Rockwell Automation 7000L User Manual

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User Manual

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

Publication 7000L-UM301D-EN-P

Important User Information

IMPORTANT

Read this document and the documents listed in the additional resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation, Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment, which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

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

Labels may also be on or inside the equipment to provide specific precautions.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

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

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

This manual contains new and updated information.

Summary of Changes

New and Updated Information

This table summarizes the changes made to this revision.

Top ic Pag e

Changed all references of “tachometer” to “encoder” Throughout

Added HPTC information to Topology section 17

Updated Speed Regulator Bandwidth 24

Updated Torque Regulator Bandwidth 24

Inserted Torque Accuracy with HPTC 24

Added Polish to list of available Languages 25

Added “Dual-port Ethernet/IP” to Communications Protocols 25

Replaced Control Overview block diagram 29

Added “Pipe Materials and Layout” section 76

Added dimensions and torque information to Pipe Flange detail images 77

Inserted “External Piping to the Drive” section 77

Inserted “Controlled Siphon into Open-top Reservoir” section 78

Added Converter Cabinet Components (3300/4160V) image 212

Added Converter Cabinet Components (6600V) image 213

Changed graphic labels for valve locations 217

Changed graphic labels for valve locations 218

Inserted “System Fill and Air Venting” and “Normal Operation” section 218

Replaced Cooling System Overview chart 328

Inserted “Pump Cabinet with Ebara Pumps” image 331

Added “Pump Replacement with Drive Running” section 331

Replaced Pressure Indicator and Switch Locations image 333

Replaced Temperature and Conductivity Sensors image 337

Replaced Deionizer Reservoir Circuit image 338

Inserted “Replacing the Mesh Filters” section 339

Replaced Catalog Number Explanation 411

Updated “When is an Encoder Required?” section and table 414

Replaced Encoder Selection table 415

Added HPTC information to Drive Torque Capabilities table 415

Updated Typical Application Load Torque Profiles 416

Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 3

Summary of Changes

Notes:

4 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Overview of Drive

Chapter 1

Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Liquid Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Benefits of Liquid Cooling Include: . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

Benefits of the 7000L “C” Frame Liquid-cooled Drive: . . . . . . . . . . 16

Topology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

Rectifier Designs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

18 Pulse Rectifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Active Front End (AFE Rectifier). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

“Direct-to-Drive” Technology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

Motor Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

SGCT Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

Simplified Electrical Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Control Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

Direct Vector Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Control Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30

Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

Drive Installation

Chapter 2

Safety and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Transportation and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

Overhead Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

Rod or Pipe Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

Fork Lift Trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Siting of the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Site Considerations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Joining Shipping Splits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Connect the Sections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Tools Required (not supplied). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Install CPVC Piping Splices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

Connect Power: M+, L+, M-, L- Power Bus . . . . . . . . . . . . . . . . . . . . 42

Control Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Removal of DC Link Choke Turnbuckle Supports . . . . . . . . . . . . . 54

Removal of Lifting Angles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54

Shock Indication Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Installation of Exhaust Air Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Internally mounted fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57

Externally mounted fans and fan hood . . . . . . . . . . . . . . . . . . . . . . . . . 58

Typical PowerFlex 7000L Drive Structure Layout. . . . . . . . . . . . . . . 59

Control/Cabling Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

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Table of Contents

IEC Component and Device Designation . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Power Wiring Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68

Cable Insulation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69

Power Cabling Access. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71

Access the Customer Power Cable Terminations: . . . . . . . . . . . . . . . 71

Power Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Incoming Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74

Liquid Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Liquid-to-Air Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

Pipe Materials and Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76

External Piping to the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

External Piping Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77

Controlled Siphon into Open-top Reservoir . . . . . . . . . . . . . . . . . . . . . . . . 78

Liquid-to-Liquid Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80

Power and Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Encoder Installation Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83

Information Regarding Termination of Customer Cables . . . . . . . . 86

Grounding Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Grounding Guidelines and Practices for Drive Signal and Safety

Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Grounding Requirements and Grounding Specification for

Customers and Power Integrators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88

Identification of Types of Electrical Supplies – Grounded and

Ungrounded Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Ground Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Interlocking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Chapter 3

Operator Interface

6 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Chapter Objectives . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Terminology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92

Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Function (Softkeys) Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Cursor (Selection) Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93

Data Entry Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

What is a Screen?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

Information Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Accessing/Writing to Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Communication Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96

Languange Changing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97

General Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98

Operator Interface Power-up Sequence. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

Top Level Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99

How To . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Table of Contents

Obtain Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100

Related Topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101

Help on Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102

Modify Operator Interface Operation (Utility) . . . . . . . . . . . . . . . . . . . . 102

Changing Backlight Delay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103

Changing Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Setting Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104

Setting Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105

Selecting Meters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106

Viewing Revision Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108

Transfer Data in Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109

Picking an Access Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Select a Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Via Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110

Via Name. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111

Via Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113

Edit Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114

Configure the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Enter/Modify an Access Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Drive Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120

Language Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121

Modify Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Numerical Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122

Enumerated Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124

Bit Encoded Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125

Analog Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126

Fault Masks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

User Definable External Text. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131

PLC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132

XIO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133

Message Prompting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134

Store/Retrieve Configuration (NVRAM) . . . . . . . . . . . . . . . . . . . . . 135

Initialize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135

Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136

Display Parameters

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137

Custom Group. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138

View Drive Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139

View and Reset Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

Help for Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141

Request Printouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Perform Diagnostic Trending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142

Assigning a Trace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Setting the Trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144

Defining Sample Rate and Positioning . . . . . . . . . . . . . . . . . . . . . . . . 146

Starting the Trace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146

Flash Memory Transfers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148

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Format Flash Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149

View a Directory. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150

Select a Filename . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Enter a Filename. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151

Loading Programs (Firmware). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152

Parameter Transfers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153

Upload to Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Download from Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . 154

Upload to Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Download from Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155

Parameter File Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

Loading Language Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156

System Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Advanced Screen Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Communications Statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158

Protocol Analyzer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159

Print Screen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Memory Dump. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160

Database Download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

Operator Interface Menu Hierarchy Chart . . . . . . . . . . . . . . . . . . . . . . . . 162

What Does It Show? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162

How Do You Read It? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163

PCMCIA Memory Card Installation Data . . . . . . . . . . . . . . . . . . . . . . . . 167

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Installing the Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167

Commissioning

Chapter 4

Start-up Commissioning Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Drive Commissioning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169

Commissioning the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170

Pre-Commissioning Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

PowerFlex 7000 ‘C’ Frame Pre-Commissioning Checklist . . . . . . . . . . 171

Receiving and Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171

Installation / Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172

Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Drive Line-up Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Cooling System Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

Commissioning Preparation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175

Recommended Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . . . . 175

Technical Publications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

PowerFlex 7000 “C” Frame Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

PowerFlex 7000 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

Additional Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

Resources Required to Complete Drive Commissioning . . . . . . . . . . . . 176

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Important Note for Commissioning Engineer . . . . . . . . . . . . . . . . . . . . . 177

Key Steps to Commissioning a PowerFlex 7000 Drive. . . . . . . . . . . . . . 178

PowerFlex 7000 “C” Frame Commissioning Datasheets . . . . . . . . . . . . 179

PowerFlex 7000 “C” Frame Drive Commissioning Checklist . . . . . . . 180

Drive Application Review. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183

Rockwell Automation Drive Line-up Drawings . . . . . . . . . . . . . . . . 183

Electrical System One-line Diagram. . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Verify One-line Diagram on Site. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Inspect Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184

Safety Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Lockout Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185

Step Down Transformer Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Fuse and O/L Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Installation Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Inspect for Shipping Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186

Inspect Cabinets for Debris . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Protective Barriers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Component Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187

Information on Splice Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Power Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188

Liquid-Cooling Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189

Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Why this Information is Needed. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190

Customer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191

Control Power Off Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

Interlocking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

Resistance Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196

SGCT Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197

SGCT Anode-to-Cathode Resistance . . . . . . . . . . . . . . . . . . . . . . . . . 198

Snubber Resistance (SGCT Device). . . . . . . . . . . . . . . . . . . . . . . . . . . 199

Snubber Capacitance (SGCT Device). . . . . . . . . . . . . . . . . . . . . . . . . 200

SCR Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200

SCR Anode-to-Cathode Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . 201

SCR Sharing Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202

SCR Gate-to-cathode Resistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203

Snubber Resistance (SCR Device) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204

Snubber Capacitance (SCR Device). . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Control Power Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

Three-Phase Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207

Three-Phase Input / Single Phase Input . . . . . . . . . . . . . . . . . . . . . . . 207

Power Supply Tests. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

Circuit Board Healthy Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208

Control Power Transformer (CPT). . . . . . . . . . . . . . . . . . . . . . . . . . . 208

AC/DC Converter (PS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

DC/DC Converter (PS2). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210

SGCT Power Supplies (IGDPS). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211

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IGDPS Board LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Commissioning the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214

Heat Exchanger Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215

Pumping Cabinet Control Power Checks. . . . . . . . . . . . . . . . . . . . . . 216

System Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217

System Fill and Air Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218

Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Gating Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

Gating Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220

SCR Firing Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222

SGCT Firing Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224

System Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

System Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225

Start/Stop Control Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226

Status Indicators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Analog I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227

Configurable Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

18 Pulse Phasing Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231

Line Terminal Resistance Measurements . . . . . . . . . . . . . . . . . . . . . . 232

Application of Medium Voltage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

Input Phasing Check. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233

DC Current Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235

Tuning Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

1. Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238

2. Motor Impedance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243

3. FluxSpeed Regulator [INDUCTION MOTORS] . . . . . . . . . . . 244

4. FluxSpeed Regulator [SYNCHRONOUS MOTORS] . . . . . . . 249

Running the Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

Motor Starting Torque. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

Reaching Specific Load Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253

Capturing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

Drive Input Voltage Phasing Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

Summary: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255

Harmonic Analysis

(required for AFE drives only) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

Summary: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257

DC Current Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

Summary:

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258

Load Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

Synchronous Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261

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Table of Contents

Component Definition and Maintenance

Control / Cabling Cabinet Components. . . . . . . . . . . . . . . . . . . . . . . . . . 266

Voltage-Sensing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269

Voltage-Sensing Circuit Board Assembly Replacement . . . . . . . . . . . . . 269

Input Transient Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270

Transient Suppression Network (TSN) . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

MOV Suppressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271

MOV Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 272

Transient Suppression Network Fuse Replacement . . . . . . . . . . . . . . . . 273

Metal-Oxide Varistor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274

Surge Arresters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276

Surge Arrester Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277

Field Test and Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 278

Output Grounding Network Capacitor Replacement . . . . . . . . . . . . . . 278

Ground Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280

Hall Effect Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281

Current Transformer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282

Filter Capacitor Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

Filter Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 283

Filter Capacitor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284

Testing Filter Capacitors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285

Converter Cabinet Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 287

Converter Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

PowerCage™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289

SGCT and Snubber Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291

Checking Clamping Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292

Clamping Pressure Adjustment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292

Symmetrical Gate Commutated Thyristor Replacement. . . . . . . . . . . . 293

Silicon Controlled Rectifier and SCR Self-Powered Gate Driver Board

Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296

Detachment of Coolant System from PowerCage Modules . . . . . . . . . 299

Reconnecting the Coolant System to a PowerCage Module . . . . . 303

Chill Block Removal and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 303

Instructions for removing Chill Block assembly . . . . . . . . . . . . . . . . 303

Instructions for inserting Chill Block assembly. . . . . . . . . . . . . . . . . 304

PowerCage Removal and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 305

Snubber Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306

Testing Snubber Resistors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

Sharing Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307

Testing Sharing Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308

Snubber and Sharing Resistor Replacement. . . . . . . . . . . . . . . . . . . . . . . . 309

Self-Powered Gate Driver Board – SPGDB. . . . . . . . . . . . . . . . . . . . . . . . 311

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

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Board Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

Test points description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311

Terminal/connections description . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312

Testing procedure for SCR self-powered gate driver board . . . . . . . . . . 313

Equipment needed: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

Procedure: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 313

Fiber Optic Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 317

DC Link Reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 319

Control Power Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

Ride-Through . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 321

AC/DC Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322

Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323

Terminal / Connections Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . 324

Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 325

UPS Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326

UPS Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327

Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328

Cooling Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329

Chill Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329

Coolant Pumps. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329

Pump Maintenance and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330

Pump Seal Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330

Pump Replacement with Drive Running. . . . . . . . . . . . . . . . . . . . . . . 331

Piping, Tubing and Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333

Non-Return Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 333

Pressure Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334

Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334

Thermostatic Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334

Thermostatic Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334

Repair Instructions - Element Testing . . . . . . . . . . . . . . . . . . . . . . . . . 335

Element Replacing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335

Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336

Fluid Conductivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337

De-Ionizing Cartridge and Mesh Filter . . . . . . . . . . . . . . . . . . . . . . . . 338

Replacing the Mesh Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 339

Reservoir Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340

Fluid Top-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340

Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340

Coolant. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341

Maintaining Coolant Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342

Leakage Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343

System Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344

Low Voltage Control Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344

DC/DC Power SupplyDescription . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345

Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345

12 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Table of Contents

Terminal/Connections Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . 346

Replacement Procedure for DC/DC Power Supply . . . . . . . . . . . . 347

Printed Circuit Board Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 348

IO Connectors on Control Boards. . . . . . . . . . . . . . . . . . . . . . . . . . . . 348

Drive Processor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 349

Drive Processor Module Replacement. . . . . . . . . . . . . . . . . . . . . . . . . 351

Instructions to Replace the Drive Processor Module. . . . . . . . . . . . 351

ACB Analog Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 353

LEDs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357

Interface Module (IFM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357

Analog Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 357

Current Loop Transmitter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358

Isolated Process Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358

Non-Isolated Process Outputs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359

Auxiliary +24V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360

ACB Analog Control Board Replacement . . . . . . . . . . . . . . . . . . . . . 360

Tachometer Feedback Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361

Encoder Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361

Quadrature Encoder Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 364

Positional Encoder Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 365

Positional Encoder Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366

External Input/Output Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367

External Input/Output Board Replacement . . . . . . . . . . . . . . . . . . . 368

Optical Interface Boards (OIB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 369

Optical Interface Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 370

Optical Interface Base Board (OIBB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 372

Optical Interface Base Board Test Points . . . . . . . . . . . . . . . . . . . . . . 373

Downloading Firmware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 374

PowerFlex 7000 in Download Mode . . . . . . . . . . . . . . . . . . . . . . . . . . 377

Reloading the Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 380

Setting Elapsed Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381

Downloading the Terminal Firmware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382

Using Flash Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382

DOSFWDL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382

Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383

Setting up Diagnostic Trending

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383

Diagnostic Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384

Setting up the Trend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384

Printing (Uploading) Data from the Drive . . . . . . . . . . . . . . . . . . . . . . . . 390

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 390

Creating an empty notepad (.txt) file. . . . . . . . . . . . . . . . . . . . . . . . . . 391

Setting up HyperTerminal Connection . . . . . . . . . . . . . . . . . . . . . . . 393

Uploading the Data from the drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . 395

Printing (Uploading) Control Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 398

Set up HyperTerminal connection. . . . . . . . . . . . . . . . . . . . . . . . . . . . 399

Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 13

Table of Contents

Catalog Number Explanation

Printing Control Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 400

Environmental Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402

Hazardous Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 402

Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404

Preventive Maintenance Check List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404

Operational Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 404

Annual Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405

Initial Information Gathering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405

Physical Checks (NO Medium Voltage and NO Control Power) 406

Control Power Checks (No Medium Voltage) . . . . . . . . . . . . . . . . . 407

Final Power Checks before Restarting . . . . . . . . . . . . . . . . . . . . . . . . . 407

Additional Tasks During Preventive Maintenance. . . . . . . . . . . . . . 408

Final Reporting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 408

Time Estimations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409

Tool / Parts / Information Requirements. . . . . . . . . . . . . . . . . . . . . . 409

Appendix A

PowerFlex 7000 Drive Selection Explanation . . . . . . . . . . . . . . . . . . . . . . 413

Service Duty Rating, Continuous Current Rating & Altitude Rating

Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 413

When is an Encoder Required? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 414

PowerFlex 7000 Drive Performance (Torque Capabilities). . . . . . . . . . 415

Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416

Torque Requirements for Threaded Fasteners

Meggering

Preventative Maintenance Schedule

Appendix B

Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 419

Appendix C

Drive Meggering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421

Meggering the PowerFlex 7000 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421

Equipment Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422

Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 422

Appendix D

PowerFlex 7000 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 427

I – Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427

M – Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427

R – Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427

C – Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 427

Rv – Review. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 428

RFB/R – Refurbishment/Replacement . . . . . . . . . . . . . . . . . . . . . . . . 428

14 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Overview of Drive

Chapter 1

Introduction

The PowerFlex® 7000 represents the third generation of medium voltage drives at Rockwell Automation. The PowerFlex 7000 medium voltage AC drive 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. Designed for end users, solution providers and OEMs, PowerFlex 7000 liquid-cooled drives meet applications ranging from

3000...9000 horsepower (2240...6715 kW).

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

The PowerFlex 7000L 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.

(1)

Liquid Cooling

The PowerFlex 7000L “C” Frame liquid-cooled drive utilizes a closed loop system to cool the converter main power components and the integral DC link inductor.

Benefits of Liquid Cooling Include:

• Smaller drive dimension compared to air-cooled drives of similar rating

• Higher power rating capability

• Quiet operation in control room

• Low loss rejection to the control room reduces air conditioner loading

• Majority of losses rejected outside the control room via a liquid-to-air or

liquid-to-liquid type heat exchanger

(1) For 2400V and 3300V designs, contact factory.

Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 15

Chapter 1 Overview of Drive

Benefits of the 7000L “C” Frame Liquid-cooled Drive:

• Completely integrated MV drive package reduces customer installation costs and start-up time.

• Higher power rating capability (up to 9000 hp / 6715 kW)

• 18 Pulse and AFE rectifiers for low harmonic solutions that meet IEEE

519-1992 Harmonic Guidelines

• Motor friendly current and voltage output waveforms for use with standard new and existing motors

– Inverter duty motors not required – Motor temperature derating not required – No additional dv/dt or peak voltage stress to motor insulation system – Tested up to 15 kilometers (9.3 miles) cable distance between drive and

motor

• Spacious cable termination cabinet for ease of use by installation contractor

• Cable termination stabs accommodate: – 3 cables in / 3 cables out (Direct-to-Drive or AFE rectifier) – 9 cables in / 3 cables out (18 Pulse) – Top or bottom entry and exit of line and load cables

• 90% of drive losses are rejected outside the control room

• Integral liquid-cooled DC link inductor reduces overall dimension and

eliminates external interwiring.

• Integral pumping panel includes: – Line supply c/w disconnect and fusing – Closed loop coolant system – Iron and chloride free liquid ethyl-glycol / deionized water mixture

– Low conductivity coolant (1-2 micro-Siemens / cm – Isolated from medium voltage – Fully serviceable low voltage compartment isolated from medium

voltage power

– Monitors coolant temperature, flow, level, conductivity, and pressure – Redundant pumping system (optional) – Automatic pump change over on pump failure – 1/2 turn valves with quick disconnect couplers for pump replacement

when drive is operating

– Full drip tray to contain any spilled coolant – Drain and fill pump for convenient filling – Industrial schedule 80 CPVC piping for pump panel, headers and

manifolds (no condensation possibility)

– Control hardware for cycling of main / redundant cooling pumps and

heat exchanger fans

• “Plug and play” Power Cage concept – Central location for easy access to all main power components

)

16 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Overview of Drive Chapter 1

2U (X1)

2V (X2)

2W (X3)

SGCT’s

LINE CONVERTER

DC LINK

L+

M+

SGCT’s

MACHINE CONVERTER

U (T1)

V (T2)

W (T3)

L-

M-

– Common modular design for rectifier / inverter – Same concept as air-cooled drive for front access, easy component

replacement, and no special tools

– 5...10 minutes to replace main power devices – No need to remove any cooling lines for device replacement – Reduced manufacturing time for faster delivery and lower cost

•Keyed mechanical interlock

– Interlocked with main disconnect means to prevent unsafe access to

medium voltage section

Topology

The PowerFlex 7000L utilizes a Pulse Width Modulated (PWM) – Current Source Inverter (CSI) for the machine side converter as shown in Figure 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. Semiconductor fuses are not required for the power structure due to the current limiting DC link inductor.

With 6500VPIV rated power semiconductor devices, the number 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.

The PowerFlex 7000L has the additional benefit of inherent regenerative braking for applications where the load is overhauling the motor (i.e. downhill conveyors, etc.), or where high inertia loads (i.e. fans, etc.) need to be slowed down quickly. Symmetrical Gate Commutated Thyristors (SGCTs) are used for machine converter switches. Silicon-controlled rectifiers (SCRs) (for 18 Pulse) or SGCTs (for AFE rectifiers) are used for the line converter switches. An AFE configuration is shown in Figure 1

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

Figure 1 - AFE Rectifier (4160 Volt)

Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 17

Chapter 1 Overview of Drive

Line current

Line-to-line voltage at PCC

Rectifier Designs

There are two offered designs for the rectifier of the PowerFlex 7000L drive.

18 Pulse Rectifier

An 18 Pulse phase controlled rectifier is shown in Figure 2. In an 18 Pulse configuration, the IEEE 519-1992 requirements are met in the majority of cases without the need for passive filters; however, a multi-winding isolation transformer is required to mitigate the low order harmonics by phase shifting principles. The 18 Pulse solution is superior to 6- or 12-pulse offerings in terms of lowering line side harmonics.

Isolation transformers are available in indoor dry type, cast coil, and outdoor oilfilled designs for maximum flexibility in dealing with floor space, installation costs, and control room air conditioner loading. (Refer to Specification 80001005, Rectifier Duty Transformers, for more details on transformer requirements and features.)

Sample line current and voltage are also shown in Figure 2 current is approximately 5.6%, while the THD of line voltage (line-to-line) is approximately 2.0%. (THD of line voltage is a function of system impedance.) The 18 Pulse rectifier consists of one master bridge and two slave bridges and will always have a total of 18 SCR switching devices.

. The THD of line

Figure 2 - 18 Pulse Rectifier and its input waveforms

Active Front End (AFE Rectifier)

An active front end (AFE rectifier) suitable for the PowerFlex 7000L topology is also commonly called a PWM rectifier. This is particularly attractive since it does not require an isolation transformer to meet IEEE 519-1992. Most available technologies in today’s MV market require a multi-winding transformer to mitigate the unwanted harmonics 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, and increases overall system efficiency.

18 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Overview of Drive Chapter 1

Line current

Line-to-line voltage at PCC

The AFE rectifier requires a switching pattern that complies with similar rules as the inverter. The pattern, used for the example shown in Figure 3

, is a 42-pulse selective harmonic elimination (SHE) pattern, which eliminates the 5th, 7th and 11th harmonics. The integral input capacitors are designed to reduce the current harmonics of the higher order. The filter transfer function technique is used to place the filter break frequency in a region where no harmonics are present. 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.

The AFE rectifier is ideal when a distribution transformer is required to step down the distribution voltage to match the VFD and motor voltage. The rectifier input current, the rectifier terminal voltage and the line current and voltage waveforms are shown in Figure 3

. 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 equal to or greater than 0.98 for the typical speed and load range when applied to variable torque loads.

Figure 3 - Active rectifier (PWM) and its input current/voltage waveforms

“Direct-to-Drive” Technology

The PowerFlex 7000L with “Direct-to-Drive” technology allows you to:

• connect supply power directly to the drive without an Isolation Tr a n s f o r m e r

• connect a new or existing motor directly to the drive without extra motor filtering.

Most Medium Voltage Drive Manufacturers use multi-winding isolation transformers to mitigate unwanted harmonics by phase shifting the transformer secondary windings. Depending on the topology, the transformer can have up to 15 sets of secondary windings. The disadvantages to this method are the high degree of drive and transformer complexity, a very high component count and many interconnecting cables and connection points. This leads to much higher maintenance requirements and lower reliability.

Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 19

Chapter 1 Overview of Drive

Manufacturers also use isolation transformers to protect motors from Common Mode Voltage stress. When transformers are used they allow the motor neutral point to be connected to ground, but with this method, the common mode voltage that would otherwise be impressed on the motor is impressed on the transformer. The disadvantage to this method is that increased transformer insulation and increased cable insulation is required between the transformer and the drive so it can withstand the common mode voltage stress.

Rather than use an Isolation Transformer, the “Direct-to-Drive” Active Front End uses the semiconductor switching pattern to reduce line current harmonics to levels that comply to the world’s most accepted harmonic standards. The Active Front End is the best method of harmonic cancellation because it does not suffer from complexity and high component count like multi-pulse drive topologies do.

“Direct-to-Drive” technology produces virtually no common mode voltage so it is suitable for new or existing motors and imposes no stress on the drive input. The advantage of “Direct-to-Drive” technology over an Isolation Transformer is that no extra insulation is required in the motor, in the motor cables or in the line cables.

In addition to mitigating Common Mode Voltage, “Direct-to-Drive” technology mitigates dv/dt or Reflected Wave Voltage Stress on motors.

The simplicity of its design results in a lower initial capital investment, lower operating cost, lower installation cost and lower maintenance cost relative to drives that require isolation transformers.

The PowerFlex 7000L with “Direct-to-Drive” technology is typically smaller and lighter than drive technologies that use Isolation Transformers. Isolation Transformers represent 30 to 50% of a drive system size and 50 to 70% of the system’s weight. This means that there is no interwiring between drive and transformer (for external transformer configurations). This makes the PowerFlex 7000L the simplest to install.

