Rockwell Automation 7000 User Manual

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User Manual

PowerFlex® 7000 Medium Voltage AC Drive Air-Cooled (“B” Frame)—ForGe Control

Publication 7000-UM202B-EN-P

Important User Information

IMPORTANT

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.

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).

Allen-Bradley, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.

Trademarks not belonging to Rockwell Automation are property of their respective companies.

This manual contains new and updated information.

Summary of Changes

New and Updated Information

This table summarizes the changes made to this revision.

Top ic Pag e

Added HPTC information to Topology section 13

Added additional SPS test harness warning 103

Added minimum gap measurement and image to Fan Installation section 119

Updated Catalog Number Explanation 169

Updated “When to use an Encoder?” section and table 201

Replaced Encoder Selection table 202

Added HPTC information to Drive Torque Capabilities table 202

Updated Typical Application Load Torque Profiles 203

Updated Speed Regulator Bandwidth 206

Updated Torque Regulator Bandwidth 206

Inserted Torque Accuracy with HPTC 206

Added Polish to list of available Languages 207

Added “Dual-port Ethernet/IP” to Communications Protocols 208

Changes made to this manual for previous revisions are included in the History of Changes on page 209

Rockwell Automation Publication 7000-UM202B-EN-P - June 2014 3

Summary of Changes

Notes:

4 Rockwell Automation Publication 7000-UM202B-EN-P - June 2014

Important User Information

Chapter 1

Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

What Is Not in this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Commissioning Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Chapter 2

PowerFlex 7000 Overview

Component Definition and Maintenance

Topology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13

Rectifier Designs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

Cooling Technology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

Motor Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Simplified Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

2400V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

3300/4160V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

6600V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Basic Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

Chapter 3

Control Power Off Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Interlocking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Control / Cabling Cabinet Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 25

Voltage-Sensing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Replacing the Voltage-Sensing Circuit Board Assembly. . . . . . . . . . 34

Input Transient Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Transient Suppression Network (TSN) . . . . . . . . . . . . . . . . . . . . . . . . 35

Surge Arresters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Filter Capacitor Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Filter Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46

Replacing Filter Capacitors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Testing Filter Capacitors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48

Converter Cabinet Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50

PowerCage™ Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Resistance Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

SGCT and Snubber Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

SGCT Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63

SGCT Anode-to-Cathode (Sharing) Resistance. . . . . . . . . . . . . . . . . 64

Snubber Resistance (SGCT Device). . . . . . . . . . . . . . . . . . . . . . . . . . . . 66

Snubber Capacitance (SGCT Device). . . . . . . . . . . . . . . . . . . . . . . . . . 67

Replacing the SGCT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Replacing Snubber and Sharing Resistor. . . . . . . . . . . . . . . . . . . . . . . . 72

Replacing Snubber Capacitor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

Replacing Sharing Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

Rockwell Automation Publication 7000-UM202B-EN-P - June 2014 5

Table of Contents

Silicon Controlled Rectifier PowerCages . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

SCR Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79

SCR Anode-to-Cathode Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

SCR Sharing Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82

SCR Gate-to-Cathode Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Snubber Resistance (SCR Device). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84

Snubber Capacitance (SCR Device) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85

Replacing SCR and SCR Self-Powered Gate Driver

Boards (SPGDB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86

Uniform Clamping Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Checking Clamping Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Clamping Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Temperature Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Replacing the Thermal Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90

Replacing Heat Sinks/Heat Pipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Replacing Heat Sinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Replacing Heat Pipes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95

PowerCage Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

Replacing PowerCage Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Removing the PowerCage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Self-Powered SGCT Power Supply - SPS . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Board Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Test Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Testing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Self-Powered Gate Driver Board – SPGDB . . . . . . . . . . . . . . . . . . . . . . . . 104

Board Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Test Points. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Terminal/Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Testing Procedure for SCR Self-Powered Gate Driver Board . . . . . . . . 106

Testing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Fiber Optic Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Air Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Replacing the Air Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

DC Link and Fan Cabinet Components . . . . . . . . . . . . . . . . . . . . . . . . . . 111

DC Link Reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115

Removing and Replacing Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .

117

Fan Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Impeller Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Impeller Removal from Motor Shaft. . . . . . . . . . . . . . . . . . . . . . . . . . . 119

Installing Impeller Assembly onto Motor Shaft. . . . . . . . . . . . . . . . . 120

Replacing Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Control Power Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Ride-Through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

AC/DC Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Terminal / Connections Descriptions (Pioneer Power Supply) . . 128

Terminal / Connections Descriptions (Cosel Power Supply) . . . . 129

6 Rockwell Automation Publication 7000-UM202B-EN-P - June 2014

Table of Contents

Output Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130

Power Supply Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

UPS Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Replacing the UPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Low Voltage Control Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

DC/DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Terminal/Connections Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . 138

Replacing a DC/DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

Drive Processor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Replacing the Drive Processor Module . . . . . . . . . . . . . . . . . . . . . . . . 142

Analog Control Board (ACB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Interface Module (IFM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

Analog Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Current Loop Transmitter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

Isolated Process Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Non-Isolated Process Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Auxiliary +24V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Replacing the ACB Analog Control Board . . . . . . . . . . . . . . . . . . . . 152

Encoder Feedback Board. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Encoder Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

20B-ENC-1 & 20B-ENC-1-MX3 Encoder Interface . . . . . . . . . . . 153

80190-759-01, 80190-759-02 Universal Encoder Interface . . . . . 154

Quadrature Encoder Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Positional Encoder Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157

External Input/Output Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Replacing the External Input/Output Board. . . . . . . . . . . . . . . . . . . 160

Optical Interface Boards (OIB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161

Replacing the Optical Interface Board. . . . . . . . . . . . . . . . . . . . . . . . . 162

Optical Interface Base Board Test Points . . . . . . . . . . . . . . . . . . . . . . 165

Catalog Number Explanation

Preventative Maintenance Schedule

Rockwell Automation Publication 7000-UM202B-EN-P - June 2014 7

Appendix A

PowerFlex 7000 Drive Selection Explanation. . . . . . . . . . . . . . . . . . . . . . 168

Service Duty Rating, Continuous Current Rating and

Altitude Rating Code. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Appendix B

Preventative Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Operational Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Annual Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Initial Information Gathering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Physical Checks (NO Medium Voltage and NO Control Power) 170

Control Power Checks (No Medium Voltage) . . . . . . . . . . . . . . . . . 171

Final Power Checks before Restarting . . . . . . . . . . . . . . . . . . . . . . . . . 172

Additional Tasks During Preventive Maintenance . . . . . . . . . . . . . 172

Final Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Table of Contents

Torque Requirements

Time Estimations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174

Tool / Parts / Information Requirements. . . . . . . . . . . . . . . . . . . . . . 174

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

PowerFlex 7000 Preventative Maintenance Schedule . . . . . . . . . . . . . . . 177

Appendix C

Torque Requirements for Threaded Fasteners . . . . . . . . . . . . . . . . . . . . . 179

Appendix D

Meggering

Line & Load Cable Sizes

Environmental Considerations

Drive Meggering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Meggering the PowerFlex 7000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181

Meggering Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

Required Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182

Appendix E

Max. Line Cable Sizes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Max. Load Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Appendix F

Air Quality Requirements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193

Hazardous Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

Capacitor Dielectric Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

Lithium Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194

Chromate Plating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

In Case Of Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

Appendix G

Encoder Use and Torque Capabilities

When to use an Encoder? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

PowerFlex 7000 Drive Performance (Torque Capabilities). . . . . . . . . . 198

Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Appendix H

Specifications

“B” Frame Drive Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

Index

8 Rockwell Automation Publication 7000-UM202B-EN-P - June 2014

Chapter 1

Important User Information

This document provides procedural information for managing daily or recurring tasks involving the PowerFlex 7000 medium voltage “B” Frame drives (heat sink and heat pipe models).

Who Should Use This Manual

What Is Not in this Manual

This manual is intended for use by personnel familiar with medium voltage and solid-state variable speed drive equipment. The manual contains material that enables regular operation and maintenance of the drive system.

This manual provides information specific to maintaining the PowerFlex 7000 “B” Frame drive. It does not include topics such as:

• Physically transporting or siting the drive cabinetry

• Installing or commissioning procedures

• Dimensional and electrical drawings generated for each customer’s order

• Spare parts lists compiled for each customer’s order

Please refer to the following documents for additional product detail or instruction relating to PowerFlex 7000 “B” Frame drives:

• Drive-specific Technical Data: additional troubleshooting, parameters, and specification information for MV variable frequency drives (7000-TD002_-EN-P

• Transportation and Handling Procedures: receiving and handling instructions for Medium Voltage variable frequency drive and related equipment (7000-IN008_-EN-P

• Installation Guide: detailed installation and pre-commissioning procedures and information (7000-IN007_-EN-P

• Commissioning Guide: required procedures and checklists for Rockwell Automation field service engineers (7000-IN006_-EN-P

• Operator Interface Guide: HMI Offering with Enhanced Functionality (7000-UM201_-EN-P

• For drives equipped with the PanelView 550 HMI, see 7000-UM151_-EN-P.

)

Rockwell Automation provides the site- and installation-specific electrical and design information for each drive during the order process cycle. If they are not available on site with the drive, contact Rockwell Automation.

Rockwell Automation Publication 7000-UM202B-EN-P - June 2014 9

Chapter 1 Important User Information

If you have multiple drive types or power ranges, ensure you have the correct documentation for each specific PowerFlex 7000 product:

• “A” Frame for lower power air-cooled configurations (up to approximately 1250 hp/933 kW)

• “B” Frame for higher-power, air-cooled configurations (standard or heat pipe models)

• “C” Frame for all liquid-cooled configurations

General Precautions

Commissioning Support

ATT EN TI ON : This drive contains ESD (Electrostatic Discharge) sensitive parts

and assemblies. Static control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference Allen-Bradley publication 8000-4.5.2, “Guarding Against Electrostatic Damage” or any other applicable ESD protection handbook.

ATT EN TI ON : An incorrectly applied or installed drive 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 may result in malfunction of the system.

ATT EN TI ON : Only personnel familiar with the PowerFlex 7000 Adjustable Speed Drive (ASD) and associated machinery should plan or implement the installation, start-up and subsequent maintenance of the system. Failure to comply may result in personal injury and/or equipment damage.

After installation, Rockwell Automation Medium Voltage Support is responsible for commissioning support and activities in the PowerFlex 7000 product line.

Phone: 519-740-4790

Option 1 for technical and option 4 for commissioning questions

MVSupport_technical@ra.rockwell.com or MVSupport_services@ra.rockwell.com

Rockwell Automation support includes, but is not limited to:

• quoting and managing product on-site start-ups

• quoting and managing field modification projects

• quoting and managing customer in-house and on-site product training

10 Rockwell Automation Publication 7000-UM202B-EN-P - June 2014

Important User Information Chapter 1

Additional Resources

These documents contain additional information concerning related products from Rockwell Automation.

Resource Description

Publication 7000-PP002_-EN-P Publication 7000A-UM150_-EN-P PowerFlex 7000 Medium Voltage AC Drive (A Frame) - Classic Control Publication 7000A-UM151_-EN-P

Publication 7000-UM150_-EN-P PowerFlex 7000 Medium Voltage AC Drive (B Frame) - Classic Control Publication 7000-UM151_-EN-P PowerFlex 7000 Medium Voltage AC Drive (B Frame) - ForGe Control

Publication 7000-UM202_-EN-P PowerFlex 7000 Medium Voltage AC Drive (B Frame) - ForGe Control Publication 7000-IN006_-EN-P PowerFlex 7000 Medium Voltage AC Drive (B Frame) Commissioning -

Publication 7000-IN007_-EN-P PowerFlex 7000 Medium Voltage AC Drive (B Frame) Installation -

Publication 7000-IN008_-EN-P

Publication 7000L-UM301_-EN-P Publication 7000L-UM302_-EN-P

Publication 7000-TD001_-EN-P

Publication 7000-TD002_-EN-P PowerFlex 7000 Medium Voltage AC Drive (Firmware Version 9.xxx) -

Publication 7000-UM201_-EN-P Publication 7000-QS002_-EN-P

Publication 7000-IN010B-EN-P Handling, Inspection, and Storage of Medium Voltage Line Filter

PowerFlex 7000 Air-Cooled Drives

PowerFlex 7000 Medium Voltage AC Drive (A Frame) - ForGe Control (Using PanelView 550)

(Using PanelView 500)

ForGe Co ntrol

ForGe Co ntrol PowerFlex 7000 Medium Voltage AC Drive (B Frame) Trans. & Handling

- ForGe Control PowerFlex 7000 Medium Voltage AC Drive (C Frame) - ForGe Control PowerFlex 7000 Medium Voltage AC Drive (C Frame) - ForGe Control

(Marine) PowerFlex 7000 Medium Voltage AC Drive (Firmware Version 6.xxx) -

Classic Control

ForGe Co ntrol PowerFlex 7000 HMI Offering with Enhanced Functionality HMI Interface Board Software Updater and Firmware Download

Procedure

Capacitors

You can view or download publications at

http:/www.rockwellautomation.com/literature/

. To order paper copies of technical documentation, contact your local Allen-Bradley distributor or Rockwell Automation sales representative.

