Allen-Bradley PowerFlex AFE User manual

PowerFlex Active Front End – Frame 10

Catalog Number 20Y

PowerFlex AFE/PowerFlex 700AFE

(400V/480V and 600V/690V)

Hardware Service Manual

Original Instructions

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. 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.

Labels may also be on or inside the equipment to provide specific precautions.

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.

IMPORTANT Identifies information that is critical for successful application and understanding of the product.

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.

ARC FLASH 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 proper Personal Protective Equipment (PPE). Follow ALL

Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017 3

Table of Contents

Preface

Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

What Is in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

What Is Not in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Additional Support Available on the Internet. . . . . . . . . . . . . . . . . . . . . 8

General Precautions for Class 1 Light-emitting Diode Product . . . . . 9

Chapter 1

Troubleshooting and Error Codes Create Fault Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

PowerFlex Active Front End Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Common Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . . 17

Chapter 2

Active Front End System Overview AFE in IP20 2500 MCC Style Enclosure. . . . . . . . . . . . . . . . . . . . . . . . 19

Main Component Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Main Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Main Bus Bar/Cable Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

AFE in IP21 Rittal Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Main Component Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Main Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Bus Bar Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

AFE in IP00 Open Chassis Configuration. . . . . . . . . . . . . . . . . . . . . . . 25

Chapter 3

Component Test Procedures View the Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Perform a Visual Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Inspect the Cooling Tunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

Inspect the Power Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Perform Forward and Reverse Biased Diode Tests for

Power Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Check Fiber-optic Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Perform Gate Driver Board Resistance Measurements . . . . . . . . . . . . 33

Check the AFE Power Structure Fan Inverter Fuses . . . . . . . . . . . . . . 34

Chapter 4

AFE Power Structure Component

Section

Understand Torque Figures in Assembly Diagrams. . . . . . . . . . . . . . . 36

Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Remove Power from the AFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Control Frame Access Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Remove the DPI Interface Assembly . . . . . . . . . . . . . . . . . . . . . . . . 38

Install the DPI Interface Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . 39

4Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017

Table of Contents

Remove the I/O Circuit Boards and Control Board . . . . . . . . . . 39

Install the I/O Circuit Boards and Control Board . . . . . . . . . . . . 40

Remove the Fiber-optic Adapter Circuit Board . . . . . . . . . . . . . . 40

Install the Fiber-optic Adapter Circuit Board . . . . . . . . . . . . . . . . 42

Remove the Control Frame (only for AFE in IP21

Rittal enclosure). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Replace the Control Frame . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Power Structure Access Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Remove AFE Protective Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Install the AFE Protective Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Remove the AFE Airflow Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Install the AFE Airflow Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Remove Protective Covers from the Power Structure . . . . . . . . . 46

Install Protective Covers on the Power Structure . . . . . . . . . . . . . 46

Remove the Gate Driver Circuit Board . . . . . . . . . . . . . . . . . . . . . . 46

Install the Gate Driver Circuit Board. . . . . . . . . . . . . . . . . . . . . . . . 48

Remove the ASIC Circuit Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Install the ASIC Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51

Remove and Install the Power Structure Fan System. . . . . . . . . . 52

Remove the Power Structure from the Enclosure . . . . . . . . . . . . . 52

Install the Power Structure in the Enclosure . . . . . . . . . . . . . . . . . 55

Remove the Power Module from the Power Structure . . . . . . . . 55

Install the Power Module on the Power Structure . . . . . . . . . . . . 61

Remove the Power Structure DC Bus Capacitors. . . . . . . . . . . . . 61

Install the Power Structure DC Bus Capacitors . . . . . . . . . . . . . . 62

Replace the Existing Power Structure with a New

Power Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

Chapter 5

AC Line Switchgear Component

Section

AFE in IP20 2500 MCC Style Enclosure. . . . . . . . . . . . . . . . . . . . . . . . 64

AFE in IP21 Rittal Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

Chapter 6

Precharge Component Section Precharge Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Replace the Precharge Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Test the Control Transformer (T4) and 24V DC Power

Supply (T10) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67

For AFE in IP20 2500 MCC Style Enclosure . . . . . . . . . . . . . . . . 67

For AFE in IP21 Rittal Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Test the Precharge Bridge by Using the Power Structure

Terminals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Replace the Precharge Bridge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70

Test the Precharge Resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Replace the Precharge Resistor Assembly . . . . . . . . . . . . . . . . . . . . . . . . 71

AFE in IP20 2500 MCC Style Enclosure . . . . . . . . . . . . . . . . . . . . 71

AFE in IP21 Rittal Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017 5

Table of Contents

Chapter 7

LCL Filter Component Section Remove the LCL Filter Protective Barrier . . . . . . . . . . . . . . . . . . . . . . . 74

Install the LCL Filter Protective Barrier . . . . . . . . . . . . . . . . . . . . . . . . . 74

Replace the LCL Filter DC Fan Fuses. . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Remove the LCL Filter Fan DC Power Supply. . . . . . . . . . . . . . . . . . . 75

Install the LCL Filter Fan DC Power Supply . . . . . . . . . . . . . . . . . . . . 77

Replace the LCL Filter Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Remove the LCL Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

From the IP20 2500 MCC Style Enclosure . . . . . . . . . . . . . . . . . . 79

From the IP21 Rittal Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Install the LCL Filter in the Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . 81

Chapter 8

DC Fuses Component Section Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Fuse Replacement Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Chapter 9

Startup After Repair Technical Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Before You Apply Power to the AFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Appendix A

Service Tools and Equipment Software Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Service Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Appendix B

Schematic Diagrams Frame 10 Circuit Board Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Frame 10 Power Module Circuitry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Frame 10 Power Structure Main Fan Connections . . . . . . . . . . . . . . . 93

Control Wiring Diagram for Frame 10 in IP20 2500

MCC Style Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

System Schematics for Frame 10 in IP20 2500

MCC Style Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Control Wiring Diagram for Frame 10 in IP21 Rittal Enclosure. . 103

System Schematics for Frame 10 AFE in IP21 Rittal Enclosure . . . 104

Appendix C

Connector Descriptions Circuit Board Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Hardware Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Appendix D

Disassembly/Assembly Diagrams

and Spare Parts

AFE Power Structure Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118

LCL Filter Assembly (used in IP20 and IP21 enclosures) . . . . . . . . 122

Precharge Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

AC Line Switchgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

6Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017

Table of Contents

Appendix E

AFE Power One-line System

Application Data

Data to Collect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

Typical Transformer Winding Types . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Index

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017 7

Preface

Summary of Changes This manual contains new and updated information as indicated in the

following table.

Intended Audience This manual is intended for qualified service personnel responsible for

troubleshooting and repairing the PowerFlex® Active Front End (AFE). You

must 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 that are in Standard for Electrical Safety in the Work Place,

publication NFPA 70E.

What Is in This Manual This manual contains hardware service information for the Frame 10

PowerFlex Active Front End. Verify that you are working on a Frame 10 by

checking the data nameplate on the AFE. The frame number is printed just

above the serial number.

What Is Not in This Manual 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-UM001.

Topic Page

Updated the basic one-line diagram for a Frame 10 AFE in IP20 2500 MCC style

enclosure to include the factory-installed common mode core at the DC bus output.

Figure 1 on page 19

Updated the system schematics for a Frame 10 AFE in IP20 2500 MCC style enclosure to

include the factory-installed common mode core at the DC bus output.

Figure 19 on page 96

Cat No. 20D J500 N 0 NNNBNNNN

UL Open Type/IP00 540V 650V

Normal Duty Power 250 kW

200 kW

450 kW

500 kW

Heavy Duty Power

DC Voltage Range 462 - 594

350

583 - 713

350

Amps

Input: DC,

AC Voltage Range 0 - 400

50 Hz

0 - 460

60 Hz

Base Hz (default)

Output: 3 Phase, 0 - 320Hz

Continuous Amps 420/500

630/550

420/500

630/550

1 Min Overload Amps

2 Sec Overload Amps 840/630 840/630

MFD. in 1989 on Nov 9 Frame #: 10

Serial Number: 2622381652

262238165

MADE IN THE USA (FAC 1B)

