User Manual PowerFlex Active Front End PowerFlex AFE / PowerFlex 700AFE Frames 10 and 13, Firmware Revision Number 1.
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.
Summary of Changes This manual contains new and updated information. New and Updated Information This table contains the changes made to this revision. Topic Page Added information for the Frame 13 AFE in an IP20 2500 MCC Style enclosure.
Summary of Changes Notes: 4 Rockwell Automation Publication 20Y-UM001E-EN-P - July 2014
Table of Contents Preface Who Should Use this Manual? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . What Is Not in this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Rockwell Automation Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Local Product Support . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Disconnecting Common Mode Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . Frame 10 LCL Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frame 13 LCL Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Frame 10 or Frame 13 Power Structure . . . . . . . . . . . . . . . . . . . . . . . . . Using the AFE with PowerFlex Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Control Wiring .
Table of Contents Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Power Cable Types Acceptable for 400…690 Volt Installations. . . Unshielded Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Shielded Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Armored Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Table of Contents Chapter 4 Programming and Parameters About Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91 How AFE Parameters are Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 File-Group-Parameter Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Basic Parameter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93 Advanced Parameter View. . . . . . .
Table of Contents DPI Communication Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . Typical Programmable Controller Configurations . . . . . . . . . . . . . Logic Command Word for PowerFlex 700/700H/700S Drives . Logic Status Word for PowerFlex 700/700H/700S Drives. . . . . . Logic Command Word for PowerFlex 750-Series Drives. . . . . . . . Logic Status Word for PowerFlex 750-Series Drives . . . . . . . . . . . .
Table of Contents 10 Rockwell Automation Publication 20Y-UM001E-EN-P - July 2014
Preface The purpose of this manual is to provide you with the basic information needed to install, start up, and troubleshoot the PowerFlex® Active Front End (AFE).
Preface Rockwell Automation Support Rockwell Automation offers support services worldwide, with over 75 sales and support offices, over 500 authorized distributors, and over 250 authorized systems integrators located throughout the United States alone. In addition, Rockwell Automation representatives are in every major country in the world.
Preface General Information The following publications are recommended for general information. Title Publication Drives in Common Bus Configurations DRIVES-AT002 Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives DRIVES-IN001 Preventive Maintenance of Industrial Control and Drive System Equipment DRIVES-TD001 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.
Preface General Precautions 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.
Preface Catalog Number Explanation Position 1-3 4 5-7 8 9 10 11 12 13 14 15 16 20Y D 460 A 0 A N N A N A 0 a b c d e f g h i j k l a d g Drive Enclosure Brake Code Type PowerFlex AFE/ PowerFlex 700AFE 20Y Code D F Type Conformal Coating A✻ IP21 Rittal Enclosure, NEMA/UL Type 1 IP00, Open-Chassis IP20, NEMA/UL Type 1 2500 MCC Style Enclosure with Power Bus, 800 mm (31.5 in.
Preface The PowerFlex Active Front End is a regenerative DC bus supply that is used to supply DC power to a lineup of common DC bus drives or a single common bus drive. The AFE uses a PWM (Pulse Width Modulated)-controlled IGBT converter to allow bi-directional power flow to the AC line. The following figures show examples of the AFE powering a lineup of PowerFlex 755 drives and the AFE powering a single PowerFlex 755 drive.
Preface The output of the DC voltage controller is the active current reference, which is compared to the measured active current. The error between them is the input for the active current controller. The output of the active current controller changes the modulation index and controls the inverter voltage. The reactive current reference can be used for reactive power compensation.
Preface Benefits of the AFE The PowerFlex Active Front End provides the following benefits: • Energy Savings with Regenerative Braking—instead of wasting energy with resistor braking technology, regenerative braking actually puts the energy back into the system to be used by other equipment. • Low AC Input Harmonics—the active front end provides low harmonics to meet IEEE 519 and CE at its input terminals.
Preface The following figure shows a basic one-line diagram for an AFE Frame 10 in a IP00, NEMA/UL Open Chassis configuration and the parts the customer must supply. AFE in IP00 Open Chassis Configuration Figure 4 - Basic One-line Diagram for an AFE Frame 10 in IP00 Open Chassis Configuration AC Line Switchgear 3 Phase AC Input Input Breaker Q0 LCL Filter (L1) Input Contactor K1 Fuses F1.1-F1.
Preface The following figure shows a basic one-line diagram for an AFE Frame 13 in a IP00, NEMA/UL Open Chassis configuration and the parts the customer must supply. Figure 5 - Basic One-line Diagram for an AFE Frame 13 in IP00 Open Chassis Configuration AC Line Switchgear 3 Phase AC Input Input Breaker Q0 LCL Filter (L1) Input Contactor K1 Fuses F1.1-F1.3 L1 L2 L3 Customersupplied Parts AFE Power Structure (U1) U2 U1 V2 W2 V1 W1 C1 C4 C2 C5 C3 PE U DC+ DC- DC Fuses F2.1 F2.
Chapter 1 AFE in IP20 2500 MCC Style Enclosure— Installation/Wiring This chapter provides information on installing and wiring the PowerFlex Active Front End in a IP20 2500 MCC Style enclosure. For information on installing and wiring the AFE in a IP21 Rittal enclosure, see Chapter 2.
Chapter 1 AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring This section describes the main component sections of AFE Frame 10 and Frame 13 systems in a IP20 2500 MCC Style enclosure. Main Component Sections Frame 10 The following figure shows a basic one-line diagram for an AFE Frame 10 in a IP20 2500 MCC Style enclosure. The main component sections consist of the following items: • AC Line Switchgear consisting of the input circuit breaker (Q0), fuses (F1.1-F1.
AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring Chapter 1 Frame 13 The following figure shows a basic one-line diagram for an AFE Frame 13 in a IP20 2500 MCC Style enclosure. The main component sections consist of the following items: • AC Line Switchgear consisting of the input circuit breaker (Q0), fuses (F1.1-F1.3), and input contactor (K1) • LCL Filter (L1) • Precharge Circuit • AFE power structure (U1) with AFE control assembly • DC fuses (F2.1…F2.
Chapter 1 AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring Main Component Locations This section shows the main component locations for AFE Frame 10 and Frame 13 systems in a IP20 2500 MCC Style enclosure. Frame 10 The following figure shows the main components of the AFE Frame 10 system in a IP20 2500 MCC Style enclosure.
AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring Chapter 1 Frame 13 The following figure shows the main components of the AFE Frame 13 system in a IP20 2500 MCC Style enclosure.
Chapter 1 AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring Mounting Considerations When mounting the Active Front End, consider the following information.
AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring Chapter 1 Frame 13 in IP20 2500 MCC Style Enclosure 73 mm (2.9 in.) Clearance to Wall 990.2 mm (39 in.) Door Swing Clearance TOP VIEW 27 mm (1.0 in.) Clearance to Wall 591.5 mm (23 in.) 790.2 mm Door Swing Clearance (31 in.) Door Swing Clearance 200 mm (7.87 in.
Chapter 1 AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring AC Supply Source Considerations The AFE Frame 10 or Frame 13 in a IP20 2500 MCC Style enclosure is suitable for use on a circuit capable of delivering 100,000 rms symmetrical amperes at 400/480V and 65,000 rms symmetrical amperes at 600/690V. The AFE must not be used on undersized or high-impedance supply systems. The supply system kVA must be equal to or greater than the drive-related kW, and the system impedance must be less than 10%.
AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring Chapter 1 • The power source has intermittent voltage spikes in excess of 6000 volts. These spikes can be caused by other equipment on the line or by events such as lightning strikes. • The power source has frequent interruptions. Grounding Requirements The Active Front End Safety Ground-PE must be connected to system ground.
Chapter 1 AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring Figure 11 - Typical Grounding Example for AFE Frame 13 in IP20 2500 MCC Style Enclosure R (L1), S (L2), T (L3) PowerFlex 750-Series Drive or PowerFlex 7-Class Drive (can be located on the right or left side of the AFE; PowerFlex 755 Frame 8 drive shown on right side) To Line PE Customer wiring or DC bus bar splice required to connect the AFE to the drive.
AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring Power Wiring Chapter 1 Because most start-up difficulties are the result of incorrect wiring, take every precaution to verify the wiring is correct. Read and understand all items in this section before beginning installation. ATTENTION: The following information is merely a guide for proper installation.
