferrazfuses com PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 8 4 DC Fuses Component Section Notes PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Chapter 9 Startup After Repair the ASIC Board located on the power structure are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION The sheet metal cover and mounting screws on Front End to perform the following start up procedure Some of the voltages present are at incoming line potential To avoid electric shock hazard or damage to equipment only qualified service personnel should perform the following procedure Thoroughly read and understand the procedure before beginning During startup if one of these pre powerup checks reveals a concern do not proceed Remove power including user supplied control voltages User supplied voltages can exist even when main AC power is not applied to the PowerFlex Active Front End Correct the malfunction before continuing ATTENTION Power must be applied to the PowerFlex Active Phone United States 1 262 512 8176 7 AM 6 PM CST
59. 3 21 Torx screw driver 25 22 Hexagonal wrench 4 5 6 23 ESD protected place of work Working surface floor covering seat and ground connections 24 ESD protective clothing Wrist wrap shoes overall clothing coat 25 Power supply service Capacity of three phase service 400 500 690V AC 30A 26 20 MAINSTND maintenance stand Maintenance stand for removing power structure from AFE enclosure 27 Fiber optic repair kit Agilent HFBR 4593 Polishing Kit consisting of a Polishing Fixture 600 grit abrasive paper and 3 mm pink lapping film 3M Company OC3 14 For Agilent HFBR 4532 latching connectors and HFBR RL cable See Agilent publications 5988 9777EN and 5988 3625EN PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P A 2 Service Tools and Equipment Notes PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Appendix B Schematic Diagrams Frame 13 Circuit Board Connections ASIC Circuit xe 00 From DC Bus Board s DC To X6 on Phase U X9 pend S Gate Driver Boar
60. 7 8 Cut and remove the cable ties that secure the input power cables to the EMC cover plate and remove the cables Remove screws and output power cables Cut cable ties 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 PZ2 4 Nem 35 Ibein Remove EMC cover Remove screws Remove screw and P72 snubber capacitors 3Nem 27 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 4 28 AFE Power Structure Component Section 11 Remove the screws that secure the Power Bus Bar and support insulators to the power structure 12 Remove the Power Bus Bar and insulators Tightening torque for reassembly is 14 Nem 124 Ibein Support insulator Remove screws 13 Disconnect the Balancing Resistor wires from the DC bus bars Remove wire connections from DC bus bar end Older Style Balancing Resistors Newer Style Balancing Resistors P2 4Nem 3 Nem on os 85 27 Ibin 35 Ibein 27 Balancing resistor assembly screws Balancing resistor assembly screws PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P AFE Power Structure Component Section 4 29 14 Remove the screws that secure
61. 80V SK Y1 DCPS1 D460 SK Y1 DCPS2 F10 1 600 690V SK Y1 DCPS1 F325 LCL Fan Wire Kit 1 This kit can be used for either voltage class 2 These discontinued kits are no longer available but spares inventory is applicable Figure D 6 LCL Filter Fan Assembly gz Table D F LCL Filter Fan Assembly Part Number Part Name Main Fan 48V DC PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Part No SK Y1 DCFAN1 SK Y1 HF1 DF Disassembly Assembly Diagrams and Spare Parts D 7 Precharge Assembly Figure D 7 Precharge Assembly for AFE in IP20 2500 MCC Style Enclosure FRONT VIEW shown with enclosure doors removed Precharge Resistors er 00 eee eg RPL m e Precharge Fuse and Fuse Holder e Precharge Kit Control Transformer T4 Control Transformer Primary Fuse and Fuse Holder e Control Transformer T10 Secondary Fuse and Fuse Holder Table D G Precharge Assembly Part Numbers for AFE in IP20 2500 MCC Style Enclosure Part Name Part No Precharge Fuse SK Y1 MCCF5 F13 Precharge Fuse Holder SK Y1 MCCF5FUSEHOLDER F13 Precharge Kit 0 SK Y1 PRE2 F13 Control Transformer T4 1500VA SK R1 OFANXFMR F13 Control Transformer Primary 400 480V SK Y1 MCCF6 D Fuse 600 690V SK Y1 MCCF6 F Control Transformer Primary Fuse Holder SK Y1 M
62. Active Front End User Manual 20Y UM001 PowerFlex 700H 7005 and 700AFE Drive Fan Systems Installation Instructions PFLEX IN029 Drives in Common Bus Configurations Application Guidelines DRIVES AT002 For spare parts information for PowerFlex 7 Class Architecture Class Low Voltage AC Drives including the PowerFlex Active Front End go online at http www ab com support abdrives powerflex70 PF7ReleasedParts pdf Become familiar with the following conventions used in this manual Terms The following words are used throughout the manual to describe an action Word Meaning Can Possible able to do something Cannot Not possible not able to do something May Permitted allowed Must Unavoidable you must do this Shall Required and necessary Should Recommended Should Not Not recommended Cross References Figure 3 1 on page 3 4 is a cross reference to Figure 3 1 on page 4 of Chapter 3 Figure 1 on page C 3 is a cross reference to Figure C 1 on page 3 of Appendix C PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Overview P 3 Additional Support Additional troubleshooting information and software tools are available on Available on Internet the Allen Bradley Drives Technical Support website at http www ab com support abdrives General Precautions for Class 1 LED Product ATTENTION Hazard of permanent eye damage exists when usi
63. CCF6FUSEHOLDER Control Transformer T10 Secondary Fuse Holder SK Y1 MCCF3F4 1 includes diode bridge V6 one resistor R6 1 and a snubber capacitor C1 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P D 8 Disassembly Assembly Diagrams and Spare Parts Figure D 8 Precharge Assembly for AFE in IP21 Rittal Enclosure e 24V DC Power Supply T10 and Circuit Breaker e Control Transformer Motor Protection Relay e Control Transformer Circuit Breaker FRONT VIEW shown with enclosure doors removed e n m 0 0 X AL AL 1d Control Transformer T4 mounted on back wall behind Control Frame assembly
64. Canada 1 440 646 5800 24 hour support Outside United You can access the phone number for your country via the States Canada Internet Go to http www ab com e Click on Support http support rockwellautomation com e Under Contact Customer Support click on Phone Support Internet Go to http www ab com support abdrives E mail gt support drives ra rockwell com Be prepared to provide the following information when you contact Allen Bradley Drives Technical Support e Product Catalog Number e Product Serial Number e Firmware Revision Level PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 9 2 Startup After Repair Before Applying Power to the AFE PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Open the power structure enclosure door If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 Check for zero volts between DC and DC Perform forward and reverse biased diode tests using a digital multimeter See Performing Forward and Reverse Biased Diode Tests for Power Structure on page 3 3 Confirm that all wiring to the AFE AC input ground DC bus and I O 1s connected to the correct AFE terminals and is secure Verify that AC line power at the disconnect device is within the rated value of the AFE Verify that the control power voltage is correct
65. Hardware Service Manual Allen Bradley PowerFlex Active Front End Frame 13 PowerFlex AFE PowerFlex 00AFE 400 480V and 600 690V Allen Bradley Rockwell Software Automation Important User Information Read this document and the documents listed in the additional resources section about installation configuration and operation of this equipment before you install configure operate or maintain this product Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes laws and standards Activities including installation adjustments putting into service use assembly disassembly and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice If this equipment is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc
66. IC Assembly Part Numbers Part Name Part No ASIC Assembly Bracket ASIC Assembly Cover Included in 20 FR10850 ASIC Assembly Insulator ASIC Board 400 480V AFE SK H1 ASICBD D1300 600 690V AFE SK H1 ASICBD E1030 Fiber Optic Cable Set 20 PP09017 1 The ASIC board is unprogrammed PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Disassembly Assembly Diagrams and Spare Parts D 5 LCL Filter Assembly used Figure 04 LCL Filter Assembly in IP20 and IP21 enclosures LCL Filter Assembly LCL High Frequency 0 Capacitor Assembly gem m f LAT located behind LCL Capacitor Assembly Table D D LCL Filter Assembly Part Numbers Part Name Part No LCL Filter Assembly 400 480V SK Y1 LCL1 D1K3 600 690V SK Y1 LCL1 E1K0 LCL High Frequency 25 uF 400 480V SK Y1 CAPHF3 DF Capacitor Assembly 20 uF 600 690V SK Y1 CAPHF2 DF LCL Capacitor Assembly 120 uF 400 480V SK Y1 CAPLCL1 D1K3 53 600 690V SK Y1 CAPLCL1 F1K0 LCL Filter Inverter Fan Fuse SK Y1 F11 F10 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P D 6 Disassembly Assembly Diagrams and Spare Parts Figure D 5 LCL Filter Power Supply Assembly Table D E LCL Filter Power Supply Assembly Part Numbers Part Name LCL Filter Power Supply Part No Universal Kit Discontinued July 2014 2 400 4
67. IP20 2500 MCC Style Enclosure 6 8 AFE in IP21 Rittal Enclosure 6 8 LCL Filter Component Section Removing the LCL Filter Protective Barriers and Vented Cover 7 2 Installing the LCL Filter Protective Barriers and Vented 7 2 Replacing the LCL Filter DC Fan 7 2 Removing the LCL Filter Fan DC Power 7 3 Installing the LCL Filter Fan DC Power 7 5 Replacing the LCL Filter 7 5 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Chapter 8 Chapter 9 Appendix A Appendix B Appendix C Appendix D Appendix E Index Table of Contents iii Removing the LCL Filter o ince yer pr EE e 7 6 From the IP20 2500 MCC Style 7 6 From the IP21 Rittal 7 7 Installing the LCL Filter in the 7 8 DC Fuses Component Section OVERVIEW erbe ere NP tet inet aan 8 1 Fuse Replacement 8 2 Startup After Repair Before Applying Power to