20 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Overview of Drive Chapter 1

200.00

100.00

0.00

-100.00

-200.00

-300.00

10.00K

7.50K

5.00K

2.50K

0.00K

-2.50K

-5.00K

-7.50K

-10.00K

100.00

110.00

120.00 130.00

)

140.00

150.00

Arms

Vrms

Motor Current

Motor Voltage

Motor Compatibility

The PowerFlex 7000L achieves near sinusoidal current and voltage waveforms to the motor, resulting in no significant additional heating or insulation stress. Temperature rise in the motor connected to the VFD is typically 3°C (5.5°F) higher compared to across the line operation. Dv/dt in the voltage waveform is less than 10 volts / microsecond. The peak voltage that the motor insulation will see is the rated motor RMS voltage divided by 0.707. Reflected wave and dv/dt issues often associated with VSI (voltage source inverter) drives are a non-issue with the PowerFlex 7000L. Typical motor waveforms are shown in Figure 4

. 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 derating, even on retrofit applications.

Motor cable distance is virtually unlimited. This technology has been tested, controlling motors up to 15 km (9.3 miles) away from the drive.

Figure 4 - Motor waveforms @ full load, full speed

300.00

TIME (ms

Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 21

Chapter 1 Overview of Drive

SGCT Features and Benefits

An SGCT is a Symmetrical Gate Commutated Thyristor with an integrated gate drive. Positioning the gate drive close to the SGCT as shown in Figure 5 low inductance path that provides more efficient and uniform gating of the device. As a result, the device is better suited than a conventional GTO to handle the fluctuating levels of voltage and current while it is switching on and off during gating.

An SGCT has similar characteristics to an IGCT (used on some VSI drives), including low conduction and switching losses, low failure rate, and double sided cooling for low thermal stress. However, the SGCT achieves voltage blocking capability in both forward and reverse directions up to 6500 volts by a NPT (N

on-Punch-Through) structure and nearly symmetrical pnp transistor in the wafer, while the current is unidirectional. Unlike many VSI topologies that use IGBTs, the semiconductors used in the PowerFlex 7000L feature a non-rupture, non-arc failure mode. In the unlikely event of a device failure, the fault would be contained within the device.

Implementing SGCTs in the PowerFlex 7000L “B” Frame results in significant advantages including:

1. Simplification of the snubber design and a reduction in the size of the snubber capacitor by a factor of 10.

, creates a

2. Operation at a higher switching frequency (420-540 Hz), hence reducing the size of passive components (DC link inductor and motor filter cap) by 50%.

3. Improving performance of the drive.

4. Reduction of component count, hence improving reliability, cost, and size

of the drive.

5. Fail safe failure mode (non-rupture).

Figure 5 - SGCT with integrated gate drive (left) and unit cell structure (right)

22 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Specifications

Overview of Drive Chapter 1

Table 1 - General Design Specifications

Description

Motor Type Induction or Synchronous

Input Voltage Rating 2400V, 3300V, 4160V, 6600V

Input Voltage Tolerance ± 10% of Nominal

Volt age Sag

Control Power Loss Ride-through 5 Cycles (Std)

Input Protection

Input Frequency 50/60 Hz, +/- 0.2%

Power Bus Input Short-circuit Current Withstand (2400…6600V

Basic Impulse Level

Power Bus Design Copper - Tin plated

Ground Bus Copper - Tin plated 6 x 51 mm (¼ x 2 in.)

Customer Control Wire Way Separate and Isolated

Input Power Circuit Protection

Output Voltage 0…2400V

Inverter Design PWM

Inverter Switch SGCT

Inverter Switch Failure Mode Non-rupture, Non-arc

Inverter Switch Failure Rate (FIT) 100 per 1 Billion Hours Operation

Inverter Switch Cooling Double Sided, Low Thermal Stress

Inverter Switching Frequency 420…440 Hz

Number of Inverter SGCTs Voltage SGCTs (per phase)

Inverter PIV Rating (Peak Inverse Voltage)

Rectifier Designs Direct-to-Drive (transformerless AFE rectifier)

Rectifier Switch SCR (18 Pulse), SGCT (AFE Rectifier)

Rectifier Switch Failure Mode Non-rupture, Non-arc

Rectifier Switch Failure Rate (FIT) 50 (SGCT) 100 (SCR) per 1 Billion Hours Operation

(1)

-30%

> 5 Cycles (Optional UPS)

(2)

Surge Arrestors (AFE/D irect-to-D rive) Metal Oxide Varistor (MOV) (18 Pulse)

25 kA RMS SYM, 5 Cycle

(3)

)

(4)

45 kV (0…1000 m)

(5)

Vacuum Contactor with Fused Isolating Switch or Circuit Breaker

0…3300V 0…4160V 0…6000V, 0…6300V, 0…6600V

2400V 3300V 4160V 6600V

2 4 4 6

Voltage PIV (each device) Total PIV

2400V 3300V 4160V 6600V

6500V 6500V 6500V 6500V

AFE with separate isolation transformer 18 Pulse with separate isolation transformer

6500V 13,000V 13,000V 19,500V

Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 23

Chapter 1 Overview of Drive

Table 1 - General Design Specifications (Continued)

Description

Rectifier Switch Cooling Double Sided, Low Thermal Stress

Number of Rectifier Devices per phase Voltage AFE 18 Pu lse

2400V 3300V 4160V 6600V

Output Current THD (1st…49th)< 5%

Output Waveform to Motor Sinusoidal Current / Voltage

Medium Voltage Isolation Fiber Optic

Modulation techniques Selective Harmonic Elimination (SHE)

Synchronous Trapezoidal PWM Asynchronous or Synchronous SVM (Space Vector Modulation)

Control Method Digital Sensorless Direct Vector

Full Vec tor Control with Encoder Feedback (Option al)

Tuning Method Auto Tuning via Setup Wizard

Speed Regulator Bandwidth 1...10 rad/s with standard control

1...20 rad/s with HPTC (optional)

Torque Regulator Bandwidth 15...50 rad/s with standard control

80...100 rad/s with HPTC (optional)

Torque Accuracy with HPTC (optional) +/- 5%

Speed Regulation

Acceleration/Deceleration Range

Acceleration/Deceleration Ramp Rates

S Ramp Rate

Critical Speed Avoidance

Stall Protection

Load Los s Detecti on Adjust able level, delay, speed set points

Control Mode Speed or Torque

Current Limit Adjustable in Motoring and Regenerative

Output Frequency Range 0.2...75 Hz (Standard)

Service Duty Rating Normal Duty Heavy Duty

Typical VFD Efficiency > 97.5% (AFE)

Input Power Fac tor AFE Rectifier

0.1% without Encoder Feedback

0.01...0.02% with Encoder Feedback

Independent Accel/Decel – 4 x 30 s

4 x Independent Accel/Decel

Independent Accel/Decel – 2 x 999 s

3 x Independent with Adjustable bandwidth

Adjustable time delay

75 Hz...85Hz (Optional - need specific Motor Filter Capacitor [MFC])

110% Overload for 1 min. every 10 min. (Variable Torque Load)

> 98% (18 Pulse)

Contact Factory for Guaranteed Efficiency of Specific Drive Rating

0.95 minimum, 10...100% Load

2 4 4 6

150% Overload for 1 min. every 10 min. (Consta nt To rque Load)

6 6 6 6

24 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Overview of Drive Chapter 1

Table 1 - General Design Specifications (Continued)

Description

IEEE 519 Harmonic Guidelines

VFD Noise Level < 85 dB (A)) per OSHA Standard 3074

Regenerative Braking Capability Inherent – No Additional Hardware or Software Required

Flying Start Capability Yes – Able to Start into and Control a Spinning Load in Forward or Reverse

Operator Interface 10” Color Touchscreen – Cat# 2711P-T10C4A9 (VAC)

Languages English, French, Spanish, Por tuguese, German, Chinese, Italian, Russian, and

Control Power 220/240V or 110/120V, Single phase - 50/60 Hz (20 A)

External I/O 16 Digital Inputs, 16 Digital Outputs

External Input Ratings 50…60 Hz AC or DC

External Output Ratings 50…60 Hz AC or DC

Analog Inputs Three Isolated, 4…20 mA or 0…10V (250 Ω)

Analog Resolution Analog input 12 Bit (4…20 mA)

Analog Outputs One Isolated, Eight Non-isolated,

Communication Interface Ethernet IP/DPI

Scan Time Internal DPI – 2 ms min., 4 ms max.

Communications Protocols (Opti onal)

Enclosure NEMA 1 (standard) IP21 (IEC)

Lifting Device Standard / Removable

Mounting Arrangement Mounting Sill Channels

Structure Finish Epoxy Powder – Paint

Interlocking Key provision for customer input Disconnecting Device

Corrosion Protection Unpainted Parts (Zinc Plated / Bronze Chromate)

Ambient Temperature 0…40 °C (32…104 °F) / 0…50 °C (32…122 °F) - optional

Fiber Optic Interface Rec tifier – Inverter – Cabinet (Warning / Trip)

Door Filter Painted Defuser with Matted Filter Media

(6)

IEEE 519 - 1992 Compliant

Direction

Built-in PDF viewer

Redesigned PanelView Plus 6 Logic Module with 512 Mb of memory

Polis h

120…240V – 1 mA

30…260V – 1 A

Internal parameter 32 Bit resolution Serial Communication 16 Bit resolution (.1Hz) (Digital Speed Reference)

4…20 mA or 0…10V (600 Ω)

DeviceNet ControlNet

Ethernet I/P Lon Works

Dual-port Ethernet I/P Can Open

Profibus RS485 HVAC

Modbus RS485 DF1

Interbus RS232 DF1

USB

NEMA 12 (optional) IP42 (IEC)

Exterior Sandtex Light Grey (RAL 7038) – Black (RAL 8022) Internal – Control Sub Plates – High Gloss White (RAL 9003)

Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 25

Chapter 1 Overview of Drive

Table 1 - General Design Specifications (Continued)

Description

Door Filter Blockage Air Flow Restriction Trip / Warning

Storage and Transportation Temperature Range

Relative Humidity Max. 95%, non-condensing

Altitude (Standard) 0…1000 m (0…3300 ft)

Altitude (Optional) 1001…5000 m (0…16,400 ft)

Seismic (UBC Rating) 1, 2, 3, 4

Standards NEMA, IEC, CSA, UL, ANSI, IEEE

(1) Voltage Sag tolerance is reduced to -25% when control power is supplied from medium voltage via CPT.

(2) MOVs are used for 18 Pulse. Surge arrestors are used for AFE/Direct-to-Drive configurations.

(3) Short-circuit fault rating based on input protection device (contactor or circuit breaker).

(4) BIL rating based on altitudes < 1000 m (3300 ft) Refer to factory for derating on altitudes >1000 m.

(5) Optional.

(6) Under certain conditions, power system analysis will be required.

-40…70 °C (-40…185 °F)

26 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Simplified Electrical Drawings

LINE CONVERTER

L- M-

L+ M+

MACHINE CONVERTER

U (T1)

V (T2)

W (T3)

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

ISTX

SCRs

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

2U (X1)

2V (X2)

2W (X3)

SGCTs

LINE CONVERTER

L- M-

L+ M+

MACHINE CONVERTER

U (T1)

V (T2)

W (T3)

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

ISTX

SCRs

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

2U (X1)

2V (X2)

2W (X3)

SGCTs

LINE CONVERTER

L- M-

DC LINK

L+ M+

MACHINE CONVERTER

U (T1)

V (T2)

W (T3)

SGCTs

2U (X1)

2V (X2)

2W (X3)

SGCTs

LINE CONVERTER

L- M-

DC LINK

L+ M+

MACHINE CONVERTER

U (T1)

V (T2)

W (T3)

SGCTs

2U (X1)

2V (X2)

2W (X3)

SGCTs

LINE CONVERTER

L- M-

L+ M+

MACHINE CONVERTER

U (T1)

V (T2)

W (T3)

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

ISTX

SCRs

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

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

SGCTs

LINE CONVERTER

L- M-

L+ M+

MACHINE CONVERTER

U (T1)

V (T2)

W (T3)

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

ISTX

SCRs

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

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

SGCTs

Figure 6 - 3300 / 4160 Volt – 18 Pulse

DC LINK

Figure 7 - 3300 / 4160 Volt – Active Front End

Overview of Drive Chapter 1

Figure 8 - 6000-6600 Volt – 18 Pulse

DC LINK

Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 27

Chapter 1 Overview of Drive

LINE CONVERTER

L- M-

L+ M+

MACHINE CONVERTER

U (T1)

V (T2)

W (T3)

2U (X1)

2V (X2)

2W (X3)

SGCTs

LINE CONVERTER

L- M-

L+ M+

MACHINE CONVERTER

U (T1)

V (T2)

W (T3)

2U (X1)

2V (X2)

2W (X3)

SGCTs

Figure 9 - 6000-6600 Volt – Active Front End

DC LINK

28 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Control Overview

Source

AC Lin e

Reactor

Rectifier

Line Filter

Cap

DC Link

Inductor

Inverter

Line

Curren t

Line Voltage

Line

Protection

Fau lts

Line Side Feedback

and Gating

Alpha

Rectifier

Motor

Filter Cap

Motor

Curren t

Alpha

Inverter

Current

Control

InvTorque

CurCmd

Inv Flux CurCmd

Flux

Control

Speed Feedback

Flux Feedback

Motor

Model

Motor

Vol tag e

Machine

Protection

Flux Range

Fau lts

Slip freq

Stator freq

Encoder

Feedback

Speed

Command

Speed

Reference

Speed

Control

Sync

Tra ns fe r

Idc Feedback

Line Side Feedback

and Gating

Figure 10 - PowerFlex 7000L “C” Frame Function Block Diagram

Overview of Drive Chapter 1

Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 29

Chapter 1 Overview of Drive

ACB

DPM

XIO

OIB

ACB – Analog Conditioning Board DPM – Drive Processor Module OIBB – Optical Interface Base Board XIO – External Input/Output OIB – Optical Interface Board

Direct Vector Control

Control Hardware

The method of control in the PowerFlex 7000 “C” Frame medium voltage AC drive is called sensorless direct vector control, meaning that the stator current is divided into torque producing and flux producing components, allowing the motor torque to be changed quickly without affecting motor flux. This method of control is used without encoder feedback for applications requiring continuous operation above 6 Hz and less than 100% starting torque.