Rockwell Automation Publication 7000-UM202B-EN-P - June 2014 11

Chapter 1 Important User Information

Notes:

12 Rockwell Automation Publication 7000-UM202B-EN-P - June 2014

Chapter 2

PowerFlex 7000 Overview

The PowerFlex 7000 is a general purpose, stand-alone, medium voltage drive that controls speed, torque, direction, starting and stopping of standard asynchronous or synchronous AC motors. It works on numerous standard and specialty applications such as fans, pumps, compressors, mixers, conveyors, kilns, fanpumps, and test stands in industries such as petrochemical, cement, mining and metals, forest products, power generation, and water/waste water.

The PowerFlex 7000 meets most common standards from the National Electrical Code (NEC), International Electrotechnical Commission (IEC), National Electrical Manufacturers Association (NEMA), Underwriters Laboratories (UL), and Canadian Standards Association (CSA). It is available with the world’s most common supply voltages at medium voltage, from 2400...6600V.

Topology

The design focus is on high reliability, ease of use, and lower total cost of ownership.

The PowerFlex 7000 uses a Pulse Width Modulated (PWM) – Current Source Inverter (CSI) topology. This topology applies to a wide voltage and power range. The power semiconductor switches used are easy-to-series for any medium voltage level. Semiconductor fuses are not required for the power structure due to the current limiting DC link inductor.

With 6500V PIV rated power semiconductor devices, the number of inverter components is minimal. For example, only six inverter switching devices are required at 2400V, 12 at 3300...4160V, and 18 at 6600V.

The PowerFlex 7000 also provides inherent regenerative braking for applications where the load is overhauling the motor (e.g. downhill conveyors, etc.), or where high inertia loads (e.g. fans, etc.) are quickly slowed down. The drive uses Symmetrical Gate Commutated Thyristors (SGCTs) for machine converter switches, SGCTs (for Active Front-end [AFE] rectifier configurations) for the line converter switches and Silicon-controlled Rectifiers (SCRs) (for 18 Pulse rectifier configurations).

The PowerFlex 7000 provides a selectable option for enhanced torque control capabilities and increased dynamic control performance. This High Performance Torque Control (HPTC) feature delivers 100% torque at zero speed and provides torque control through zero speed with smooth direction transition.

Rockwell Automation Publication 7000-UM202B-EN-P - June 2014 13

Chapter 2 PowerFlex 7000 Overview

Rectifier Designs

Configurations

The PowerFlex 7000 offers three rectifier configurations for "B" Frame drives:

• Direct-to-Drive (AFE rectifier with integral line reactor and Common Mode Choke)

• AFE rectifier with separate isolation transformer

• 18 Pulse rectifier with separate isolation transformer

Direct-to-Drive

Direct-to-DriveTM technology does not require an isolation transformer or multiple rectifier bridges as in Voltage Source Inverter (VSI) topologies offered by others. The approach is completely different. Instead of multiple uncontrolled rectifiers, a single AFE rectifier bridge is supplied. The rectifier semiconductors used are SGCTs. Unlike the diodes used in VSI rectifier bridges, SGCTs are turned on and off by a gating signal. A PWM gating algorithm controls the firing of the rectifier devices, very similar to the control philosophy of the inverter. The gating algorithm uses a specific 42 pulse switching pattern (Figure 1 and 11th harmonic orders.

Figure 1 - Typical PWM switching pattern, line voltage waveform

) called Selective Harmonic Elimination (SHE) to mitigate the 5th, 7th,

A small integral line reactor and capacitor addresses the high harmonic orders (13th and above) and provides virtually sinusoidal input voltage and current waveforms back to the distribution system. This delivers excellent line-side harmonic and power factor performance to meet IEEE 519-1992 requirements and other global harmonic standards in virtually all cases, while still providing a simple, robust power structure that maximizes uptime by minimizing the number of discrete components and the number of interconnections required.

A Common Mode Choke (CMC) mitigates the common mode voltage seen at the motor terminals, so standard (non-inverter duty rated) motors and motor cables can be used, making this technology ideal for retrofitting existing motor applications.

14 Rockwell Automation Publication 7000-UM202B-EN-P - June 2014

PowerFlex 7000 Overview Chapter 2

SGCTs

LINE CONVERTER

OMMON MODE CHOKE

L+

M+

SGCTs

MACHINE CONVERTER

U(T1)

V(T2)

W(T3)

L-

M-

SGCTs

LINE CONVERTER DC LINK

L+

M+

SGCTs

MACHINE CONVERTER

U(T1)

V (T2)

W(T3)

L-

M-

2U (X1)

2V (X2)

2W (X3)

ISTXISTX

REMOTE

Figure 2 - 3300/4160V Direct-to-Drive (transformerless AFE rectifier)

AFE Rectifier with Separate Isolation Transformer

For applications when the line voltage is higher than the motor voltage, a transformer is required for voltage matching. In this case, providing an AFE rectifier with a separate isolation transformer is ideal (indoor and outdoor transformer versions are offered). The isolation transformer provides the input impedance (replaces the requirement for an integral line reactor) and addresses the common mode voltage (replaces the requirement for a CMC that is supplied in the Direct-to-Drive rectifier configuration). However, the AFE rectifier, its operation, and advantages are the same as the Direct-to-Drive configuration.

Figure 3 - 3300/4160 AFE Rectifier with separate isolation transformer

Rockwell Automation Publication 7000-UM202B-EN-P - June 2014 15

Chapter 2 PowerFlex 7000 Overview

LINE CONVERTER

L- M-

L+ M+

MACHINE CONVERTER

U (T1)

V (T2)

W (T3)

4U (Z1) 4V (Z2) 4W (Z3)

ISTX

SCRs

3U (Y1) 3V (Y2) 3W (Y3)

2U (X1) 2V (X2) 2W (X3)

SGCTs

LINE CONVERTER

L- M-

L+ M+

MACHINE CONVERTER

U (T1)

V (T2)

W (T3)

4U (Z1) 4V (Z2) 4W (Z3)

ISTX

SCRs

3U (Y1) 3V (Y2) 3W (Y3)

2U (X1) 2V (X2) 2W (X3)

SGCTs

REMOTE

18 Pulse Rectifier with Separate Isolation Transformer

For high power constant torque applications and/or when the line voltage is higher than the motor voltage, a transformer is required for voltage matching (indoor and outdoor transformer options are available). The 18 Pulse rectifier uses SCRs instead of the SGCTs used for an AFE rectifier. When used for high power constant torque applications, the 18 Pulse rectifier has lower losses than the AFE rectifier, making it ideal for the highest power requirements. The 18 Pulse isolation transformer provides the required input impedance and addresses common mode voltage just like the separate isolation transformer used with the AFE rectifier. However, instead of a PWM rectifier switching pattern and a single rectifier bridge, the 18 Pulse configuration mitigates line side harmonics through harmonic current cancellation in the isolation transformer phase shifted secondary windings. The inverter is the same configuration for all available rectifier options.

Figure 4 - 3300/4160V 18 Pulse rectifier with Separate Isolation Transformer

DC LINK

Cooling Technology

These VFDs are supplied with heat sinks for most configurations and heat pipes for the highest-power AFE configurations. While both configurations draw heat away from the semiconductors, heat pipes are bigger, more efficient, and require larger fans and airflow.

Information and graphics in this manual show both configurations.

16 Rockwell Automation Publication 7000-UM202B-EN-P - June 2014

PowerFlex 7000 Overview Chapter 2

300.00

200.00

100.00

0.00

-100.00

-200.00

-300.00

10.00K

7.50K

5.00K

2.50K

0.00K

-2.50K

-5.00K

-7.50K

-10.00K

100.00

110.00

120.00 130.00

140.00

150.00

Vrms

CURRENT

VOLTAGE

Motor Compatibility

The PowerFlex 7000 achieves near-sinusoidal current and voltage waveforms to the motor, resulting in no significant additional heating or insulation stress. Temperature rise in the motor connected to the VFD is typically 3 °C (5.5 °F) higher compared to across-the-line operation. Voltage waveform has dv/dt of less than 50 V/

µs. The peak voltage across the motor insulation is the rated motor

RMS voltage divided by 0.707.

Reflected wave and dv/dt issues often associated with voltage source inverter (VSI) drives are a non-issue with the PowerFlex 7000. Figure 5

shows typical motor waveforms. The drive uses a selective harmonic elimination (SHE) pattern in the inverter to eliminate major order harmonics, plus a small output capacitor (integral to the drive) to eliminate harmonics at higher speeds.

Standard motors are compatible without de-rating, even on retrofit applications.

Motor cable distance is virtually unlimited. Rockwell Automation has tested this technology for controlling motors up to 15 km (9.3 mi) away from the drive.

Figure 5 - Motor waveforms @ full load, full speed

Arms

TIME (ms)

Rockwell Automation Publication 7000-UM202B-EN-P - June 2014 17

Chapter 2 PowerFlex 7000 Overview

SGCTs

LINE CONVERTER

L+

M+

SGCTs

MACHINE CONVERTER

U(T1)

V(T2)

W(T3)

L-

M-

OMMON MODE CHOKE

SGCTs

LINE CONVERTER DC LINK

L+

M+

SGCTs

MACHINE CONVERTER

U (T1)

V (T2)

W (T3)

L-

M-

2U (X1)

2V (X2)

2W (X3)

ISTXISTX

REMOTE

LINE CONVERTER

L- M-

L+ M+

MACHINE CONVERTER

U (T1)

V (T2)

W (T3)

4U (Z1) 4V (Z2) 4W (Z3)

ISTX

SCRs

3U (Y1) 3V (Y2) 3W (Y3)

2U (X1) 2V (X2) 2W (X3)

SGCTs

LINE CONVERTER

L- M-

L+ M+

MACHINE CONVERTER

U (T1)

V (T2)

W (T3)

4U (Z1) 4V (Z2) 4W (Z3)

ISTX

SCRs

3U (Y1) 3V (Y2) 3W (Y3)

2U (X1) 2V (X2) 2W (X3)

SGCTs

REMOTE

Simplified Electrical Diagrams

2400V

Figure 6 - 2400V – Direct-to-Drive (transformerless AFE rectifier)

Figure 7 - 2400V – AFE Rectifier with Separate Isolation Transformer

Figure 8 - 2400V – 18 Pulse Rectifier with Separate Isolation Transformer

DC LINK

18 Rockwell Automation Publication 7000-UM202B-EN-P - June 2014

PowerFlex 7000 Overview Chapter 2

SGCTs

LINE CONVERTER

L+

M+

SGCTs

MACHINE CONVERTER

U(T1)

V(T2)

W(T3)

L-

M-

OMMON MODE CHOKE

SGCTs

LINE CONVERTER DC LINK

L+

M+

SGCTs

MACHINE CONVERTER

U(T1)

V (T2)

W(T3)

L-

M-

2U (X1)

2V (X2)

2W (X3)

ISTXISTX

REMOTE

LINE CONVERTER

L- M-

L+ M+

MACHINE CONVERTER

U (T1)

V (T2)

W (T3)

4U (Z1) 4V (Z2) 4W (Z3)

ISTX

SCRs

3U (Y1) 3V (Y2) 3W (Y3)

2U (X1) 2V (X2) 2W (X3)

SGCTs

LINE CONVERTER

L- M-

L+ M+

MACHINE CONVERTER

U (T1)

V (T2)

W (T3)

4U (Z1) 4V (Z2) 4W (Z3)

ISTX

SCRs

3U (Y1) 3V (Y2) 3W (Y3)

2U (X1) 2V (X2) 2W (X3)

SGCTs

REMOTE

3300/4160V

Figure 9 - 3300/4160V – Direct-to-Drive (transformerless AFE rectifier)

Figure 10 - 3300/4160V – AFE Rectifier with Separate Isolation Transformer

Figure 11 - 3300/4160V – 18 Pulse Rectifier with Separate Isolation Transformer

DC LINK

Rockwell Automation Publication 7000-UM202B-EN-P - June 2014 19

Chapter 2 PowerFlex 7000 Overview

SGCTs

L+

M+

SGCTs

U(T1)

V(T2)

W(T3)

L-

M-

OMMON MODE CHOKE

SGCTs

LINE CONVERTER DC LINK

L+

M+

SGCTs

MACHINE CONVERTER

U (T1)

V (T2)

W (T3)

L-

M-

2U (X1)

2V (X2)

2W (X3)

ISTXISTX

REMOTE

LINE CONVERTER

L- M-

L+ M+

MACHINE CONVERTER

U (T1)

V (T2)

W (T3)

4U (Z1) 4V (Z2) 4W (Z3)

ISTX

SCRs

3U (Y1) 3V (Y2) 3W (Y3)

2U (X1) 2V (X2) 2W (X3)

SGCTs

LINE CONVERTER

L- M-

L+ M+

MACHINE CONVERTER

U (T1)

V (T2)

W (T3)

4U (Z1) 4V (Z2) 4W (Z3)

ISTX

SCRs

3U (Y1) 3V (Y2) 3W (Y3)

2U (X1) 2V (X2) 2W (X3)

SGCTs

REMOTE

6600V

Figure 12 - 6600V – Direct-to-Drive (transformerless AFE rectifier)

LINE CONVERTER

Figure 13 - 6600V – AFE Rectifier with Separate Isolation Transformer

MACHINE CONVERTER

Figure 14 - 6600V - 18 Pulse Rectifier with Separate Isolation Transformer

DC LINK

20 Rockwell Automation Publication 7000-UM202B-EN-P - June 2014

PowerFlex 7000 Overview Chapter 2

Operator Interface

The HMI Interface Board is an HMI-enabling device for the PowerFlex 7000 drive. It allows the user to acquire all the necessary executable tools, documentation and reports required to commission, troubleshoot and maintain the drive.

