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

PowerFlex Active Front End—Frame 10
PowerFlex AFE / PowerFlex 700AFE
(400/480V and 600/690V)
Hardware Service Manual

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.
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.
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).

PowerFlex Active Front End—Frame 10 Hardware Service Manual
Publication 20Y-TG001B-EN-P
Summary of Changes
The information below summarizes the changes to this manual since its last
release (June 2011).
Topic Page
Added information for Frame 10 AFE in IP20 2500 MCC Style enclosure. Throughout
manual

soc-ii Summary of Changes
PowerFlex Active Front End—Frame 10 Hardware Service Manual
Publication 20Y-TG001B-EN-P

PowerFlex Active Front End—Frame 10 Hardware Service Manual
Publication 20Y-TG001B-EN-P
Table of Contents
Preface Overview
Who Should Use this Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
What is in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
What is Not in this Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-1
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
PowerFlex Active Front End Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
Understanding Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
Terms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
Cross References . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-2
Additional Support Available on Internet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3
General Precautions for Class 1 LED Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . P-3
Chapter 1 Troubleshooting and Error Codes
Creating Fault Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Addressing PowerFlex Active Front End Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2
Common Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-7
Chapter 2 Active Front End System Overview
AFE in IP20 2500 MCC Style Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Main Component Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Main Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Main Bus Bar/Cable Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
AFE in IP21 Rittal Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Main Component Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Main Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-5
Bus Bar Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-6
AFE in IP00 Open Chassis Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-7
Chapter 3 Component Test Procedures
Viewing the Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Performing Visual Inspections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Inspecting the Cooling Tunnel . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Inspecting the Power Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2
Performing Forward and Reverse Biased Diode Tests for Power Structure . . . . . . . . . . . 3-3
Checking Fiber Optic Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5
Performing Gate Driver Board Resistance Measurements . . . . . . . . . . . . . . . . . . . . . . . . 3-7
Checking the AFE Power Structure Fan Inverter Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . 3-8
Chapter 4 AFE Power Structure Component Section
Understanding Torque Figures in Assembly Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Torque Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2
Removing Power from the AFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Control Frame Access Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Removing the DPI Interface Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Installing the DPI Interface Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Removing the I/O Circuit Boards and Control Board. . . . . . . . . . . . . . . . . . . . . . . . . . 4-5
Installing the I/O Circuit Boards and Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6

ii Table of Contents
PowerFlex Active Front End—Frame 10 Hardware Service Manual
Publication 20Y-TG001B-EN-P
Removing the Fiber Optic Adapter Circuit Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
Installing the Fiber Optic Adapter Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-8
Removing the Control Frame (only for AFE in IP21 Rittal enclosure). . . . . . . . . . . . . 4-9
Replacing the Control Frame. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-9
Power Structure Access Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Removing AFE Protective Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Installing the AFE Protective Barriers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-10
Removing the AFE Air Flow Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Installing the AFE Air Flow Plate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-11
Removing Protective Covers from the Power Structure . . . . . . . . . . . . . . . . . . . . . . . 4-12
Installing Protective Covers on the Power Structure . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Removing the Gate Driver Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-12
Installing the Gate Driver Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Removing the ASIC Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-14
Installing the ASIC Circuit Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Removing and Installing the Power Structure Fan System . . . . . . . . . . . . . . . . . . . . . 4-17
Removing the Power Structure from the Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . 4-17
Installing the Power Structure in the Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-19
Removing the Power Module from the Power Structure. . . . . . . . . . . . . . . . . . . . . . . 4-20
Installing the Power Module on the Power Structure . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Removing the Power Structure DC Bus Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . 4-26
Installing the Power Structure DC Bus Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-27
Replacing the Existing Power Structure with a New Power Structure . . . . . . . . . . . . 4-27
Chapter 5 AC Line Switchgear Component Section
AFE in IP20 2500 MCC Style Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
AFE in IP21 Rittal Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2
Chapter 6 Precharge Component Section
Precharging Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Replacing the Precharge Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-2
Testing the Control Transformer (T4) and 24V DC Power Supply (T10). . . . . . . . . . . . . 6-3
For AFE in IP20 2500 MCC Style Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-3
For AFE in 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 Resistor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-7
Replacing the Precharge Resistor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
AFE in IP20 2500 MCC Style Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
AFE in IP21 Rittal Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-8
Chapter 7 LCL Filter Component Section
Removing the LCL Filter Protective Barrier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Installing the LCL Filter Protective Barrier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Replacing the LCL Filter DC Fan Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-2
Removing the LCL Filter Fan DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-3
Installing the LCL Filter Fan DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5
Replacing the LCL Filter Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-5