Full vector control can also be achieved with encoder feedback for applications requiring continuous operation down to 0.2 Hz with up to 150% starting torque. Vector control offers superior performance over volts/hertz type drives. The speed bandwidth range is 5...25 rad/s, while the torque bandwidth range is

15...50 rad/s.

The control hardware includes a processor board (DPM) with an interface to six fiber optic boards (depending on the voltage and number of switching devices) via OIBB, an analog conditioning board (ACB) and an external IO board (XIO). The control hardware is used for rectifier and inverter, induction or synchronous drive control and the two rectifier types (18 Pulse or Active Front End).

The DPM features two floating point DSPs (Digital Signal Processor) and a FPGA (Field Programmable Gate Array) for advanced functions such as gating and diagnostics, fault handling and drive synchronization control.

Figure 11 - Control Hardware Layout for PowerFlex 7000 “C” Frame

OIBB OIBB

30 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Overview of Drive Chapter 1

Operator Interface

Figure 12 - PowerFlex 7000L 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 7000L 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 start-ups, smooth operation, and less down time.

Up to five test modes are available including low voltage gate check, and running at full current without motor connected.

Enhanced diagnostic functions are available on the operator interface terminal including separate fault and warning queues in non-volatile RAM (NVRAM), extended fault text strings and on line help, and trend buffers for 16 variables.

Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 31

Chapter 1 Overview of Drive

Notes:

32 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Drive Installation

IMPORTANT

Chapter 2

Safety and Codes

Unpacking and Inspection

WARNING: 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.

Before leaving the factory, all drives have been tested both mechanically and electrically. Immediately upon receiving the drive, remove the packing and check for possible shipping damage. Report any damage immediately to the claims office of the common carrier.

After unpacking the material, check the item(s) received against the bill of lading to assure that the nameplate description of each item agrees with the material ordered. Inspect the PowerFlex 7000 drive for physical damage, as stated in the Rockwell Automation Conditions of Sale.

All claims for breakage and damage whether concealed or obvious must be made to the carrier by the Customer as soon as possible after receipt of the shipment. Rockwell Automation will be glad to give the Customer reasonable assistance in the securing of adjustment for such damage claims.

Transportation and Handling

Remove all packing material, wedges, or braces from within the drive. Operate the contactors and relays manually to assure that they operate freely. If any part of the equipment will not be installed when it is unpacked, it should be stored in a clean, dry place. The storage temperature must be between -40°C (-40°F) and 70°C (185°F) with a maximum humidity of 95%, non-condensing, to guard against damage to temperature sensitive components in the controller.

The PowerFlex 7000 drive is shipped on a wooden skid, which is bolted to the underside of the cabinetry. The drive should remain bolted to the shipping skid until it is delivered to its final installation area. Lifting angles are supplied bolted to the top of the cabinetry. The drive must be kept in an upright position during any handling. Refer to General Handling Procedures, publication 7000-IN002_EN-P for a more detailed description.

The drive must be transported on a pallet or via use of the lifting beam supplied as part of all 2300 mm (91 in.) high cabinets.

Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 33

Chapter 2 Drive Installation

IMPORTANT

ATT EN TI ON : Ensure that the load rating of the lifting device is sufficient to

safely raise the controller sections. Refer to the packing slip enclosed with shipment for shipping weights.

Round rollers can be used to assist in moving the drive to the installation site. Once at the final site, the pipe rolling technique can be used to place the cabinet in the desired position.

WARNING: Care must be exercised when using either a forklift or the pipe rolling technique for positioning purposes to ensure that the equipment is not scratched, dented or damaged in any manner. Always exercise care to stabilize the drive during handling to guard against tipping and injury to personnel.

It is extremely important that the customer’s installation duties are performed correctly. Any errors will cause damage to the Drive and delays in commissioning.

Never attempt to lift or move the drive by any means other than the methods listed, as structural damage or personal injury could result. The following methods of handling are recommended:

Overhead Lifting

1. Attach rigging to the lifting angles on the top of the cabinetry.

ATTENTION: Ensure that the load rating of the lifting device and rigging is sufficient to safely raise the drive. Refer to shipping weights on the packing slip enclosed with the shipment.

2. Do not pass ropes or cables through the support holes in the lifting angles. Use slings with safety hooks or shackles.

3. Select or adjust the rigging lengths to compensate for an unequal weight distribution of load and maintain the drive in an upright position.

4. To reduce the tension on the rigging and the compressive load on the lifting device, do not allow the angle between the lifting cables/chains and vertical to exceed 45 degrees.

ATTENTION: Drives may contain heavy equipment that could be adversely affected by tilting.

34 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Figure 13 - Overhead Lifting

(50.8 mm x 152.4 mm)

Drive Installation Chapter 2

Rod or Pipe Rollers

This method is only suitable when there are no inclines and the drive is being moved on one floor level.

1. Boards 50.8 mm x 152.4 mm (2 in. x 6 in.) or equivalent and at least 300 mm (12 inches) longer than the drive must be placed under the shipping skid.

2. Carefully ease the shipping platform over the roller pipes until the drive weight is borne on the roller pipes.

3. The drive can be rolled to its designated location. Steady the load to prevent tipping.

Figure 14 - Rod or Pipe Rollers

Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 35

Chapter 2 Drive Installation

Fork Lift Trucks

A single fork lift truck may be used on drives not exceeding 3 m (120 inches) in length if the lift truck has sufficient lifting capacity. Larger drives can be moved with two forklift trucks operating in tandem.

1. Insert forks into openings of shipping skids from the rear of the drive.

2. Carefully balance the drive on the forks because the drives are usually

heavier at one side.

3. Use safety straps when handling to steady the drive while moving.

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 (-40°F) and 70°C (185°F). If storage temperature fluctuates or if humidity exceeds 85%, 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.

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

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).

36 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Drive Installation Chapter 2

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.

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

system reliability and inhibits cooling.

Installation

(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 CSI-PWM topology utilized in the PowerFlex 7000 medium voltage AC drive has been tested with motors located up to 15 km (9.3 miles) 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. If back access is desired, set drive 300 mm (12 inches) out from wall.

ATTENTION: 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.

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.

Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 37

Chapter 2 Drive Installation

CAB

CABLE

CAB

CONV

CAB

CAP CAB

DC LINK

CHOKE

CAB

PUMP

CAB

Wood Skid

1st SECTION

2nd SECTION

The location of the anchor points is provided with the dimension drawing of the drive.

Install and tighten the anchor bolts. (M12 or 1/2" hardware required). Engineered 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.

Joining Shipping Splits

The Drive may have been shipped in two or more shipping sections which are to be connected at installation. It is essential that the surfaces are level. Arrange the sections per the information provided in the dimension drawings and move the sections together. Ground bus, power and control connections are to be made per the electrical diagrams provided. Side sheets of the enclosures are to be joined with thread forming screws using the available holes.

Liquid-cooled Drives may require joining of the coolant pipes. Some enclosure ratings may require the addition of silicone sealant where cabinets join together to prevent the possible ingress of dripping water.

For Direct-to-Drive liquid-cooled 6600V Drives (430A, 495A and 575A rated current) the Drive will be shipped in two sections as shown in Figure 15

Figure 15 - Typical Split Drive

LiftingAngles

The 1st section consists of 5 cabinets.

The 2nd section consists of 2 cabinets.

Final placement requires that the 1st and 2nd sections are joined at final installation site.

38 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Drive Installation Chapter 2

WARNING: Heavy Magnetic DC Link Chokes up to 4600 kg (10,000 lb) are shipped inside DC Link Choke cabinet. Professional Millwright/Rigging contractors are required for safe final placement of Drive sections.

Connect the Sections

Field connect the following:

• CPVC pipe splices – 2 pieces

• Power Bus Splice Kit – 4 pieces

• Ground Bus Splice – 1 piece

• Control Wiring

Tools Required (not supplied)

• Adjustable or socket wrenches for 6-, 10-, 12-mm and 5/8" bolt and nut hardware

• Strap wrench for tightening CPVC unions

• Screwdriver assortment

• Cable ties

• Wire cutters

Install CPVC Piping Splices

• Open doors of capacitor cabinet (Cabinet #5) next to DC Link Choke cabinet (Cabinet #6). Refer to Figure 16

• Remove capacitor from position #3, if installed (not all configurations have a capacitor in this location). It is not necessary to remove capacitor from position #2.

ATTENTION: Capacitors weigh up to 100 kg (220 lb). Use two people to remove the unit from the structure.

Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 39

Chapter 2 Drive Installation

Capacitor

Position #1

Capacitor

Position #2

Capacitor

Position #3

CPVC Pipe Splices

Figure 16 - Capacitor Cabinet

• Remove CPVC pipe splices shipped in the capacitor cabinet. Install and tighten the 4 CPVC unions with strap wrench (1/4 to 1/2 turn past hand tight). Ensure O-ring is seated inside male end of union. Refer to

Figure 17

, Figure 18 and Figure 19. Do not use CPVC primer or cement.

40 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Figure 17 - CPVC Pipe Splices (Capacitor #2 not shown for clarity)

Pipe Splice #1

Capacitor

Cabinet

DC Link

Choke Cabinet

Pipe Splice #2

Drive Installation Chapter 2

Figure 18 - Typical Strap Wrench (not supplied) used to tighten unions on CPVC pipe splices

Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 41

Chapter 2 Drive Installation

TIP

Figure 19 - Capacitor Cabinet and DC Link Choke Cabinet after Pipe Splices installed

Install according to flow direction labels as shown.

Connect Power: M+, L+, M-, L- Power Bus

• Locate the four (4) Power Bus pieces of the splice kit in DC Link Choke cabinet and remove shipping wrapping. See Figure 20

• Connect Power Bus M+, L+, M-, L- on the red insulators in the DC Link Choke cabinet and mating bus pieces in the capacitor cabinet. Hardware required is pre-attached to bus connections, cabling, and insulators in the cabinet where the power bus splice kit will attach. Remove and attach as shown in Figure 20

to Figure 24.

• Torque M10 carriage bolts connecting bus to bus in the capacitor cabinet to 29 Nm (21 ft-lb). Torque M12 hardware supplied for cable to bus stab connections to 50 Nm (37 ft-lb).

• After cable connections have been made, ensure cable connections to choke stabs are torqued to 50 Nm (37 ft-lb).

• Ensure a minimum of 3" (75mm) clearance exists between Medium Voltage Bus field connections (including hardware) and all cabinet sidesheets.

42 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Figure 20 - DC Link Choke Cabinet

MV Bus (4 pieces) Ground Bus Link (1 piece) Inside DC Link Choke Cabinet

Power Bus (4) pieces; Ground bus (1) shipped disassembled

Drive Installation Chapter 2

Figure 21 - DC Link Choke Cabinet before field power bus connections

Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 43

Chapter 2 Drive Installation

M-

M+

L+

L-

M+

L+

L-

M-

Figure 22 - DC Link Choke Cabinet after field connections of power bus

Figure 23 - Capacitor Cabinet after field connections of power bus

44 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Figure 24 - Capacitor Cabinet (Connect left side of Medium Voltage bus pieces with M10 hardware)

Drive Installation Chapter 2

• Connect cables from DC Link Choke to MV Bus pieces using supplied M12 hardware.

Figure 25 - DC Link Choke Cabinet after connection of cables from DC Link Choke to red insulators

• Connection points are labeled on bus and DC Link Choke. Connect cables from labeled stabs M+, L+, L-, L+ on DC Link Choke to corresponding labeled stabs M+, L+, M-, L+ on bus.

Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 45

Chapter 2 Drive Installation

Figure 26 - DC Link Choke Cabinet Typical Cable Connection

• Connect Ground Bus Link from top left of DC Link Choke cabinet to ground bus in adjacent capacitor cabinet by sliding underneath wire duct. Use supplied hardware.

Figure 27 - Ground Bus Link

Figure 28 - Install Ground Bus Link

46 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Figure 29 - Ground Bus Connection Points (Install Ground Bus Link using Supplied Hardware)

Drive Installation Chapter 2

Control Wiring Connections

Refer to EDs and wiring diagrams supplied with Drive. Contact Rockwell Automation representative for assistance. Final wiring connections to be performed by Rockwell Automation field service representative.

1. Remove the wireway covers located on top of the line and motor filter

capacitor sections and the DC Link section.

2. If drive has strip heater wiring, it will be coiled up in the top wireway.

Route these wires down through the grommeted cutout for connection on the terminal blocks located in the upper left side of the capacitor section.

Figure 30 - Strip heater terminal block

Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 47

Chapter 2 Drive Installation

3. Route the control wiring which has been coiled up and left hanging in the upper area of the motor filter capacitor section, back up through the two grommeted cutouts back into the wireway. There is a fiber optic cable in this bundle and care must be taken not to damage it. The fiber optic cable, control power wires and the “XIO link” cable will be required in the pump control cabinet.

Figure 31 - Control Wiring

4. Route the 8 gauge black and red twisted pairs of wire and the Belden shielded cables down through the grommeted cutout into the AC\DC power supply section.

Figure 32 - Belden Shielded Cables

48 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Drive Installation Chapter 2

5. Route the 3-fan control wires, 2 cabinet over-temperature control wires down through the grommeted cutout into the center of the DC choke section (Figure 33

Figure 33 - Fan Thermostat Control Wires

6. Route the control wires down through the grommeted cutout into the control power disconnect section (Figure 34

7. Connect the numbered wires to the corresponding numbered terminal blocks (Figure 35

Figure 34 - Route control wires through grommeted cutout

to Figure 38).

Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 49

Chapter 2 Drive Installation

8. Refer to the electrical drawing and make the above control wiring connections.

Figure 35 - 56V DC Connections

Figure 36 - AC DC fails Belden Cable Connection

50 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Figure 37 - Control Wire Power Connections

Drive Installation Chapter 2

Figure 38 - Thermostat and Fan Connections

9. Once all the connections have been made and neatly routed in each section, the excess control wires can be looped up in the top wireways.

10. Swing out the control section in the pump control cabinet.

11. Route the XIO link cable, control power wires and the fiber optic cable

down through the wire ways grommeted cutout.

12. Route the XIO link cable, the control power wires into the pump control cabinet through the upper side grommeted cutout.

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Chapter 2 Drive Installation

13. Route the fiber optic cable into the pump control cabinet through the lower side grommeted cutout.

Figure 39 - 120V and XIO cables through upper cutout

14. Connect the XIO link cable to the XIO board “XIO link A” connector. (Figure 40

)

15. Connect the control power wires to the control power terminal blocks. Refer to Electrical Drawings for corresponding wire numbers and terminal blocks.

16. Connect the fiber optic cable to the TFB board.

Figure 40 - XIO link Cable

52 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Figure 41 - TFB Fiber Optic connected

Silicone sealant

Drive Installation Chapter 2

• Use supplied silicone (see Figure 42) to seal between cabinets to prevent moisture or dirt from entering. Join sidesheets with M6 Taptite thread forming screws in holes provided.

Figure 42 - Capacitor Cabinet

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Chapter 2 Drive Installation

Remove cotter pins

Removal of DC Link Choke Turnbuckle Supports

Remove turnbuckles which attach choke to top lifting angle pair as follows:

• Remove cotter pins (see Figure 43 Carefully remove turnbuckles. Retain for future use.

Figure 43 - Choke Cabinet

) from bottom turnbuckle jaw then top.

• Re-install any capacitors that were removed.

• Proceed with Removal of Lifting Angles.

Removal of Lifting Angles

Lifting angles should be removed only when the Drive is in its final location. The lifting angles are retained with 5/8"-11 hardware. The 5/8" bolts need to be reinstalled in their holes in the top of the Drive to prevent the ingress of foreign matter into the enclosures. See Figure 44

54 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Figure 44 - Insert bolts

Drive Installation Chapter 2

ATT EN TI ON : Refer to the technical drawings and installation manual for your

Drive mounting instructions. Failure to correctly anchor the cabinet may result in damage to the equipment or injury to personnel. Contact the area Rockwell Automation sales office if you do not have these documents.

Shock Indication Labels

Shock indication labels are devices that permanently record the physical shock to which equipment is subjected.

At the time of final preparation for shipment from the factory, a shock indication label is installed on the inside door of the converter cabinet.

During the shipping and installation process drives may inadvertently be subjected to excess shock and vibration which may impair its functionality.

When the drive has been placed in its installation area, the converter door is to be opened and the shock indication labels inspected.

The drive is shipped with a label that records shock levels in excess of 10G. If these shock levels have been attained, the chevron shaped window will appear blue in one of the two windows.

If these shock levels have been attained, record the values. There is a greater possibility of the drive having sustained internal damage if it has been subjected to physical shock during the shipping and installation process.

Even if the indicators show that no shock was attained, full inspection and verification in accordance with the Commissioning process outlined in Chapter 4 is still essential.

Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 55

Chapter 2 Drive Installation

TIP

Red Plastic Housing

Window Area appears Blue

if subjected to shock

51 mm

(2.0)

21 mm (0.8)

Figure 45 - Shock Indicator

Installation of Exhaust Air Hood

Even though this is a liquid-cooled drive, some sections still require air circulation.

On the top of the cabinets with cooling fans, sheet metal exhaust hoods are to be installed. The components to make up the exhaust hood have been packaged and shipped with the drive and are to be found in the control/cabling cabinet.

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 reuse.

Secondly, loosely assemble the two L-shaped panel components shipped with the drive.

For AFE Rectifiers with a line reactor cabinet, there may be a provision for small fans in the roof of the cabinet. This cabinet will still have a full-size exhaust air hood.

Locate the exhaust hood on top of the cabinet per Figure 46 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.

ATT EN TI ON : Any screws that are accidentally dropped in the equipment must be retrieved as damage or injury may occur.

and re-install the

56 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Drive Installation Chapter 2

Fan Hood to be installed on site

Internally mounted fans

Capacitor cabinets have internally mounted fans which are installed and wired by Rockwell Automation (refer to Figure 46 fan hood.

Figure 46 - Fan Hood Installation (Internally Mounted Fans)

). The customer only needs to install the

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Chapter 2 Drive Installation

Fan Hood

External fans

Terminal blocks

Externally mounted fans and fan hood

The converter has cooling fans that are externally mounted (refer to Figure 47). It is necessary to re-install and connect the fans, and install the fan hood.

Shipped with the drive is a plate with the fans mounted and wired to terminal blocks. On site, the fan assembly is to be mounted on the top plate of the converter cabinet as shown in Figure 47

Wiring for fan power is to be routed through the hole near the terminal blocks. The plate is fastened to the cabinet with M6 hardware. Connect wires to the terminal blocks per the electrical diagram.

Position the fan hood over the fan assembly and fasten with M6 hardware.

Figure 47 - Fan Hood Installation (Externally Mounted Fans and Fan Hood)

58 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Typical PowerFlex 7000L Drive Structure Layout

Control and

Cabling Cabinet

Converter Cabinet

Capacitor Cabinet

DC Link Inductor

Cabinet

Pump Cabinet

TIP

Figure 48 - Typical PowerFlex 7000 “C” Frame Drive Structure Layout

Drive Installation Chapter 2

Control/Cabling Cabinet

Major Components

Shows the medium voltage area located in the control/cabling cabinet behind the low voltage compartment and with barriers removed.

The control/cabling cabinet comes in two different configurations:

• AFE rectifier (Figure 49

• 18 Pulse rectifier (Figure 50

)

The following seven diagrams show the typical layout of each cabinet for PowerFlex 7000 “C” Frame Drives.

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Chapter 2 Drive Installation

Hall-effect Sensor

Motor Terminals

Line Terminals

Volt age Sens ing

Hall-effect Sensor

Surge Arrestors

Curren t Transformer

Figure 49 - Control and Cabling Cabinet (AFE Rectifier version shown) (with Control Panel removed)

60 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Curren t Tra ns fo rm er s

Voltage Sensing

Hall Effect Sensor

Line Terminals

Tra ns ie nt

Suppression

Networks

Motor Terminals

Drive Installation Chapter 2

Figure 50 - Control and Cabling Cabinet (18 Pulse version shown) (with Control Panel removed)

Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 61

Chapter 2 Drive Installation

ANALOG

CONTROL

BOARD

Analog Control Board Drive Processor

Module (DPM)

Tach Feedback Circuit Board

DC/DC Power Supply Fiber Optic Interface Boards

Figure 51 - Low Voltage Tub Compartment

62 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Ground Bus

Isolated Gate Drive Power Supplies (IGDPS)

Inverter Modules

Rectifier Modules

Coolant Piping

Drive Installation Chapter 2

Figure 52 - Converter Cabinet Components (4160V AFE shown)

Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 63

Isolated Gate Driver Power Supplies (IGDPS)

Ground Bus

Inverter Modules

Rectifier Modules

Chapter 2 Drive Installation

Figure 53 - Converter Cabinet Components (6600V AFE shown)

64 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Grounding Network

Line Capacitors

Motor Line

Capacitors

Cooling Fan

Drive Installation Chapter 2

Figure 54 - Capacitor Cabinet

Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 65

Chapter 2 Drive Installation

Liquid-cooled DC Link Reacotr

Fuse Blocks

Power Transformer

AC/DC Power

Supplies

Cooling Pipes

Figure 55 - DC Link Inductor Cabinet

66 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Figure 56 - Pump Cabinet (showing swing-out low voltage panel)

Coolant Pumps

Deioni zer CartridgePumping Panel

Swingou t Low Voltage Panel

Drive Installation Chapter 2

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Chapter 2 Drive Installation

IEC Component and Device Designation

PowerFlex 7000 electrical drawings use conventions that are based on IEC (International Electrotechnical Commission) standards, while remaining basically compatible with North American ANSI (American National Standards Institute) standards. The symbols used to identify components on the drawings are international and a full listing of the symbols is given as part of each PowerFlex 7000 elementary drawing (ED) set. The device designations used on the drawings and labeling are also listed with explanations on each drawing set.

Wiring identification uses a source/destination wire number convention on point to point multi-conductor wiring and in situations where the system is warranted. The wire-numbering system of unique, single numbers for multi-drop and point to point wiring continues to be used for general control and power wiring. Wiring that connects between the sheets or that ends at one point and starts at another point on a drawing has an arrow and drawing reference to indicate the ongoing connection. The drawing reference indicates the sheet and the X/Y coordinates of the continuation point. The reference system is explained on a sheet in each drawing set. The unique wire numbering system serves as confirmation that the correct wire is being traced from sheet to sheet or across a drawing. Wires in multi-conductor cables are typically identified by color rather than by number. The abbreviations used to identify the colors on the drawings are fully identified on a sheet in the drawing set.

Power Wiring Selection

The following tables identify general wire selections that will be encountered when installing the PowerFlex 7000 drive line-up.

General Notes

Adherence to the following recommended field power cabling insulation levels for medium voltage drives will help to ensure trouble-free start-up and operation. The cable insulation level must be increased over that which would be supplied for an across-the-line application with the same rated line-to-line voltage.

Either shielded or unshielded cable may be used based on the criteria considered by the distribution system designer and local standards. However, NEC requires shielded cable for installations above 2 kV.

68 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Drive Installation Chapter 2

Cable Insulation

The cable insulation requirements for the PowerFlex 7000 drive are given in the tables below.

ATT EN TI ON : Voltage ratings shown in the following tables are peak line-toground. Some cable manufacturers rate voltage line-to-line RMS. Ensure the cable meets the rating specified in the following tables.

Table 2 - Cable Insulation Requirements for 18 Pulse and 6P / AFE Drives with Isolation Tra nsfor mer

System Voltage (V, RMS) Cable Insulation Rating (kV) (Maximum Peak Line-to-Ground)

Line Side Machine Side

2400 ≥4.1 ≥2.2

3000 ≥5.12 ≥2.75

3300 ≥5.63 ≥3.0

4160 ≥7.1 ≥3.8

6000 ≥10.8 ≥5.5

6300 ≥11.4 ≥5.8

6600 ≥11.8 ≥6.0

Table 3 - Cable Insulation Requirements for “Direct-to-Drive” Technology

System Voltage (V, RMS) Cable Insulation Rating (kV) (Maximum Peak Line-to-Ground)

Line Side Machine Side

2400 ≥2.2 ≥2.2

3000 ≥2.75 ≥2.75

3300 ≥3.0 ≥3.0

4160 ≥3.8 ≥3.8

6000 ≥5.5 ≥5.5

6300 ≥5.8 ≥5.8

6600 ≥6.0 ≥6.0

The following table identifies general wire categories that will be encountered when installing the PowerFlex 7000 Drive. Each category has an associated wire group number that is used in the following sections to identify the wire to be used. Application and signal examples along with the recommended type of cable for each group are provided. A matrix providing the recommended minimum spacing between different wire groups run in the same tray or separate conduit is also provided.