Series: A

Standard I/O: NONE

Original Firmware No. 2.04

ULUSC Æ

LISTED

IND CONT EQ

9D42

Cat No. 20D J300 N 0 NNNBNNNN

UL Open Type/IP00 540V 650V

Normal Duty Power 160 kW

132 kW

250 kW

200 kW

Heavy Duty Power

DC Voltage Range 462 - 594

350

583 - 713

350

Amps

Input: DC,

AC Voltage Range 0 - 400

50 Hz

0 - 460

60 Hz

Base Hz (default)

Output: 3 Phase, 0 - 320Hz

Continuous Amps 300/245

330/368

300/245

330/368

1 Min Overload Amps

2 Sec Overload Amps 450/490 450/490

MFD. in 1989 on Nov 9

Serial Number: 2622381652

2622381652

MADE IN THE USA (FAC 1B)

Series: A

Standard I/O: NONE

Original Firmware No. 2.04

ULUSC Æ

LISTED

IND CONT EQ

AFE

0/435

-842

Serial Number: 12345678

0035

Frame: 10

Data Nameplate on AFE in IP21

Rittal Enclosure

Data Nameplate on AFE in IP20

2500 MCC Style Enclosure

8Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017

Preface

Additional Resources These documents contain additional information concerning related products

from Rockwell Automation.

You can view or download publications at

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

To order paper copies of technical documentation, contact your local

Allen-Bradley distributor or Rockwell Automation sales representative.

Spare Parts For spare parts information on PowerFlex 7-Class Architecture-Class

Low-Voltage AC Drives, including the PowerFlex Active Front End, click this

link:

http://www.ab.com/support/abdrives/powerflex70/PF7ReleasedParts.pdf.

Additional Support Available

on the Internet

Additional troubleshooting information and software tools are available on the

Allen-Bradley® Drives Service and Support website at http://www.ab.com/

support/abdrives.

Resource Description

PowerFlex Active Front End User Manual, publication 20Y-UM001 Provides information for installation, startup, and programming for the PowerFlex Active Front

End units.

PowerFlex 700H, 700S, and 700AFE Drive Fan Systems Installation Instructions,

publication PFLEX-IN029

Provides information for drive fan system service and installation.

Drives in Common Bus Configurations Application Guidelines, publication

DRIVES-AT002

Provides guidelines, considerations, and limitations for the proper application of PowerFlex

drives used in common bus configurations.

Wiring and Grounding Guidelines for pulse Width Modulated AC Drives,

publication DRIVES-IN001

Provides basic information to properly wire and ground Pulse Width Modulated (PWM) AC

drives.

Safety Guidelines for the Application, Installation, and Maintenance of Solid-

State Control, publication SGI-1.1

Provides general guidelines for the application, installation, and maintenance of solid-state

control in the form of individual devices or packaged assemblies with solid-state components.

Guarding Against Electrostatic Damage, publication 8000-4.5.2 Provides an explanation of the causes of Electrostatic Damage, and how you can guard against

its effects.

Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.

Product Certifications website, http://www.rockwellautomation.com/global/

certification/overview.page

Provides declarations of conformity, certificates, and other certification details.

Rockwell Automation Publication 20Y-TG001C-EN-P - April 2017 9

Preface

General Precautions for Class

1 Light-emitting Diode

Product

ATTENTION: Hazard of permanent eye damage exists when using 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

that is on the power structure are energized at (-) DC bus potential high

voltage. Risk of electrical shock, injury, or death exists if someone comes into

contact with the assembly.

ATTENTION: 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: 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 that

is correctly grounded to an earth ground.

ATTENTION: The PowerFlex Active Front End contains electrostatic discharge

(ESD) sensitive parts and assemblies that can be damaged if you do not follow

ESD control procedures. Static control precautions are required to install, test,

service, or repair this unit. If you are unfamiliar with static control procedures,

see Guarding Against Electrostatic Damage, publication 8000-4.5.2, or any

other applicable ESD protection handbook.

ATTENTION: An incorrectly applied or installed PowerFlex Active Front End

can result in component damage or a reduction in product life. Wiring or

application errors such as, undersizing the motor, incorrect or inadequate AC

supply, or excessive ambient temperatures can result in malfunction of the

system.

ATTENTION: Only qualified personnel familiar with adjustable frequency AC

drives and associated machinery can plan or implement the installation, start-

up, and subsequent maintenance of the system. Failure to comply can result in

personal injury and/or equipment damage.

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

Preface

Notes:

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