Table of Contents iii
PowerFlex Active Front End—Frame 10 Hardware Service Manual
Publication 20Y-TG001B-EN-P
Removing the LCL Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
From the IP20 2500 MCC Style Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-6
From the IP21 Rittal Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-8
Installing the LCL Filter in the Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-9
Chapter 8 DC Fuses Component Section
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Fuse Replacement Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Chapter 9 Startup After Repair
Before Applying Power to the AFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-2
Appendix A Service Tools and Equipment
Software Tools. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Service Tools . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . A-1
Appendix B Schematic Diagrams
Frame 10 Circuit Board Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-1
Frame 10 Power Module Circuitry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2
Frame 10 Power Structure Main Fan Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-3
Control Wiring Diagram for Frame 10 in IP20 2500 MCC Style Enclosure . . . . . . . . . . B-4
System Schematics for Frame 10 in IP20 2500 MCC Style Enclosure . . . . . . . . . . . . . . B-6
Control Wiring Diagram for Frame 10 in IP21 Rittal Enclosure . . . . . . . . . . . . . . . . . . B-13
System Schematics for Frame 10 AFE in IP21 Rittal Enclosure . . . . . . . . . . . . . . . . . . B-14
Appendix C Connector Descriptions
Circuit Board Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-1
Hardware Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . C-4
Appendix D Disassembly/Assembly Diagrams and Spare Parts
AFE Power Structure Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-2
LCL Filter Assembly (used in IP20 and IP21 enclosures) . . . . . . . . . . . . . . . . . . . . . . . . D-5
Precharge Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-7
AC Line Switchgear . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-9
Appendix E AFE Power One-line System Application Data
Data to Collect. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
Typical Transformer Winding Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-2
Index

iv Table of Contents
PowerFlex Active Front End—Frame 10 Hardware Service Manual
Publication 20Y-TG001B-EN-P

PowerFlex Active Front End—Frame 10 Hardware Service Manual
Publication 20Y-TG001B-EN-P
Preface
Overview
Who Should Use this
Manual?
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.
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.
Additional Resources 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.
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: 3Phase, 0 - 320Hz
Continuous Amps420/500
630/550
420/500
630/550
1 Min Overload Amps
2 Sec Overload Amps840/630840/630
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
ULUSCÆ
LISTED
IND CONT EQ
9D42
CatNo. 20D J300N 0 NNNBNNNN
ULOpenType/IP00 540V 650V
NormalDuty Power 160kW
132kW
250kW
200kW
HeavyDuty Power
DCVoltage Range 462 - 594
350
583- 713
350
Amps
Input:DC,
ACVoltage Range 0 - 400
50Hz
0- 460
60Hz
BaseHz (default)
Output:3Phase, 0 - 320Hz
ContinuousAmps300/245
330/368
300/245
330/368
1Min Overload Amps
2Sec Overload Amps450/490 450/490
MFD.in1989 on Nov 9
SerialNumber: 2622381652
2622381652
MADEINTHE USA (FAC 1B)
Series:A
StandardI/O:NONE
OriginalFirmware No. 2.04
ULUSCÆ
LISTED
INDCONT 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

P-2 Overview
PowerFlex Active Front End—Frame 10 Hardware Service Manual
Publication 20Y-TG001B-EN-P
General Information
The following publications provide general drive information.
PowerFlex Active Front End Information
The following publications provide specific AFE information.
For spare parts information on 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.
Understanding Manual
Conventions
Become familiar with the following conventions used in this manual.
Terms
The following words are used throughout the manual to describe an action.
Cross References
‘Figure 3.1 on page 3-4’ is a cross reference to Figure 3.1 on page 4 of
Chapter 3.
‘Figure C.1 on page C-3’ is a cross reference to Figure C.1 on page 3 of
Appendix C.
Title Publication
Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives DRIVES-IN001
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
Title Publication
PowerFlex Active Front End User Manual 20Y-UM001
PowerFlex 700H, 700S, and 700AFE Drive Fan Systems Installation Instructions PFLEX-IN029
Drives in Common Bus Configurations Application Guidelines DRIVES-AT002
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

Overview P-3
PowerFlex Active Front End—Frame 10 Hardware Service Manual
Publication 20Y-TG001B-EN-P
Additional Support
Available on Internet
Additional troubleshooting information and software tools are available on
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
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 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
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,
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 should 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.