68. Input Disconnect Switch Motor Controlled Circuit Breaker Table D J AC Line Switchgear Part Numbers for AFE in IP21 Rittal Enclosure 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 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Data to Collect LLJ T Supply AFE 9 o Drive Drive Appendix E AFE Power One line System Application Data Collect the following AFE system data before contacting Allen Bradley Technical Support Utility Transformer Delta Delta Delta Wye etc Type Input Volts Output Volts kVA Z None Solid High Resistive Ground Cable Length Cable Type Secondary Transformer Type Input Volts Output Volts kVA Z None Solid High Resistive Ground Cable Length Cable Type Line Reactor Mfgr Cat Num Impedance Isolation Mfgr Cat Num Impedance Input Contactor AFE Cat Num SCR Cat Num Output Contactor Cable Length Cable Type Drive Cat Num Output Reactor Mfgr Cat Num Q Terminator Mfgr Cat N
69. OZIDRIV 3 Nem 27 Ibein POZIDRIV is a registered trademark of the Phillips Screw Company Phillips is a registered trademark of Phillips Screw Company PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Removing Power from the AFE AFE Power Structure Component Section 4 3 ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing Check the DC bus voltage between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements Remove power before making or breaking cable connections When you remove or insert a cable connector with power applied an electrical arc can occur An electrical arc can cause personal injury or property damage by the following e Sending an erroneous signal to your system s field devices causing unintended machine motion e Causing an explosion in a hazardous environment Electrical arcing causes excessive wear to contacts on both the module and its mating connector Worn contacts can create electrical resistance 1 Turn off and lock out input power 2 Wait five minutes 3 Verify that there is no voltage at the AFE input power terminals 4 Check the DC bus voltage between the DC and DC terminals between the DC terminal and the chassis and between the DC
70. P 2 2 Active Front End System Overview Main Component Locations The following figure shows the main components of the AFE Frame 13 system in a IP20 2500 MCC Style enclosure Figure 2 2 AFE Frame 13 Main Component Locations IP20 2500 MCC Style Enclosure FRONT VIEW shown with enclosure doors removed FRONT VIEW reduced size shown with enclosure doors closed 00 5999 ok 2 Item Description Precharge Circuit Precharge Resistor R6 1 LCL Filter L1 Active Front End Power Structure U1 Input Circuit Breaker 00 AC Line Switchgear Input Fuses F1 1 F1 3 Input Contactor K1 DC Fuses F2 1 F2 6 AFE Control Box Assembly on the AFE door and shown with user installed HIM oocoocococe PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Active Front End System Overview 2 3 Main Bus Bar Locations There are several sets of bus bars in the AFE Frame 13 system that connect main system components e Bus bars between Input Breaker QO and AC Fuses F1 1 F1 3 e Bus bars between AC Fuses F1 1 F1 3 and Input Contactor K1 e Bus bars between Input Contactor K1 and the LCL Filter L1 e Bus bars between the AFE Power Structure U1 and DC Bus The following figure shows these bus bar locations Fi
71. RONT VIEW shown with enclosure doors removed o DC Bus Fuses Table D I AC Line Switchgear Part Numbers for AFE in IP20 2500 MCC Style Enclosure Part Name Part No AC Input Fuses 400 480V SK Y1 MCCF1 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 MCCQO 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 Y1 BUSSPLICE F13L MCC Bus Splice Barrier Kit not shown optional SK Y1 MCCBARRIER 1 The MCC Bus Splice Barrier kit must be used when installing Right side Bus Splice kit SK Y1 BUSSPLICE F13R or a Left side Bus Splice kit SK Y 1 BUSSPLICE F13R PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P D 10 Disassembly Assembly Diagrams and Spare Parts Figure D 10 AC Line Switchgear Components for AFE in IP21 Rittal Enclosure FRONT VIEW shown with enclosure doors removed o
72. Rittal enclosure 2 5 main component sections AFE IP20 2500 MCC Style enclosure 2 1 in 21 Rittal enclosure 2 4 measurement points for forward and reverse diode tests 3 4 motor controlled circuit breaker MCCB 5 2 0 one line diagram AFE in IP00 open chassis configuration 2 7 AFE in IP20 2500 MCC Style enclosure 2 1 AFE in IP21 Rittal enclosure 2 4 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P P performing forward biased diode test 3 3 gate driver board resistance measurements 3 7 reverse biased diode test 3 3 visual inspections 3 2 powering down 4 3 precharge assembly parts AFE in IP20 2500 MCC Style enclosure D 7 AFE in IP21 Rittal enclosure D 8 bridge replacement 6 6 bridge testing 6 6 fuse replacement 6 2 resistor replacement 6 8 testing control transformer and 24V DC power supply 6 3 testing resistor 6 7 precharging functions 6 2 R removing AFE air flow plate 4 12 AFE protective barriers 4 10 ASIC circuit board 4 15 control frame only AFE 21 Rittal enclosure 4 9 DPI HIM assembly 4 4 fiber optic adapter circuit board 4 6 gate driver circuit boards 4 13 circuit boards and control board 4 5 LCL filter fan DC power supply 7 3 from IP20 2500 MCC Style enclosure 7 6 from 21 Rittal enclosure 7 7 protective covers 7 2 power from AFE 4 3 power modules from U V or W phase assembly 4 25 power st
73. a aQ g Semi g x10 On o o Approx 166 ohms g D e L7 e raion Gate Interface for U V or W High H Note Connectors X7 and X8 are connected in parallel with connectors X10 and X11 respectively and therefore do not have to be tested PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 3 8 Component Test Procedures Checking the AFE Power Structure Fan Inverter Fuses PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 1 5 Remove power from the AFE See Removing Power from the AFE on page 4 3 If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 Remove the protective front covers and terminal covers from the power structure for each phase U V and W See Removing Protective Covers from the Power Structure on page 4 13 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 Using a multi meter verify that they are not open Reinstall the good fuses and replace any open fuse with an equivalent rated fuse Chapter 4 AFE Power Structure Component Section gt gt bb ATTENTION To avoid an electric shock hazard verify that all power to the PowerFlex Active Front End has been removed before performing any servicing or repairs ATTENTION
74. a i e joe 4 NE e c 241 DES gt 1 F Tale o g esa A gt 5 LS al ny N Au 1 7 D ree 49 d PTE 2 2 o F XE B Y n 5 2 E iz EI 8 E 2 T S N o co 1 A eu mom 1 ai i Es es ge m Bex 9 49 5 5o 9 e oz 25 lt HE g S BEE 4 eo s 583 amp o t 285 5 TT e 84 58 2 E 0 0 gt uer sfa ojl sg 5 NS EXE Ro ge Wc com RU 8 oh PESE 0 9 on e fle Ge ak 5 do o 40 _ Ies E 9 7 0 us s M E 0 5 79 Le e d zi 8 Soo 5 lt LL PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P B 17 Schematic Diagrams A069 009 Z 19945 ensojou3 1241 4 9128 31n d JlavNa3 JOH1NOO U3183ANI Qe E aX 8 5 os vs aa Q 0 2 o Rs ev Bou cz 2 lt pr 88 mv VEU P 6 31015 gly 1015 40 60 70 po zo 189 9 190 002 100 202 Ed ERE
75. and appropriately discard the old precharge bridge Install the new precharge bridge in reverse order of removal while referring to Torque Specifications on page 4 2 Remove power from the AFE See Removing Power from the AFE on page 4 3 Open the LCL Filter enclosure door If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 Measure the resistance between the following two points with an ohmmeter Between the side of the precharge resistor R6 1 and the terminal on the TB of the precharge circuit NOTE This measurement applies to an AFE in either a IP20 2500 MCC Style enclosure or an AFE in a IP21 Rittal enclosure Between the side of the precharge resistor R6 2 and the terminal on the TB of the precharge circuit NOTE This measurement only applies to an AFE in a IP21 Rittal enclosure The precharge resistance is approximately 11 ohms for each measurement for an AFE in a IP20 2500 MCC Style enclosure or 20 ohms for each measurement for an AFE in a IP21 Rittal enclosure If the measured value is not correct disconnect a resistor wire and re measure again If the measured value is still not correct replace the precharge resistor Important Verify that the precharge resistor has not been engineered to a different value by the system engineer to accommodate a larger system capacitance as this may change the value of the precharge resistor See the PowerFlex Act
76. awmut Type IP20 2500 MCC 1100 170M6499 13 1100 PC73UD95V11CTF 21 Rittal 1250 170M6566 Table 8 B 600 690 Volt DC Fusing Frame AFE Fuse Size Enclosure Style Amps Bussman Type Ferraz Shawmut Type IP20 2500 MCC 630 170M6454 13 630 PC73UD13C630TF IP21 Rittal 700 170M6305 replace fuses use the following procedure 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 2 Open the power structure enclosure door 3 If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 Remove and discard the blown fuse Insert the fuse body between the bus bars Turn the threaded rod into the fuse body SX GO d Place the Belleville domed washer and hexagonal nut on the threaded rod and hand tighten 8 Hold the threaded rod with the hex key while tightening the nut to the specified torque Stud Tightening Nut Tightening Stud Type Torque max Torque max M8 x 30 10 Nem 18 5 Nem M8 x 35 88 5 132 8 Ibein M10x30 15Nem 26 Nem M10 50 132 8 Ibin 230 1 Ibein M12x35 15Nem 46 Nem M12x50 132 8 407 1 Ibein 15 Nem 46 Nem M12 x40 439 8 Ipeip 407 1 Ibsin Important Do not apply torque or twisting force to the fuse body as this can damage the fuse PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG00
77. ces can cause severe burns Do not touch the heatsink surface during operation of the PowerFlex Active Front End After disconnecting power allow time for cooling ATTENTION The PowerFlex Active Front End contains electrostatic discharge ESD sensitive parts and assemblies that can be damaged if you do not follow ESD control procedures Static control precautions are required to install test service or repair this assembly If you are unfamiliar with static control procedures see Guarding Against Electrostatic Damage publication 8000 4 5 2 or any other applicable ESD protection handbook PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 1 2 Troubleshooting and Error Codes Creating Fault Reports Complete fault reports are critical for analysis and repair of modules returned to the factory At a minimum do the following e Using an Allen Bradley drive configuration tool such as Connected TM Components Workbench software DriveExplorer software or DriveExecutive software do the following Upload all parameters from the PowerFlex Active Front End Run the Technical Support Wizard Collect the AFE system application data shown in Appendix E f possible record the contents of the fault queue faults and times of occurrence e Make record of the following Any burn marks on the rectifying module DC capacitors inverter bridge charging resistors balanci
