Resource. Description. PowerFlex Active Front End—Frame 10 Hardware Service Manual, publication 20Y-TG001. Provides information for how to troubleshoot ...
User Manual Original Instructions PowerFlex Active Front End Catalog Number 20Y PowerFlex AFE/PowerFlex 700AFE Frames 10 and 13, Firmware Revision Number 1.xxx 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. 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. Labels may also be on or inside the equipment to provide specific precautions. 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). Table of Contents Preface Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 What Is Not in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Rockwell Automation Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Technical Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 Drive Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13 Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14 Benefits of the AFE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16 AFE in IP00 Open Chassis Configuration. . . . . . . . . . . . . . . . . . . . . . . 17 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring Chapter 1 Main Component Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Frame 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 Frame 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21 Main Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Frame 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22 Frame 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 Mounting Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Operating Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 Minimum Mounting Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24 AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Unbalanced, Ungrounded, or Resistive Grounded Distribution Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 Input Power Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27 Recommended Grounding Scheme . . . . . . . . . . . . . . . . . . . . . . . . . 27 Safety Ground - PE and Shield Termination - SHLD . . . . . . . . . 29 Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Power Cable Types Acceptable for 400...690 Volt Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29 Unshielded Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Shielded Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Armored Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 Cable Trays and Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31 Select and Verify Control Transformer Voltage . . . . . . . . . . . . . . 31 Power Terminals for AFE in IP20 2500 MCC Style Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34 Route the AC Input, Ground (PE), and DC Bus Output Wiring for AFE in IP20 2500 MCC Style Enclosure . . . . . . . . . 36 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 3 Table of Contents AFE in IP21 Rittal Enclosure Installation/Wiring Disconnect the Common Mode Capacitors . . . . . . . . . . . . . . . . . . . . . 37 Frame 10 LCL Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 Frame 13 LCL Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Frame 10 or Frame 13 Power Structure . . . . . . . . . . . . . . . . . . . . . . 39 Use the AFE with PowerFlex Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Signal and Control Wire Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 I/O Terminal Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 I/O Cable Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Typical I/O Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 Analog I/O Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Hardware Enable Circuitry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46 Analog I/O Wiring Examples for AFE in IP20 2500 MCC Style Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Precharging the AFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 Important Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Low Voltage Directive (2006/95/EC). . . . . . . . . . . . . . . . . . . . . . . 49 EMC Directive (2004/108/EC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 General Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 Essential Requirements for CE Compliance. . . . . . . . . . . . . . . . . . 49 Chapter 2 Main Component Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Frame 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 Frame 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53 Main Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Frame 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 Frame 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55 Mounting Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Operating Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 Minimum Mounting Clearances . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56 AC Supply Source Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Unbalanced, Ungrounded, or Resistive Grounded Distribution Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 Input Power Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Grounding Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59 Recommended Grounding Scheme . . . . . . . . . . . . . . . . . . . . . . . . . 59 Safety Ground - PE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Shield Termination - SHLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61 Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Power Cable Types Acceptable for 400...690 Volt Installations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Unshielded Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 Shielded Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 4 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Table of Contents Armored Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Cable Trays and Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64 Select and Verify Control Transformer Voltage . . . . . . . . . . . . . . 64 Power Terminals for AFE in IP21 Rittal Enclosure . . . . . . . . . . . 66 DC Bus Output Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Route the AC Input, Ground (PE), and DC Bus Output Wiring for AFE in IP21 Rittal Enclosure . . . . . . . . . . . . . . . . . . . . 68 Disconnect the Common Mode Capacitors . . . . . . . . . . . . . . . . . . . . . 69 Frame 10 LCL Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69 Frame 13 LCL Filter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 Frame 10 Power Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 Frame 13 Power Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 Using the AFE with PowerFlex Drives . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74 Signal and Control Wire Types . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75 I/O Terminal Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76 I/O Cable Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 Typical I/O Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 Analog I/O Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79 Hardware Enable Circuitry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Analog I/O Wiring Examples for AFE in IP21 Rittal Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80 Precharging the AFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 Important Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Low Voltage Directive (2006/95/EC). . . . . . . . . . . . . . . . . . . . . . . 82 EMC Directive (2004/108/EC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 General Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82 Essential Requirements for CE Compliance. . . . . . . . . . . . . . . . . . 82 Startup Chapter 3 AFE in IP20 2500 MCC Style Enclosure . . . . . . . . . . . . . . . . . . . . . . . . 85 Startup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85 Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88 AFE in IP21 Rittal Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Startup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90 Control Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 MCCB (Motor-controlled Circuit Breaker) and Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92 Programming and Parameters Chapter 4 About Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95 How AFE Parameters are Organized . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 File-Group-Parameter Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 5 Table of Contents Troubleshooting Supplemental Information Basic Parameter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97 Advanced Parameter View . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98 Monitor File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99 Dynamic Control File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101 Utility File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105 Communication File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111 Inputs and Outputs File . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113 Parameter Cross Reference by Name . . . . . . . . . . . . . . . . . . . . . . . . 117 Parameter Cross Reference by Number . . . . . . . . . . . . . . . . . . . . . . 120 Chapter 5 AFE Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 Front Panel Indications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125 HIM Indication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Faults and Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126 Manually Clearing Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Fault and Alarm Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127 Clear the Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131 Common Symptoms and Corrective Actions . . . . . . . . . . . . . . . . . . . 131 Technical Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135 Appendix A Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137 Derating Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Ambient Temperature/Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139 Altitude/Load 400/480V AC Input . . . . . . . . . . . . . . . . . . . . . . . 139 Altitude/Load 600/690V AC Input . . . . . . . . . . . . . . . . . . . . . . . 139 AFE Current Ratings and Watts Loss . . . . . . . . . . . . . . . . . . . . . . . . . . 140 400 Volt AC Input Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 480 Volt AC Input Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 600 Volt AC Input Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 690 Volt AC Input Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140 Fusing and Circuit Breakers for AFE in IP20 2500 MCC Style Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 AC Input Fuse and Circuit Breaker Ratings. . . . . . . . . . . . . . . . . 141 DC Bus Output Fuse Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141 Fusing and Circuit Breakers for AFE in IP21 Rittal Enclosure. . . . 142 AC Input Fuse and Circuit Breaker Ratings. . . . . . . . . . . . . . . . . 142 DC Bus Output Fuse Ratings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142 Dimensions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 DPI Communication Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Typical Programmable Controller Configurations. . . . . . . . . . . 152 Logic Command Word for PowerFlex 700/700H/700S Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152 Logic Status Word for PowerFlex 700/700H/700S Drives . . . 153 Logic Command Word for PowerFlex 750-Series Drives. . . . . 155 6 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 HIM Overview Application Notes Table of Contents Logic Status Word for PowerFlex 750-Series Drives . . . . . . . . . 156 Appendix B External and Internal Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159 LCD Display Elements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 ALT Functions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160 Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Diagnostics Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161 Parameter Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Device Select Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Memory Storage Menu. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Start-up Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 Preferences Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162 View and Edit Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 HIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Numeric Keypad Shortcut. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Remove/Install the HIM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163 Appendix C Sizing Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Basic Procedure to Size the AFE . . . . . . . . . . . . . . . . . . . . . . . . . . . 165 Advanced Procedure to Size the AFE. . . . . . . . . . . . . . . . . . . . . . . 166 Voltage Boost . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167 Paralleling AFEs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168 Guidelines for AFEs in IP20 2500 MCC Style Enclosure . . . . 168 Guidelines for AFEs in IP21 Rittal Enclosure . . . . . . . . . . . . . . . 172 Paralleling an AFE with One or More PowerFlex SCR Bus Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176 Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 7 Table of Contents Notes: 8 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Preface The purpose of this manual is to provide the basic information to install, startup, and troubleshoot the PowerFlex® Active Front End (AFE). Topic Page Summary of Changes 9 Intended Audience 9 What Is Not in This Manual 9 Manual Conventions 10 Rockwell Automation Support 10 Additional Resources 10 General Precautions 12 Catalog Number Explanation 13 Description of Operation 14 Benefits of the AFE 16 AFE in IP00 Open Chassis Configuration 17 Summary of Changes This manual contains new and updated information as indicated in the following table. Topic Page Updated the basic one-line diagram for a Frame 10 AFE in IP20 2500 MCC style Figure 6 on page 20 enclosure to include the factory-installed common mode core at the DC bus output. Updated the system schematics for a Frame 13 AFE in IP20 2500 MCC style enclosure to Figure 7 on page 21 include the factory-installed common mode core at the DC bus output. Updated the drawing for connecting parallel Frame 10 AFEs in IP20 2500 MCC style Figure 56 on page 170 enclosures to include the factory-installed common mode core at the DC bus output. Updated the drawing for connecting parallel Frame 13 AFEs in IP20 2500 MCC Style Figure 57 on page 171 Enclosures to include the factory-installed common mode core at the DC bus output. Added information for KCC and Regulatory compliance mark (RCM) certifications. 137 Intended Audience This manual is intended for qualified personnel. You must be able to program and operate an Active Front End unit and adjustable frequency AC drives. In addition, you must have an understanding of the parameter settings and functions. What Is Not in This Manual This manual provides installation, start-up, and programming information for the PowerFlex Active Front End. For detailed drive information, see Drive Information on page 11. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 9 Preface Manual Conventions The following conventions are used throughout this manual: · In this manual, we also refer to the PowerFlex Active Front End as AFE, Active Front End, or unit. · To differentiate parameter names and LCD display text from other text, the following conventions are used: Parameter names appear in [brackets]. For example: [DC Bus Voltage]. Display text appears in `quotes'. For example, `Enabled'. Rockwell Automation Support Contact your local Rockwell Automation representative for these items: · Sales and order support · Product technical training · Warranty support · Support service agreements Technical Support For technical support, first review the information in Chapter 5. If you still need help, click the link for Allen-Bradley® Drives Service and Support website at http://www.ab.com/support/abdrives. When you contact Technical Support, be prepared to provide the information that is listed on page 135. Additional Resources These documents contain additional information concerning related products from Rockwell Automation. Resource Description PowerFlex Active Front End--Frame 10 Hardware Service Manual, publication 20Y-TG001 Provides information for how to troubleshoot Frame 10 AFE units. PowerFlex Active Front End--Frame 13 Hardware Service Manual, publication 20Y-TG002 Provides information for how to troubleshoot Frame 13 AFE units. PowerFlex 700H, 700S, and 700AFE Drive Fan Systems Installation Instructions, publication PFLEX-IN029 Provides information for how to install drive fan systems. Drives in Common Bus Configurations, publication DRIVES-AT002 Provides information for common bus configurations. Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001 Provides information for wiring and grounding AC drives. Preventive Maintenance of Industrial Control and Drive System Equipment, publication DRIVES-TD001 Provides information for preventative maintenance control and drive systems. Safety Guidelines for the Application, Installation, and Maintenance of Solid-state Control, publication SGI-1.1 Provides safety guidelines for drive systems. Guarding Against Electrostatic Damage, publication 8000-4.5.2 Provides information for how to prevent electrostatic damage. Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system. Product Certifications website, http://www.rockwellautomation.com/global/certification/overview.page Provides declarations of conformity, certificates, and other certification details. 10 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Preface You can view or download publications at http://www.rockwellautomation.com/global/literature-library/overview.page. To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative. Drive Information The following publications provide detailed information for PowerFlex drives that are compatible with the PowerFlex Active Front End. Drive Resource PowerFlex 700 Series A Drive PowerFlex 700 Series B Drive PowerFlex 700 Series A User Manual, publication 20B-UM001 PowerFlex 700 Series B User Manual, publication 20B-UM002 PowerFlex 700 Frames 0...6 Installation Instructions, publication 20B-IN019 PowerFlex 700 Frames 7...10 Installation Instructions, publication 20B-IN014 PowerFlex 70/700 Reference Manual, publication PFLEX-RM001 PowerFlex 70 Installation Instructions, publication 20A-IN009 PowerFlex 70EC/700VC Reference Manual, publication PFLEX-RM004 PowerFlex 700 Technical Data, publication 20B-TD001 PowerFlex Dynamic Braking Resistor Calculator, publication PFLEX-AT001 PowerFlex 700H Drive PowerFlex 700H Installation Manual, publication PFLEX-IN006 PowerFlex 700H Programming Manual, publication 20C-PM001 PowerFlex 700H Technical Data, publication 20C-TD001 PowerFlex 700S Drive PowerFlex 700S with Phase II Control Installation Manual (Frames 1...6), publication 20D-IN024 PowerFlex 700S with Phase II Control Installation Manual (Frames 9...14), publication PFLEX-IN006 PowerFlex 700S with Phase II Control Programming Manual (All Frame Sizes), publication 20D-PM001 PowerFlex 700S with Phase II Control Reference Manual, publication PFLEX-RM003 PowerFlex 700S with Phase II Control Technical Data, publication 20D-TD002 PowerFlex 750-Series Drive PowerFlex 750-Series Drive Installation Instructions, publication 750-IN001 PowerFlex 750-Series Drive Programming Manual, publication 750-PM001 PowerFlex 750-Series Technical Data, publication 750-TD001 PowerFlex SCR Bus Supply PowerFlex SCR Bus Supply User Manual, publication 20S-UM001 Description Provides information for how to install, configure, and use PowerFlex 700 Series A and Series B drives. Provides information for how to install, configure, and use PowerFlex 700H drives. Provides information for how to install, configure, and use PowerFlex 700S drives. Provides information for how to install, configure, and use PowerFlex 750-Series drives. Provides information for SCR bus supplies. You can view or download publications at http://www.rockwellautomation.com/global/literature-library/overview.page. To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative. To find your local Rockwell Automation distributor or sales representative, visit http://www.rockwellautomation.com/global/distributor-locator/saleslocator.page Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 11 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. ATTENTION: To guard against personal injury and equipment damage that is caused by an arc flash, you must identify the arc flash requirements per NFPA 70E. 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 when you install, test, service, or repair this unit. If you are unfamiliar with static control procedures, see Guarding Against Electrostatic Damage, publication 8000-4.5.2, or any other applicable ESD protection handbook. ATTENTION: An incorrectly applied or installed PowerFlex Active Front End can result in component damage or a reduction in product life. Wiring or application errors, such as undersizing the motor, incorrect or inadequate AC supply, or excessive ambient temperatures, can result in malfunction of the system. ATTENTION: Only qualified personnel familiar with adjustable frequency AC drives and associated machinery can plan or implement the installation, start-up, and subsequent maintenance of the system. Failure to comply can result in personal injury and/or equipment damage. 12 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 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 Drive Code Type 20Y PowerFlex AFE/ PowerFlex 700AFE b Voltage Rating Code Input Voltage Phase D 400/480V AC 3 F 600/690V AC 3 c1 400/480V Input Code Input Amps ND (HD) kW at 400V ND (HD) Hp at 480V ND (HD) Frame Size 460 460 (385) 309 (258) 497 (416) 10 1K3 1300 (1150) 873 (772) 1404 (1242) 13 c2 600/690V Input Input Code Amps ND (HD) Hp at 600V ND (HD) kW at 690V ND (HD) Frame Size 325 325 (240) 439 (324) 376 (278) 10 1K0 1030 (1) 1390 (1) 1193 (1) 13 (1) There is no heavy-duty rating for Frame 13 600/690V. d Enclosure Code Type Conformal Coating A (1) IP21 Rittal Enclosure, NEMA/UL Type 1 Yes N (2) IP00, open-chassis Yes IP20, NEMA/UL Type 1 2500 MCC Style enclosure P (3) with power bus, 800 mm (31.5 in.) deep, Yes standard cabinet color (RAL7032) IP20, NEMA/UL Type 1 2500 MCC Style enclosure W (3) with power bus, 800 mm (31.5 in.) deep, Yes CenterLine 2100 gray (ASA49) (1) Includes AFE power module, LCL filter, control assembly, motor-controlled circuit breaker, and precharge circuit in a Rittal enclosure. (2) Restricted to SSB. Includes AFE power module, LCL filter, and control assembly. Excludes circuit breaker or precharge circuit. (3) Includes AFE power module, LCL filter, control assembly, Incoming circuit breaker, and precharge circuit in 2500 MCC Style enclosure. Frame 10 has 1250 amp DC bus and Frame 13 has 3000 amp DC bus. e HIM Code Operator Interface 0 No HIM Mount AFE f Documentation Code Documents Ship Carton A User Manual Yes g Brake Code With Brake IGBT N No h Brake Resistor Code With Resistor N No i Equipment Type Code Description A AFE with power line filter j Comm Slot Code Communication Option N None k I/O Option Code Type A (1) Standard, with outputs (1) A 120V AC I/O option is not available. I/O Volts 24V DC l Feedback Code Type Installed On 0 None N/A Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 13 Preface Description of Operation 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 one common bus drive. The AFE uses a pulse width modulated (PWM)-controlled IGBT converter to allow bi-directional power flow to the AC line. Figure 1 and Figure 2 show examples of the AFE powering a lineup of PowerFlex 755 drives and the AFE powering one PowerFlex 755 drive. For additional information and bus conditioning requirements, see Drives in Common Bus Configurations, publication DRIVES-AT002. Figure 1 - AFE Supplying a Lineup of Common Bus Drives 3-Phase 400VAC PowerFlex Active Front End L1 DC+ L2 DC- L3 * Bus Conditioner * DC+ BR1 BR2 DC- DC+ BR1 BR2 DC- DC+ BR1 BR2 DC- DC+ BR1 BR2 DC- * See Drives in Common Bus Configurations, publication DRIVES-AT002, for bus conditioning requirements L1 L2 L3 PowerFlex 755 L1 L2 L3 PowerFlex 755 L1 L2 L3 PowerFlex 755 L1 L2 L3 PowerFlex 755 M M M M Figure 2 - AFE Supplying a Single Drive 3-Phase 400VAC PowerFlex Active Front End L1 DC+ L2 DC- L3 * Bus Conditioner PowerFlex 755 DC+ * DC- * See Drives in Common Bus Configurations, publication DRIVES-AT002, for bus M conditioning requirements 14 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Preface Active current and reactive currents are calculated from the three input phase current measurements (IL1, IL2, and IL3) as shown in Figure 3. The DC voltage controller is a PI type regulator. A DC voltage reference sets the value of the DC link voltage to be maintained. It is compared to measured DC voltage to obtain a DC voltage error as the input for the DC voltage controller. 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. A positive reactive current reference indicates inductive and a negative reactive current reference indicates capacitive reactive power compensation. The default value of the reactive current reference parameter is zero. The set value of the reactive current reference is compared to its measured value and the error is fed to the PI regulator. The PI regulator is also referred to as the synchronizing controller because its function is to keep the inverter synchronized with line supply. The frequency reference to the AFE is derived from the reactive current controller output. Normally the active current Kp, active current Ki, reactive current Kp, and reactive current Ki default values of the two current controllers are satisfactory with the standard LCL filter. Do not change the default values. Figure 3 - AFE Block Diagram Park Transform IL1 IL2 IL3 3 I Alpha Cartesian 2 I Beta Polar Reactive Current Active Currrent Modulator Voltage Angle DC Volt Measured DC Volt Reference _ PI Active Current Ref Active Currrent _ PI Modulation Index DC Volt Kp DC Volt Ki Active Curr Kp Active Curr Ki Reactive Current Ref Reactive Current _ PI Freq Reference PD Reactive Curr Kp Reactive Curr Ki Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 15 Preface Benefits of the AFE The PowerFlex Active Front End provides these benefits: · Energy savings with regenerative braking instead of wasted energy with resistor brake technology, regenerative braking 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. · Improved power factor the AFE actively controls the power factor regardless of motor speed and load. In addition, the PowerFlex AFE can be used for power factor correction on the power system. · Voltage boost the AFE boosts the DC voltage. See Voltage Boost on page 167 for guidelines regarding voltage boost. This voltage boost also helps protect critical processes from the potentially disruptive effects of input voltage dips and sags. ATTENTION: The PowerFlex Active Front End 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. 16 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Preface AFE in IP00 Open Chassis Configuration Figure 4 shows a basic one-line diagram for an AFE Frame 10 in an IP00, NEMA/UL Open chassis configuration, and the parts that the customer must supply. Figure 4 - Basic One-line Diagram for an AFE Frame 10 in IP00 Open Chassis Configuration 3-phase AC Input L1 L2 L3 AC Line Switchgear Input Input Breaker Contactor Q0 Fuses K1 F1.1...F1.3 Customer Supplies these Parts LCL Filter (L1) U2 V2 W2 C1 C4 C2 C5 C3 C6 AFE DC Power Structure (U1) Fuses U1 U1 U V1 W1 V DC+ F2.1 W F2.2 PE DC- PE Precharge Fuses F5 Precharge Contactor Precharge Circuit DC Bus Output Customer Supplies these Parts PowerFlex Active Front End System Customer Supplies these Parts K6 R6.1 + R6.2 - Customer Supplies the Enclosure Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 17 Preface Figure 5 shows a basic one-line diagram for an AFE Frame 13 in an IP00, NEMA/UL Open chassis configuration, and the parts that the customer must supply. Figure 5 - Basic One-line Diagram for an AFE Frame 13 in IP00 Open Chassis Configuration 3-phase AC Input L1 L2 L3 AC Line Switchgear Input Input Breaker Contactor Q0 Fuses K1 F1.1...F1.3 Customer Supplies these Parts LCL Filter (L1) U2 V2 W2 C1 C4 C2 C5 C3 C6 AFE Power Structure (U1) PE U1 U DC+ V1 DC- W1 PE V DC+ DC- PE W DC+ PE DC- DC Fuses F2.1 F2.2 F2.3 F2.4 F2.5 F2.6 Precharge Fuses F5 Precharge Contactor Precharge Circuit DC Bus Output Customer Supplies these Parts PowerFlex Active Front End System Customer Supplies these Parts K6 R6.1 + - Customer Supplies the Enclosure 18 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 1 Chapter AFE in IP20 2500 MCC Style Enclosure Installation/Wiring This chapter provides information on how to install and wire the PowerFlex® Active Front End in an IP20 2500 MCC Style enclosure. For information on how to install and wire the AFE in an IP21 Rittal enclosure, see Chapter 2. Topic Page Main Component Sections 20 Main Component Locations 22 Mounting Considerations 24 AC Supply Source Considerations 26 Grounding Requirements 27 Fuses and Circuit Breakers 29 Power Wiring 29 Disconnect the Common Mode Capacitors 37 Use the AFE with PowerFlex Drives 39 Control Wiring 40 Precharging the AFE 47 CE Conformity 49 Most start-up difficulties are the result of incorrect wiring. Verify that the wiring is done as instructed. Read and understand the instructions before you begin to installation the AFE. ATTENTION: The following information is a guide for proper installation. Rockwell Automation does not assume responsibility for the compliance or the noncompliance to any code, national, local, or otherwise, for the proper installation of this 700AFE or associated equipment. A hazard of personal injury and/or equipment damage exists if codes are ignored during installation. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 19 Chapter 1 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring Main Component Sections This section describes the main component sections of AFE Frame 10 and Frame 13 systems in an IP20 2500 MCC Style enclosure. Frame 10 Figure 6 shows a basic one-line diagram for an AFE Frame 10 in an 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 and F2.2) Figure 6 - Basic One-line Diagram for a Frame 10 AFE in IP20 2500 MCC Style Enclosure 3-phase AC Input L1 L2 L3 AC Line Switchgear Input Input Breaker Contactor Q0 Fuses K1 F1.1...F1.3 LCL Filter (L1) U2 V2 W2 C1 C4 C2 C5 C3 C6 AFE DC Power Structure (U1) Fuses U1 U1 U V1 V F2.1 W1 DC+ W F2.2 PE DC- PE Factory-installed Common Mode Core DC Bus Output Precharge Fuses F5 Precharge Contactor Precharge Circuit PowerFlex Active Front End System K6 R6.1 + R6.2 - 20 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 3-phase AC Input L1 L2 L3 AC Line Switchgear Input Input Breaker Contactor Q0 Fuses K1 F1.1...F1.3 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring Chapter 1 Frame 13 Figure 7 shows a basic one-line diagram for an AFE Frame 13 in an 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...F2.6) Figure 7 - Basic One-line Diagram for a Frame 13 AFE in IP20 2500 MCC Style Enclosure LCL Filter (L1) U2 V2 W2 C1 C4 C2 C5 C3 C6 Precharge Fuses F5 Precharge Contactor AFE DC Power Structure (U1) Fuses PE U1 F2.1 U DC+ V1 DC- W1 F2.2 PE F2.3 V DC+ DC- F2.4 PE F2.5 W DC+ PE DC- F2.6 Precharge Circuit Factory-installed Common Mode Core DC Bus Output PowerFlex Active Front End System K6 R6.1 + - Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 21 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 an IP20 2500 MCC Style enclosure. Frame 10 Figure 8 shows the main components of the AFE Frame 10 system in an IP20 2500 MCC Style enclosure. Figure 8 - AFE Frame 10 Main Component Locations in IP20 2500 MCC Style Enclosure Front View (shown with enclosure doors closed) Front View (shown with enclosure doors removed) 1 1 4 8 7 2 3 5 6 Item Description 1 Precharge circuit and precharge resistor 2 LCL filter (L1) 3 Active Front End power structure (U1) 4 Input circuit breaker 5 AC line switchgear Input fuses 6 Input contactor 7 DC fuses 8 AFE control assembly (on the AFE door and shown with user-installed Human Interface Module [HIM]) 22 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Front View (reduced size - shown with enclosure doors closed) 2 9 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring Chapter 1 Frame 13 Figure 9 shows the main components of the AFE Frame 13 system in an IP20 2500 MCC Style enclosure. Figure 9 - AFE Frame 13 Main Component Locations in IP20 2500 MCC Style Enclosure Front View (shown with enclosure doors removed) 8 5 4 6 7 3 1 Item Description 1 Precharge circuit 2 Precharge resistor 3 LCL filter (L1) 4 Active Front End power structure (U1) 5 Input circuit breaker 6 AC line switchgear Input fuses 7 Input contactor 8 DC fuses 9 AFE control assembly (on the AFE door and shown with user-installed HIM) Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 23 Chapter 1 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring Mounting Considerations When mounting the Active Front End, consider the following information. Operating Temperatures Frame Size 10 13 (1) Surrounding Air Temperature (2) Normal Duty Heavy Duty 0...40 °C (32...104 °F) 0...40 °C (32...104 °F) Minimum Airflow Power Module 1400 m3/hr (824 cfm) 4200 m3/hr (2472 cfm) LCL Filter 1100 m3/hr (647 cfm) 1300 m3/hr (765 cfm) (1) The Frame 13 690V AFE has only normal duty operation at nominal rated power and maximum ambient temperature at 35 °C (95 °F). (2) For an AFE in the IP20 2500 MCC Style enclosure, this air means surrounding the outside of the enclosure. Minimum Mounting Clearances Figure 10 - Frame 10 in IP20 2500 MCC Style Enclosure 50 mm (2.0 in.) Clearance to Wall Top View 50 mm (2.0 in.) Clearance to Wall 565.9 mm (22 in.) Door Swing Clearance 200 mm (7.87 in.) Height Clearance Front View 24 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring Chapter 1 Figure 11 - Frame 13 in IP20 2500 MCC Style Enclosure 73 mm (2.9 in.) Clearance to Wall Top View 27 mm (1.0 in.) Clearance to Wall 591.5 mm 790.2 mm (23 in.) 990.2 mm (31 in.) Door Swing Clearance (39 in.) Door Swing Clearance Door Swing Clearance 200 mm (7.87 in.) Height Clearance Front View Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 25 Chapter 1 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring AC Supply Source Considerations The AFE Frame 10 or Frame 13 in an IP20 2500 MCC Style enclosure is suitable for use on a circuit capable of delivering these ratings: · 100,000 rms symmetrical amperes at 400/480V · 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%. Operation outside these limits can cause instability that results in the shutdown of the AFE. System Impedance = (PowerFlex 700AFE kVA ÷ Transformer kVA) x Transformer % Impedance You must consider the kVA of all PowerFlex AFEs on the distribution system and the system impedance of upstream transformers. ATTENTION: To guard against personal injury and equipment damage that is caused by improper fusing or circuit breaker selection, use only the recommended line fuses or circuit breakers that are specified in Appendix A. If a residual current detector (RCD) is used as a system ground fault monitor, use only Type B (adjustable) devices to avoid nuisance tripping. Unbalanced, Ungrounded, or Resistive Grounded Distribution Systems If phase-to-ground voltage exceeds 125% of normal, or the supply system is ungrounded, see Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001, for more information. ATTENTION: The PowerFlex Active Front End is not designed to be used on IT (insulated tera) or corner-grounded power networks above 600V (phase-tophase voltage). Operation on such a network can cause a hazardous failure of the insulation system of the AFE. ATTENTION: The LCL filter of the PowerFlex Active Front End contains common mode capacitors that are referenced to ground. These devices must be disconnected if the AFE is installed on a resistive grounded distribution system or an ungrounded distribution system. See Figure 20 on page 38 or Figure 21 on page 39 for jumper locations. 