Via the HMI Interface Board, the user can choose the style and size of the desired Windows-based operator terminal to interact with the drive (e.g. PanelView CE terminal, laptop, or desktop computer). The HMI Interface Board removes past issues with compatibility between the drive and configuration tools, as all the necessary tools are acquired from the drive.

The HMI Interface Board is well suited for applications that require remote placement of the operator terminal and remote maintenance.

Figure 15 - Operator Interface

Basic Configurations

There are three basic configurations for the HMI.

Remote-mounted HMI

The HMI is not mounted in the traditional location on the low voltage door of the Variable Frequency Drive (VFD). A remote mounting plate, complete with E-Stop push button, and HMI is supplied loose for the customer to mount wherever desired. The HMI connects to the VFD via a hardwired Ethernet cable. There is no significant functional distance limitation.

Rockwell Automation Publication 7000-UM202B-EN-P - June 2014 21

Chapter 2 PowerFlex 7000 Overview

This is ideal for non-PLC users wanting to control and monitor remotely (e.g. at the driven machine, control room, etc.). Also ideal for customers having policies in place to control access to medium voltage equipment and the associated requirements of PPE when using the operator interface at the VFD, etc.

Locally-mounted HMI

Similar to the previously offered PanelView 550, the HMI is mounted on the LV door of the VFD. There is also a service access port (RJ-45 connector) on the LV door.

No HMI supplied

A service access port (RJ-45 connector) is located on the LV door of the VFD. Customers use their own laptop as the HMI. All programs required to use the laptop as the HMI are stored in the VFD. Their laptop is connected to the VFD via a hardwired Ethernet cable, when required. This is ideal for unmanned sites, where a dedicated HMI is not required.

See Publication 7000-UM201_-EN-P HMI.

See Publication 7000-UM151_-EN-P drives using the PanelView 550 HMI.

for detailed instruction for the

for detailed instruction for “B” Frame

22 Rockwell Automation Publication 7000-UM202B-EN-P - June 2014

Chapter 3

IMPORTANT

Component Definition and Maintenance

This section provides an overview of the control components and cabling of your PowerFlex 7000 “B” Frame drive. It also details a number of regular or recurring maintenance tasks that will keep your drive in peak operating condition.

The following illustrations identify the control components and cabling of your drives. Where appropriate, separate diagrams and instructions are available for both the heat sink and the heat pipe “B” Frame models.

For information regarding power wiring and cabling connections (as might be necessary for routine maintenance) refer to the PowerFlex 7000 “B” Frame Installation Manual (7000-IN007_-EN-P

Control Power Off Tests

Perform the following checks before applying control power to the drive. Rockwell Automation recommends that you complete these checks in the sequence they are presented here.

This section is also available in the PowerFlex “B” Frame Commissioning Guide (7000-IN006_-EN-P drive testing.

); refer to that document for additional information on

Interlocking

When the input contactor option is purchased, a key interlock is provided to prevent access to the medium voltage compartments of the drive unless the input isolation switch is locked in the open position.

Where the input switching device is provided by others, Rockwell Automation will provide a key interlock on the medium voltage compartment of the drive, and a matching interlock for installation by others on the upstream device. The interlock shall be installed in a manner that ensures the power to the drive is off and the drive is electrically isolated whenever the key is freed.

Although Key interlocks shipped with all medium voltage equipment are aligned in the factory, they often move out of position during shipping or are often misaligned when the cabinet is set down on an uneven floor. The following instructions will assist the field engineers in quickly and accurately aligning the deadbolt key interlock with its counterpart.

Rockwell Automation Publication 7000-UM202B-EN-P - June 2014 23

Chapter 3 Component Definition and Maintenance

ATT EN TI ON : Servicing energized industrial control equipment can be

hazardous. Severe injury or death can result from electrical shock, burn, or unintended actuation of control equipment. Hazardous voltages may exist in the cabinet even with the circuit breaker in the off position. Recommended practice is to disconnect or lock out control equipment from power sources, and confirm discharge of stored energy in capacitors. If it is necessary to work in the vicinity of energized equipment, the safety related work practices of NFPA 70E, Electrical Safety requirements for Employee Work places, must be followed.

Figure 16 - Deadbolt assembly mounted to door

1. Lock out and isolate the drive from medium voltage. Verify with a hot stick that there is no medium voltage present.

2. Determine that the key interlock is correctly aligned by securely bolting the medium voltage doors of the cabinet closed and removing the key from the lock. The key should turn easily; if any force is required to turn the key, the deadbolt alignment requires adjustment.

3. Open the doors of the cabinet and inspect the key assembly. Place high visibility grease on the pins of the deadbolt counterpart. The factory recommends using yellow torque sealant, however if it is unavailable almost any grease will do (Figure 17

24 Rockwell Automation Publication 7000-UM202B-EN-P - June 2014

Component Definition and Maintenance Chapter 3

Figure 17 - Deadbolt counterpart mounted to cabinet

4. Bolt the cabinet door closed so the pins on the dead bolt counterpart make contact with the deadbolt assembly. Doing so should leave two marks of torque sealant or grease on the assembly where the pins made contact (see

Figure 16 on page 24

Control / Cabling Cabinet Components

5. Slightly loosen the adjustment bolts on the counterpart and make the necessary movements on the counterpart to ensure that the pins align with the landing plates on the deadbolt assembly. As the amount of counterpart movement required is an estimate, it may take a couple attempts to properly align the assembly.

6. Clean the torque seal/grease from the key interlock once finished aligning the counterpart.

Once properly aligned, the key should turn freely when the cabinet door is fully bolted shut. If the key does not function when the door is tightly bolted closed, adjustments will have to be made to the depth of the counterpart. This can be done by adding shims on the landing plate where the counterpart is mounted.

For converter cabinets, see Converter Cabinet Components on page 50.

For DC link/fan cabinets, see DC Link and Fan Cabinet Components

page 111.

Rockwell Automation Publication 7000-UM202B-EN-P - June 2014 25

Chapter 3 Component Definition and Maintenance

Grounding Network (For use with Isolation Transformer) or Ground Filter (For use with Line Reactor)

Motor Filter Capacitors

Hall Effect Sensors

Sensing Boards

Line Terminals

Motor Terminals

Current Transformers

Surge Arresters

Figure 18 - Cabling cabinet for AFE rectifier (heat sink model)

26 Rockwell Automation Publication 7000-UM202B-EN-P - June 2014

Grounding Network (For use with Isolation Transformer) or Ground Filter (For use with Line Reactor)

Surge Arresters

Voltage Sensing Boards

Line Terminals

Current Transfo rmers

Zero Sequence Current Transformer (used with Line Reactor)

Motor Terminals

Hall Effect Current Sensors

Component Definition and Maintenance Chapter 3

Figure 19 - Cabling cabinet for AFE rectifier (heat pipe model)

Rockwell Automation Publication 7000-UM202B-EN-P - June 2014 27

Chapter 3 Component Definition and Maintenance

Surge Arrestors

Zero Sequence

Curren t

Transformer

Current Transformer

Grounding Filter (for use with Line Reactor)

Hall Effect Current Sensors

Voltage Sensing Boards

Motor Terminals

Line Terminals

Figure 20 - Cabling Cabinet for AFE Rectifier (6600V heat pipe model)

28 Rockwell Automation Publication 7000-UM202B-EN-P - June 2014

Component Definition and Maintenance Chapter 3

Hall Effect Sensor

Vol tag e Se nsi ng Boards

Hall Effect Sensor

Curren t Tra ns fo rm er s

Motor Terminals

Tra ns ie nt

Suppression

Network

Line Terminals

Figure 21 - Cabling cabinet for 18 Pulse rectifier (motor filter capacitors not shown)

Rockwell Automation Publication 7000-UM202B-EN-P - June 2014 29

Chapter 3 Component Definition and Maintenance

Line Filter

Capacitors

Zero Sequence

Current Transformer (if supplied)

Line

Reactor

Line Terminals

Motor Terminals

Motor Filter Capacitor s

Figure 22 - AC line reactor cabinet with connection cabinet (heat sink model)

30 Rockwell Automation Publication 7000-UM202B-EN-P - June 2014

Fans

Resistors

Line Reactor

Line Reactor Baffle

Component Definition and Maintenance Chapter 3

Figure 23 - AC Line Reactor Cabinet (6600V heat pipe model)

Rockwell Automation Publication 7000-UM202B-EN-P - June 2014 31

Chapter 3 Component Definition and Maintenance

Fans

Line Filter Capacitors

Line Reactor Baffle

Line Reactor

Resistors

Motor Filter

Capacitors

Figure 24 - AC Line Reactor with connection cabinet (heat pipe model)

32 Rockwell Automation Publication 7000-UM202B-EN-P - June 2014

Component Definition and Maintenance Chapter 3

Voltage-Sensing Assembly

The voltage-sensing assembly consists of the voltage sensing board and the mounting plate. The voltage sensing board has six independent channels that convert voltages as high as 10,800V (7.2kV x 1.5 pu) down to low voltage levels that the PowerFlex 7000 control logic (i.e. Signal Conditioning Board - SCB) can use. To measure up to twelve independent voltage channels, link two assemblies together, with one assembly acting as the master assembly and the second as the slave assembly. In linked assemblies, the master assembly sends the twelve voltage signals to the SCB board. For drives requiring the synchronous transfer option, use one additional module.

This assembly uses a separate connector to output the transfer voltages directly to the SCB board.

The following table shows the input voltage ranges for each input terminal on the voltage-sensing board. There are four separate inputs taps for each independent channel. This assembly operates at a nominal input voltage of up to 7200V with a continuous 40% overvoltage. The output voltages scale to provide almost 10V peak for a 140% input voltage at the high end of each of the voltage ranges.

Each channel has four taps that provide a range of input voltages and software to provide a given amount of gain, so that 140% will correspond to the maximum numerical value of the analogue to digital converter.

Nominal input voltage range

Tap Voltage Range

D 800...1449V

C 1450...2499V

B 2500...4799V

A 4800...7200V

ATT EN TI ON : Reconnect the grounds on the voltage sensing boards. Failure to do so may result in injury, death or damage to equipment.

Rockwell Automation Publication 7000-UM202B-EN-P - June 2014 33

Chapter 3 Component Definition and Maintenance

Replacing the Voltage-Sensing Circuit Board Assembly

The number of sensing boards is dependent upon the drive rectifier configuration.

1. Verify there is no power to the equipment.

ATT EN TI ON : To prevent electrical shock, disconnect the main power before working on the sensing board. Verify that all circuits are voltage-free, using a hot stick or appropriate high voltage-measuring device. Failure to do so may result in injury or death.

2. Mark the position of the ribbon cables and wires.

3. Remove the screws and lift the ring lugs from the terminals to remove the

wires.

4. Release the locking mechanism located on each side of the ribbon cable connector and pull the ribbon cable straight out to prevent bending the pins.

5. Remove the four nuts and washers that secure the assembly to the studs welded to the frame.

6. Remove the old VSB and replace with the new VSB on the studs, using the existing hardware to secure the assembly. Do not over-torque the connections or you may break the studs.

7. Replace ring lugs on terminals. Plug in ribbon cables making sure that cables are positioned properly and fitting is secure (locking mechanism is engaged).

8. For personnel and equipment safety, ensure both grounding connections are re-connected to the sensing board.

Figure 25 - Sensing board with mounting hardware placement

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Component Definition and Maintenance Chapter 3

Input Transient Protection

The drive provides input transient protection in one of two forms:

• Transient Suppression Network (TSN), or

• Surge arresters

The TSN is optimized for 18 Pulse rectifier designs. Surge arresters are optimized for AFE and Direct-to-Drive rectifier designs.

Transient Suppression Network (TSN)

The TSN module consists of an assembly of suppressors connected to each of the three phase input lines and the structure’s ground bus. There are three assemblies for an 18 Pulse drive.

A transient voltage spike in excess of the semiconductor rating will destroy or shorten the lifespan of the device. The TSN module suppresses transient overvoltages on the drive input, and is a standard feature of the drive. The two basic blocks of the TSN module are the MOV suppressor and the MOV fuse.

MOV Suppressor

The transient suppressors used in the module are heavy-duty metal oxide varistors (MOVs). Varistors are voltage dependent, nonlinear resistors. They have symmetrical voltage/current characteristics similar to back-to-back connected Zener diodes. The varistor has very high resistance below its voltage rating and appears as an open circuit.

The leakage current through the device would be very small in this region. When a voltage transient occurs in which the voltage exceeds the ‘knee’ in the curve, the varistor resistance changes from its high state by several orders of magnitude to a very low level. The voltage is clamped for a change in current of several orders of magnitude (Figure 26

Rockwell Automation Publication 7000-UM202B-EN-P - June 2014 35

Chapter 3 Component Definition and Maintenance

10-710-610-510

-4

-3

-2

-1

10010

10310

-8

CURRENT (AMPERES) -log scale

VOLTAGE

(VOLTS)

log scale

High Resistance

Region

Voltage Clamping Region

Short Circuit

Region

Figure 26 - Typical MOV V-I Characteristic Curve

When the MOV clips the voltage transient, the MOV absorbs the transient energy. The varistor has a limited energ y absorbing capability and there is insufficient time to conduct heat out of the device. The MOV size depends on the steady-state voltage rating, the energy in the transient, and the repetition rate of the transients. A critical element in selecting a MOV for protection is the impedance in the line supplying the transient. The isolation transformer or the AC line reactor on the input of the drive provides this impedance, which is why an impedance level is necessary for these input devices.

MOV Fuse

A medium voltage fuse is in series with each of the Phase MOVs. As seen in

Figure 27 on page 37

, these fuses may reside on either the assembly or remote from the assembly (on the Line Terminal module). Check the part number on your module and the information in this documentation to determine which assembly your drive requires.

The fuses provide overload protection for the conductors feeding the suppression network (and overturned protection if a short circuit occurs on the downstream side of the fuse.) These conductors will normally have a much smaller current carrying capacity than the drive input conductors; they are not protected by the drive input fuses. The fuses also isolate a failed MOV. Varistors initially fail in a short-circuited condition. The high follow-through current will open the fuse and remove the MOV from the circuit.

36 Rockwell Automation Publication 7000-UM202B-EN-P - June 2014

Component Definition and Maintenance Chapter 3

IMPORTANT

Drive Input Power from Line Terminals

Transient Suppression Network Medium Voltage Input Fuses

Phase MOV Suppressor

Ground MOV Suppressor

The fuses are E-rated, current-limiting fuses with a high interrupting rating. Because they are current-limiting, they limit both the magnitude and duration of fault currents. They are small dimension, ferrule-type fuses with a fiberglass body, and mount in standard fuse clips.

Rockwell Automation selects the fuses sent with the Transient Suppression Network based on their characteristics (including internal resistance) for optimum MOV performance and protection. Do not substitute other fuses without contacting the factory first.

Voltage sensing occurs after the MOV fuse and will detect open fuses in the drive control as a Master or Slave Undervoltage or Unbalance.

Figure 27 - Simplified wiring diagram

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Chapter 3 Component Definition and Maintenance

IMPORTANT

Ground location

Var ist ors

5 kV fuse example

7.2 kV fuse example

Connecting links

Var ist ors

5 kV fuse location

7.2 kV fuse location

Replacing Transient Suppression Network Fuses

Two sizes of fuses (5 kV, 7.2 kV) are available within the TSN located inside the connection cabinet. The 18 Pulse drive contains three TSNs.

1. Ensure there is no power to the equipment.

ATT EN TI ON : To prevent electrical shock, disconnect the main power before working on the drive. Verify that all circuits are voltage-free using a hot stick or appropriate voltage-measuring device. Failure to do so may result in injury or death.

2. Fuses are held in a place with a fuse clip. To remove the fuse pull firmly.

3. To replace the fuse, hold it in position and push firmly until the fuse is

seated within the fuse clip. Install fuses so that the rating is visible.

Replace the fuse with another of the same rating. (See Figure 28 on page 38 for location.)

Figure 28 - Transient Suppression Network

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Component Definition and Maintenance Chapter 3

Replacing Metal-Oxide Varistors

Metal-oxide varistors (MOV) are part of the TSN located within the connection cabinet.

1. Ensure there is no power to the equipment.

2. Observe the locations of the connecting links.

3. Detach the connecting links by removing the screws.

4. Using a screwdriver remove the screws at the base.

5. Replace the MOV (polarity is not an issue).

6. Continue by replacing the screws and connecting links.

Each MOV panel is grounded. Ensure that one MOV (see Figure 28 on page 38 for location) connects to the grounding lead.

Surge Arresters

These medium voltage drives use heavy duty distribution class surge arresters for transient overvoltage protection in the drives with AFE rectifiers. The arresters are certified as per ANSI/IEEE Std C62.11-1993.

The surge arresters are MOVs, with or without an air gap in series, in sealed housing. They provide overvoltage protection similar to that of the TSN module. They differ from the TSN in that fusing is not mandatory for the operation of surge arresters.

There are three types of surge arresters depending on the voltage class of the drive:

Drive Voltage 2.4 kV 3.3 kV, 4.16 kV, 4.8 kV 6.0...6.9 kV

Arrester rating (RMS) 3 kV 6 kV 9 kV

Arrester MCOV (RMS) 2.55 5.10 7.65

The most severe temporary overvoltage occurs when one phase is grounded in an ungrounded system. The full line-to-line voltage applies to the arrester in this case. The arresters operate under this condition continuously without any problems as indicated by their Maximum Continuous Operating Voltage (MCOV) rating.

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Chapter 3 Component Definition and Maintenance

Drive Input from Line Terminals

Heavy-duty Distribution Class Surge Arrestor

Three Y-connected surge arresters attach to the incoming MV lines. The neutral point of the arresters connects to the ground bus.

Figure 29 - Surge arresters on incoming MV lines

Operation

Arrester operation without a gap is the same as that of MOVs in the TSN. Depending on design, the arrester may also have a gap. Both gapped and ungapped arresters provide adequate overvoltage protection.

The arresters can withstand most commonly-seen bus transients within their capability. If there is a harmonic filter on the MV bus connected to the drive, the filter must satisfy relevant international or local standards, such as IEEE Std 1531— Clause 6.4, to avoid high inrush currents.

The surge arrester is certified as per ANSI/IEEE Std C62.11-1993. Certification tests include high current short duration tests, low current long duration tests, and fault current withstand tests. The fault current withstand tests consist of different combinations of kA and number of cycles, including a 20kA 10-cycle test, under which the arresters are non-fragmenting without expelling any internal components.

When the incoming energy exceeds the handling capability of the arrester and causes arrester failure, the housing splits open to vent without causing damage to any adjacent components.

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Component Definition and Maintenance Chapter 3

Surge Arresters

Replacing the Surge Arrester

1. Isolate and lock out all power to the drive.

2. Wait a minimum of ten minutes for the drive to discharge stored energy.

3. Observe the location of the connecting leads.

4. Use proper method to ensure the leads are at ground potential. Use

temporary grounding when necessary.

5. Detach the connecting leads.

6. Loosen the bolt that attaches the surge arrester to the ground bus. Remove

the arrester. Remove temporary ground when applicable.

7. Replace the surge arrester with an equivalent one (make sure that the voltage rating is the same).

8. Connect the leads to the surge arrester.

9. Torque the surge arrester hardware to 28 N•m (21 lb•ft).

Figure 30 - Surge Arresters (heat sink model)

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Chapter 3 Component Definition and Maintenance

Surge Arresters

Figure 31 - Surge Arresters (heat pipe model)

When you disconnect the surge arrester from drive, the arrester may retain a small amount of static charge. As a precautionary measure, install a temporary ground on the line-end of the arrester and discharge the stored energy. Remove temporary ground before reinstalling the arrester. To avoid electrical shock when removing the arrester from service, treat it as fully energized until you disconnect both the line and ground leads.

Field Test and Care

No field testing is necessary. The arresters do not require special care. At very dusty sites, however, you should clean the arrester when cleaning the entire drive.

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Component Definition and Maintenance Chapter 3

IMPORTANT

Replacing Output Grounding Network Capacitors

PowerFlex 7000 18 Pulse and select AFE drives come with an installed grounding network.

The number of capacitors varies depending on the system voltage.

1. Isolate and lock out all power to the drive.

2. Note the position of the leads.

3. Remove the 6.4 mm (¼ in.) hardware and disconnect the leads connected

to the terminals.

4. Four brackets secure the capacitor. Loosen the four screws at the base of the brackets and lift the capacitor out.

5. Place the new capacitor and tighten the screws securely.

6. Replace the ring lugs and 6.4 mm (¼ in.) hardware (see Figure 31

The maximum torque for the capacitor terminal is 3.4 N•m (30 lb•in).

Figure 32 - Capacitor in grounding network

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Chapter 3 Component Definition and Maintenance

IMPORTANT

Replacing the Hall Effect Current Sensor (HECS)

1. Isolate and lock out all power to the drive.

2. Note the location of all wires and the orientation of the HECS. For quick reference when checking the orientation of the HECS, look for the white arrow.

The Hall Effect Current Sensor (HECS) and wires must be in the proper orientation. Note the position before disassembly.

3. Remove the round bus bar. Remove the M10 hardware and slide the bar out.

4. Remove the output connector. Note the orientation.

5. Remove the four screws on the base of the Hall Effect sensor and remove

the sensor.

6. Insert the new sensor. Orient the arrows as shown in Figure 34

7. Slide the bus bar back into place and secure with the M10 hardware.

8. Replace the output connector, noting the correct orientation.

44 Rockwell Automation Publication 7000-UM202B-EN-P - June 2014

Component Definition and Maintenance Chapter 3

Bus Bar

Hall Effect Current Sensor

M10 Hardware

Base H ardware

Arrows must be

oriented properly

Figure 33 - Hall Effect Current Sensor located within cabinet

Figure 34 - Hall Effect Current Sensor (detail)

Rockwell Automation Publication 7000-UM202B-EN-P - June 2014 45

Chapter 3 Component Definition and Maintenance

IMPORTANT

Replacing the Current Transformer (CT)

1. Isolate and lock out all power to the drive.

ATTENTION: To prevent electrical shock, disconnect the main power before working on the drive. Verify that all circuits are voltage-free using a hot stick or appropriate voltage-measuring device. Failure to do so may result in injury or death.

2. Note the location of all wires and the orientation of the CT. For quick reference when checking the orientation of the CT, look for the white dot.

The CT and wires must be in the proper orientation. Note the position before disassembly.

3. Disconnect the wires.

4. Disassemble the bus bar to remove the CT. Remove the M10 hardware to

slide out the bus bar.

Filter Capacitor Cabinet

5. Remove the four screws located in the base of the CT and remove the CT.

6. Replace the CT, ensuring the proper orientation. Fasten the CT securely

with the four screws in the base

7. Reconnect the ring lugs. Do not overtighten or you will break the threaded stud. For torque specifications, refer to Torque Requirements for

Threaded Fasteners on page 183. Replace the bus bar and tighten into

place.

Filter Capacitors

All “B” Frame drives use filter capacitors on the motor side. The AFE rectifier options also include filter capacitors on the line side. Refer to Figure 19 on

page 27 (Cabling Cabinet for AFE Rectifier) and Figure 21 on page 29 (Cabling

Cabinet for 18 Pulse Rectifier).

The filter capacitors are three-phase, oil-filled, four-bushing units. The threephase capacitors are internal single-phase units connected in a Y configuration. The neutral point of the Y connects to the fourth bushing, which is available to use as a neutral point voltage measurement or other protection/diagnostics purposes. The metal cases of the capacitors are grounded through a stud on the capacitor housing.

The capacitors have internal “bleeding resistors” to discharge the capacitor and reduce its voltage below 50V in five minutes when disconnected. Figure 35 a typical three-phase capacitor.

46 Rockwell Automation Publication 7000-UM202B-EN-P - June 2014

shows

Figure 35 - Motor filter capacitor

IMPORTANT

Component Definition and Maintenance Chapter 3

WARNING: Allow 5...10 minutes for motor capacitors to safely discharge voltage prior to opening cabinet doors.

Replacing Filter Capacitors

See Publication 7000-IN010_-EN-P, “Handling, Inspection, and Storage of Medium Voltage Line Filter Capacitors”.

1. Isolate and lock out all power to the drive.

2. Note the location of all the cables and mark them accordingly.

3. Remove the 4 power connections to the terminals, and the single ground

connector from the drive to the capacitor frame, located at the back top right corner of the capacitor.

4. Remove the front bracket that holds the capacitor in place. At the rear of the capacitor, there is no hardware securing the capacitor; it fits into a slot in the assembly.

5. Remove the capacitor from the drive.

Capacitors can weigh as much as 100 kg (220 lbs). Use two or more people to remove a capacitor.

Rockwell Automation Publication 7000-UM202B-EN-P - June 2014 47

Chapter 3 Component Definition and Maintenance

ATT EN TI ON : The porcelain bushings are extremely fragile and any force applied

to the bushings can damage the seal between the bushing and the body causing potential leaks or chipping.

6. Install the new capacitor, sliding it back until it fits into the slot. Fasten the front bracket.

7. Reconnect all the power cables and the ground connection. These use M14 hardware, but should only be tightened to 30 N•m (22 lb•ft) due to capacitor mechanical constraints. You may want to fasten these connections before fully sliding the capacitor into place depending on the available space.

8. Follow the instruction labels on each capacitor to tighten the terminal connections.

9. Reinstall the removed sheet metal, and complete one final check to ensure connections are secure and correct.

Testing Filter Capacitors

There are two ways to test line filter capacitors. Rockwell Automation recommends the first method as it reduces the chance of re-torque issues because the capacitors are not disconnected. If the readings are unsatisfactory, the second method is more accurate, but involves disconnecting and testing them individually.

First Method

1. Ensure there is no power to the equipment.

ATT EN TI ON : Verify the load is not running due to process. A freewheeling motor can generate voltage that feeds back to the equipment.

2. Follow appropriate safety steps to isolate the equipment from medium voltage.

3. Verify that there is no voltage present on the capacitor by using a hot stick or any other appropriate voltage-measuring device.

4. Perform visual inspection to ensure there is no oil leak or bulge in any of the capacitors.

48 Rockwell Automation Publication 7000-UM202B-EN-P - June 2014

Component Definition and Maintenance Chapter 3

ATT EN TI ON : Capacitors that appear bulged or are leaking oil indicate potential problems with the internal elements. DO NOT USE. These units must be replaced. Failure to do so may lead to personal injury or death, property damage, or economic loss.

5. Using a DMM measure the capacitance across each phase-to-neutral of capacitors without removing any connections.

If the difference between the highest and the lowest readings is below 15%, then all capacitors are in good condition. If the difference between the highest and the lowest readings is off by 15% or more, then you might have a bad capacitor. If more than one capacitor is used in the circuit, then you would need to isolate each of them and check them separately to identify which one is defective.

6. Before disconnecting the capacitors, note the location of all the cables and mark them accordingly.

7. Disconnect power cables from the capacitor terminals on all four bushings and isolate them from the capacitor (see Replacing Filter Capacitors

page 47).

8. Repeat step 5 to check each capacitor separately to confirm which is defective.

Second Method

1. Ensure there is no power to the equipment.

ATT EN TI ON : Verify the load is not running due to process. A freewheeling motor can generate voltage that feeds back to the equipment.

2. Perform visual inspection to ensure there is no oil leak or bulge in any of the capacitors.

3. Note the location of all the cables and mark them accordingly.

4. Disconnect power cables from the capacitor terminals on all four bushings

and isolate them from the capacitor (see Replacing Filter Capacitors

page 47).

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Chapter 3 Component Definition and Maintenance

5. Connect a low voltage single-phase test power, for instance 110V or 220V, across a phase and the neutral of the capacitor. Switch on the test power and measure the test voltage and current drawn by the capacitor. Repeat the test for all three phases and note down the test voltage and current.

ATT EN TI ON : The capacitor will charge during this test so take care to prevent a shock or injury. When moving the test connections from one phase to the next, wait five minutes minimum for the capacitor to discharge.

6. Calculate the capacitance from the measured values of test voltage and current. For a good capacitor, the calculated capacitance value for each of the three readings should be within ±15% of the capacitor nameplate micro-Farad. If it is outside this range, the capacitor must be replaced.

Suppose a capacitor under test is rated at 400 kVAR, 6600V, 50 Hz, 29.2 F. Assume you are using 200V, 50 Hz test power with the recorded voltage and current values for each test as shown in the table below.

Phase - Neutral L1-N L2-N L3-N

Test Voltage 200V 200V 200V Measured Current 1.87 A 1.866 A 1.861 A

Converter Cabinet Components

Calculate the capacitance using the first reading. In this case:

V = 200V, I = 1.87 for L1-N Xc = V/I = 200/1.87 = 106.95

C= 1/ (2

π F Xc)

Where: F = frequency of the applied voltage.

C= 1/(2 x 3.14 x 50 x 106.95 C=29.7 F

Similarly, you can calculate the capacitance for the remaining two measurements for L2-N and L3-N.

This section describes the converter cabinet components of your PowerFlex 7000 “B” Frame drive. It also details a number of regular or recurring maintenance tasks that will keep your drive in peak operating condition.

The converter cabinet contains three rectifier modules and three inverter modules. Isolated Gate Driver Power Supplies (IGDPS) are available on the cabinet’s right side sheet.

Thermal sensors are available on the top module of the inverter and rectifier. The exact location depends on the drive configuration. These sensors connect to temperature feedback boards that return signals to the drive control.

For control/cabling cabinets, see Control / Cabling Cabinet Components

page 25. For DC link/fan cabinets, see DC Link and Fan Cabinet Components on page 111.

50 Rockwell Automation Publication 7000-UM202B-EN-P - June 2014

Isolated Gate Driver Power Supplies (IGDPS)

Rectifier IGDPS not required in drives with SPS boards installed

Ground Bus

Inverter Modules

Differential Pressure

Sensor

Rectifier Modules

Component Definition and Maintenance Chapter 3

Figure 36 - Converter cabinet (heat sink model, 2400V)

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Chapter 3 Component Definition and Maintenance

Isolated Gate Driver Power Supplies (IGDPS)

Rectifier IGDPS not required in drives with SPS boards installed

Ground Bus

Inverter Modules

Differential Pressure

Sensor

Rectifier Modules

Figure 37 - Converter cabinet (heat sink model, 3300...4160V version shown)

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Component Definition and Maintenance Chapter 3

Differential Pressure

Sensor

Ground Bus

Isolated Gate Driver Power Suppli es (IGDPS)

Rectifier IGDPS not required in drives with SPS boards installed

Rectifier Modules

Inverter Modules

Figure 38 - Converter cabinet (heat sink model, 6600V version shown)

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Chapter 3 Component Definition and Maintenance

Isolated Gate Driver Power Supplies (IGDPS)

Rectifier modules

Inverter modules

Ground bus

Rectifier modules

Isolated Gate Driver Power Supplies (IGDPS)

Inverter modules

Figure 39 - Converter Cabinet, 3300...4160V (heat pipe model)

Figure 40 - Converter Cabinet, 6600V (heat pipe model)

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Component Definition and Maintenance Chapter 3

PowerCage™ Overview

A PowerCage is a converter module, consisting of the following elements:

• epoxy resin housing

• power semiconductors with gate driver circuit boards

• heat sinks or heat pipes

• clamp

• snubber resistors

• snubber capacitors

• sharing resistors (not applicable for 2400V models)

Each drive consists of three PowerCage rectifier modules and three PowerCage inverter modules. There are two principal classes of rectifiers:

• AFE and 18 Pulse – AFE type rectifiers use SGCTs – 18 Pulse rectifiers use SCRs

All inverter modules use SGCTs as semiconductors.

The size of the PowerCage depends on the system voltage, and the components will also vary in the system current.

This table illustrates power semiconductor usage in the converter section.

Configuration Rectifier SGCTs Rectifier SCRs Inverter SGCTs

2400V, AFE 6 0 6 2400V, 18 Pulse 0 18 6 3300/4160V, AFE 12 0 12 3300/4160V, 18 Pulse 0 18 12 6600V, AFE 18 0 18 6600V, 18 Pulse 0 18 18

Some PowerFlex 7000 configurations contain Self-Powered SGCT Power Supply (SPS) boards. These boards are applicable on all “A” Frame drives and all AFE “B” Frame drives with heat sinks. See Self-Powered SGCT Power Supply - SPS

page 101 for more information

ATT EN TI ON : To prevent electrical shock, disconnect the main power before working on the drive. Verify that all circuits are voltage-free, using a hot stick or appropriate voltage-measuring device. Failure to do so may result in injury or death.

ATT EN TI ON : The PowerCage can house either SCRs or Symmetrical Gate Commutated Thyristors (SGCT). The SGCT circuit board is sensitive to static charges. Never handle these boards without proper grounding.

ATT EN TI ON : Some circuit boards can be destroyed by static charges. Use of damaged circuit boards may also damage related components. Use a grounding wrist strap when handling sensitive circuit boards.

ATT EN TI ON : If equipped, the SPS circuit board is sensitive to static charges. Do not handle these boards without proper grounding.

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Chapter 3 Component Definition and Maintenance

Resistance Checks

Prior to applying control power to the drive, power semiconductor and snubber circuit resistance measurements must be taken. Doing so will ensure that no damage has occurred to the converter section during shipment. The instructions provided below detail how to test the following components:

• Inverter or AFE Rectifier Bridge – Anode-to-Cathode Resistance Test (Sharing Resistor and SGCT) – Snubber Resistance Test (Snubber Resistor) – Snubber Capacitance Test (Snubber Capacitor)

• SCR Rectifier Bridge – Anode-to-Cathode Resistance Test (Sharing Resistor and SCR) – Gate-to-Cathode Resistance Test (SCR) – Snubber Resistance Test (Snubber Resistor) – Snubber Capacitance Test (Snubber Capacitor)

ATT EN TI ON : Before attempting any work, verify that the system has been locked out and tested to have no potential.

Snubber Resistors

Snubber resistors connect in series with the snubber capacitors. Together they form a simple RC snubber that connects across each thyristor (SCR or SGCT). The snubber circuit reduces the dv/dt stress on the thyristors and reduces the switching losses. The snubber resistors connect as sets of various wire-wound resistors connected in parallel. The number of resistors in parallel depends on the type of the thyristor and the configuration and frame size of the drive.

Snubber Capacitors

Snubber capacitors are connected in series with the snubber resistors. Together they form a simple RC snubber that is connected across each thyristor (SGCT). The purpose of the snubber circuit is to reduce the voltage stress (dv/dt and peak) of the thyristor and to reduce the switching loss.

Sharing Resistors

Sharing resistors provides equal voltage sharing when using matched devices in series. Please note, SGCT PowerCages for 2400V systems do not need matched devices and have no sharing resistor.

SCR PowerCages always have sharing resistors even if matched devices are not necessary. Sharing resistors in SCR PowerCages provide a diagnostic function.

56 Rockwell Automation Publication 7000-UM202B-EN-P - June 2014

Component Definition and Maintenance Chapter 3

Rsn-2

Rsn-1

Anode

Cs-1

Rsh

Cs-2

Snubber Resistor Test

Cathode

Heatsink Heatsink

Rsn-2

Rsn-1

Anode

Cs-1

Rsh

Cs-2

Snubber Resistor Test

Cathode

Heatsink Heatsink

SPS Board J1-1 J1-2

SGCT and Snubber Circuit

With all power semiconductors or thyristors, the SGCT requires a snubber circuit. The snubber circuit for the SGCT consists of a snubber resistor in series with a snubber capacitor.

Figure 41

shows the snubber circuit. Figure 51 shows the physical locations of the same circuit. Measure the resistance across two adjacent heat sinks. A value between 60 kΩ and 75 kΩ indicates a good sharing resistor.