78. crew and detach the four plastic standoffs that secure the ASIC board to the ASIC chassis and remove the ASIC board Remove screw Remove ASIC circuit board from chassis If the plastic insulator requires replacement do the following a Remove the four screws that secure the board holder to the metal frame and remove the metal frame and insulator Remove screws Remove metal frame and insulator PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 4 18 AFE Power Structure Component Section b Carefully remove the four fasteners that secure the insulator to the metal frame and remove the insulator Remove insulator Remove fasteners c Replace the insulator Installing the ASIC Circuit Board Install the ASIC circuit board in reverse order of removal while referring to Torque Specifications on page 4 2 Reconnect cables and jumpers to the ASIC board while referring to Figure 1 on page 1 the ASIC circuit board located on the power structure are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly Verify that the DC bus wire is properly connected to the ASIC chassis cover ATTENTION The sheet metal cover and mounting screws on Removing and Installing the Power Structure Fan System There are three Main Cooling Fans on the power structure For complete deta
79. d H8 To H15 on Phase U X15 Gate Driver Board PIS Charge PN To H16 on Phase U m Relay He 1 Gate Driver Board X600 X11 Fan Control 3 x4 0 X6 on Phase V To Fan Inverter X8 Gate Driver Board H10 To H15 on Phase V X26 Gate Driver Board ASIC Board Fan n To H16 on Phase V 4 Gate Driver Board D X5 To X6 on Phase W X10 1 Gate Driver Board T H12 To H15 on Phase W H2 1 Gate Driver Board ji H13 To H16 on Phase W Gate Driver Board x2 1 Fiber Optic Cables x29 24V 4 HIMHOHAHSHOHT 225 Fiber Optic 2 SHENI 20 VB00601 Adapter Board Gnd 2 DPI Interface Board ra i Nil fue DEVE CP NL WO vw i yo HIM 700 Control Board RS 232 Bezel g Programming Ia 2 Ji p X2 X3 J3 slot A slot B 20 nmm 59 Dor X PORT 1 Example 20C DA1 A AMOD iai 20C D01 i 20C DPI ANETA l Digtal Output Option Option Analog 1 0 Option Option DPI Assembly i 1 jJ 1 X3 HP HIM Analog Digital 3 3 20C DPI1 External DPI VO Inputs DPI Comm 10 8 10 Option Board Figure B 1 Frame 13 Circuit Board Connections PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P B 2 Schematic Diagrams DC DC Bus Output DC d Frame 13 Power Structure Power Circuitry Block Diagram
80. d Power Module it is recommended to replace all three Power Modules to avoid potential failure on the remaining Power Modules due to residual damage The following procedure describes removing the Power Module from one Phase Assembly Repeat this procedure for each Phase Assembly 1 Remove the power structure from the AFE enclosure See Removing the Power Structure from the Enclosure on page 4 19 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 4 26 AFE Power Structure Component Section 2 Remove the U V or W Phase Assembly from the power structure See Removing the U V or W Phase Assembly from the Power Structure on page 4 23 3 Remove 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 Ifthe bus bar Airflow Channel is damaged remove and replace it Remove screws P72 Exe 4 Nem Pod 35 Ibein Remove insulator holding plate Remove bus bar terminals Optional remove airflow channel only if damaged 7 Remove the M8 x 20 hexagonal screws that secure the input power cables to the input power bus bar Tightening torque for reassembly is 14 Nem 124 Ibein PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P AFE Power Structure Component Section 4 2
81. d remove the screening plate 11 Remove the two stand offs that support the Gate Driver board Remove plastic screws Remove screening plate Remove stand offs 12 Repeat steps 5 through 11 for each of the remaining Gate Driver boards Installing the Gate Driver Circuit Boards Install the Gate Driver circuit boards in the reverse order of removal Removing the ASIC Circuit Board 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 2 If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 3 Remove the Air Flow Plate See Removing the AFE Air Flow Plate on page 4 12 4 Remove the protective front covers and terminal covers from the power structure See Removing Protective Covers from the Power Structure on page 4 13 the ASIC circuit board located on the power structure are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION The sheet metal cover and mounting screws on PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 4 16 AFE Power Structure Component Section 5 6 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 ASIC Remove screws assembly and cover ASIC cover
82. dary network if connected ion adapter is installed in the AFE and operating on the connected Important Always remove power from the Active Front End before performing visual inspections See Removing Power from the AFE on page 4 3 Inspecting the Cooling Tunnels 1 Remove the main cooling fans from the bottom of the power structure For details see PowerFlex 7005 700H and 700AFE Drive Fan Systems Installation Instructions publication PFLEX IN029 2 Inspect the tunnels Clean the heatsinks and tunnels if necessary Inspecting the Power Structure 1 Remove the protective barriers See Removing AFE Protective Barriers on page 4 10 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Performing Forward and Reverse Biased Diode Tests for Power Structure Component Test Procedures 3 3 2 Remove the protective front covers and terminal covers from the power structure for each phase U V and W See Removing Protective Covers from the Power Structure on page 4 13 3 Check components for burn marks breakage or foil delamination on circuit boards Check all the boards on the power structure Replace any of these components if they show evidence of burn marks breakage or foil delamination A forward biased diode test checks the semiconductor junctions between the terminals and measures the voltage drop across those junctions To pass each te
83. e shown with enclosure door and protective barriers removed Remove Protective Barriers The following components are located behind the vented cover e CL Filter DC Fan Fuses e CL Filter Fan e DC Power Supply Front Bracket Installing the LCL Filter Reinstall the protective barriers and vented cover in reverse order of Protective Barriers and removal while referring to Torque Specifications on page 4 2 Vented Cover Replacing the LCL Filter DC The LCL Filter DC fan fuses are located behind the vented cover at the Fan Fuses bottom of the LCL Filter Important Replace LCL Filter fan fuses with only ATQ8 Ferraz Shawmut fuses For complete details on LCL fan system information see PowerFlex 700H 7005 and 700AFE Drive Fan Systems Installation Instructions publication PFLEX INO29 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P LCL Filter Component Section 7 3 Removing the LCL Filter Fan The following figures show the LCL Filter fan DC Power Supply wiring DC Power Supply diagram with the connections to the AFE power structure and DC bus For complete details on LCL fan system information see the PowerFlex 700H 7005 700AFE Drive Fan Systems Installation Instructions publication PFLEX IN029 Figure 7 2 LCL Filter Fan DC Power Supply Wiring Diagram older version LCL Filter KLIXON L x52 4
84. e is less than the value set by parameter 078 DC Bus DC voltage exceeds the value set by parameter 079 DC Bus Troubleshooting and Error Codes 1 7 Action if appropriate 1 Check for closure on the following devices For AFE in IP20 enclosure input contactor K1 For AFE in IP21 enclosure MCCB Q1 2 Check digital input 4 on the Control board of the power structure Check the parameter settings of parameters 221 226 1 Check the parameter setting 2 Verify the bus voltage to be above the parameter value 3 Troubleshoot the cause of the low voltage condition 1 Check the parameter setting 2 Verify the bus voltage to be below the parameter value 3 Troubleshoot the cause of the high voltage condition Check the parameter setting Check the parameter setting AFE does not Start from Start or Run Inputs wired to the terminal block Cause AFE is faulted Incorrect input wiring See the Control Wiring section in the PowerFlex Active Front End User Manual publication 20 0 001 for information NOTE Jumper from terminal 17 to 20 is required when using the 24V DC internal supply Incorrect digital input programming There is some other start inhibit Indication Flashing red status light Corrective Action Clear fault e Press Stop Cycle power e Set parameter 121 Fault Clear to 1 e Clear Faults on the HIM Diagnostic menu None
85. eased inside bend radii PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 2 Connector Descriptions Table C B ASIC Board to Gate Driver Board Connections ASIC Board Gate Driver Board Signal Description X3 4 phase Ribbon Cable Signal Description Pin 1 U_Feedback Pin 2 U_Power_OK Pin 3 U Pin 4 U ETR 2 Pin 5 U ITR 9 Pin 6 U DC Pin 7 Ul Pin 8 U DC I Pin 9 U TEMP Pin 10 U DC T X4 X1 V phase Ribbon Cable Signal Description Pin 1 V Feedback Pin 2 V Power OK Pin 3 v 0 Pin 4 ETR 2 5 ITR 9 Pin 6 DC Pin 7 VI Pin 8 V DC I Pin 9 V TEMP Pin 10 V DCT X5 x1 wW phase Ribbon Cable Signal Description Pin 1 W_Feedback Pin 2 W_Power_OK Pin 3 W prR 1 Pin 4 W_ETR 2 Pin 5 WTR 9 6 DC 7 WI Pin 8 W DC I Pin 9 W TEMP Pin 10 W DC T H13 WL WL H4 H12 WH H2 H11 VL VL H4 Fiber Optic Gate Signals H10 VH VH H2 connect UH to UH UL to UL and so forth H9 UL UL H4 H8 UH UH H2 DTR N 0 Phase 3 Phase Overcurrent PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P C 3 Connector Descriptions Figure C 1 Fiber Optic Cable Routing obed uo gd 9192 ees uomeuuoyul ped 1 3429 104 00 se
86. eek D 7 AC Line Switchgear tigerat ohhh daw hod eee ads heen D 9 AFE Power One line System Application Data Data to Colect n iE a Rs SEE a Ua S es ols E 1 Typical Transformer Winding E 2 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P iv Table of Contents PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Who Should Use this Manual What is in this Manual Data Nameplate on AFE in 20 2500 MCC Style Enclosure What is Not in this Manual Additional Resources erial Number 123456 Preface Overview This manual is intended for qualified service personnel responsible for troubleshooting and repairing the PowerFlex Active Front End AFE You should have previous experience with and basic understanding of electrical terminology procedures required troubleshooting equipment equipment protection procedures and methods and safety precautions See safety related practices contained in Standard for Electrical Safety in the Work Place publication NFPA 70E This manual contains hardware service information for the Frame 13 PowerFlex Active Front End Verify that you are working on a Frame 13 by checking the data nameplate on the AFE The frame number is printed just above the serial number Data Nameplate