Chapter 1 AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring Consider all of the general specifications dictated by the environment of the installation, including temperature, flexibility, moisture characteristics, and chemical resistance. In addition, include a braided shield, specified by the cable manufacturer as having coverage of at least 75%. An additional foil shield can be greatly improve noise containment. A good example of recommended cable is Belden® 29528 - 29532 (AWG-1 through AWG-410).
AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring Chapter 1 Cable Trays and Conduit ATTENTION: To avoid a possible shock hazard caused by induced voltages, unused wires in the conduit must be grounded at both ends. For the same reason, if a drive sharing a conduit is being serviced or installed, all drives using this conduit must be disabled. This helps minimize the possible shock hazard from ‘cross coupled’ motor leads.
Chapter 1 AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring 2. Move the wire shown in Figure 13 to the appropriate X3 terminal to match the AC line voltage. Figure 13 - Input Voltage Setting for Control Voltage on Frames 10 and 13 in IP20 2500 MCC Style Enclosure For 400/480V or 600/690VAC Input X3 Terminal Block 400 480 600 690 Move this wire to the terminal that matches the AC line voltage.
AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring Chapter 1 Power Terminals for AFE in IP20 2500 MCC Style Enclosure The following figures and tables show the power terminal locations and specifications for AFE Frames 10 and 13 in an IP20 2500 MCC Style enclosure.
Chapter 1 AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring Figure 15 - AFE Frame 13 Power Terminal Locations in IP20 2500 MCC Style Enclosure (Shown with enclosure doors and side removed) FRONT VIEW RIGHT SIDE VIEW Table 3 - AFE Frame 13 Power Terminal Specifications in IP20 2500 MCC Style Enclosure Torque Maximum Minimum Recommended Input power 380 mm2 (750 MCM) 53 mm2 (1/O AWG) 50 N•m (442 lb•in) N/A 13 Terminating point for wiring shields 300 mm2 (600 MCM) 2.
AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring Chapter 1 Routing the AC Input, Ground (PE), and DC Bus Output Wiring for AFE in IP20 2500 MCC Style Enclosure ATTENTION: To minimize disruption of air flow through the enclosure and avoid overheating within the AFE enclosure, remove only the minimum area needed to route the power cables.
Chapter 1 AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring Figure 17 - Routing Areas for AC Input, Ground, and DC Bus Output Wiring for AFE Frame 13 in IP20 2500 MCC Style Enclosure Area for routing AC input and ground (PE) connections Shaded areas for routing DC bus output connections—on either the left or right side of the enclosure When the side cover plate is removed for DC bus routing, always use the Barrier Kit SK-Y1-MCCBARRIER to maintain proper air flow in the AFE enclosure and prevent ov
AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring Chapter 1 Figure 18 - AFE Frame 10 LCL Filter Common Mode Capacitor Jumper Locations RIGHT SIDE VIEW OF LCL FILTER Remove Three Jumpers Remove Three Jumpers Frame 13 LCL Filter The Frame 13 AFE LCL Filter contains common mode capacitors that are referenced to ground.
Chapter 1 AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring Figure 19 - AFE Frame 13 LCL Filter Common Mode Capacitor Jumper Locations Remove Three Jumpers Remove Three Jumpers FRONT VIEW OF LCL FILTER Frame 10 or Frame 13 Power Structure IMPORTANT Using the AFE with PowerFlex Drives The Frame 10 or Frame 13 AFE in a IP20 2500 MCC Style enclosure is shipped from the factory with the common mode capacitors removed so the user need not do this.
AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring Chapter 1 control is required, will the control wiring and correspondent digital I/O parameter setting need to be changed. Here are some important points to remember about I/O wiring: • Always use copper wire. • Wire with an insulation rating of 600V or greater is recommended. • Control and signal wires must be separated from power wires by at least 0.3 meters (1 foot).
Chapter 1 AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring Table 5 - Recommended Control Wire for Digital I/O Type Wire Type(s) Description Minimum Insulation Rating Unshielded Per US NEC or applicable national or local code — Shielded Multi-conductor shielded cable such as Belden 8770(or equivalent) 0.5 mm2 (22 AWG), 3 conductor, shielded 300V, 60 °C (140 °F) Figure 20 - Door Control Box I/O Terminal Blocks and Jumpers For jumper configurations, see Table 8 on page 45.
AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring Chapter 1 I/O Cable Grounding When installing shielded multi-conductor cable for analog and digital I/O, strip the cable at a distance from the terminal plug so you can fix it to the cable clamp for grounding. Position the exposed shield so the clamp grips it. NOTE: This clamp is not designed for strain relief.
Chapter 1 AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring ATTENTION: For the AFE in the IP20 2500 MCC Style enclosure, Digital Inputs 1, 3, 4, and 5, and Digital Outputs 1 and 2 are factory wired and programmed to operate from the controls on the front of the enclosure. Digital Output 3 is programmable and factory wired for +24V DC only. Do not change the wiring and programming for those digital inputs and outputs, or it will result in malfunction of the system.
AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring Chapter 1 Typical I/O Wiring The IP20 2500 MCC Style enclosure for the AFE is factory wired and programmed to operate from the operator switches on the front of the enclosure. The AFE in the IP20 2500 MCC Style enclosure has an input contactor K1. The AFE is configured to run when precharge is complete, the contactor is closed, and no faults are present. The following figure shows the factory-installed wiring.
Chapter 1 AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring Hardware Enable Circuitry ATTENTION: For the AFE in the IP20 2500 MCC Style enclosure, Digital Inputs 1, 3, 4, and 5, and Digital Outputs 1 and 2 are factory wired and programmed to operate from the controls on the front of the enclosure. Do not change the wiring and programming for those digital inputs and outputs, or it will result in malfunction of the system. You can program a digital input as an Enable input.
AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring Precharging the AFE Chapter 1 This section contains important information about AFE precharging. Introduction An AFE in the IP20 2500 MCC Style enclosure contains an internal precharging circuit. The precharging unit is used to charge the DC bus capacitors. The charging time depends on the capacitance of the intermediate circuit and the resistance of the charging resistors.
Chapter 1 AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring CE Conformity Conformity with the Low Voltage (LV) Directive and Electromagnetic Compatibility (EMC) Directive has been demonstrated by using harmonized European Norm (EN) standards published in the Official Journal of the European Communities. PowerFlex Active Front End units comply with the EN standards listed below when installed according to this User Manual and the PowerFlex drive Reference Manual.
AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring Chapter 1 5. All shielded cables must terminate with proper shielded connector. 6. Motor cables of DC input drives used with the AFE must be shielded cable wire with a coverage of 75% or more, or must be inside metal conduit or have shielding/cover with equivalent attenuation.
Chapter 1 AFE in IP20 2500 MCC Style Enclosure—Installation/Wiring Notes: 50 Rockwell Automation Publication 20Y-UM001E-EN-P - July 2014
Chapter 2 AFE in IP21 Rittal Enclosure—Installation/ Wiring This chapter provides information on installing and wiring the PowerFlex Active Front End in a IP21 Rittal enclosure. For information on installing and wiring the AFE in a IP20 2500 MCC Style enclosure, see Chapter 1.
Chapter 2 AFE in IP21 Rittal Enclosure—Installation/Wiring This section describes the main component sections of AFE Frame 10 and Frame 13 systems in a IP21 Rittal enclosure. Main Component Sections Frame 10 The following figure shows a basic one-line diagram for an AFE Frame 10 in a IP21 Rittal enclosure.
AFE in IP21 Rittal Enclosure—Installation/Wiring Chapter 2 Frame 13 The following figure shows a basic one-line diagram for an AFE Frame 13 in a IP21 Rittal enclosure. The main component sections consist of the following items: • AC Line Switchgear consisting of the input disconnect (Q0) and MCCB motor-controlled circuit breaker (Q1) • LCL Filter (L1) • Precharge Circuit • AFE power structure (U1) with AFE control assembly • DC fuses (F2.1…F2.
Chapter 2 AFE in IP21 Rittal Enclosure—Installation/Wiring Main Component Locations This section shows the main component locations for AFE Frame 10 and Frame 13 systems in a IP21 Rittal enclosure. Frame 10 The following figure shows the main components of the AFE Frame 10 system in a IP21 Rittal enclosure.
AFE in IP21 Rittal Enclosure—Installation/Wiring Chapter 2 Frame 13 The following figure shows the main components of the AFE Frame 13 system in a IP21 Rittal enclosure. Figure 25 - AFE Frame 13 Main Component Locations in IP21 Rittal Enclosure FRONT VIEW (shown with enclosure doors removed) ➐ ➌ ➋ ➎ ➍ ➏ These components are located on a sub-panel mounted in front of the bus bars shown above.
Chapter 2 AFE in IP21 Rittal Enclosure—Installation/Wiring Mounting Considerations When mounting the Active Front End, consider the following information.
AFE in IP21 Rittal Enclosure—Installation/Wiring Chapter 2 Frame 13 in IP21 Rittal Enclosure 50 mm (2.0 in.) Clearance to Wall TOP VIEW 50 mm (2.0 in.) Clearance to Wall 800 mm (31.5 in.) Door Swing Clearance 200 mm (7.87 in.
Chapter 2 AFE in IP21 Rittal Enclosure—Installation/Wiring AC Supply Source Considerations The AFE Frame 10 or Frame 13 in a IP21 Rittal enclosure is suitable for use on a circuit capable of delivering up to a maximum of 100,000 rms symmetrical amperes, 600/690 volts with recommended fuses or circuit breakers. The AFE must not be used on undersized or high-impedance supply systems. The supply system kVA must be equal to or greater than the drive-related kW, and the system impedance must be less than 10%.
AFE in IP21 Rittal Enclosure—Installation/Wiring Chapter 2 Input Power Conditioning Certain events on the power system supplying an AFE can cause component damage or shortened product life. This includes the following events: • The power system has power factor correction capacitors switched in and out of the system, either by the user or by the power company. • The power source has intermittent voltage spikes in excess of 6000 volts.
Chapter 2 AFE in IP21 Rittal Enclosure—Installation/Wiring Figure 27 - Typical Grounding Example for AFE Frame 13 in IP21 Rittal Enclosure PowerFlex 750-Series Drive or PowerFlex 7-Class Drive (PowerFlex 700S Frame 10 drive shown) PowerFlex AFE Frame 13 DC+ DC- Customer wiring required to connect the AFE to the drive. DC+ DC- U (T1), V (T2), W (T3) PE PE PE SHLD R (L1), S (L2), T (L3) To Line PE Safety Ground - PE This is the safety ground for the AFE that is required by code.
AFE in IP21 Rittal Enclosure—Installation/Wiring Chapter 2 Fuses and Circuit Breakers The IP21 Rittal enclosure for the AFE includes a motor-controlled circuit breaker (MCCB) and DC bus output fusing. The MCCB is used for precharge operation. For details on MCCB and precharge operation, see page 78. For fuse and circuit breaker information, see Appendix A. Local/national electrical codes can determine additional requirements for the installations.
Chapter 2 AFE in IP21 Rittal Enclosure—Installation/Wiring Shielded Cable Shielded cable contains all of the general benefits of multi-conductor cable with the added benefit of a copper braided shield that can contain much of the noise generated by a typical AC drive. Strongly consider shielded cable in installations with sensitive equipment such as weigh scales, capacitive proximity switches, and other devices that can be affected by electrical noise in the distribution system.
AFE in IP21 Rittal Enclosure—Installation/Wiring Chapter 2 Table 11 - Recommended Shielded/Armored Wire for AFE in IP21 Rittal Enclosure Location Rating/Type Description Standard (Option 1) 1000V, 90 °C (194 °F) XHHW2/ RHW-2 Anixter B29528-B29532, Belden 29528-29532, or equivalent • Four tinned copper conductors with XLPE insulation. • Copper braid/aluminum foil combination shield and tinned copper drain wire. • PVC jacket.
Chapter 2 AFE in IP21 Rittal Enclosure—Installation/Wiring Figure 28 - X3 Terminal Block Location for AFE in IP21 Rittal Enclosure Frame 10 (Shown with enclosure doors removed) Frame 13 (Shown with enclosure doors removed) X3 Terminal Block Location X3 Terminal Block Location FRONT VIEW FRONT VIEW 2. Move the wire shown in Figure 29 to the appropriate X3 terminal to match the AC line voltage.
AFE in IP21 Rittal Enclosure—Installation/Wiring Chapter 2 Power Terminals for AFE in IP21 Rittal Enclosure The following figures and tables show the power terminal locations and specifications for AFE Frames 10 and 13 in an IP21 Rittal enclosure.
Chapter 2 AFE in IP21 Rittal Enclosure—Installation/Wiring Figure 31 - AFE Frame 13 Power Terminal Locations in IP21 Rittal Enclosure (Shown with enclosure doors removed) FRONT VIEW RIGHT SIDE VIEW Table 13 - AFE Frame 13 Power Terminal Specifications in IP21 Rittal Enclosure Wire Size Range (1) (2) Torque Maximum Minimum Recommended Input power 300 mm2 (600 MCM) 2.1 mm2 (14 AWG) 70 N•m (620 lb•in) M12 13 Terminating point for wiring shields 300 mm2 (600 MCM) 2.
AFE in IP21 Rittal Enclosure—Installation/Wiring Chapter 2 Routing the AC Input, Ground (PE), and DC Bus Output Wiring for AFE in IP21 Rittal Enclosure ATTENTION: To minimize disruption of air flow through the enclosure and avoid overheating within the AFE enclosure, remove only the minimum area needed to route the power cables. In addition, remove only the minimum area from the enclosure within the shaded areas shown in Figure 32 for routing the AC input, ground (PE), and DC bus output wiring.
Chapter 2 AFE in IP21 Rittal Enclosure—Installation/Wiring Disconnecting Common Mode Capacitors Frame 10 LCL Filter The Frame 10 AFE LCL Filter contains common mode capacitors that are referenced to ground. To guard against AFE damage, these devices must be disconnected if the AFE is installed on a high resistance grounded distribution system, or an ungrounded distribution system where the line-to-ground voltages on any phase exceed 125% of the nominal line-to-line voltage.
AFE in IP21 Rittal Enclosure—Installation/Wiring Chapter 2 Frame 13 LCL Filter The Frame 13 AFE LCL Filter contains common mode capacitors that are referenced to ground. To guard against AFE damage, these devices must be disconnected if the AFE is installed on a high resistance grounded distribution system, or an ungrounded distribution system where the line-to-ground voltages on any phase exceed 125% of the nominal line-to-line voltage.
Chapter 2 AFE in IP21 Rittal Enclosure—Installation/Wiring Frame 10 Power Structure The AFE Frame 10 power structure in the IP21 Rittal enclosure contains common mode capacitors that must be removed. Use the following procedure to remove these capacitors from the AFE Frame 10 power structure. 1. Locate the common mode capacitors on the Frame 10 power structure. Location of Common Mode Capacitors on Frame 10 Power Structure 2. Remove the common mode capacitors. a. Disconnect the two black wires. b.
AFE in IP21 Rittal Enclosure—Installation/Wiring Chapter 2 Frame 13 Power Structure The AFE Frame 13 power structure in the IP21 Rittal enclosure contains common mode capacitors that must be removed. These capacitors are located on the Phase V (center) module of the power structure. Use the following procedure to remove these capacitors from the AFE Frame 13 power structure. 1. Locate the common mode capacitors on the Phase V module of the Frame 13 power structure.
Chapter 2 AFE in IP21 Rittal Enclosure—Installation/Wiring Using the AFE with PowerFlex Drives When the Active Front End is used with drives that have common mode capacitors (for example, PowerFlex 7-Class or PowerFlex 750-Series drives), the common mode capacitors of these drives must be disconnected. See the documentation of the respective drives. When supplying power to PowerFlex drives of different frame sizes on the same DC bus, additional bus capacitance may be needed.
AFE in IP21 Rittal Enclosure—Installation/Wiring Chapter 2 Signal and Control Wire Types Table 14 - Recommended Signal Wire for AFE in IP21 Rittal Enclosure Signal Type Analog I/O Wire Type(s) Description Minimum Insulation Rating Belden 8760/9460 (or equivalent) 0.5 mm2 (22 AWG), twisted pair, 100% shield with drain (1) Belden 8770 (or equivalent) 0.5 mm2 (22 AWG), 3 conductor, shielded for remote pot only 300V, 75…90 °C (167…194 °F) See CE Conformity on page 79 for details.