26 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring Chapter 1 Input Power Conditioning These events on the power system that supplies an AFE can cause component damage or shortened product life: · The power system has power factor correction capacitors that are switched in and out of the system, either by you or by the power company. · 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. Ground impedance must conform to the requirements of national and local industrial safety regulations and electrical codes. Periodically check the integrity of all ground connections. Recommended Grounding Scheme For installations in which the AFE is within an enclosure, use one safety ground point or ground bus bar connected directly to building steel. All circuits including the AC input ground conductor must be grounded independently and directly to this point or ground bus bar. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 27 Chapter 1 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring Figure 12 - Typical Grounding Example for AFE Frame 10 in IP20 2500 MCC Style Enclosure R (L1), S (L2), T (L3) To Line PE PowerFlex 750-Series Drive or PowerFlex 7-Class Drive (can be on the right or left side of the AFE; PowerFlex 755 Frame 8 drive is shown on the right side). Customer wiring or DC bus bar splice is required to connect the AFE to the drive. DC+ DC+ DC- DC- U (T1), V (T2), W (T3) PE PowerFlex AFE Frame 10 PE PE SHLD Figure 13 - Typical Grounding Example for AFE Frame 13 in IP20 2500 MCC Style Enclosure R (L1), S (L2), T (L3) To Line PE PowerFlex 750-Series Drive or PowerFlex 7-Class Drive (can be on the right or left side of the AFE; PowerFlex 755 Frame 8 drive is shown on right side). DC+ DC+ DC- DC- Customer wiring or DC bus bar splice is required to connect the AFE to the drive. U (T1), V (T2), W (T3) PE PowerFlex AFE Frame 13 PE PE SHLD 28 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring Chapter 1 Safety Ground - PE and Shield Termination - SHLD This ground is the safety ground for the AFE that code requires. This point must be connected to adjacent building steel (girder or joist), a floor ground rod, or bus bar (see Figure 13). Grounding points must comply with national and local industrial safety regulations and/or electrical codes. The Shield terminal (Figure 16 or Figure 17) provides a grounding point for the AFE cable shield. It must be connected to an earth ground by a separate continuous lead. The drive cable shield must be connected to this terminal on the AFE end and the drive frame on the drive end. Use a shield terminating or EMI clamp to connect the shield to this terminal. Fuses and Circuit Breakers The IP20 2500 MCC Style enclosure for the AFE includes AC input fuses, input circuit breaker (Q0), an input contactor (K1), and DC bus output fusing. The contactor is used for precharge operation. For details on precharge operation, see page 47. For fuse and circuit breaker information, see Appendix A. Local and national electrical codes can determine additional requirements for the installations. Power Wiring Most start-up difficulties are the result of incorrect wiring. Verify that the wiring is done as instructed. Read and understand the instructions before you begin to installation the AFE. ATTENTION: The following information is a guide for proper installation. Rockwell Automation does not assume responsibility for the compliance or noncompliance to any code, national, local, or otherwise, for the proper installation of this unit or associated equipment. A risk of personal injury and/ or equipment damage exists if codes are ignored during installation. Power Cable Types Acceptable for 400...690 Volt Installations ATTENTION: National Codes and standards (NEC, VDE, CSA, BSI, and so forth) and local codes outline provisions for safely installing electrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protection, and disconnect devices. Failure to do so can result in personal injury and/or equipment damage. Various cable types are acceptable for PowerFlex Active Front End installations. For many installations, unshielded cable is adequate, provided it can be separated from sensitive circuits. As an approximate guide, use a spacing of 0.3 meters (1 ft) for every 10 meters (32.8 ft) of length. In all cases, avoid long parallel runs. Do not use cable with an insulation thickness less than or equal to 15 mils (0.4mm/0.015 in.). Use only copper wire. Wire gauge requirements Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 29 Chapter 1 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring and recommendations are based on 7 5°C (167 °F). Do not reduce wire gauge when using higher temperature wire. Unshielded Cable THHN, THWN, or similar wire is acceptable for PowerFlex Active Front End installation in dry environments provided adequate free air space and/or conduit fill rate limits are provided. Do not use THHN or similarly coated wire in wet areas. Any wire that is chosen must have a minimum insulation thickness of 15 mils and cannot have large variations in insulation concentricity. Shielded Cable Shielded cable contains the general benefits of multi-conductor cable with the added benefit of a copper braided shield. The shield can contain much of the noise that is generated by a typical AC drive. Shielded cable is recommended in installations with sensitive equipment such as weigh scales, capacitive proximity switches, and other devices affected by electrical noise in the distribution system. Applications with large numbers of drives in a similar location, imposed EMC regulations, or a high degree of communication and networking are also good candidates for shielded cable. Consider the general specifications that are dictated by the environment of the installation, including temperature, flexibility, moisture characteristics, and chemical resistance. Also, include a braided shield that is specified by the manufacturer as having coverage of at least 75%. An additional foil shield can improve noise containment. A good example of recommended cable is Belden 29528 - 29532 (AWG-1 through AWG-410). This cable has three XLPE insulated conductors plus ground with a spiral copper shield that is surrounded by a PVC jacket. Armored Cable Cable with continuous aluminum armor is often recommended in drive system applications or specific industries. It offers most of the advantages of standard shielded cable and also combines considerable mechanical strength and resistance to moisture. It can be installed in concealed and exposed manners, and removes the requirement for conduit (EMT) in the installation. It can also be directly buried or embedded in concrete. Because noise containment is affected by incidental grounding of the armor to building steel when the cable is mounted, we recommend that the armored cable has an overall PVC jacket. See Chapter 2, `Wire Types' in Wiring and 30 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring Chapter 1 Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001. Interlocked armor is acceptable for shorter cable runs, but continuous welded armor is preferred. Best performance is achieved with three spaced ground conductors, but acceptable performance below 200 Hp is provided by use of one ground conductor. Recommended shielded/armored wire is listed in Table 1. Table 1 - Recommended Shielded/Armored Wire for AFE in IP20 2500 MCC Style Enclosure Location Standard (option 1) Standard (option 2) Class I & II; Division I & II Rating/Type 1000V, 90 °C (194 °F) XHHW2/RHW-2 Anixter B29528-B29532 Belden 29528-29532 Or equivalent Tray rated 1000V, 90 °C (194 °F) RHH/RHW-2 Anixter OLFLEX-76xxx03 Or equivalent Tray rated 1000V, 90 °C (194 °F) RHH/RHW-2 Anixter 7VFD-xxxx Or equivalent Description · Four tinned copper conductors with XLPE insulation. · Copper braid/aluminum foil combination shield and tinned copper drain wire. · PVC jacket. · Three tinned copper conductors with XLPE insulation. · Corrugated copper tape with three bare copper grounds in contact with shield. · PVC jacket. · Three bare copper conductors with XLPE insulation and impervious corrugated continuously welded aluminum armor. · Black sunlight resistant PVC jacket overall. · Three copper grounds. Cable Trays and Conduit ATTENTION: To avoid a possible shock hazard that is caused by induced voltages, unused wires in the conduit must be grounded at both ends. For the same reason, if a drive that shares a conduit is being serviced or installed, all drives that use this conduit must be disabled. Disable the drives to help minimize the possible shock hazard from `cross coupled' motor leads. If cable trays or large conduits are used, see the guidelines in Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001. Select and Verify Control Transformer Voltage The control transformer in the AFE is used to match the input AC line voltage of the AFE in an IP20 2500 MCC Style enclosure to the 230V and 120V control voltage. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 31 Chapter 1 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring Frame 10 (shown with enclosure doors removed) Verify that the control voltage is set appropriately for the supplied AC line voltage. If necessary, use this procedure to change the control voltage. 1. Locate the X3 terminal block (Figure 14). Figure 14 - X3 Terminal Block Location for AFE in IP20 2500 MCC Style Enclosure X3 Terminal BXl3ocTkerLmocinaatilon Block Location Frame 13 (shown with enclosure doors removed) Front View X3 Terminal Block Location Front View 2. To match the AC line voltage, move the wire that is shown in Figure 15 to the appropriate X3 terminal. 32 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring Chapter 1 Figure 15 - Input Voltage Setting for Control Voltage on Frames 10 and 13 in IP20 2500 MCC Style Enclosure For 400/480V or 600/690VAC Input 400 480 600 690 Move this wire to the terminal that matches the AC line voltage. X3 Terminal Block Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 33 Chapter 1 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring Power Terminals for AFE in IP20 2500 MCC Style Enclosure Figure 16 and Figure 17 show the power terminal locations and specifications for AFE Frames 10 and 13 in an IP20 2500 MCC Style enclosure. Figure 16 - AFE Frame 10 Power Terminal Locations in IP20 2500 MCC Style Enclosure Shown with enclosure doors and side removed. 2 1 2 4 4 4 3 Front View Right Side View Table 2 - AFE Frame 10 Power Terminal Specifications in IP20 2500 MCC Style Enclosure Item Name Frame Description 1 Input power terminals 10 L1, L2, L3 (1) 2 SHLD terminal, line PE, ground (3) 10 3 SHLD terminal, motor PE, ground (3) 4 DC bus (3) (DC, DC+) 10 Input power Terminating point for wiring shields DC output (using cable) DC output (using splice kit SK-Y1-BUSSPLICE-F10) Wire Size Range (1) (2) Max Min 240 mm2 95 mm2 (500 MCM) (3/O AWG) Torque Recommended 40 N·m (354 lb·in) Terminal Bolt Size(3) (4) N/A 300 mm2 2.1 mm2 40 N·m (600 MCM) (14 AWG) (354 lb·in) M5-M10 240 mm2 2.1 mm2 70 N·m M12 (500 MCM) (14 AWG) (620 lb·in) -- -- 40 N·m M10 (354 lb·in) (1) Maximum/minimum sizes that the terminals can accept. These sizes are not recommendations. (2) Do not exceed maximum wire size. Parallel connections can be required. (3) These connections are bus bar type terminations and require the use of lug type connectors. (4) Apply counter-torque to the nut on the other side of terminations when tightening or loosening the terminal bolt to avoid damage to the terminal. 34 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring Chapter 1 Figure 17 - AFE Frame 13 Power Terminal Locations in IP20 2500 MCC Style Enclosure Shown with enclosure doors and side removed. 2 1 4 3 Front View Right Side View Table 3 - AFE Frame 13 Power Terminal Specifications in IP20 2500 MCC Style Enclosure Item Name Frame Description 1 Input power terminals 13 L1, L2, L3 (1) 2 SHLD terminal, line PE, ground (3) 13 3 SHLD terminal, motor PE, ground (3) 4 DC bus (3) (DC, DC+) 13 Input power Terminating point for wiring shields DC output (using cable) DC output (using right-side splice kit SK-Y1-BUSSPLICE-F13R) DC output (using left-side splice kit SK-Y1-BUSSPLICE-F13L) Wire Size Range (1) (2) Max Min 380 mm2 53 mm2 (750 MCM) (1/O AWG) Torque Recommended 50 N·m (442 lb·in) Terminal Bolt Size(3) (4) N/A 300 mm2 2.1 mm2 40 N·m (600 MCM) (14 AWG) (354 lb·in) M5-M10 380 mm2 2.1 mm2 70 N·m M12 (750 MCM) (14 AWG) (620 lb·in) -- -- -- -- 40 N·m (354 lb·in) M10 (1) Maximum/minimum sizes that the terminals can accept. These sizes are not recommendations. (2) Do not exceed maximum wire size. Parallel connections can be required. (3) These connections are bus bar type terminations and require the use of lug type connectors. (4) Apply counter-torque to the nut on the other side of terminations when tightening or loosening the terminal bolt to avoid damage to the terminal. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 35 Chapter 1 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring Route the AC Input, Ground (PE), and DC Bus Output Wiring for AFE in IP20 2500 MCC Style Enclosure ATTENTION: To minimize disruption of airflow through the enclosure and avoid overheating within the AFE enclosure, remove only the minimum area that is needed to route the power cables. When you remove any of the five side cover-plates (shaded areas that are shown in Figure 18) for routing the AC input, ground (PE), and DC bus output wiring, always use the barrier kit, catalog number SK-Y1-MCCBARRIER, to maintain airflow integrity through the enclosure. When you remove sections for routing in other areas, airflow is disrupted throughout the enclosure, and causes overheating. Frame 10 The AC input and ground (PE) wiring for the IP20 2500 MCC Style enclosure must be routed through the top of the enclosure. The DC bus output can be routed through either the left or right side of the enclosure (see shaded areas in Figure 18). Figure 18 - Routing Areas for AC Input, Ground, and DC Bus Output Wiring for AFE Frame 10 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, catalog number SK-Y1-MCCBARRIER, to maintain proper airflow in the AFE enclosure and help to prevent overheating. Frame 13 The AC input and ground (PE) wiring for the IP20 2500 MCC Style enclosure must be routed through the top of the enclosure. 36 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring Chapter 1 The DC bus output can be routed through either the left or right side of the enclosure (see shaded area in Figure 19). Figure 19 - 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, catalog number SK-Y1MCCBARRIER, to maintain proper airflow in the AFE enclosure and help to prevent overheating. Disconnect the 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, disconnect these devices if the AFE is installed in either of these systems: · A high-resistance grounded distribution system · An ungrounded distribution system where the line-to-ground voltages on any phase exceed 125% of the nominal line-to-line voltage. To access the common mode capacitors, the LCL filter must be removed from the enclosure. To remove the Frame 10 AFE LCL filter from the IP20 2500 MCC Style enclosure, see the instructions in the PowerFlex Active Front End--Frame 10 Hardware Service Manual, publication 20Y-TG001. ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged completely before you remove or install any jumpers. 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. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 37 Chapter 1 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring Right Side View of LCL Filter To disconnect the common mode capacitors, remove the jumpers that are shown in Figure 20. For more information on ungrounded system installation, see Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001. Figure 20 - AFE Frame 10 LCL Filter Common Mode Capacitor Jumper Locations 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. To guard against AFE damage, disconnect these devices if the AFE is installed in either of these systems: · A high-resistance grounded distribution system · An ungrounded distribution system where the line-to-ground voltages on any phase exceed 125% of the nominal line-to-line voltage. To remove the AFE Frame 13 LCL filter from the IP20 2500 MCC Style enclosure, see the instructions in the PowerFlex Active Front End--Frame 13 Hardware Service Manual, publication 20Y-TG002. ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged completely before you remove or install any jumpers. 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. 38 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring Chapter 1 To disconnect the common mode capacitors, remove the upper guard and then remove the jumpers that are shown in Figure 21. For more information on ungrounded system installation, see Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001. Figure 21 - 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 The Frame 10 or Frame 13 AFE in an IP20 2500 MCC Style enclosure is shipped from the factory with the common mode capacitors removed. You do not need to remove the capacitors. However, when you replace a power structure, you must remove the common mode capacitors in the new power structure before installation. See Frame 10 Power Structure on page 72 or Frame 13 Power Structure on page 73 for instructions. Use 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 for the respective drives. When supplying power to PowerFlex drives of different frame sizes on the same DC bus, additional bus capacitance can be needed. For details, see Drives in Common Bus Configurations, publication DRIVES-AT002. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 39 Chapter 1 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring Control Wiring The AFE in an IP20 2500 MCC Style enclosure is wired at the factory and programmed to operate from the operator switches on the front of the enclosure. See Table 7 and Figure 23 for I/O terminal designations. If customized (or remote) control is required, then you must change the control wiring and correspondent digital I/O parameter setting. 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). · When it is unavoidable to cross control and signal wires with power wires, always cross power wires at a 90° angle. IMPORTANT I/O terminals that are labeled `()' or `Common' are not referenced to earth ground. They are designed to reduce common mode interference. Grounding these terminals can cause signal noise. ATTENTION: Inputs must be configured with software and jumpers (see Analog I/O Configuration on page 46). If you configure an analog input for 0...20 mA operation and drive it from a voltage source, you can cause component damage. Verify proper configuration before you apply input signals. ATTENTION: It is important to disable the variable frequency drives that are connected to the AFE output when the AFE is not active (not modulating). Connect the 'Inverter Enable' output of the AFE to each variable frequency drive enable input, or enable parameter 132 [Contact Off Cnfg] to force off the main contactor if there is a fault. This action makes sure that once the AFE stops modulating, there is no motoring current flowing through the AFE IGBT diodes. Failure to disable the AFE output can result in component damage or a reduction in product life. When you enable parameter 132, see page 109 for details. The AFE is shipped with parameter 132 disabled. The disabled parameter does not stop or shut down DC output when a fault occurs. 40 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring Chapter 1 For jumper configurations, see Table 8 on page 46. J4 J3 J2 J1 Signal and Control Wire Types Table 4 - Recommended Signal Wire for AFE in IP20 2500 MCC Style Enclosure Signal Type Analog I/O Wire Types Belden 8760/9460 (or equivalent) Belden 8770 (or equivalent) Description 0.5 mm2 (22 AWG), twisted pair, 100% shield with drain(1) 0.5 mm2 (22 AWG), 3-conductor, shielded for remote pot only Minimum Insulation Rating 300V, 75...90 °C (167...194 °F) EMC compliance See CE Conformity on page 49 for details. (1) If the wires are short and contained within an enclosure that has no sensitive circuits, the use of shielded wire is not necessary, but is always recommended. Table 5 - Recommended Control Wire for Digital I/O Type Unshielded Shielded Wire Types Description Per US NEC or applicable national or local code -- Multi-conductor shielded cable such as Belden 0.5 mm2(22 AWG), 8770 (or equivalent) 3-conductor, shielded Minimum Insulation Rating 300V, 60 °C (140 °F) Figure 22 - Door Control Box I/O Terminal Blocks and Jumpers J5 1 2 3 Components that are mounted on inside of AFE enclosure (see Figure 14 for location). 4 (X3 Terminals) Door Control Box Components X3 Term. No. 57 and 60 58 and 61 63 and 64 65 and 66 400 and 480 600 and 690 Default -- -- -- -- 480 690 Description Remote momentary pulse of 0.4...1.0 sec. across these terminals starts precharge in REM mode when terminals 58 and 61 are remotely closed. These terminals must be remotely closed to start precharge. Opening these terminals opens the main contactor K1. Remotely closing these terminals resets an AFE fault. AFE run signal to the inverter enable input. Control input voltage setting. See Table 6 for door-control box item number descriptions and specifications. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 41 Chapter 1 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring I/O Terminal Blocks Table 6 - Door Control Box I/O Terminal Block Specifications for AFE in IP20 2500 MCC Style Enclosure No. Name Description Wire Size Range (1) Torque Max Min Max 1 Analog I/O Analog I/O signals 2.5 mm2 0.5 mm2 0.2 N·m (14 AWG) (22 AWG) 1.8 lb·in 2 Digital inputs Digital input signals 2.5 mm2 0.5 mm2 0.2 N·m (14 AWG) (22 AWG) 1.8 lb·n 3 Digital outputs Digital out relays 2.5 mm2 0.5 mm2 0.5 N·m (14 AWG) (22 AWG) 4.5 lb·in 4 Control terminal Customer input and 2.5 mm2 0.5 mm2 0.8 N·m output control (14 AWG) (22 AWG) 7.1 lb·in (1) Maximum/minimum that the terminal block can accept. These sizes are not recommendations. Recommended 0.2 N·m 1.8 lb·in 0.2 N·m 1.8 lb·in 0.5 N·m 4.5 lb·in 0.8 N·m 7.1 lb·in 42 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 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 from the terminal plug so you can fix it to the cable clamp for grounding. Position the exposed shield so the clamp grips it. IMPORTANT: This clamp is not designed for strain relief. 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 wired at the factory 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 results in malfunction of the system. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 43 Chapter 1 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring Table 7 - Door Control Box I/O Terminal Designations for AFE in IP20 2500 MCC Style Enclosure No. Signal Default Description Configuration 1 Analog In 1 ()(1) (2) 1 2 Analog In 1 (+)(1) 3 Analog In 2 ()(1) Isolated (3), bipolar, differential, 9-bit and sign, 88k input impedance. A jumper (see Table 8) selects 0...10V, ±10V, or 4...20 mA. 4 Analog In 2 (+)(1) Default: 0...10V (Ri = 200k ), 4...20 mA (Ri = 100 ohm). 10 20 5 10V Pot Reference -- 6 Pot Common (GND) 2k min, 10 mA max load, 1% accuracy For (+) and () 10V pot references 7 +10V Pot Reference -- 8 Analog Out 1 (+) (2) 9 Analog Out Common 10 Analog Out 2 (+) 2k min, 10 mA max load, 1% accuracy Bipolar (current out is not bipolar), 9-bit and sign, 2k min load. A jumper (see Table 8) selects 0...10V, ±10V, or 4...20 mA. 11 Digital In 1 12 Digital In 2 13 Digital In 3 14 Digital In 4 15 Digital In 5 16 Digital In 6/Hardware Enable, see page 46 RunCmd Ext. Reset Enable Mcont Contactor Ack LCL Temp 24V DC - Opto isolated (250V) Low state: less than 5V DC High state: greater than 20V DC, 11.2 mA DC Enable: digital input 6 is jumper selectable for HW Enable. On-time: < 16.7 ms, Off-Time < 1 ms 17 Digital In Common Allows source or sink operation 18 19 +24V DC (4) -- Unit supplied logic input power 20 24V Common(4) -- Common for internal power supply 21 Digital Out 1 N.C.(5) Contact Ctrl Max Resistive Load: 21 22 Digital Out 1 Common 23 Digital Out 1 N.O.(5) 240V AC/30V DC 1200VA, 150 W Max current: 5 A, Min Load: 10 mA Max. Inductive Load: 24 Digital Out 2 N.C.(5) Fault 26 25 Digital Out 2/3 Com. 26 Digital Out 3 N.O.(5) (6) Active 240V AC/30V DC 840VA, 105 W Max current: 3.5 A, Min Load: 10 mA IMPORTANT: See the Attention above this table for more details. (1) Important: Input must be configured with a jumper. AFE damage can occur if jumper is not installed properly. See Analog I/O Configuration on page 46. (2) These inputs/outputs are dependent on a number of parameters. (3) Differential Isolation - External source must be maintained at less than 160V regarding PE. Input provides high common mode immunity. (4) 150 mA maximum load. Can be used to provide control power from an external 24V source when main power is not applied. (5) Contacts in unpowered state. Any relay that is programmed as Fault or Alarm energizes (pick up) when power is applied to the AFE, and de-energizes (drop out) when a fault or alarm exists. Relays selected for other functions energize only when that condition exists and de-energizes when the condition is removed. (6) These sizes are not recommendationsWhen this output is configured as active, it can be wired to the Enable input of the connected drives to prevent the AFE from supplying power when the AFE is not running. 44 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 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 wired at the factory 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. Figure 23 shows the factoryinstalled wiring. Figure 23 - Factory-installed Wiring Diagram for AFE in IP20 2500 MCC Style Enclosure Fault Reset AFE On Remote Fault Reset (optional) Input Contactor On Request Input Contactor Acknowledge LCL OverTemp AFE Ready 24V to LCL AFE Fault X3(64) 3 S11 See Analog I/O Configuration on page 46 for jumper settings. 4 X3(63) 14 13 K20 K1 11 14 K4 H3.1 2 READY 1 K4 H5 2 FAULT 1 20C-DA1-A Slot A (A11) 20C-DO1 Slot B (A12) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 AIA1- AIA1+ AIA2- AIA2+ -10Vref PotGND +10Vref AOUT1 AOUTC AOUT2 DIN1 DIN2 DIN3 DIN4 DIN5 DIN6 D_COM D_COM +24V 24VCOM HIM Cradle (A14) 20C-DPI1 Slot E (A13) Input R1 R1 Contactor 21 22 23 Control R2 R3 24 25 26 Input Contactor Close Input Contactor Supply Fault Relay 4 24V Charging 1 Interlocker 2 K4 X3(66) X3(65) 24V DC To User-supplied Drive Inverter Enable Input Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 45 Chapter 1 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring Analog I/O Configuration IMPORTANT Analog I/O must be configured through programming, and the jumpers shown in Table 8. See Figure 22 for jumper locations and Table 8 for I/O jumper configurations. Table 8 - I/O Configuration for AFE in IP20 2500 MCC Style Enclosure Signal Analog inputs Jumper J1 (analog in 1) J2 (analog in 2) Setting 0...20 mA J1 J2 ABCD ABCD 0...10V J1 J2 ABCD ABCD ±10V J1 J2 ABCD ABCD Analog outputs J3 (analog out 1) J4 (analog out 2) 0...20 mA J3 J4 ABCD ABCD 0...10V J3 J4 ABCD ABCD ±10V J3 J4 ABCD ABCD 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 wired at the factory 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 results in malfunction of the system. You can program a digital input as an Enable input. The AFE software interprets the status of this input. If the application requires the AFE to be disabled without software interpretation, a dedicated hardware enable configuration can be used. Remove jumper J5 (Figure 22) and wire the enable input to Digital In 6 (see Table 9). Verify that [Digital In6 Sel], parameter 226, is set to `1' (Enable). Table 9 - Hardware Enable Configuration for AFE in IP20 2500 MCC Style Enclosure Signal Hardware Enable Jumper J5 Setting Hardware enable J5 AB Input programmable (no hardware enable) J5 AB 46 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring Chapter 1 Analog I/O Wiring Examples for AFE in IP20 2500 MCC Style Enclosure Input/Output Connection Example Potentiometer unipolar DC volt reference 10k Pot. recommended (2k Min) 3 4 6 6 7 Analog voltage input unipolar DC volt reference 3 4 0...10V input Analog current input unipolar DC volt reference 3 4 4...20 mA input Analog output ±10V, 4...20 mA bipolar +10V unipolar (shown) +8 9 Required Parameter Changes · Configure input for voltage: Parameter 200 and set appropriate jumper per Table 8. · Adjust scaling: Parameters 80/81 and 204/205 · View results: Parameter 018 · Configure input for voltage: Parameter 200 and set appropriate jumper per Table 8. · Adjust scaling: Parameters 80/81 and 204/205 · View results: Parameter 018 · Configure input for current: Parameter 200 and set appropriate jumper per Table 8. · Adjust scaling: Parameters 80/81 and 204/205 · View results: Parameter 018. · Configure with Parameter 207 and set appropriate jumper per Table 8. · Select source value: Parameter 209 - [Analog Out1 Sel] · Adjust scaling: Parameters 210/211 Precharging the AFE 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. Table 10 shows the technical specifications for the precharge in the AFE enclosure. For correct operation of the precharging circuit, verify that the input circuit breaker (Q0) is on, and the input contactor (K1) and precharging circuit contactor are controlled by the AFE. Table 10 - Total DC Bus Capacitance Limits for Precharging Circuit of AFE in IP20 2500 MCC Style Enclosure Frame Size 10 13 Resistance 2 x 25 1 x 11 (3 x 3.67 ) Capacitance, min (1) 9900 F 29,700 F Capacitance, max (2) 70,000 F 128,000 F Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 47 Chapter 1 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring (1) The minimum capacitance is built into the AFE. (2) The maximum capacitance is the capacitance of the AFE plus the external capacitance. ATTENTION: If the maximum capacitance is exceeded, component damage in AFE occurs. Important Guidelines Read and understand these guidelines: · If drives without internal precharge are used and a disconnect is installed between the input of the drive and the DC bus, you must use an external precharge circuit between the disconnect and the DC input of the drive. · If drives with internal precharge are used with a disconnect switch to the common bus, you must connect an auxiliary contact on the disconnect to a digital input of the drive. The corresponding input must be set to the `Precharge Enable' option. This option provides the proper precharge interlock, guarding against possible damage to the drive when connected to a common DC bus. · The precharge status of the AFE must be interlocked with the connected drives, such that the drives are disabled (not running) when the AFE is in a precharge state. 48 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 CE Conformity AFE in IP20 2500 MCC Style Enclosure Installation/Wiring Chapter 1 Conformity with the Low Voltage (LV) Directive and Electromagnetic Compatibility (EMC) Directive has been demonstrated by using harmonized European Norm (EN) standards that are published in the Official Journal of the European Communities. PowerFlex Active Front End units comply with the EN standards listed here when installed according to this User Manual and the PowerFlex Drive Reference Manual. Declarations of Conformity are available online at this link: http://www.rockwellautomation.com/certification/overview.page Low Voltage Directive (2006/95/EC) EN61800-5-1 Adjustable speed electrical power drive systems Part 5-1: Safety requirements Electrical, thermal and energy. EMC Directive (2004/108/EC) EN61800-3 Adjustable speed electrical power drive systems Part 3: EMC product standard including specific test methods. General Notes · The AFE can cause radio frequency interference if used in a residential or domestic environment. You are required to take measures to help prevent interference, and follow the essential requirements for CE compliance that is listed here, if necessary. · Conformity of the AFE with CE EMC requirements does not guarantee an entire machine or installation complies with CE EMC requirements. Many factors can influence total machine/installation compliance. Essential Requirements for CE Compliance Conditions 1...6 listed here must be satisfied for the PowerFlex Active Front End to meet the requirements of EN61800-3. 1. Use a standard PowerFlex Active Front End CE-compatible unit. 2. Review important precautions and attention statements throughout this document before installing the Active Front End. 3. Grounding as described on page 27. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 49 Chapter 1 AFE in IP20 2500 MCC Style Enclosure Installation/Wiring 4. Control (I/O) and signal wiring must be braided, shielded cable with a coverage of 75% or better, metal conduit, or have shielding/cover with equivalent attenuation. 5. All shielded cables must terminate with proper shielded connector. 6. Motor cables of DC input drives that are 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. 50 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 2 Chapter AFE in IP21 Rittal Enclosure Installation/ Wiring This chapter provides information on how to install and wire the PowerFlex® Active Front End in an IP21 Rittal enclosure. For information on how to install and wire the AFE in an IP20 2500 MCC Style enclosure, see Chapter 1. Topic Page Main Component Sections 52 Main Component Locations 54 Mounting Considerations 56 AC Supply Source Considerations 58 Grounding Requirements 59 Fuses and Circuit Breakers 62 Power Wiring 62 Disconnect the Common Mode Capacitors 69 Using the AFE with PowerFlex Drives 74 Control Wiring 74 Precharging the AFE 81 CE Conformity 82 Most start-up difficulties are the result of incorrect wiring. Verify that the wiring is done as instructed. Read and understand the instructions before you begin to installation the AFE. ATTENTION: The following information is a guide for proper installation. Rockwell Automation does not assume responsibility for the compliance or the noncompliance to any code, national, local, or otherwise, for the proper installation of this 700AFE or associated equipment. A hazard of personal injury and/or equipment damage exists if codes are ignored during installation. This section describes the main component sections and main component locations of AFE Frame 10 and Frame 13 systems in an IP21 Rittal enclosure. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 51 Chapter 2 AFE in IP21 Rittal Enclosure Installation/Wiring Main Component Sections This section describes the main component sections of AFE Frame 10 and Frame 13 systems in an IP21 Rittal enclosure. Frame 10 Figure 24 shows a basic one-line diagram for an AFE Frame 10 in an 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 and F2.2) Figure 24 - Basic One-line Diagram for an AFE Frame 10 in IP21 Rittal Enclosure 3-phase AC Input L1 L2 L3 AC Line Switchgear Q0 Q1 LCL Filter (L1) U2 V2 W2 C1 C4 C2 C5 C3 C6 AFE DC Power Structure (U1) Fuses U1 U1 U V1 W1 V DC+ F2.1 W F2.2 PE DC- PE DC Bus Output Motor Protection Precharge Relay Precharge Fuses Contactor Precharge Circuit F6 Q5 K6 PowerFlex Active Front End System R6.1 + R6.2 - 52 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 AFE in IP21 Rittal Enclosure Installation/Wiring Chapter 2 Frame 13 Figure 25 shows a basic one-line diagram for an AFE Frame 13 in an 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...F2.6) Figure 25 - Basic One-line Diagram for an AFE Frame 13 in IP21 Rittal Enclosure 3-phase AC Input L1 L2 L3 AC Line Switchgear Q0 Q1 LCL Filter (L1) U2 V2 W2 C1 C4 C2 C5 C3 C6 AFE Power Structure (U1) PE U1 U DC+ V1 DC- W1 PE V DC+ DC- PE W DC+ PE DC- Motor Protection Precharge Relay Precharge Fuses Contactor Precharge Circuit DC Fuses F2.1 F2.2 F2.3 F2.4 F2.5 F2.6 DC Bus Output F6 Q5 K6 PowerFlex Active Front End System R6.1 + R6.2 - Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 53 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 an IP21 Rittal enclosure. Frame 10 Figure 26 shows the main components of the AFE Frame 10 system in an IP21 Rittal enclosure. Figure 26 - AFE Frame 10 Main Component Locations in IP21 Rittal Enclosure Front View 1 (shown with enclosure doors removed) 7 3 2 4 5 6 Item Description 1 Precharge circuit 2 LCL filter (L1) 3 Active Front End power structure (U1) 4 AC line Motor-controlled circuit breaker 5 switchgear Input disconnect 6 AFE control assembly (shown with user-installed HIM) 7 DC fuses 54 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 AFE in IP21 Rittal Enclosure Installation/Wiring Chapter 2 Frame 13 Figure 27 shows the main components of the AFE Frame 13 system in an IP21 Rittal enclosure. Figure 27 - AFE Frame 13 Main Component Locations in IP21 Rittal Enclosure Front View (shown with enclosure doors removed) 7 3 2 5 4 6 These components are on a subpanel that is mounted in front of the bus bars shown here. 1 Item Description 1 Precharge circuit 2 LCL filter (L1) 3 Active Front End power structure (U1) 4 AC line Motor-controlled circuit breaker 5 switchgear Input disconnect 6 AFE control assembly (shown with user-installed HIM) 7 DC fuses Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 55 Chapter 2 AFE in IP21 Rittal Enclosure Installation/Wiring Mounting Considerations When mounting the Active Front End, consider the following information. Operating Temperatures Frame Size 10 13 (1) Surrounding Air Temperature (2) Normal Duty Heavy Duty 0...40 °C (32...104 °F) 0...40 °C (32...104 °F) Minimum Airflow Power Module 1400 m3/hr (824 cfm) 4200 m3/hr (2472 cfm) LCL Filter 1100 m3/hr (647 cfm) 1300 m3/hr (765 cfm) (1) The Frame 13 690V AFE has only normal duty operation at nominal rated power and maximum ambient temperature at 35 °C (95 °F). (2) For an AFE in the IP21 Rittal enclosure, this means air surrounding the module. Minimum Mounting Clearances Figure 28 - Frame 10 in IP21 Rittal Enclosure 50 mm (2.0 in.) Clearance to Wall Top View 50 mm (2.0 in.) Clearance to Wall 400 mm (15.7 in.) Door Swing Clearance 200 mm (7.87 in.) Height Clearance 600 mm (23.6 in.) Door Swing Clearance Front View 56 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 AFE in IP21 Rittal Enclosure Installation/Wiring Chapter 2 Figure 29 - Frame 13 in IP21 Rittal Enclosure 50 mm (2.0 in.) Clearance to Wall Top View 50 mm (2.0 in.) Clearance to Wall 200 mm (7.87 in.) Height Clearance 800 mm (31.5 in.) Door Swing Clearance Front View Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 57 Chapter 2 AFE in IP21 Rittal Enclosure Installation/Wiring AC Supply Source Considerations The AFE Frame 10 or Frame 13 in an 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%. Operation outside these limits can cause instability that results in AFE shutdown. System Impedance = (PowerFlex 700AFE kVA ÷ Transformer kVA) x Transformer % Impedance You must consider the kVA of all PowerFlex AFEs on the distribution system and the system impedance of upstream transformers. ATTENTION: To guard against personal injury and equipment damage that is caused by improper fusing or circuit breaker selection, use only the recommended line fuses or circuit breakers that are specified in Appendix A. If a residual current detector (RCD) is used as a system ground fault monitor, use only Type B (adjustable) devices to avoid nuisance tripping. Unbalanced, Ungrounded, or Resistive Grounded Distribution Systems If phase-to-ground voltage exceeds 125% of normal or the supply system is ungrounded, see Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001, for more information. ATTENTION: The PowerFlex Active Front End is not designed to be used on IT (insulated tera) or corner-grounded power networks above 600V (phase-tophase voltage). Operation on such a network can cause a hazardous failure of the insulation system of the AFE. ATTENTION: The LCL filter of the PowerFlex Active Front End contains common mode capacitors that are referenced to ground. These devices must be disconnected if the AFE is installed on a resistive grounded distribution system or an ungrounded distribution system. See Figure 37 on page 70 or Figure 38 on page 70 for jumper locations. ATTENTION: The power structure of the PowerFlex Active Front End in the IP21 Rittal enclosure contains common mode capacitors that must be disconnected, regardless of the application in which the AFE is used. For locations of the common mode capacitors and instructions to remove them, see Frame 10 Power Structure on page 72 or Frame 13 Power Structure on page 73. 58 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 AFE in IP21 Rittal Enclosure Installation/Wiring Chapter 2 Input Power Conditioning These events on the power system that supplies an AFE can cause component damage or shortened product life: · The power system has power factor correction capacitors that are switched in and out of the system, either by you or by the power company. · 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. Ground impedance must conform to the requirements of national and local industrial safety regulations and/or electrical codes. Check the integrity of all ground connections periodically. Recommended Grounding Scheme For installations in which the AFE is within an enclosure, use one safety ground point or ground bus bar connected directly to building steel. All circuits including the AC input ground conductor must be grounded independently and directly to this point or ground bus bar. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 59 Chapter 2 AFE in IP21 Rittal Enclosure Installation/Wiring Figure 30 - Typical Grounding Example for AFE Frame 10 in IP21 Rittal Enclosure PowerFlex 700AFE (Frame 10 shown in IP21 Rittal enclosure) PowerFlex 750-Series Drive or PowerFlex 7-Class Drive (PowerFlex 700S Frame 10 drive shown) DC+ DC+ DC- DC- Customer wiring required to connect the AFE to the drive. U (T1), V (T2), W (T3) PE PE PE SHLD R (L1), S (L2), T (L3) To Line PE Figure 31 - Typical Grounding Example for AFE Frame 13 in IP21 Rittal Enclosure PowerFlex AFE Frame 13 PowerFlex 750-Series Drive or PowerFlex 7-Class Drive (PowerFlex 700S Frame 10 drive shown) DC+ DC+ DC- DC- Customer wiring required to connect the AFE to the drive. U (T1), V (T2), W (T3) PE PE PE SHLD R (L1), S (L2), T (L3) To Line PE 60 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 AFE in IP21 Rittal Enclosure Installation/Wiring Chapter 2 Safety Ground - PE This ground is the safety ground for the AFE that code requires. This point must be connected to adjacent building steel (girder or joist), a floor ground rod, or bus bar (see Figure 31). Grounding points must comply with national and local industrial safety regulations and/or electrical codes. Shield Termination - SHLD The Shield terminal (Figure 34 or Figure 35) provides a grounding point for the AFE cable shield. It must be connected to an earth ground by a separate continuous lead. The drive cable shield must be connected to this terminal on the AFE end and the drive frame on the drive end. Use a shield terminating or EMI clamp to connect the shield to this terminal. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 61 Chapter 2 AFE in IP21 Rittal Enclosure Installation/Wiring 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 81. For fuse and circuit breaker information, see Appendix A. Local/national electrical codes can determine additional requirements for the installations. Power Wiring Most start-up difficulties are the result of incorrect wiring. Verify that the wiring is done as instructed. Read and understand the instructions before you begin to installation the AFE. ATTENTION: The following information is a guide for proper installation. Rockwell Automation does not assume responsibility for the compliance or noncompliance to any code, national, local, or otherwise, for the proper installation of this unit or associated equipment. A risk of personal injury and/ or equipment damage exists if codes are ignored during installation. Power Cable Types Acceptable for 400...690 Volt Installations ATTENTION: National Codes and standards (NEC, VDE, CSA, BSI, and so forth) and local codes outline provisions for safely installing electrical equipment. Installation must comply with specifications regarding wire types, conductor sizes, branch circuit protection, and disconnect devices. Failure to do so can result in personal injury and/or equipment damage. Various cable types are acceptable for PowerFlex Active Front End installations. For many installations, unshielded cable is adequate, provided it can be separated from sensitive circuits. As an approximate guide, use a spacing of 0.3 meters (1 ft) for every 10 meters (32.8 ft) of length. In all cases, avoid long parallel runs. Do not use cable with an insulation thickness less than or equal to 15 mils (0.4mm/0.015 in.). Use only copper wire. Wire gauge requirements and recommendations are based on 75 °C (167 °F). Do not reduce wire gauge when using higher temperature wire. Unshielded Cable THHN, THWN, or similar wire is acceptable for PowerFlex Active Front End installation in dry environments provided adequate free air space and/or conduit fill rates limits are provided. Do not use THHN or similarly coated wire in wet areas. Any wire that is chosen must have a minimum insulation thickness of 15 mils and cannot have large variations in insulation concentricity. 62 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 AFE in IP21 Rittal Enclosure Installation/Wiring Chapter 2 Shielded Cable Shielded cable contains the benefits of multi-conductor cable with the added benefit of a copper braided shield that can contain much of the noise that is generated by a typical AC drive. Consider shielded cable in installations with sensitive equipment such as weigh scales, capacitive proximity switches, and other devices affected by electrical noise in the distribution system. Applications with large numbers of drives in a similar location, imposed EMC regulations, or a high degree of communication and networking are also good candidates for shielded cable. Consider the general specifications that are dictated by the environment of the installation, including temperature, flexibility, moisture characteristics, and chemical resistance. Also, include a braided shield that is specified by the manufacturer as having coverage of at least 75%. An additional foil shield can improve noise containment. A good example of recommended cable is Belden 29528 - 29532 (AWG-1 through AWG-410). This cable has three XLPE insulated conductors plus ground with a spiral copper shield that is surrounded by a PVC jacket. Armored Cable Cable with continuous aluminum armor is often recommended in drive system applications or specific industries. It offers most of the advantages of standard shielded cable and also combines considerable mechanical strength and resistance to moisture. It can be installed in concealed and exposed manners, and removes the requirement for conduit (EMT) in the installation. It can also be directly buried or embedded in concrete. Because noise containment is affected by incidental grounding of the armor to building steel when the cable is mounted, we recommend that the armored cable has an overall PVC jacket. See Chapter 2, `Wire Types' in Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001. Interlocked armor is acceptable for shorter cable runs, but continuous welded armor is preferred. Best performance is achieved with three spaced ground conductors, but acceptable performance below 200 Hp is provided by use of one ground conductor. Recommended shielded/armored wire is listed in Table 11. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 63 Chapter 2 AFE in IP21 Rittal Enclosure Installation/Wiring Table 11 - Recommended Shielded/Armored Wire for AFE in IP21 Rittal Enclosure Location Standard (option 1) Standard (option 2) Class I & II; Division I & II Rating/Type 1000V, 90 °C (194 °F) XHHW2/RHW-2 Anixter B29528-B29532 Belden 29528-29532 Or equivalent Tray rated 1000V, 90 °C (194 °F) RHH/RHW-2 Anixter OLFLEX-76xxx03 Or equivalent Tray rated 1000V, 90 °C (194 °F) RHH/RHW-2 Anixter 7VFD-xxxx or equivalent Description · Four tinned copper conductors with XLPE insulation. · Copper braid/aluminum foil combination shield and tinned copper drain wire. · PVC jacket. · Three tinned copper conductors with XLPE insulation. · Corrugated copper tape with three bare copper grounds in contact with shield. · PVC jacket. · Three bare copper conductors with XLPE insulation and impervious corrugated continuously welded aluminum armor. · Black sunlight resistant PVC jacket overall. · Three copper grounds. Cable Trays and Conduit ATTENTION: To avoid a possible shock hazard that is caused by induced voltages, unused wires in the conduit must be grounded at both ends. For the same reason, if a drive that shares a conduit is being serviced or installed, all drives that use this conduit must be disabled. Disable the drives to help minimize the possible shock hazard from `cross coupled' motor leads. If cable trays or large conduits are used, see the guidelines in Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-IN001. Select and Verify Control Transformer Voltage The control transformer in the AFE is used to match the input AC line voltage of the AFE in an IP21 Rittal enclosure to the 230V control voltage. Verify that the control voltage is set appropriately for the supplied AC line voltage. If necessary, use this procedure to change the control voltage. 64 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 AFE in IP21 Rittal Enclosure Installation/Wiring Chapter 2 Frame 10 (shown with enclosure doors removed) 1. Locate the X3 terminal block (Figure 32). Figure 32 - X3 Terminal Block Location for AFE in IP21 Rittal Enclosure Frame 13 (shown with enclosure doors removed) X3 Terminal Block Location X3 Terminal Block Location Front View Front View 2. To match the AC line voltage, move the wire that is shown in Figure 33 to the appropriate X3 terminal. Figure 33 - Input Voltage Setting for Control Voltage on Frames 10 and 13 in IP21 Rittal Enclosure For 400/480V AC Input For 600/690V AC Input 400 440 460 480 500 525 600 690 X3 Terminal Block X3 Terminal Block Move this wire to the terminal that matches the AC line voltage. Move this wire to the terminal that matches the AC line voltage. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 65 Chapter 2 AFE in IP21 Rittal Enclosure Installation/Wiring Power Terminals for AFE in IP21 Rittal Enclosure Figure 34 and Figure 35 show the power terminal locations and specifications for AFE Frames 10 and 13 in an IP21 Rittal enclosure. Figure 34 - AFE Frame 10 Power Terminal Locations in IP21 Rittal Enclosure 3 3 (Shown with enclosure doors removed) 1 2 Front View Right Side View Table 12 - AFE Frame 10 Power Terminal Specifications in IP21 Rittal Enclosure Item Name Frame Description 1 Input power terminals 10 L1, L2, L3 (1) 2 SHLD terminal, PE, 10 ground (3) 3 DC bus (3) (DC, DC+) 10 Input power Terminating point for wiring shields DC output Wire Size Range(1) (2) Max 300 mm2 (600 MCM) 300 mm2 (600 MCM) 300 mm2 (600 MCM) Min 2.1 mm2 (14 AWG) 2.1 mm2 (14 AWG) 2.1 mm2 (14 AWG) Torque Recommended 40 N·m (354 lb·in) 40 N·m (354 lb·in) 70 N·m (620 lb·in) Terminal Bolt Size (3) (4) M10 M10 M12 (1) Maximum/minimum sizes that the terminals accept. These sizes are not recommendations. (2) Do not exceed maximum wire size. Parallel connections can be required. (3) These connections are bus bar type terminations and require the use of lug type connectors. (4) Apply counter-torque to the nut on the other side of terminations when tightening or loosening the terminal bolt to avoid damage to the terminal. 66 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 AFE in IP21 Rittal Enclosure Installation/Wiring Chapter 2 Figure 35 - AFE Frame 13 Power Terminal Locations in IP21 Rittal Enclosure 3 3 Shown with enclosure doors removed. 1 2 Front View Right Side View Table 13 - AFE Frame 13 Power Terminal Specifications in IP21 Rittal Enclosure Item Name 1 Input power terminals L1, L2, L3 (1) 2 SHLD terminal, PE, ground (3) 3 DC bus (3) (DC, DC+) Frame 13 13 13 Description Input power Terminating point for wiring shields DC output Wire Size Range(1) (2) Maximum 300 mm2 (600 MCM) 300 mm2 (600 MCM) 300 mm2 (600 MCM) Minimum 2.1 mm2 (14 AWG) 2.1 mm2 (14 AWG) 2.1 mm2 (14 AWG) Torque Recommended 70 N·m (620 lb·in) 40 N·m (354 lb·in) 70 N·m (620 lb·in) Terminal Bolt Size(3) (4) M12 M10 M12 (1) Maximum/minimum sizes that the terminals accept. These sizes are not recommendations. (2) Do not exceed maximum wire size. Parallel connections can be required. (3) These connections are bus bar type terminations and require the use of lug type connectors. (4) Apply counter-torque to the nut on the other side of terminations when tightening or loosening the terminal bolt to avoid damage to the terminal. DC Bus Output Wiring The length of the DC bus connections between the AFE and the drive or drives must be minimized to keep the bus inductance low for reliable system operation. For more information, see Drives in Common Bus Configurations, publication DRIVES-AT002. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 67 Chapter 2 AFE in IP21 Rittal Enclosure Installation/Wiring Route the AC Input, Ground (PE), and DC Bus Output Wiring for AFE in IP21 Rittal Enclosure ATTENTION: To minimize disruption of airflow through the enclosure and avoid overheating within the AFE enclosure, remove only the minimum area that is needed to route the power cables. In addition, remove only the minimum area from the enclosure within the shaded areas that are shown in Figure 36 for routing the AC input, ground (PE), and DC bus output wiring. When you remove sections for routing in other areas, airflow is disrupted throughout the enclosure, and causes overheating. Frame 10 The AC input and ground (PE) wiring for the IP21 Rittal enclosure can be routed through either the bottom of the enclosure, or through the bottom right side of the enclosure (see shaded area in Figure 36). The DC bus output wiring for the IP21 Rittal enclosure must be routed through the top right side of the enclosure (see shaded area in Figure 36). Figure 36 - Routing Areas for AC Input, Ground, and DC Bus Output Wiring for AFE Frame 10 in IP21 Rittal Enclosure Area for routing DC bus output connections. Do not allow hot air to enter the bottom of the enclosure. Area for routing AC input and ground (PE) connections. Frame 13 The AC input, ground (PE), and DC bus output are located in the right-most bay (see front view of Figure 35). The AC input, ground, and DC bus output 68 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 AFE in IP21 Rittal Enclosure Installation/Wiring Chapter 2 wiring can be routed through the top, bottom, or right side of the right-most bay. Disconnect the 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. To access the common mode capacitors, the LCL filter must be removed from the enclosure. To remove the Frame 10 AFE LCL filter from the IP21 Rittal enclosure, see the instructions in the PowerFlex Active Front End--Frame 10 Hardware Service Manual, publication 20Y-TG001. ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged completely before you remove or install any jumpers. 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. To disconnect the common mode capacitors, remove the jumpers that are shown in Figure 37. For more information on ungrounded system installation, see Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-AT001. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 69 Chapter 2 AFE in IP21 Rittal Enclosure Installation/Wiring Figure 37 - 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. 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. To remove the AFE Frame 13 LCL filter from the IP21 Rittal enclosure, see the instructions in the PowerFlex Active Front End--Frame 13 Hardware Service Manual, publication 20Y-TG002. ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged completely before you remove or install any jumpers. 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. To disconnect the common mode capacitors, remove the upper guard and then remove the jumpers that are shown in Figure 38. For more information on ungrounded system installation, see Wiring and Grounding Guidelines for Pulse Width Modulated (PWM) AC Drives, publication DRIVES-AT001. Figure 38 - AFE Frame 13 LCL Filter Common Mode Capacitor Jumper Locations 70 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 AFE in IP21 Rittal Enclosure Installation/Wiring Chapter 2 Remove Three Jumpers Remove Three Jumpers Front View of LCL Filter Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 71 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. To remove these capacitors from the AFE Frame 10 power structure, follow these steps. 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. Unscrew and remove the capacitor assembly consisting of two capacitors on a small metal bracket. Close-up View of Common Mode Capacitor Assembly Close-up View of Common Mode Capacitor Assembly 72 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 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 on the Phase V (center) module of the power structure. To remove these capacitors from the AFE Frame 13 power structure, follow these steps. 1. Locate the common mode capacitors on the Phase V module of the Frame 13 power structure. Location of Common Mode Capacitors on Phase V Module of Frame 13 AFE Power Structure Phase V Module of Frame 13 Power Structure 2. Remove the common mode capacitors. a. Disconnect the two black wires. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 73 Chapter 2 AFE in IP21 Rittal Enclosure Installation/Wiring b. Unscrew and remove the capacitor assembly consisting of two capacitors on a small metal bracket. Close-up View of Common Mode Capacitors on Phase V Module of Frame 13 AFE Power Structure Close-up View of Common Mode Capacitor Assembly Disconnect Wires and Unscrew Capacitor Assembly Using the AFE with PowerFlex Drives Control Wiring 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 can be needed. For details, see Drives in Common Bus Configurations, publication DRIVES-AT002. The AFE in an IP21 Rittal enclosure is wired at the factory and programmed to operate from the operator switches on the front of the enclosure. See Table 17 and Figure 40 for I/O terminal designations. If customized (or remote) control is required, then you must change the control wiring and correspondent digital I/O parameter setting. 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). 74 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 AFE in IP21 Rittal Enclosure Installation/Wiring Chapter 2 · When it is unavoidable to cross control and signal wires with power wires, always cross power wires at a 90° angle. IMPORTANT I/O terminals that are labeled `()' or `Common' are not referenced to earth ground. They are designed to reduce common mode interference. Grounding these terminals can cause signal noise. ATTENTION: Inputs must be configured with software and jumpers (see Analog I/O Configuration on page 79). If you configure an analog input for 0...20 mA operation and drive it from a voltage source, you can cause component damage. Verify proper configuration before you apply input signals. ATTENTION: It is important to disable the variable frequency drives that are connected to the AFE output when the AFE is not active (not modulating). Connect the 'Inverter Enable' output of the AFE to each variable frequency drive enable input, or enable parameter 132 [Contact Off Cnfg] to force off the main contactor if there is a fault. This action makes sure that once the AFE stops modulating, there is no motoring current flowing through the AFE IGBT diodes. Failure to disable the AFE output can result in component damage or a reduction in product life. When you enable parameter 132, see page 109 for details. The AFE is shipped with parameter 132 disabled. The disabled parameter does not stop or shut down DC output when a fault occurs. Signal and Control Wire Types Table 14 - Recommended Signal Wire for AFE in IP21 Rittal Enclosure Signal Type Wire Types Description Minimum Insulation Rating Analog I/O Belden 8760/9460 (or equivalent) Belden 8770 (or equivalent) 0.5 mm2 (22 AWG), twisted pair, 100% shield with drain (1) 0.5 mm2 (22 AWG), 3-conductor, shielded for remote pot only 300V, 75...90 °C (167...194 °F) EMC compliance See CE Conformity on page 82 for details. (1) If the wires are short and contained within an enclosure that has no sensitive circuits, the use of shielded wire is not necessary, but is always recommended. Table 15 - Recommended Control Wire for Digital I/O Type Unshielded Shielded Wire Types Description Per US NEC or applicable national or local code Multi-conductor shielded cable such as Belden 8770(or equivalent) -- 0.5 mm2 (22 AWG), 3-conductor, shielded Minimum Insulation Rating 300V, 60 °C (140 °F) Figure 39 - AFE I/O Terminal Blocks and Jumpers Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 75 Chapter 2 AFE in IP21 Rittal Enclosure Installation/Wiring J5 J4 J3 J2 J1 1 2 3 I/O Terminal Blocks Table 16 - I/O Terminal Block Specifications for AFE in IP21 Rittal Enclosure No. Name Description 1 Analog I/O Analog I/O signals 2 Digital inputs Digital input signals 3 Digital outputs Digital out relays Wire Size Range (1) Max 2.5 mm2 (14 AWG) 2.5 mm2 (14 AWG) 2.5 mm2 (14 AWG) Min 0.5 mm2 (22 AWG) 0.5 mm2 (22 AWG) 0.5 mm2 (22 AWG) Torque Max 0.2 N·m 1.8 lb·in 0.2 N·m 1.8 lb·n 0.5 N·m 4.5 lb·in (1) Maximum/minimum that the terminal block can accept. These sizes are not recommendations. Recommended 0.2 N·m 1.8 lb·in 0.2 N·m 1.8 lb·in 0.5 N·m 4.5 lb·in 76 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 AFE in IP21 Rittal Enclosure Installation/Wiring Chapter 2 I/O Cable Grounding When installing shielded multi-conductor cable for analog and digital I/O, strip the cable from the terminal plug so you can fix it to the cable clamp for grounding. Position the exposed shield so the clamp grips it. IMPORTANT: This clamp is not designed for strain relief. ATTENTION: For the AFE in the IP21 Rittal enclosure, digital inputs 1, 3, 4, and 5, and digital outputs 1 and 2, are wired at the factory 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 results in malfunction of the system. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 77 Chapter 2 AFE in IP21 Rittal Enclosure Installation/Wiring Table 17 - I/O Terminal Designations for AFE in IP21 Rittal Enclosure No. Signal Default Description Configuration 1 Analog In 1 ()(1) (2) 1 2 Analog In 1 (+)(1) 3 Analog In 2 ()(1) Isolated (3), bipolar, differential, 9-bit and sign, 88k input impedance. A jumper (see Table 18) selects 0...10V, ±10V, or 4...20 mA. 4 Analog In 2 (+)(1) Default: 0...10V (Ri = 200k ), 4...20 mA (Ri = 100 ). 10 20 5 10V Pot Reference -- 6 Pot Common (GND) 2k min, 10 mA max load, 1% accuracy For (+) and () 10V pot references 7 +10V Pot Reference -- 8 Analog Out 1 (+) (2) 9 Analog Out Common 10 Analog Out 2 (+) 2k min, 10 mA max load, 1% accuracy Bipolar (current out is not bipolar), 9-bit and sign, 2k min load. A jumper (see Table 18) selects 0...10V, ±10V, or 4...20 mA. 11 Digital In 1 12 Digital In 2 13 Digital In 3 14 Digital In 4 15 Digital In 5 16 Digital In 6/Hardware Enable, see page 80 RunCmd Ext. Reset Enable Mcont Contactor Ack LCL Temp 24V DC - Opto isolated (250V) Low state: less than 5V DC High state: greater than 20V DC, 11.2 mA DC Enable: Digital Input 6 is jumper selectable for HW Enable. On-time: < 16.7 ms, Off-Time < 1 ms 17 Digital In Common Allows source or sink operation 18 19 +24V DC (4) -- Unit supplied logic input power 20 24V Common(4) -- Common for internal power supply 21 Digital Out 1 N.C.(5) Contact Ctrl Max. Resistive Load: 21 22 Digital Out 1 Common 23 Digital Out 1 N.O.(5) 24 Digital Out 2 N.C.(5) Fault 26 25 Digital Out 2/3 Com. 26 Digital Out 3 N.O.(5) (6) Active 240V AC/30V DC 1200VA, 150 W Max current: 5 A, Min Load: 10 mA Max. Inductive Load: 240V AC/30V DC 840VA, 105 W Max current: 3.5 A, Min Load: 10 mA IMPORTANT: See the Attention above this table for more details. (1) Important: Input must be configured with a jumper. AFE damage can occur if jumper is not installed properly. See Analog I/O Configuration on page 79. (2) These inputs/outputs are dependent on a number of parameters. (3) Differential Isolation - External source must be maintained at less than 160V regarding PE. Input provides high common mode immunity. (4) 150 mA maximum load. Can be used to provide control power from an external 24V source when main power is not applied. (5) Contacts in unpowered state. Any relay that is programmed as Fault or Alarm energizes (pick up) when power is applied to the AFE, and de-energizes (drop out) when a fault or alarm exists. Relays selected for other functions energize only when that condition exists and de-energizes when the condition is removed. (6) When this output is configured as active, it can be wired to the Enable input of the connected drives to prevent the AFE from supplying power when the AFE is not running. Typical I/O Wiring The IP21 Rittal enclosure for the AFE is wired at the factory 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 78 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 AFE in IP21 Rittal Enclosure Installation/Wiring Chapter 2 closed, and no faults are present. The Figure 40 shows the factory-installed wiring. Figure 40 - Factory-installed Wiring Diagram for AFE in IP21 Rittal Enclosure AFE Run MCCB On Request MCCB Acknowledge LCL OverTemp 24V to LCL AFE Ready See Analog I/O Configuration on page 79 for jumper settings. 14 34 K20 Q1 11 31 K4 H3.1 1 READY 2 20C-DA1-A Slot A (A11) 20C-DO1 Slot B (A12) 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 AIN1+ AIN2- AIN2+ -10VRef PotGND +10VRef AOUT1 AOUTC AOUT2 DIN1 DIN2 DIN3 DIN4 DIN5 DIN6 D_COM D_COM +24V 24VCOM HIM Cradle (A14) 20C-DPI1 Slot E (A13) Input R1 R1 Contactor 21 22 23 Control MCCB Close MCCB Supply MCCB Open R2 R3 24 25 26 Fault Relay 4 24V Charging 1 Interlocker 2 K4 24V DC Com To User-supplied Drive Inverter Enable Input Analog I/O Configuration IMPORTANT Analog I/O must be configured through programming, and the jumpers shown in Table 18. See Figure 39 for jumper locations and Table 18 for I/O jumper configurations. Table 18 - I/O Configuration for AFE in IP21 Rittal Enclosure Signal Analog inputs Jumper J1 (analog in 1) J2 (analog in 2) Setting 0...20 mA J1 J2 ABCD ABCD 0...10V J1 J2 ABCD ABCD ±10V J1 J2 ABCD ABCD Analog outputs J3 (analog out 1) J4 (analog out 2) 0...20 mA J3 J4 ABCD ABCD 0...10V J3 J4 ABCD ABCD ±10V J3 J4 ABCD ABCD Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 79 Chapter 2 AFE in IP21 Rittal Enclosure Installation/Wiring 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 wired at the factory 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 results in malfunction of the system. You can program a digital input as an Enable input. The AFE software interprets the status of this input. If the application requires the AFE to be disabled without software interpretation, a `dedicated' hardware enable configuration can be used. Remove jumper J5 (Figure 39) and wire the enable input to Digital In 6 (see Table 19). Verify that [Digital In6 Sel], parameter 226 is set to `1' (Enable). Table 19 - Hardware Enable Configuration for AFE in IP21 Rittal Enclosure Signal Hardware Enable Jumper J5 Setting Hardware Enable J5 AB Input Programmable (no hardware enable) J5 AB Analog I/O Wiring Examples for AFE in IP21 Rittal Enclosure Input/Output Connection Example Potentiometer unipolar DC volt reference 10k Pot. recommended (2k m min) 3 4 6 6 7 Analog voltage input unipolar DC volt reference 3 4 0...10V input Analog current input unipolar DC volt reference 3 4 4...20 mA input Analog output ±10V, 4...20 mA bipolar +10V unipolar (shown) +8 9 Required Parameter Changes · Configure input for voltage: Parameter 200 and set appropriate jumper per Table 18. · Adjust scaling: Parameters 80/81 and 204/205 · View Results: Parameter 018 · Configure input for voltage: Parameter 200 and set appropriate jumper per Table 18. · Adjust scaling: Parameters 80/81 and 204/205 · View results: Parameter 018 · Configure input for current: Parameter 200 and set appropriate jumper per Table 18. · Adjust scaling: Parameters 80/81 and 204/205 · View results: Parameter 018. · Configure with Parameter 207 and set appropriate jumper per Table 18. · Select source value: Parameter 209 - [Analog Out1 Sel] · Adjust scaling: Parameters 210/211 80 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Precharging the AFE AFE in IP21 Rittal Enclosure Installation/Wiring Chapter 2 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. For correct operation of the precharging circuit, the input circuit breaker and the precharging circuit contactor must be controlled by the AFE. Table 20 - Total DC Bus Capacitance Limits for Precharging Circuit of AFE in IP21 Rittal Enclosure Frame Size 10 13 Resistance 2 x 20 2 x 11 Capacitance, min (1) 9900 F 29,700 F Capacitance, max (2) 70,000 F 128,000 F (1) The minimum capacitance is built into the AFE. (2) The maximum capacitance is the capacitance of the AFE plus the external capacitance. ATTENTION: If the maximum capacitance is exceeded, component damage in AFE occurs. Important Guidelines Read and understand these guidelines: · If drives without internal precharge are used and a disconnect is installed between the input of the drive and the DC bus, you must use an external precharge circuit between the disconnect and the DC input of the drive. · If drives with internal precharge are used with a disconnect switch to the common bus, you must connect an auxiliary contact on the disconnect to a digital input of the drive. The corresponding input must be set to the `Precharge Enable' option. This option provides the proper precharge interlock, guarding against possible damage to the drive when connected to a common DC bus. · The precharge status of the AFE must be interlocked with the connected drives, such that the drives are disabled (not running) when the AFE is in a precharge state. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 81 Chapter 2 AFE in IP21 Rittal 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 here when installed according to this User Manual and the PowerFlex drive Reference Manual. Declarations of Conformity are available online at this link: http://www.rockwellautomation.com/certification/overview.page Low Voltage Directive (2006/95/EC) EN61800-5-1 Adjustable speed electrical power drive systems Part 5-1: Safety requirements Electrical, thermal and energy. EMC Directive (2004/108/EC) EN61800-3 Adjustable speed electrical power drive systems Part 3: EMC product standard including specific test methods. General Notes · The AFE can cause radio frequency interference if used in a residential or domestic environment. You are required to take measures to help prevent interference, and follow the essential requirements for CE compliance listed here, if necessary. · Conformity of the AFE with CE EMC requirements does not guarantee an entire machine or installation complies with CE EMC requirements. Many factors can influence total machine/installation compliance. Essential Requirements for CE Compliance Conditions 1...6 listed here must be satisfied for the PowerFlex Active Front End to meet the requirements of EN61800-3. 1. Use a standard PowerFlex Active Front End CE-compatible unit. 2. Review important precautions and attention statements throughout this document before installing the Active Front End. 3. Grounding as described on page 59. 82 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 AFE in IP21 Rittal Enclosure Installation/Wiring Chapter 2 4. Control (I/O) and signal wiring must be braided, shielded cable with a coverage of 75% or better, metal conduit, or have shielding/cover with equivalent attenuation. 5. All shielded cables must terminate with proper shielded connector. 6. Motor cables of DC input drives that are 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. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 83 Chapter 2 AFE in IP21 Rittal Enclosure Installation/Wiring Notes: 84 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Startup 3 Chapter This chapter describes how to start up the Active Front End. For a brief description of the HIM, see Appendix B. Topic Page AFE in IP20 2500 MCC Style Enclosure 85 AFE in IP21 Rittal Enclosure 90 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. To avoid electric shock hazard or damage to equipment, only qualified service personnel must perform the following procedure. Thoroughly read and understand the procedure before beginning. If an event does not occur while performing this procedure, do not proceed. Remove power, including user-supplied control voltages. User-supplied voltages can exist even when main AC power is not applied to the AFE. Correct the malfunction before continuing. The basic start-up procedure must be performed when starting a new AFE to verify the condition of the unit, and to configure essential parameters for operating the AFE. Names of the switches, push buttons, and status indicators are different for an AFE in an IP20 2500 MCC Style enclosure and an AFE in an IP21 Rittal enclosure. See the appropriate subsection for your enclosure. AFE in IP20 2500 MCC Style Enclosure This procedure requires that a HIM is 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 input circuit breaker is 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. Verify that AC line power at the disconnect device is within the rated value of the AFE. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 85 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. 091 [Reset to Defaults] Default: 0 Resets parameters to default configurations except parameters 093 [Language] and Options: 0 090 [Param Access Lvl]. 1 0 (ready) = A new value can be entered. 2 1 (factory) = Resets parameters to default configurations. 3 2 (low voltage) = Resets parameters to default configurations and configures parameters for a: 400/480V AFE unit for 400V operation. 600/690V AFE unit for 600V operation. 3 (high voltage) = Resets parameters to default configurations and configures parameters for a: 400/480V AFE unit for 480V operation. 600/690V AFE unit for 690V operation. IMPORTANT: The DC bus voltage must be present to set the voltage class. Ready Ready Factory Low voltage High voltage 3. Use the HIM to enter the Assisted Start-up procedure. Step a. In the Main Menu, use the or key to scroll to `Start Up'. b. Press the (Enter) key. Example LCD Display F-> Stopped Auto 0.0 Volt Main Menu: Memory Storage Start Up Preferences Main Menu: Startup Figure 41 - Active Front End Start-up Procedure Menu Input Voltage Select Alarm/Flt Cnfg Limits DC Bus Ctrl Start/Stop/I/O Sets Input Voltage Defines Configurable Alarms and Faults Sets Current and Power Limits Sets the DC Bus Voltage Reference Configures Digital Inputs (including Run), Digital Outputs, and Analog Outputs 86 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 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. For basic applications, the default settings for the parameters 75 [Motor Power Lmt], 76 [Regen Power Lmt], and 77 [Current Lmt Val] can be used. By default, [Regen Power Lmt] and [Current Lmt Val] are set to let maximum peak power flow from the DC bus to the AC line, and helps prevent DC bus overvoltage faults on the inverters. To accept each default setting, press Enter. 7. Enter the DC Bus Ctrl section of the Start-up routine. By default, the DC bus voltage reference is set to come from parameter 61 [DC Volt Ref ]. With this setting, the DC Volt Ref is calculated based on the selected AC input voltage. For basic applications, this setting for the DC bus voltage reference is sufficient. To accept each default setting, press Enter. 8. Enter the Start/Stop/IO section. Parameters 221...225 [Digital In 1...5 Sel] and parameters 228, 229, and 233 [Digital Out 1...3 Sel] are set to run the AFE from the operator switches on the AFE door (see Figure 23 on page 45 for the typical I/O wiring diagram). To run the AFE through a network communication adapter, change digital input 1 from `Run' to `Not Used', and send a Start command through the communication adapter. (For DPITM communication details, see DPI Communication Configurations on page 152.) To accept each default setting, press Enter. Analog outputs can also be programmed through this procedure if desired. 9. Disable the AFE output when the AFE is not active (not modulating). Connect the `Inverter Enable' output of the AFE to the variable frequency drive enable input, or enable parameter 132 [Contact Off Cnfg] to force off the main contactor if there is a fault. This configuration makes sure that once the AFE stops modulating, there is no motoring current flowing through the AFE IGBT diodes. Failure to disable the AFE output can result in component damage or a reduction in product life. When enabling parameter 132, see page 109 for details. The AFE is shipped with parameter 132 disabled. This disabled parameter does not stop or shut down DC output when a fault occurs. 10. To complete the Assisted Start-up procedure, select Done/Exit. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 87 Chapter 3 Startup Status Indicators For information on AFE status indicators, see AFE Status on page 125. Control Devices Figure 42 shows the operators or control devices (switches, push buttons, and status indicators) on an IP20 2500 MCC Style enclosure. Figure 42 - Control Devices for AFE in IP20 2500 MCC Style Enclosure AFE FAULT AFE READY AFE RESET OFF -- ON -- START ON OFF START (REM -- MAN -- AUTO) MAN REM AUTO The AFE READY status indicator lights up when precharge is completed, the input contactor K1 is closed, AC power is connected to the AFE, and no faults are active. The AFE READY status indicator operates independent of the control method. The AFE FAULT status indicator lights to indicate that the AFE is in a fault state. In an overcurrent situation, the fault that caused the input circuit breaker (Q0) to trip must be identified and fixed before resetting the breaker. Modes of Operation There are three different modes in which the contactor and precharge can be controlled. The desired control is selected with the REM-AUTO-MAN selector switch. 1. AUTO Automatic operation that precharges and closes the contactor when the supply voltage is energized. a. Set the REM-AUTO-MAN switch to AUTO. b. Set the OFF-ON-START switch to ON. 88 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Startup Chapter 3 The precharging of the units 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. IMPORTANT Pressing the (Stop) key on the HIM only stops the AFE output it does not open the input contactor to stop the AFE. When a voltage drop or a blackout occurs in the supplying network, the unit precharges automatically and closes the input contactor when the main supply voltage returns. 2. MAN Manual operation by the OFF-ON-START switch on the enclosure door. a. Set the REM-AUTO-MAN switch to MAN. b. Turn the OFF-ON-START switch to START and let it automatically return to ON. The precharging takes about 5...10 seconds depending on the connected DC bus capacitance. When the DC bus voltage has reached its nominal value, the AFE control closes the contactor. The precharging can be aborted by turning the switch to OFF. To stop the AFE, turn the OFF-ON-START switch to OFF. IMPORTANT Pressing the (Stop) key on the HIM only stops the AFE output--it does not open the input contactor to stop the AFE. When a voltage drop or a blackout occurs in the supplying network, the input contactor opens. To turn on the AFE, turn the OFF-ONSTART switch to START and let it automatically return to ON. 3. REM Remote operation with signals to the control terminals. a. Set the REM-AUTO-MAN switch to REM. b. Connect a normally closed (NC) contact to terminals X3:58 and X3:61. This contact has to be in the NC-state for the AFE to precharge and run. A remote pulse of 0.4...1.0 seconds duration, connected to terminals X3:57 and X3:60, starts the precharging of the AFE. When the DC voltage has reached its nominal value, the AFE unit automatically closes the input contactor. To stop the AFE, turn the OFF-ON-START switch to OFF. IMPORTANT Pressing the (Stop) key on the HIM only stops the AFE output--it does not open the input contactor to stop the AFE. When a voltage drop or a blackout occurs in the supplying network, the input contactor opens. When the supply is restored, the precharging must be reinitiated. To turn on the AFE, turn the OFFON-START switch to START and let it automatically return to ON. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 89 Chapter 3 Startup AFE in IP21 Rittal Enclosure This procedure requires that a HIM is 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. Verify that AC line power at the disconnect device is within the rated value of the AFE. 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 MCCB CONTROL switch to MAN. 7. Set the 0-1-START switch to 0 (off ). Programming the AFE 1. Push the AFE disconnect lever to on. 2. Set parameter 091 [Reset To Defaults] to the appropriate setting for your installation. 091 [Reset to Defaults] Default: 0 Resets parameters to default configurations except parameters 093 [Language] and Options: 0 090 [Param Access Lvl]. 1 0 (ready) = A new value can be entered. 2 1 (factory) = Resets parameters to default configurations. 3 2 (low voltage) = Resets parameters to default configurations and configures parameters for a: 400/480V AFE unit for 400V operation. 600/690V AFE unit for 600V operation. 3 (high voltage) = Resets parameters to default configurations and configures parameters for a: 400/480V AFE unit for 480V operation. 600/690V AFE unit for 690V operation. IMPORTANT: The DC bus voltage must be present to set the voltage class. Ready Ready Factory Low voltage High voltage 3. Use the HIM to enter the Assisted Start-up procedure. Step a. In the Main Menu, use the or key to scroll to `Start Up'. b. Press the (Enter) key. Example LCD Display F-> Stopped Auto 0.0 Volt Main Menu: Memory Storage Start Up Preferences 90 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Startup Chapter 3 See Figure 41 for the Active Front End start-up procedure. 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. For basic applications, the default settings for the parameters 75 [Motor Power Lmt], 76 [Regen Power Lmt], and 77 [Current Lmt Val] can be used. By default, [Regen Power Lmt] and [Current Lmt Val] are set to let maximum peak power flow from the DC bus to the AC line. This power flow helps to prevent DC bus overvoltage faults on the inverters. To accept each default setting, press Enter. 7. Enter the DC Bus Ctrl section of the Start-up routine. By default, the DC bus voltage reference is set to come from parameter 61 [DC Volt Ref ]. With this setting, the DC Volt Ref is calculated based on the selected AC input voltage. For basic applications, this setting for the DC bus voltage reference is sufficient. To accept each default setting, press Enter. 8. Enter the Start/Stop/IO section. Parameters 221...225 [Digital In 1...5 Sel] and parameters 228, 229, and 233 [Digital Out 1...3 Sel] are set to run the AFE from the operator switches on the AFE door (see Figure 40 on page 79 for the typical I/O wiring diagram). To run the AFE through a network communication adapter, change digital input 1 from `Run' to `Not Used', and send a Start command through the communication adapter. (For DPI communication details, see DPI Communication Configurations on page 152.) To accept each default setting, press Enter. Analog outputs can also be programmed through this procedure if desired. 9. Disable the AFE output when the AFE is not active (not modulating). Connect the `Inverter Enable' output of the AFE to the variable frequency drive enable input, or enable parameter 132 [Contact Off Cnfg] to force off the main contactor if there is a fault. This configuration makes sure that once the AFE stops modulating, there is no motoring current flowing through the AFE IGBT diodes. Failure to disable the AFE output can result in component damage or a reduction in product life. When enabling parameter 132, see page 109 for details. The AFE is shipped with parameter 132 disabled. This disabled parameter does not stop or shut down DC output when a fault occurs. 10. To complete the Assisted Start-up procedure, select Done/Exit. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 91 Chapter 3 Startup 92 Status Indicators For information on AFE status indicators, see AFE Status on page 125. Control Devices Figure 43 shows the operators or control devices (switches, push buttons, and status indicators) on an IP21 Rittal enclosure. Figure 43 - Control Devices for AFE in IP21 Rittal Enclosure MCCB FAULT AFE READY MCCB RESET 0 -- 1 -- START 1 START 0 MCCB CONTROL (REM -- MAN -- AUTO) MAN REM AUTO The AFE READY status indicator lights up when precharge is completed, the MCCB is closed, AC power is connected to the AFE, and no faults are active. The AFE READY status indicator operates independent of the control method. The MCCB FAULT status indicator lights to indicate that the circuit breakers are in a tripped state. In an overcurrent situation, the fault that caused the circuit breaker to trip must be identified and fixed before resetting the circuit breakers. The MCCB can be reset only by pressing the MCCB RESET push button when the MCCB CONTROL switch is in MAN. MCCB (Motor-controlled Circuit Breaker) and Modes of Operation There are three different modes in which the MCCB and precharge can be controlled. The desired control is selected with the MCCB CONTROL selector switch. 1. AUTO Automatic operation that automatically precharges and closes the MCCB when the supply voltage is energized. a. Set the MCCB CONTROL switch to AUTO. b. Set the 0-1-START switch to 1 (on). Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 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 ). IMPORTANT Pressing the (Stop) key on the HIM only stops the AFE output--it does not open the MCCB to stop the AFE. When a voltage drop or a blackout occurs in the supplying network, the unit precharges automatically and closes the circuit breakers when the main supply voltage returns. 2. MAN Manual operation by the 0-1-START switch on the enclosure door. a. Set the MCCB CONTROL switch to MAN. b. Turn the 0-1-START switch to START and let it automatically return to 1. The precharging takes about 5...10 seconds depending on the connected DC bus capacitance. When the DC bus voltage has reached its nominal value, the AFE control automatically closes the circuit breaker. The precharging can be aborted by turning the switch to 0 (off ). To stop the AFE, turn the 0-1-START switch to 0 (off ). IMPORTANT Pressing the (Stop) key on the HIM only stops the AFE output--it does not open the MCCB to stop the AFE. When a voltage drop or a blackout occurs in the supplying network, the under voltage release coil opens the circuit breaker. To turn on the AFE, turn the 0-1-START switch to START and let it automatically return to 1 (on). 3. REM Remote operation with signals to the control terminals. a. Set the MCCB CONTROL switch to REM. b. Connect a normally closed (NC) contact to terminals X1:58 and X1:61. This contact has to be in the NC-state for the AFE to precharge and run. A remote pulse of 0.4...1.0 seconds duration, connected to terminals X1:57 and X1:60, starts the precharging of the AFE. When the DC voltage has reached its nominal value, the AFE unit automatically closes the circuit breakers. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 93 Chapter 3 Startup To stop the AFE, turn the 0-1-START switch to 0 (off ). IMPORTANT Pressing the (Stop) key on the HIM only stops the AFE output it does not open the MCCB to stop the AFE. When a voltage drop or a blackout occurs in the supplying network, the undervoltage release coil opens the circuit breaker. When the supply is restored, the precharging and MCCB closing must be reinitiated. To turn on the AFE, turn the 0-1-START switch to START and let it automatically return to 1 (on). 94 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 About Parameters Programming and Parameters 4 Chapter This chapter provides a complete listing and description of the PowerFlex® Active Front End parameters. The parameters can be programmed (viewed or edited) by using a HIM. Alternatively, programming can be performed using a personal computer with a configuration tool such as Connected Components WorkbenchTM software, DriveExecutiveTM software, or DriveExplorerTM software. Topic Page About Parameters 95 How AFE Parameters are Organized 96 Monitor File 99 Dynamic Control File 101 Utility File 105 Communication File 111 Inputs and Outputs File 113 Parameter Cross Reference by Name 117 Parameter Cross Reference by Number 120 To configure the AFE to operate in a specific way, certain AFE parameters have to be configured appropriately. There are three types of parameters: · Numeric Parameters These parameters have a numeric value (such as 1V AC). · ENUM Parameters These parameters allow a selection from two or more items. The HIM displays a text message for each item. · Bit Parameters These parameters have individual bits associated with features or conditions. If the bit is 0, the feature is off or the condition is false. If the bit is 1, the feature is on or the condition is true. The following example table shows how each parameter type is presented in this manual. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 95 Chapter 4 Programming and Parameters Example Parameter Tables No. Parameter Name and Description Values File Group DYNAMIC CONTROL Control Modes 040 [Nom Input Volt] Default: Based on Unit Rating Sets the incoming supply voltage level that is used to calculate the DC voltage level for charging Min/Max: Based on Unit Rating control. Units: 1V AC 046 [Start/Stop Mode] Default: 0 Normal Selects the operating mode for the regenerative unit. 0 (Normal) = The converter starts only with a Run request. Options: 0 Normal 1 Auto 1 (Auto) = The converter starts regenerative operation automatically whenever the DC voltage is higher than the DC voltage reference and stops when there is no regeneration. The converter starts by a Run or Start command. To avoid starting, a digital input can be configured to `enable'. Auto mode selection is allowed only if an external motoring bus supply is installed. 154 [Logic Mask] Determines which communication adapters can control the unit. If the bit for an adapter is set to `0', the adapter has no control functions except for stop. DPI Port 5 DPI Port 4 DPI Port 3 DPI Port 2 DPI Port 1 Digital In Bit Definition Default Bit xxxxxxxxxx111111 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 0 = Control Permitted 1 = Control Masked x = Reserved COMMUNICATION Masks and Owners Description File Lists the major parameter file category. Group Lists the parameter group within a file. No. Parameter number. = Parameter value cannot be changed until the AFE is stopped. 32 = 32-bit parameter. Parameter Name and Description Parameter name as it appears on a HIM, with a brief description of the parameter function. Values Defines the various operating characteristics of the parameter. Three parameter types exist. ENUM Default: Lists the value assigned at the factory. Read Only = no default. Options: Displays the available programming selections. Bit Bit: Lists the bit place holder and definition for each bit. Numeric Default: Min/Max: Units: Lists the value assigned at the factory. Read Only = no default. The range (lowest and highest setting) possible for the parameter. Unit of measure and resolution as shown on the HIM. How AFE Parameters are Organized The HIM displays parameters in a File-Group-Parameter or Numbered List view order. To switch display mode, access the Main Menu, press the ALT key, and release it, and while the cursor is on the parameter selection, press the Sel key. In addition, parameter 090 [Param Access Lvl] can be set to display basic parameters (basic view) or all parameters (advanced view). File-Group-Parameter Order This organization groups parameters that are used for similar functions. The parameters are organized into files. Each file is divided into groups, and each group contains a set of parameters related to a specific purpose. By default, the HIM displays parameters by File-Group-Parameter view. 96 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Programming and Parameters Chapter 4 Basic Parameter View Parameter 090 [Param Access Lvl] set to option `0' (Basic). File Monitor Monitor Group Metering Converter Data Parameters Input Voltage AC Line Freq Total Current Rated kW Rated Volts 001 Active Current 004 Input Current S 007 002 Reactive Current 005 Input Current T 008 003 Input Current R 006 DC Bus Volt 011 030 Rated Amps 032 031 Control SW Ver 033 Dynamic Control Control Modes Nom Input Volt 040 Start/Stop Mode 046 Dynamic Control Voltage Loop DC Volt Ref Sel 060 DC Volt Ref 061 Limits Motor Power Lmt 075 Current Lmt Val 077 DC Bus Hi Alarm 079 Regen Power Lmt 076 DC Bus Lo Alarm 078 Utility Utility Converter Memory Param Access Lvl 090 Voltage Class 094 Reset to Defaults 091 Language 093 Diagnostics Start Inhibits 100 Dig In Status 102 Dig Out Status 103 Faults Fault Config 120 Alarms Alarm Config 135 Inputs and Analog Inputs Anlg In Config 200 Analog In 2 Hi 204 Outputs Analog In 1 Hi 201 Analog In 2 Lo 205 Analog In 1 Lo 202 Inputs & Outputs Analog Outputs Analog Out1 Sel 209 Analog Out2 Sel 212 Analog Out1 Hi 210 Analog Out2 Hi 213 Analog Out1 Lo 211 Analog Out2 Lo 214 Digital Inputs Digital In1 Sel 221 Digital In4 Sel 224 Digital In2 Sel 222 Digital In5 Sel 225 Digital In3 Sel 223 Digital In6 Sel 226 Digital Outputs Digital Out1 Sel 228 Digital Out3 Sel 233 Digital Out2 Sel 229 Dig Out3 Invert 234 Dig Out2 Invert 230 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 97 Chapter 4 Programming and Parameters Advanced Parameter View Parameter 090 [Param Access Lvl] set to option `1' (Advanced). File Group Parameters Monitor Monitor Metering Input Voltage AC Line Freq Total Current Active Current Reactive Current Input Current R Input Current S Input Current T 001 I Imbalance 002 Ground Current 003 DC Bus Volt 004 DC Bus Current 005 AC Line kW 006 AC Line kVar 007 AC Line kVA 008 Power Factor 009 Heatsink Temp 017 010 Cmd DC Volt 018 011 Motoring MWh 019 012 Regen MWh 020 013 Elapsed Run Time 021 014 Analog In1 Value 022 015 Analog In2 Value 023 016 Converter Data Rated kW Rated Volts 030 Rated Amps 032 031 Control SW Ver 033 Dynamic Control Control Modes Nom Input Volt 040 RatedLineCurrent 045 Auto Stop Level 049 PWM Frequency 041 Start/Stop Mode 046 Contact On Delay 050 Dynamic Control Modulation Type 042 Restart Delay 047 Control Options 051 Modulation Index 043 Stop Delay 048 Restart Modes AutoRstrt Config 052 Auto Rstrt Tries 053 Auto Rstrt Delay 054 Voltage Loop DC Volt Ref Sel 060 DC Volt Kp 062 DC Volt Ref 061 DC Volt Ki 063 Current Loop Active I Ref 064 Active I Ki 067 Reactive I Sel 070 Reactive I Ref 065 Reactive I Kp 068 Active I Kp 066 Reactive I Ki 069 Limits Motor Power Lmt 075 DC Bus Lo Alarm 078 DC Ref Hi Lmt 081 Regen Power Lmt 076 DC Bus Hi Alarm 079 Ground I Lvl 082 Current Lmt Val 077 DC Ref Lo Lmt 080 Parallel Mode Droop 085 PWM Synch 086 Start Up Delay 087 Utility Utility Converter Memory Param Access Lvl 090 Reset Meters 092 Voltage Class 094 Reset To Defaults 091 Language 093 Diagnostics Cnvrtr Status 1 095 Dig Out Status 103 Alarm 2 @ Fault 111 Cnvrtr Status 2 096 Fault Frequency 104 Testpoint 1 Sel 112 Cnvrtr Alarm 1 097 Fault Total Curr 105 Testpoint 1 Data 113 Cnvrtr Alarm 2 098 Fault Bus Volts 106 Testpoint 2 Sel 114 DC Ref Source 099 Fault Temp 107 Testpoint 2 Data 115 Start Inhibits 100 Status 1 @ Fault 108 Cnvrtr OL Count 116 Last Stop Source 101 Status 2 @ Fault 109 Dig In Status 102 Alarm 1 @ Fault 110 Faults Fault Config 120 Fault 2 Code 125 Fault 3 Time 130 Fault Clear 121 Fault 3 Code 126 Fault 4 Time 131 Fault Clear Mode 122 Fault 4 Code 127 Contact Off Cnfg 132 Power Up Marker 123 Fault 1 Time 128 Cnvrtr OL Factor 133 Fault 1 Code 124 Fault 2 Time 129 Alarms Alarm Config 135 Alarm 1 Code 137 Alarm 3 Code 139 Alarm Clear 136 Alarm 2 Code 138 Alarm 4 Code 140 Communication Communication Comm Control DPI Baud Rate Cnvrtr LogicRslt Masks and Owners Logic Mask Fault Clr Mask 150 DPI Port Sel 151 DPI Port Value 154 Stop Owner 155 Start Owner 152 153 156 Fault Clr Owner 158 157 Datalinks Data In A1 Data In A2 Data In B1 Data In B2 Data In C1 Data In C2 170 Data In D1 176 Data Out C1 184 171 Data In D2 177 Data Out C2 185 172 Data Out A1 180 Data Out D1 186 173 Data Out A2 181 Data Out D2 187 174 Data Out B1 182 175 Data Out B2 183 Inputs and Outputs Inputs & Outputs Analog Inputs Anlg In Config Analog In 1 Hi Analog In 1 Lo 200 Analog In 1 Loss 203 Analog In 2 Loss 206 201 Analog In 2 Hi 204 202 Analog In 2 Lo 205 Analog Outputs Anlg Out Config 207 Analog Out1 Lo 211 Anlg Out1 Scale 215 Anlg Out Absolut 208 Analog Out2 Sel 212 Anlg Out2 Scale 216 Analog Out1 Sel 209 Analog Out2 Hi 213 Anlg Out1 Setpt 217 Analog Out1 Hi 210 Analog Out2 Lo 214 Anlg Out2 Setpt 218 Digital Inputs Digital In1 Sel 221 Digital In3 Sel 223 Digital In5 Sel 225 Digital In2 Sel 222 Digital In4 Sel 224 Digital In6 Sel 226 Digital Outputs Dig Out Setpt Digital Out1 Sel Digital Out2 Sel Dig Out2 Invert 227 Dig Out2 OnTime 231 Dig Out3 OnTime 235 228 Dig Out2 OffTime 232 Dig Out3 OffTime 236 229 Digital Out3 Sel 233 230 Dig Out3 Invert 234 98 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Programming and Parameters Chapter 4 Monitor File No. Parameter Name and Description Values File Group MONITOR Metering 001 [Input Voltage] Default: Read Only Displays the incoming supply voltage, only when the AFE is in the Run state. Min/Max: 0.0/1000.0V AC Units: 0.1V AC 002 [AC Line Freq] Default: Read Only Displays the supply frequency. The sign indicates the phase order, only when the AFE is in the Run state. Min/Max: -63.0/63.0 Hz Units: 0.1 Hz 003 [Total Current] Default: Read Only 32 Displays the total AC input current present at L1, L2, and L3 inputs. Min/Max: 0.0/[Rated Amps] x 2 Units: 0.1 Amps 004 [Active Current] Default: Read Only 32 Displays the amount of AC input current that is in phase with the AC input fundamental voltage component. Positive value indicates motoring; negative value indicates regeneration. Min/Max: +/- [Rated Amps] x 2 Units: 0.1 Amps 005 [Reactive Current] Default: Read Only 32 Displays the amount of AC input current that is out of phase with the AC input fundamental voltage component. Positive value indicates inductive current; negative value indicates capacitive current. Min/Max: +/- [Rated Amps] x 2 Units: 0.1 Amps 006 [Input Current R] 007 [Input Current S] 008 [Input Current T] Displays the RMS value of the L1, L2, and L3 phase AC input current. Default: Read Only Min/Max: 0.0/6553.5 Amps Units: 0.1 Amps 009 [I Imbalance] Default: Read Only Displays the current imbalance calculated between phases L1, L2, and L3. Min/Max: 0.0/100.0% The RMS current for each phase is calculated by summing the instantaneous current squared as sampled Units: 0.1% at the PWM peak and valley, and then taking the square root of the sum every AC line cycle. The imbalance is then evaluated every AC line cycle by first finding the largest, smallest, and average phase current. Two equations are then used to calculate the value displayed: Based_on_Largest = (Largest - Average) x 100 / Average Based_on_Largest = (Largest - Average) x 100 / Average The equation that gives the higher value is used for the display. 010 [Ground Current] Default: Read Only Displays the ground current measured by summing the three input phase currents. Min/Max: 0.0/[Rated Amps] x 2 Units: 0.1 Amps 011 [DC Bus Volt] Default: Read Only Displays the filtered DC bus voltage. The filter time constant is 32 milliseconds. Min/Max: 0.0/Based on Unit Rating Units: 0.1V DC 012 [DC Bus Current] Default: Read Only 32 Displays the DC bus current. Positive value indicates motoring; negative value indicates regeneration. Min/Max: +/- Based on Unit Rating Units: 0.1 Amps 013 [AC Line kW] Default: Read Only 32 Displays the real power on the AC side. Positive value indicates motoring; negative value indicates regeneration. Min/Max: +/- Based on Unit Rating Units: 0.1 kW 014 [AC Line kVar] Default: Read Only 32 Displays the reactive power on the AC line. Min/Max: +/- Based on Unit Rating Units: 0.1 kVar 015 [AC Line kVA] Default: Read Only 32 Displays the apparent power on the AC line. Min/Max: 0.0/Based on Unit Rating Units: 0.1 kVA 016 [Power Factor] Default: Read Only Displays the power factor. Positive value indicates motoring power; negative sign indicates regenerative Min/Max: +/-1.00 power. Units: 0.01 017 [Heatsink Temp] Default: Read Only Displays the measured heatsink temperature. Min/Max: 0/200 °C Units: 1 °C Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 99 Chapter 4 Programming and Parameters File Group Metering MONITOR No. Parameter Name and Description Values 018 [Cmd DC Volt] Default: Read Only Displays the commanded DC bus voltage reference. Min/Max: 0.0/1500.0V DC Units: 0.1V DC 019 [Motoring MWh] Default: Read Only 32 Displays the accumulated motoring MWh. This parameter can be reset with parameter 092 [Reset Meters]. Min/Max: 0.0/429496729.5 MWh Units: 0.1 MWh 020 [Regen MWh] Default: Read Only 32 Displays the accumulated regenerative MWh fed back to the AC line. This parameter can be reset with Min/Max: 0.0/429496729.5 MWh parameter 092 [Reset Meters]. Units: 0.1 MWh 021 [Elapsed Run Time] Default: Read Only 32 Displays the accumulated amount of time that the AFE has been in Run. This parameter can be reset with Min/Max: 0.0/214748364.0 Hr parameter 092 [Reset Meters]. Units: 0.1 Hr 022 [Analog In1 Value] 023 [Analog In2 Value] Displays the value of the signal at the analog inputs. Default: Read Only Min/Max: 0.000/20.000 mA or -/+10.000V Units: 0.001 mA or 0.001V 030 [Rated kW] Default: Read Only 32 Displays the nominal power rating of the AFE. Min/Max: 0.00/3000.00 kW Units: 0.01 kW 031 [Rated Volts] Default: Read Only Displays the nominal input voltage class (400V, 480V, 600V, or 690V) of the AFE. Min/Max: 0.0/1000.0V AC Units: 0.1V AC 032 [Rated Amps] Default: Read Only Displays the nominal AC input current rating of the AFE. Min/Max: 0.0/6553.5 Amps Units: 0.1 Amps 033 [Control SW Ver] Default: Read Only Displays the software version of the main control board of the AFE. Min/Max: 0.000/255.255 Units: 0.001 Converter Data 100 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Programming and Parameters Chapter 4 Dynamic Control File No. Parameter Name and Description Values File Group DYNAMIC CONTROL Control Modes 040 [Nom Input Volt] Default: Based on Unit Rating Sets the incoming supply voltage level. It is used to calculate the DC voltage level for charging control. Min/Max: Based on Unit Rating Units: 1V AC 041 [PWM Frequency] Default: 3.6 kHz Sets the carrier frequency for the PWM output. This frequency is fixed to 3.6 kHz, and cannot be changed due to the LCL filter. Min/Max: 3.0/16.0 kHz Units: 0.1 kHz 042 [Modulation Type] Default: 2 Software 2 Selects the modulation type. Options: 0 0 (HW Modulator) = ASIC modulator with the classical third harmonic injection. The current distortion 1 is lower and spectrum is slightly better compared to the Software Modulator. 2 1 (Software 1) = Symmetric vector modulator with symmetrical zero vectors. Current distortion is less 3 than with software modulator 2 if boosting is used. HW Modulator Software 1 Software 2 Software 3 2 (Software 2) = Symmetric BusClamp, in which one switch always conducts 60° either to negative or positive DC-rail. Switching losses are reduced compared to the modulation type 0 and 1, and spectrum is narrow. 3 (Software 3) = Unsymmetrical BusClamp, in which one switch always conducts 120° to negative DCrail to reduce switching losses. Drawback is that upper and lower switches are unevenly loaded and spectrum is wide. We recommend using the Software 2 setting. For AFE parallel operation, the Software 3 setting in all AFEs must be used. 043 [Modulation Index] Default: 100% Sets the modulation index limit. The default setting of modulation index is 100%. To get the Min/Max: maximum 1 minute overload current (ND/HD), adjust the modulation index from 100% to 120%. Units: However, this adjustment affects the modulated output voltage and current waveform (THD) during overload operation. 20/200% 1% 045 [RatedLineCurrent] Default: Unit Current Sets the rated current of the supply transformer. This parameter can be set if the AFE is oversized compared to the supply or feeding transformer capacity. Min/Max: 0.0/6553.5 Amps Units: 1.0 Amps 046 [Start/Stop Mode] Default: 0 Normal Selects the operating mode for the AFE. 0 (Normal) = The AFE starts only with the Run request by a RUN or START command. Options: 0 Normal 1 Auto 1 (Auto) = The AFE starts regenerative operation automatically whenever the DC bus voltage is higher than the DC voltage reference, and stops when there is no regeneration. To avoid starting, a digital input can be configured to `Enable', and turning off the digital input stops the automatic starting. 047 [Restart Delay] Default: 220 ms Sets the minimum time between a previous stop command and the next start request to start the Min/Max: 0/32000 ms AFE. This parameter takes effect only if parameter 46 [Start/Stop Mode] is set to `0' (Normal). Units: 1 ms 048 [Stop Delay] Default: 100 ms Sets the off time delay between the removal of a Run request and stopping the modulation. This Min/Max: parameter takes effect only if parameter 046 [Start/Stop Mode] is set to `1' (Auto). The converter stops Units: modulating after [Stop Delay] when the converter changes from regenerative to motoring mode and the DC bus voltage is at least 3% below the DC voltage reference. 0/32000 ms 1 ms 049 [Auto Stop Level] Default: -3.0% Sets the active current level for the Auto operation mode when parameter 046 [Start/Stop Mode] is Min/Max: -100.0/100.0% set to `1' (Auto). When the active current value is higher than this value, the regeneration stops. Units: 1.0% 050 [Contact On Delay] Default: 0.40 secs Sets the Main contactor on delay time (the delay from Main contactor acknowledge to modulation Min/Max: 0.00/10.00 secs start). Units: 0.01 secs Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 101 Chapter 4 Programming and Parameters File Group Control Modes DYNAMIC CONTROL Restart Modes LCL OverTemp HeatsinkUndTp Anlg In Loss Ground Fault AC OverCurr IGBTOverTemp DC OverVolt DC UnderVolt Auxiliary In No. Parameter Name and Description Values 051 [Control Options] A set of bits to select AFE control options to disable different harmonic compensation. Bit Definition DC Ref Follow 5th Comp Off Default Bit xxxxxxxxxx1xxxxx 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 = Condition True 0 = Condition False x = Reserved · Bit 5 (5th Comp Off) Disables 5th harmonic elimination when Bit 5 = 1. · Bit 12 (DC Ref Follow) Allows the DC Voltage Reference to follow the AC Input Voltage if the input voltage is rising when Bit 12 = 1. In this case, the DC Bus Voltage Ref = P1 [Input Voltage] x P61 [DC Volt Ref] P40 [Nom Input Voltage]. However, the following limits apply to tracking the DC voltage Reference: Low Limit: Parameter 1 [Input Voltage] x 1.35 x 1.05 for all units High Limit: Parameter 40 [Nom Input Voltage] x 1.35 x 1.30 for 400V/480V units Parameter 40 [Nom Input Voltage] x 1.35 x 1.15 for 600V/690V units 052 [AutoRstrt Config] Selects the faults cleared by the auto restart function. Parameter 053 [AutoRstrt Tries] sets the attempt numbers. Bit Definition Default Bit xxxxxxx000010101 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 = Condition True 0 = Condition False x = Reserved 053 [Auto Rstrt Tries] Default: 0 Sets the maximum number of times the AFE attempts to reset a configured fault and restart. 0 = No automatic restarting after fault trip. Min/Max: 0/10 Units: None 054 [Auto Rstrt Delay] Default: 1.0 sec Sets the time between restart attempts when parameter 053 [Auto Rstrt Tries] is set to a value other Min/Max: 0.5/30.0 sec than zero. Units: 0.1 sec 060 [DC Volt Ref Sel] Default: 0 DC Volt Ref Selects the source of the DC bus voltage reference to the AFE. Options: 0 1 2 3 4 5 6 7 DC Volt Ref Analog In1 Analog In2 DPI Port 1 DPI Port 2 DPI Port 3 DPI Port 4 DPI Port 5 061 [DC Volt Ref] Default: Parameter 031 [Rated Volts] x 1.35 x 1.1 Sets the DC voltage reference. Used when parameter 060 [DC Volt Ref Sel] is set to `0' (DC Volt Ref). Min: Max: Units: [Rated Volts] x 1.35 x 1.05 [Rated Volts] x 1.35 x 1.3 (for 400/480V units) [Rated Volts] x 1.35 x 1.15 (for 600/690V units) 0.1V DC 062 [DC Volt Kp] Default: 200 Sets the proportional gain for the bus regulator to adjust regulator response. Min/Max: 0/10000 Units: None 063 [DC Volt Ki] Default: 0.0040 sec Sets the voltage loop integral gain for responsiveness of the bus regulator. Min/Max: 0.0000/6.0000 sec Units: 0.0001 sec Voltage Loop 102 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 File Group Current Loop Programming and Parameters Chapter 4 No. Parameter Name and Description Values 064 [Active I Ref] Default: Read Only Displays the active current reference. Min/Max: +/- 3200.0 Amp Units: 0.1 Amp 065 [Reactive I Ref] Default: 0.0 Amp If selected by [Reactive I Sel], this parameter sets the reference for the reactive current. This parameter Min/Max: can be used for power factor correction of the power system. Positive value gives inductive current; Units: negative value gives capacitive current. The maximum reactive current is limited by the following formula: +/- Based on parameter 032 [Rated Amps] 0.1 Amp Maximum Reactive I Ref = P032 [Rated Amps] 2 - P004 [Active Current] 2 066 [Active I Kp] Default: 400 Sets the active current controller gain. Min/Max: 0/4000 Units: None 067 [Active I Ki] Default: 0.0266 sec Sets the integral gain of the active current controller. Min/Max: 0.0000/6.0000 sec Units: 0.0001 sec 068 [Reactive I Kp] Default: 2000 Sets the synchronization controller gain. Min/Max: 0/32000 Units: None 069 [Reactive I Ki] Default: 0.040 sec Sets the integral of the synchronization controller. Min/Max: 0.000/20.000 sec Units: 0.001 sec 070 [Reactive I Sel] Default: 0 React I Ref Selects the source from which the reactive current is taken. Options: 0 1 2 React I Ref Analog In1 Analog In2 075 [Motor Power Lmt] Default: 300.0% Sets the limit for motoring power on the AC line. Min/Max: 0.1/300.0% Units: 0.1% 076 [Regen Power Lmt] Default: -300.0% Sets the limit for regenerative power allowed to the AC line. Min/Max: -0.1/-300.0% Units: 0.1% 077 [Current Lmt Val] Default: 1.5 x [Rated Amps] Sets the current limit value. Min/Max: 0.0/Based on Unit Rating Units: 0.1 Amps 078 [DC Bus Lo Alarm] Default: Based on Unit Rating Sets the lowest acceptable DC bus voltage for the application. A warning is indicated if the DC bus Min/Max: 0.0/2000.0V DC voltage falls below the value of this parameter. Units: 0.1V DC 079 [DC Bus Hi Alarm] Default: Based on Unit Rating Sets the highest acceptable DC bus voltage for the application. A warning is indicated if the DC bus Min/Max: 0.0/2000.0V DC voltage exceeds the value of this parameter. Units: 0.1V DC 080 [DC Ref Lo Lmt] Default: Read Only Displays the limit value of the DC bus reference low limitation, which is calculated based on the voltage class x 1.35 x 1.05. Min/Max: 0.0/1500.0V DC Units: 0.1V DC 081 [DC Ref Hi Lmt] Default: Read Only Displays the limit value of the DC bus reference high limitation. This limit is calculated based on the Min/Max: 0.0/1500.0V DC voltage class x 1.35 x 1.3 (for 400/480V units) or voltage class x 1.35 x 1.15 (for 600/690V units). Units: 0.1V DC 082 [Ground I Lvl] Default: 50.0% Sets the limit value of ground current in % of the unit rating before a ground current alarm or fault is Min/Max: 0.0/100.0% activated. For AFE parallel operation, the values in all AFEs must be set to 100%. Units: 0.1% (Based on unit rating) DYNAMIC CONTROL Limits Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 103 Chapter 4 Programming and Parameters File Group DYNAMIC CONTROL Parallel Mode No. Parameter Name and Description Values 085 [Droop] Default: 0.00% Sets the droop as % of active current reference for current balancing when AFEs are used in parallel Min/Max: 0.00/100.00% independent mode. It affects DC bus voltage if enabled. Recommended value for parallel AFEs is 5%. Units: 0.01% 086 [PWM Synch] Default: 0 Disabled Sets synchronization to reduce the circulating current between parallel connected AFEs when they are Options: 0 connected to the same DC bus and are fed from the same incoming power source without an isolation 1 transformer. In this case, parameter 085 [Droop] must be set to 5% in all AFEs, and this parameter 086 [PWM Synch] must be set to `1' (Enabled). Disabled Enabled 087 [Start Up Delay] Default: 0.00 sec Sets a starting delay when Run command is given. When programming different delay to parallel Min/Max: 0.00/300.00 sec AFEs, the AFEs start in sequence. Units: 0.01 sec 104 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Programming and Parameters Chapter 4 Utility File No. Parameter Name and Description Values File Group Converter Memory UTILIT Y 090 [Param Access Lvl] Selects the parameter display level. 0 (Basic) = Reduced parameter set. 1 (Advanced) = Full parameter set. 091 [Reset to Defaults] Resets parameters to factory defaults except parameters 093 [Language] and 090 [Param Access Lvl]. 0 (Ready) = A new value can be entered. 1 (Factory) = Resets parameters to factory defaults. 2 (Low Voltage) = Resets parameters to factory defaults and configures parameters for a: 400/480V AFE unit for 400V operation. 600/690V AFE unit for 600V operation. 3 (High Voltage) = Resets parameters to factory defaults and configures parameters for a: 400/480V AFE unit for 480V operation. 600/690V AFE unit for 690V operation. IMPORTANT: The DC bus voltage must be present to set the voltage class. 092 [Reset Meters] Resets these selected meters (Motoring MWh, Regen MWh, and Elapsed Time) to zero. 093 [Language] Limited to English language only. 094 [Voltage Class] Displays the last `Reset To Defaults' operation. 095 [Cnvrtr Status 1] Displays the present operating condition of the AFE. Bit Definition DCVoltRefD2 DCVoltRefD1 DCVoltRefD0 Cmd Delayed Regen CurLim Mot CurLim At Reference Faulted Alarm Droop Active In Precharge Regenerating Motoring Active Ready Default Bit x000000000000000 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 = Condition True 0 = Condition False x = Reserved · Bit 0 (Ready) indicates all inhibits are cleared. · Bit 1 (Active) indicates that the AFE is modulating. · Bit 2 (Motoring) indicates that the AFE is running in Motoring mode. · Bit 3 (Regenerating) indicates that the AFE is regenerating power to the AC line. · Bit 4 (In Precharge) indicates that the AFE is in precharging status. · Bit 5 (Droop Active) indicates that the droop function for AFE paralleling is activated. · Bit 6 (Alarm) indicates that the AFE has detected an alarm. · Bit 7 (Faulted) indicates that the AFE has detected a fault. · Bit 8 (At Reference) indicates that the DC bus voltage is at the command value. · Bit 9 (Mot CurLim) indicates that the AFE exceeds the current limit in Motoring mode. · Bit 10 (Regen CurLim) indicates that the AFE exceeds the current limit in regenerative mode. · Bit 11 (Cmd Delayed) indicates pending start command. · Bits 12...14 indicate the DC bus voltage reference selection. Default: 0 Options: 0 1 Basic Basic Advanced Default: 0 Options: 0 1 2 3 Ready Ready Factory Low Voltage High Voltage Default: Options: Default: Options: Default: Options: 0 Ready 0 Ready 1 Motoring MWh 2 Regen MWh 3 Elapsed Time 0 Not Selected 0 Not Selected 1 English Read Only 0 = Low Voltage 1 = High Voltage Read Only Bits Description 14 13 12 0 0 0 DC Volt Ref 0 0 1 Analog In1 0 1 0 Analog In2 0 1 1 DPI Port 1 1 0 0 DPI Port 2 1 0 1 DPI Port 3 1 1 0 DPI Port 4 1 1 1 DPI Port 5 Diagnostics Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 105 Chapter 4 Programming and Parameters File Group DPI at 500k AutoRst Act AutoRst Ctdn ModIndexLim Active Ready UTILITY Diagnostics No. Parameter Name and Description 096 [Cnvrtr Status 2] Displays the present operating condition of the AFE and active source. Bit Definition Default Bit xx0xxx00xxxxx000 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 = Condition True 0 = Condition False x = Reserved · Bit 0 (Ready) indicates all inhibits are cleared. · Bit 1 (Active) indicates that the AFE is modulating. · Bit 2 (ModIndexLim) indicates that the AFE reached the modulation index limitation. · Bit 8 (AutoRst Ctdn) indicates that the auto restart timer is counting down. · Bit 9 (AutoRst Act) indicates that the auto restart function is activated. · Bit 13 (DPI at 500k) indicates DPI communication with 500k of baud rate. 097 [Cnvrtr Alarm 1] Displays alarm conditions that presently exist in the unit. Bit Definition Values Read Only Read Only Overload DCBusHiAlarm DCBusLoAlarm DCRefHighLim DCRefLowLim LCL Fan Stop HeatsinkOvTp LineSyncFail Anlg In Loss DC UnderVolt Prechrg Actv Default Bit xxxxx11111111111 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 = Condition True 0 = Condition False x = Reserved · Bit 0 (Prechrg Actv) indicates that precharging is not completed. · Bit 1 (DC UnderVolt) indicates that the DC link voltage exceeded the limit. · Bit 2 (Anlg In Loss) indicates the analog input loss. · Bit 3 (LineSync Fail) indicates that the AC input line phase is missing. · Bit 4 (HeatsinkOv Tp) indicates that the heatsink temperature is over temperature (90 °C [194 °F]). · Bit 5 (LCL Fan Stop) indicates that the LCL fan has been stopped. · Bit 6 (DCRefLowLim) indicates that the DC voltage reference is less than the limit in parameter 080 [DC Ref Lo Lmt]. · Bit 7 (DCRefHighLim) indicates that the DC voltage reference exceeds the limit in parameter 081 [DC Ref Hi Lmt]. · Bit 8 (DCBusLo Alarm) indicates that the DC voltage is less than the value set by parameter 078 [DC Bus Lo Alarm]. · Bit 9 (DCBusHi Alarm) indicates that the DC voltage exceeds the value set by parameter 079 [DC Bus Hi Alarm]. · Bit 10 (Overload) indicates that parameter 003 [Total Current] exceeds the rated current. 098 [Cnvrtr Alarm 2] Displays alarm conditions that presently exist in the unit. Bit Definition Read Only Contact Fdbk DigInConflict Default Bit xxxxxxxxxxxxxx00 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 = Condition True 0 = Condition False x = Reserved · Bit 0 (DigInConflict) indicates that there is a conflict with the digital input settings. · Bit 1 (Contact Fdbk) indicates that there is no feedback from the main contact. 099 [DC Ref Source] Displays the source of the DC bus voltage reference to the unit. Default: Options: 0 1 2 3 4 5 6 7 Read Only DC Volt Ref Analog In1 Analog In2 DPI Port 1 DPI Port 2 DPI Port 3 DPI Port 4 DPI Port 5 106 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 File Group DPI Port 5 DPI Port 4 DPI Port 3 DPI Port 2 DPI Port 1 Startup Actv Params Reset Stop Assertd DC Bus Pchrg Enable Type 2 Alarm Fault Programming and Parameters Chapter 4 No. Parameter Name and Description Values 100 [Start Inhibits] Displays the inputs presently preventing the AFE from starting. Bit Definition Read Only Default Bit xx00000xx0000000 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 = Inhibit True 0 = Inhibit False x = Reserved · Bit 0 (Fault) is set when the AFE is faulted. · Bit 1 (Type 2 Alarm) is set when the AFE has an alarm of type 2. · Bit 2 (Enable) is set when the AFE is not enabled. · Bit 3 (DC Bus Pchrg) is set when the AFE is in precharging. · Bit 4 (Stop Assertd) is set when a stop command is asserted. · Bit 5 (Params Reset) is set when parameter 091 [Reset To Defaults] is reset to defaults. · Bit 6 (Startup Actv) is set when the AFE is in startup sequencing. · Bits 9...13 indicate that the AFE start is inhibited by the respective DPI port. 101 [Last Stop Source] Default: Displays the source that initiated the most recent stop sequence. It will be cleared (set to zero) during the next Options: start sequence. 102 [Dig In Status] Displays the status of the digital inputs. Bit Definition Default Bit xxxxxxxxxx000000 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Digital In6 Digital In5 Digital In4 Digital In3 Digital In2 Digital In1 1 = Input Present 0 = Input Not Present x = Reserved Read Only 0 Pwr Removed 1...5 DPI Port 1...5 6 Reserved 7 Digital In 8 Fault 9 Not Enabled Read Only 103 [Dig Out Status] Displays the status of the digital outputs. Bit Definition Read Only DigitalOut 3 DigitalOut 2 DigitalOut 1 Default Bit xxxxxxxxxxxxx000 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 = Output Present 0 = Output Not Present x = Reserved 104 [Fault Frequency] Captures and displays the AC line frequency at the time of the last fault. 105 [Fault Total Curr] 32 Captures and displays the DC bus amps at the time of the last fault. 106 [Fault Bus Volts] Captures and displays the DC bus voltage at the time of the last fault. 107 [Fault Temp] Captures and displays the heatsink temperature at the time of the last fault. Default: Min/Max: Units: Default: Min/Max: Units: Default: Min/Max: Units: Default: Min/Max: Units: Read Only -63.0/63.0 Hz 0.1 Hz Read Only 0.0/[Rated Amps] x 2 0.1 Amps Read Only 0/Max Bus Volts 1V DC Read Only 0/200 °C 1 °C UTILITY Diagnostic Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 107 Chapter 4 Programming and Parameters File Group DCVoltRefD2 DCVoltRefD1 DCVoltRefD0 Cmd Delayed Regen CurLim Mot CurLim At Reference Faulted Alarm Droop Active In Precharge Regenerating Motoring Active Ready UTILITY Diagnostic No. Parameter Name and Description 108 [Status 1 @ Fault] Captures and displays the bit pattern of parameter 095 [Cnvrtr Status 1] at the time of the last fault. Bit Definition Default Bit x000000000000000 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 = Condition True 0 = Condition False x = Reserved 109 [Status 2 @ Fault] Captures and displays the bit pattern of parameter 096 [Cnvrtr Status 2] at the time of the last fault. Bit Definition DPI at 500 k AutoRst Act AutoRst Ctdn ModIndexLim Active Ready Default Bit xx0xxx00xxxxx000 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 = Condition True 0 = Condition False x = Reserved 110 [Alarm 1 @ Fault] Captures and displays the bit pattern of parameter 097 [Cnvrtr Alarm 1] at the time of the last fault. Bit Definition Values Read Only Bits Description 14 13 12 0 0 0 DC Volt Ref 0 0 1 Analog In1 0 1 0 Analog In2 0 1 1 DPI Port 1 1 0 0 DPI Port 2 1 0 1 DPI Port 3 1 1 0 DPI Port 4 1 1 1 DPI Port 5 Read Only Read Only Overload DCBusHiAlarm DCBusLoAlarm DCRefHighLim DCRefLowLim LCL Fan Stop HeatsinkOvTp LineSyncFail Anlg In Loss DC UnderVolt Prechrg Actv Default x 0 x 0 0 0 0 0 0 0 0 0 0 0 0 0 Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 = Condition True 0 = Condition False x = Reserved 111 [Alarm 2 @ Fault] Captures and displays the bit pattern of parameter 098 [Cnvrtr Alarm 2] at the time of the last fault. Bit Definition Read Only Contact Fdbk DigInConflct Default x x x x x x x x x x x 0 x x 0 0 Bit 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 = Condition True 0 = Condition False x = Reserved 112 [Testpoint 1 Sel] Default: 499 Selects the function whose value is displayed in parameter 113 [Testpoint 1 Data]. These internal values are not Min/Max: 0/65535 accessible through parameters. Units: None 113 [Testpoint 1 Data] Default: Read Only Displays the present value of the function selected in parameter 112 [Testpoint 1 Sel]. Min/Max: -/+32767 Units: None 114 [Testpoint 2 Sel] Default: 499 Selects the function whose value is displayed in parameter 115 [Testpoint 2 Data]. These internal values are not Min/Max: 0/65535 accessible through parameters. Units: None 115 [Testpoint 2 Data] Default: Read Only Displays the present value of the function selected in parameter 114 [Testpoint 2 Sel]. Min/Max: -/+32767 Units: None 116 [Cnvrtr OL Count] Default: Read Only Displays the accumulated percentage of AFE overload. Continuously operating the AFE over the set level increases this value to 100% and cause an AFE fault. Min/Max: 0.1%/+100.0% Units: 0.1% 108 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 File Group AutoResetLim Overload LineSyncFail DC UnderVolt Programming and Parameters Chapter 4 No. Parameter Name and Description 120 [Fault Config] Enables/disables annunciation of the listed faults. Bit Definition Values Default Bit xxxxxxxxxx000x0x 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 = Enabled 0 = Disabled x = Reserved 121 [Fault Clear] Default: 0 Ready Resets a fault and clears the fault queue. 0 (Ready) = A new value can be entered. 1 (Clear Faults) = A fault is reset. Options: 0 1 2 Ready Clear Faults Clr Fault Que 2 (Clr Fault Que) = The fault queue is cleared. 122 [Fault Clear Mode] Default: 1 Enabled Enables/disables a fault reset (clear faults) attempt from any source. This mode does not apply to fault codes Options: 0 Disabled that are cleared indirectly through other actions. 1 Enabled 123 [Power Up Marker] Default: Read Only 32 Displays the elapsed hours since initial AFE power-up. This value rolls over to `0' after the AFE has been Min/Max: 0.0000/429496.7295 Hr powered on for more than the maximum value shown. For relevance to most recent power-up, see parameters Units: 0.0001 Hr 128...131 [Fault x Time]. 124 [Fault 1 Code] 126 [Fault 2 Code] 128 [Fault 3 Code] 130 [Fault 4 Code] Default: Read Only Min/Max: 0/65535 Units: None Displays a code that represents the fault that tripped the AFE. The codes appear in these parameters in the order they occur (parameter 124 [Fault 1 Code] = the most recent fault). 125 [Fault 1 Time] 127 [Fault 2 Time] 129 [Fault 3 Time] 131 [Fault 4 Time] Default: Read Only Min/Max: 0.0000/429496.7295 Hr Units: 0.0001 Hr 32 Displays the time between initial AFE power-up and the occurrence of the associated trip fault. The time that is shown by these parameters can be compared to parameter 123 [Power Up Marker] for the time from the most recent power-up. Therefore, [Fault x Time] - [Power Up Marker] = Time difference to the most recent powerup. A negative value indicates that the fault occurred before the most recent power-up. A positive value indicates that the fault occurred after the most recent power-up. 132 [Contact Off Cnfg] Configures faults that force the main contactor off in case of fault. This configuration is only possible if the precharge contactor is off or controlled over the network (digital output selection) and the AFE is supplied by an external 24V DC power supply. This configuration provides an option to protect the AFE when the AFE is faulted, modulating is stopped, and the motoring current can still flow through the IGBT diode. Bit Definition All Fault LCL OverTemp HeatsinkOvTp Overload AC OverCurr IGBTOverTemp DC OverVolt Auxiliary In Default Bit xxxxxx0000x000x0 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 = Enabled Contactor Off command from fault* 0 = Disabled Contactor Off command from fault x = Reserved *If enabled, the auto restart function is disabled. 133 [Cnvrtr OL Factor] Sets the operating level for the AFE overload. (AFE rated current) x (AFE OL Factor) = Operating Level Default: 1.00 Min/Max: 0.50/1.50 Units: None UTILIT Y Faults Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 109 Chapter 4 Programming and Parameters File Group UTILIT Y Alarms No. Parameter Name and Description 135 [Alarm Config] Enables/disables alarm conditions that initiate an AFE alarm. Bit Definition Values DCBusHiAlarm DCBusLoAlarm DCRefHighLim DCRefLowLim LCL Fan Stop HeatsinkOvTp LineSyncFail Anlg In Loss DC UnderVolt Prechrg Actv Default Bit xxxxxx1111111111 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 = Enabled 0 = Disabled x = Reserved · Bit 0 (Prechrg Actv) sets an alarm when the precharging is not completed. · Bit 1 (DC UnderVolt) sets an alarm when the DC link voltage exceeded the limit. · Bit 2 (Anlg In Loss) sets an alarm when the analog input is lost. · Bit 3 (LineSyncFail) sets an alarm when the AC input line phase is missing. · Bit 4 (HeatsinkOvTp) sets an alarm when the heatsink temperature is over temperature (90 °C [194 °F]). · Bit 5 (LCL Fan Stop) sets an alarm when the LCL fan has been stopped. · Bit 6 (DCRefLowLim) sets an alarm when the DC voltage reference is less than the limit in parameter 080 [DC Ref Lo Lmt]. · Bit 7 (DCRefHighLim) sets an alarm when the DC voltage reference exceeds the limit in parameter 081 [DC Ref Hi Lmt]. · Bit 8 (DCBusLoAlarm) sets an alarm when the DC voltage is less than the value set by parameter 078 [DC Bus Lo Alarm]. · Bit 9 (DCBusHiAlarm) sets an alarm when the DC voltage exceeds the value set by parameter 079 [DC Bus Hi Alarm]. 136 [Alarm Clear] Default: 0 Ready Resets all [Alarm 1...4 Code] parameters to `0'. Options: 0 Ready 1 Clr Alarm Que 137 [Alarm 1 Code] 138 [Alarm 2 Code] 139 [Alarm 3 Code] 140 [Alarm 4 Code] Default: Read Only Min/Max: 0/65535 Units: None Displays a code that represents a converter alarm. The codes appear in the order they occur ([Alarm 1 Code] = the most recent alarm). A time stamp is not available with alarms. 110 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Programming and Parameters Chapter 4 Communication File No. Parameter Name and Description Values File Group 150 [DPI Baud Rate] Displays the `500 kbps' baud rate that DPI uses for peripherals attached to the AFE. 151 [Cnvrtr Logic Rslt] Captures and displays the final Logic Command that results 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. Bit Definition Default: Read Only Read Only Cmd LogicOut Clear Fault Start Stop Comm Control COMMUNICATION Default Bit xxxxx0xx0xxx0x00 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 = Condition True 0 = Condition False x = Reserved 152 [DPI Port Sel] Selects which DPI port reference value appears in parameter 153 [DPI Port Value]. 153 [DPI Port Value] Displays the value of the DPI reference selected in parameter 152 [DPI Port Sel]. 154 [Logic Mask] Sets which adapters can control the AFE. If the bit for an adapter is set to `0', the adapter has no control functions except for stop. Default: Options: Default: Min/Max: Units: 1 DPI Port 1 1 DPI Port 1 2 DPI Port 2 3 DPI Port 3 4 DPI Port 4 5 DPI Port 5 Read Only 0.0/1500.0V DC 0.1V DC DPI Port 5 DPI Port 4 DPI Port 3 DPI Port 2 DPI Port 1 Digital In Bit Definition Default Bit xxxxxxxxxx111111 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 = Control Permitted 0 = Control Masked x = Reserved 155 [Fault Clr Mask] Sets which adapters can clear a fault. 156 [Stop Owner] Displays the adapters that are presently issuing a valid stop command. Bit Definition Default Bit xxxxxxxxxx000001 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 DPI Port 5 DPI Port 4 DPI Port 3 DPI Port 2 DPI Port 1 Digital In See [Logic Mask]. Read Only 1 = digital outputIssuing Command 0 = No Command 157 [Start Owner] Displays the adapters that are presently issuing a valid start command. 158 [Fault Clr Owner] Displays the adapters that are presently clearing a fault. See [Stop Owner]. See [Stop Owner]. Masks and Owners Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 111 Chapter 4 Programming and Parameters File Group COMMUNICATION Datalinks No. Parameter Name and Description Values 170 [Data In A1] - Link A Word 1 Default: 0 (0 = Disabled) 171 [Data In A2] - Link A Word 2 Sets the parameter number whose value is written from a communication device data table. Min/Max: 0/236 Units: None 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. See the communication adapter User Manual for datalink information. 172 [Data In B1] - Link B Word 1 173 [Data In B2] - Link B Word 2 See [Data In A1] - Link A Word 1 [Data In A2] Link A Word 2. 174 [Data In C1] - Link C Word 1 175 [Data In C2] - Link C Word 2 See [Data In A1] - Link A Word 1 [Data In A2] Link A Word 2. 176 [Data In D1] - Link D Word 1 177 [Data In D2] - Link D Word 2 See [Data In A1] - Link A Word 1 [Data In A2] Link A Word 2. 180 [Data Out A1] - Link A Word 1 181 [Data Out A2] - Link A Word 2 Sets the parameter number whose value is written to a communication device data table. 182 [Data Out B1] - Link B Word 1 183 [Data Out B2] - Link B Word 2 184 [Data Out C1] - Link C Word 1 185 [Data Out C2] - Link C Word 2 186 [Data Out D1] - Link D Word 1 187 [Data Out D2] - Link D Word 2 Default: 0 (0 = Disabled) Min/Max: 0/236 Units: None See [Data Out A1] - Link A Word 1 [Data Out A2] Link A Word 2. See [Data Out A1] - Link A Word 1 [Data Out A2] Link A Word 2. See [Data Out A1] - Link A Word 1 [Data Out A2] Link A Word 2. 112 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 File Group Inputs and Outputs File No. Parameter Name and Description 200 [Anlg In Config] Selects the mode for the analog inputs. Bit Definition Programming and Parameters Chapter 4 Values An2 (0 = V, 1 = mA) An1 (0 = V, 1 = mA) Analog Inputs INPUTS and OUTPUTS Default Bit xxxxxxxxxxxxxx00 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 = Current 0 = Voltage x = Reserved 201 [Analog In 1 Hi] Default: 10.000V Sets the highest input value to the Analog Input 1 scaling block. Parameter 200 [Anlg In Config] defines if this input is -/+10V or 4...20 mA. Min/Max: Units: 4.000/20.000 mA -/+10.000V 0.001 mA 0.001V 202 [Analog In 1 Lo] Default: 0.000V Sets the lowest input value to the Analog Input 1 scaling block. Parameter 200 [Anlg In Config] defines if this input is -/+10V or 4...20 mA. Min/Max: Units: 4.000/20.000 mA -/+10.000V 0.001 mA 0.001V 203 [Analog In 1 Loss] Default: 0 Disabled Selects the AFE action when an analog signal loss is detected. Signal loss is defined as an analog signal Options: 0 less than 1V or 2 mA. The signal loss event ends and normal operation resumes when the input signal 1 level is greater than or equal to 1.5V or 3 mA. 2 3 4 Disabled Fault Hold Input Set Input Lo Set Input Hi 204 [Analog In 2 Hi] Default: 10.000V Sets the highest input value to the Analog Input 2 scaling block. Parameter 200 [Anlg In Config] defines if this input is -/+10V or 4...20 mA. Min/Max: Units: 4.000/20.000 mA -/+10.000V 0.001 mA 0.001V 205 [Analog In 2 Lo] Default: 0.000V Sets the lowest input value to the Analog Input 2 scaling block. Parameter 200 [Anlg In Config] defines if this input is -/+10V or 4...20 mA. Min/Max: Units: 4.000/20.000 mA -/+10.000V 0.001 mA 0.001V 206 [Analog In 2 Loss] Default: 0 Disabled Selects the AFE action when an analog signal loss is detected. Signal loss is defined as an analog signal Options: 0 less than 1V or 2 mA. The signal loss event ends and normal operation resumes when the input signal 1 level is greater than or equal to 1.5V or 3 mA. 2 3 4 Disabled Fault Hold Input Set Input Lo Set Input Hi 207 [Anlg Out Config] Selects the mode for the analog outputs. Bit Definition An2 (0 = V, 1 = mA) An1 (0 = V, 1 = mA) Analog Outputs Default x x x x x 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 1 = Current 0 = Voltage x = Reserved Important: Make sure that the jumpers are in the correct position or the output is wrong: J3 = Analog Output 1; J4 = Analog Output 2 Position AB = Current; Position BC = Voltage 0-10V (default); Position CD = Voltage -/+10V Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 113 Chapter 4 Programming and Parameters File Group INPUTS and OUTPUTS Analog Outputs No. Parameter Name and 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. Bit Definition Analog Out2 Analog Out1 Default Bit xxxxxxxxxxxxxx11 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 = Absolute 0 = Signed x = Reserved 209 [Analog Out1 Sel] Selects the source for Analog Output 1. Options 0 Input Volt 1 AC Line Freq 2 Total Curr 3 Active Curr 4 ReactiveCurr 5 Input Curr R 6 Input Curr S 7 Input Curr T 8 DC Bus Volt 9 DC Bus Curr 10 AC Line kW 11 AC Line kVar 12 AC Line kVA 13 Power Factor 14 DC Bus V Ref 15 Param Cntl (1) 16 TestPt Data1 [Analog Out1 Lo] Value Parameter [Anlg Out Absolut] = Signed Absolute 0V AC 0V AC 63.0 Hz 0 Hz 0 Amps 0 Amps 200% Rated 0 Amps 200% Rated 0 Amps 0 Amps 0 Amps 0 Amps 0 Amps 0 Amps 0 Amps 0V DC 0V DC 200% Rated 0 Amps 200% Rated 0 kW 200% Rated 0 kVar 0 kVA 0 kVA -1.00 0 P080 [V DC] P080 [V DC] -- -- -32767 0 [Analog Out1 Hi] Value 200% Rated (2) 63.0 Hz 200% Rated (3) 200% Rated (3) 200% Rated (3) 200% Rated (3) 200% Rated (3) 200% Rated (3) 300% Rated (2) 200% Rated (3) 200% Rated (4) 200% Rated (4) 200% Rated (4) 1.00 P081 [V DC] -- 32767 (1) Parameter controlled analog output allows PLC to control analog outputs through datalinks. Set in parameter 217 [Anlg Out1 Setpt] and parameter 218 [Anlg Out2 Setpt]. (2) 100% corresponds to parameter 031 [Rated Volts]. (3) 100% corresponds to parameter 032 [Rated Amps]. (4) 100% corresponds to parameter 030 [Rated kW]. Default: 0 = Input Volt Options: See Table 210 [Analog Out1 Hi] Sets the Analog Output 1 value when the source value is at maximum. 211 [Analog Out1 Lo] Sets the Analog Output 1 value when the source value is at minimum. 212 [Analog Out2 Sel] Selects the source for Analog Output 2. 213 [Analog Out2 Hi] Sets the Analog Output 2 value when the source value is at maximum. 214 [Analog Out2 Lo] Sets the Analog Output 2 value when the source value is at minimum. Default: Min/Max: Units: Default: Min/Max: Units: Default: Options: Default: Min/Max: Units: Default: Min/Max: Units: 20.000 mA, 10.000V 4.000/20.000 mA -/+10.000V 0.001 mA 0.001V 0.000 mA, 0.000V 4.000/20.000 mA -/+10.000V 0.001 mA 0.001V 0 = AC Line Freq See [Analog Out1 Sel] Table 20.000 mA, 10.000V 4.000/20.000 mA -/+10.000V 0.001 mA 0.001V 0.000 mA, 0.000V 4.000/20.000 mA -/+10.000V 0.001 mA 0.001V 114 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 File Group Analog Outputs INPUTS and OUTPUTS Programming and Parameters Chapter 4 No. Parameter Name and Description Values 215 [Anlg Out1 Scale] Default: 0.0 32 Sets the high value for the range of Analog Output 1 scale. Entering `0.0' disables this scale and the Min/Max: Based on [Analog Out1 Sel] maximum scale is used. Units: Based on [Analog Out1 Sel] Example: If parameter 209 [Analog Out1 Sel] = `DC Bus Volt', the maximum value is 2 * parameter 031 [Rated Volts] = 800V DC. By setting parameter 215 [Anlg Out1 Scale] = 600V DC, then 600V DC instead of 800V DC is used for the parameter 210 [Analog Out1 Hi] value at the analog output. 216 [Anlg Out2 Scale] Default: 0.0 32 Sets the high value for the range of Analog Output 2 scale. Entering `0.0' disables this scale and max Min/Max: Based on [Analog Out2 Sel] scale is used. Units: Based on [Analog Out2 Sel] Example: If parameter 212 [Analog Out2 Sel] = `DC Bus Volt', the maximum value is 2 * parameter 031 [Rated Volts] = 800V DC. By setting parameter 216 [Anlg Out2 Scale] = 600V DC, then 600V DC instead of 800V DC is used for the parameter 213 [Analog Out2 Hi] value at the analog output. 217 [Anlg Out1 Setpt] Default: 0.000 mA, 0.000V Sets the Analog Output 1 value from a communication device. Example: Set parameter 170 [Data In A1] to `217' (value from communication device). Then set parameter 209 [Analog Out1 Sel] to `Param Cntl'. Min/Max: Units: 4.000/20.000 mA -/+10.000V 0.001 mA 0.001V 218 [Anlg Out2 Setpt] Default: 0.000 mA, 0.000V Sets the Analog Output 2 value from a communication device. Example: Set parameter 171 [Data In A2] to `218' (value from communication device). Then set unit parameter 212 [Analog Out2 Sel] to `Param Cntl'. Min/Max: Units: 4.000/20.000 mA -/+10.000V 0.001 mA 0.001V 221 [Digital In1 Sel] 222 [Digital In2 Sel] 223 [Digital In3 Sel] 224 [Digital In4 Sel] 225 [Digital In5 Sel] (Only this parameter is fixed and non-configurable.) 226 [Digital In6 Sel] Default In1: 1 Default In2: 2 Default In3: 3 Default In4: 6 Default In5: 4 Default In6: 5 Run Clear Fault Enable Mcont ContactorAck LCL OverTemp Not Used Selects the function for the digital inputs. Options: 0 Not Used 1 (Run) - Selects the digital input to command the AFE to start modulating as long as the stop input is 1 Run not on. It is selectable for other functions, if the Run is controlled over DPI. 2 Clear Fault 2 (Clear Fault) - Selects the digital input, if a fault is pending, to clear it if the condition is no longer present. It is also selectable if this function is controlled by Comm Bus. 3 Aux Fault 4 LCL OverTemp 3 (Aux Fault) - Selects the digital input to be a customer-supplied external signal wired into the AFE unit. Opening this contact issues an external fault command, disabling the converter. 4 (LCL OverTemp) - Selects the digital input to be used as temperature protection to the LCL filter. 5 (LCL Fan Stop) - Selects the digital input to be used as an acknowledge signal from the LCL filter fan operation. 6 (ContactorAck) - Selects the digital input to be used as an acknowledge signal from the main 5 LCL Fan Stop 6 ContactorAck 7 Excl Link 8 Enable 9 Enable Mcont 10 Mcont Off contactor. 7 (Excl Link) - Selects the digital input to control a digital output. 8 (Enable) - Selects the digital input to allow a Run command. If J5 jumper on the digital input card is removed, the enable function is assigned to Digital Input 6 (enable input) and creates a fault if opened. 9 (Enable Mcont) - Selects the digital input, when opened, to command the main contactor to open. This option is to force the main contactor open and discharge the DC bus. 10 (Mcont Off) - Selects the digital input, when closed, to command the main contactor to open. This option is to force the main contactor open and discharge the DC bus. We recommend not to change the factory default wiring and setting, except that [Digital In6 Sel] can be configured for any other function. Digital Inputs Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 115 Chapter 4 Programming and Parameters File Group INPUTS and OUTPUTS Digital Outputs No. Parameter Name and 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. Bit Definition Net DigOut3 Net DigOut2 Default Bit xxxxxxxxxxxxx00x 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 1 = Output Energized 0 = Output Deenergized x = Reserved 228 [Digital Out1 Sel] Default: Read Only Digital Output 1 is specified for controlling the main contactor. This parameter is read only as `10' (Contact Ctrl). 229 [Digital Out2 Sel] Default 1: 1 Fault Selects the AFE status that energizes a (CRx) output relay. Options: (1) Any relay that is programmed as Fault or Alarm energizes (pick up) when power is applied to the AFE and de-energizes (drop out) when a fault or alarm exists. Relays selected for other functions energize only when that condition exists and de-energizes when the condition is removed. (2) These selections correspond to bits in parameter 097 [Cnvrtr Alarm]. Therefore, these selections work only if the corresponding alarm is configured in parameter 135 [Alarm Config]. (3) When a digital output is set to one of these options (for example, Input 3 Link) with Digital Input 3 set to `Excel Link', the Digital Input 3 state (on/off) is echoed in the digital output. (4) Bit 7 of parameter 151 [Cnvrtr LogicRslt] controls the digital output. (5) Parameter controlled digital output lets the PLC control digital outputs through data links. Set in parameter 227 [Dig Out Setpt]. (6) Charging contactor control over the network by Bit 7 of parameter 151 [Cnvrtr LogicRslt] and as soon as the main contactor is on, the output is switched off. An impulse over the network is enough to charge. Use this feature only if the control board is supplied from an external 24V DC power supply. 0 Not Used 1 Fault (1) 2 Alarm (1) 3 Ready 4 Active 5 Motoring 6 Regenerating 7 In Precharge 8 Current Limit 9 At Reference 10 Contact Ctrl 11 ContactorAck 12 Charge Cntrl (6) 13 Anlg In Loss (2) 14 DC UnderVolt (2) 15 DCRefLowLim (2) 16 DCRefHighLim (2) 17 Reserved 18... Input 1...6 Link (3) 23 LogicCmdBit (4) 24 Param Cntrl (5) 25 230 [Dig Out2 Invert] Default: 1 True Selects if the Digital Output 2 is inverted or not. Options: 0 False 1 True 231 [Dig Out2 OnTime] Default: 0.00 sec Sets the `ON Delay' time for Digital Output 2. This value is the time between the occurrence of a condition and activation of the relay. Min/Max: 0.00/163.00 sec Units: 0.01 sec 232 [Dig Out2 OffTime] Default: 0.00 sec Sets the `OFF Delay' time for Digital Output 2. This value is the time between the disappearance of a Min/Max: 0.00/163.00 sec condition and de-activation of the relay. Units: 0.01 sec 233 [Digital Out3 Sel] Default: 4 = Active See [Digital Out2 Sel]. Options: See [Digital Out2 Sel]. 234 [Dig Out3 Invert] Default: 0 False Selects if the Digital Output 3 is inverted or not. Min/Max: 0 False Units: 1 True 235 [Dig Out3 OnTime] Default: 0.00 sec Sets the `ON Delay' time for Digital Output 3. This value is the time between the occurrence of a condition and activation of the relay. Min/Max: 0.00/163.00 sec Units: 0.01 sec 236 [Dig Out3 OffTime] Default: 0.00 sec Sets the `OFF Delay' time for Digital Output 3. This value is the time between the disappearance of a Min/Max: 0.00/163.00 sec condition and de-activation of the relay. Units: 0.01 sec 116 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Programming and Parameters Chapter 4 Parameter Cross Reference by Name Parameter Name Number Group Page AC Line Freq 002 Metering 65 AC Line kVA 015 Metering 99 AC Line kVar 014 Metering 99 AC Line kW 013 Metering 99 Active Current 004 Metering 99 Active I Ki 067 Current Loop 103 Active I Kp 066 Current Loop 103 Active I Ref 064 Current Loop 103 Alarm 1 @ Fault 110 Diagnostics 108 Alarm 2 @ Fault 111 Diagnostics 108 Alarm Clear 136 Alarms 110 Alarm Config 135 Alarms 110 Alarm X Code 137...140 Alarms 110 Analog In 1 Hi 201 Analog Inputs 113 Analog In 1 Lo 202 Analog Inputs 113 Analog In 1 Loss 203 Analog Inputs 113 Analog In 2 Hi 204 Analog Inputs 113 Analog In 2 Lo 205 Analog Inputs 113 Analog In 2 Loss 206 Analog Inputs 113 Analog In1 Value 022 Metering 100 Analog In2 Value 023 Metering 100 Analog Out1 Hi 210 Analog Outputs 114 Analog Out1 Lo 211 Analog Outputs 114 Analog Out1 Sel 209 Analog Outputs 114 Analog Out2 Hi 213 Analog Outputs 114 Analog Out2 Lo 214 Analog Outputs 114 Analog Out2 Sel 212 Analog Outputs 114 Anlg In Config 200 Analog Inputs 113 Anlg Out Absolute 208 Analog Outputs 114 Anlg Out Config 207 Analog Outputs 113 Anlg Out1 Scale 215 Analog Outputs 115 Anlg Out1 Setpt 217 Analog Outputs 115 Anlg Out2 Scale 216 Analog Outputs 115 Anlg Out2 Setpt 218 Analog Outputs 115 Auto Rstrt Delay 054 Restart Modes 102 Auto Rstrt Tries 053 Restart Modes 102 Auto Stop Level 049 Control Modes 101 AutoRstrt Config 052 Restart Modes 102 Cmd DC Volt 018 Metering 100 Cnvrtr Alarm 1 097 Diagnostics 106 Cnvrtr Alarm 2 098 Diagnostics 106 Cnvrtr Logic Rslt 151 Comm Control 111 Cnvrtr OL Count 116 Diagnostics 108 Cnvrtr OL Factor 133 Faults 109 Cnvrtr Status 1 095 Diagnostics 105 Cnvrtr Status 2 096 Diagnostics 106 Contact Off Cnfg 132 Faults 109 Contact On Delay 050 Control Modes 101 Control Options 051 Control Modes 102 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 117 Chapter 4 Programming and Parameters Parameter Name Number Group Page Control SW Ver 033 Converter Data 100 Current Lmt Val 077 Limits 103 Data In AX 170, 171 Datalinks 112 Data In BX 172, 173 Datalinks 112 Data In CX 174, 175 Datalinks 112 Data In DX 176, 177 Datalinks 112 Data Out AX 180, 181 Datalinks 112 Data Out BX 182, 183 Datalinks 112 Data Out CX 184, 185 Datalinks 112 Data Out DX 186, 187 Datalinks 112 DC Bus Current 012 Metering 99 DC Bus Hi Alarm 079 Limits 103 DC Bus Lo Alarm 078 Limits 103 DC Bus Volt 011 Metering 99 DC Ref Hi Lmt 081 Limits 103 DC Ref Lo Lmt 080 Limits 103 DC Ref Source 099 Diagnostics 106 DC Volt Ki 063 Voltage Loop 102 DC Volt Kp 062 Voltage Loop 102 DC Volt Ref 061 Voltage Loop 102 DC Volt Ref Sel 060 Voltage Loop 102 Dig In Status 102 Diagnostics 107 Dig Out Setpt 227 Digital Outputs 116 Dig Out Status 103 Diagnostics 107 Dig Out2 Invert 230 Digital Outputs 116 Dig Out2 OffTime 232 Digital Outputs 116 Dig Out2 OnTime 231 Digital Outputs 116 Dig Out3 Invert 234 Digital Outputs 116 Dig Out3 OffTime 236 Digital Outputs 116 Dig Out3 OnTime 235 Digital Outputs 116 Digital InX Sel 221...226 Digital Inputs 115 Digital Out1 Sel 228 Digital Outputs 116 Digital Out2 Sel 229 Digital Outputs 116 Digital Out3 Sel 233 Digital Outputs 116 DPI Baud Rate 150 Comm Control 111 DPI Port Sel 152 Comm Control 111 DPI Port Value 153 Comm Control 111 Droop 085 Parallel Mode 104 Elapsed Run Time 021 Metering 100 Fault 1 Code 124 Faults 109 Fault 1 Time 125 Faults 109 Fault 2 Code 126 Faults 109 Fault 2 Time 127 Faults 109 Fault 3 Code 128 Faults 109 Fault 3 Time 129 Faults 109 Fault 4 Code 130 Faults 109 Fault 4 Time 131 Faults 109 Fault Bus Volts 106 Diagnostics 107 Fault Clear 121 Faults 109 Fault Clear Mode 122 Faults 109 118 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Programming and Parameters Chapter 4 Parameter Name Fault Clr Mask Fault Clr Owner Fault Config Fault Frequency Fault Temp Fault Total Curr Ground Current Ground I Lvl Heatsink Temp I Imbalance Input Current R Input Current S Input Current T Input Voltage Language Last Stop Source Logic Mask Modulation Index Modulation Type Motor Power Lmt Motoring MWh Nom Input Volt Param Access Lvl Power Factor Power Up Marker PWM Frequency PWM Synch Rated Amps Rated kW Rated Volts RatedLineCurrent Reactive Current Reactive I Ki Reactive I Kp Reactive I Ref Reactive I Sel Regen MWh Regen Power Lmt Reset Meters Reset To Defaults Restart Delay Start Inhibits Start Owner Start Up Delay Start/Stop Mode Status 1 @ Fault Status 2 @ Fault Stop Delay Stop Owner Testpoint 1 Data Number 155 158 120 104 107 105 010 082 017 009 006 007 008 001 093 101 154 043 042 075 019 040 090 016 123 041 086 032 030 031 045 005 069 068 065 070 020 076 092 091 047 100 157 087 046 108 109 048 156 113 Group Page Masks and Owners 111 Masks and Owners 111 Faults 109 Diagnostics 107 Diagnostics 107 Diagnostics 107 Metering 99 Limits 103 Metering 99 Metering 99 Metering 99 Metering 99 Metering 99 Metering 99 Converter Memory 105 Diagnostics 107 Masks and Owners 111 Control Modes 101 Control Modes 101 Limits 103 Metering 100 Control Modes 101 Converter Memory 105 Metering 99 Faults 109 Control Modes 101 Parallel Mode 104 Converter Data 100 Converter Data 100 Converter Data 100 Control Modes 101 Metering 99 Current Loop 103 Current Loop 103 Current Loop 103 Current Loop 103 Metering 100 Limits 103 Converter Memory 105 Converter Memory 105 Control Modes 101 Diagnostics 107 Masks and Owners 111 Parallel Mode 104 Control Modes 101 Diagnostics 108 Diagnostics 108 Control Modes 101 Masks and Owners 111 Diagnostics 108 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 119 Chapter 4 Programming and Parameters Parameter Name Testpoint 1 Sel Testpoint 2 Data Testpoint 2 Sel Total Current Voltage Class Number 112 115 114 003 094 Group Page Diagnostics 108 Diagnostics 108 Diagnostics 108 Metering 99 Converter Memory 105 Parameter Cross Reference by Number Number Parameter Name Group Page 001 Input Voltage Metering 99 002 AC Line Freq Metering 99 003 Total Current Metering 99 004 Active Current Metering 99 005 Reactive Current Metering 99 006 Input Current R Metering 99 007 Input Current S Metering 99 008 Input Current T Metering 99 009 I Imbalance Metering 99 010 Ground Current Metering 99 011 DC Bus Volt Metering 99 012 DC Bus Current Metering 99 013 AC Line kW Metering 99 014 AC Line kVar Metering 99 015 AC Line kVA Metering 99 016 Power Factor Metering 99 017 Heatsink Temp Metering 99 018 Cmd DC Volt Metering 100 019 Motoring MWh Metering 100 020 Regen MWh Metering 100 021 Elapsed Run Time Metering 100 022 Analog In1 Value Metering 100 023 Analog In2 Value Metering 100 030 Rated kW Converter Data 100 031 Rated Volts Converter Data 100 032 Rated Amps Converter Data 100 033 Control SW Ver Converter Data 100 040 Nom Input Volt Control Modes 101 041 PWM Frequency Control Modes 101 042 Modulation Type Control Modes 101 043 Modulation Index Control Modes 101 045 RatedLineCurrent Control Modes 101 046 Start/Stop Mode Control Modes 101 047 Restart Delay Control Modes 101 048 Stop Delay Control Modes 101 049 Auto Stop Level Control Modes 101 050 Contact On Delay Control Modes 101 051 Control Options Control Modes 102 052 AutoRstrt Config Restart Modes 102 053 Auto Rstrt Tries Restart Modes 102 120 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Programming and Parameters Chapter 4 Number 054 060 061 062 063 064 065 066 067 068 069 070 075 076 077 078 079 080 081 082 085 086 087 090 091 092 093 094 095 096 097 098 099 100 101 102 103 104 105 106 107 108 109 110 111 112 113 114 115 116 Parameter Name Group Page Auto Rstrt Delay Restart Modes 102 DC Volt Ref Sel Voltage Loop 102 DC Volt Ref Voltage Loop 102 DC Volt Kp Voltage Loop 102 DC Volt Ki Voltage Loop 102 Active I Ref Current Loop 103 Reactive I Ref Current Loop 103 Active I Kp Current Loop 103 Active I Ki Current Loop 103 Reactive I Kp Current Loop 103 Reactive I Ki Current Loop 103 Reactive I Sel Current Loop 103 Motor Power Lmt Limits 103 Regen Power Lmt Limits 103 Current Lmt Val Limits 103 DC Bus Lo Alarm Limits 103 DC Bus Hi Alarm Limits 103 DC Ref Lo Lmt Limits 103 DC Ref Hi Lmt Limits 103 Ground I Lvl Limits 103 Droop Parallel Mode 104 PWM Synch Parallel Mode 104 Start Up Delay Parallel Mode 104 Param Access Lvl Converter Memory 105 Reset To Defaults Converter Memory 105 Reset Meters Converter Memory 105 Language Converter Memory 105 Voltage Class Converter Memory 105 Cnvrtr Status 1 Diagnostics 105 Cnvrtr Status 2 Diagnostics 106 Cnvrtr Alarm 1 Diagnostics 106 Cnvrtr Alarm 2 Diagnostics 106 DC Ref Source Diagnostics 106 Start Inhibits Diagnostics 107 Last Stop Source Diagnostics 107 Dig In Status Diagnostics 107 Dig Out Status Diagnostics 107 Fault Frequency Diagnostics 107 Fault Total Curr Diagnostics 107 Fault Bus Volts Diagnostics 107 Fault Temp Diagnostics 107 Status 1 @ Fault Diagnostics 108 Status 2 @ Fault Diagnostics 108 Alarm 1 @ Fault Diagnostics 108 Alarm 2 @ Fault Diagnostics 108 Testpoint 1 Sel Diagnostics 108 Testpoint 1 Data Diagnostics 108 Testpoint 2 Sel Diagnostics 108 Testpoint 2 Data Diagnostics 108 Cnvrtr OL Count Diagnostics 108 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 121 Chapter 4 Programming and Parameters Number Parameter Name Group Page 120 Fault Config Faults 109 121 Fault Clear Faults 109 122 Fault Clear Mode Faults 109 123 Power Up Marker Faults 109 124 Fault 1 Code Faults 109 125 Fault 1 Time Faults 109 126 Fault 2 Code Faults 109 127 Fault 2 Time Faults 109 128 Fault 3 Code Faults 109 129 Fault 3 Time Faults 109 130 Fault 4 Code Faults 109 131 Fault 4 Time Faults 109 132 Contact Off Cnfg Faults 109 133 Cnvrtr OL Factor Faults 109 135 Alarm Config Alarms 110 136 Alarm Clear Alarms 110 137...140 Alarm X Code Alarms 110 150 DPI Baud Rate Comm Control 111 151 Cnvrtr Logic Rslt Comm Control 111 152 DPI Port Sel Comm Control 111 153 DPI Port Value Comm Control 111 154 Logic Mask Masks and Owners 111 155 Fault Clr Mask Masks and Owners 111 156 Stop Owner Masks and Owners 111 157 Start Owner Masks and Owners 111 158 Fault Clr Owner Masks and Owners 111 170, 171 Data In AX Datalinks 112 172, 173 Data In BX Datalinks 112 174, 175 Data In CX Datalinks 112 176, 177 Data In DX Datalinks 112 180, 181 Data Out AX Datalinks 112 182, 183 Data Out BX Datalinks 112 184, 185 Data Out CX Datalinks 112 186, 187 Data Out DX Datalinks 112 200 Anlg In Config Analog Inputs 113 201 Analog In 1 Hi Analog Inputs 113 202 Analog In 1 Lo Analog Inputs 113 203 Analog In 1 Loss Analog Inputs 113 204 Analog In 2 Hi Analog Inputs 113 205 Analog In 2 Lo Analog Inputs 113 206 Analog In 2 Loss Analog Inputs 113 207 Anlg Out Config Analog Outputs 113 208 Anlg Out Absolute Analog Outputs 114 209 Analog Out1 Sel Analog Outputs 114 210 Analog Out1 Hi Analog Outputs 114 211 Analog Out1 Lo Analog Outputs 114 212 Analog Out2 Sel Analog Outputs 114 213 Analog Out2 Hi Analog Outputs 114 214 Analog Out2 Lo Analog Outputs 114 215 Anlg Out1 Scale Analog Outputs 115 122 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Programming and Parameters Chapter 4 Number Parameter Name Group Page 216 Anlg Out2 Scale Analog Outputs 115 217 Anlg Out1 Setpt Analog Outputs 115 218 Anlg Out2 Setpt Analog Outputs 115 221...226 Digital InX Sel Digital Inputs 115 227 Dig Out Setpt Digital Outputs 116 228 Digital Out1 Sel Digital Outputs 116 229 Digital Out2 Sel Digital Outputs 116 230 Dig Out2 Invert Digital Outputs 116 231 Dig Out2 OnTime Digital Outputs 116 232 Dig Out2 OffTime Digital Outputs 116 233 Digital Out3 Sel Digital Outputs 116 234 Dig Out3 Invert Digital Outputs 116 235 Dig Out3 OnTime Digital Outputs 116 236 Dig Out3 OffTime Digital Outputs 116 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 123 Chapter 4 Programming and Parameters Notes: 124 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 AFE Status Troubleshooting 5 Chapter 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. Topic Page AFE Status 125 Faults and Alarms 126 Manually Clearing Faults 127 Fault and Alarm Descriptions 127 Clear the Alarms 131 Common Symptoms and Corrective Actions 131 Technical Support 135 The condition or state of the AFE is constantly monitored. The status indicators and/or the HIM (if present) indicate any changes. Front Panel Indications 1 2 Item Name Color State Description 1 PWR (power) Green Steady 2 PORT (1) MOD (1) NET A (1) See the Communication Adapter User Manual (publication 20COMMUMxxx) NET B (1) Illuminates when power is applied to the AFE. Status of DPITM port internal communication (if present). Status of communication adapter (when installed). Status of network (if connected). Status of secondary network (if connected). (1) These indicators operate only when a 20-COMM-X communication adapter is installed in the AFE and operating on the connected network. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 125 Chapter 5 Troubleshooting Faults and Alarms HIM Indication The HIM also provides visual notification of a fault or alarm condition. Condition AFE is indicating a fault. The HIM reports the fault condition and displays the following data: · `Faulted' appears in the status line · Fault number · Fault name · Time that has passed since fault occurred Press Esc to regain HIM control. Display F-> Faulted Auto 0.0 Volt -- Fault -- F 5 MaDiCn MOevneur: Volt DiTaginmoestiScsince Fault Parame0t0e0r 0:23:52 AFE is indicating an alarm. The HIM reports the alarm condition and displays the following data: · Alarm name (only type 2 alarms) · Alarm bell graphic F-> Power Loss Auto 0.0 Volt Main Menu: Diagnostics Parameter Device Select A fault is a condition that stops the AFE. There are three fault types. Fault Type Fault Description 1 Auto-reset run 2 Non-resettable 3 Configurable When this type of fault occurs, and [Auto Rstrt Tries] (page 102) is set to a value greater than `0', a user-configurable timer, [Auto Rstrt Delay] (page 102) begins. When the timer reaches zero, the AFE attempts to reset the fault. If the condition that caused the fault is no longer present, the fault is reset and the AFE is restarted. This type of fault normally requires AFE or motor repair. The cause of the fault must be corrected before the fault can be cleared. After repair, the fault is reset on power-up. These faults can be enabled and disabled to annunciate or ignore a fault condition by using [Fault Config] (page 109). An alarm is a condition that, if left untreated, can stop the AFE. There are two alarms types. Alarm Type Alarm Description 1 Configurable 2 Non-configurable These alarms can be enabled or disabled by using [Alarm Config] (page 110). These alarms are always enabled. See Fault and Alarm Descriptions on page 127. 126 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Manually Clearing Faults Troubleshooting 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). `Clear Faults' by using the HIM Diagnostic menu. Fault and Alarm Descriptions Table 21 - Fault/Alarm Types, Descriptions, and Actions No. Name Description Action (if appropriate) Fault Alarm 1 PrechargeActv 1 The charging switch is open, when the START command has been given. · Faulty operation · Component failure Reset the fault and restart. If the fault reoccurs, contact technical support (see page 135). 2 Auxiliary In 1 The auxiliary input interlock is open. Check all remote wiring. 4 DC UnderVolt 1 1 The DC bus voltage fell below the minimum value of Monitor the incoming AC line for low voltage or 3 333V for 400/480V AFEs or 461V for 600/690V AFEs. power interruption. You can enable/disable this fault with parameter 120 [Fault Config]. 5 DC OverVolt 1 The DC bus voltage exceeded the maximum value of 911V for 400/480V AFEs or 1200V for 600/690V AFEs. 1. Check if the AFE was in a regenerative current limit condition, which can indicate an excess regenerative load. 2. Adjust parameter [Regen Power Lmt]. 3. Monitor incoming AC line for high voltage or voltage transients. 7 Overload 3 When input current exceeds 125% for 60 seconds or Reduce the current consumption of the AFE or 150% for 30 seconds. The overload is a linear type in increase parameter 133 [Cnvrtr OL Factor]. counting up. 8 HeatsinkOvrTp 2 1 The heatsink temperature has exceeded the maximum allowable value. 85 °C (185 °F) = Alarm 90 °C (194 °F) = Fault 1. Verify that the maximum ambient temperature has not been exceeded. 2. Check the fans (including the ASIC board on frame 10 and higher converters). 3. Check for an excess load. 9 IGBT OverTemp 1 The output transistors have exceeded their maximum 1. Verify that the maximum ambient operating temperature due to an excessive load. temperature has not been exceeded. 2. Check the fan or fans. 3. Check for an excess load. 10 System Fault 2 A hardware problem exists in the power structure. 1. Cycle the power. 2. Verify the fiber-optic connections. 3. Contact technical support (see page 135). 4. If the problem persists, replace the converter unit. 12 AC OverCurr 1 The AC line current has exceeded the hardware current limit. Check programming for an excess load or other causes of excess current. 13 Ground Fault 1 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 2 A hardware problem exists in the power structure. 1. Cycle the power. 2. Contact technical support (see page 135). 3. If the problem persists, replace the converter unit. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 127 Chapter 5 Troubleshooting Table 21 - Fault/Alarm Types, Descriptions, and Actions (Continued) No. Name Description Action (if appropriate) Fault Alarm 17 LineSync Fail 2 1 One input line phase is missing. 3 1. Check all user-supplied fuses. 2. Check the AC input line voltage. 19 Unbalanced PU 2 An imbalance between the power modules exists (paralleled units - only Frame 13). 1. Check for DC voltage imbalance between the power modules. 2. Check for current input imbalance between the power modules. 21 Phase Loss 2 There is no current in one of the three phases. Check supply voltage, fuses, and cable. 29 Anlg In Loss 1 1 An analog input is configured to fault on a signal loss. 1. Check parameter settings. 3 A signal loss has occurred. Configure this fault with 2. Check for broken/loose connections at the parameter [Anlg In x Loss]. inputs. 30 MicroWatchdog 2 A microprocessor watchdog timeout has occurred. 1. Cycle the power. 2. Replace the main control board. 31 IGBT Temp Hw 2 The drive output current has exceeded the instantaneous current limit. 1. Check for an excess load. 2. Contact technical support (see page 135). 32 Fan Cooling 2 Fan is not energized at start command. 1. Check the status of parameter 097 [Cnvrtr Alarm 1] bit 5 (LCL Fan Stop). If set to `1', check the fan on the LCL filter. If set to `0', check the fan on the converter. 2. If the LCL filter fan is not operating, check its DC power supply. 33 AutoReset Lim 3 The AFE unsuccessfully attempted to reset a fault and Correct the cause and manually clear the fault. resumed running for the programmed number in parameter 053 [Auto Rstrt Tries]. You can enable/ disable this fault with parameter 120 [Fault Config]. 34 CAN Bus Flt 2 A sent message was not acknowledged. 1. Cycle the power. 2. Replace the main control board. 35 Application 1 Problem in application software with task overload. Contact technical support (see page 135). 37 HeatsinkUndTp 1 The ambient temperature is too low. Raise the ambient temperature. 44 Device Change 2 The new power unit or option board that is installed Clear the fault and reset the AFE to the default is a different type. configurations. 45 Device Add 2 A new option board was added. Clear the fault. 47 NvsReadChksum 2 There is an error reading parameters 019 [Motoring 1. Cycle the power. MWh], 020 [Regen MWh], and 021 [Elapsed Run 2. Replace the main control board. Time] from EEPROM. 54 Zero Divide 2 This event occurred because a mathematical function 1. Cycle the power. had a dividend of zero. 2. Replace the main control board. 58 Start Prevent 1 Startup has been prevented. 1. Cancel prevention of startup if the cancellation can be done safely. 2. Remove Run Request. 65 I/O Removed 2 An I/O option board has been removed. Clear the fault. 70 Power Unit 1 One or more of the IGBTs were operating in the active Clear the fault. region instead of desaturation. Excessive transistor current or insufficient base drive voltage causes this fault. 71 Periph Loss 2 The 20-COMM-x communication adapter has a fault Check the DPI device event queue and on the network side. corresponding fault information for the device. 128 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Troubleshooting Chapter 5 Table 21 - Fault/Alarm Types, Descriptions, and Actions (Continued) No. Name Description Action (if appropriate) Fault Alarm 81 Port DPI Loss 2 94 Hardware Enbl 2 100 Param Chksum 2 104 PwrBrd Chksum 2 106 MCB-PB Config 2 107 New IO Option 2 113 Fatal App 2 120 I/O Change 2 121 I/O Comm Loss 2 The DPI port has stopped communicating. A SCANportTM device was connected to a drive operating DPI devices at 500k baud. 1. If the adapter was not intentionally disconnected, check the wiring to the port. Replace the wiring, port expander, adapters, main control board, or complete AFE as required. 2. Check the HIM connection. 3. If an adapter was intentionally disconnected and the [Logic Mask] bit for that adapter is set to `1', this fault occurs. To disable this fault, set the bit in parameter [Logic Mask] for the adapter to `0'. An enable signal is missing from the control terminal 1. Check the control wiring. block. 2. Check the position of the hardware enable jumper. 3. Check the digital input programming. The checksum read from the main control board does 1. Restore the AFE to the default configurations. not match the checksum calculated. 2. Cycle the power. 3. Reload User Set, if used. The checksum read from the EEPROM does not match 1. Cycle the power. the checksum calculated from the EEPROM data. 2. Contact technical support (see page 135). 3. If the problem persists, replace the AFE. The AFE rating information that is stored on the power board is incompatible with the main control board. 1. Reset the fault or cycle the power. 2. Replace the main control board. A new option board was added to the main control 1. Restore the AFE to default configurations. board. 2. Reprogram parameters as necessary. A fatal application error has occurred. Replace the main control board. An option board has been replaced. Reset the fault. An I/O board lost communications with the main control board. 1. Check the connector. 2. Check for induced noise. 3. Replace I/O board or main control board. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 129 Chapter 5 Troubleshooting Table 21 - Fault/Alarm Types, Descriptions, and Actions (Continued) No. Name Description Action (if appropriate) Fault Alarm 125 LCL OverTemp 1 The LCL filter has been overheated or the signal is not Check the LCL filter sensor connections, the fan, connected to input. and fan power supply. There are nine total thermal switches that are connected in series to monitor temperature inside the coil of each filter inductor. Thermal Switch 1 X52 Thermal Switch 9 To Digital Input 5 X52 is on the LCL filter. X52 approximate location 128 Contact Fdbk 133 DigInConflict 138 DCRefLowLim 139 DCRefHighLim 140 DCBusLoAlarm 141 DCBusHiAlarm Frame 10 LCL Filter Frame 13 LCL Filter 2 The input of the acknowledge signal from the main Check if the main contactor is closed. contactor is missing. Check the wiring of the feedback signal. 2 Digital input functions are in conflict. Check the parameter settings to correct the problem. 1 DC voltage reference is less than the limit in parameter 080 [DC Ref Lo Lmt]. Check the parameter setting. 1 DC voltage reference exceeds the limit in parameter Check the parameter setting. 081 [DC Ref Hi Lmt]. 1 DC voltage is less than the value set by parameter Check the parameter setting. 078 [DC Bus Lo Alarm]. 1 DC voltage exceeds the value set by parameter 079 Check the parameter setting. [DC Bus Hi Alarm]. 130 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Troubleshooting Chapter 5 Fault Alarm Fault Alarm Table 22 - Fault/Alarm Cross-reference By Name Fault/Alarm Name AC OverCurr Anlg In Loss Application AutoReset Lim Auxiliary In CAN Bus Flt Contact Fdbk Converter Flt DC OverVolt DC UnderVolt DCBusHiAlarm DCBusLoAlarm DCRefHighLim DCRefLowLim Device Add Device Change DigIn Cnflct Fan Cooling Fatal App Ground Fault Hardware Enbl HeatsinkOvrTp HeatsinkUndTp No. 12 x 29 x x 35 x 33 x 2x 34 x 128 x 14 x 5x 4 xx 141 x 140 x 139 x 138 x 45 x 44 x 133 x 32 x 113 x 13 x 94 x 8 xx 37 x Fault/Alarm Name No. I/O Change 120 x I/O Comm Loss 121 x I/O Removed 65 x IGBT OverTemp 9 x IGBT Temp Hw 31 x LCL OverTemp 125 x LineSync Fail 17 x x MCB-PB Config 106 x MicroWatchdog 30 x New IO Option 107 x NvsReadChksum 47 x Overload 7x Param Chksum 100 x Periph Loss 71 x Phase Loss 21 x Port DPI Loss 81 x Power Unit 70 x PrechargeActv 1 x PwrBrd Chksum 104 x Start Prevent 58 x System Fault 10 x Unbalanced PU 19 x Zero Divide 54 x Clear the Alarms Alarms are automatically cleared when the condition that caused the alarm is no longer present. Common Symptoms and Corrective Actions Table 23 - AFE Does Not Start from Start or Run Inputs Wired to the Terminal Block Causes AFE is faulted Indication Flashing red status light Incorrect input wiring; see Control Wiring None on page 40 or Control Wiring on page 74 for wiring examples. IMPORTANT: Jumper between terminals 17, 18, and 20 is required when using the 24V DC internal supply. Corrective Action Clear fault. · Press the HIM (Stop) key. · Cycle power to the AFE. · Set parameter 121 [Fault Clear] to `1' (Clear Faults); see page 109. · `Clear Faults' by using the HIM diagnostic menu. Wire inputs correctly and/or install jumper. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 131 Chapter 5 Troubleshooting Causes Incorrect digital input programming. Indication None There is some other start inhibit. Check status bits of parameter 100 [Start Inhibits]. Corrective Action Program [Digital Inx Sel] for correct inputs (see page 115). Run programming can be missing. Correct the source of the inhibit. Table 24 - Instability in the AC Line Input Current and DC Bus Voltage Causes AC line voltage more than 5% above normal. Negative reactive I Ref on parameter 065 [Reactive I Ref] with a soft (high impedance) AC line. Indication Instability in AC line current and DC bus voltage. Can trip on fault F7 `Overload'. Instability in AC line current and DC bus voltage. Can trip an F7 overload. Corrective Action Increase parameter 060 [DC Volt Ref] proportional to the percentage of the AC line voltage above nominal. Change parameter 065 [Reactive I Ref] value to zero. Verify if the AFE is running on a soft line per AC line source considerations. 132 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Troubleshooting Chapter 5 Figure 44 - AFE Start Sequence Troubleshooting Diagram Init Software initialize complete. Ready to switch on. Charging the DC link with external charging circuit. DC link voltage No > 0.8*DC nominal? Yes Request to close No input contactor on Digital In3? Yes Input Contactor Close through Digital Out1, should be set = `Contact Ctrl' Input Contactor Ack (Digital Input 4, should be set = `Contactor Ack'; see No P102 - [Dig In Status] for digital input status) Yes Ready to Run (see P95 - [Cnvrtr Status1] Ready bit = 1) Run command from I/O, keypad or Fieldbus (depends on the selected control). Startup delay elapsed? No (see P087 - [Start Up Delay], default = 0 secs) Yes Synchronize with input. Sychronizing OK? Yes AFE Running (run LED is on) Sychronizing tries 5 No Yes Fault F10: LineSyncFail Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 133 Chapter 5 Troubleshooting Figure 45 - AFE Fault Handling Sequence Troubleshooting Diagram Yes New Run Command Edge? No AFE Running Fault Active Stop the AFE Is Input Contactor or Circuit Breaker Yes Open? No Fault Acknowledge Input Contactor or Circuit Breaker Open Fault Acknowledge Input Contactor or Circuit Breaker Closed 134 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Troubleshooting Chapter 5 Technical Support When you contact technical support, be prepared to provide this information: · Order number · Product catalog number and drives series number (if applicable) · Product serial number · Firmware revision level (verify with parameter 033 [Control SW Ver]) · Most recent fault code · Your application Parameter 104 105 106 107 108 109 110 111 124 126 128 130 125 127 129 131 137...140 Name Fault Frequency Fault Total Curr Fault Bus Volts Fault Temp Status 1 @ Fault Status 2 @ Fault Alarm 1 @ Fault Alarm 2 @ Fault Fault 1 Code Fault 2 Code Fault 3 Code Fault 4 Code Fault 1 Time Fault 2 Time Fault 3 Time Fault 4 Time Alarm Code 1...4 The data that are contained in the following parameters helps in initial troubleshooting of a faulted drive. Record the data provided for each listed parameter in this table. Description Captures and displays the AC line frequency at time of last fault. Captures and displays the DC bus amps at time of last fault. Captures and displays the DC bus voltage at time of last fault. Captures and displays the heatsink temperature at time of last fault. Captures and displays [Cnvrtr Status 1] bit pattern at time of last fault. Captures and displays [Cnvrtr Status 2] bit pattern at time of last fault. Captures and displays [Cnvrtr Alarm 1] bit pattern at time of last fault. Captures and displays [Cnvrtr Alarm 2] bit pattern at time of last fault. Displays a code that represents the fault that tripped the AFE. The codes appear in these parameters in the order they occur ([Fault 1 Code] equals the most recent fault). Recorded Parameter Data Displays the time between initial unit power-up and the occurrence of the associated trip fault. Can be compared to [Power Up Marker] for the time from the most recent power-up. [Fault x Time] - [Power Up Marker] = Time difference to the most recent power-up. A negative value indicates that fault occurred before most recent power-up. A positive value indicates that fault occurred after most recent power-up. Time stamp of the fault occurrence. Displays a code that represents a converter alarm. The codes appear in the order they occur ([Alarm 1 Code] = the most recent alarm). A time stamp is not available with alarms. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 135 Chapter 5 Troubleshooting Notes: 136 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Specifications Supplemental Information A Appendix Topic Page Specifications 137 Derating Guidelines 139 AFE Current Ratings and Watts Loss 140 Fusing and Circuit Breakers for AFE in IP20 2500 MCC Style Enclosure 141 Fusing and Circuit Breakers for AFE in IP21 Rittal Enclosure 142 Dimensions 143 DPI Communication Configurations 152 This table provides certification information. Certifications Description C-UL-US CE KCC UL and C-UL Listed to UL508C and CAN/CSA - 22.2 No. 14-05. UL Listing is applicable up to 600V AC. Marked for all applicable European Directives (1) EMC Directive (2014/35/EU) EN 61800-3 Adjustable speed electrical power drive systems Part 3: EMC requirements and specific test methods Low Voltage Directive (2014/30/EU) EN 61800-5-1 Adjustable speed electrical power drive systems Part 5-1: Safety requirements - Electrical, thermal and energy Korean KC registration(2) Regulatory compliance mark (RCM) Certified by Rockwell Automation to be in conformity with the requirements of the applicable Australian legislation and standards referenced here: IEC 61800-3 The AFE is also designed to meet the following specifications: NFPA 70 - US National Electrical Code NFPA 79 - Electrical Standard for Industrial Machinery 2002 Edition NEMA ICS 7.0 - Safety standards for Construction and Guide for Selection, Installation and Operation of Adjustable Speed Drive Systems (1) Applied noise impulses can be counted with the standard pulse train. These applied noise impulses can cause erroneously high [Pulse Freq] readings. (2) Registration KCC-REM-RAA-20A. See the certificate of registration for specific drive catalog numbers that have this certification. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 137 Appendix A Supplemental Information Category Protection Environment Electrical Control Specification AFE Voltage Class Bus overvoltage trip Bus undervoltage shutoff/fault Heat sink thermistor Ground fault protection Input phase loss protection Input overcurrent protection Overtemperature protection LCL filter overtemperature protection Line transients Control logic noise immunity Ground fault trip Altitude Max surrounding air temperature without derating Storage temperature (all constructions) Atmosphere Relative humidity Shock (non-operational) Vibration Sound: Frame 10 Frame 13 AC input voltage tolerance Frequency tolerance Input phases Displacement power factor Efficiency Short circuit rating: · AFE Frame 10 in IP20 · AFE Frame 13 in IP20 · AFE in IP21 or AFE IP00 AFE Voltage Class DC output voltage range Method Carrier frequency Intermittent overload: · Normal duty · Heavy duty Current limit capability 380/400V 480V 600V 690V 911V DC 911V DC 1200V DC 1200V DC 333V DC 333V DC 461V DC 461V DC Monitored by microprocessor overtemp trip Yes Yes Yes Yes Yes Up to 6000V peak per IEEE C62.41-1991 Showering arc transients up to 1500V peak DC bus-to-ground current exceeds par 082 [Ground I Lvl] value 1000 m (3300 ft) max. without derating 0...40 °C (32...104 °F); Frame 13 600/690V AFE is rated at 35 °C (95 °F). See Derating Guidelines on page 139 for derating above 35 °C (95 °F). 40...+60 °C (40...+140 °F) Important: The AFE unit must not be installed in an area where the ambient atmosphere contains volatile or corrosive gas, vapors, or dust. If the AFE is not going to be installed for some time, store the AFE in an area where it is not exposed to a corrosive atmosphere. 5...95% noncondensing 15G peak for 11 ms duration EN50178 / EN60068-2-27 1 mm (0.039 in.) displacement, 1G peak EN50178 / EN60068-2-6 71 dB at 1 m (3.28 ft) 80 dB at 1 m (3.28 ft) ±10% 48...63 Hz Three-phase input provides full rating for all AFEs. The AFE cannot be operated with single-phase input. 1.0 default across entire range 97.5% at rated amps, nominal line volts · 100 kA for 400/480V unit; 65 kA for 600/690V unit · 100 kA for 400/480V unit; 100 kA for 600/690V unit · Determined by AIC rating of installed fuse/circuit breaker 380/400V 480V 600V 690V 462...702 583...842 700...932 802...1071 Sine-coded PWM 3.6 kHz · 110% overload capability for up to 1 minute · 150% overload capability for up to 1 minute (this heavy-duty rating does not apply to Frame 13 600/690V AFEs Current limit programmable from 20...150% of rated input current. 138 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Derating Guidelines Supplemental Information Appendix A The following charts illustrate derating guidelines based on conditions. Ambient Temperature/Load 120 100 80 % of Rated Power 60 40 20 Frame 13, 600/690V 0 0 10 20 30 40 50 Ambient Temperature (°C) Frame 10, 400/480V Frame 10, 600/690V Frame 13, 400/480V 60 70 80 Altitude/Load 400/480V AC Input 120 100 80 % of Rated Power 60 40 20 0 0 500 1000 1500 2000 2500 3000 3500 4000 Installation Altitude Above Sea Level (m) Altitude/Load 600/690V AC Input 120 100 80 % of Rated Power 60 40 20 0 0 500 1000 1500 2000 2500 3000 Installation Altitude Above Sea Level (m) Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 139 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 20YD460... 20YD1K3... Frame Size 10 13 kW Rating ND HD 309 -- -- 258 873 -- -- 772 PWM AC Input Amps Freq. kHz Cont. 1 Min. 3.6 460 A 506 A 3.6 385 A 578 A 3.6 1300 A 1430 A 3.6 1150 A 1725 A DC Output Typical Amps Watts Loss Cont. 520 A 8000 W 435 A 1469 A 23,000 W 1299 A 480 Volt AC Input Ratings AFE Catalog Frame Hp Rating Number Size PWM AC Input Amps Freq. ND HD kHz Cont. 1 Min. 20YD460... 10 497 -- 3.6 460 A 506 A -- 416 3.6 385 A 578 A 20YD1K3... 13 1404 -- 3.6 1300 A 1430 A -- 1242 3.6 1150 A 1725 A DC Output Typical Amps Watts Loss Cont. 520 A 8000 W 435 A 1469 A 23,000 W 1299 A 600 Volt AC Input Ratings AFE Catalog Number 20YF325... 20YF1K0... Frame Size 10 13 (1) Hp Rating ND HD 439 -- -- 324 1390 -- PWM AC Input Amps Freq. kHz Cont. 1 Min. 3.6 325 A 358 A 3.6 240 A 360 A 3.6 1030 A 1133 A (1) Heavy-duty rating does not apply to Frame 13 600/690V AFE. DC Output Typical Amps Watts Loss Cont. 367 A 8000 W 272 A 1164 A 26,000 W 690 Volt AC Input Ratings AFE Catalog Number 20YF325... Frame Size 10 kW Rating ND HD 376 -- PWM AC Input Amps Freq. kHz Cont. 1 Min. 3.6 325 A 358 A -- 278 3.6 20YF1K0... 13 (1) 1193 -- 3.6 240 A 1030 A 360 A 1133 A (1) Heavy-duty rating does not apply to Frame 13 600/690V AFE. DC Output Typical Amps Watts Loss Cont. 367 A 8000 W 272 A 1164 A 26,000 W 140 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Supplemental Information Appendix A Fusing and Circuit Breakers for AFE in IP20 2500 MCC Style 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 an IP20 2500 MCC Style enclosure includes the recommended AC input fusing and circuit breaker. 400/480 Volt AC Fusing and Circuit Breaker Ratings Frame Size 10 13 Fuse Rating Amps Bussman Type 800 A 170M6696 2200 A 170M7090 Main Circuit Breaker Rating Amps ABB Type 600 A T5L600BW 1600 A T8VBC3FC000000xx 600/690 Volt AC Fusing and Circuit Breaker Ratings Frame Size 10 13 Fuse Rating Amps Bussman Type 630 A 170M6694 1800 A 170M7532 Main Circuit Breaker Rating Amps ABB Type 400 A T5L400BW 1600 A T8VBC3FC000000xx DC Bus Output Fuse Ratings DC Bus Output fuses must be used for short circuit protection. The tables in this section provide the ratings of the DC Bus Output fuses used for the AFE in an IP20 2500 MCC Style enclosure. 465...800 Volt DC Fusing Frame Size 10 13 Fuse Rating Amps 1100 A 1100 A (2 per phase) Bussman Type 170M6499 170M6499 640...1100 Volt DC Fusing Frame Size 10 13 Fuse Rating Amps 630 A 630 A (2 per phase) Bussman Type 170M6454 170M6454 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 141 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 an IP21 Rittal enclosure includes the recommended MCCB (motor-controlled circuit breaker). 400/480 Volt AC Fusing and MCCB Ratings Frame Size 10 13 Fuse Ratings Amps 800 1000 2200 1000 (3 per phase) (1) Suitable for replacement fuse. Bussman Type (1) -- 170M6277 -- 170M6277 Ferraz Shawmut Type NH3UD69V800PV -- PC44UD75V22CTQ -- MCCB Ratings Amps ABB Type 630 T5H630FF3LS 1600 T7516FF3PR231LS 600/690 Volt AC Fusing and MCCB Ratings Frame Size 10 13 Fuse Amps 700 700 1800 700 (3 per phase) (1) Suitable for replacement fuse. Bussman Type (1) -- 170M6305 -- 170M6305 Ferraz Shawmut Type PC73UD13C630PA -- PC84UD12C18CTQ -- MCCB Ratings Amps ABB Type 400 T5H400LS 1600 T7516FF3PR231LS DC Bus Output Fuse Ratings DC Bus Output fuses must be used for short circuit protection. The tables in this section provide the ratings of the DC Bus Output fuses used for the AFE in an IP21 Rittal enclosure. 465...800 Volt DC Fusing Frame Size 10 13 Fuse Amps 1100 1250 2400 1250 (2 per phase) (1) Suitable for replacement fuse. Bussman Type (1) -- 170M6566 -- 170M6566 Ferraz Shawmut Type PC73UD95V11CTF -- PC84UD11C24CTQ -- 640...1100 Volt DC Fusing Frame Fuse Size Amps 10 630 700 13 2000 1000 (2 per phase) (1) Suitable for replacement fuse. Bussman Type (1) -- 170M6305 -- 170M8510 Ferraz Shawmut Type PC73UD13C630TF -- PC84UD11C20CTQ -- 142 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Dimensions Supplemental Information Appendix A Figure 46 - AFE Frame 10 in IP20 2500 MCC Style Enclosure Dimensions Dimensions are in millimeters and (inches). 640 (25) 1754.6 (69.1) 2380.1 2265.5 (94) (89.2) 1204.1 (47) Front View 461.4 138.6 (18) (5) 800.7 (31.5) 955.1 (38) Right Side View 699.1 (28) 1061.4 (42) Bottom View Overall Dimensions, mm (in.) Height Width 2380.1 (94) 1204.1 (47) Depth 955.1 (38) Weight, kg (lb) 1035 (2282) Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 143 Appendix A Supplemental Information Figure 47 - AFE Frame 13 in IP20 2500 MCC Style Enclosure Dimensions 1747.4 (69) 878.1 (35) Dimensions are in millimeters and (inches). 2265.5 (89.2) 2379.8 (93.7) 2400.1 (95) Front View 43.1 43.1 (1.7) (1.7) 557 757 957 (21.9) (29.8) (37.7) 803.4 (32) 958 (38) Right Side View 699.1 (27.5) 2356.9 (92.8) Bottom View Overall Dimensions, mm (in.) Height Width 2379.8 (93.7) 2400.1 (95) Depth 958 (38) Weight, kg (lb) 2200 (4850) 144 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Supplemental Information Appendix A Figure 48 - AFE Frame 10 in IP21 Rittal Enclosure Dimensions Dimensions are in millimeters and (inches). 935 498 42 (36.8) (19.6) (1.7) 1090.25 (42.9) 2270.5 (89.4) 1000 (39.4) Front View 125 (4.9) 275 475 (10.8) (18.7) 475 (18.7) 670.7 (26.4) Right Side View 862.08 (33.9) Bottom View 6.43 95.5 (0.3) (3.8) Overall Dimensions, mm (in.) Height Width 2270.5 (89.4) 1000 (39.4) Depth 670.7 (26.4) Weight, kg (lb) 600 (1323) Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 145 Appendix A Supplemental Information Figure 49 - AFE Frame 13 in IP21 Rittal Enclosure Dimensions Dimensions are in millimeters and (inches). 1264.7 (49.8) 536 25 (21.1) (1.0) 2270 (89.4) 1088.8 (42.9) 2242.5 (88.3) Height to Lifting Lug 61 (2.4) 61 (2.4) 475 (18.7) 475 (18.7) 1800 (70.9) Front View 125 (4.9) 675 (26.6) 125 (4.9) 275 (10.8) 37 653 (1.5) (25.7) Right Side View 95 Bottom View (3.7) Overall Dimensions, mm (in.) Height Width 2270.5 (89.4) 1800 (70.9) Depth 690 (27.2) Weight, kg (lb) 1280 (2821.9) 146 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 420.1 (16.5) 340.94 (13.4) 298.1 (11.7) Figure 50 - AFE Frame 10 LCL Filter Dimensions Dimensions are in millimeters and (inches). Supplemental Information Appendix A 214 (8.4) 113.1 (4.5) 210 (8.3) 105 (4.1) 949.53 (37.4) 1761.5 (69.4) 1674.5 (65.9) 66 (2.6) 1404.5 (55.3) 1056.5 (41.6) 177 (7.0) 43 (1.7) 183.9 (7) 368.1 (14.5) 478.1 (18.8) 496.94 (19.6) Left Side View 429.5 (16.9) 43.7 11 (1.7) (0.4) 288.5 (11.4) Front View 87 (3.4) 169.1 (6.7) Right Side View AFE Input Voltage 400/480V 600/690V Overall Dimensions, mm (in.) Height Width 1761.5 (69.4) 288.5 (11.4) Depth 496.9 (19.6) Weight, kg (lb) 263 (580) 304 (670) Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 147 Appendix A Supplemental Information Figure 51 - AFE Frame 13 LCL Filter Dimensions Dimensions are in millimeters and (inches). 280 (11.0) 140 (5.5) 26 (1.0) 32 (1.3) 1477 (58.2) 1407 (55.4) 883 (34.8) 585 (23.0) 391 (15.4) Height with Wheel Guide Trays 525 (20.7) 559.9 (22.0) 592.5 (23.3) Left Side View 34 (1.3) 1421 (55.9) 703.5 (27.7) 553.5 (21.8) 403.5 (15.9) Height from Bottom 37 Surface of Unit (1.5) Front View AFE Input Voltage 400/480V 600/690V Overall Dimensions, mm (in.) Height Width 1442 (56.8) 494 (19.4) Depth 525 (20.7) Weight, kg (lb) 477 (1052) 473 (1043) 148 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Supplemental Information Appendix A Figure 52 - AFE Frame 10 Power Structure Dimensions Dimensions are in millimeters and (inches). 190 (7.5) 85 (3.3) 77 (3.0) 24.5 (1.0) 237 (9.0) Minimum to Enclosure Roof 75 (3.0) Minimum to Enclosure Wall 495.8 (19.5) Left Side View 373 (14.7) 108 (4.3) Ø 26 (1.0) Both Sides 205 (8.1) 140 (5.5) 75 (3.0) 113.5 (4.5) 239 (9.4) Front View 1050 (41.3) 1032 (40.6) 1009 (39.7) 520.8 (20.5) 552 (21.7) 566 (22.3) Right Side View Bottom View Overall Dimensions, mm (in.) Height Width 1050 (41.3) 239 (9.4) Depth 556 (22.3) Weight, kg (lb) 100 (221) Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 149 Appendix A Supplemental Information 566 (22.3) Figure 53 - AFE Frame 13 Power Structure Dimensions Dimensions are in millimeters and (inches). 147 (5.8) Typ 85 (3.3) Typ 1012.5 (39.9) 514.8 (20.3) Left Side View 373 (14.7) 107 (4.2) Ø 26 (1.0) Both Sides Front View 620.5 (24.4) 388.5 (15.3) 156.5 (6.2) Bottom View 142.6 (5.6) 192.6 (7.6) 242.6 (9.6) Right Side View 708 (27.9) Overall Dimensions, mm (in.) Height Width 1032 (40.6) 708 (27.9) Depth 553 (21.8) Weight, kg (lb) 306 (675) 150 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Supplemental Information Appendix A Figure 54 - 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 10 13 Overall Dimensions, mm (in.) A B 532.24 (20.6) 446 (17.6) 733.67 (28.9) 448 (17.6) C 135.96 (5.4) 135.96 (5.4) Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 151 Appendix A Supplemental Information DPI Communication Configurations This section contains information for how to use DPITM communication with the PowerFlex Active Front End. Typical Programmable Controller Configurations IMPORTANT If programs are written that continuously write information to the AFE control, be sure to format the block transfer correctly. If attribute 10 is selected for the block transfer, values are written only to RAM and are not saved by the drive. Attribute 10 is the preferred attribute for continuous transfers. If attribute 9 is selected, each program scan completes a write to the drives nonvolatile memory (EEPROM). Because the EEPROM accommodates only a fixed number of writes, excessive continuous block transfers can quickly damage the EEPROM. Therefore, do not assign attribute 9 to continuous block transfers. See the individual communication adapter user manual for details. Logic Command Word for PowerFlex 700/700H/700S Drives Logic Bits 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1 0 Command x Stop x Start (1) x x Reserved Clear Fault (2) x x x x Reserved Reserved Reserved Cmd LogicOut x x x x x x x x Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Description 0 = Not Stop 1 = Normal Stop 0 = Not Start 1 = Start 0 = Not Clear Fault 1 = Clear Fault 0 = Network-controlled Digital Output off 1 = Network-controlled Digital Output on (1) A Not Stop condition (logic bit 0 = 0, logic bit 8 = 0, and logic bit 9 = 0) must first be present before a 1 = Start condition starts the AFE. (2) To perform this command, the value must switch from `0' to `1'. 152 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 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 0 Status x Ready x Active x Motoring x Regenerating x In Precharge x Droop Active x x x x Alarm Faulted At Reference Mot CurLim x Regen CurLim x x x x Cmd Delayed DCVoltRefID0 DCVoltRefID1 DCVoltRefID2 Description 0 = Not ready 1 = Ready 0 = Not active 1 = Active 0 = Not motoring 1 = Motoring 0 = Not regenerating 1 = Regenerating 0 = Not in precharge 1 = In precharge 0 = Not droop active for AFE paralleling 1 = Droop active for AFE paralleling 0 = No alarm 1 = Alarm 0 = Not faulted 1 = Faulted 0 = Not at reference 1 = At reference 0 = Not exceeding current limit in Motoring Mode 1 = Exceeding current limit in Motoring Mode 0 = Not exceeding current limit in Regenerative Mode 1 = Exceeding current limit in Regenerative Mode 0 = Condition false 1 = Condition true Bits Description 14 13 12 0 0 0 = DC Volt Ref 0 0 1 = Analog In 1 0 1 0 = Analog In 2 0 1 1 = DPI Port 1 1 0 0 = DPI Port 2 1 0 1 = DPI Port 3 1 1 0 = DPI Port 4 1 1 1 = DPI Port 5 x Reserved The AFE reference is the commanded bus voltage (for example, a value of 6000 represents 600.0V DC). The feedback value is the bus voltage measured in the AFE. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 153 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 shows a 20-COMM-E EtherNet/IP adapter that uses a 32-bit parameter (Datalink A) on the input, and two 16-bit parameters on the output. The data is used as shown in the table. Logix to 20-COMM-x Word Output I/O 1 Logic Command 2 Reference (bus voltage) 3 Datalink In A1 4 Datalink In A2 5 Datalink In B1 6 Datalink In B2 7 Datalink In C1 8 Datalink In C2 9 Datalink In D1 10 Datalink In D2 20-COMM-x to Logix Word Input I/O 1 Logic Status 2 Feedback (bus voltage) 3 Datalink Out A1 4 Datalink Out A2 5 Datalink Out B1 6 Datalink Out B2 7 Datalink Out C1 8 Datalink Out C2 9 Datalink Out D1 10 Datalink Out D2 154 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 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 0 Command x Normal Stop x Start (1) x Jog 1 (2) x Clear Fault (3) xx Unipolar Direction x x xx Manual Reserved Accel Time xx Decel Time x x x Ref Select 1 Ref Select 2 Ref Select 3 x x x x x x x x x x x x x x x x x (1) A Not Stop condition (logic bit 0 = 0) must first be present before a 1 = Start condition starts the drive. (2) A Not Stop condition (logic bit 0 = 0) must first be present before a 1 = Jog 1/Jog 2 condition jogs the drive. A transition to a `0' stops the drive. (3) To perform this command, the value must switch from `0' to `1'. (4) A Not Stop condition (logic bit 0 = 0) must first be present before a 1 = Run condition runs the drive. A transition to a `0' stops the drive. Reserved Coast Stop Current Limit Stop Run (4) Jog 2 (2) Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Reserved Description 0 = Not normal stop 1 = Normal stop 0 = Not start 1 = Start 0 = Not jog 1 (Par. 556) 1 = Jog 1 0 = Not clear fault 1 = Clear fault 00 = No command 01 = Forward command 10 = Reverse command 11 = Hold direction control 0 = Not manual 1 = Manual 00 = No command 01 = Use Accel Time 1 (Par. 535) 10 = Use Accel Time 2 (Par. 536) 11 = Use present time 00 = No command 01 = Use Decel Time 1 (Par. 537) 10 = Use Decel Time 2 (Par. 538) 11 = Use present time 000 = No command 001 = Ref A Select (Par. 545) 010 = Ref B Select (Par. 550) 011 = Preset 3 (Par. 573) 100 = Preset 4 (Par. 574) 101 = Preset 5 (Par. 575) 110 = Preset 6 (Par. 576) 111 = Preset 7 (Par. 577) 0 = Not coast to stop 1 = Coast to stop 0 = Not current limit stop 1 = Current limit stop 0 = Not run 1 = Run 0 = Not Jog 2 (Par. 557) 1 = Jog 2 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 155 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 0 Command x Run Ready x Active x Command Direction x Actual Direction x Accelerating x Decelerating x Alarm x Fault x At Setpt Spd x Manual x x x x x Spd Ref ID 0 Spd Ref ID 1 Spd Ref ID 2 Spd Ref ID 3 Spd Ref ID 4 x x x x x x x x x x x x x x Reserved Running Jogging Stopping DC Brake DB Active Speed Mode Position Mode Torque Mode At Zero Speed At Home At Limit Current Limit Bus Freq Reg Description 0 = Not ready to run 1 = Ready to run 0 = Not active 1 = Active 0 = Reverse 1 = Forward 0 = Reverse 1 = Forward 0 = Not accelerating 1 = Accelerating 0 = Not decelerating 1 = Decelerating 0 = No alarm (Par. 959 and 960) 1 = Alarm 0 = No fault (Par. 952 and 953) 1 = Fault 0 = Not at setpoint speed 1 = At setpoint speed 0 = Manual mode not active 1 = Manual mode active 00000 = Reserved 00001 = Auto Ref A (Par. 545) 00010 = Auto Ref B (Par. 550) 00011 = Auto Preset Speed 3 (Par. 573) 00100 = Auto Preset Speed 4 (Par. 574) 00101 = Auto Preset Speed 5 (Par. 575) 00110 = Auto Preset Speed 6 (Par. 576) 00111 = Auto Preset Speed 7 (Par. 577) 01000 = Reserved 01001 = Reserved 01010 = Reserved 01011 = Reserved 01100 = Reserved 01101 = Reserved 01110 = Reserved 01111 = Reserved 10000 = Man Port 0 10001 = Man Port 1 10010 = Man Port 2 10011 = Man Port 3 10100 = Man Port 4 10101 = Man Port 5 10110 = Man Port 6 10111 = Reserved 11000 = Reserved 11001 = Reserved 11010 = Reserved 11011 = Reserved 11100 = Reserved 11101 = Man Port 13 (embedded EtherNet/ IP) 11110 = Man Port 14 (DriveLogixTM) 11111 = Alternate Man Ref Sel 0 = Not running 1 = Running 0 = Not jogging (Par. 556 and 557) 1 = Jogging 0 = Not stopping 1 = Stopping 0 = Not DC brake 1 = DC Brake 0 = Not dynamic brake active 1 = Dynamic brake active 0 = Not Speed Mode (Par. 309) 1 = Speed Mode 0 = Not Position Mode (Par. 309) 1 = Position Mode 0 = Not Torque Mode (Par. 309) 1 = Torque Mode 0 = Not at zero speed 1 =At zero speed 0 = Not at home 1 = At home 0 = Not at limit 1 = At limit 0 = Not at current limit 1 = At current limit 0 = Not Bus Freq Reg 1 = Bus Freq Reg 156 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Supplemental Information Appendix A 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 0 Command x Enable On x Motor Overload x Regen Description 0 = Not enable on 1 = Enable on 0 = Not motor overload 1 = Motor overload 0 = Not regen 1= Regen Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 157 Appendix A Supplemental Information Notes: 158 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 HIM Overview B Appendix External and Internal Connections Topic Page External and Internal Connections 159 LCD Display Elements 160 ALT Functions 160 Menu Structure 161 View and Edit Parameters 163 Remove/Install the HIM 163 The PowerFlex® Active Front End provides a number of cable connection points. 1 X2 X1 4 2, 3 HIM panel opens to allow access to DPITM interface. To open the panel, remove the screws on left side of the HIM panel and swing open. To Drive Control (DPI Interface Board) No. Connector (1) 1 DPI port 1 2 DPI port 2 3 DPI port 3 or 2 4 DPI port 5 Description HIM connection when installed in AFE. Cable connection for handheld and remote options. Splitter cable that is connected to DPI Port 2, which provides an additional port. Cable connection for communications adapter. (1) There is no port 4 on PowerFlex 7-Class products. Port 4 only exists on legacy SCANportTM products. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 159 Appendix B HIM Overview LCD Display Elements ALT Functions Display F-> Power Loss Auto 0.0 Volt Main Menu: Diagnostics Parameter Device Select Description Direction | Drive Status | Alarm | Auto/Man | Information Commanded or Output Volts Programming / Monitoring / Troubleshooting To use an ALT function, press the ALT key and release it, and then press the programming key that is associated with the desired function that is listed in the following table. Table 25 - ALT Key Functions ALT Key plus... Sel View Lang Function Selects how parameters are viewed or shows detailed information about a parameter or component. Displays the language selection screen. Auto/Man Switches between Auto and Manual Modes. ALT Remove Lets the HIM be removed without causing a fault if the HIM is not the last controlling device and does not have manual control of the AFE. . Exp Lets the value to be entered as an exponent. +/ Param # Enters a parameter number for viewing or editing. 