Figure 41 - Snubber Circuit for SGCT module

Figure 42 - Snubber Circuit for SGCT module (with SPS board)

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Chapter 3 Component Definition and Maintenance

Clamp Base

SGCTs

Heat sink

Module Housing

Tem p er at u re Feedba ck Board

Clamp Head

Clamp Base

Heat sink

Module Housing

SPS Board Mounting Assembly without Temperature Feedback Board

Clamp Head

SGCT

SPS Mounting Assembly with Temperature Feedback Board

SGCT

Figure 43 - 2400V Two Device PowerCage (heat sink model)

Figure 44 - 2400V Two Device PowerCage (with SPS Boards installed)

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Component Definition and Maintenance Chapter 3

Clamp Base

Matched Set Two SGC Ts

Heat sink

Module Housing

Temperature Feedback Board

Clamp Head

Clamp Base

Matched Set Two SGC Ts

SPS Mounting Assembly with Temperature Feedback Board

Matched Set Two SGC Ts

Clamp Head

Heat sink

SPS Mounting Board Assembly without Temperature Feedback Board

Module Housing

Figure 45 - 3300/4160V Four Device PowerCage (heat sink model)

Figure 46 - 3300/4160V Four Device Rectifier PowerCage (with SPS Boards installed)

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Chapter 3 Component Definition and Maintenance

Clamp Base

Matched Set Three SGCTs

Clamp Head

Heat sink

Temperature Feedback Board

Module Housing

Clamp Base

Matched Set Three SGCTs

Clamp Head

Heatsink

SPS Mounting Assembly with Temperature Feedback Board

SPS Mounting Assembly without Temperature Feedback Board

Module Housing

Figure 47 - 6600V Six Device PowerCage (heat sink model)

Figure 48 - 6600V Six Device PowerCage (with SPS Boards installed)

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Component Definition and Maintenance Chapter 3

Heat Pipe Suppor t Channel

Module Housing

Clamp Base

Matched Set Two SGC Ts

Tem p er at u re Feedback Board

Matched Set Two SGC Ts

Clamp Head

Heat Pipe Assembly

Figure 49 - 3300/4160V Four Device PowerCage (heat pipe model)

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Chapter 3 Component Definition and Maintenance

Cs-1

Rsh

Rsn-2

Rsn-1

Anode

Cs-2

Cathode

Rsn-2

Cs-1

Cs-2

Rsn-1

Cathode

Rsh

Anode

Figure 50 - Snubber Circuit Assembly for SGCT module

Figure 51 - Snubber Circuit Assembly (heat pipe model)

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Component Definition and Maintenance Chapter 3

In addition to the snubber circuit, a sharing resistor connects in parallel with the SGCT. The sharing resistor ensures the voltage’s equal distribution among SGCTs connected in series. Connect SGCTs in series to increase the total reverse voltage blocking (PIV) capacity, as seen by the electrical circuit. A single SGCT has a PIV rating of 6500V. This single device provides sufficient design margin for electrical systems with 2400V medium voltage supply. At 4160V, connect two SGCTs in series to provide a net PIV of 13,000V to achieve the necessary design margin. Similarly, connect three SGCTs in series at 6.6 kV, providing a net PIV of 19,500V to achieve the necessary design margin.

To meet the cooling requirements of the SGCT, place the SGCT between two forced air-cooled heat sinks, one heat sink on the anode and the other heat sink on the cathode. The force on the SGCTs differs with the size of the device. The clamp assembly on the right hand side of the inverter module generates these forces.

The SGCTs require uniform pressure to prevent damage and to ensure low thermal resistance. Achieve uniform pressure by loosening the heat sink mounting bolts, tightening the clamp, then tightening the heat sink bolts.

This design directs external filtered air through the heat sink slots to dissipate heat from the SGCTs. The door filter ensures the heat sink slots stay clear of dust particles.

SGCT Testing

The following steps outline how to verify SGCT semiconductors and all associated snubber components. A quick reference to the expected resistance and capacitance values as well as a simple schematic diagram is located in the table below. A simple schematic diagram in Figure 41 on page 57 snubber components are connected across an SGCT.

SGCT Rating Sharing Resistor¹ Snubber Resistor Snubber Capacitor

1500 A 80 kΩ 6 Ω (AFE Rectifier) 0.2 μf 1500 A 80 kΩ 7.5 Ω (Inverter) 0.2 μf 800 A 80 kΩ 10 Ω 0.1 μf 400 A 80 kΩ 15 Ω (AFE Rectifier) 0.1 μf 400 A 80 kΩ 17.5 Ω (Inverter) 0.1 μf

¹— 2400V drives will not have a sharing resistor on devices.

shows how the

Table 1 - SGCT/snubber resistance values

SGCT Resistance Measurement Measured Resistance

Inverter Rectifier (AFE only)

SGCT Anode-Cathode Resistance (heat sink to heat sink) k-Ω

(Lowest) (Highest) (Lowest) (Highest)

Snubber Resistance (Test point: Heat sink above) Ω

(Lowest) (Highest) (Lowest) (Highest)

Snubber Capacitance (Test Point – heat sink on Right) μF

(Lowest) (Highest) (Lowest) (Highest)

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Chapter 3 Component Definition and Maintenance

Resistance value between two heat sinks is sharing resistance in parallel with anode-cathode resista nce

Resistance value between heat sink and test point is snubber resistance

SGCT Anode-to-Cathode (Sharing) Resistance

The anode-cathode resistance check measures the parallel combination of the sharing resistor and SGCT anode-cathode resistance. The sharing resistor has a resistance much lower than that of a good SGCT, so the measurement will be slightly less than the resistance of the sharing resistor. A measurement between 60 kΩ and 75 kΩ indicates the SGCT is in good condition and that wiring to the SGCT is correct. If the SGCT fails, it will be in the shorted mode, 0 Ω. The anode-to-cathode resistance check will be 0 Ω.

There is a test point inside the PowerCage to measure the resistance of the snubber resistor and capacitance of the snubber capacitor. The test point is the electrical connection between the snubber resistor and snubber capacitor. Place one probe of the multi-meter on the test point and the other probe on the appropriate heat sink to determine the value of the resistor or capacitor. See

Figure 52

Figure 52 - SGCT PowerCage

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Component Definition and Maintenance Chapter 3

Resistance value between two heat sinks is sharing resistance in parallel with anode-cathode resista nce

Resistance value between heat sink and test point is snubber resistance

Snubber Test Point

Resistance between heat sink and test point is snubber resistance

Resistance between two heat sinks is sharing resistance in parallel with anodecathode resistance

Figure 53 - Resistance Measurements SGCT PowerCage (with SPS Board Mounting Assembly)

Figure 54 - Resistance Measurements (heat pipe model)

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Chapter 3 Component Definition and Maintenance

Snubber test point

Measure resistance between heat sink and test point

Heatsink Heatsink

SGCT

Snubber Resistor

Snubber Capacitor

Sharing Resistor

Tes t Po in t

Resistance value between heat sink and test point is Snubber Resistance

Heatsink H eatsink

Snubber Resistor

Snubber Capacitor

Sharing Resistor

SPS Board

SGCT

Tes t Po int

Resistance Value between two heat sinks is sharing resistance in parallel with Anode-Cathode Resistance

Snubber Resistance (SGCT Device)

Access to the snubber resistor is not required to test the resistance. The snubber circuit test point is located within the PowerCage under the heat sinks. For each device, there is one test point. To verify the resistance, measure the resistance between the test point and the heat sink above.

Figure 55 - Snubber resistor test

Figure 56 - Snubber Resistor Test (with SPS Board)

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Component Definition and Maintenance Chapter 3

Heatsink Heatsink

Snubber Resistor

Snubber Capacitor

Sharing Resistor

SGCT

Tes t Po in t

Measure capacitance between heat sink and test point (or from heat sink to heat sink)

Snubber test point

Refer to Tab l e 1 on p ag e 6 3 to determine the appropriate snubber resistance value for the current rating of the SGCT used.

If the resistor is found to be out of tolerance, refer to page page 72

for detailed

instructions on replacing the snubber resistor assembly.

Snubber Capacitance (SGCT Device)

Turn the multimeter from the resistance to capacitance measurement mode. Verify the snubber capacitor by measuring from the test point to the heat sink adjacent to the right for standard rectifiers, or from heat sink to heat sink. For SPS rectifiers, measure from the test point to pin 1 of the Phoenix connector that plugs into J1 of the SPS board (disconnect the J1 connector from the SPS board first).

Figure 57 - Snubber Capacitor Test

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Chapter 3 Component Definition and Maintenance

Heatsink Heatsink

Snubber Resistor

Snubber Capacitor

Sharing Resistor

SPS Board

SGCT

Tes t Po in t

Snubber Capacitor Wire

Use Connector Terminal Screw for Testing Snubber Capacitor

SGCT Cathode Wire

Snubber Test Point

Figure 58 - Snubber Capacitor Test (shown with SPS Board installed)

Refer to Tab le 1 on p ag e 63 to determine the appropriate snubber capacitance value for the current rating of the SGCT used.

The capacitance measured is actually affected by the snubber capacitor and other capacitance in the circuit, including capacitance from the gate driver circuit. You are actually looking for a consistent reading for all devices.

If the capacitor is out of tolerance, refer to page 76

for detailed instructions on

how to replace the snubber capacitor.

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Component Definition and Maintenance Chapter 3

IMPORTANT

Replacing the SGCT

The SGCT (“device”) with attached circuit board is located within the PowerCage assembly. You must replace SGCTs in matched sets (2 sets for 4160V, 3 sets for 6600V).

The SGCT and associated control board are a single component. Never change the device or the circuit board individually. There are four LEDs on the SGCT, and the following table describes their functions.

LED 4 Green Solid Green indicates that the Power Supply to the Card is OK

LED 3 Green Solid Green indicates that the Gate-Cathode resistance is OK

LED 2 Yellow LED ON indicates the gate is ON, and Flashes alternately with LED 1 while gating

LED 1 Red LED ON indicates the gate is OFF, and Flashes alternately with LED 2 while gating

1. Isolate and lock out all power to the drive.

2. Note the position of the fiber optic cables for assembly.

3. To remove the SGCT, remove the gate driver power cable and fiber optic

cables. Exceeding the minimum bend radius (50 mm [2 in.]) of the fiber optic cables may result in damage.

Remove the SPS snubber connector ( J1 on the SPS board) and remove the SPS mounting bracket with the SPS board, if installed.

ATT EN TI ON : You may damage the fiber optic cables if you strike or bend them sharply. The minimum bend radius is 50 mm (2 in.). The connector has a locking feature that requires pinching the tab and gently pulling straight out. Hold the component on the printed circuit board to prevent damage.

Nylon screws are installed on the 6600V heat pipe model only; these must be removed when replacing the SGCTs. The purpose of these screws is for additional support while in transit and they are not required once the drive is installed on site. They must not be used again when the SGCTs are replaced.

4. Remove the load on the clamp head assembly as described under Checking

Clamping Pressure on page 89.

5. Two brackets secure the board to the heat sink. Loosen the captive screws to free the circuit board. If necessary, adjust the position of the heat sinks to move the SGCT freely.

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Chapter 3 Component Definition and Maintenance

IMPORTANT

6. Slide the circuit board straight out.

ATT EN TI ON : Static charges can damage or destroy the SGCT. Properly ground yourself before removing the replacement SGCT from the protective anti-static bag. Using damaged circuit boards may also damage related components. Use a grounding wrist strap for handling sensitive circuit boards.

SGCTs come in matched sets in systems with more than one device per leg. When replacing the device, you must replace all SGCTs in the set even if only one has failed. Arrange the devices from left to right in sets (i.e. set 1+2, 3+4, 5+6).

7. While grounded, remove the SGCT from its anti-static bag.

8. Clean the heat sink with a soft cloth and rubbing alcohol.

9. Apply a thin layer of Electrical Joint Compound (Alcoa EJC No. 2 or

approved equivalent) to the contact faces of the new SGCTs. Apply the compound to the pole faces using a small brush, and then gently wipe the pole face with an industrial wipe so that a thin film remains. Examine the pole face before proceeding to ensure that no brush bristles remain.

Too much joint compound may result in contamination of other surfaces leading to system damage.

10. Slide the SGCT into place until the mounting brackets contact the surface of the heat sink and tighten the captive screws located in the brackets.

11. Follow procedure Uniform Clamping Pressure

on page 88 to clamp the

heat sinks to a uniform pressure. If equipped, re-install the SPS board and mounting bracket, and reconnect

the snubber connection to J1 of the SPS board.

12. Connect the power cable and fiber optic cables (do not exceed the bend radius).

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Figure 59 - Replacing the SGCT

SGCT captive screws

Clamp head block

Disc Springs

Inside nut for loosening and applying load to assembly

DO NOT ADJUST outside nut

Clamp head block

SPS board mounting assembly captive screws

SGCT captive screws

Inside nut for loosening and applying load to assembly

DO NOT ADJUST outside nut

Component Definition and Maintenance Chapter 3

Figure 60 - Replacing the SGCT (if SPS board is installed)

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Chapter 3 Component Definition and Maintenance

Clamp Head

DO NOT ADJUST outside nut

Inside nut used for loosening and applying load to assembly

Disc Springs

SGCT Captive Screws

Figure 61 - Replacing the SGCT (heat pipe model)

Replacing Snubber and Sharing Resistor

The snubber and sharing resistors are part of the resistor assembly located behind the PowerCage.

1. Remove the PowerCage as outlined in Removing the PowerCage

page 99.

Note the connection of the leads for correct replacement.

2. Detach the leads located on the bottom of the resistor assembly.

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Figure 62 - PowerCage removal (Heat sink PowerCage)

Push Nuts

Common Snubber and Sharing Resistor Connection

Snubber Resistor Connection

Sharing Resistor Connection

Push Nuts

Snubber Capacitor

Cathode

Connect ion

Anode Connection

Make vertical cut on gasket at these two locations between Resistor Cage and main PowerCage

Remove Hardware

Component Definition and Maintenance Chapter 3

Figure 63 - PowerCage removal (Heat pipe PowerCage)

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Chapter 3 Component Definition and Maintenance

1. Detach leads of resistor assembly

2. Pinch and remove clips at end of retaining rod

3. Extract retaining rod

Detach the leads of the resistor assembly

Remove h ardware for resistor retaining bracket

3. Remove the push nuts on the end of the retaining rod. Pinch the clip together and pull off. Pull out the retaining rod.