Chapter 2 AFE in IP21 Rittal Enclosure—Installation/Wiring I/O Cable Grounding When installing shielded multi-conductor cable for analog and digital I/O, strip the cable at a distance from the terminal plug so you can fix it to the cable clamp for grounding. Position the exposed shield so the clamp grips it. NOTE: This clamp is not designed for strain relief.
AFE in IP21 Rittal Enclosure—Installation/Wiring Chapter 2 ATTENTION: For the AFE in the IP21 Rittal enclosure, Digital Inputs 1, 3, 4, and 5, and Digital Outputs 1 and 2 are factory wired and programmed to operate from the controls on the front of the enclosure. Digital Output 3 is programmable and factory wired for +24V DC only. Do not change the wiring and programming for those digital inputs and outputs, or it will result in malfunction of the system.
Chapter 2 AFE in IP21 Rittal Enclosure—Installation/Wiring Typical I/O Wiring The IP21 Rittal enclosure for the AFE is factory wired and programmed to operate from the operator switches on the front of the enclosure. The AFE in the IP21 Rittal enclosure has a motor-controlled circuit breaker (MCCB). The AFE is configured to run when precharge is complete, the MCCB is closed, and no faults are present. The following figure shows the factory-installed wiring.
AFE in IP21 Rittal Enclosure—Installation/Wiring Chapter 2 Hardware Enable Circuitry ATTENTION: For the AFE in the IP21 Rittal enclosure, Digital Inputs 1, 3, 4, and 5, and Digital Outputs 1 and 2 are factory wired and programmed to operate from the controls on the front of the enclosure. Do not change the wiring and programming for those digital inputs and outputs, or it will result in malfunction of the system. You can program a digital input as an Enable input.
Chapter 2 AFE in IP21 Rittal Enclosure—Installation/Wiring Precharging the AFE This section contains important information about AFE precharging. Introduction An AFE in the IP21 Rittal enclosure contains an internal precharging circuit. The precharging unit is used to charge the DC bus capacitors. The charging time depends on the capacitance of the intermediate circuit and the resistance of the charging resistors. Table 20 shows the technical specifications for the precharge in the AFE enclosure.
AFE in IP21 Rittal Enclosure—Installation/Wiring CE Conformity Chapter 2 Conformity with the Low Voltage (LV) Directive and Electromagnetic Compatibility (EMC) Directive has been demonstrated by using harmonized European Norm (EN) standards published in the Official Journal of the European Communities. PowerFlex Active Front End units comply with the EN standards listed below when installed according to this User Manual and the PowerFlex drive Reference Manual.
Chapter 2 AFE in IP21 Rittal Enclosure—Installation/Wiring 5. All shielded cables must terminate with proper shielded connector. 6. Motor cables of DC input drives used with the AFE must be shielded cable wire with a coverage of 75% or more, or must be inside metal conduit or have shielding/cover with equivalent attenuation.
Chapter 3 Startup This chapter describes how to start up the Active Front End. For a brief description of the HIM (Human Interface Module), see Appendix B. Topic Page AFE in IP20 2500 MCC Style Enclosure 81 AFE in IP21 Rittal Enclosure 86 ATTENTION: Power must be applied to the Active Front End to perform the following start-up procedure. Some of the voltages present are at incoming line potential.
Chapter 3 Startup 4. Verify that the control power voltage is correct. 5. When DC disconnects are used for each inverter, verify that the disconnect levers for all inverters are set to off. 6. Set the REM-MAN-AUTO switch to MAN. 7. Set the OFF-ON-START switch to OFF. Programming the AFE 1. Turn the AFE circuit breaker handle to on. 2. Set parameter 091 [Reset To Defaults] to the appropriate setting for your installation.
Startup Chapter 3 4. Enter the Input Voltage Selection in the Start-up Routine. Select the appropriate AC input voltage for your installation (480, for example). To accept each default setting, press Enter. 5. Enter the Alarm/Flt Cnfg selection. The Alarm/Flt Cnfg sets parameters 120 [Fault Config] and 135 [Alarm Config]. For basic applications, the default settings can be used. To accept each default setting, press Enter. 6. Enter the Limits section.
Chapter 3 Startup Status Indicators For information on AFE status indicators, see AFE Status on page 115. Control Devices The following figure shows the operators or control devices (switches, pushbuttons, and status indicators) on a IP20 2500 MCC Style enclosure.
Startup Chapter 3 The precharging of the units automatically starts when input power is present. When the DC Bus Voltage reaches its nominal value, the contactor closes. To stop the AFE, turn the OFF-ON-START switch to OFF. NOTE: Pressing the (Stop) key on the HIM only stops the AFE output—it does not open the input contactor to stop the AFE.
Chapter 3 Startup AFE in IP21 Rittal Enclosure This procedure requires that a HIM be installed. If an operator interface is not available, remote devices must be used to start up the AFE. Startup Procedure Before Applying Power to the AFE 1. Verify that the disconnect lever is pushed to off. 2. Confirm that all wiring to the AFE (AC Input, ground, DC bus, and I/O) is connected to the correct AFE terminals and is secure. 3.
Startup Chapter 3 4. Enter the Input Voltage Selection in the start-up routine. Select the appropriate AC input voltage for your installation (480, for example). To accept each default setting, press Enter. 5. Enter the Alarm/Flt Cnfg selection. The Alarm/Flt Cnfg sets parameters 120 [Fault Config] and 135 [Alarm Config]. For basic applications, the default settings can be used. To accept each default setting, press Enter. 6. Enter the Limits section.
Chapter 3 Startup Status Indicators For information on AFE status indicators, see AFE Status on page 115. Control Devices The following figure shows the operators or control devices (switches, pushbuttons, and status indicators) on a IP21 Rittal enclosure.
Startup Chapter 3 The precharging of the unit automatically starts when input power is present. When the DC Bus Voltage reaches its nominal value, the circuit breaker automatically closes. To stop the AFE, turn the 0-1-START switch to 0 (off ). NOTE: Pressing the (Stop) key on the HIM only stops the AFE output—it does not open the MCCB to stop the AFE.
Chapter 3 Startup Notes: 90 Rockwell Automation Publication 20Y-UM001E-EN-P - July 2014
Chapter 4 Programming and Parameters This chapter provides a complete listing and description of the PowerFlex Active Front End parameters. The parameters can be programmed (viewed or edited) using an LCD HIM (Human Interface Module). Alternatively, programming can be performed using a personal computer with a configuration tool such as Connected Components Workbench™ software, DriveExecutive™ software, or DriveExplorer™ software.
Chapter 4 Programming and Parameters ➎ No. Parameter Name & Description Values 040 [Nom Input Volt] Sets the incoming supply voltage level used to calculate the DC voltage level for charging control. 046 [Start/Stop Mode] Selects the operating mode for the regenerative unit. 0 (Normal) = The converter starts only with a Run request.
Programming and Parameters Chapter 4 Basic Parameter View Parameter 090 [Param Access Lvl] set to option ‘0’ (Basic).
Chapter 4 Programming and Parameters Advanced Parameter View Parameter 090 [Param Access Lvl] set to option ‘1’ (Advanced).
Programming and Parameters Chapter 4 Group File Monitor File No. Parameter Name & Description Values 001 [Input Voltage] Displays the incoming supply voltage, only when the AFE is in the Run state. 002 [AC Line Freq] Displays the supply frequency. The sign indicates the phase order, only when the AFE is in the Run state. 003 [Total Current] Displays the total AC input current present at L1, L2, and L3 inputs.
Group File Chapter 4 Programming and Parameters No. Parameter Name & Description 018 [Cmd DC Volt] Displays the commanded DC bus voltage reference. 019 Metering 32 020 32 021 32 MONITOR 022 023 030 Converter Data 32 031 032 033 96 Values Default: Min/Max: Units: [Motoring MWh] Default: Displays the accumulated motoring MWh. This parameter may be reset with parameter 092 [Reset Min/Max: Meters].
Programming and Parameters Chapter 4 Group File Dynamic Control File No. Parameter Name & Description 040 [Nom Input Volt] Default: Sets the incoming supply voltage level. It is used to calculate the DC voltage level for charging control. Min/Max: Units: [PWM Frequency] Default: Sets the carrier frequency for the PWM output. This frequency is fixed to 3.6 kHz, and cannot be Min/Max: changed due to the LCL filter. Units: Default: [Modulation Type] Selects the modulation type.