160 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Menu Structure HIM Overview Appendix B Figure 55 - HIM Menu Structure Diagnostics Parameter Device Select User Display Esc Sel Alarms Faults Status Info Device Items Device Version HIM Version View Alarm Queue Clr Alarm Queue PowerFlex 700AFE Product Data Control Board Power Board Slot A-E LCD HIM Product Data LCD HIM Control Board Keyboard Numeric View selected through ALT Sel Cnvrtr Status 1 Cnvrtr Status 2 Cnvrtr Alarm 1 Cnvrtr Alarm 2 DC Ref Source Start Inhibits Last Stop Source Dig In Status Dig Out Status Heatsink Temp Fault Info View Fault Queue Clear Faults Clr Fault Queue Reset Device Param Access Lvl File-Group-Par Numbered List Changed Params FGP: File File 1 Name File 2 Name File 3 Name PowerFlex 700AFE Connected DPI Devices FGP: Group Group 1 Name Group 2 Name Group 3 Name Basic Advanced FGP: Parameter Parameter Name Parameter Name Parameter Name Value Screen Memory Storage Him CopyCat Reset To Defaults Device -> HIM Device <- HIM Delete HIM Set Start-Up Preferences Continue Start Over Introduction Only available if power cycled during startup Device Identity Change Password User Dspy Lines User Dspy Time User Dspy Video Reset User Dspy Contrast Press Complete Steps: 1. Input Voltage 2. Alarm/Flt Cnfg 3. Limits 4. DC Bus Ctrl 5. Strt/Stop/I/O 6. Done/Exit Make a selection: Esc Abort Backup Resume Start-Up Menu to move between menu items Press to select a menu item Press Esc to move 1 level back in the menu structure Press ALT Sel to select how to view parameters Diagnostics Menu When a fault trips the Active Front End, use this menu to access detailed data about the AFE. Option Faults Status Info Device Version HIM Version Description View fault queue or fault information, clear faults, or reset the AFE. View parameters that display status information about the AFE. View the firmware revision and hardware series of components. View the firmware revision and hardware series of the HIM. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 161 Appendix B HIM Overview Parameter Menu See View and Edit Parameters on page 163. 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 that are stored in permanent nonvolatile HIM memory. Option HIM Copycat: Device -> HIM Device <- HIM Reset To Defaults Description Save data to a HIM set, load data from a HIM set to active AFE memory, or delete a HIM set. Restore the AFE to its default configuration settings. Start-up Menu See Chapter 3. Preferences Menu The HIM and AFE have features that you can customize. Option AFE Identity Change Password User Dspy Lines User Dspy Time User Dspy Video Reset User Dspy Description Add text to identify the AFE. Enable/disable or modify the password. Select the display, parameter, scale, and text for the user display. The user display is two lines of user-defined data that appears when the HIM is not being used for programming. Set the wait time for the user display or enable/disable it. Select reverse or normal video for the frequency and user display lines. Return all options for the user display to default configuration values. The AFE is initially set to Basic Parameter View. To view all parameters, set parameter 196 [ParamAccessLvl] to option `1' (Advanced). The Reset to Defaults function does not affect Parameter 196. 162 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 HIM Overview Appendix B View and Edit Parameters HIM Step Example Screen 1. In the Main Menu, press the 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. To scroll through the files, press the or key. FGP: File Monitor Dynamic Control Utility 4. To select a file, press the (Enter) key. The groups in the file are displayed under it. 5. Repeat step 3 and step 4 to select a group and then a parameter. The parameter value screen appears. FGGP: Group Control Modes Voltage Loop Limits FGP:PParameter DC Volt Ref Sel DC Volt Ref 6. To edit the parameter, press the (Enter) key. 7. To change the value, press the or key. If desired, press the Sel key to move from digit to digit, letter to letter, or bit to bit. The digit or bit that can be changed is highlighted. 8. To save the value, press the (Enter) key. To cancel a change, press the Esc key to escape. 9. To scroll through the parameters in the group, press the or key, or press the Esc key to return to the group list. FGP: Par 61 DC Volt Ref 712.8 VDC 583 < > 842 FGP: Par 61 DC Volt Ref 700.0 VDC 583 < > 842 Remove/Install the HIM Numeric Keypad Shortcut When using a HIM with a numeric keypad, press the ALT key and +/ key to access the parameter by typing its number. The HIM can be removed or installed while the AFE is powered. Step To remove the HIM, do the following. 1. Press the ALT key and then the (Enter) key. The Remove HIM configuration screen appears. 2. To confirm that you want to remove the HIM, press the key. 3. Remove the HIM from the AFE. (Enter) To install the HIM, insert it into the AFE or connect its cable to the AFE. Example Displays - Remove HIM Do you wish to continue? Press Enter Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 163 Appendix B HIM Overview Notes: 164 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Sizing Guidelines Application Notes C Appendix Topic Page Sizing Guidelines 165 Voltage Boost 167 Paralleling AFEs 168 Use the following guidelines to 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. This step compensates for the boosted DC bus voltage that is provided by the AFE. 3. Select the AFE with the DC current rating that meets or exceeds the value calculated in step 2. Examples: Normal-duty (ND), 110%, 1 minute DC Input Rating of Connected Drives DC ND Voltage Power ND Currents 650V 5 x 60 Hp 5 x 84.5 = 422.5 A 1 x 30 Hp 1 x 85.8 A ND Current Sum x 0.9 457.5 A AFE ND Cont. DC Output Amps 520 A AC Input Voltage 480V Heavy-duty (HD), 150%, 1 minute DC Input Rating of Connected Drives DC HD Voltage Power HD Currents 650V 5 x 60 Hp 5 x 84.5 = 422.5 A 1 x 30 Hp 1 x 55.7 = 55.7 A HD Current Sum x 0.9 430.4 A AFE HD Cont. DC Output Amps 435 A AC Input Voltage 480V Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 165 Appendix C Application Notes 166 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. IInput = PAccel x 1000 / ( 3 x VLL x 1.1), where PAccel is in kW, and VLL = RMS line-to-line AC input voltage. 3. Determine the total power and input current required during steadystate run operation.(1) For Motoring Loads: PDrive = PMotor / Motor Efficiency For Regenerating Loads: PDrive = PMotor * Motor Efficiency PRun = PDrive1 + PDrive2 + ... Calculate the steady-state input current required on the regenerative unit. IInput = PRun x 1000 / ( 3 x VLL), where PRun is in kW, and VLL = RMS line-to-line AC input voltage. 4. Determine the total power and input current required during deceleration.(1) For Motoring Loads: PDrive = PMotor / Motor Efficiency For Regenerating Loads: PDrive = PMotor * Motor Efficiency PDecel = PDrive1 + PDrive2 + ... Calculate the input current required on the regenerative unit during deceleration, taking advantage of the 110% for 1 minute overload rating of the regenerative unit. IInput = PDecel x1000 / ( 3 x VLL x 1.1), where PDecel is in kW, and VLL = RMS line-to-line AC input voltage. 5. Compare the absolute values of the input current required for the regenerative unit during acceleration, deceleration, and steady state. 6. Select the regenerative unit with the input current rating that meets or exceeds the worst case input current. (1) PMotor is the motor power required for the application. The PMotor could be positive if that section of the machine is motoring, or negative if that section of the machine is regenerating. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Voltage Boost Application Notes 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. Th e maximum AC output to the motor = [DC Volt Ref ] / ( 2 x 1.1) Example: AC line voltage = 400V AC Motor = 460V AC Max [DC Volt Ref ] = 400 x 1.35 x 1.3 = 702V DC Maximum AC output to motor = 702V DC / ( 2 x 1.1) = 451V AC In addition, the AC input current required by the AFE increases when using voltage boost. The continuous and overload AC input current ratings must not be exceeded, or the AFE trips on overload. See the Advanced Procedure to Size the AFE on page 166 for sizing guidelines. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 167 Appendix C Application Notes Paralleling AFEs 168 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 one frame size is not enough, or when redundancy is needed. For additional information, see Drives in Common Bus Configurations, publication DRIVES-AT002. Guidelines for AFEs in IP20 2500 MCC Style Enclosure Follow these guidelines for paralleling AFEs in IP20 2500 MCC Style enclosures: · For AFEs in IP20 2500 MCC Style enclosures, a maximum of two AFEs of the same power size (for example, two Frame 10 AFEs) and same voltage class can be paralleled. · 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. When paralleling, you must check the sufficient short circuit capacity of the system. · Derate the AFE units by 5% of their power rating. · Configure the following parameters for parallel operation: Set Parameter 42 - [Modulation Type] to `3'. Set Parameter 82 - [Ground I Lvl] to 100%. Set Parameter 85 - [Droop] to 5% for current sharing of the AFEs. Set Parameter 86 - [PWM Synch] to `1' to reduce circulating currents between AFEs connected to the same DC bus and fed from the same power source. · If one of the paralleled AFEs is isolated from the AC and DC voltages, you must isolate the AC input and DC output. The AC input can be isolated with a circuit breaker or a disconnect switch. Contactors are not suitable for isolating the AC input because they cannot be locked in the safe position. The DC output can be isolated with a disconnect. A load isolation switch or safety isolation switch can be used to isolate the precharging circuit from the AC input. · Each AFE must use a separate precharging circuit, precharging control switch, DC bus output fusing, and main contactor. Each AFE controls its own precharging and main contactor. Therefore, it is possible to disconnect the AFE when other parallel AFEs are powered up but not modulating. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Application Notes Appendix C · The fault relay of both AFEs must be interlocked with each other, such that both AFEs are disabled (not running) when either AFE is faulted. · 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. To connect the AFE to the DC bus, close the DC disconnect. 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 contactor. b. Open the contactor 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 one AFE due to the 5% droop. See Drives in Common Bus Configurations, publication DRIVES-AT002, for supported drives that can be used in various AFE configurations. · Figure 56 on page 170 shows an example of paralleling two AFEs in their IP20 2500 MCC Style enclosures, where each AFE has its own precharging circuit, precharging control, and fusing on the DC bus output and main contactor. In this case, turn the disconnects (Q0) of all AFEs to ON, and set all REM-AUTO-MAN selector switches on the door to AUTO to enable automatic operation. When turning on the main power, the two AFEs precharge automatically. After charging, the contactors (K1) are closed and the AFEs start the modulation. The control signal `Inverter Enable' shown in Figure 23 on page 45 can be used to interlock the drives connected to the DC bus. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 169 Appendix C Application Notes 3-phase AC Input L1 L2 L3 AC Line Switchgear Input Input Breaker Contactor Q0 Fuses K1 F1.1...F1.3 Figure 56 - Connecting Parallel Frame 10 AFEs in IP20 2500 MCC Style Enclosures LCL Filter (L1) U2 V2 W2 C1 C4 C2 C5 C3 C6 AFE DC Power Structure (U1) Fuses U1 U1 U V1 W1 V DC+ F2.1 W F2.2 PE DC- PE Factory-installed Common Mode Core DC+ DC Bus DC- Output Precharge Fuses F5 Precharge Contactor Precharge Circuit PowerFlex 700 AFE System K6 R6.1 + R6.2 - AC Line Switchgear Input Input Breaker Contactor Q0 Fuses K1 F1.1...F1.3 LCL Filter (L1) U2 V2 W2 C1 C4 C2 C5 C3 C6 AFE DC Power Structure (U1) Fuses U1 U1 U V1 W1 V DC+ F2.1 W F2.2 PE DC- PE Precharge Fuses F5 Precharge Contactor Precharge Circuit Factory-installed Common Mode Core PowerFlex 700 AFE System K6 R6.1 + R6.2 - 170 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 3-phase AC Input L1 L2 L3 AC Line Switchgear Input Input Breaker Contactor Q0 Fuses K1 F1.1...F1.3 Application Notes Appendix C Figure 57 - Connecting Parallel Frame 13 AFEs in IP20 2500 MCC Style Enclosures LCL Filter (L1) U2 V2 W2 C1 C4 C2 C5 C3 C6 Precharge Fuses F5 Precharge Contactor AFE Power Structure (U1) PE U1 U DC+ V1 DC- W1 PE V DC+ DC- PE W DC+ PE DC- DC Fuses F2.1 F2.2 F2.3 F2.4 F2.5 F2.6 Precharge Circuit Factory-installed Common Mode Core DC+ DC Bus Output DC- PowerFlex 700 AFE System K6 R6.1 + - AC Line Switchgear Input Input Breaker Contactor Q0 Fuses K1 F1.1...F1.3 LCL Filter (L1) U2 V2 W2 C1 C4 C2 C5 C3 C6 Precharge Fuses F5 Precharge Contactor AFE DC Power Structure (U1) Fuses U1 PE F2.1 U DC+ V1 DC- W1 F2.2 PE F2.3 V DC+ DC- F2.4 PE F2.5 PE W DC+ DC- F2.6 Precharge Circuit Factory-installed Common Mode Core PowerFlex 700 AFE System K6 R6.1 + - Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 171 Appendix C Application Notes 172 Guidelines for AFEs in IP21 Rittal Enclosure Follow these guidelines for paralleling AFEs in IP21 Rittal enclosures: · 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, the capacity of the DC bus bar can limit the number of AFEs. · 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. When paralleling, you must check the sufficient short circuit capacity of the system. · Derate the AFE units by 5% of their power rating. · Configure the following parameters for parallel operation: Set Parameter 42 - [Modulation Type] to `3'. Set Parameter 82 - [Ground I Lvl] to 100%. Set Parameter 85 - [Droop] to 5% for current sharing of the AFEs. Set Parameter 86 - [PWM Synch] to `1' to reduce circulating currents between AFEs connected to the same DC bus and fed from the same power source. · If one of the paralleled AFEs is isolated from the AC and DC voltages, you must isolate the AC input and DC output. The AC input can be isolated with a circuit breaker or a disconnect switch. Contactors are not suitable for isolating the AC input because they cannot be locked in the safe position. The DC output can be isolated with a disconnect. A load isolation switch or safety isolation switch can be used to isolate the precharging circuit from the AC input. · Each AFE must use a separate precharging circuit, precharging control switch, DC bus output fusing, and main contactor. Each AFE controls its own precharging and main contactor. Therefore, it is possible to disconnect the AFE when other parallel AFEs are powered up but not modulating. · The fault relay of both AFEs must be interlocked with each other, such that both AFEs are disabled (not running) when either AFE is faulted. · 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. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Application Notes Appendix C When completed, the AFE control closes the MCCB. b. To connect the AFE to the DC bus, close the DC disconnect. 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 one AFE due to the 5% droop. See Drives in Common Bus Configurations, publication DRIVES-AT002, for supported drives that can be used in the various AFE configurations. · Figure 58 on page 174 shows an example of paralleling two AFEs in their IP21 Rittal enclosures, where each AFE has its own precharging circuit, precharging control, and fusing on the DC bus output and input contactor. In this case, turn the disconnects (Q0) of all AFEs to ON, and set all MCCB CONTROL selector switches on the door to AUTO to enable automatic operation. When turning on the main power, the two AFEs precharge automatically. After charging, the MCCB motor-controlled circuit breakers (Q1) are closed and the AFEs start the modulation. The control signal `Inverter Enable' shown in Figure 40 on page 79 can be used to interlock the drives connected to the DC bus. Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 173 Appendix C Application Notes 3-phase AC Input L1 L2 L3 AC Line Switchgear Q0 Q1 Figure 58 - Connecting Parallel Frame 10 AFEs in IP21 Rittal Enclosure LCL Filter (L1) U2 V2 W2 C1 C4 C2 C5 C3 C6 AFE DC Power Structure (U1) Fuses U1 U1 U V1 W1 V DC+ F2.1 W F2.2 PE DC- PE Motor Protection Precharge Relay Precharge Fuses Contactor Precharge Circuit DC+ DC Bus DC- Output PowerFlex 700 AFE 1 F6 Q5 K6 R6.1 + R6.2 - AC Line Switchgear Q0 Q1 LCL Filter (L1) U2 V2 W2 C1 C4 C2 C5 C3 C6 AFE Power Structure (U1) U1 U1 U V1 W1 V DC+ W PE DC- PE DC Fuses F2.1 F2.2 Motor Protection Precharge Relay Precharge Fuses Contactor Precharge Circuit PowerFlex 700 AFE 2 F6 Q5 K6 R6.1 + R6.2 - 174 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 3-phase AC Input L1 L2 L3 AC Line Switchgear Q0 Q1 Application Notes Appendix C Figure 59 - Connecting Parallel Frame 13 AFEs in IP21 Rittal Enclosure LCL Filter (L1) U2 V2 W2 C1 C4 C2 C5 C3 C6 AFE Power Structure (U1) PE U1 U DC+ V1 DC- W1 PE V DC+ DC- PE W DC+ PE DC- Motor Protection Precharge Relay Precharge Fuses Contactor Precharge Circuit DC Fuses F2.1 F2.2 F2.3 F2.4 F2.5 F2.6 DC+ DC Bus Output DC- PowerFlex 700 AFE 1 F6 Q5 K6 R6.1 + R6.2 - AC Line Switchgear Q0 Q1 LCL Filter (L1) U2 V2 W2 C1 C4 C2 C5 C3 C6 AFE Power Structure (U1) PE U1 U DC+ V1 DC- W1 PE V DC+ DC- PE PE W DC+ DC- Motor Protection Precharge Relay Precharge Fuses Contactor Precharge Circuit DC Fuses F2.1 F2.2 F2.3 F2.4 F2.5 F2.6 PowerFlex 700 AFE 2 F6 Q5 K6 R6.1 + R6.2 - Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 175 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 DRIVES-AT002. 176 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Index A AC Line Freq parameter 99 AC Line kVA parameter 99 AC Line kVar parameter 99 AC Line kW parameter 99 AC supply source unbalanced 26, 58 ungrounded 26, 58 Active Current parameter 99 Active I Ki parameter 103 Active I Kp parameter 103 Active I Ref parameter 103 AFE dimensions 143 fault descriptions 127 Frame 10 main component locations in IP20 2500 MCC Style enclosure 22 in IP21 Rittal enclosure 54 Frame 13 main component locations in IP20 2500 MCC Style enclosure 23 in IP21 Rittal enclosure 55 main component sections in IP20 2500 MCC Style enclosure 20 in IP21 Rittal enclosure 52 parameters 95 Alarm 1 @ Fault parameter 108 Alarm 1 Code parameter 110 Alarm 2 @ Fault parameter 108 Alarm 2 Code parameter 110 Alarm 3 Code parameter 110 Alarm 4 Code parameter 110 Alarm Clear parameter 110 alarm clearing 131 Alarm Config parameter 110 Alarms Parameter Group 110 Analog In 1 Hi parameter 113 Analog In 1 Lo parameter 113 Analog In 1 Loss parameter 113 Analog In 2 Hi parameter 113 Analog In 2 Lo parameter 113 Analog In 2 Loss parameter 113 Analog In1 Value parameter 100 Analog In2 Value parameter 100 Analog Inputs Parameter Group 113 Analog Out1 Hi parameter 114 Analog Out1 Lo parameter 114 Analog Out1 Sel parameter 114 Analog Out2 Hi parameter 114 Analog Out2 Lo parameter 114 Analog Out2 Sel parameter 114 Analog Outputs Parameter Group 113 Anlg In Config parameter 113 Anlg Out Absolute parameter 114 Anlg Out Config parameter 113 Anlg Out1 Scale parameter 115 Anlg Out1 Setpt parameter 115 Anlg Out2 Scale parameter 115 Anlg Out2 Setpt parameter 115 armored cable 30, 63 Auto Rstrt Delay parameter 102 Auto Rstrt Tries parameter 102 Auto Stop Level parameter 101 Auto-Reset/Start 126 AutoRstrt Config parameter 102 B bus capacitors, discharging 12 C cables, power armored 30, 63 insulation 29, 62 separation 29, 62 shielded 29, 30, 62, 63 unshielded 29, 30, 62 capacitors 37, 69 capacitors - bus, discharging 12 catalog number explanation 13 CE Conformity 49, 82 clearing alarms 131 faults 127 Cmd DC Volt parameter 100 Cnvrtr Alarm 1 parameter 106 Cnvrtr Alarm 2 parameter 106 Cnvrtr Logic Rslt parameter 111 Cnvrtr OL Count parameter 108 Cnvrtr OL Factor parameter 109 Cnvrtr Status 1 parameter 105 Cnvrtr Status 2 parameter 106 Comm Control Parameter Group 111 Common Mode capacitors 37, 69 interference 40, 75 Communication File 111 communications - programmable controller configurations 152 component locations Frame 10 AFE in IP20 2500 MCC Style enclosure 22 Frame 10 AFE in IP21 Rittal enclosure 54 Frame 13 AFE in IP20 2500 MCC Style enclosure 23 Frame 13 AFE in IP21 Rittal enclosure 55 component sections AFE in IP20 2500 MCC Style enclosure 20 AFE in IP21 Rittal enclosure 52 configuring parameters 95 Conformity - CE 49, 82 Contact Off Cnfg parameter 109 Contact On Delay parameter 101 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 177 Index control I/O terminal block in IP20 2500 MCC Style enclosure 44 I/O terminal block in IP21 Rittal enclosure 78 wire 41, 75 Control Modes Parameter Group 101 Control Options parameter 102 Control SW Ver parameter 100 conventions used in this manual 10 Converter Data Parameter Group 100 Converter Memory Parameter Group 105 CopyCat HIM function 162 cross-reference of parameters by name 117 by number 120 Current Lmt Val parameter 103 Current Loop Parameter Group 103 D Data In A1 parameter 112 Data In A2 parameter 112 Data In B1 parameter 112 Data In B2 parameter 112 Data In C1 parameter 112 Data In C2 parameter 112 Data In D1 parameter 112 Data In D2 parameter 112 Data Out A1 parameter 112 Data Out A2 parameter 112 Data Out B1 parameter 112 Data Out B2 parameter 112 Data Out C1 parameter 112 Data Out C2 parameter 112 Data Out D1 parameter 112 Data Out D2 parameter 112 data, saving 162 Datalinks Parameter Group 112 DC Bus Current parameter 99 DC Bus Hi Alarm parameter 103 DC Bus Lo Alarm parameter 103 DC Bus Volt parameter 99 DC Ref Hi Lmt parameter 103 DC Ref Lo Lmt parameter 103 DC Ref Source parameter 106 DC Volt Ki parameter 102 DC Volt Kp parameter 102 DC Volt Ref parameter 102 DC Volt Ref Sel parameter 102 defaults, resetting to 162 diagnostic data, viewing 161 Diagnostics Parameter Group 105 Dig In Status parameter 107 Dig Out Setpt parameter 116 Dig Out Status parameter 107 Dig Out2 Invert parameter 116 Dig Out2 OffTime parameter 116 Dig Out2 OnTime parameter 116 Dig Out3 Invert parameter 116 Dig Out3 OffTime parameter 116 Dig Out3 OnTime parameter 116 Digital In1 Sel parameter 115 Digital In2 Sel parameter 115 Digital In3 Sel parameter 115 Digital In4 Sel parameter 115 Digital In5 Sel parameter 115 Digital In6 Sel parameter 115 Digital Inputs Parameter Group 115 Digital Out1 Sel parameter 116 Digital Out2 Sel parameter 116 Digital Out3 Sel parameter 116 Digital Outputs Parameter Group 116 discharging bus capacitors 12 distribution systems 37, 69 unbalanced 26, 58 ungrounded 26, 58 DPI Baud Rate parameter 111 DPI communication configurations 152 DPI Port Sel parameter 111 DPI Port Value parameter 111 Droop parameter 104 Dynamic Control File 101 E editing parameters 95 Elapsed Run Time parameter 100 electrostatic discharge (ESD) 12 EMC Directive 49, 82 F factory defaults, resetting to 162 fault descriptions 127 queue 161 Fault 1 Code parameter 109 Fault 1 Time parameter 109 Fault 2 Code parameter 109 Fault 2 Time parameter 109 Fault 3 Code parameter 109 Fault 3 Time parameter 109 Fault 4 Code parameter 109 Fault 4 Time parameter 109 Fault Bus Volts parameter 107 Fault Clear Mode parameter 109 Fault Clear parameter 109 Fault Clr Mask parameter 111 Fault Clr Owner parameter 111 Fault Config parameter 109 Fault Frequency parameter 107 Fault Temp parameter 107 178 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Index Fault Total Curr parameter 107 Faults Parameter Group 109 File Communication 111 Dynamic Control 101 Inputs & Outputs 113 Monitor 99 Utility 105 File-Group-Parameter 96 fuse and circuit breaker ratings 141, 142 G general precautions 12 Ground Current parameter 99 Ground I Lvl parameter 103 grounding recommended scheme 27, 59 requirements 27, 59 shields 29, 61 Group - Parameter Alarms 110 Analog Inputs 113 Analog Outputs 113 Comm Control 111 Control Modes 101 Converter Data 100 Converter Memory 105 Current Loop 103 Datalinks 112 Diagnostics 105 Digital Inputs 115 Digital Outputs 116 Faults 109 Limits 103 Masks & Owners 111 Metering 99 Parallel Mode 104 Restart Modes 102 Voltage Loop 102 H hardware enable 46, 80 Heatsink Temp parameter 99 HIM 159 ALT functions 160 Diagnostics menu 161 external and internal connections 159 LCD display elements 160 Memory Storage menu 162 menu structure 161 Preferences menu 162 removing 163 I I Imbalance parameter 99 Input Current R parameter 99 Input Current S parameter 99 Input Current T parameter 99 input potentiometer 47, 80 input power conditioning 27, 59 Input Voltage parameter 99 Inputs & Outputs File 113 L Language parameter 105 Last Stop Source parameter 107 Limits Parameter Group 103 linear list of parameters 120 Logic Command Word PowerFlex 700/700H/700S drives 152 PowerFlex 750-Series drives 155 Logic Mask parameter 111 Logic Status Word PowerFlex 700/700H/700S drives 153 PowerFlex 750-Series drives 156 Low Voltage Directive 49, 82 M main component locations Frame 10 AFE in IP20 2500 MCC Style enclosure 22 Frame 10 AFE in IP21 Rittal enclosure 54 Frame 13 AFE in IP20 2500 MCC Style enclosure 23 Frame 13 AFE in IP21 Rittal enclosure 55 main component sections AFE in IP20 2500 MCC Style enclosure 20 AFE in IP21 Rittal enclosure 52 manual conventions 10 Masks & Owners Parameter Group 111 Metering Parameter Group 99 mode capacitors 37, 69 Modulation Index parameter 101 Modulation Type parameter 101 Monitor File 99 Motor Power Lmt parameter 103 Motoring MWh parameter 100 N Nom Input Volt parameter 101 non-resettable faults 126 O operator interface 163 P Parallel Mode Parameter Group 104 Param Access Lvl parameter 105 parameter changing/editing 163 cross-reference by name 117 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 179 Index by number 120 linear list 120 viewing 163 180 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Index Parameters AC Line Freq 99 AC Line kVA 99 AC Line kVar 99 AC Line kW 99 Active Current 99 Active I Ki 103 Active I Kp 103 Active I Ref 103 Alarm 1 @ Fault 108 Alarm 1 Code 110 Alarm 2 @ Fault 108 Alarm 2 Code 110 Alarm 3 Code 110 Alarm 4 Code 110 Alarm Clear 110 Alarm Config 110 Analog In 1 Hi 113 Analog In 1 Lo 113 Analog In 1 Loss 113 Analog In 2 Hi 113 Analog In 2 Lo 113 Analog In 2 Loss 113 Analog In1 Value 100 Analog In2 Value 100 Analog Out1 Hi 114 Analog Out1 Lo 114 Analog Out1 Sel 114 Analog Out2 Hi 114 Analog Out2 Lo 114 Analog Out2 Sel 114 Anlg In Config 113 Anlg Out Absolute 114 Anlg Out Config 113 Anlg Out1 Scale 115 Anlg Out1 Setpt 115 Anlg Out2 Scale 115 Anlg Out2 Setpt 115 Auto Rstrt Delay 102 Auto Rstrt Tries 102 Auto Stop Level 101 AutoRstrt Config 102 Cmd DC Volt 100 Cnvrtr Alarm 1 106 Cnvrtr Alarm 2 106 Cnvrtr Logic Rslt 111 Cnvrtr OL Count 108 Cnvrtr OL Factor 109 Cnvrtr Status 1 105 Cnvrtr Status 2 106 Contact Off Cnfg 109 Contact On Delay 101 Control Options 102 Control SW Ver 100 Current Lmt Val 103 Data In A1 112 Data In A2 112 Data In B1 112 Data In B2 112 Data In C1 112 Data In C2 112 Data In D1 112 Data In D2 112 Data Out A1 112 Data Out A2 112 Data Out B1 112 Data Out B2 112 Data Out C1 112 Data Out C2 112 Data Out D1 112 Data Out D2 112 DC Bus Current 99 DC Bus Hi Alarm 103 DC Bus Lo Alarm 103 DC Bus Volt 99 DC Ref Hi Lmt 103 DC Ref Lo Lmt 103 DC Ref Source 106 DC Volt Ki 102 DC Volt Kp 102 DC Volt Ref 102 DC Volt Ref Sel 102 Dig In Status 107 Dig Out Setpt 116 Dig Out Status 107 Dig Out2 Invert 116 Dig Out2 OffTime 116 Dig Out2 OnTime 116 Dig Out3 Invert 116 Dig Out3 OffTime 116 Dig Out3 OnTime 116 Digital In1 Sel 115 Digital In2 Sel 115 Digital In3 Sel 115 Digital In4 Sel 115 Digital In5 Sel 115 Digital In6 Sel 115 Digital Out1 Sel 116 Digital Out2 Sel 116 Digital Out3 Sel 116 DPI Baud Rate 111 DPI Port Sel 111 DPI Port Value 111 Droop 104 Elapsed Run Time 100 Fault 1 Code 109 Fault 1 Time 109 Fault 2 Code 109 Fault 2 Time 109 Fault 3 Code 109 Fault 3 Time 109 Fault 4 Code 109 Fault 4 Time 109 Fault Bus Volts 107 Fault Clear 109 Fault Clear Mode 109 Fault Clr Mask 111 Fault Clr Owner 111 Fault Config 109 Fault Frequency 107 Fault Temp 107 Fault Total Curr 107 Ground Current 99 Ground I Lvl 103 Heatsink Temp 99 I Imbalance 99 Input Current R 99 Input Current S 99 Input Current T 99 Input Voltage 99 Language 105 Last Stop Source 107 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 181 Index Logic Mask 111 Modulation Index 101 Modulation Type 101 Motor Power Lmt 103 Motoring MWh 100 Nom Input Volt 101 Param Access Lvl 105 Power Factor 99 Power Up Marker 109 PWM Frequency 101 PWM Synch 104 Rated Amps 100 Rated kW 100 Rated Volts 100 RatedLineCurrent 101 Reactive Current 99 Reactive I Ki 103 Reactive I Kp 103 Reactive I Ref 103 Reactive I Sel 103 Regen MWh 100 Regen Power Lmt 103 Reset Meters 105 Reset to Defaults 86, 90, 105 Restart Delay 101 Start Inhibits 107 Start Owner 111 Start Up Delay 104 Start/Stop Mode 101 Status 1 @ Fault 108 Status 2 @ Fault 108 Stop Delay 101 Stop Owner 111 Testpoint 1 Data 108 Testpoint 1 Sel 108 Testpoint 2 Data 108 Testpoint 2 Sel 108 Total Current 99 Voltage Class 105 PE 27, 59 potentiometer, wiring 47, 80 power cables/wiring AFE in IP20 2500 MCC Style enclosure 29 AFE in IP21 Rittal enclosure 62 terminal locations/specifications Frame 10 in IP20 2500 MCC Style enclosure 34 Frame 10 in IP21 Rittal enclosure 66 Frame 13 in IP20 2500 MCC Style enclosure 35 Frame 13 in IP21 Rittal enclosure 67 power conditioning, input 27, 59 Power Factor parameter 99 Power Up Marker parameter 109 precautions, general 12 preferences, setting 162 programmable controller configurations 152 PWM Frequency parameter 101 PWM Synch parameter 104 R Rated Amps parameter 100 Rated kW parameter 100 Rated Volts parameter 100 RatedLineCurrent parameter 101 Reactive Current parameter 99 Reactive I Ki parameter 103 Reactive I Kp parameter 103 Reactive I Ref parameter 103 Reactive I Sel parameter 103 Regen MWh parameter 100 Regen Power Lmt parameter 103 Reset Meters parameter 105 Reset to Defaults 162 Reset to Defaults parameter 86, 90, 105 Residual Current Detector (RCD) 26, 58 Restart Delay parameter 101 Restart Modes Parameter Group 102 S saving data 162 setting preferences 162 shielded cables - power 30, 63 SHLD termination 29, 61 signal wire 41, 75 specifications 137 control 138 electrical 138 environment 138 protection 138 Start Inhibits parameter 107 Start Owner parameter 111 Start Up Delay parameter 104 Start/Stop Mode parameter 101 start-up 85 static discharge (ESD) 12 Status 1 @ Fault parameter 108 Status 2 @ Fault parameter 108 Stop Delay parameter 101 Stop Owner parameter 111 supplemental information 137 supply source - AC 26, 58 T technical support 10, 135 terminal block I/O in IP20 2500 MCC Style enclosure 44 I/O in IP21 Rittal enclosure 78 wire size 42, 76 182 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 Index terminals - power Frame 10 in IP20 2500 MCC Style enclosure 34 Frame 10 in IP21 Rittal enclosure 66 Frame 13 in IP20 2500 MCC Style enclosure 35 Frame 13 in IP21 Rittal enclosure 67 Testpoint 1 Data parameter 108 Testpoint 1 Sel parameter 108 Testpoint 2 Data parameter 108 Testpoint 2 Sel parameter 108 Total Current parameter 99 troubleshooting 125 U unbalanced/ungrounded AC supply source 26, 58 ungrounded distribution systems 37, 69 unshielded power cables 30, 62 user configurable alarms 126 Utility File 105 V viewing and changing parameters 163 Voltage Class parameter 105 Voltage Loop Parameter Group 102 W website technical support 10 wire control 41, 75 signal 41, 75 wiring hardware enable 46, 80 potentiometer 47, 80 power for AFE in IP20 2500 MCC Style enclosure 29 power for AFE in IP21 Rittal enclosure 62 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 183 Index Notes: 184 Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017 . Rockwell Automation Support Use the following resources to access support information. Technical Support Center Local Technical Support Phone Numbers Direct Dial Codes Literature Library Product Compatibility and Download Center (PCDC) Knowledgebase Articles, How-to Videos, FAQs, Chat, User Forums, and Product Notification Updates. https://rockwellautomation.custhelp.com/ Locate the phone number for your country. http://www.rockwellautomation.com/global/support/get-support-now.page Find the Direct Dial Code for your product. Use the code to route your call directly to a technical support engineer. http://www.rockwellautomation.com/global/support/direct-dial.page Installation Instructions, Manuals, Brochures, and Technical Data. http://www.rockwellautomation.com/global/literature-library/overview.page Get help determining how products interact, check features and capabilities, and find associated firmware. http://www.rockwellautomation.com/global/support/pcdc.page Documentation Feedback Your comments will help us serve your documentation needs better. If you have any suggestions on how to improve this document, complete the How Are We Doing? form at http://literature.rockwellautomation.com/idc/groups/literature/documents/du/ra-du002_-en-e.pdf. Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page. Allen-Bradley, Connected Components Workbench, DPI, DriveExecutive, DriveExplorer, DriveLogix, PowerFlex, SCANport, Rockwell automation, and Rockwell Software are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies. Rockwell Otomasyon Ticaret A.., Kar Plaza Merkezi E Blok Kat:6 34752 çerenköy, stanbul, Tel: +90 (216) 5698400 Publication 20Y-UM001F-EN-P - April 2017 Supersedes Publication 20Y-UM001E-EN-P - July 2014 Copyright © 2017 Rockwell Automation, Inc. All rights reserved. Printed in the U.S.A.Acrobat Distiller 11.0 (Windows)