87. emove and install components from the Active Front End To remove and install components on the power structure and to remove a Power Module from the power structure see Power Structure Access Procedures on page 4 10 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 4 2 AFE Power Structure Component Section Understanding Torque Figures in Assembly Diagrams hardware Fastener Type POZIDRIV Screw Phillips Screw Hexagonal Bolt or Standoff Hexagonal Screw Hexagonal Nut Torque Specifications Torx Head Screw 35 Ibein Icons and numbers in the assembly diagrams indicate how to tighten Tool Type and Size PZ indicates POZIDRIV screwdriver bit P indicates Phillips screwdriver bit 4 amp Tightening Torque The following table lists fastener torque specifications for the circuit boards and main components of the Active Front End Item Hardware Final Torque AC Input Terminals M10 nut 40 Nem 354 Ibsin ASIC Circuit Board Mounting M4 x 8 POZIDRIV screws 0 9 Nem 8 Ibein ASIC Circuit Board Cover M4 x 8 POZIDRIV screws 0 9 Nem 8 Ibein ASIC Fan M4 x 16 POZIDRIV screws 0 4 Nem 3 5 Ibein Capacitor x 8 self tapping screws 1 Nem 9 Ibein DC DC Terminals M6 x 20 POZIDRIV screws 5 Nem 44 Ibsin DC Connective Bus Bars M10 x 20 hexagonal screws 8 Nem 71 Ibsin M8 x 25 hexagonal
88. er Supply see publication PFLEX IN029 for complete details Main Cooling Fan Assembly Air Flow Channel see publication PFLEX IN029 Em for complete details 2 5 Screening Plate Gate Driver Board Table D B AFE Power Structure Internal Component Part Numbers for U V or W Phase Assembly Part Name Part No Air Flow Channel n a Balancing Resistors n a DC Bus Bar Assembly n a DC Bus Bar Terminal Assembly n a Electrolytic Capacitors ELKO 3300 420V for 400 480V AFE 20 01005 ELKO 5600 420V for 600 690V AFE 20 PP01099 EMC Cover n a Gate Driver Board 400 480V SK H1 GDB1 F1314D 600 690V SK H1 GDB1 F1314E Power Module 400 480V SK H1 QOUT D1K3 600 690V SK H1 QOUT E1K0 Power Bus Bar n a Screening Plate for Gate Driver Board n a Snubber Capacitor Assembly n a PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P D 4 Disassembly Assembly Diagrams and Spare Parts the ASIC Board located on the power structure are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION The sheet metal cover and mounting screws on Figure 0 3 AFE Power Structure ASIC Assembly ASIC Assembly Cover ASIC Board Es ASIC Insulator ASIC Assembly Bracket Table D C AFE Power Structure AS
89. er of removal Table 6 A 400 480 Volt Precharge Fuse Rating Fuse Holder 9 Enclosure Style Amps Type Type IP20 2500 MCC 50 Bussmann DFJ 50 7 Bussmann CH60J3 IP21 Rittal 32 ABB OFAF000H32 ABB 0540012000 1 Precharge fuse designation is F5 for AFE in 20 2500 MCC style enclosure Precharge fuse designation is 6 for AFE 21 Rittal enclosure 3 Precharge fuse holder holds a quantity of three fuses PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Testing the Control Transformer T4 and 24V DC Power Supply T10 Control Transformer T4 Precharge Component Section 6 3 Table 6 B 600 690 Volt Precharge Fuse Rating Fuse Holder 3 Enclosure Style Type 20 2500 MCC 50 Bussmann DFJ 50 1 Bussmann CH60J3 IP21 Rittal 32 ABB OFAA000GG32 2 ABB 0540012000 1 Precharge fuse designation is F5 for AFE in IP20 2500 style enclosure Precharge fuse designation is 6 for AFE in IP 21 Rittal enclosure 8 Fuse holder holds a quantity of three fuses For AFE in IP20 2500 MCC Style Enclosure 1 If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 personnel During these tests the AFE is powered Take proper ATTENTION These tests must be performed by qualified precautions to avoid injury from electrical shock 2 Locate
90. erify parameter 203 or 206 Anlg In x Loss setting Input signal level should be greater than or equal to 1 5V 3 mA 2 Check for broken loose connections at the inputs 1 Cycle the power 2 Replace the Control board See page 4 5 Check for an excess load 1 If the LCL Filter fan is not operating check the fan DC power supply board located in front of the LCL Filter fan 2 If the power structure fan is not operating check the fan inverter board in back of the converter fan For additional information see PowerFlex 700H 7005 and 700 Drive Fan Systems Installation Instructions publication 029 Correct the cause and manually clear the fault 1 Cycle the power 2 Replace the Control board on the power structure See page 4 5 Contact Technical Support Raise the ambient temperature Clear the fault and verify the correct parameters for the new option board Clear the fault 1 Cycle the power 2 Replace the Control board See page 4 5 No 58 65 70 71 81 94 100 104 106 Name Start Prevent 1 0 Removed Power Unit Periph Loss Port DPI Loss Hardware Enbl Param Chksum PwrBrd Chksum MCB PB Config Troubleshooting and Error Codes 1 5 Description Startup has been prevented An I O option board has been removed Incorrect output power device operation The 20 COMM x communication adapter has a fault on the
91. ervice packs You can also visit our Support Center at https rockwellautomation custhelp com for software updates support chats and forums technical information FAQs and to sign up for product notification updates In addition we offer multiple support programs for installation configuration and troubleshooting For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com services online phone Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwellautomation com rockwellautomation support overview page or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact
92. ex Active Front End After disconnecting power allow time for cooling ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION The PowerFlex Active Front End contains electrostatic discharge ESD sensitive parts and assemblies that can be damaged if you do not follow ESD control procedures Static control precautions are required to install test service or repair this assembly If you are unfamiliar with static control procedures see Guarding Against Electrostatic Damage publication 8000 4 5 2 or any other applicable ESD protection handbook An AFE system in IP20 2500 MCC Style enclosure or IP21 Rittal enclosure contains the protective DC bus fuses Important For PowerFlex AFE systems in the Open Chassis configuration output fuses must be supplied by the user See the PowerFlex Active Front End User Manual publication 20Y UMODOI for the DC bus output fusing recommendations PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 8 2 DC Fuses Component Section Fuse Replacement DC bus fuses are required for short circuit protection The following tables Guidelines list the recommended DC bus fuses Table 8 A 400 480 Volt DC Fusing Frame AFE Size Enclosure Style Amps Bussman Type Ferraz Sh
93. from the X10 branch emitter pin to the same branch power terminal U T1 V T2 and W T3 is approximately 0 5 ohms The resistance from the X11 branch emitter to the same branch DC bus terminal is approximately 0 5 ohms If any of the gate interfaces fails this test replace the appropriate left middle or right power module See Removing the Power Module from the U V or W Phase Assembly on page 4 25 Gate Interface for ale 9 ile J D J U T1 V T2 W T3 Approx 0 5 ohms U V or W Low L FQ S 2 gt Emitter Hi 3 Approx 166 ohms o 2 O 99 aE OO ct 49 m 2
94. ge between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION Hot surfaces can cause severe burns Do not touch the heatsink surface during operation of the PowerFlex Active Front End After disconnecting power allow time for cooling ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION The PowerFlex Active Front End contains electrostatic discharge ESD sensitive parts and assemblies that can be damaged if you do not follow ESD control procedures Static control precautions are required to install test service or repair this assembly If you are unfamiliar with static control procedures see Guarding Against Electrostatic Damage publication 8000 4 5 2 or any other applicable ESD protection handbook PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 6 2 Precharge Component Section Precharging Functions Replacing the Precharge Fuse The p
95. gure 2 3 AFE Frame 13 Bus Bar Locations in IP20 2500 MCC Style Enclosure FRONT VIEW shown with enclosure doors removed DC bus bar AC power bus bars between Input Contactor K1 and LCL Filter L1 DC bus bar TEE Sr DC bus bars between RI e A Oo de AFE Power Structure Optional Bus Splice eao 22 5022 U1 and DC bus Kit not shown Optional Bus Splice Kit not shown AC bus bars between Input Circuit Breaker 00 and AC input fuses F1 1 F1 3 AC bus bars between AC fuses F1 1 F1 3 and Input Contactor K1 AC power bus bars between Input Contactor K1 and LCL Filter L1 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 2 4 Active Front End System Overview AFE in IP21 Rittal Enclosure Main Component Sections The following figure shows a basic one line diagram for an AFE system in a IP21 Rittal enclosure The main component sections consist of the following items e AC Line Switchgear consisting of the input disconnect 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 2 4 Basic One line Diagram for AFE in IP21 Rittal Enclosure
96. ication 8000 4 5 2 or any other applicable ESD protection handbook ATTENTION An incorrectly applied or installed PowerFlex Active Front End can result in component damage or a reduction in product life Wiring or application errors such as undersizing the motor incorrect or inadequate AC supply or excessive ambient temperatures can result in malfunction of the system ATTENTION Only qualified personnel familiar with adjustable frequency AC drives and associated machinery should plan or implement the installation start up and subsequent maintenance of the system Failure to comply may result in personal injury and or equipment damage gt gt PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P P 4 Overview Notes PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Chapter 1 Troubleshooting and Error Codes ATTENTION To avoid an electric shock hazard verify that all gt gt power to the PowerFlex Active Front End has been removed before performing any servicing or repairs ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing Check the DC bus voltage between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements ATTENTION Hot surfa