Programming and Parameters No. Parameter Name & Description 051 [Control Options] A set of bits to select AFE control options to disable different harmonic compensation.
Group File Programming and Parameters No. Parameter Name & Description 064 [Active I Ref] Displays the active current reference. 065 Values Default: Min/Max: Units: [Reactive I Ref] Default: If selected by [Reactive I Sel], this parameter sets the reference for the reactive current. This can be Min/Max: used for power factor correction of the power system. Positive value gives inductive current; negative Units: value gives capacitive current.
Group Parallel Mode DYNAMIC CONTROL File Chapter 4 Programming and Parameters No. Parameter Name & Description 085 [Droop] Default: Sets the droop as % of active current reference for current balancing when AFEs are used in parallel Min/Max: independent mode. It affects DC bus voltage if enabled. Recommended value for parallel AFEs is 5%.
Programming and Parameters Chapter 4 Default: Options: 0 0 1 2 3 Ready Ready Factory Low Voltage High Voltage Default: Options: 093 [Language] Limited to English language only. Default: Options: 094 [Voltage Class] Displays the last ‘Reset To Defaults’ operation. Default: Options: 095 [Cnvrtr Status 1] Displays the present operating condition of the AFE.
Programming and Parameters Default x 0 0 x x x x x 0 0 0 Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 DPI at 500k Bit Definition x 0 x x Overload DCBusHiAlarm DCBusLoAlarm DCRefHighLim DCRefLowLim LCL Fan Stop HeatsinkOvTp LineSyncFail Anlg In Loss DC UnderVolt Prechrg Actv Default x 1 1 1 1 1 1 1 1 1 1 1 Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 x x x x DigInConflict Default x x x x x x x x x 0 0 Bit 15 14 13 12 11 10 9 8 7
Enable Type 2 Alarm Fault 0 0 0 0 0 0 0 Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 0 0 0 0 0 Digital In5 Digital In4 Digital In3 Digital In2 Digital In1 [Dig In Status] Displays the status of the digital inputs.
Programming and Parameters Mot CurLim At Reference Faulted Alarm Droop Active In Precharge Regenerating Motoring Active Ready 0 0 0 0 0 0 0 0 0 0 0 0 0 0 0 Default x Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 AutoRst Ctdn ModIndexLim Active Ready Default x 0 0 x x x x x 0 0 0 Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 DPI at 500 k Bit Definition x 0 x x DCBusHiAlarm DCBusLoAlarm DCRefHighLim DCRefLowLim LCL Fan Stop HeatsinkOvTp Lin
No. Parameter Name & Description 120 [Fault Config] Enables/disables annunciation of the listed faults. 132 LineSyncFail 0 0 x 0 x Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 = Enabled 0 = Disabled x = Reserved [Fault Clear] Resets a fault and clears the fault queue. 0 (Ready) = A new value may be entered. 1 (Clear Faults) = A fault is reset. 2 (Clr Fault Que) = The fault queue is cleared. [Fault Clear Mode] Enables/disables a fault reset (clear faults) attempt from any source.
Programming and Parameters HeatsinkOvTp LineSyncFail Anlg In Loss DC UnderVolt Prechrg Actv [Alarm Config] Enables/disables alarm conditions that will initiate an AFE alarm. LCL Fan Stop 135 DCRefLowLim Values DCRefHighLim Parameter Name & Description DCBusLoAlarm No.
Programming and Parameters Chapter 4 No. Parameter Name & Description Values 150 [DPI Baud Rate] Displays the ‘500 kbps’ baud rate that DPI uses for peripherals attached to the AFE. [Cnvrtr Logic Rslt] Captures and displays the final Logic Command resulting from the combination of all DPI and discrete inputs. This parameter has the same structure as the product-specific Logic Command received via DPI, and is used in peer-to-peer communications.
Group Datalinks COMMUNICATION File Chapter 4 Programming and Parameters No. Parameter Name & Description Values 170 171 Default: Min/Max: Units: 172 173 [Data In A1] - Link A Word 1 [Data In A2] - Link A Word 2 Sets the parameter number whose value is written from a communication device data table. If parameters that can only be changed while the unit is stopped are used as datalink inputs, they are not updated until the unit is stopped.
Programming and Parameters Chapter 4 Parameter Name & Description Values 200 [Anlg In Config] Selects the mode for the analog inputs. An1 (0 = V, 1 = mA) No. An2 (0 = V, 1 = mA) Group File Inputs & Outputs File Default x x x x x x x x x 0 0 Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Bit Definition 201 x x x x x 1 = Current 0 = Voltage x = Reserved Default: Min/Max: [Analog In 1 Hi] Sets the highest input value to the Analog Input 1 scaling block.
Programming and Parameters Parameter Name & Description Values 208 [Anlg Out Absolute] Selects whether the signed value or absolute value of a parameter is used before being scaled to drive the analog output. Analog Out1 No.
Group File Programming and Parameters No. Parameter Name & Description Values 215 [Anlg Out1 Scale] Sets the high value for the range of Analog Output 1 scale. Entering ‘0.0’ disables this scale and the maximum scale will be used. Example: If parameter 209 [Analog Out1 Sel] = ‘DC Bus Volt’, the maximum value is 2 * parameter 031 [Rated Volts] = 800V DC.
Group File Chapter 4 Programming and Parameters No. Parameter Name & Description Values 227 [Dig Out Setpt] Sets the digital output from a communication device. Example: Set parameter 172 [Data In B1] to ‘227’ and parameter 229 [Digital Out2 Sel] to ‘Param Cntl’. Digital Output 2 can be controlled by controlling Bit 1 of this parameter over Datalink B1.
Programming and Parameters Parameter Cross Reference – by Name Chapter 4 Parameter Name Number Group Page Parameter Name Number Group Page Data Out AX 180-181 Datalinks 108 Last Stop Source 101 Diagnostics 103 Data Out BX 182-183 Datalinks 108 Logic Mask 154 Masks & Owners 107 Data Out CX 184-185 Datalinks 108 Modulation Index 043 Control Modes 97 Parameter Name Number Group Page Data Out DX 186-187 Datalinks 108 Modulation Type 042 Control Modes 97 AC Line Fre
Chapter 4 Programming and Parameters Parameter Cross Reference – by Number Number Parameter Name Group Page Number Parameter Name Group Page 078 DC Bus Lo Alarm Limits 99 157 Start Owner Masks & Owners 107 079 DC Bus Hi Alarm Limits 99 158 Fault Clr Owner Masks & Owners 107 080 DC Ref Lo Lmt Limits 99 170-171 Data In AX Datalinks 108 Number Parameter Name Group Page 081 DC Ref Hi Lmt Limits 99 172-173 Data In BX Datalinks 108 001 Input Voltage Metering 95 0
Chapter 5 Troubleshooting This chapter provides information to guide you in troubleshooting the PowerFlex Active Front End. Included is a listing and description of AFE faults (with possible solutions, when applicable) and alarms.
Chapter 5 Troubleshooting HIM Indication The LCD HIM also provides visual notification of a fault or alarm condition. Condition Display AFE is indicating a fault. The LCD HIM immediately reports the fault condition by displaying the following: • ‘Faulted’ appears in the status line • Fault number • Fault name • Time that has passed since fault occurred Press Esc to regain HIM control. AFE is indicating an alarm.
Troubleshooting Manually Clearing Faults Chapter 5 Steps 1. Press the HIM Esc (Escape) key to acknowledge the fault. The fault information is removed so that you can use the HIM. 2. Address the condition that caused the fault. The cause must be corrected before the fault can be cleared. 3. After corrective action has been taken, clear the fault with one of these methods: • Press the HIM (Stop) key. • Cycle power to the AFE. • Set AFE parameter 121 - [Fault Clear] to ‘1’ (Clear Faults).
Chapter 5 Troubleshooting Name Description Action (if appropriate) 13 Ground Fault ➀ 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. Check the cables. 14 Converter Flt ➁ A hardware problem exists in the power structure. 1. Cycle the power. 2. Contact Technical Support (see page 124). 3. If the problem persists, replace the converter unit.