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Chapter 2 Drive Installation

Wire

Power Cabling Access

The drive is built with provision for either the top or bottom power cable entry.

Cable access plates are provided on the top and bottom plates of the connection cabinet identified by the customer specific dimension drawing.

Access the Customer Power Cable Terminations:

• Open the door of the low voltage control compartment. The low voltage control compartment is hinged on its left side. The power terminals are behind the low voltage control compartment.

• Note that there is a key interlock to prevent swinging the low voltage control compartment open unless the medium voltage source is locked out.

• Turn each of the three latches on the right side of the low voltage compartment one-quarter turn using an 8-mm hexagonal key wrench. There is a pull handle provided on the right side of the low voltage compartment.

• Slowly pull the handle so that the low voltage compartment swings out. The power terminals are now visible.

• The installer is responsible for modifying the power cable access plates to suit the requirements.

• Note that appropriate connectors must be used to maintain the environmental rating of the enclosure.

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Chapter 2 Drive Installation

Latch

Key Interlo ck

Handle

Terminal Blocks Customer (TBC)

Figure 57 - Swing-out of Low Voltage Compartment

72 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Figure 58 - Access to Power Terminals

Low Voltage Door

Low Voltag e Compartment (Open)

Drive Installation Chapter 2

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Chapter 2 Drive Installation

Power Connections

The installer must ensure that interlocking with the upstream power source has been installed and is functioning.

The installer is responsible for ensuring that power connections are made to the equipment in accordance with local electrical codes.

The drive is supplied with provision for cable lugs. The power terminals are identified as follows:

Incoming Connections

• Drives with AFE Rectifiers: 2U, 2V, 2W

• Drives with 18 Pulse Rectifiers – Secondary (d0) 2U, 2V, 2W – Secondary (d-20) 3U, 3V, 3W – Secondary (d+20) 4U, 4V, 4W

• Motor Connections U, V, W

The installer is responsible for ensuring that power connections are made with appropriate torque. (Refer to Torque Requirements for Threaded Fasteners

page 419 (Appendix B).)

The drive is supplied with provision for grounding of cable shields and stress cones near the power terminals.

74 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Drive Installation Chapter 2

Piping to Heat Exchanger

through top of cabinet

Outlet Coolant Connection

Warm Fluid to Heat Echaanger

Inlet Coolant Connection

Fluid Return from heat Exchanger

Piping to Heat Exchanger

Routing through right side of cabinet

Piping to Heat Exchanger

Routing through bottom of cabinet

Liquid Connections

Liquid-to-Air Heat Exchangers

There are three options for routing piping between the liquid-to-air heat exchanger and the pumping cabinet of the drive:

• Pipes through top plate of cabinet

• Pipes through bottom plate of cabinet

• Pipes through right side of cabinet

Removable plates are provided in each of these locations.

Figure 59 - Connection to Liquid-to-Air Heat Exchanger (rear of pumping cabinet shown with back plates removed)

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Chapter 2 Drive Installation

Pump Section

Fluid Cooler

Pipe Materials and Layout

All material that contacts fluid between the heat exchanger and drive must be either Schedule 80 CPVC or stainless steel. Rockwell Automation recommends using stainless steels AISI 304L or 316L to connect the drives to heat exchangers. Use 304L and 316L welding wire to avoid sensitization of the welded material. Sensitization due to incorrect welding causes localized corrosion of the welded area. Pressures expected within a drive are below 75 psi with test pressures of 110 psi.

Schedule 80 CPVC piping may be installed within a climate controlled building with any outside pipe of stainless steel. Shield CPVC from direct sunlight to prevent UV damage. Use expansion loops for long pipe runs.

See document CTS-3 "CPVC CTS Products Design and Installation Manual" from Spears Manufacturing Company (www.spearsmfg.com

) for more

information.

Figure 60 - Plan View of Piping to Heat Exchanger (Piping may vary with exchanger)

Ensure exit flow from the pump cabinet is routed to the inlet flange of the exchanger.

The estimated flow rate and pressure is printed on the cooling system schematic, which is posted on the inside of the pumping cabinet door.

The pipes to which connections are made are Schedule 80 CPVC: 38 mm (1.50 in.) or 50 mm (2.00 in.).

76 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Drive Installation Chapter 2

98.4 (3.9)

98.4

3.9

14.2 (0.560)

• Dimensions in mm (in.)

• Use M12 (0.5 in.) bolt with

washer. Torque to

27...41 N•m (20...30 lb•ft)

• Torque in a cross pattern, slowly working toward torque rating

• The flange used must be a flat type flange. Raised flanges may break.

• Dimensions in mm (in.)

• Use M16 (5/8 in.) bolt

with washer. Torque to

27...41 N•m (20...30 lb•ft)

• Torque in a cross pattern,

slowly wo rking toward torque rating

• The flange used must be a

flat type flange. Raised flanges may break.

18.7 (0.74)

120.6 (4.7)

Figure 61 - Drive CPVC Class 150 Flange, 1.5 in. (38.1 mm) (ANSI B16.5; ASTM D4024)

Figure 62 - Drive CPVC Class 150 Flange, 2 in. (50.8 mm) (ANSI B16.5; ASTM D4024)

External Piping to the Drive

External Piping Cleaning

Rockwell Automation liquid-cooled drive piping and heat exchangers are flushed and cleaned at the factory and piping is capped to prevent contamination. Leave the drive pipe caps installed until final assembly.

Use stainless steel capped piping and valves to maintain cleanliness before welding or assembly. Parts must be stored in a clean, dry area.

All external piping must be cleaned and flushed before installation to ensure proper coolant system and drive pump operation.

Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 77

Chapter 2 Drive Installation

Before welding or assembly:

• Remove debris, particulate, oils and greases from inside pipes and valves before welding.

• Use a high-pressure water spray to remove debris and particulate from pipes and valve.

• Remove oils and greases with solvents.

Finished pipe system

1. Circulate hot water with industrial detergent through external piping system only for at least 4...8 hours. Maintain a water temperature of 60…71 °C (140…160 °F). Do not circulate through the drive piping.

2. Circulate clean hot water until the effluent is clear.

Do not allow oils, greases, solvents, cleaning detergents or other cleaning agents to contact or enter the drive piping as this may cause stress cracking of CPVC piping.

Refer to ASTM A 380-06 "Standard Practice for Cleaning, Descaling, and Passivation of Stainless Steel Parts, Equipment, and Systems" for additional information.

Controlled Siphon into Opentop Reservoir

Rockwell Automation recommends this method of pipe routing for pipes and heat exchangers higher than the reservoir coolant level. The reservoir is located in the VFD pump cabinet. This method controls the siphoning of coolant into the open top reservoir when the coolant pumps are off for maintenance. It prevents the siphoning of all pipes higher than the reservoir liquid level causing reservoir overflow. Siphoning occurs only when both pumps are off.

1. Ensure vertical pipe from drive to vent valve is the same size (1-1/2" or

2.0") as the main VFD pipe. The rear outlet flanges may be 1-1/2" or 2.0" size. Keep the vertical pipe this exact size to maintain minimum coolant siphon flow into reservoir. Add 1-1/2" Ball Check Valve (Rockwell Part 80025-750-01, Flow Coefficient Cv 80 or equivalent) into vertical exit piping. Increase pipe size to 2.0" or 3.0" respectively for the remainder of the pipe circuit.

2. Vents to the top of the reservoir may be 1.0" CPVC pipe or PVC hose. The end shall not be immersed into the reservoir coolant. Cut a hole into the top of the reservoir to allow leakage flow.

Vent valve ARV100VS-CP may be obtained from www.plastomatic.com

78 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Drive Installation Chapter 2

Drain

Fill

2 or 3 in. piping

Ball Check Val ve

1.5 or 2 in. piping

Ven t Valv e (x4 ) ARV100VS Plastomatic Mounting Notes:

• 2 ft max section of horizontal piping for vent valve mounting

• Horizontal vent valve piping for exit and return must be mounted at the same level

Heat Exchanger

3. Fill heat exchanger and pipe using fill line and main VFD piping before starting pump to purge air. Ensure pumps do not run dry as damage may occur. Follow priming and valve operation instructions located on pump cabinet door before operating pumps.

Figure 63 - Controlled Siphon Method

Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 79

Chapter 2 Drive Installation

Drain

Fill

2 or 3 in. piping

Ball Check Val ve

1.5 or 2 in. piping

horizontal piping for vent valve mounting

for exit and return must be mounted at the same level

Heat Exchanger

Figure 64 - Controlled Siphon Method with Elevated Heat Exchanger

Liquid-to-Liquid Heat Exchangers

There are three options for routing piping between the liquid-to-liquid heat exchanger to the supply and return coolant:

• Pipes through top plate of cabinet

• Pipes through bottom plate of cabinet

• Pipes through right side of cabinet

Removable plates are provided in each of these locations.

80 Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014

Access for connections through top of cabinet

Access for connections to

heat exchanger through

right side of cabinet

Liquid-to-Liquid Heat Exchanger

Access for connections to heat

exchanger through bottom of cabinet

Drive Installation Chapter 2

Figure 65 - Connection to Liquid-to-Liquid Heat Exchanger (rear of pumping cabinet shown with back plates removed)

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Chapter 2 Drive Installation

Process Water Inlet

Drive Coolant Outlet

1.25 in. or 2.0 in. NPTF Female Pipe Threads

Process Water Outlet

Drive Coolant Inlet

Figure 66 - Pipe Flange Detail

Table 5 - Customer Cooling Requirements for Liquid-to-Liquid Heat Exchangers

Drive Min. Flow Rate Max. Pressure

Rectifier Voltage Amps US Gpm

(1)

L/m

(2)

(psig)

18 Pulse 4160 375 19.5 72 435 7 > 0 <32

430 21.5 80 435 8 > 0 <32

495 26.5 100 435 13 > 0 <32

575 29.0 109 435 15 > 0 <32

657 37.5 142 435 25 > 0 <32

6600 375 33.0 125 435 18 > 0 <32

430 44.5 167 435 34 > 0 <32

495 48.5 184 435 40 > 0 <32

575 54.5 206 435 43 > 0 <32

657 62.6 237 435 49 > 0 <32

AFE 4160 375 19.5 74 435 7 > 0 <32

430 24.0 90 435 10 > 0 <32

495 26.5 100 435 13 > 0 <32

575 33.0 125 435 19 > 0 <32

6600 375 37.0 139 435 24 > 0 <32

430 44.5 167 435 34 > 0 <32

495 48.5 184 435 40 > 0 <32

575 54.5 206 435 43 > 0 <32

Pressure Drop

(kPa)

Temperature (°C)

Min. Max.

(1) US Gpm = Gallons per minute (U.S.) (2) L/m = Liters per minute

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Drive Installation Chapter 2

IMPORTANT

Power and Control Wiring

Drive line-ups (i.e. Drive and Input Starter) which are delivered in two or more sections, for ease of handling, will require that the power and control wiring be re-connected. After the sections are brought together, the power and control wiring is to be reconnected as per the schematic drawings provided.

Control Cables

Control cable entry/exit should be located near the terminal block “TBC” – the customer’s connections are to be routed along the empty side of the TBC terminals. These terminals are sized to accept a maximum AWG #14 wire gauge. The low voltage signals (includes 4-20mA) are to be connected using twisted shielded cable, with a minimum AWG #18 wire gauge. (Based on using a W4 terminal block for customer connections, comparable wire sizes would be

0.5...4 mm

Of special concern is the encoder signal. Two encoder inputs are provided to accommodate a quadrature encoder (senses motor direction). The encoder power supply is isolated and provides +15V and a ground reference. Many encoder outputs have an open collector output, in which case a pull-up resistor must be added to ensure that proper signals are fed to the system logic. (Refer to When is

an Encoder Required? on page 414 (Appendix A) to see if one needs to be

supplied.)

as equivalent to #22-#10 AWG.)

Low voltage signals are to be connected using twisted shielded cable with the shield connected at the signal source end only. The shield at the other end is to be wrapped with electrical tape and isolated. Connections are to be made as shown on the drawings provided.

Encoder Installation Guidelines

The most frequent problems encountered when transmitting an encoder’s signal(s) to the drive are signal distortion and electrical noise. Either of these problems can result in a gain or loss of encoder data counts (quadrature encoders) or corrupt positional data (absolute encoders). Many of these problems can be avoided by applying good installation and wiring practices. This section is a general guideline and recommended practices for field installed equipment. It applies to either encoder board and both quadrature and absolute encoders.