97. ify that the capacitor on the bridge and terminals is still in the circuit Disconnect the white wires from the terminal block by the bridge Remove the mounting screws from the failed precharge resistor and appropriately discard the resistor Install the new precharge resistor in reverse order of removal while referring to Torque Specifications on page 4 2 Chapter LCL Filter Component Section gt ATTENTION To avoid an electric shock hazard verify that all power to the PowerFlex Active Front End has been removed before performing any servicing or repairs ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing Check the DC bus voltage between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION Hot surfaces can cause severe burns Do not touch the heatsink surface during operation of the PowerFlex Active Front End After disconnecting power allow time for cooling ATTENTION Hazard of permanent eye damage exists when using optical transmission equ
98. ils on all fan system related information see the PowerFlex 7008 700H and 700AFE Drive Fan Systems Installation Instructions publication PFLEX INO29 including removal and installation of the following items AC fan inverters AC fan capacitors AC main cooling fans DC fan power supplies DC main cooling fans Fan fusing PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P AFE Power Structure Component Section 4 19 Removing the Power Structure from the Enclosure Important Power structure removal is required only when it or its internal components Power Module DC bus capacitors balancing resistors and so forth needs to be replaced 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 2 If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 3 Remove the Air Flow Plate See Removing the AFE Air Flow Plate on page 4 12 4 Remove the DC and DC wires from the Fan Inverter Fuse assemblies 5 Disconnect the seven fiber optic cables connected to the fiber optic adapter board located behind the control assembly for AFE in IP20 2500 MCC Style enclosure or the Control Frame for AFE inIP21 Rittal enclosure For location of connections see Removing the Fiber Optic Adapter Circuit Board on page 4 6 6 Depending on the enclosure in which the AFE is installed follow the appropriate procedure below to
99. ing substeps When replacing components within an individual phase assembly see Removing the U V or W Phase Assembly from the Power Structure on page 4 23 f Secure appropriate lifting 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 INOOI PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P AFE Power Structure Component Section 4 21 g Remove the six hexagonal bolts from the upper portion of the chassis backside and the six hexagonal bolts from the lower portion of the chassis backside to detach the power structure from its cart assembly Remove Six Hexagonal Bolts on Upper Portion Remove Six Hexagonal Bolts on Lower Portion Assembly h Remove the six hexagonal screws three on each lower side to detach the power structure from its cart assembly Remove screws three on each lower side of power structure i Remove the six DC output fuses two per phase from the power structure bus bars For DC fuse removal instructions see Fuse Replacement Guidelines on page 8 2 Separate the power structure from its cart assembly and remove the power structure by using appropriate lifting equipment
100. ipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION The PowerFlex Active Front End contains electrostatic discharge ESD sensitive parts and assemblies that can be damaged if you do not follow ESD control procedures Static control precautions are required to install test service or repair this assembly If you are unfamiliar with static control procedures see Guarding Against Electrostatic Damage publication 8000 4 5 2 or any other applicable ESD protection handbook PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 7 2 LCL Filter Component Section Removing the LCL Filter Protective Barriers and Vented Cover Remove power from the AFE See Removing Power from the AFE on page 4 3 Remove the protective barriers from the LCL Filter enclosure For an AFE in a IP20 MCC Style enclosure see Removing AFE Protective Barriers on page 4 10 For an AFE in a IP21 Rittal enclosure see Figure 7 1 below Remove the four T25 Torx self tapping screws that secure the front bracket shown in the figure below This bracket holds the LCL Filter in the enclosure Remove the vented cover from the bottom of the LCL Filter to access the DC fan fuses fan and DC power supply Figure 7 1 Removing Protective Barriers and Vented Cover from LCL Filter FRONT VIEW LCL Filter in IP21 Rittal Enclosur
101. iqe 1equ eje5 ebed 00270 9145 ees Jaquunu 915 104 Q X2 Publication 20Y TG002B EN P PowerFlex Active Front End Frame 13 Hardware Service Manual fel D 59029 4 eje5 seyd A X4 b pieog 19014 9ISV H13 H12 H11 pjeog M 4 Connector Descriptions Hardware Connections
102. is now new Chapter 9 Startup After Repair 9 1 In Appendix B e Added Frame 13 Control Wiring Diagram for AFE in IP20 2500 MCC Style enclosure e Added Frame 13 Control Wiring Diagram for AFE in IP21 Rittal enclosure e Added all system schematics for Frame 13 AFE in IP20 2500 MCC Style enclosure B 8 B 14 In Appendix C added new information and drawings Appendix C In Appendix D e Added LCL Filter Assembly section D 5 e Added Precharge Assembly section D 7 e Added AC Line Switchgear section D 9 Added new Appendix E AFE Power One line System Application Data E 1 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P soc ii Summary of Changes PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Preface Chapter 1 Chapter 2 Chapter 3 Chapter 4 Table of Contents Overview Who Should Use this 12 P 1 What 18 in this Manua ee eee eae et eene e Ue e evel ede P 1 What is Not in this Manual 2 P 1 Additional 5 Wud Gada sac d Gana cach des 1 General Information Drusi aet rca pe ros EC Er Pot P 2 PowerFlex Active Front End P 2 Understanding Manual 2
103. ive Front End User Manual publication 20Y UMO001 for total DC bus capacitance limits for the precharging circuit PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 6 8 Precharge Component Section Replacing the Precharge Resistor Assembly PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 20 2500 MCC Style Enclosure 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 Open the LCL Filter enclosure door If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 Disconnect the R6 1 precharge resistor wires from the resistor terminals on the precharge resistor assembly Remove the two precharge resistor assembly mounting screws that secure the assembly to the bracket on the LCL enclosure bay Remove the mounting screws from the failed precharge resistor and appropriately discard the resistor Install the new precharge resistor in reverse order of removal while referring to Torque Specifications on page 4 2 21 Rittal Enclosure 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 Open the LCL Filter enclosure door If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 Disconnect the wires from the and terminals on the precharge resistor assembly Ver
104. k injury or death exists if someone comes into contact with the assembly ATTENTION Hot surfaces can cause severe burns Do not touch the heatsink surface during operation of the PowerFlex Active Front End After disconnecting power allow time for cooling ATTENTION Hazard of permanent eye damage exists when using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION The PowerFlex Active Front End contains electrostatic discharge ESD sensitive parts and assemblies that can be damaged if you do not follow ESD control procedures Static control precautions are required to install test service or repair this assembly If you are unfamiliar with static control procedures see Guarding Against Electrostatic Damage publication 8000 4 5 2 or any other applicable ESD protection handbook gt gt gt PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 5 2 AC Line Switchgear Component Section AFE in IP20 2500 MCC Style Enclosure 21 Rittal Enclosure For a PowerFlex AFE system in the IP20 2500 MCC Style enclosure the AC line switchgear components are the input circuit breaker Q0 AC input fuses F1 1 F1 3 and input contactor K1 The input circuit breaker either connects or disconnects the AFE system to the AC line The input contactor co
105. le radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION Hazard of permanent eye damage exists when c Remove the four screws that secure the Power Supply Voltage Feedback board and cover to the V phase assembly module fan housing d Carefully remove the Power Supply Voltage Feedback board and cover e Disconnect the cable from connector J8 on the Power Supply Voltage Feedback board and secure this unused cable to the adjacent fan housing so that it is out of the way 4 Install the new replacement power structure See Installing the Power Structure in the Enclosure on page 4 23 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Chapter 5 AC Line Switchgear Component Section ATTENTION To avoid an electric shock hazard verify that all power to the PowerFlex Active Front End has been removed before performing any servicing or repairs ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing Check the DC bus voltage between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be zero for all three measurements ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at DC bus potential high voltage Risk of electrical shoc
106. ming 1 Restore the AFE to the factory defaults 2 Cycle the power 3 Replace the Control board in the power structure See page 4 5 1 Cycle the power 2 Check the fiber optics between the Fiber Optic Adapter board and the ASIC board See page 1 page C 2 and page C 3 for connections 3 Replace the Fiber Optic Adapter board see page 4 6 and or the ASIC board see page 4 15 in the converter unit 4 Contact Technical Support 1 Reset the fault 2 Cycle the power 3 Replace the Control board on the power structure See page 4 5 4 Contact Technical Support PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 1 6 Troubleshooting and Error Codes No 107 113 120 121 125 126 Name New IO Option Fatal App Change 1 0 Comm Loss LCL OverTemp LCL Fan Stop Description A new option board was added to the Control board A Fatal Application error has occurred An option board has been replaced A defective option board or I O board slot The LCL Filter has been overheated or the signal is not connected to input Action if appropriate 1 Clear the fault and verify the correct parameters for the new option board 2 Reprogram parameters as necessary 1 Oycle the power 2 Replace the Control board on the power structure See page 4 5 Reset the fault 1 Check the Control board to I O option