P-4 Overview
PowerFlex Active Front End—Frame 10 Hardware Service Manual
Publication 20Y-TG001B-EN-P
Notes:

PowerFlex Active Front End—Frame 10 Hardware Service Manual
Publication 20Y-TG001B-EN-P
Chapter 1
Troubleshooting and Error Codes
!
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: 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.

1-2 Troubleshooting and Error Codes
PowerFlex Active Front End—Frame 10 Hardware Service Manual
Publication 20Y-TG001B-EN-P
Creating Fault Reports Complete fault reports are critical for analysis and repair of modules
returned to the factory.
At a minimum, do the following:
•Using an Allen-Bradley drive configuration tool such as Connected
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.
•If possible, record the contents of the fault queue (faults and times of
occurrence).
•Make record of the following:
–Any burn marks on the rectifying module, DC capacitors, inverter
bridge, charging resistors, balancing/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.
•Record the size and type of main fuses.
•Record any other important marks and damage.
•Note grounding type (solid, high resistance, or floating) and source
impedance of the power distribution system.
Addressing PowerFlex
Active Front End Faults
No. Name Description Action (if appropriate)
1 PrechargeActv The AFE is still in precharge
because the charging switch
(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.
•faulty operation
•component failure
Reset the fault and restart.
Should the fault re-occur, contact
Technical Support.
2 Auxiliary In The AFE control digital input
interlock is open.
Verify wiring to the digital inputs on
the AFE control board are correct.
4 DC UnderVolt The DC bus voltage fell below
the minimum value of 333V for
400/480V units, or 461V for 600/
690V units. You can enable/
disable this fault with parameter
120 [Fault Config].
Monitor the incoming AC line for low
voltage or power interruption.

Troubleshooting and Error Codes 1-3
PowerFlex Active Front End—Frame 10 Hardware Service Manual
Publication 20Y-TG001B-EN-P
5 DC OverVolt The DC bus voltage exceeded
the maximum value of 911V for
400/480V units, or 1200V for
600/690V units.
1. Check if the AFE was in a
regenerative current limit
condition, which may indicate an
excess regenerative load.
2. Adjust parameter 076 [Regen
Power Lmt].
3. Monitor incoming AC line for high
voltage or voltage transients.
7 Overload When input current exceeds
125% for 60 seconds or 150%
for 30 seconds. The overload is
a linear type in counting up.
Reduce the current consumption of
the AFE or increase parameter 133
[Cnvrtr OL Factor].
8 HeatsinkOvrTp The power structure heatsink
temperature has exceeded the
maximum allowable value.
85 °C = Alarm
90 °C = Fault
1. Verify that the maximum ambient
temperature has not been
exceeded.
2. Check the fans (including ASIC
board on the power structure).
3. Check for an excess load.
4. Verify that the airflow plate is
installed. See page 4-11.
9 IGBT OverTemp The output transistors have
exceeded their maximum
operating temperature due to an
excessive load.
1. Verify that the maximum ambient
temperature has not been
exceeded.
2. Check the fan(s).
3. Check for an excess load.
10 System Fault A hardware problem exists in the
power structure.
1. Reset the fault and restart.
2. Verify the fiber optic connections.
3. Verify ASIC Board jumper
connections from X9 to X15 (see
Figure B.1 on page B-1).
4. Contact Technical Support.
5. If the problem persists, replace or
repair the power structure.
12 AC OverCurr The AC line current has
exceeded the hardware current
limit.
Check for an excessive load or other
causes of excess current.
13 Ground Fault A current path to earth ground
exists that is greater than the
parameter 082 [Ground I Lvl]
value. The current must appear
for 800 milliseconds before the
unit will fault.
Using a digital voltmeter to check for
low impedance to ground, verify the
bus cables/bars between the:
•Disconnect and AC input lines
•Power structure and LCL Filter
•For AFE in IP20 enclosure:
– Q0 input breaker and K1 input
contactor, which includes the
precharge disconnect
– LCL Filter and K1 input cont.
•For AFE in IP21 enclosure:
– Q1 (MCCB) and Q0 disconnect
switch, which includes the
precharge disconnect
– LCL Filter and Q1 (MCCB)
14 Power Structure
Fault
A hardware problem exists in the
power structure.
1. Cycle the power.
2. Contact Technical Support.
3. If the problem persists, replace
the converter unit.
No. Name Description Action (if appropriate)

