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: