Rockwell Automation 7000A User Manual

Bulletin 7000 User Manual

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

(Using PanelView 550)

Publication 7000A-UM151D-EN-P

Important User Information

IMPORTANT

Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/ important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.

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.

available from

) describes some

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.

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).

Identifies information that is critical for successful application and understanding of the product.

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.

Preface Overview Who should use this Manual .................................................... P-1

What is not in this Manual ....................................................... P-1

Manual Conventions ................................................................ P-2

General Precautions ................................................................. P-3

Who to call for Commissioning ............................................... P-3

Chapter 1 Overview of Drive Introduction .............................................................................. 1-1

Drive Configurations ............................................................... 1-2

Topology .................................................................................. 1-3

Rectifier Designs

Active Front End (AFE) Rectifier .................................... 1-4

“Direct-to-Drive” Technology ................................................ 1-5

Motor Compatibility ................................................................ 1-6

Simplified Electrical Drawings

2400 volt – Active Front End (AFE) Rectifier .................. 1-7

3300/4160 volt – Active Front End (AFE) Rectifier ......... 1-8

6600 volt – Active Front End (AFE) Rectifier .................. 1-9

Operator Interface .................................................................. 1-10

Chapter 2 Drive Installation Safety and Codes ..................................................................... 2-1

General Handling Procedures .................................................. 2-1

Drive Storage ........................................................................... 2-1

Siting of the Drive ................................................................... 2-2

Site Considerations ............................................................ 2-2

Installation ............................................................................... 2-4

Installation of Exhaust Air Hood ...................................... 2-4

Installation of Integral Transformer Cooling Fan ............. 2-8

Neutral Resistor Assembly ............................................... 2-9

Installation of Neutral Resistor Assembly ...................... 2-10

Cabinet Layout and Dimensional Drawings of Drive ............ 2-11

PowerFlex 7000 “A” Frame Dimensional Drawing .............. 2-12

Drive Layout .......................................................................... 2-13

Direct-to-Drive AFE Rectifier Configuration #1 ............ 2-13

AFE Rectifier (Separate Isol. Transformer (Config. #2) ..... 2-14

AFE Rectifier (Integral Isol. Transformer (Config. #3) ....... 2-15

Cabling Cabinet #1 (with Input Starters) .............................. 2-16

Cabling Cabinet #1 (without Input Starters) ......................... 2-17

Cabling Cabinet #2 ............................................................... 2-18

Cabling Cabinet #3 ............................................................... 2-19

Converter Cabinet .................................................................. 2-20

Control/DC Link/Fan Cabinet ............................................... 2-21

Low Voltage Control Tub ...................................................... 2-22

IEC Component and Device Designations ............................ 2-24

Power Wiring Selection ......................................................... 2-24

Cable Insulation .............................................................. 2-25

Wire Group Numbers ...................................................... 2-26

7000 “A” Frame 7000A-UM151D-EN-P – March 2013

ii Table of Contents

Chapter 2 Drive Installation

Power Cabling Access ........................................................... 2-27

(cont.)

To access the customer power cable terminations .......... 2-27

Power Connections ................................................................ 2-28

Line/Motor Terminations ................................................ 2-28

Power Cabling Installation Requirements ....................... 2-28

Dimension Views:

Cabling Cabinet for Config. #1 with Input Starter ......... 2-29

Cabling Cabinet for Config. #1 without Input Starter ..... 2-30

Cabling Cabinet for Config. #2 ...................................... 2-31

Cabling Cabinet for Config. #3 ...................................... 2-32

Power and Control Wiring ..................................................... 2-33

Control Cables ................................................................ 2-33

Grounding Practices ............................................................... 2-34

Grounding Guidelines and Practices for Drive Signal

and Safety Grounds ................................................... 2-35

Grounding Requirements and Specifications for

Customer and Power Integrators .............................. 2-36

Identification of Types of Electrical Supplies

– Grounded and Ungrounded Systems ..................... 2-36

Ground Bus ..................................................................... 2-36

Interlocking ............................................................................ 2-37

Chapter 3 Operator Interface Chapter Objectives ................................................................... 3-1

Terminology ............................................................................ 3-1

Overview ................................................................................. 3-3

Keypad .............................................................................. 3-3

Function (Softkeys) Keys ........................................... 3-3

Cursor (Selection) Keys .............................................. 3-4

Data Entry Keys .......................................................... 3-4

What is a Screen? .............................................................. 3-5

Components ................................................................ 3-5

Information Windows ................................................. 3-6

Accessing/Writing to Drive .................................. 3-7

Communication Error ........................................... 3-7

Language Changing ............................................. 3-8

General Operation ....................................................... 3-8

Operator Interface Power-up Sequence ............................. 3-9

Top Level Menu .............................................................. 3-11

How to:

Obtain Help ..................................................................... 3-12

Related Topics .......................................................... 3-12

Help On Help ............................................................ 3-13

Modify Operator Interface Operation (Utility) ............... 3-14

Changing Backlight Delay ........................................ 3-14

Changing Contrast .................................................... 3-15

7000A-UM151D-EN-P – March 2013 7000 “A” Frame

Table of Contents iii

Chapter 3 Operator Interface

Setting Time ............................................................. 3-16

(cont.)

Setting Date .............................................................. 3-17

Selecting Meters ....................................................... 3-17

Viewing Revision Levels .......................................... 3-20

Transfer Data in Memory ......................................... 3-21

Picking an Access Level ........................................... 3-21

Select a Parameter ............................................................ 3-22

Via Groups ................................................................ 3-22

Via Name .................................................................. 3-23

Via Code ................................................................... 3-24

Edit Text .......................................................................... 3-26

Configure the Drive ......................................................... 3-28

Enter/Modify an Access Level ................................. 3-28

Drive Set-up .............................................................. 3-32

Language Selection ............................................ 3-33

Modify Parameters ............................................. 3-34

Numerical Value ................................................ 3-34

Enumerated Value .............................................. 3-36

Bit Encoded Value ............................................. 3-37

Analog Ports ....................................................... 3-38

Fault Masks ........................................................ 3-39

User Definable External Text ............................. 3-42

PLC .................................................................... 3-43

XIO ..................................................................... 3-45

Message Prompting .................................................. 3-45

Store/Retrieve Configuration (NVRAM) ................. 3-46

Initialize ............................................................. 3-46

Save .................................................................... 3-47

Load ................................................................... 3-47

Display Parameters .......................................................... 3-48

Custom Group ........................................................... 3-50

View Drive Status ........................................................... 3-51

View and Reset Alarms ................................................... 3-51

Help for Alarms ........................................................ 3-52

Request Printouts ............................................................ 3-53

Loading Programs (Firmware) ........................................ 3-54

Parameter Transfers ........................................................ 3-56

Upload to Operator Interface ............................. 3-57

Download from Operator Interface .................... 3-57

Upload to Memory Card .................................... 3-57

Download from Memory Card ........................... 3-58

Parameter File Format ........................................ 3-58

Loading Language Modules ............................................ 3-59

System Programming ...................................................... 3-60

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iv Table of Contents

Operator Interface Menu Hierarchy Chart

Chapter 3 Operator Interface

What does it show? ......................................................... 3-61

(cont.)

How do you read it? ........................................................ 3-61

Example ........................................................................... 3-62

PowerFlex 7000 “A” Frame Terminal Menu Tree .......... 3-63

PCMCIA Memory Card Installation Data

Description ...................................................................... 3-65

Installing the Memory Card ............................................ 3-65

Cabling Cabinet for Config. #1 (Direct-to-Drive) ................. 4-1

Chapter 4 Component Definition

Cabling Cabinet for Config. #1

and Maintenance

(Direct-to-Drive, optional Input Starter) .......................... 4-2

Cabling Cabinet for Config. #2

(AFE Rectifier with Separate Isolation Transformer) ....... 4-3

Cabling Cabinet for Config. #3

(AFE Rectifier with Integral Isolation Transformer) ....... 4-4

Converter Cabinet Components ............................................... 4-5

Converter Cabinet .................................................................... 4-6

Surge Arresters ....................................................................... 4-6

Description ....................................................................... 4-6

Operation .......................................................................... 4-7

Field Test and Care .......................................................... 4-7

PowerCage™ ........................................................................... 4-8

SGCT and Snubber Circuit .................................................... 4-11

Uniform Clamping Pressure .................................................. 4-12

Checking Clamping Pressure ................................................. 4-13

Clamping Pressure Adjustment ....................................... 4-13

Temperature Sensing ............................................................. 4-14

Symmetrical Gate Commutated Thyristor Replacement ....... 4-15

Snubber Resistors .................................................................. 4-18

Testing Snubber Resistors ............................................... 4-18

Fiber Optic Cabling .............................................................. 4-19

Air Pressure Sensor ................................................................ 4-19

DC Link/Fan/Control Components ........................................ 4-20

Filter Capacitors .............................................................. 4-21

Filter Capacitor Replacement .......................................... 4-22

Testing Filter Capacitors ................................................ 4-23

First Method ............................................................ 4-23

Second Method ........................................................ 4-24

Recommended Digital Multimeters (DMM) .................. 4-27

Fan Replacement ................................................................... 4-28

DC Link Section .............................................................. 4-28

Safety Notes .................................................................... 4-28

Fan Installation ................................................................ 4-29

Top of Integral Isolation Transformer Section ................ 4-29

Top of Integral Line Reactor/Input Starter Section ......... 4-29

7000A-UM151D-EN-P – March 2013 7000 “A” Frame

Table of Contents v

Impeller Maintenance (DC Link/Fan Section) ...................... 4-31

Chapter 4 Component Definition

Impeller Removal from Motor Shaft ............................... 4-31

and Maintenance

Safety Notes .................................................................... 4-31

(cont.)

Installation of Impeller Assembly onto Motor Shaft ....... 4-32

Impeller Maintenance ........................................................... 4-34

Isolation Transformer Cooling Fan ................................. 4-34

Inlet Ring Removal and Replacement ................................... 4-34

Safety Notes .................................................................... 4-34

DC Link / Fan Section ..................................................... 4-34

Procedure ......................................................................... 4-34

Top on Integral Isolation Transformer Section ............... 4-35

Replacement of Air Filters ..................................................... 4-35

Procedure ......................................................................... 4-35

Control Power Components ................................................... 4-38

Ride-Through .................................................................. 4-38

AC/DC Power Supply ............................................................ 4-41

Description ...................................................................... 4-41

Location ........................................................................... 4-42

Low Voltage Control Section ................................................ 4-44

DC/DC Power Supply ............................................................ 4-46

Description ...................................................................... 4-46

IO Connectors on Control Boards ........................................ 4-47

Drive Processor Module ........................................................ 4-48

ACB Analog Control Board .................................................. 4-49

Interface Module (IFM) ................................................. 4-50

Analog Inputs and Outputs .............................................. 4-50

External Input/Output Boards ................................................ 4-51

Optical Interface Boards ........................................................ 4-53

Environmental Considerations ............................................... 4-55

Hazardous Materials ........................................................ 4-55

Disposal ........................................................................... 4-57

Appendix A Commissioning Start-up Commissioning Services ........................................... A-1

Drive Commissioning ...................................................... A-1

Appendix B Catalog Number Catalog Number Explanation................................................... B-1

Control Power Transformer Selection ............................... B-2

PowerFlex 7000 Drive Selection Explanation ........................ B-3

When is a Tachometer Required? ........................................... B-4

PowerFlex 7000 Drive Performance ....................................... B-5

Glossary of Terms ................................................................... B-5

Typical Application Load Torque Profiles ............................. B-6

Explanation Supply Voltage, Control Voltage, Frequency and

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vi Table of Contents

Appendix C Torque Requirements Torque Requirements for Threaded Fasteners ........................ C-1

Appendix D Meggering Drive Meggering ..................................................................... D-1

Meggering the PowerFlex 7000A ........................................... D-1

Equipment Required ......................................................... D-2

Procedure .......................................................................... D-2

Preventive Maintenance Check List ....................................... E-1

Appendix E Preventative

Operational Maintenance ........................................................ E-1

Maintenance

Annual Maintenance ............................................................... E-2

Initial Information Gathering ........................................... E-2

Physical Checks (NO Medium Voltage and

NO Control Power) .................................................... E-2

Control Power Checks (NO Medium Voltage) ................ E-4

Final Power Checks before Restarting ............................. E-4

Additional Tasks During Preventive Maintenance .......... E-5

Final Reporting ................................................................. E-5

Time Estimations ............................................................. E-6

Tool / Parts / Information Requirements .......................... E-7

Maintenance Schedule ........................................................... E-8

Preventative Maintenance Service Schedule ......................... E-9

General Notes ...................................................................... E-11

Maintenance of MV Motor Control Equipment ............ E-11

Periodic Inspection ........................................................ E-11

Contamination ............................................................... E-12

High Voltage Testing .................................................... E-12

Maintenance after a Fault Condition ............................. E-12

Part-specific Notes ............................................................... E-13

Cooling Fans ................................................................. E-13

Operating Mechanisms .................................................. E-13

Contacts ......................................................................... E-13

Vacuum Contactors ....................................................... E-13

Power Cable and Control Wire Terminals ................... E-14

Coils ............................................................................. E-14

Batteries ......................................................................... E-14

Pilot Lights .................................................................... E-14

Solid-State Devices ....................................................... E-15

Locking and Interlocking Devices ................................ E-15

Appendix F Specifications Specifications ........................................................................... F-1

Dimensions/Weights ............................................................... F-4

Nominal Power Ratings .......................................................... F-4

7000A-UM151D-EN-P – March 2013 7000 “A” Frame

Preface

Overview

Who Should Use This Manual This User Manual is intended for use by personnel familiar with

medium voltage and variable speed solid-state drive equipment. The manual contains material that will allow the user to operate the drive system.

What Is Not in this Manual This manual is designed to provide only information specific to the

PowerFlex 7000 “A” Frame drive. Therefore customer specific topics are not presented. These customer specific topics include:

• Dimensional and Electrical Drawings generated for each customer specific order. (This manual does provide generic drawings for illustrative purposes only.)

• Spare Parts Lists compiled for each customer specific order. (This manual does provide a generic list of possible components and a description of their characteristics and functionality.)

The above information is provided to the customer during the

Three User Manuals address this product line:

If you have multiple drive types or power ranges, ensure you have

For detailed information on Troubleshooting, Parameters and

For detailed information on receiving and handling for Medium

Reference Manuals (for “A”, “B” and “C” Frame drives) are also

Please note: This manual deals specifically with the PowerFlex 7000

order process cycle.

 “A” Frame for lower power air-cooled configurations

(up to approximately 1250 hp/933 kW)

 “B” Frame for higher power air-cooled configurations  “C” Frame for all liquid-cooled configurations

the correct manual.

Functional Description for MV variable frequency drives, please refer to Technical Data publication 7000-TD002_-EN-P.

Voltage variable frequency drive and related equipment, please refer to General Handling Procedures, publication 7000-IN002_-EN-P.

available. These manuals provide additional technical information about the drive components. Contact your local Rockwell Automation Sales office to order copies of these publications.

“A” Frame drive. Information on auxiliary cabinetry or special components we are contracted to supply with the drive will be contained within the Service Manual you will receive with your order.

7000 “A” Frame 7000A-UM151D-EN-P – March 2013

P-2 Preface

Manual Conventions Symbols are used throughout this manual to indicate specific types

of information.

W A R N I N GW A R N I N G

Warnings tell readers where people may be hurt if procedures are not followed properly.

A T T E N T I O NA T T E N T I O N

Cautions tell readers where machinery may be damaged or economic loss can occur if procedures are not followed properly.

Both of the above could indicate:

• A possible trouble spot

• Tell what causes the trouble spot

• Give the result of an improper action

• Tell the reader how to avoid trouble

S H O C K H A Z A R DS H O C K H A Z A R D

This symbol alerts the user to a potential electrical shock hazard that exists on a component or printed circuit board.

7000A-UM151D-EN-P – March 2013 7000 “A” Frame

Preface P-3

General Precautions

A T T E N T I O NA T T E N T I O N

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.

A T T E N T I O NA T T E N T I O N

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.

A T T E N T I O NA T T E N T I O N

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.

Who to Call for Commissioning Rockwell Automation Medium Voltage Support group is

responsible for Commissioning Support and activities in our product line.

They may be contacted at 519-740-4100, request Medium Voltage

Support – Project Manager.

The support they offer 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.

7000 “A” Frame 7000A-UM151D-EN-P – March 2013

P-4 Preface

7000A-UM151D-EN-P – March 2013 7000 “A” Frame

Chapter 1

Overview of Drive

Introduction The PowerFlex® 7000 represents the third generation of medium

voltage drives from Rockwell Automation, and is part of the PowerFlex family of AC drive products. The Allen-Bradley PowerFlex® family of Drives incorporates leading-edge technology, embedded communications, and significant commonality across multiple platforms, networks, operator interface programming and hardware.

The PowerFlex 7000 is a general purpose stand alone medium

voltage drive that controls speed, torque, direction, starting, and stopping of standard induction or synchronous AC motors. It is intended for use on a host of standard and specialty applications such as fans, pumps, compressors, mixers, conveyors, kilns, and test stands. Primary industries for these applications include petrochemical, cement, mining and metals, forest products, power generation, and water/waste water.

The PowerFlex 7000 is a global product that adheres to the most

common standards from NEC, IEC, NEMA, UL, and CSA. It is available with the world’s most common supply voltages at medium voltage, from 2400-6600 volts.

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

cost of ownership.

7000 “A” Frame 7000A-UM151D-EN-P – March 2013

1-2 Overview of Drive

Drive Configurations – PowerFlex 7000 “A” Frame

Configuration #1

Direct-to-Drive

(AFE with DTC DC Link)

 Elimination of isolation transformer results in lower

losses and saved space

 An integrated system solution for fewer connections

and reduced installation costs

 New or existing motors  Small system footprint  3 cables in/3 cables out on entire system for easy

installation

 Low line harmonics and high power factor (typical

current THD < 5%, PF > 0.98)

 Fan control power and control circuit power

Configuration #2

AFE Rectifier

(Separate isolation transformer)

supplied internally

 Input starter optional

 Optimum installation flexibility with connection to

indoor or outdoor isolation transformers

 Compact packaging for smallest footprint

requirements

 New or existing motors  3 cables in/3 cables out for easy installation  Low line harmonics and high power factor (typical

current THD < 5%, PF > 0.98)

 Fan control power supplied internally (1-phase

control circuit power supplied by customer, 120V/60 Hz, 110V/50 Hz, 20 amp)

Directto-Drive (Optional Input Starter)

AFE Rectifier

Configuration #3

AFE Rectifier

(Integral isolation transformer)

 An integrated system solution for fewer connections

and reduced installation costs

 Small system footprint  New or existing motors  3 cables in/3 cables out for easy installation  Integral cooling fans for VFD and transformer  Low line harmonics and high power factor (typical

current THD < 5%, PF > 0.98)

 Fan control power supplied internally (1-phase

control circuit power supplied by customer, 120V/60 Hz, 110V/50 Hz, 20 amp)

Integral Isolation Transforme

7000A-UM151D-EN-P – March 2013 7000 “A” Frame

Overview of Drive 1-3

Topology

With 6500 volt PIV rated power semiconductor devices, the number

The PowerFlex 7000 has the additional benefit of inherent

The PowerFlex 7000 utilizes a Pulse Width Modulated (PWM) –

Current Source Inverter (CSI) for the machine side converter as shown in Figure 1.1. This topology offers a simple, reliable, cost-effective power structure that is easy to apply to a wide voltage and power range. The power semiconductor switches used are easy-to-series for any medium voltage level. Semi-conductor fuses are not required for the power structure due to the current limiting DC link inductor.

of inverter components is kept to a minimum. For example, only six inverter switching devices are required at 2400V, 12 at 3300-4160V, and 18 at 6600V.

regenerative braking for applications where the load is overhauling the motor, or where high inertia loads need to be slowed down quickly. Symmetrical Gate Commutated Thyristors (SGCTs) are used for machine converter switches and line converter switches.

INE CONVERTER DCLIN

L+

M+

CHINE CONVERTER

2U (X1)

2V (X2)

2W (X3)

SGCTs

L-

M-

SGCTs

U(T1)

V(T2)

W(T3)

Figure 1.1 – PWM-CSI AC Drive

7000 “A” Frame 7000A-UM151D-EN-P – March 2013

1-4 Overview of Drive

Rectifier Designs

An Active Front-End rectifier is particularly attractive since it does

Many competing technologies in today’s MV market require a multi-

The AFE rectifier requires a switching pattern that complies with

The filter resonant frequency is placed below 300 Hz (for a 60 Hz

The small integral AC line reactor (see Fig. 1.2) provides additional

Active Front-End (AFE) Rectifier

not require an isolation transformer to meet IEEE 519-1992.

winding transformer to mitigate the unwanted harmonics through cancellation by phase shifting the transformer secondary windings. Depending on the topology, the transformer can have up to 15 sets of secondary windings.

Elimination of the isolation transformer reduces capital and

installation costs, saves on valuable floor space, reduces operating costs and increases overall system efficiency.

similar rules as the inverter. The pattern used for the example shown in Figure 1.3 is a 42-pulse selective harmonic elimination (SHE) pattern, which eliminates the 5

, 7th and 11th harmonics. The integral input capacitors are designed to reduce the current harmonics of the higher order.

system) where no residual harmonics exist. This prevents the excitation of system harmonic frequencies. Other factors that are considered when designing the filter are the input power factor and the requirement on Total Harmonic Distortion (THD) of input current and voltage waveforms.

filtering and current limiting features to a line side short circuit fault. The line current and voltage waveforms are also shown in Figure 1.2. The line current THD is approximately 4.5%, while line-to-line voltage THD is approximately 1.5%. (THD of line voltage is a function of system impedance.) Input power factor with the AFE rectifier is near unity throughout a typical operating speed range for variable torque loads.

7000A-UM151D-EN-P – March 2013 7000 “A” Frame

Overview of Drive 1-5

a) Line current

Figure 1.2 – AFE rectifier and its input current/voltage waveforms

b) Line-to-line voltage at PCC

The AFE rectifier can be used in conjunction with a rectifier duty

isolation transformer or with an AC line reactor (as shown in Figure 1.2).

Isolation transformers are available:

1) Integral to the Drive

2) Remote indoor dry type, or

3) Outdoor oil-filled type

This allows for maximum flexibility in dealing with floor space,

installation cost and control room air conditioner loading.

“Direct-to-Drive” Technology Reduce the cost, size and weight of your medium voltage drive

system with the Allen-Bradley PowerFlex 7000 with Direct-to-Drive technology. This is the first and only technology that allows you to directly connect a medium voltage drive to utility power without the requirement of an isolation transformer. Isolation transformers with multiple secondary windings are required for traditional AC drives to address line-side harmonic concerns and common mode voltage. However, typical isolation transformers are large, heavy, costly, complex and inefficient. Direct-to-Drive technology combines an Active Front End (AFE) rectifier to dramatically lower line-side harmonics and a patented DC link inductor to address common mode voltage at its source. By addressing harmonics and common mode voltage, the isolation transformer becomes redundant. This reduces system complexity to maximize uptime and increases system efficiency to lower operational costs. Exceptional output voltage and current waveforms, true of our entire product line, make this ideal for retrofit applications and allow the use of standard motors for new applications.

7000 “A” Frame 7000A-UM151D-EN-P – March 2013

1-6 Overview of Drive

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 (5.4 °F) higher compared to across-the-line operation. Voltage waveform has dv/dt of less than 10 volts per microsecond. Reflected wave and dv/dt issues often associated with VSI (voltage source inverter) drives do not exist with the PowerFlex

7000. Typical motor waveforms are shown in Figure 1.3. These motor friendly waveforms are achieved by utilizing a selective harmonic elimination (SHE) pattern in the inverter to eliminate major order harmonics, in conjunction with 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. This technology is capable

of controlling motors up to 15 km (9.3 miles) away from the drive.

rms

300.00

200.00

100.00

Motor current

Motor voltage

-10.00K

0.00

-100.00

-200.00

-300.00

10.00K

7.50K

5.00K

2.50K

0.00K

-2.50K

-5.00K

-7.50K

Vrms

100.00

110.00

120.00 130.00 TIME (ms)

140.00

150.0

Figure 1.3 – Motor waveform @ full load, full speed

7000A-UM151D-EN-P – March 2013 7000 “A” Frame

LIN

ECONVERTERDCLIN

ACHIN

ECONVERTE

Simplified Electrical Drawings – 2400V with AFE Rectifier

L+

Overview of Drive 1-7

M+

SGCTs

L-

M-

2400 Volt – AFE Rectifier, Configuration #1 – Direct-to-Drive

(Configurations without Integral Input Starter are available)

REMOTE ISTX

2U (X1)

2V (X2)

2W (X3)

LINE CONVERTER DC LINK

SGCTs

L+

M+

CHINE CONVERTER

SGCTs

U(T1)

V(T2)

W(T3)

U(T1)

V(T2)

W(T3)

L-

M-

2400 Volt – AFE Rectifier, Configuration #2 – Separate Isolation Transformer

INTEGRAL ISTX

2U (X1)

2V (X2)

2W (X3)

LINE CONVERTER DC LINK

SGCTs

L+

M+

L-

M-

CHINE CONVERTER

SGCTs

U(T1)

V(T2)

W(T3)

2400 Volt – AFE Rectifier, Configuration #3 – Integral Isolation Transformer

7000 “A” Frame 7000A-UM151D-EN-P – March 2013

LIN

ECONVERTERDCLIN

ACHIN

ECONVERTE

MAC

ECONV

ERTERD

MAC

ECONV

ERTE

1-8 Overview of Drive

Simplified Electrical Drawings – 3300/4160V with AFE Rectifier

L+

M+

SGCTs

L-

M-

SGCTs

3300/4160 Volt – AFE Rectifier, Configuration #1 – Direct-to-Drive

(Configurations without Integral Input Starter are available)

REMOTE ISTX

2U (X1)

2V (X2)

2W (X3)

LINECONVERTER

SGCTs

LIN

L+

M+

HINECONVERTER

SGCTs

U(T1)

V(T2)

W(T3)

U(T1)

V(T2)

W(T3)

L-

M-

3300/4160 Volt – AFE Rectifier, Configuration #2 – Separate Isolation Transformer

INTEGRAL ISTX

LIN

SGCTs

2U (X1)

2V (X2)

2W (X3)

LIN

L+

M+

L-

M-

SGCTs

HIN

U (T1)

V (T2)

W (T3)

3300/4160 Volt – AFE Rectifier, Configuration #3 – Integral Isolation Transformer

7000A-UM151D-EN-P – March 2013 7000 “A” Frame

LIN

ECONVERTERDCLIN

ACHIN

ECONVERTE

MAC

NECONVE

RTERD

CLIN

ACHINECONVE

RTE

Simplified Electrical Drawings – 6600 V with AFE Rectifier

L+

M+

SGCTs

Overview of Drive 1-9

SGCTs

L-

M-

6600 Volt – AFE Rectifier, Configuration #1 – Direct-to-Drive

(Configurations without Integral Input Starter are available)

HINECONVERTER

SGCTs

REMOTE ISTX

LINECONVERTER

SGCTs

2U (X1)

2V (X2)

2W (X3)

LIN

L+

M+

L-

M-

6600 Volt – AFE Rectifier, Configuration #2 – Separate Isolation Transformer

INTEGRAL ISTX

SGCTs

L+

M+

SGCTs

U(T1)

V(T2)

W(T3)

U (T1)

V(T2)

W(T3)

2U (X1)

2V (X2)

2W (X3)

L-

M-

U(T1)

V(T2)

W(T3)

6600 Volt – AFE Rectifier, Configuration #3 – Integral Isolation Transformer

7000 “A” Frame 7000A-UM151D-EN-P – March 2013

1-10 Overview of Drive

Operator Interface

Figure 1.4 – PowerFlex 7000 Operator interface terminal

The operator interface terminal features a 16-line, 40-character, pixel

based LCD display that makes text and graphics easy to read. Bar chart meters are configurable for common process variables including speed, voltage and load.

Everything is user friendly about the PowerFlex 7000 operator interface

terminal including the greeting on the opening screen. The terminal is designed for the greatest ease of use for start-up, monitoring and troubleshooting. The setup wizard helps the user to set the required parameter menus by asking questions or prompting selections for desired operation. Warnings and comments appear complete with help text to keep the user on the right track. The setup wizard combined with the auto-tuning feature allows the drive to be tuned to the motor and load as quickly and accurately as possible, resulting in fast startups, smooth operation, and less down time.

7000A-UM151D-EN-P – March 2013 7000 “A” Frame

Chapter 2

Drive Installation

Safety and Codes

W A R N I N GW A R N I N G

General Handling Procedures Refer to “General Handling Procedures for PowerFlex 7000 Medium

Voltage Drives”, publication no. 7000-IN002_-EN-P supplied in the drive shipment (affixed to the drive). Additional copies can be ordered through your local Rockwell Automation Sales office.

Drive Storage If it is necessary to store the drive, be certain to store in a clean dry

dust free area.

Storage temperature should be maintained between -40°C and 70°C (-40°F and 185°F). If storage temperature fluctuates or if humidity exceeds 95%, space heaters should be used to prevent condensation. The drive should be stored in a heated building having adequate air circulation. The drive must never be stored outdoors.

The Canadian Electrical Code (CEC), National Electrical Code (NEC), or local codes outline provisions for safely installing electrical equipment. Installation MUST comply with specifications regarding wire type, conductor sizes, branch circuit protection and disconnect devices. Failure to do so may result in personal injury and/or equipment damage.

7000 “A” Frame 7000A-UM151D-EN-P – March 2013

2-2 Drive Installation

Siting of the Drive Site Considerations

The standard environment in which the equipment is designed to

operate is:

• Elevation above sea level less than 1000 meters (3250 feet)

• Ambient air temperature between 0°C (32°F) and 40°C (104°F)

• Relative humidity of the air not to exceed 95% non-condensing

For the equipment to operate in conditions other than those specified

consult the local Rockwell Automation Sales office.

The equipment requires the following site conditions:

(A) Indoor installation only, no dripping water or other fluids

(B) Clean air for cooling requirements

drawings for the location of the anchoring points.

(D) The room in which the equipment is located must allow for full

opening of the doors of the equipment, typically 1200 mm (48 inches). Also, allowances have to be made for clearance for fan removal. This fan allowance must be greater than 700 mm (27.5 inches) above the drive.

Dimension drawings can be obtained by contacting the local Rockwell Automation Sales office. The equipment does not require rear access for servicing.

(E) Allowance must be made for the stream of cooling air which

exits the drive at the top. The flow of cooling air into and out the drive must be kept clear and uninhibited.

(F) The room in which the equipment is located must be large

enough to accommodate the thermal losses of the equipment since air conditioning may be required; the ambient temperature must not exceed that for which the equipment is rated. The heat created by the drive is directly proportional to the power of the motor being driven and the efficiency of equipment within the room. If thermal load data is required contact the Rockwell Automation Sales office.

(G) The area in which the drive is located should be free of radio

frequency interference such as encountered with some welding units. This may cause erroneous fault conditions and shut down the drive.

7000A-UM151D-EN-P – March 2013 7000 “A” Frame

Drive Installation 2-3

(H) The equipment must be kept clean. Dust in the equipment

decreases system reliability and inhibits cooling.

(I) Power cable lengths to the motor are virtually unlimited due to

the near sinusoidal voltage and current waveforms. Unlike voltage source drives, there are no capacitive coupling, dv/dt, or peak voltage issues that can damage the motor insulation system. The topology utilized in the PowerFlex 7000 medium voltage AC drive does not produce dv/dt or peak voltage problems, and has been tested with motors located up to 15 kilometers from the drive.

(J) Only personnel familiar with the function of the drive should

have access to the equipment.

(K) The drive is designed for front access and should be installed

with adequate and safe clearance to allow for total door opening. The back of the unit may be placed against a wall although some customers prefer back access also.

A T T E N T I O NA T T E N T I O N

Generator Note:

A T T E N T I O NA T T E N T I O N

An incorrectly applied or installed drive can result in component damage or a reduction in product life. Ambient conditions not within the specified ranges may result in malfunction of the drive.

Verify that the load is not turning due to the process. A freewheeling motor can generate voltage that will be back-fed to the equipment being worked on.

7000 “A” Frame 7000A-UM151D-EN-P – March 2013

2-4 Drive Installation

Installation When the drive has been placed at its installation area, the lag bolts

that fasten the shipping skid to the drive must be removed. The drive is moved off the shipping skid and the shipping skid can be discarded.

Position the drive in its desired location. Verify that the drive is on a

level surface and that the position of the drive will be vertical when the anchor bolts are installed.

The location of the anchor points is provided with the dimension

drawing of the drive.

Install and tighten the anchor bolts. (M12 or ½” hardware required).

Engineering bolt systems are required for seismic requirements. Consult factory.

Remove the top lifting angles, retain the hardware.

Install the hardware from the lifting angles in the tapped holes at the

top of drive; this prevents leakage of cooling air as well as keeping dust out of the equipment.

Installation of Exhaust Air Hood

On the top of the cabinet with the cooling fan, a sheet metal exhaust

hood is to be installed. The components to make up the exhaust hood have been packaged and shipped with the drive. (For drives with an acoustic hood, the components are shipped assembled. See Figure 2.2)

The first step is to remove the protective plate covering the fan

opening on the drive. It is a flat cover plate bolted to the top plate. Remove the bolts and plate and set aside for re-use.

Secondly, loosely assemble the two L-shaped panel components

shipped with the drive as per Figure 2.1.

7000A-UM151D-EN-P – March 2013 7000 “A” Frame

Drive Installation 2-5

Flat plate (Quantity = 1)

Figure 2.1 – Fan Hood Assembly

All the components are shipped assembled.

Exhaust hood panels (Quantity = 2)

M6 thread forming screws (Quantity = 20)

Figure 2.2 – Acoustic Fan Hood Assembly

7000 “A” Frame 7000A-UM151D-EN-P – March 2013

2-6 Drive Installation

Installation (cont.) Locate the exhaust hood on top of the cabinet per Figure 2.3 and re-

install the original cover plate previously set aside. (Care must be taken that the notches on the bottom flange are oriented toward the sides of the drive). Affix assembly to the drive top plate. Tighten all hardware.

For drives with an acoustic hood (shown in Figure 2.2), locate the

exhaust hood (refer to Figure 2.4).

A T T E N T I O NA T T E N T I O N

Any screws that are accidentally dropped in the equipment must be retrieved as damage or injury may occur.

Assembled Exhaust Hood

M6 Screw (Quantity = 12)

Ensure notch orientation to sides

Figure 2.3 – Fan Hood Installation

7000A-UM151D-EN-P – March 2013 7000 “A” Frame

Drive Installation 2-7

Assembled Acoustic Exhaust Hood

Top Plate for Converter

and Common Mode Choke/

DC Link Cabinet

Figure 2.4 – Acoustic Fan Hood Installation

M6 Screw. Remove Existing Scre and reinsert with Hood. (Quantity = 11)

7000 “A” Frame 7000A-UM151D-EN-P – March 2013

2-8 Drive Installation

Installation (cont.) Installation of Integral Transformer Cooling Fan

1. Remove the protective plate covering the fan opening on the top of Isolation Transformer cabinet and discard.

2. Locate the cooling fan on top of the cabinet. Position it over the opening and align the mounting holes and wire harness connections.

3. Affix the fan to the drive top plate with the M6 thread forming screws provided.

4. Connect the fan wire harness to fan.

Assembled Exhaust Hood

M6 Screw

M6 Screw (Qty = 12)

(Qty = 12)

Figure 2.5 – Fan Installation for Integral Isolation Transformer

7000A-UM151D-EN-P – March 2013 7000 “A” Frame

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