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PowerFlex 700AFE User Manual

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PowerFlex Active Front EndCatalog Number 20YPowerFlex AFE/PowerFlex 700AFEFrames 10 and 13, Firmware Revision Number 1.xxxUser ManualOriginal InstructionsImportant User InformationRead 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 prohibitedThroughout this manual, when necessary, we use notes to make you aware of safety considerations.Labels may also be on or inside the equipment to provide specific precautions. WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.IMPORTANTIdentifies information that is critical for successful application and understanding of the product.SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).Rockwell Automation Publication 20Y-UM001F-EN-P - April 20173Table of ContentsPreface Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Intended Audience. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9What Is Not in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9Manual Conventions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Rockwell Automation Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Technical Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Additional Resources. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10Drive Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Catalog Number Explanation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13Description of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14Benefits of the AFE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16AFE in IP00 Open Chassis Configuration. . . . . . . . . . . . . . . . . . . . . . . 17Chapter 1AFE in IP20 2500 MCC Style Enclosure – Installation/WiringMain Component Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Frame 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Frame 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Main Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Frame 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22Frame 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23Mounting Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Operating Temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24Minimum Mounting Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24AC Supply Source Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Unbalanced, Ungrounded, or Resistive Grounded Distribution Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26Input Power Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Grounding Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27Recommended Grounding Scheme . . . . . . . . . . . . . . . . . . . . . . . . . 27Safety Ground - PE and Shield Termination - SHLD. . . . . . . . . 29Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Power Cable Types Acceptable for 400…690 Volt Installations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Unshielded Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Shielded Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Armored Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Cable Trays and Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31Select and Verify Control Transformer Voltage . . . . . . . . . . . . . . 31Power Terminals for AFE in IP20 2500 MCC Style Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34Route the AC Input, Ground (PE), and DC Bus OutputWiring for AFE in IP20 2500 MCC Style Enclosure . . . . . . . . . 364Rockwell Automation Publication 20Y-UM001F-EN-P - April 2017Table of ContentsDisconnect the Common Mode Capacitors . . . . . . . . . . . . . . . . . . . . . 37Frame 10 LCL Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37Frame 13 LCL Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38Frame 10 or Frame 13 Power Structure. . . . . . . . . . . . . . . . . . . . . . 39Use the AFE with PowerFlex Drives . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40Signal and Control Wire Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41I/O Terminal Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42I/O Cable Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43Typical I/O Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Analog I/O Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Hardware Enable Circuitry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46Analog I/O Wiring Examples for AFE in IP20 2500 MCC Style Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Precharging the AFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47Important Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Low Voltage Directive (2006/95/EC). . . . . . . . . . . . . . . . . . . . . . . 49EMC Directive (2004/108/EC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49General Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49Essential Requirements for CE Compliance. . . . . . . . . . . . . . . . . . 49Chapter 2AFE in IP21 Rittal Enclosure – Installation/WiringMain Component Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Frame 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Frame 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Main Component Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Frame 10 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54Frame 13 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55Mounting Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Operating Temperatures. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Minimum Mounting Clearances. . . . . . . . . . . . . . . . . . . . . . . . . . . . 56AC Supply Source Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Unbalanced, Ungrounded, or Resistive Grounded Distribution Systems. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58Input Power Conditioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Grounding Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59Recommended Grounding Scheme . . . . . . . . . . . . . . . . . . . . . . . . . 59Safety Ground - PE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Shield Termination - SHLD. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61Fuses and Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Power Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Power Cable Types Acceptable for 400…690 Volt Installations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Unshielded Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62Shielded Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Rockwell Automation Publication 20Y-UM001F-EN-P - April 20175Table of ContentsArmored Cable . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63Cable Trays and Conduit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64Select and Verify Control Transformer Voltage . . . . . . . . . . . . . . 64Power Terminals for AFE in IP21 Rittal Enclosure. . . . . . . . . . . 66DC Bus Output Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Route the AC Input, Ground (PE), and DC Bus Output Wiring for AFE in IP21 Rittal Enclosure . . . . . . . . . . . . . . . . . . . . 68Disconnect the Common Mode Capacitors . . . . . . . . . . . . . . . . . . . . . 69Frame 10 LCL Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Frame 13 LCL Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70Frame 10 Power Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72Frame 13 Power Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73Using the AFE with PowerFlex Drives . . . . . . . . . . . . . . . . . . . . . . . . . . 74Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Signal and Control Wire Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75I/O Terminal Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76I/O Cable Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77Typical I/O Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78Analog I/O Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79Hardware Enable Circuitry. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Analog I/O Wiring Examples for AFE in IP21 Rittal Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80Precharging the AFE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81Important Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81CE Conformity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82Low Voltage Directive (2006/95/EC). . . . . . . . . . . . . . . . . . . . . . . 82EMC Directive (2004/108/EC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82General Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82Essential Requirements for CE Compliance. . . . . . . . . . . . . . . . . . 82Chapter 3StartupAFE in IP20 2500 MCC Style Enclosure. . . . . . . . . . . . . . . . . . . . . . . . 85Startup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85Control Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88AFE in IP21 Rittal Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90Startup Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90Control Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92MCCB (Motor-controlled Circuit Breaker) and Modes of Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92Chapter 4Programming and ParametersAbout Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95How AFE Parameters are Organized. . . . . . . . . . . . . . . . . . . . . . . . . . . . 96File-Group-Parameter Order . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

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