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.
Table of Contents
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
7000 “A” Frame 7000A-UM151D-EN-P – March 2013
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
r
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
L
K
A
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.
M
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
th
, 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)
b)
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
0
A
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
K
M
ACHIN
ECONVERTE
A
1
1
A
Simplified Electrical Drawings – 2400V with AFE Rectifier
L+
Overview of Drive 1-7
M+
R
SGCTs
L1
L2
L3
LR
L-
M-
2400 Volt – AFE Rectifier, Configuration #1 – Direct-to-Drive
(Configurations without Integral Input Starter are available)
REMOTE
ISTX
1U
1V
W
2U (X1)
2V (X2)
2W (X3)
LINE CONVERTER DC LINK
SGCTs
L+
M+
CHINE CONVERTER
M
SGCTs
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
1U
1V
W
2U (X1)
2V (X2)
2W (X3)
LINE CONVERTER DC LINK
SGCTs
L+
M+
L-
M-
CHINE CONVERTER
M
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
K
M
ACHIN
ECONVERTE
D
C
K
MAC
1
ECONV
ERTERD
C
K
MAC
ECONV
ERTE
1-8 Overview of Drive
Simplified Electrical Drawings – 3300/4160V with AFE Rectifier
L+
M+
R
SGCTs
L1
L2
L3
LR
L-
M-
SGCTs
3300/4160 Volt – AFE Rectifier, Configuration #1 – Direct-to-Drive
(Configurations without Integral Input Starter are available)
1U
1V
1W
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
1U
1V
W
2U (X1)
2V (X2)
2W (X3)
LIN
L+
M+
L-
M-
SGCTs
HIN
R
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
K
M
ACHIN
ECONVERTE
D
C
K
MAC
NECONVE
RTERD
CLIN
K
ACHINECONVE
RTE
R
Simplified Electrical Drawings – 6600 V with AFE Rectifier
L+
M+
SGCTs
Overview of Drive 1-9
R
SGCTs
L1
L2
L3
LR
L-
M-
6600 Volt – AFE Rectifier, Configuration #1 – Direct-to-Drive
(Configurations without Integral Input Starter are available)
HINECONVERTER
SGCTs
1U
1V
1W
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
LI
SGCTs
L+
M+
M
SGCTs
U(T1)
V(T2)
W(T3)
U (T1)
V(T2)
W(T3)
1U
1V
1W
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
(C) Level floor for anchoring the equipment. Refer to dimension
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.
or
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
w
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
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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