Figure 64 - Snubber and Sharing Resistor replacement (heat sink model)

Figure 65 - Snubber and Sharing Resistor replacement (heat pipe model)

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Component Definition and Maintenance Chapter 3

Push Nut

Resistor Bank

Retaining Rod

Resistor Bank

Resistor Retaining Bracket

4. Use silicone gel to secure the snubber resistor assembly to the PowerCage. The gel minimizes possible damages to the resistor bank during transportation from the factory. You do not need to reapply it when inserting the new resistor bank. Remove the resistor bank from the PowerCage.

Figure 66 - Removing Resistor Bank from PowerCage

Figure 67 - Removing Resistor Bank from PowerCage (heat pipe model)

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Chapter 3 Component Definition and Maintenance

Snubber Capacitor

Sharing Resistor Connection

Snubber Resistor Connection

Cathode Connection

Anode Connection

Common Snubber and Sharing Resistor Connection

5. Place the new resistor bank assembly back into the PowerCage.

6. Slide the retaining rod into place and push the clips back into place.

7. Connect the leads to the resistor bank

8. Install the PowerCage as outlined in Removing the PowerCage

page 99.

Replacing Snubber Capacitor

The snubber capacitors are part of the capacitor assembly located behind the PowerCage.

1. Remove the PowerCage (see Removing the PowerCage

Note the connection of the leads for correct replacement.

2. Detach the lead located on the top of the capacitor.

Figure 68 - Removal of the PowerCage

on page 99).

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Component Definition and Maintenance Chapter 3

1. Detach leads of resistor assembly

2. Pinch and remove clips at end of retaining rod

3. Extract retaini ng rod

Push Nut

Retaining Rod

Resistor Bank

3. Remove the push nuts on the end of the retaining rod. Pinch the clip together and pull off. Pull out the retaining rod.

4. Remove two bolts and swing out PowerCage plug-in stab assembly.

Figure 69 - Snubber Capacitor Replacement

Figure 70 - Removing capacitor bank from PowerCage

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Chapter 3 Component Definition and Maintenance

Rsn-2

Cs-1

Rsh

Anode

Cs-2

SPGDB

Cathode

Rsn-1

5. Remove the capacitor from the PowerCage.

6. Place the new capacitor back into the PowerCage.

Ensure the bottom lead of the capacitor is on the stud.

7. Slide the retaining rod into place and push the clips back into place.

8. Connect the top lead to the capacitor.

Silicon Controlled Rectifier PowerCages

9. Install the PowerCage as outlined in Removing the PowerCage

page 99.

Replacing Sharing Resistors

Normally the sharing resistor is part of the snubber resistor assembly. Replacing the sharing resistor requires also replacing the snubber resistor.

The sharing and snubber resistors are normally located on the backside of the PowerCage. See page 72

Figure 71 shows the snubber circuit. Figure 72 shows the physical locations of the

same circuit.

Disconnect the 2-pole plug to the Gate Driver board marked TB1 on the circuit board. Measure the resistance from the point of the plug that connects to the point labeled V.SENSE on the Gate Driver board to the anode side heat sink. A value of 80 kΩ indicates a good sharing resistor.

Figure 71 - Snubber Circuit for SCR Rectifier Module

for removing and replacing snubber resistors.

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Component Definition and Maintenance Chapter 3

Cathode

Cs-2

Cs-1

Rsh

Rsn-2

Rsn-1

Anode

Figure 72 - Snubber Circuit Assembly for SCR Rectifier Module

SCR Testing

The following procedure verifies SCR semiconductors and all associated snubber components. For quick reference to the expected resistance and capacitance values, refer to Ta b l e 2 snubber component connections across an SGCT.

Table 2 - SCR Snubber Circuit Resistance and Capacitance Values

SCR Rating Sharing Resistance Snubber Resistance Snubber Capacitance

350, 400, 815 A 80 kΩ 60 Ω 0.5 μf

below. A simple schematic diagram in Figure 73 shows the

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Chapter 3 Component Definition and Maintenance

HeatsinkHeatsink

To G ate Dr ive r Bo ard

Heatsink

Snubber Resistor

Snubber Capacitor

Sharing Resistor

Tes t Po in t

Figure 73 - SCR snubber circuit connections

SCR Resistance Measurement Measured Resistance

Inverter Rectifier (SCR only)

SCR Anode-Cathode Resistance (heat sink to heat sink) k-Ω

(Lowest) (Highest) (Lowest) (Highest)

SCR Gate-Cathode Resistance (across SCR Phoenix Connector) Ω

Snubber Resistance (Test point: Heat sink above) Ω

(Lowest) (Highest) (Lowest) (Highest)

Snubber Capacitance (Test Point – heat sink on Right) μF

Sharing Resistance (Red wire from snubber Phoenix connector—heat sink on left) k-Ω

(Lowest) (Highest) (Lowest) (Highest)

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Component Definition and Maintenance Chapter 3

Resistance value between two heat sinks is Anode-toCathode resistance

SCR Anode-to-Cathode Resistance

Performing an Anode-to-Cathode resistance test verifies the integrity of the SCR. The SCR uses the snubber circuit to power the self-powered gate driver boards. The resistance measurement taken across each SCR should be constant; an inconsistent value may indicate a damaged sharing resistor, self-powered gate driver board or SCR.

Using an ohmmeter, measure the anode-to-cathode resistance across each SCR in the rectifier bridge, while looking for similar resistance values across each device. Easy access from the anode-to-cathode is available by going from heat sink-toheat sink (Figure 74

Figure 74 - Anode-to-cathode test

A good SCR and circuit should read between 22 and 24 k.

An SCR that has failed from anode-to-cathode will commonly produce a resistance value of 0 for a shorted device or

∞Ω for an opened device. Unlike the

SGCT, it is highly irregular for an SCR to have a partially shorted device. If an SCR is found to be out of tolerance, refer to page 86

for detailed instructions on

how to replace the SCR assembly.

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Chapter 3 Component Definition and Maintenance

Resistance between heat sink and red wire at plug is sharing resistance

SCR Sharing Resistance Test

To test the sharing resistor of an SCR module, disconnect the 2-pole plug of the self-powered gate driver board labeled SHARING and SNUBBER on the circuit board. The red wire of the plug is the sharing resistor. Measure the resistance between the red wire of the plug and the heat sink to the left. A value of 80 kohms indicates a healthy sharing resistor.

Figure 75 - SCR sharing resistance test

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Component Definition and Maintenance Chapter 3

Test points for Gate-to-Cathode

Disconnect SCR Phoenix connector from board

SCR Gate-to-Cathode Resistance

One test that can be performed on SCRs that cannot be performed on SGCTs is a Gate-to-Cathode Resistance Test. Performing a Gate-to- Cathode resistance measurement will identify damage to an SCR by revealing either an open or shorted gate to cathode connection. To test an SCR from gate-to-cathode, disconnect the SCR gate leads from the self powered gate driver board and measure the gate-to-cathode resistance on the SCR firing card Phoenix connector.

Figure 76 - SCR gate-to-cathode test

The resistance value from gate-to-cathode should be between 10 Ω to 20 Ω. A value close to 0 Ω indicates that there is an internal short in the SCR. An extremely high value indicates that the gate connection in the device has broken.

If a Gate-to-Cathode test reveals a damaged SCR, refer to page 86

for the SCR

replacement procedure.

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Chapter 3 Component Definition and Maintenance

HeatsinkHeatsink

To Gate Driver Board

Heatsink

Snubber Resistor

Snubber Capacitor

Sharing Resistor

Tes t Po int

Resistance value between test point and heat sink to its left is snubber resistance

Snubber Resistance (SCR Device)

Figure 77 - Snubber resistance test

Refer to Tab l e 2 on p ag e 7 9 to determine the appropriate snubber resistance value for the current rating of the SCR used.

If the resistor is found to be out of tolerance, refer to page 72 resistor assembly replacement procedure.

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for the snubber

Component Definition and Maintenance Chapter 3

HeatsinkHeatsink

To G ate D ri ver Bo ard

Heatsink

Snubber Resistor

Snubber Capacitor

Sharing Resistor

Tes t Po int

Resistance value between test point and white wire at 2-hole plug is snubber capacitance

Snubber Capacitance (SCR Device)

Turn the multimeter from the resistance to capacitance measurement mode. Proceed to verify the snubber capacitor by measuring from the test point and the white wire at the 2-pole device snubber plug (labeled snubber).

Figure 78 - Snubber capacitance test

To test the snubber capacitance, disconnect the plug of the self-powered gate driver board labeled SHARING and SNUBBER. The resistance between the white wire of the plug and the Test Point to its left is the snubber capacitance.

Refer to Tab le 2 on p ag e 79 value for the current rating of the SCR used. Read the actual snubber capacitor value shown in the table.

If the capacitor is out of tolerance, refer to page 76 replacement procedure.

Rockwell Automation Publication 7000-UM202B-EN-P - June 2014 85

to determine the appropriate snubber capacitance

for the snubber capacitor

Chapter 3 Component Definition and Maintenance

IMPORTANT

Replacing SCR and SCR Self-Powered Gate Driver Boards (SPGDB)

Replacing the SCR is similar to replacing the SGCT, except that you can replace the SCR and circuit board independently of one another.

1. Isolate and lock out all power to the drive.

2. Note the position of the fiber optic cables for reassembly.

3. To remove the SCR and SCR SPGDB, first remove the Gate Driver Power

Supply connector (from snubber circuit), the fiber optic cable, and the SCR gate-cathode connection. Exceeding the minimum bend radius (50 mm / 2 in.) of the fiber optic cables may result in damage.

4. Remove the load on the clamp head assembly as described under Checking

Clamping Pressure on page 89.

5. Loosen the 2 captive screws with a long Phillips screwdriver until the circuit board is free. If necessary, adjust the position of the heat sinks to allow free movement of the SCR.

6. Slide the SCR and SCR SPGDB straight out.

7. While grounded, unplug the Gate-Cathode connector from the SCR

SPGD board.

ATT EN TI ON : Static charges can destroy or damage the SCR and SCR SPGD board. Properly ground yourself before removing the replacement SCR and SCR SPGD board from the protective anti-static bag. Using damaged circuit boards may also damage related components. Use a grounding wrist strap for handling sensitive circuit boards.

Never adjust the orientation of the SCR using the Gate and Cathode Leads. These connections are sensitive; adjust the device orientation by turning the device itself.

To replace the SCR, follow steps 8-11 and 15-18.

To replace the SCR SPGDB, follow steps 12-18.

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Component Definition and Maintenance Chapter 3

IMPORTANT

8. Loosen the tie wrap holding the G-C wire in place, and remove the device from the assembly.

9. Install the new device in the same position and using the same orientation as the original SCR, and firmly secure the G-C wires with the same tie wrap.

10. Connect the Gate-Cathode connector to the Gate Driver board.

11. Apply a thin layer of electrical joint compound (Alcoa EJC No.2 or

approved equivalent) to the contact faces of the new SCRs. The recommended procedure is to apply the compound to the pole faces using a small brush and then gently wiping the pole face with an industrial wipe so that a thin film remains. Examine the pole face before proceeding to ensure that no brush bristles remain.

Too much joint compound may result in contamination of other surfaces leading to system damage.

12. While grounded, use a long Phillips screwdriver to remove the two screws that hold the SCR SPGDB to the metal bracket on the red glastic assembly. Retain the hardware.

13. Pull the 4 plastic clips that secure the SCR SPGDB to the glastic assembly. Retain the hardware.

14. Install the new SCR SPGDB in the assembly with the 4 plastic clips and use the screws to secure the board to the metal bracket.

15. Clean the heat sink with a soft cloth and rubbing alcohol.

16. Slide the SCR and SPGDB back into place until the mounting bracket

makes contact with the heat sink. Use the Phillips screwdriver to tighten the assembly to the heat sink.

17. Reapply the clamping load as described in Uniform Clamping Pressure

page 88.

18. Connect the control power cable and the fiber optic cables, ensuring that you do not exceed the bend radius.

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Chapter 3 Component Definition and Maintenance

Heat sink bolt location

Figure 79 - SCR and SPGDB assembly

Uniform Clamping Pressure

Always maintain proper pressure on the thyristors. Follow this procedure whenever changing devices or loosening the clamp completely.

1. Apply a thin layer of Electrical Joint Compound (Alcoa EJC No. 2 or approved equivalent) to the clamp head pressure pad face (Figure 81 Apply the compound using a small brush, and gently wipe the pad face with an industrial wipe until a thin film remains. Ensure no brush bristles remain.

2. Torque the heat sink bolts to 13.5 N•m (10 ft•lb.), then loosen each bolt two complete turns.

Figure 80 - Location of Heat sink bolts

3. Tighten the clamp to the proper force until you can turn the indicating washers by the fingers with some resistance.

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Component Definition and Maintenance Chapter 3

Calibration Nut - DO NOT ADJUST

Clamp Bar

Disc Springs

Pressure Pad Face

Indicating Washer

Adjustment Nut

IMPORTANT

4. Torque the heat sink bolts to 13.5 N•m (10 ft•lb.) starting with the center heat sink and moving outward alternating left to right.

5. Check the clamp indicating washer.

Checking Clamping Pressure

Periodically inspect the clamping force in the PowerCage. Ensure there is no power to the equipment.

Figure 81 - Clamp head illustration

Clamping Pressure Adjustment

1. Disconnect all power to the drive.

2. Do not loosen the adjustment nut. If you loosen the clamping pressure,

3. Tighten with a 21-mm wrench on the adjustment nut (upward motion)

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carry out the assembly procedure to ensure uniform pressure on the thyristors.

until you can turn the indicating washer by fingers with some resistance. IT SHOULD NOT SPIN FREELY.

Never rotate the lock nut located outside the indicating washer at the end of the threaded rod. The rotation of the outer nut will affect the torque calibration, which is factory-defined. Only adjust the inside nut (see Figure 81

Chapter 3 Component Definition and Maintenance

Temperature Sensing

Thermal sensors are available on one heat sink in the rectifier and one heat sink in the inverter. The thermal sensors are mounted on the heat sink with the temperature feedback board, or on the SPS mounting bracket which is mounted to the heat sink, if equipped.

Replacing the Thermal Sensor

1. Ensure there is no power to the equipment.

2. Remove the heat sink with the thermal sensor from the PowerCage. If equipped, first remove the SPS mounting bracket.

3. Remove clamp load (Figure 81 on page 89

4. Remove the device (SGCT or SCR) from the heat sink with the thermal

sensor.

5. Disconnect the fiber optic cable to the temperature feedback board.

6. Remove two M8 screws holding the heat sink in place.

7. Remove the heat sink with the temperature feedback board (may be on the

SPS bracket, if equipped) from the PowerCage.

8. Disconnect the plug connecting the thermal sensor and circuit board.

9. Remove the screw attaching the thermal sensor to the heat sink.

10. Replace with the new thermal sensor and cable assembly.

11. Note the small voltage difference between the thermal sensor and its heat

sink. For proper function, mount the small insulating pad between the thermal sensor and the heat sink, and the insulating bushing between the thermal sensor mounting screw and the thermal sensor.

12. Reverse the removal order to replace the heat sink with the new thermal sensor.

13. Follow procedure Uniform Clamping Pressure heat sinks to a uniform pressure.

on page 88 to clamp the

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Component Definition and Maintenance Chapter 3

Tem p er at u re Feedback Circuit Board

Mounting Pad

Insulating Bushing

Mounting Screw

Thermal Sensor and Cable Assembly

Mounting Screw

Insulating Bushing

Mounting Pad

Thermal Sensor and Cable Assembly

Temperature Feedback Circuit Board

Figure 82 - Thermal sensor replacement (heat sink model)

Figure 83 - Thermal Sensor Replacement (SPS Board Model)

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Chapter 3 Component Definition and Maintenance

Air flow sensor plugs into feed back circuit board

Air flow sensor mounting bracket

Thermal sensor plugs into feedback circuit board

Temperature feedback air flow circuit board

Figure 84 - Thermal sensor replacement (heat pipe model)

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Component Definition and Maintenance Chapter 3

Aluminum Type W

Aluminum Type M

Coppe r

Heat Pipe

Replacing Heat Sinks/ Heat Pipes

There are three different styles of heat sinks and one type of heat pipe used in PowerFlex air-cooled drives, depending on thermal requirements:

• Aluminum Type W heat sinks have a plurality of short internal fins along the internal surfaces

• Aluminum Type M heat sinks have internal fins with flat surfaces.

• Copper heat sinks have internal fins made from folded copper foil

• Heat pipes have a stack of aluminum fins

Figure 85 - Styles of Heat Sinks / Heat Pipes

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Chapter 3 Component Definition and Maintenance

Replacing Heat Sinks

The copper heat sinks can weigh about 9 kg (20 lb), while the aluminum heat sinks will weigh approximately 4 kg (9 lb).

1. Isolate and lock out all power to the drive.

ATT EN TI ON : To prevent electrical shock, disconnect the main power before working on the drive. Verify that all circuits are voltage free using a hot stick or appropriate voltage-measuring device. Failure to do so may result in injury or death.

2. Remove the load from the clamp head as described in Checking Clamping

Pressure on page 89.

3. Completely remove the SGCT or SCR from the heat sink that is being replaced (see Replacing the SGCT

Self-Powered Gate Driver Boards (SPGDB) on page 86).

4. There are two bolts that secure the heat sink to the PowerCage. They are 13-mm bolts, and must be removed using several extenders to get the socket wrench out past all the sensitive gate driver boards.

on page 69 or Replacing SCR and SCR

5. Loosen the two bolts and carefully remove the heat sink from the PowerCage.

ATT EN TI ON : If present, remove plastic film from the heat sink before installation. Failure to remove the film will result in device failure.

6. Install the new heat sink and hand-tighten the bolts.

7. Replace the SGCT or SCR (see Replacing the SGCT

on page 69 or Replacing SCR and SCR Self-Powered Gate Driver Boards (SPGDB) page 86).

8. Follow procedure Uniform Clamping Pressure

on page 88 to ensure the

heat sinks are clamped to a uniform pressure.

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Component Definition and Maintenance Chapter 3

Replacing Heat Pipes

For the largest power ratings of AFE rectifiers, heat pipes are used. Heat pipes weigh approximately 13 kg (28 lb). To replace a heat pipe:

1. Loosen heat pipe locking nuts on top of heat pipe horizontal fin support (center nut at each sink).

On 6600V drives only: Loosen heatsink nylon shipping bolts on bottom white heatsink retaining bracket (Figure 86

2. Remove the load from the clamp head as described in Checking Clamping

Pressure on page 89.

3. Completely remove SGCT from the heat pipe that is being replaced as described in Replacing the SGCT

on page 69.

4. Remove snubber resistor lugged connection at front of heatsink block and the thermistor connection if present.

5. Remove top heatsink horizontal fin support.

6. Remove the front white heat pipe retaining bracket at bottom of heatsink

block.

7. Pull heatsink forward, and lift up and out of powercage. Do not remove clamp head glass rods.

On both the ends and middle heat pipes there will be resistance pulling the heatsink forward due to the pin in the socket power connection is being disconnected as the heat pipe is being pulled forward).

ATT EN TI ON : If present, remove plastic film from the heat sink before installation. Failure to remove the film will result in device failure.

8. Install the new heat pipe.

9. Replace front white heat pipe retaining bracket.

10. Replace top heatsink horizontal fin support.

11. Replace the snubber resistor wire lugged connection and thermistor

connection, if present.

12. Replace the SGCT as described in Replacing the SGCT

on page 69.

13. Re-apply clamp force to heat pipes: a. Apply a thin layer of Electrical Joint Compound (Alcoa EJC No.2 or

approved equivalent) to the clamp head pressure pad face.

b. Tighten the clamp to the proper force until you can turn the indicating

washers by the fingers with some resistance.

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Chapter 3 Component Definition and Maintenance

IMPORTANT

Heat Pipe locking nuts

Horizontal Fin Support

Clamp Head Glass Rods

Clamp Head

White Heat Pipe Retaining Bracket

Nylon Shipping Bolt

Heat Pipe

14. Once clamp force has been re-applied, tighten heat pipe locking nuts on top of horizontal fin support (center nut at each sink) to 8.13 N•m (6 ft•lb).

Do not re-tighten nylon shipping bolts on 6600V drives. They are for shipping purposes only.

Figure 86 - Heat Pipe PowerCage

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Component Definition and Maintenance Chapter 3

Power Connection

Gasket

Resistors

Power Connection

PowerCage Housing

PowerCage Gasket

To ensure all air movement is through the slots of the heat sinks, all possible air leaks are sealed with a rubber gasket between the surface of the PowerCage and heat sink module. The gasket maintains proper cooling of the SGCTs or SCRs.

Figure 87 - PowerCage gasket location (heat sink model)

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Chapter 3 Component Definition and Maintenance

Resistors

Gasket

PowerCage Housing

Figure 88 - PowerCage gasket location (heat pipe model)

Replacing PowerCage Gaskets

The gaskets do not normally require replacement, but in the event that they become damaged, you may have to replace them.

Remove Old Gasket Material

Remove as much material as possible by hand to leave an even, bondable surface. Scrape off as much material as possible with a sharp knife, but avoid scoring the PowerCage. Clean away any loose pieces of gasket before proceeding with the gasket installation.

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Component Definition and Maintenance Chapter 3

IMPORTANT

Clean the PowerCage with a general purpose household cleaner. Do not spray onto the PowerCage as it promotes electrical tracking. Apply the cleaner to a paper towel and wipe the surface of the PowerCage where you will apply the gasket. Liberally spray the surface with distilled water, then wipe dry with a clean paper towel.

Apply a thin bead of Loctite 454 adhesive to the PowerCage surface in a zigzag pattern using the original nozzle size. Use the tip to spread the adhesive around to cover at least 50% of the area. There should be sufficient quantity of adhesive to remain wet long enough for the gasket to be applied. The adhesive uses the moisture in the air as it cures. The higher the humidity the faster the adhesive will cure.

This adhesive will bond anything quickly, including fingers!

Position the gaskets ensuring the gasket is oriented correctly. Center the gasket over the opening for the heat sinks with the narrow end positioned closest to the test points. Apply the porous surface of the gasket to the PowerCage. The gasket will bond almost immediately. Apply some pressure to the gasket for 15...30 seconds.

After all the gaskets have been placed check to see that the gasket has bonded properly. Repair any loose areas.

Removing the PowerCage

1. Ensure there is no power to the equipment.

2. Before removing the PowerCage, remove all the components located within the PowerCage to avoid any damage to the components. Consult the required sections to remove clamping pressure, as well as remove the SGCT or SCR, circuit boards, and thermal sensor.

3. Remove the 13 mm bolts in the two flanges that connect the heat sink to the PowerCage, then remove the heat sink from the PowerCage. This reduces the PowerCage weight for easier handling.

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Chapter 3 Component Definition and Maintenance

IMPORTANT

4. To detach the PowerCage itself, remove the bolts on the outer flange. Carefully lift the PowerCage down, placing the forward face down. Do not over-torque these bolts when replacing the PowerCage.

The PowerCage can be heavy. Use two people to extract the PowerCage from the drive to prevent injury or damage to the module.

5. Refer to appropriate section for component replacement.

6. When replacing the PowerCage, it is important to place the bolts on the

outer flange in loosely. Torque bolts alternately on one flange and then the opposite flange to ensure even tightening of the module. Use the suggested torquing sequence shown in Figure 89

Figure 89 - Typical torque sequence

Note: The PowerCage is shown with switching components, heat sinks and clamps removed for ease of lifting.

7. Replace interior assembly in the reverse order of removal.

A heat pipe PowerCage does not have to be removed to access the snubber resistors. The resistor cage can be removed within a heat pipe PowerCage (Figure 63

100 Rockwell Automation Publication 7000-UM202B-EN-P - June 2014

Rockwell Automation 7000 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Summary of Changes

Table of Contents

Who Should Use This Manual

What Is Not in this Manual

General Precautions

Commissioning Support

Additional Resources

Topology

Rectifier Designs

Configurations

Cooling Technology

Motor Compatibility

Simplified Electrical Diagrams

2400V

3300/4160V

6600V

Operator Interface

Basic Configurations

Control Power Off Tests

Interlocking

Control / Cabling Cabinet Components

Voltage-Sensing Assembly

Replacing the Voltage-Sensing Circuit Board Assembly

Input Transient Protection

Transient Suppression Network (TSN)

Surge Arresters

Filter Capacitor Cabinet

Filter Capacitors

Replacing Filter Capacitors

Testing Filter Capacitors

Converter Cabinet Components

PowerCage™ Overview

Resistance Checks

SGCT and Snubber Circuit

SGCT Testing

SGCT Anode-to-Cathode (Sharing) Resistance

Snubber Resistance (SGCT Device)

Snubber Capacitance (SGCT Device)

Replacing the SGCT

Replacing Snubber and Sharing Resistor

Replacing Snubber Capacitor

Silicon Controlled Rectifier PowerCages

Replacing Sharing Resistors

SCR Testing

SCR Anode-to-Cathode Resistance

SCR Sharing Resistance Test

SCR Gate-to-Cathode Resistance

Snubber Resistance (SCR Device)

Snubber Capacitance (SCR Device)

Replacing SCR and SCR Self-Powered Gate Driver Boards (SPGDB)

Uniform Clamping Pressure

Checking Clamping Pressure

Clamping Pressure Adjustment

Temperature Sensing

Replacing the Thermal Sensor

Replacing Heat Sinks/ Heat Pipes

Replacing Heat Sinks

Replacing Heat Pipes

PowerCage Gasket

Replacing PowerCage Gaskets

Removing the PowerCage