Rockwell Automation Allen-Bradley PowerFlex Active Front End... User manual

PowerFlex Active Front End
Catalog Number 20Y
PowerFlex AFE/PowerFlex 700AFE
Frames 10 and 13, Firmware Revision Number 1.xxx
User 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 aboutpractices or circumstances that can cause an explosion ina 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 topersonal injury or death, property
damage, or economic loss. Attentions help you identify ahazard, avoid a hazard, and recognize the consequence.
IMPORTANT Identifies information that iscritical 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 onor insidethe equipment, for example, adriveormotor,toalert people thatsurfacesmay
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potentialArcFlash.ArcFlashwillcausesevereinjuryor death. WearproperPersonalProtectiveEquipment(PPE).FollowALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 3
Table of Contents
Preface
Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
What Is Not in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Rockwell Automation Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Technical Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Drive Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Benefits of the AFE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
AFE in IP00 Open Chassis Configuration. . . . . . . . . . . . . . . . . . . . . . . 17
Chapter 1
AFE in IP20 2500 MCC Style
Enclosure – Installation/Wiring
Main Component Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Frame 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Frame 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Main Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Frame 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Frame 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Mounting Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Operating Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Minimum Mounting Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Unbalanced, Ungrounded, or Resistive Grounded
Distribution Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Input Power Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Recommended Grounding Scheme . . . . . . . . . . . . . . . . . . . . . . . . . 27
Safety Ground - PE and Shield Termination - SHLD . . . . . . . . . 29
Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Power Cable Types Acceptable for 400…690 Volt
Installations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Unshielded Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Shielded Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Armored Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Cable Trays and Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Select and Verify Control Transformer Voltage . . . . . . . . . . . . . . 31
Power Terminals for AFE in IP20 2500 MCC
Style Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Route the AC Input, Ground (PE), and DC Bus Output
Wiring for AFE in IP20 2500 MCC Style Enclosure . . . . . . . . . 36

4Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017
Table of Contents
Disconnect the Common Mode Capacitors . . . . . . . . . . . . . . . . . . . . . 37
Frame 10 LCL Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Frame 13 LCL Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Frame 10 or Frame 13 Power Structure. . . . . . . . . . . . . . . . . . . . . . 39
Use the AFE with PowerFlex Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Signal and Control Wire Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
I/O Terminal Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
I/O Cable Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Typical I/O Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Analog I/O Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Hardware Enable Circuitry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Analog I/O Wiring Examples for AFE in IP20 2500
MCC Style Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Precharging the AFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Important Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Low Voltage Directive (2006/95/EC). . . . . . . . . . . . . . . . . . . . . . . 49
EMC Directive (2004/108/EC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
General Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Essential Requirements for CE Compliance. . . . . . . . . . . . . . . . . . 49
Chapter 2
AFE in IP21 Rittal Enclosure –
Installation/Wiring
Main Component Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Frame 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Frame 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Main Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Frame 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Frame 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Mounting Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Operating Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Minimum Mounting Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Unbalanced, Ungrounded, or Resistive Grounded
Distribution Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Input Power Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Recommended Grounding Scheme . . . . . . . . . . . . . . . . . . . . . . . . . 59
Safety Ground - PE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Shield Termination - SHLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Power Cable Types Acceptable for 400…690 Volt
Installations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Unshielded Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62
Shielded Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 5
Table of Contents
Armored Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Cable Trays and Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Select and Verify Control Transformer Voltage . . . . . . . . . . . . . . 64
Power Terminals for AFE in IP21 Rittal Enclosure . . . . . . . . . . . 66
DC Bus Output Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Route the AC Input, Ground (PE), and DC Bus Output
Wiring for AFE in IP21 Rittal Enclosure . . . . . . . . . . . . . . . . . . . . 68
Disconnect the Common Mode Capacitors . . . . . . . . . . . . . . . . . . . . . 69
Frame 10 LCL Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Frame 13 LCL Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Frame 10 Power Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72
Frame 13 Power Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73
Using the AFE with PowerFlex Drives . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Signal and Control Wire Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
I/O Terminal Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
I/O Cable Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Typical I/O Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Analog I/O Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Hardware Enable Circuitry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Analog I/O Wiring Examples for AFE in IP21
Rittal Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Precharging the AFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Important Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Low Voltage Directive (2006/95/EC). . . . . . . . . . . . . . . . . . . . . . . 82
EMC Directive (2004/108/EC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
General Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Essential Requirements for CE Compliance. . . . . . . . . . . . . . . . . . 82
Chapter 3
Startup AFE in IP20 2500 MCC Style Enclosure. . . . . . . . . . . . . . . . . . . . . . . . 85
Startup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
AFE in IP21 Rittal Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Startup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
MCCB (Motor-controlled Circuit Breaker) and Modes of
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Chapter 4
Programming and Parameters About Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
How AFE Parameters are Organized. . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
File-Group-Parameter Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

6Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017
Table of Contents
Basic Parameter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Advanced Parameter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Monitor File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Dynamic Control File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Utility File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Communication File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Inputs and Outputs File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Parameter Cross Reference – by Name . . . . . . . . . . . . . . . . . . . . . . . . 117
Parameter Cross Reference – by Number . . . . . . . . . . . . . . . . . . . . . . 120
Chapter 5
Troubleshooting AFE Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Front Panel Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
HIM Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Faults and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Manually Clearing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Fault and Alarm Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Clear the Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Common Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . 131
Technical Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Appendix A
Supplemental Information Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Derating Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Ambient Temperature/Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
Altitude/Load 400/480V AC Input . . . . . . . . . . . . . . . . . . . . . . . 139
Altitude/Load 600/690V AC Input . . . . . . . . . . . . . . . . . . . . . . . 139
AFE Current Ratings and Watts Loss . . . . . . . . . . . . . . . . . . . . . . . . . . 140
400 Volt AC Input Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
480 Volt AC Input Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
600 Volt AC Input Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
690 Volt AC Input Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Fusing and Circuit Breakers for AFE in IP20 2500
MCC Style Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
AC Input Fuse and Circuit Breaker Ratings. . . . . . . . . . . . . . . . . 141
DC Bus Output Fuse Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Fusing and Circuit Breakers for AFE in IP21 Rittal Enclosure. . . . 142
AC Input Fuse and Circuit Breaker Ratings. . . . . . . . . . . . . . . . . 142
DC Bus Output Fuse Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
DPI Communication Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Typical Programmable Controller Configurations. . . . . . . . . . . 152
Logic Command Word for PowerFlex 700/700H/700S
Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Logic Status Word for PowerFlex 700/700H/700S Drives. . . 153
Logic Command Word for PowerFlex 750-Series Drives. . . . . 155

Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 7
Table of Contents
Logic Status Word for PowerFlex 750-Series Drives . . . . . . . . . 156
Appendix B
HIM Overview External and Internal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
LCD Display Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
ALT Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Parameter Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Device Select Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Memory Storage Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Start-up Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Preferences Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
View and Edit Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
HIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Numeric Keypad Shortcut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Remove/Install the HIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Appendix C
Application Notes Sizing Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Basic Procedure to Size the AFE . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Advanced Procedure to Size the AFE. . . . . . . . . . . . . . . . . . . . . . . 166
Voltage Boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Paralleling AFEs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
Guidelines for AFEs in IP20 2500 MCC Style Enclosure . . . . 168
Guidelines for AFEs in IP21 Rittal Enclosure . . . . . . . . . . . . . . . 172
Paralleling an AFE with One or More PowerFlex SCR
Bus Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177

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

Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 9
Preface
The purpose of this manual is to provide the basic information to install,
startup, and troubleshoot the PowerFlex® Active Front End (AFE).
Summary of Changes This manual contains new and updated information as indicated in the
following table.
Intended Audience This manual is intended for qualified personnel. You must be able to program
and operate an Active Front End unit and adjustable frequency AC drives. In
addition, you must have an understanding of the parameter settings and
functions.
What Is Not in This Manual This manual provides installation, start-up, and programming information for
the PowerFlex Active Front End. For detailed drive information, see Drive
Information on page 11.
Topic Page
Summary of Changes 9
Intended Audience 9
What Is Not in This Manual 9
Manual Conventions 10
Rockwell Automation Support 10
Additional Resources 10
General Precautions 12
Catalog Number Explanation 13
Description of Operation 14
Benefits of the AFE 16
AFE in IP00 Open Chassis Configuration 17
Topic Page
Updated the basic one-line diagram for a Frame 10 AFE in IP20 2500 MCC style
enclosure to include the factory-installed common mode core at the DC bus output. Figure 6 on page 20
Updatedthesystemschematicsfor a Frame13AFEin IP202500MCCstyle enclosureto
include the factory-installed common mode core at the DC bus output. Figure 7 on page 21
Updated the drawing for connecting parallel Frame 10 AFEs in IP20 2500 MCC style
enclosures to include the factory-installed common mode core at the DCbus output. Figure 56 on page 170
Updated the drawing for connecting parallel Frame 13 AFEs in IP20 2500 MCC Style
Enclosures to include the factory-installed common mode core at the DC bus output. Figure 57 on page 171
Added information for KCC and Regulatory compliance mark (RCM) certifications. 137

10 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017
Preface
Manual Conventions The following conventions are used throughout this manual:
• In this manual, we also refer to the PowerFlex Active Front End as AFE,
Active Front End, or unit.
• To differentiate parameter names and LCD display text from other text,
the following conventions are used:
– Parameter names appear in [brackets].
For example: [DC Bus Voltage].
– Display text appears in ‘quotes’.
For example, ‘Enabled’.
Rockwell Automation
Support
Contact your local Rockwell Automation representative for these items:
• Sales and order support
• Product technical training
•Warranty support
• Support service agreements
Technical Support
For technical support, first review the information in Chapter 5. If you still
need help, click the link for Allen-Bradley® Drives Service and Support website
at http://www.ab.com/support/abdrives. When you contact Technical
Support, be prepared to provide the information that is listed on page 135.
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
Resource Description
PowerFlex Active Front End—Frame 10 Hardware Service Manual, publication 20Y-TG001 Provides information for how to troubleshootFrame 10 AFE units.
PowerFlex Active Front End—Frame 13 Hardware Service Manual, publication 20Y-TG002 Provides information for how to troubleshootFrame 13 AFE units.
PowerFlex 700H, 700S, and 700AFE Drive Fan Systems Installation Instructions, publication PFLEX-IN029 Provides information for how to install drive fan systems.
Drives in Common Bus Configurations,publication DRIVES-AT002 Provides information for common bus configurations.
Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001 Provides information for wiring and grounding AC drives.
Preventive Maintenance of Industrial Control and Drive System Equipment, publication DRIVES-TD001 Provides information for preventative maintenance control and
drive systems.
Safety Guidelines for the Application, Installation, and Maintenance ofSolid-state Control, publication SGI-1.1 Provides safety guidelines for drive systems.
Guarding Against Electrostatic Damage, publication 8000-4.5.2 Provides information for how to prevent electrostatic damage.
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.