Troubleshooting Chapter 5 Name Description Action (if appropriate) 70 Power Unit ➀ One or more of the IGBTs were operating in the active region instead of desaturation. This can be caused by excessive transistor current or insufficient base drive voltage. Clear the fault. 71 Periph Loss ➁ 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.
Chapter 5 Troubleshooting Name 125 LCL OverTemp ➀ Alarm No. Fault Table 21 - Fault/Alarm Types, Descriptions, and Actions (Continued) Description Action (if appropriate) The LCL Filter has been overheated or the signal is not connected to input. Check the LCL Filter sensor connections, the fan, and fan power supply. There are nine total thermal switches connected in series to monitor temperature inside the coil of each filter inductor.
Troubleshooting Chapter 5 Clearing Alarms 12 ✔ Name No.
Chapter 5 Troubleshooting Common Symptoms and Corrective Actions AFE does not Start from Start or Run Inputs wired to the terminal block. Cause(s) Indication Corrective Action AFE is faulted Flashing red status light Clear fault. • Press the HIM (Stop) key. • Cycle power to the AFE. • Set parameter 121 [Fault Clear] to ‘1’ (Clear Faults); see page 105. • ‘Clear Faults’ by using the HIM Diagnostic menu.
Troubleshooting Chapter 5 Figure 40 - AFE Start Sequence Troubleshooting Diagram Init Software initialize complete Ready to switch on Charging the DC link with external charging circuit No DC link voltage > 0.
Chapter 5 Troubleshooting Figure 41 - AFE Fault Handling Sequence Troubleshooting Diagram AFE Running Yes Fault active New Run Command Edge? Stop the AFE No Is Input Contactor or circuit breaker open? Yes No Fault acknowledge Input Contactor or circuit breaker open Fault acknowledge Input Contactor or circuit breaker closed When contacting Technical Support, be prepared to provide this information: • Order number • Product catalog number and drives series number (if applicable) • Product serial nu
Appendix A Supplemental Information Specifications Topic Page Specifications 125 Derating Guidelines 127 AFE Current Ratings and Watts Loss 128 Fusing and Circuit Breakers for AFE in IP20 2500 MCC Style Enclosure 129 Fusing and Circuit Breakers for AFE in IP21 Rittal Enclosure 130 DC Bus Output Fuse Ratings 130 Dimensions 131 DPI Communication Configurations 140 Category Agency Certification Specification C UL ® US UL and cUL Listed to UL508C and CAN/CSA - 22.2 No. 14-05.
Appendix A Supplemental Information Category Specification Protection AFE Voltage Class 380/400V 480V 600V 690V Bus Overvoltage Trip 911V DC 911V DC 1200V DC 1200V DC Bus Undervoltage Shutoff/Fault 333VDC 333V DC 461V DC 461V DC Heat Sink Thermistor Monitored by microprocessor overtemp trip Environment Electrical Ground Fault Protection Yes Input Phase Loss Protection Yes Input Overcurrent Protection Yes Overtemperature Protection Yes LCL Filter Overtemperature Protection Ye
Supplemental Information Derating Guidelines Appendix A The following charts illustrate derating guidelines based on conditions.
Appendix A Supplemental Information AFE Current Ratings and Watts Loss The following tables provide PowerFlex Active Front End current ratings (including continuous and 1 minute) and typical watts loss. 400 Volt AC Input Ratings AFE Catalog Number Frame Size 20YD460… 10 20YD1K3… 13 kW Rating PWM Freq. AC Input Amps DC Output Amps ND HD kHz Cont. 1 Min. Cont. 309 — 3.6 460 A 506 A 520 A — 258 3.6 385 A 578 A 435 A 873 — 3.6 1300 A 1430 A 1469 A — 772 3.
Supplemental Information Fusing and Circuit Breakers for AFE in IP20 2500 MCC Style Enclosure Appendix A AC Input Fuse and Circuit Breaker Ratings The tables in this section provide the recommended AC input line fuses and circuit breakers. The AFE in a IP20 2500 MCC Style enclosure includes the recommended AC input fusing and circuit breaker.
Appendix A Supplemental Information Fusing and Circuit Breakers for AFE in IP21 Rittal Enclosure AC Input Fuse and Circuit Breaker Ratings The tables in this section provide the recommended AC input line fuses and circuit breakers. The AFE in a IP21 Rittal enclosure includes the recommended MCCB (Motor-Controlled Circuit Breaker).
Supplemental Information Dimensions Appendix A Figure 42 - AFE Frame 10 in IP20 2500 MCC Style Enclosure Dimensions Dimensions are in millimeters and (inches) 640 (25) 2265.5 (89.2) 2380.1 (94) 1754.6 (69.1) 1204.1 (47) 800.7 (31.5) 955.1 (38) FRONT VIEW RIGHT SIDE VIEW 461.4 (18) 138.6 (5) 699.1 (28) 1061.4 (42) BOTTOM VIEW Overall Dimensions mm (inches) Weight kg (lbs) Height Width Depth 2380.1 (94) 1204.1 (47) 955.
Appendix A Supplemental Information Figure 43 - AFE Frame 13 in IP20 2500 MCC Style Enclosure Dimensions Dimensions are in millimeters and (inches) 1747.4 (69) 878.1 (35) 2265.5 (89.2) 2400.1 (95) 803.4 (32) 958 (38) FRONT VIEW 43.1 (1.7) 557 (21.9) RIGHT SIDE VIEW 43.1 (1.7) 757 (29.8) 957 (37.7) 699.1 (27.5) 2356.9 (92.8) BOTTOM VIEW Overall Dimensions mm (inches) 132 Weight kg (lbs) Height Width Depth 2379.8 (93.7) 2400.
Supplemental Information Appendix A Figure 44 - AFE Frame 10 in IP21 Rittal Enclosure Dimensions Dimensions are in millimeters and (inches) 935 (36.8) 498 (19.6) 42 (1.7) 2270.5 (89.4) 1090.25 (42.9) 1000 (39.4) 670.7 (26.4) FRONT VIEW RIGHT SIDE VIEW 125 (4.9) 475 (18.7) 275 (10.8) 475 (18.7) 862.08 (33.9) 6.43 (0.3) 95.5 (3.8) BOTTOM VIEW Overall Dimensions mm (inches) Weight kg (lbs) Height Width Depth 2270.5 (89.4) 1000 (39.4) 670.7 (26.
Appendix A Supplemental Information Figure 45 - AFE Frame 13 in IP21 Rittal Enclosure Dimensions Dimensions are in millimeters and (inches) 536 (21.1) 1264.7 (49.8) 2242.5 (88.3) Height to Lifting Lug 2270 (89.4) 1088.8 (42.9) 37 (1.5) 1800 (70.9) FRONT VIEW 125 (4.9) 61 (2.4) 61 (2.4) 475 (18.7) 95 (3.7) 653 (25.7) RIGHT SIDE VIEW 125 (4.9) 675 (26.6) 275 (10.8) 475 (18.7) BOTTOM VIEW Overall Dimensions mm (inches) 134 25 (1.0) Weight kg (lbs) Height Width Depth 2270.5 (89.
Supplemental Information Appendix A Figure 46 - AFE Frame 10 LCL Filter Dimensions Dimensions are in millimeters and (inches). 420.1 (16.5) 340.94 (13.4) 214 (8.4) 298.1 (11.7) 113.1 (4.5) 210 (8.3) 105 (4.1) 1674.5 (65.9) 1761.5 (69.4) 1404.5 (55.3) 66 (2.6) 949.53 (37.4) 1056.5 (41.6) 429.5 (16.9) 177 (7.0) 43 (1.7) 183.9 (7) 368.1 (14.5) 478.1 (18.8) 496.94 (19.6) 87 (3.4) 43.7 (1.7) 11 (0.4) 288.5 (11.4) 169.1 (6.
Appendix A Supplemental Information Figure 47 - AFE Frame 13 LCL Filter Dimensions Dimensions are in millimeters and (inches). 280 (11.0) 140 (5.5) 26 (1.0) 32 (1.3) 34 (1.3) 1477 (58.2) 1421 (55.9) 1407 (55.4) 703.5 (27.7) 883 (34.8) 553.5 (21.8) 585 (23.0) 403.5 (15.9) 391 (15.4) Height with Wheel Guide Trays 525 (20.7) Height from Bottom Surface of Unit 37 (1.5) 559.9 (22.0) 592.5 (23.
Supplemental Information Appendix A Figure 48 - AFE Frame 10 Power Structure Dimensions Dimensions are in millimeters and (inches). 190 (7.5) 85 (3.3) 77 (3.0) 237 (9.0) Minimum to Enclosure Roof 24.5 (1.0) 75 (3.0) Minimum to Enclosure Wall 1050 (41.3) 1032 (40.6) 1009 (39.7) 373 (14.7) 108 (4.3) 495.8 (19.5) Ø 26 (1.0) Both Sides LEFT SIDE VIEW 113.5 (4.5) 520.8 (20.5) 239 (9.4) 552 (21.7) FRONT VIEW 566 (22.3) 205 (8.1) 140 (5.5) 75 (3.
Appendix A Supplemental Information Figure 49 - AFE Frame 13 Power Structure Dimensions Dimensions are in millimeters and (inches). 147 (5.8) Typ 85 (3.3) Typ 566 (22.3) 1012.5 (39.9) 373 (14.7) 107 (4.2) 514.8 (20.3) LEFT SIDE VIEW 142.6 (5.6) FRONT VIEW Ø 26 (1.0) Both Sides 192.6 (7.6) 620.5 (24.4) 242.6 (9.6) 388.5 (15.3) RIGHT SIDE VIEW 156.5 (6.2) BOTTOM VIEW 708 (27.9) Overall Dimensions mm (inches) 138 Weight kg (lbs) Height Width Depth 1032 (40.6) 708 (27.9) 553 (21.
Supplemental Information Appendix A Figure 50 - Control Box Dimensions (only for AFE in IP21 Rittal Enclosure) Dimensions are in millimeters and (inches). A 190.7 (7.5) 213.36 (8.4) B C Frame Size Overall Dimensions mm (inches) A B C 10 532.24 (20.6) 446 (17.6) 135.96 (5.4) 13 733.67 (28.9) 448 (17.6) 135.96 (5.
Appendix A Supplemental Information This section contains information about using DPI communication with the PowerFlex Active Front End. DPI Communication Configurations Typical Programmable Controller Configurations If programs are written that continuously write information to the AFE control, take care to properly format the block transfer. If attribute 10 is selected for the block transfer, values are written to only RAM and are not saved by the drive.
Supplemental Information Appendix A Logic Status Word for PowerFlex 700/700H/700S Drives Logic Bits 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 x x x x x x x x x x x x x x x 0 Status Description x Ready 0 = Not Ready 1 = Ready Active 0 = Not Active 1 = Active Motoring 0 = Not Motoring 1 = Motoring Regenerating 0 = Not Regenerating 1 = Regenerating In Precharge 0 = Not In Precharge 1 = In Precharge Droop Active 0 = Not Droop Active for AFE Paralleling 1 = Droop Active for AFE Par
Appendix A Supplemental Information The AFE supports 16-bit and 32-bit datalinks, which can be selected on the Logix module definition screen (for details, see the communication adapter documentation). The example screen below shows a 20-COMM-E Ethernet/IP adapter using a 32-bit parameter (Datalink A) on the input and two 16-bit parameters on the output. The data is used as shown below.
Supplemental Information Appendix A Logic Command Word for PowerFlex 750-Series Drives Logic Bits 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x x (1) (2) (3) (4) 0 x Command Normal Stop Start (1) Jog 1 (2) Clear Fault (3) Unipolar Direction Manual Reserved Accel Time Decel Time Ref Select 1 Ref Select 2 Ref Select 3 Reserved Coast Stop Current Limit Stop Run (4) Jog 2 (2) Description 0
Appendix A Supplemental Information Logic Status Word for PowerFlex 750-Series Drives Logic Bits 31 30 29 28 27 26 25 24 23 22 21 20 19 18 17 16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 x x x x x x x x x x x x x x x x x x x Command Run Ready Active Command Direction Actual Direction Accelerating Decelerating Alarm Fault At Setpt Spd Manual Spd Ref ID 0 Spd Ref ID 1 Spd Ref ID 2 Spd Ref ID 3 Spd Ref ID 4 Reserved Running Jogging Stopping DC Brake x DB Active x Speed Mode x Position Mode x To
Appendix B HIM Overview External and Internal Connections Topic Page External and Internal Connections 145 LCD Display Elements 146 ALT Functions 146 Menu Structure 147 Viewing and Editing Parameters 149 Removing/Installing the HIM 149 The PowerFlex Active Front End provides a number of cable connection points. ➊ X2 X1 ➍ ➋➌ HIM panel opens to allow access to DPI interface. To open panel, remove screws on left side of HIM panel and swing open. To Drive Control (DPI Interface Board) No.
Appendix B HIM Overview LCD Display Elements Display Description F-> Power Loss Auto Direction⎥ Drive Status⎥ Alarm⎥ Auto/Man⎥ Information Commanded or Output Volts 0.0 Volt Main Menu: Diagnostics Parameter Device Select ALT Functions Programming / Monitoring / Troubleshooting To use an ALT function, press the ALT key and release it, and then press the programming key associated with the desired function listed in the following table.
HIM Overview Menu Structure Appendix B Figure 51 - HIM Menu Structure User Display Esc Diagnostics Sel View Alarm Queue Clr Alarm Queue Alarms Faults Status Info Device Items Device Version HIM Version Fault Info View Fault Queue Clear Faults Clr Fault Queue Reset Device Cnvrtr Status 1 Cnvrtr Status 2 PowerFlex 700AFE Cnvrtr Alarm 1 Product Data Cnvrtr Alarm 2 Control Board DC Ref Source Power Board Slot A-E Start Inhibits Last Stop Source LCD HIM Product Data Dig In Status LCD HIM Control Board D
Appendix B HIM Overview Parameter Menu See Viewing and Editing Parameters on page 149. Device Select Menu Use this menu to access parameters in connected peripheral devices. Memory Storage Menu AFE data can be saved to, or recalled from, HIM sets. HIM sets are files stored in permanent nonvolatile HIM memory. Option Description HIM Copycat Device -> HIM Device <- HIM Save data to a HIM set, load data from a HIM set to active AFE memory, or delete a HIM set.
HIM Overview Viewing and Editing Parameters Appendix B LCD HIM Step 1. In the Main Menu, press the Example Screen or key to scroll to Parameter. Main Menu: Diagnostics Parameter Device Select 2. Press the (Enter) key. FGP File appears on the top line and the first three files appear below it. 3. Press the or key to scroll through the files. FGP: File Monitor Dynamic Control Utility 4. Press the (Enter) key to select a file. The groups in the file are displayed under it. 5.
Appendix B HIM Overview Notes: 150 Rockwell Automation Publication 20Y-UM001E-EN-P - July 2014
Appendix C Application Notes Sizing Guidelines Topic Page Sizing Guidelines 151 Voltage Boost 153 Paralleling AFEs 154 Use the following guidelines to properly size the AFE. Basic Procedure to Size the AFE 1. Sum the DC Input current rating of the connected drives. See the respective drive documentation specifications, or Drives in Common Bus Configurations, publication DRIVES-AT002. 2. Multiply the total DC current by 0.9.
Appendix C Application Notes Advanced Procedure to Size the AFE 1. Convert all motor powers to kW (kW = HP x 0.746). 2. Determine the total power and input current required during acceleration.(1) For Motoring Loads: PDrive = PMotor / Motor Efficiency For Regenerating Loads: PDrive = PMotor * Motor Efficiency PAccel = PDrive1 + PDrive2 + … Calculate the input current required on the regenerative unit during acceleration, taking advantage of the 110% for 1 minute overload rating of the regenerative unit.
Application Notes Voltage Boost Appendix C ATTENTION: The AFE can be used for voltage boost but cannot be used to lower the DC bus voltage. The minimum DC bus voltage is limited by the rectified diode bridge voltage. AFE parameter 61 [DC Volt Ref ] can be adjusted to boost the DC voltage. The maximum value of parameter 61 [DC Volt Ref ] is: [Rated Volts] x 1.35 x 1.3 for 400/480V units [Rated Volts] x 1.35 x 1.15 for 600/690V units, where [Rated Volts] is the AC input voltage for the AFE.