1-4 Troubleshooting and Error Codes
PowerFlex Active Front End—Frame 10 Hardware Service Manual
Publication 20Y-TG001B-EN-P
17 LineSync Fail One input of the known phase
rotation is missing.
1. Check all user-supplied fuses.
2. Check the AC input line voltage.
21 Phase Loss There is zero current in one of
the three phases.
Check supply voltage, fuses, and
cable.
29 Anlg In Loss 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].
1. Verify parameter 203 or 206 [Anlg
In x Loss] setting. Input signal
level should be greater than or
equal to 1.5V or 3 mA.
2. Check for broken/loose
connections at the inputs.
30 MicroWatchdog A microprocessor watchdog
timeout has occurred.
1. Cycle the power.
2. Replace the Control board. See
page 4-5.
31 IGBT Temp Hw The AFE input current has
exceeded the 1 minute overload
rating.
Check for an excess load.
32 Fan Cooling Fan is not energized at start
command. This includes the
power structure or LCL Filter
fans.
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 located behind the fan.
For additional information, see
PowerFlex 700H, 700S, and 700AFE
Drive Fan Systems Installation
Instructions, publication
PFLEX-IN029.
33 AutoReset Lim 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].
Correct the cause and manually clear
the fault.
34 CAN Bus Flt A sent message was not
acknowledged.
1. Cycle the power.
2. Replace the Control board on the
power structure. See page 4-5..
35 Application Problem in application software
with task overload.
Contact Technical Support.
37 HeatsinkUndTp The ambient temperature
around the power structure
heatsink is too low.
Raise the ambient temperature.
44 Device Change The new power unit or option
board installed is a different
type.
Clear the fault and verify the correct
parameters for the new option board.
45 Device Add A new option board was added. Clear the fault.
47 NvsReadChksum There was an error reading
parameters 019 [Motoring
MWh], 020 [Regen MWh], and
021 [Elapsed Run Time] from
EEPROM.
1. Cycle the power.
2. Replace the Control board. See
page 4-5..
No. Name Description Action (if appropriate)

Troubleshooting and Error Codes 1-5
PowerFlex Active Front End—Frame 10 Hardware Service Manual
Publication 20Y-TG001B-EN-P
54 Zero Divide This event occurred because a
mathematical function had a
dividend of zero.
1. Cycle the power.
2. Replace the Control board. See
page 4-5..
58 Start Prevent Startup has been prevented. 1. Cancel prevention of startup if this
can be done safely.
2. Remove Run Request.
65 I/O Removed An I/O option board has been
removed.
Clear the fault.
70 Power Unit Incorrect output power device
operation.
1. Check the power structure for
damaged components. Replace if
defective.
2. Replace the power structure.
71 Periph Loss The 20-COMM-x communication
adapter has a fault on the
network side.
Check the DPI device event queue
and corresponding fault information
for the device.
81 Port DPI Loss The DPI port has stopped
communicating. A SCANport
device was connected to a drive
operating DPI devices at 500k
baud.
1. Check the HIM connection.
2. If the 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.
94 Hardware Enbl An enable signal is missing from
the control terminal block, only
when jumper J5 is removed on
the digital I/O board.
1. Check the control wiring.
2. Check the position of the J5
hardware enable jumper.
3. Check the digital input
programming.
100 Param Chksum The checksum read from the
Control board does not match
the checksum calculated.
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..
104 PwrBrd Chksum The checksum read from the
EEPROM does not match the
checksum calculated from the
EEPROM data.
1. Cycle the power.
2. Check the fiber optics between
the Fiber Optic Adapter board and
the ASIC board. See page C-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 4-14) in
the power structure.
4. Contact Technical Support.
No. Name Description Action (if appropriate)