107. move the protective covers to access internal components of the power structure 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 Remove the four M5 POZIDRIV screws that secure the protective front covers and terminal covers to the power structure Remove the covers NOTE You need to remove only the terminal covers to gain access to the cooling fan connections Terminal Covers Installing Protective Covers on the Power Structure Install the protective covers on the power structure in reverse order of removal while referring to Torque Specifications on page 4 2 Removing the Gate Driver Circuit Boards There are three Gate Driver circuit boards on the front of the power structure 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 4 14 AFE Power Structure Component Section 3 Remove the Air Flow Plate See Removing the AFE Air Flow Plate on page 4 12 4 Remove the protective front covers and terminal covers from the power structure See Removing Protective Covers from the Power Structure on page 4 13
108. moving the Fiber Optic Adapter Circuit 4 6 Installing the Fiber Optic Adapter Circuit Board 4 8 Removing the Control Frame only for AFE in IP21 Rittal 4 9 Replacing the Control 4 9 Power Structure Access Procedures 4 10 Removing AFE Protective 4 10 Installing AFE Protective 4 11 Removing the AFE Air Flow Plate 4 12 Installing the AFE Air Flow 4 12 Removing Protective Covers from the Power Structure 4 13 Installing Protective Covers on the Power 5 4 13 Removing the Gate Driver Circuit 4 13 Installing the Gate Driver Circuit Boards 4 15 Removing the ASIC Circuit Board 4 15 Installing the ASIC Circuit 4 18 Removing and Installing the Power Structure Fan 4 18 Removing the Power Structure from the Enclosure 4 19 Installing the Power Structure in the
109. n using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION The PowerFlex Active Front End contains electrostatic discharge ESD sensitive parts and assemblies that can be damaged if you do not follow ESD control procedures Static control precautions are required to install test service or repair this assembly If you are unfamiliar with static control procedures see Guarding Against Electrostatic Damage publication 8000 4 5 2 or any other applicable ESD protection handbook PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 3 2 Component Test Procedures Viewing the Status Indicators Item Name OOOOO OOOOO OOOOO ogogo OOOOO LJ Table Status Indicator Descriptions Color o PWR Power Green State Steady Description Lights when power is applied to the AFE PORT 1 MOD 0 NET A NET B See to the Communication Adapter User Manual publication 2000MM UMxxx 1 These indicators operate only when a 20 COMM X communicat network Performing Visual Inspections Status of DPI port internal communication if present Status of communication adapter when installed Status of network if connected Status of secon
110. network side The DPI port has stopped communicating A SCANport device was connected to a drive operating DPI devices at 500k baud An enable signal is missing from the control terminal block only when jumper J5 is removed on the digitial I O board The checksum read from the Control board does not match the checksum calculated The checksum read from the EEPROM does not match the checksum calculated from the EEPROM data The AFE rating information stored on the power board is incompatible with the Control board Action if appropriate 1 Cancel prevention of startup if this can be done safely 2 Remove Run Request Clear the fault 1 Check the power structure for damaged components Replace if defective 2 Replace the power structure Check the DPI device event queue and corresponding fault information for the device 1 Check the HIM connection 2 Ifthe adapter was not intentionally disconnected check the wiring to the port Replace the wiring port expander adapters Control board or complete AFE as required 3 If an adapter was intentionally disconnected and the Logic Mask bit for that adapter is set to 1 this fault will occur To disable this fault set the bit in parameter 154 Logic Mask to 0 for the port in which the adapter is connected 1 Check the control wiring 2 Check the position of the J5 hardware enable jumper 3 Check the digital input program
111. ng optical transmission equipment This product emits intense light and invisible radiation Do not look into module ports or fiber optic cable connectors ATTENTION The sheet metal cover and mounting screws on the ASIC Board located on the power structure are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION To avoid an electric shock hazard verify that the AN voltage on the bus capacitors has discharged completely before servicing Check the DC bus voltage between the DC and DC terminals between the DC terminal and the chassis and between the DC terminal and the chassis The voltage must be Zero for all three measurements ATTENTION Potentially fatal voltages can result from improper usage of an oscilloscope and other test equipment The oscilloscope chassis can be at a potentially fatal voltage if not properly grounded Use high voltage differential voltage probes for all voltage measurements with the oscilloscope chassis correctly grounded to an earth ground ATTENTION The PowerFlex Active Front End contains electrostatic discharge ESD sensitive parts and assemblies that can be damaged if you do not follow ESD control procedures Static control precautions are required to install test service or repair this unit If you are unfamiliar with static control procedures see Guarding Against Electrostatic Damage publ
112. ng precharging resistors printed circuit boards bus bars cabling and fiber optic cabling Any liquid and condensation marks on printed circuit boards components and mechanical parts Amount of dust and other additional particles on drive and drive components Any mechanical damage to the drive and drive components e Record the size and type of main fuses e Record any other important marks and damage e Note grounding type solid high resistance or floating and source impedance of the power distribution system Addressing PowerFlex No Name Description Action if appropriate Active Front End Faults 1 PrechargeActv The AFE is still in precharge Reset the fault and restart because the charging switch K20 K6 and K1 for AFE in IP20 2500 MCC Style enclosure or K20 K6 and Q1 for AFE in IP21 Rittal enclosure is open Should the fault re occur contact Technical Support e faulty operation e component failure 2 Auxiliary In The AFE control digital input Verify wiring to the digital inputs on interlock is open the AFE control board are correct 4 DC UnderVolt The DC bus voltage fell below Monitor the incoming AC line for low the minimum value of 333V for voltage or power interruption 400 480V units or 461V for 600 690V units You can enable disable this fault with parameter 120 Fault Config PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P
113. nnects the internal AFE system AC line to the AFE power structure through the LCL filter The AFE power structure contains the control logic that opens or closes the input contactor See the PowerFlex Active Front End User Manual publication 20Y UMODOI for the AC input fusing and circuit breaker protection recommendations For a PowerFlex AFE system in the IP21 Rittal enclosure the AC line switchgear components are the input disconnect Q0 and MCCB Q1 The input disconnect either connects or disconnects the AFE system to the AC line The MCCB connects the internal AFE system AC line to the AFE power structure through the LCL filter The AFE power structure contains the control logic that enables or disables the resettable trip mechanism that is integrated into the MCCB The trip mechanism controls the MCCB functionality See the PowerFlex Active Front End User Manual publication 20Y UMO001 for the AC input fusing and MCCB protection recommendations PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Chapter 6 Precharge Component Section gt gt gt ATTENTION To avoid an electric shock hazard verify that all power to the PowerFlex Active Front End has been removed before performing any servicing or repairs ATTENTION To avoid an electric shock hazard verify that the voltage on the bus capacitors has discharged completely before servicing Check the DC bus volta
114. nual Publication 20Y TG002B EN P 7 4 LCL Filter Component Section 1 Remove the LCL Filter protective barriers See Removing the LCL Filter Protective Barriers and Vented Cover on page 7 2 2 Remove the two M4 x 10 mm POZIDRIVE screws that secure the cover X8 X3 X1 X4 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Installing the LCL Filter Fan DC Power Supply Replacing the LCL Filter Fan 5 LCL Filter Component Section 7 5 Remove the six fasteners that secure the DC to DC power supply Install the DC to DC power supply in reverse order of removal while referring to Torque Specifications on page 4 2 Remove the LCL Filter protective barriers See Removing the LCL Filter Protective Barriers and Vented Cover on page 7 2 Disconnect terminal blocks X51 and X53 X51 X53 Lower the front fan sheet metal edge and slide it forward to remove the alignment studs from their respective holes in the fan frame sheet metal Slide out the fan assembly Remove the LCL Filter Fan DC Power supply See Removing the LCL Filter Fan DC Power Supply on page 7 3 Reinstall the LCL Filter Fan in reverse order of removal while referring to Torque Specifications on page 4 2 Note the following LCL Filter air flow cooling requirements LCL Filter Required Air Flow LCL 460 1100 m3 hr LCL 1300 1300 m hr PowerFlex Active Front End Frame 13