Appendix C Application Notes Paralleling AFEs The power of the AFE input group can be increased by connecting several groups in parallel. Paralleling refers to AFE units connected on the same input transformer and the same DC bus. No communication between the units is required—they work independently. Paralleling is typically used when the power range of a single frame size is not enough, or when redundancy is needed.
Application Notes Appendix C • An AFE can be connected while other parallel AFE units are running. When connecting the AFE to the DC bus, follow these steps in the order shown. a. Precharged the isolated AFE. When completed, the AFE control closes the contactor. b. Close the DC disconnect to connect the AFE to the DC bus. When disconnecting the AFE from the DC bus, follow these steps in the order shown. a. Stop the inverters and AFEs connected to the same DC bus from modulating.
Appendix C Application Notes Figure 52 - Connecting Parallel Frame 10 AFEs in IP20 2500 MCC Style Enclosures AC Line Switchgear 3 Phase AC Input L1 Input Breaker Q0 Input Contactor K1 Fuses F1.1-F1.3 L2 L3 LCL Filter (L1) AFE Power Structure (U1) U2 U1 V2 W2 V1 W1 C1 C4 C2 C5 C3 C6 Precharge Fuses F5 U1 DC Fuses U V W PE DC+ DC- F2.1 DC+ F2.2 DC- PE Precharge Contactor Precharge Circuit K6 R6.
Application Notes Appendix C Figure 53 - Connecting Parallel Frame 13 AFEs in IP20 2500 MCC Style Enclosures AC Line Switchgear 3 Phase AC Input L1 Input Breaker Q0 Input Contactor K1 Fuses F1.1-F1.3 L2 L3 LCL Filter (L1) AFE Power Structure (U1) U2 U1 V2 W2 V1 W1 C1 C4 C2 C5 C3 C6 PE U PE V DC+ DC- DC+ DC- DC Fuses F2.1 DC+ F2.2 DC- DC Bus Output F2.3 F2.4 PE W PE DC+ DC- F2.5 F2.6 Precharge Fuses F5 Precharge Contactor Precharge Circuit K6 R6.
Appendix C Application Notes Guidelines for AFEs in IP21 Rittal Enclosure • AFE units of different power sizes can be connected in parallel. • For AFEs in IP21 Rittal enclosures, a maximum of six AFEs can be paralleled. However, this can be limited by the capacity of the DC bus bar. • Each AFE must have its own LCL filter. • Each AFE must have its own short-circuit protection on AC and DC sides. See Appendix A for fusing information.
Application Notes Appendix C When disconnecting the AFE from the DC bus, follow these steps in the order shown. a. Stop the inverters and AFEs connected to the same DC bus from modulating. The AFE load must be zero before being disconnected to reduce the load on the MCCB. b. Open the MCCB of the AFE. c. Open the DC disconnect switch. d. Restart the other AFE units. • When AFEs are paralleled, the DC bus voltage at regeneration is 5% higher than with a single AFE due to the 5% droop.
Appendix C Application Notes Figure 54 - Connecting Parallel Frame 10 AFEs in IP21 Rittal Enclosure AC Line Switchgear 3 Phase AC Input Q0 AFE Power Structure (U1) LCL Filter (L1) DC Fuses Q1 L1 L2 L3 U2 U1 V2 W2 V1 W1 C1 C4 C2 C5 C3 C6 Precharge Fuses U V W PE DC+ DC- F2.1 DC+ F2.2 DC- PE Motor Protection Relay F6 U1 Q5 Precharge Contactor Precharge Circuit K6 R6.1 + PowerFlex 700AFE 1 AC Line Switchgear Q0 R6.
Application Notes Appendix C Figure 55 - Connecting Parallel Frame 13 AFEs in IP21 Rittal Enclosure AC Line Switchgear 3 Phase AC Input Q0 AFE Power Structure (U1) LCL Filter (L1) DC Fuses Q1 L1 L2 L3 U2 U1 V2 W2 V1 W1 C1 C4 C2 C5 C3 PE U DC+ DC- PE V DC+ DC- F2.1 DC+ F2.2 DC- F2.3 DC Bus Output F2.4 PE W C6 PE DC+ DC- F2.5 F2.6 Precharge Fuses Motor Protection Relay F6 Q5 Precharge Contactor Precharge Circuit K6 R6.1 + PowerFlex 700AFE 1 AC Line Switchgear Q0 R6.
Appendix C Application Notes Paralleling an AFE with One or More PowerFlex SCR Bus Supplies For information about paralleling an AFE with one or more PowerFlex SCR Bus Supplies, see Drives in Common Bus Configurations, publication DRIVESAT002.
Index A AC Line Freq parameter 95 AC Line kVA parameter 95 AC Line kVar parameter 95 AC Line kW parameter 95 AC supply source unbalanced 28, 58 ungrounded 28, 58 Active Current parameter 95 Active I Ki parameter 99 Active I Kp parameter 99 Active I Ref parameter 99 AFE dimensions 131 fault descriptions 117 Frame 10 main component locations in IP20 2500 MCC Style enclosure 24 in IP21 Rittal enclosure 54 Frame 13 main component locations in IP20 2500 MCC Style enclosure 25 in IP21 Rittal enclosure 55 main com
Index control I/O terminal block in IP20 2500 MCC Style enclosure 44 I/O terminal block in IP21 Rittal enclosure 75 wire 42, 73 Control Modes Parameter Group 97 Control Options parameter 98 Control SW Ver parameter 96 conventions used in this manual 11 Converter Data Parameter Group 96 Converter Memory Parameter Group 101 CopyCat HIM function 148 cross-reference of parameters by name 113 by number 114 Current Lmt Val parameter 99 Current Loop Parameter Group 99 D Data In A1 parameter 108 Data In A2 parame
Index Fault Total Curr parameter 103 Faults Parameter Group 105 File Communication 107 Dynamic Control 97 Inputs & Outputs 109 Monitor 95 Utility 101 File-Group-Parameter 92 fuse and circuit breaker ratings 129, 130 G general precautions 14 Ground Current parameter 95 Ground I Lvl parameter 99 grounding recommended scheme 29, 59 requirements 29, 59 shields 30, 60 Group - Parameter Alarms 106 Analog Inputs 109 Analog Outputs 109 Comm Control 107 Control Modes 97 Converter Data 96 Converter Memory 101 Curre
Index linear list 114 viewing 149 Parameters AC Line Freq 95 AC Line kVA 95 AC Line kVar 95 AC Line kW 95 Active Current 95 Active I Ki 99 Active I Kp 99 Active I Ref 99 Alarm 1 @ Fault 104 Alarm 1 Code 106 Alarm 2 @ Fault 104 Alarm 2 Code 106 Alarm 3 Code 106 Alarm 4 Code 106 Alarm Clear 106 Alarm Config 106 Analog In 1 Hi 109 Analog In 1 Lo 109 Analog In 1 Loss 109 Analog In 2 Hi 109 Analog In 2 Lo 109 Analog In 2 Loss 109 Analog In1 Value 96 Analog In2 Value 96 Analog Out1 Hi 110 Analog Out1 Lo 110 Anal
Index Language 101 Last Stop Source 103 Logic Mask 107 Modulation Index 97 Modulation Type 97 Motor Power Lmt 99 Motoring MWh 96 Nom Input Volt 97 Param Access Lvl 101 Power Factor 95 Power Up Marker 105 PWM Frequency 97 PWM Synch 100 Rated Amps 96 Rated kW 96 Rated Volts 96 RatedLineCurrent 97 Reactive Current 95 Reactive I Ki 99 Reactive I Kp 99 Reactive I Ref 99 Reactive I Sel 99 Regen MWh 96 Regen Power Lmt 99 Reset Meters 101 Reset to Defaults 82, 86, 101 Restart Delay 97 Start Inhibits 103 Start Owne
Index Testpoint 1 Data parameter 104 Testpoint 1 Sel parameter 104 Testpoint 2 Data parameter 104 Testpoint 2 Sel parameter 104 Total Current parameter 95 troubleshooting 115 V viewing and changing parameters 149 Voltage Class parameter 101 Voltage Loop Parameter Group 98 W U unbalanced/ungrounded AC supply source 28, 58 ungrounded distribution systems 38, 68 unshielded power cables 31, 61 user configurable alarms 116 Utility File 101 168 Rockwell Automation Publication 20Y-UM001E-EN-P - July 2014 web
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