1-6 Troubleshooting and Error Codes
PowerFlex Active Front End—Frame 10 Hardware Service Manual
Publication 20Y-TG001B-EN-P
106 MCB-PB Config The AFE rating information
stored on the power board is
incompatible with the Control
board.
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.
107 New IO Option A new option board was added
to the Control board.
1. Clear the fault and verify the
correct parameters for the new
option board.
2. Reprogram parameters as
necessary.
113 Fatal App A Fatal Application error has
occurred.
1. Cycle the power.
2. Replace the Control board on the
power structure. See page 4-5..
120 I/O Change An option board has been
replaced.
Reset the fault.
121 I/O Comm Loss A defective option board or I/O
board slot.
1. Check the Control board-to-I/O
option board connection.
2. Verify the ground integrity from
the Control board to the option
board.
3. Replace the Control board and/or
I/O board. See page 4-5..
125 LCL OverTemp The LCL Filter has been
overheated or the signal is not
connected to input.
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 is located on the LCL FIlter.
126 LCL Fan Stop 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’.
No. Name Description Action (if appropriate)
Thermal Switch 1 Thermal Switch 9 To Digital
Input 5
X52
Frame 10 LCL Filter
X52 approximate
location

Troubleshooting and Error Codes 1-7
PowerFlex Active Front End—Frame 10 Hardware Service Manual
Publication 20Y-TG001B-EN-P
Common Symptoms and
Corrective Actions
AFE does not Start from Start or Run Inputs wired to the terminal block.
128 Contact Fdbk The input of the acknowledge
signal from the main contactor is
missing.
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.
133 DigInConflict Digital input functions are in
conflict.
Check the parameter settings of
parameters 221…226.
138 DCRefLowLim DC voltage reference is less
than the limit in parameter 080
[DC Ref Lo Lmt].
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.
139 DCRefHighLim DC voltage reference exceeds
the limit in parameter 081 [DC
Ref Hi Lmt].
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.
140 DCBusLoAlarm DC voltage is less than the value
set by parameter 078 [DC Bus
Lo Alarm].
Check the parameter setting.
141 DCBusHiAlarm DC voltage exceeds the value
set by parameter 079 [DC Bus
Hi Alarm].
Check the parameter setting.
No. Name Description Action (if appropriate)
Cause Indication Corrective Action
AFE is faulted Flashing red status
light
Clear the fault.
•Press Stop.
•Cycle the power.
•Set parameter 121 [Fault
Clear] to ‘1’.
•‘Clear Faults’ on the HIM
Diagnostic menu.
Incorrect input wiring. See the ‘Control
Wiring’ section in the PowerFlex Active
Front End User Manual, publication
20Y-UM001, for information.
NOTE: Jumper from terminal 17 to 20
is required when using the 24V DC
internal supply.
None Wire inputs correctly and/or
install jumper.
Incorrect digital input programming. None Program parameters 221…226
[Digital Inx Sel] for correct inputs.
Run programming may be
missing.
There is some other start inhibit. Check status bits of
parameter 100 [Start
Inhibits].
Correct the source of the inhibit.

1-8 Troubleshooting and Error Codes
PowerFlex Active Front End—Frame 10 Hardware Service Manual
Publication 20Y-TG001B-EN-P
Instability in the AC Line Input Current and DC Bus Voltage.
Cause Indication Corrective Action
AC line voltage more than 5% above
normal.
Instability in AC line
current and DC bus
voltage.
May trip on fault F7
‘Overload’.
Increase parameter 060 [DC Volt
Ref] proportional to the
percentage of the AC line voltage
above nominal.
Negative reactive I Ref on parameter
065 [Reactive I Ref] with a soft (high
impedance) AC line.
Instability in AC line
current and DC bus
voltage.
May trip an F7
overload.
Change parameter 065 [Reactive
I Ref] value to zero. Verify if the
AFE is running on a soft line per
the AC line source
considerations.