115. ol Frame b Loosen the T8 screws to open the Control Frame c Swing open the Control Frame which exposes the back of the Control box to access the fiber optic adapter board PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P AFE Power Structure Component Section 4 7 3 Disconnect the cables from X2 and X3 of the Fiber Optic Adapter board Important Note polarity when removing X2 and X3 wires If polarity is not maintained when re installing these wires the ASIC board or fiber optic board can be damaged U O X1 disconnects from the Control board when you remove the board from the Control Frame Sockets for Fiber Optic cables Connects to 24V DC power 4 Carefully disconnect the fiber optic cables from the right side of the circuit board and carefully set them aside Important When mishandled the ability of fiber optic cables to transmit data is greatly diminished using optical transmission equipment This product emits intense light and invisible radiation Do not look into fiber optic ports or fiber optic cable connectors ATTENTION Hazard of permanent eye damage exists when Important The minimum inside bend radius for fiber optic cable is 25 4 mm 1 in Any bends with a shorter inside radius can permanently damage the fiber optic cable Signal attenuati
116. ol Frame assembly Precharge Circuit and Precharge Resistors R6 1 and R6 2 Active Front End Power Structure U1 Motor controlled Circuit Breaker Q1 Input Disconnect 00 AFE Control Assembly shown with user installed HIM Item Description LCL Filter L1 ACLine Switchgear 9 DC Fuses F2 1 F2 6 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 2 6 Active Front End System Overview AC bus bars between LCL Filter L1 and AFE Power Structure U1 Bus Bar Locations There are several sets of bus bars in the AFE Frame 13 system that connect main system components e Bus bars between Input Disconnect 00 and Q1 e Bus bars between MCCB Q1 and the LCL Filter 11 e Bus bars between the LCL Filter L1 and AFE Power Structure U1 e Bus bars between the AFE Power Structure U1 and DC Bus Bars The following figure shows these bus bar locations Figure 2 6 AFE Frame 13 Bus Bar Locations in IP21 Rittal Enclosure FRONT VIEW shown with enclosure doors removed DC bus bar DC bus bar DC bus bars between AFE Power Structure U1 and DC fuses AC bus bars between AC bus bars between Motor Controlled Circuit Breaker Q1 and LCL Filter L1 Main Disconnect Q0 and Motor Controlled Circuit Breaker Q1 AC Input bus ba
117. on AFE in 21 Rittal Enclosure 78 0 460 60 Hz 420 500 630 550 840 630 Powe Frame 13 Serial Number 2622381652 This manual does not contain installation start up and programming information This information is available in the PowerFlex Active Front End User Manual publication 20Y UMO001 You can view or download publications at http www rockwellautomation com literature To order paper copies of technical documentation contact your local Rockwell Automation distributor or sales representative PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P P 2 Overview Understanding Manual Conventions General Information The following publications provide general drive information Title Publication Wiring and Grounding Guidelines for Pulse Width Modulated PWM AC Drives DRIVES INO01 Safety Guidelines for the Application Installation and Maintenance of Solid State Control SGI 1 1 A Global Reference Guide for Reading Schematic Diagrams 100 2 10 Guarding Against Electrostatic Damage 8000 4 5 2 PowerFlex Active Front End Information The following publications provide specific AFE information Title Publication PowerFlex
118. on increases with decreased inside bend radii PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 4 8 AFE Power Structure Component Section 5 Remove the four screws that secure the Fiber Optic Adapter board to the stand offs on the back of the Control box IP20 or Control Frame 21 and remove the Fiber Optic Adapter board For AFE in IP20 2500 For AFE in 21 MCC Style Enclosure Rittal Enclosure Installing the Fiber Optic Adapter Circuit Board Install the Fiber Optic Adapter circuit board in reverse order of removal while referring to Torque Specifications on page 4 2 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P AFE Power Structure Component Section 4 9 Removing the Control Frame only for AFE in 21 Rittal enclosure 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 X50 terminal block 85521 eses 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 Loosen T8 Torx head screws Replacing the Control Frame
119. proper Personal Protective Equipment PPE Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment PPE gt gt gt Allen Bradley Rockwell Software and Rockwell Automation are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Summary of Changes The information below summarizes the changes to this manual since its last release January 2010 Change Page Added information for Frame 13 AFE in 20 2500 MCC Style enclosure Throughout manual In Chapter 1 revised faults table information 1 2 1 7 Added new Chapter 2 Active Front End System Overview 2 1 Old Chapter 2 is now new Chapter 3 Component Test Procedures 3 1 Old Chapter 3 is now new Chapter 4 AFE Power Structure Component Section Reorganized the following Power Structure Access Procedures subsections Subsection Removing Installing AFE Protective Barriers is now first 4 10 Subsection Removing Installing the Air Flow Plate is now second 4 12 Subsection Removing Installing Protective Covers is now third 4 13 Added new Chapter 5 AC Line Switchgear Component Section 5 1 Added new Chapter 6 Precharge Component Section 6 1 Added new Chapter 7 LCL Filter Component Section 7 1 Added new Chapter 8 DC Fuses Component Section 8 1 Old Chapter 4
120. r structure are energized at DC bus potential high voltage Risk of electrical shock injury or death exists if someone comes into contact with the assembly ATTENTION The sheet metal cover and mounting screws on Front Covers ASIC Assembly Upgrade Kit Bus Bar Assembly Fuse Holders for Fan Inverters Table D A AFE Power Structure Assembly External Component Part Numbers Part Name Part No ASIC Assembly Upgrade Kit without ASIC Board 20 FR10850 Bus Bar Assembly n a Fuse Holders for Fan Inverters only AC fan system 20 PP01094 Fan Inverter Fuse only AC fan system 20 PP20202 Terminal Covers n a Front Covers n a Power Structure 400 480V 1300A SK Y1 PWRMOD D1K3 600 690V 1030A SK Y1 PWRMOD E1K0 Maintenance Stand 20 MAINSTD For additional AC fan system information see publication PFLEX IN029 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Disassembly Assembly Diagrams and Spare Parts D 3 Figure 0 2 AFE Power Structure Internal Components U V or W Phase Assembly Cover DC Bus Bar Assembly N Snubber Capacitor Assembly Power Bus Bar A Balancing Resistors Electrolytic Capacitors Power Module IGBTs DC Bus Bar Terminal Assembly AC Fan Inverter Assembly or DC Fan Pow
121. recharge circuitry has two main functions e It provides AFE system enclosure control power t provides the precharge circuitry to charge the DC bus The AFE system is available in both 400 480V AC and 600 690V AC system voltage configurations Control logic voltages are as follows For an AFE in a IP20 2500 MCC Style enclosure it is 120V AC single phase and also 24V DC power e Foran AFE ina IP21 Rittal enclosure it is 230V AC single phase and also 24V DC power The precharge circuitry lets the DC capacitors located in the AFE power structure to be properly charged with in line current limiting resistors to DC bus voltage magnitudes See the PowerFlex Active Front End User Manual publication 20Y UMO001 for the minimum and maximum system capacitance requirements The precharge fuse assembly for an AFE in a IP20 enclosure is located in the Input Power enclosure For an AFE in a IP21 enclosure the precharge fuse assembly is located in the Power Structure enclosure 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 2 Open the appropriate enclosure door 3 If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 4 Slide the fuse sleeve out from the fuse holder 5 Remove the fuse from the sleeve and appropriately discard the old fuse 6 See the appropriate table below for the recommended new replacement fuse and install the fuse in reverse ord
122. rs PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Active Front End System Overview 2 7 AFE in IP00 Open Chassis The following figure shows a basic one line diagram for an AFE system a Configuration 00 NEMA UL Open Chassis configuration and the parts the customer must supply Figure 2 7 Basic One line Diagram for AFE IP00 Open Chassis Configuration I 1 XR 7 AC Line Switchgear LCL Filter L1 AFE i DC dnput input Power Structure U1 Fuses Breaker Contactor E 3 Phase i 00 ues ACInput ot F1 1 F1 3 Ld i 02 UI 1 H 1 NNN i 0 1 6 DC Bus D a 2 00 le le M E 1 Output B gt PB WARN ANAMI M T d eo 1 23 4 Ly a Lt Customer 2 G supplied Fd Parts 54 6 CT E E ow 85 ____ I Customer l supplied Precharge Precharge Precharge Parts Fuses Contactor Hon Circuit 1 K6
123. rs Remove insulators 5 Remove the M6 x 12 screws that secure the Connective DC Bus Bars and insulators to the Phase Assembly DC bus bar Insulator DC bus bar Location Fasteners Qty Torque 1 M10 x 20 hexagonal screws M10 spring washers and M10 washers 6 8 Nem 70 2 M8 x 25 hexagonal screws M8 spring washers and M8 washers 6 8 Nem 70 3 M6 x 12 screws 2 4 Nem 35 bein PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P AFE Power Structure Component Section 4 25 6 Remove the three M8 x 20 hexagonal screws from the top section of each Phase Assembly U V or W that you want to remove Note that only two screws are shown for each Phase Assembly in the top section of the drawing Remove screws Remove screws 7 Remove three M8 x 20 hexagonal screws from the bottom section of each Phase Assembly U V or W that you want to remove Note that only one screw is shown for each Phase Assembly in the bottom section of the drawing 8 Disconnect the three input power cables from the lower section of the Phase Assembly that you want to remove 9 Remove the Phase Assembly by using appropriate lifting equipment Removing the Power Module from the U V or W Phase Assembly Important Do not attempt to disassemble the Power Module within the U V or W Phase Assembly Important When replacing a damage
124. ructure DC bus capacitors from U V or W phase assembly 4 30 power structure from enclosure 4 19 power structure main cooling fans 4 18 protective covers from the power structure 4 13 U V or W phase assembly from AFE power structure 4 23 replacing power structure with a new power structure 4 31 resources publications P 2 website P 1 reverse biased diode tests 3 3 S schematic diagrams B 1 service tools A 1 software tools A 1 spare parts information D 1 website P 2 D 1 startup after repair 9 1 status indicators 3 2 system overview 2 1 Index 3 T testing control transformer and 24V DC power supply 6 3 forward biased diode 3 3 gate driver board resistance 3 7 precharge bridge 6 6 precharge resistor 6 7 reverse biased diode 3 3 torque specifications 4 2 troubleshooting and error codes 1 1 turning off the AFE 4 3 V viewing the status indicators 3 2 visual inspections 3 2 W website additional resources P 1 spare parts P 2 D 1 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Index 4 PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http www rockwellautomation com support you can find technical and application notes sample code and links to software s
125. sei 20C DA1 4 OX2 A11 SLOTA R1 Control R1 R2 R3 _ PE o oe ee ee 1 eo 1 7 1 7 1 X3 2 t 20C DO1 20C DPI1 Of Al21 O21 O22 023 024 05 026 SLOTB 13 SLOT E X1 72 Inverter Enable Figure B 14 Control Wiring Diagram for Frame 13 21 Rittal Enclosure PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P B 16 Schematic Diagrams System Schematics for Frame 13 in IP21 Rittal Enclosure The following system schematics are for the Frame 13 AFE in a IP21 Rittal enclosure The PowerFlex AFE catalog number has an enclosure code of A as shown in the example catalog string below For other enclosure designs contact the supplier of the system for the system schematics Position 1 3 4 5 7 8 9 10 11 12 13 14 15 16 a b c d e f g h i j k l eb db cb 2 mes 5 e x CX e 6 7
126. sing procedures described in this manual Damaged or improperly connected fiber optic cables can cause apparent Gate Driver board malfunctions For fiber optic cable connections see page C 1 page C 2 and page C 3 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 2 If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 3 Remove the protective front covers and terminal covers from the power structure See Removing Protective Covers from the Power Structure on page 4 13 4 Locate the three Gate Driver boards on the front of the power structure right side AFE enclosure 5 domu c B B D a 60 o qe di Gate Driver Boards ASIC Board PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 3 6 Component Test Procedures PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P Verify that the fiber optic cables are properly connected between the Gate Driver boards and the ASIC board Important The minimum inside bend radius for fiber optic cable is 25 4 mm 1 in Any bends with a shorter inside radius can permanently damage the fiber
127. socket head screws 8 Nem 71 Ibsin M6 x 12 POZIDRIV screws 4 Nem 35 DPI HIM Assembly Door M3 x 6 Phillips screws 0 9 Nem 8 Ibein DPI HIM Assembly Mounting M3 x 6 Phillips screws 0 9 Nem 8 Ibein Fan Inverter Assembly M5 x 10 POZIDRIV screws 4 Nem 35 bein Fan Inverter Fuse Base M4 x 8 POZIDRIV screws 3 Nem 27 Fan Inverter Fuse Holder M4 x 8 POZIDRIV screws 3 Nem 27 Ibsin Gate Driver Circuit Board Mounting M4 x 8 POZIDRIV screws 1 35 Nem 12 Ibin Main Cooling Fan Mounting M5 x 10 POZIDRIV screws 3 Nem 27 Precharge Bridge Wire Fasteners M5 x 12 machine screws 4 5 Nem 40 Ibein Assembly Mounting 5 nuts 3 9 Nem 35 Precharge Bridge Resistor Assembly 5 x 12 Torx self tapping screws 4 5 Nem 40 Ibein LCL Filter Upper In IP20 Encl M8 x 20 M6 x 16 screws 6 7 Nem 60 Ibsin 4 5 Nem 40 Ibein Front Bracket In IP21 Encl 5 x 12 Torx self tapping screws 4 5 Nem 40 Power Structure Input In 20 Encl M10 x 40 bolt 37 9 Nem 336 Terminals U V W IP21 Encl 8 20 20 Nem 177 Ibein Power Structure Block Mounting M10 x 12 hexagonal screw 20 Nem 177 Power Structure DC Bus In IP20 Encl Terminals In IP21 Encl M6 x 16 POZIDRIV Protective Covers on Front M5 x 10 POZIDRIV 3 Nem 27 Power Structure Terminal 5 x 16 P
128. st 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 01 zero load Important The actual voltage readings can vary depending upon your equipment If your readings are not near the indicated values in the following tables verify that the actual voltage measured is consistent for the Power module A reverse biased diode test finds an open circuit and the meter displays OL zero load Forward biased test Reverse biased test on PN junction on PN junction 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 2 Remove the protective barriers See Removing AFE Protective Barriers on page 4 10 3 Disconnect any drives connected to the DC bus from the DC bus or remove the DC bus fuses from the AFE PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 3 4 Component Test Procedures 4 Conduct forward and reverse biased diode tests on the power structure Figure 3 1 Measurement Points for Forward and Reverse Diode Tests Front View Front View AFE in IP20 2500 MCC Style Enclosure shown with doors removed AFE 21 Rittal Enclosure shown with doors removed 1 95755 eee WW WS ALR
129. tive barriers See Removing AFE Protective Barriers on page 4 10 To test the precharge bridge measure the points on the power structure listed in the table below Table 6 C Precharge Bridge Tests on Power Structure Meter Leads Nominal Meter Reading Test Point Locations DC L1 DC L2 DC L3 Value should gradually rise to about 0 48V 1 L1 DC L2 DC L3 BOR pue L1 DC BEL 2 L2 DC L3 DC Des F Meter should display charging voltage DC L2 DC L3 The actual voltage reading can vary depending upon your equipment If your readings are not near 0 48V verify that the actual voltage measured is consistent for the power structure Remove power from the AFE See Removing Power from the AFE on page 4 3 Open the power structure enclosure door If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 Remove the protective front covers and terminal covers from the power structure See Removing Protective Covers from the Power Structure on page 4 13 Remove the four POZIDRIVE screws that secure the bridge protective cover Remove the bridge protective cover Prior to removal note the locations of the DC DC L1 L2 and L3 wires and then disconnect these wires Testing the Precharge Resistor 10 Precharge Component Section 6 7 Remove the precharge bridge mounting nuts Remove
130. tructure Main DC Fan Connections newer version B 5 Schematic Diagrams Frame 13 Power Structure Main Fan Connections UOISJ9A suonoeuuo DY 4 4 6 8 1 a lt gt L pn zm 4 1 2 Aouanbal4 4 yms dnjes LS ae uo uo 0 ZH 0S OW 22 8 TA ris EIS 215 HIS 24 lt lt ys M OV A00 z b eX v9 zaa 11 a ex TIT lt lt ld rh xx E gt al e Jeyaauog Aouenbai4 uej YAMS dnias LS Sg vo o uo OV ACE T ZH 0S OW LSS wee DFSIFSX TA 718 619 219 FIS 24 ZN lt lt e npojN A eseug ueeJO MOI SA OV Ave 5 v9 SOLL 1 4 lt 4 8 8X oX eng 9 LLX 215 Te s lt lt iy lt nz ya
131. ture has not been exceeded Check the fans including the ASIC board on the converter 3 Check for an excess load 4 Verify that the airflow plate is installed See page 4 12 Verify that the maximum ambient temperature has not been exceeded Check the fan s Check for an excess load Reset the fault and restart Verify the fiber optic connections Verify ASIC Board jumper connections from X9 to X15 see Figure B 1 on page B 1 Contact Technical Support Ifthe problem persists replace or repair the power structure Check for an excessive load or other causes of excess current Using a digital voltmeter to check for low impedance to ground verify the bus cables bars between the Disconnect and AC input lines Converter and LCL Filter For AFE in IP20 enclosure 00 input breaker and K1 input contactor which includes the precharge disconnect Filter and K1 input cont For in 21 enclosure Q1 MCCB and 00 disconnect switch which includes the precharge disconnect LCL Filter and Q1 MCCB Cycle the power 2 Contact Technical Support 3 If the problem persists replace the converter unit Publication 20Y TG002B EN P 1 4 PowerFlex Active Front End Frame 13 Hardware Service Manual Troubleshooting and Error Codes Publication 20Y TG002B EN P No 21 29 30 31 32 33 34 35 37
132. um Cable Length Cable Type Motor Mfgr Volts Amps RPM Hz Power Design No Encoder Brake Motor Heater PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P E 2 AFE Power One line System Application Data Typical Transformer The following diagrams show typical transformer winding types Winding Types Delta Wye with Grounded Wye Neutral Delta Delta with Grounded Leg or Four Wire Connected Secondary Delta Ungrounded Secondary ay A PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P A AC line switchgear components AFE in IP20 2500 MCC Style enclosure D 9 AFE in 21 Rittal enclosure D 10 overview 5 1 Active Front End system overview 2 1 additional resources publications P 2 website P 1 AFE power structure ASIC assembly parts D 4 checking fan inverter fuses 3 8 external components D 2 internal components for U V or W phase assembly D 3 assembly disassembly diagrams D 1 bus bar locations AFE IP20 2500 MCC Style enclosure 2 3 AFE in 21 Rittal enclosure 2 6 checking fan inverter fuses 3 8 fiber optic connections 3 5 circuit board connections C 1 common symptoms and corrective actions 1 7 component test procedures 3 1 connections for circuit boards C 1 fiber optic cable routing C 3 control
133. verse order of removal PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P 4 12 AFE Power Structure Component Section Removing Air Flow Plate for Removing the AFE Air Flow Plate You must remove the Air Flow Plate to remove the power structure from the AFE 1 Remove power from the AFE See Removing Power from the AFE on page 4 3 2 If present remove the protective barriers See Removing AFE Protective Barriers on page 4 10 3 Foran AFE in a IP20 2500 MCC Style enclosure remove the four M6 x 16 screws that secure the Air Flow Plate to the AFE and remove the two M6 x 16 screws that secure the Air Flow Plate to the LCL filter For an AFE in 21 Rittal enclosure remove the four T8 Torx head screws that secure the Air Flow Plate to the AFE 4 Slide the Air Flow Plate from the AFE AFE 20 2500 MCC Style Enclosure Remove Screws Remove screws Installing the AFE Air Flow Plate Removing Air Flow Plate for AFE 21 Rittal Enclosure rN see NS Remove screws Install the Air Flow Plate in reverse order of removal PowerFlex Active Front End Frame 13 Hardware Service Manual Publication 20Y TG002B EN P AFE Power Structure Component Section 4 13 Removing Protective Covers from the Power Structure You must re
134. your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature Rockwell Automation maintains current product environmental information on its website at http www rockwellautomation com rockwellautomation about us sustainability ethics product environmental compliance page Rockwell Otomasyon Ticaret 5 Kar Plaza Is Merkezi E Blok Kat 6 34752 erenk y stanbul Tel 90 216 5698400 www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 20Y TG002B EN P February 2015 Supersedes Publication 20Y TG002A EN P January 2010 Copyright 2015 Rockwell Automation Inc All rights reserved Printed in the U S A

PowerFlex 700AFE Frame 13 Hardware Service Manual

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