Protection from Radiated and Conducted Noise

Reasonable care should be taken when connecting and routing power and signal wiring on a machine or system. Radiated noise from nearby relays, solenoids, transformers, non linear loads (such as motor drives) etc. can couple onto signal wires producing undesired pulses. In fact the encoder itself may induce noise into signal lines run adjacent to it.

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Chapter 2 Drive Installation

Wrong Shield

Connection

Encoder

Drive

To avoid radiated and/or conducted noise, power and signal lines should be run separately with a minimum distance between them of at least 75 mm (3 inches). If they have to overlap somewhere in the system, then the power lines should be run at 90° to the signal lines. Signal lines should also use twisted pair shielded cable and run in separate conduit that should be grounded to the building ground.

Encoder wires and shields should maintain continuity throughout, from the encoder to the drive. Avoid the use of a terminal block in a junction box. This has the potential of creating radiated noise and ground loops.

The encoder case must be grounded to the building ground to insure proper and reliable operation. Most encoders have provision for a case ground connection through the connector/cable pair if a ground connection cannot be made through the mounting bracket/machine ground. DO NOT ground the encoder case through both the machine and cable wiring. Use low capacitance wires (≤40pf/ft) with 100% shield coverage for long cable runs and connect the shield only at the drive end.

Figure 67 - Detail Power Terminal Dimensions

For more protection against electrical noise, specify an encoder with complementary outputs and connect with twisted pair cable. With this type of cabling, the induced currents will self-cancel.

As a final precaution, ground the shield together with all other parts of the system that require grounding to a single point ground. This will reduce varying ground potentials caused by high current fluxes created by motors, remote control switches and magnetic fields.

Signal Distortion

The primary cause of signal distortion is cable length, more specifically cable capacitance. Generally speaking the longer the cable length the more there is a chance of signal distortion at the receiving end. The receiving end responds to either a logical ‘0’ or a logical ‘1’. Anywhere in between is undefined and the transition through this region should be < 1.0us. If the leading edge of the waveform is distorted it causes the transition time through this region to increase. At some point, the receiver may become unstable and either gain or lose encoder counts.

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Drive Installation Chapter 2

To reduce the effects of signal distortion at the encoder receiving electronics, the following guidelines should be considered:

1. Use a low capacitance cable. Purchase a cable that has a capacitance of <120pf/m (40pf/ft). As an example Belden 1529A is an 18Awg 3pair cable having a capacitance of 114pf/m (35pf/ft).

2. Use twisted pair cabling with a shield that covers 100% of the cable. This is especially true in the case of quadrature encoders. It is still a better choice for absolute encoders, although the data in these encoders will not exhibit the same frequency spectrum as quadrature encoders and single wire cabling can be used. In either case, always check with the encoder manufacturer for the recommended cable.

3. Keep cable distances as short as is practically possible. Rockwell Automation’s recommendation for cable distances are:

a. For the 20B-ENC encoders, the distance should be kept to a maximum

of 65m (200 ft). Longer cable distances could cause excessive surge currents. The operating frequency of the encoder has no bearing on this recommended distance due to AC Termination used. However, if the frequency can be kept so that the cable's characteristic impedance is around 348ohms, this will improve the surge currents and may increase the maximum distance to 100m (330 ft).

b. For the Universal Encoder Interface, the distance can be extended out

to 200 m (650 ft) @ 100 Khz. This distance can be increased to 500m at frequencies below 55 Khz. It is not recommended to exceed this distance since the voltage drop across the cable could cause a lower than expected power at the encoder.

Unused Inputs

Not all inputs, in either the quadrature or absolute encoders, may be necessary. For example, the absolute encoder can accept a 12bit encoder but will work with a lower resolution. Likewise, quadrature encoders may not utilize the Z track. The following should be used for unused inputs:

1. 20B-ENC Board. Any unused input should be wired to the encoder power rail. This also includes the B and B’ inputs if using a pulse encoder. Failure to do this will result in phase loss warnings and improper operation of the encoder feedback logic (i.e. missing counts).

2. Universal Encode Interface. When used as a quadrature encoder interface, the same rule applies as for the 20B-ENC Board. When operating as an absolute encoder interface, the wiring of unused inputs is dependent on the position of the POL_QRDNT jumper. If the jumper is installed, then wire all unused inputs to ENC PWR, otherwise use ENC COM.

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Chapter 2 Drive Installation

4-hole Insulator

Bolts

Lug pad shown with bottom cable entry orientation

M10 bus connection hardware

Customer supplied lugs 4 lugs per phase maximum

Lug pad oriented for top cable entry

Information Regarding Termination of Customer Cables

Customer termination assemblies can accommodate either top or bottom customer cable entry.

Figure 68 - Typical Line Cable Termination (shown assembled for bottom cable entry – 18 Pulse)

For top line cable entry, it is necessary to remove the lug pads and re-orient them as shown in Figure 69

. To remove the lug pads, disconnect the M10 bus connection hardware (17 mm hex tooling required). Remove the two bolts that secure the lug pad to the 4-hole insulator. Refer to Torque Requirements for

Threaded Fasteners on page 419 (Appendix B) for Torque Values of electrical

connections.

Figure 69 - Typical Line Cable Terminal Assembly (modified for top cable entry – 18 Pulse)

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Drive Installation Chapter 2

IMPORTANT

ISOLATION

TRANSFORMER

MOTOR

U (T1)

V (T2)

W (T3)

GROUND BUS

Connected to the neutral point of the output capacitor

OUTPUT

GROUND

NETWORK

ISOLATION

TRANSFORMER

MOTOR

U (T1)

V (T2)

W (T3)

GROUND BUS

Connected to the neutral point of the output capacitor

OUTPUT

GROUND

NETWORK

MOTOR

U (T1)

V (T2)

W (T3)

GROUND BUS

AC LI NE

REACTOR

TRANSFORMER

Connected to the neutral point of the output capacitor

GROUND

FILTER

MOTOR

U (T1)

V (T2)

W (T3)

GROUND BUS

AC LI NE

REACTOR

TRANSFORMER

Connected to the neutral point of the output capacitor

GROUND

FILTER

Grounding Practices

The purpose of grounding is to:

• provide for the safety of personnel

• limit dangerous voltages on exposed parts with respect to ground

• facilitate proper overcurrent device operation under ground fault

conditions, and

• provide for electrical interference suppression

Generally, the means used for external grounding of equipment should be in accordance with the Canadian Electrical Code (CEC), C22.1 or the National Electrical Code (NEC), NFPA 70 and applicable local codes.

Refer to the grounding diagrams that follow for ground connections. The drive’s main ground bus must be connected to the system ground. This ground bus is the common ground point for all grounds internal to the drive.

Figure 70 - Ground Connection Diagram with Isolation Transformer

Figure 71 - Ground Connection Diagram with Line Reactor

Each power feeder from the substation transformer to the drive must be provided with properly sized ground cables. Utilizing the conduit or cable armor as a ground on its own is not adequate.

Note that if a drive isolation transformer is used, the WYE secondary neutral point should not be grounded.

Each AC motor frame must be bonded to grounded building steel within 6 m (20 feet) of its location and tied to the drive’s ground bus via ground wires within

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Chapter 2 Drive Installation

the power cables and/or conduit. The conduit or cable armor should be bonded to ground at both ends.

Grounding Guidelines and Practices for Drive Signal and Safety Grounds

When interface cables carrying signals, where the frequency does not exceed 1 MHz, are attached for communications with the drive, the following general guidelines should be followed:

• It is good practice for the mesh of a screen to be grounded around its whole circumference, rather than forming a pigtail that is grounded at one point.

• Coaxial cables with a single conductor surrounded by a mesh screen should have the screen grounded at both ends.

• Where a multi-layer screened cable is used (that is, a cable with both a mesh screen and a metal sheath or some form of foil), there are two alternative methods:

– The mesh screen may be grounded at both ends to the metal sheath.

The metal sheath or foil (known as the drain) should, unless otherwise specified, be grounded at one end only, again, as specified above, at the receiver end or the end which is physically closest to the main equipment ground bus.

– The metal sheath or foil may be left insulated from ground and the

other conductors and the mesh cable screen grounded at one end only as stated above.

Grounding Requirements and Grounding Specification for Customers and Power Integrators

An external ground must be attached to the main ground bus. The grounding means must comply with applicable local codes and standards. As general guidelines, for information only, the ground path must be of sufficiently low impedance and capacity that:

• the rise in potential of the drive ground point when subjected to a current of twice the rating of the supply should be no higher than 4 volts over ground potential.

• the current flowing into a ground fault will be of sufficient magnitude to cause the protection to operate.

The main grounding conductor(s) should be run separately from power and signal wiring so that faults:

• do not damage the grounding circuit

• will not cause undue interference with or damage to protection or metering systems, or cause undue disturbance on power lines.

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Drive Installation Chapter 2

Identification of Types of Electrical Supplies – Grounded and Ungrounded Systems

When dealing with an ungrounded, three-phase electrical supply system, the cable insulation must be capable of handling not only the phase-to-phase voltage, but also the voltage-to-ground if one of the other phases develops a ground fault. In practice, the cable insulation of an ungrounded, three-phase system must be good for at least a continuous voltage of root three (1.732) times (1.1) times the rated voltage of the supply. (1.732 x 1.1 = 1.9 times the rated line-to-line voltage)

Ground Bus

The drive ground bus runs along the top of the drive at the front. The ground bus is accessible at the top of each of the drive enclosures when the enclosure door is opened (and the low voltage compartment hinged out in the case of the incomer cabinet). It is the responsibility of the installer to ensure that the drive is grounded properly, typically at the point on the ground bus in the incomer cabinet, close to the incoming power terminations.

Interlocking

Access to the medium voltage areas of the drive is restricted by the use of key interlocking for safety.

At installation the key interlocking is set up so that access to the medium voltage compartments of the equipment can only be made when the upstream power is locked in the off position.

Additionally, the key interlocking prohibits the upstream power being applied until the medium voltage drive’s access doors have been closed and locked shut.

It is the responsibility of the installer to ensure that the key interlocking is installed properly to the upstream equipment.

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Chapter 2 Drive Installation

Notes:

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Operator Interface

Chapter 3

Chapter Objectives

Terminology

This chapter describes how you use the operator interface to modify and obtain information contained within the drive. In this chapter you will learn how to:

• Modify information associated with the initial drive setup.

• View:

• drive parameters

• drive status

• View and Reset Alarm Conditions.

• Request printouts of the information in the drive.

• Perform diagnostic trending.

• Modify the operation of the operator interface.

The chapter deals only with the operation of the operator interface. Specific references to a particular parameter are only for illustrative purposes. Refer to Publication 7000-TD002_-EN-P the drive and their use.

Parameter – A memory location within the drive to which data may be written to or read. Setting a parameter (i.e. writing to it) will modify how the drive behaves. Prior to using the drive a number of parameters must be set. Additional parameters may be changed while the drive is in use in order to adjust its operation, (i.e. the speed could be changed via a parameter).

for information about the actual 'tags' within

Read-only Parameter – A memory location which can only be read. A read-only parameter contains real-time data and is used to read the current conditions within the drive, such as running speed.

Ta g – A generic reference to either a parameter or a read-only parameter.

PanelView 550 – The PanelView 550 is a product marketed by Rockwell

Automation consisting of a hardware terminal and a software package, integrated into a single product. The Medium Voltage Drive only uses the hardware portion of the product and has replaced the software package.

PowerFlex Operator interface – References to the operator interface refer to the product consisting of the PanelView 550 interface hardware and the unique software contained within it, which allows it to function with the Medium Vol ta ge D ri ve.

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Chapter 3 Operator Interface

Editing Field – An area of a screen that is displayed in reverse video. When the field is in this state, data may be entered into it via the keypad.

XIO – the eXternal Inputs and Output adapters used by the drive to interface hardwired signals to the drive.

Operation – A task which is to be performed. In order to complete the task, a number of screens may be involved; i.e. selecting a parameter is an operation that requires at minimum two screens. This operation itself is an operation of modifying a parameter.

NVRAM – Non-Volatile Random Access Memory. This is memory that is not affected by loss of power. It is used for long term storage of data such as parameters and alarm queues.

Flash – A type of memory technology which will indefinitely store information and is unaffected by power loss. It is used for storage of firmware, parameters and data files.

PCMCIA – A standard for flash memory cards. Personal Computer Memory Card International Association.

Overview

The operator interface used on the PowerFlex 7000 Medium Voltage Drive is that of the PanelView 550 terminal (Figure 72 behave as a PanelView, as only the hardware for the operator interface has been utilized. The PanelView software has been replaced with unique software to tailor it to the requirements of the Medium Voltage Drive, and its faceplate has been modified (Figure 72

Figure 72 - PowerFlex 7000 Drive Operator Interface Terminal

). This terminal however does not

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Operator Interface Chapter 3

Keypad

The keypad of the operator interface consists of two rows of five function keys (item 1 of Figure 72

Figure 72

will be referred to as the cursor keys (item 2 of Figure 72 are data entry keys consisting of the numeric values 0...9, a decimal point (.), a negative (-), a backspace key and a data entry key (item 3 of Figure 72

All keys are of a membrane type. The key is executed upon release.

). In the lower right corner of the operator interface are four keys, which

) located below the operator interface display area (item 4 of

). Above the cursor keys

Function (Softkeys) Keys

Along the bottom of the display area is one or two rows of 'Softkeys'. These 'Softkeys' represent the physical function keys. The function of the actual keys will vary between displays. The bottom row of keys (i.e. F6 through F10) is always shown. The upper row is shown only if they are required for keys (F2 through F5). Thus a single row of 'Softkeys' always refers to the keys F6 through F10.

Even though the upper row of Softkeys (e.g. F1 through F5) may not be shown on some displays, the F1-HELP key is always active. (F2 through F5) are only active if shown.

Cursor (Selection) Keys

The cursor keys are normally used to select an item on the display. When an item on the display is selected, that item will be displayed in reverse video. To change the selection, press the key in the desired direction.

On selection screens having more than one page, the page will automatically change when the cursor is moved beyond the displayed list.

Some displays, such as the Utility screen, use these keys to modify the data value. Pressing the [cursor up] and [cursor down] keys will change the value by a fine amount, e.g. one unit. Using the [cursor left] and [cursor right] keys will change the value by a course amount, e.g. 10 units.

For entries requiring a HEX value, the keys (cursor up/down) are used to scroll to the desired HEX value.

For parameters which contain an Enumeration string, pressing either the up or down key will provide a list of options to pick from. Using the cursor keys, make a selection and press enter. If more options exist than can be displayed on the screen, a triangle symbol or inverted triangle to the right of the list will show that there are more selections available in the indicated direction. Continue to use the up/down cursor keys to move to these additional selections.

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Chapter 3 Operator Interface

For parameters that are comprised of bit fields, the left/right keys are used to move to the desired bit field. The up and down keys toggle the bit between its possible states.

All four cursor keys have an auto feature such that after holding the key for two seconds, the key will automatically repeat at a rate of five ‘presses’ per second.

Data Entry Keys

As the name implies, these keys are used to enter data. Pressing the keys [0] through [9] will enter the corresponding value into the 'editing field'. Pressing the [-] key will change the value to a negative number. Pressing the [.] will allow a fractional value to be entered.

While entering a value, the value may be edited using the [backspace] key. This key will remove the right most digit (or decimal point or negative). The help screen uses the backspace key to return to the previous level of help.

What is a Screen?

The enter key varies depending on the screen. If you are in the process of a selection operation, the enter key will accept the selection and proceed to a different screen based on the selection in order to complete the operation. If you are in the process of entering data, the enter key will accept the edited data.

The operator interface uses menu driven screens to perform various operations on the drive. You can think of a screen as a window or template, overlaying data from the drive. The operator interface combines a screen with the drive data, to formulate what you see on the display area of the operator interface. Individual screens display a particular type of data and allow selected operations to be performed on this data. A number of different screens may be used while performing a single operation.

Components

Although the data displayed on any particular screen will vary, the general makeup of a screen is the same for all. Figure 73 components.

shows a typical screen and its

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Operator Interface Chapter 3

Figure 73 - Screen Components

The upper left-hand corner contains the name of the screen (i.e. SELECT GROUP:). Knowing the name of the screen will assist you in the orientation of the menu system. On some screens to the right of the screen name, will be the name of the selected item from the previous screen as shown in Figure 74

Some screens have more than one page associated with them. The current page number and the number of pages which make up the data currently being displayed on the screen is shown in the upper right hand corner (e.g. showing page 1 of 2 pages).

Along the bottom of the screen are one or two rows of 'Softkeys' which represent the assignment to the actual function keys. In Figure 73

, Softkeys F6 through F10

are shown. Pressing F8 will display the next page of data.

In the very lower right-hand corner is a small dot. This dot indicates the healthy state of the operator interface terminal. Under normal conditions this dot will flash at a rate of .5 Hz. During communication errors, the dot will flash at a rate of .1 Hz.

Figure 74 - Screen Name & Item

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Chapter 3 Operator Interface

The remainder of the screen shows the data from the drive. The presentation of the data is dependent on the screen. Screens that allow an item to be selected show the current selection in reverse video. An example of this is shown in

Figure 73

in which the Speed Control group is selected.

Information Windows

Numerous screens require communications with the drive in order to function. At times, the duration of this activity will be noticeable to you. During this activity, a special 'window' is used within the current screen to inform you of this activity. The time required for the activity will vary.

Accessing/Writing to Drive

When first powered up, the operator interface knows very little about the information in the drive. As each screen is activated, the operator interface requests information from the drive, which it will store within the operator interface for future reference. When the operator interface requests information from the drive, a window is used to display a message "Accessing Drive ...". During this time, the operator interface will not respond to any user input, until the task at hand is completed. You will notice that subsequent activation of the same screen for the same data will be much quicker since the operator interface already has most or all of its required information.

You can selectively choose to download the complete database to the operator interface on command, thus eliminating the initial access the operator interface will automatically download the database on power-up, or during periods of inactivity. Refer to Database Download

Some screens require that information be written to the drive. During this task, a window is used to display the message "Writing to Drive...” During this time, the operator interface will not respond to any user input, until the task at hand is completed.

delays. If uninterrupted,

on page 162.

Communication Error

While the operator interface is reading or writing to the drive, it is possible for communications to be disrupted for a number of reasons. If this were to occur, a special window is used to inform you of this. During this time, the operator interface will not respond to any user input, until the task at hand is completed.

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Operator Interface Chapter 3

The window for the "Communication Error" can take on two forms. If a window has already been displayed showing "Accessing Drive" or Writing to Drive", then the communication error message will be added to the window already in use. Some screens constantly read from the drive in order to show real-time data. An example of this is the 'Top Level Menu’. When a communication error occurs on a screen showing real-time data, a window is opened showing a box around the "Communication Error". Two examples of this are shown in Figure 75

Figure 76

and

In both cases, once communications has been re-established, the information window will be removed and the operator interface will return to normal operation.

Figure 75 - Communications Error

Figure 76 - Communications Error

Languange Changing

When the language used by the drive changes, (either via the operator interface or an external device), the operator interface must do considerable work. The database strings are all invalidated, the character set for the server is changed and all strings used by the operator interface are linked to the new language. During this possibly lengthy process, the “Language Changing ...” message is displayed.

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Chapter 3 Operator Interface

General Operation

The operations that can be performed on a screen vary depending on the actual screen being displayed. The majority of the operations are activated by the function keys located along the bottom of the screen. Although the meaning of these keys does change from one screen to the next, there are some functions which are available on most screens and always have the same assignment.

The operations for these latter keys will not be explained within the description of individual screen operations. They are explained here and apply equally to all screens.

F1 - Help

This operation is active on every screen, even if the 'Softkey' is not displayed. Help is context sensitive and will display help that relates to the screen that you are currently viewing.

F6 - Alarms

The F6 'Softkey' will always get you to the Alarm Summary Screen. A new alarm will cause this key to flash in reverse video.

F8 - Next Page

When a screen is capable of displaying data that requires more than one page, this 'Softkey' will be active. The 'Softkey' will increment the page number being viewed.

F9 - Previous Page

When a screen is capable of displaying data that requires more then one page, this 'Softkey' will be active. The 'Softkey' will decrement the page number being viewed.

F10 - Exit

When you are viewing any screen other than the Top Level Menu, this 'Softkey' will return you to the previous screen.

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Operator Interface Power-up Sequence

When the operator interface is powered up or reset, it will go through two

noticeable operations:

1. Linking to Drive - During this phase the operator interface is establishing communications with the drive communications board. The screen will also show information about the software product contained in the PowerFlex operator interface, such as:

a. software part number and revision level b. date and time stamp of program creation

2. Obtaining Drive Database - During this phase, the database of information about the drive is obtained from the drive. Obtaining the database at this point in time is optional and may be aborted by pressing any key on the operator interface. Obtaining the entire database does however speed up subsequent operations since relevant portions of the database do not have to be obtained. (Without obtaining the entire database, the operator interface will access portions of the drive database as required. This slows down the first access to the operation that requires the data. Subsequent operations requiring the same data are not affected). Aborting the download will not affect portions of the database already obtained.

Once the database has been obtained, the operator interface will start up in one of two modes, depending on to what degree the drive has previously been configured:

Top Level Menu

1. On an unconfigured drive, the operator interface will enter the 'Setup Wizard' mode. Until the user has gone through the entire 'Setup Wizard', this will be the default mode to power up in. The 'Setup Wizard' can be cancelled at any time by pressing the appropriate softkey.

2. Once the drive has been configured through the 'Setup Wizard', the Top Level Menu, will be displayed from this point forward. The 'Setup Wizard' can be re-entered via the Setup Menu.

This screen (Figure 77) represents the main menu from which all other screens (and the operations which they perform) are activated. To activate an operation, simply press the function key corresponding to the 'Softkey' shown on the screen. A screen for that operation will be displayed. Refer to the section entitled "How To:" for information about the various operations which may be performed.

The screen identifies the drive product to which the operator interface is attached and its overall state of operation. Four digital meters show four selected parameters located in the drive. A Hobbs meter displays the number of hours that the drive has been running.

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Chapter 3 Operator Interface

The status of the drive will show one of the following:

NOT READY – drive is not ready to start

READY – drive will start when commanded

FORWARD RN – drive is running in the forward direction

REVERSE RN – drive is running in the reverse direction

WA RN IN G – d ri ve ha s a wa rn in g

FAULTED – the drive is faulted

DISCHARGING – waiting for the input filter capacitor to discharge on an Active Front End drive before re-start

Figure 77 - Top Level Menu

How To

The following sections describe how to perform the various operations on the drive, using the operator interface. Throughout the discussion, a number of screens will be used to achieve the desired operation. In many cases, the same screen will be used for more than one operation, however with possibly different data from the drive.

Throughout the section, you want to focus on how the operation is performed. The operator interface will take care of what screens are needed to perform the operation.

Obtain Help

Help is obtained for any screen by pressing the [F1] function key. Figure 78 shows the help screen, which is displayed for the Top Level Menu. After the name of the screen (i.e. HELP:) is the name of the screen for which help is being accessed. (In this case the name of the Top Level Menu is REV.) This particular help screen contains three pages. To view page two, press the [F8] key. Page 2 is displayed. To return to page 1, press the [F9] key.

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Rockwell Automation 7000L User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

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

Important User Information

Summary of Changes

Table of Contents

Introduction

Liquid Cooling

Benefits of Liquid Cooling Include:

Benefits of the 7000L “C” Frame Liquid-cooled Drive:

Topology

Rectifier Designs

18 Pulse Rectifier

Active Front End (AFE Rectifier)

“Direct-to-Drive” Technology

Motor Compatibility

SGCT Features and Benefits

Specifications

Simplified Electrical Drawings

Control Overview

Direct Vector Control

Control Hardware

Operator Interface

Safety and Codes

Unpacking and Inspection

Transportation and Handling

Overhead Lifting

Rod or Pipe Rollers

Fork Lift Trucks

Storage

Siting of the Drive

Site Considerations

Installation

Joining Shipping Splits

Connect the Sections

Tools Required (not supplied)

Install CPVC Piping Splices

Connect Power: M+, L+, M-, L- Power Bus

Control Wiring Connections

Removal of DC Link Choke Turnbuckle Supports

Removal of Lifting Angles

Shock Indication Labels

Installation of Exhaust Air Hood

Internally mounted fans

Externally mounted fans and fan hood

Typical PowerFlex 7000L Drive Structure Layout

Control/Cabling Cabinet

Major Components

IEC Component and Device Designation

Power Wiring Selection

General Notes

Cable Insulation

Power Cabling Access

Access the Customer Power Cable Terminations:

Power Connections

Incoming Connections

Liquid Connections

Liquid-to-Air Heat Exchangers

Pipe Materials and Layout

External Piping to the Drive

External Piping Cleaning

Liquid-to-Liquid Heat Exchangers

Power and Control Wiring

Control Cables

Encoder Installation Guidelines

Information Regarding Termination of Customer Cables

Grounding Practices

Grounding Guidelines and Practices for Drive Signal and Safety Grounds

Grounding Requirements and Grounding Specification for Customers and Power Integrators

Identification of Types of Electrical Supplies – Grounded and Ungrounded Systems

Ground Bus

Interlocking

Chapter Objectives

Terminology

Overview

Keypad

Function (Softkeys) Keys

Cursor (Selection) Keys