Rockwell Automation 7000L User Manual
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
Table of Contents
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
Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 5
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
Rockwell Automation Publication 7000L-UM301D-EN-P - June 2014 7
Table of Contents
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
3
– 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-
1U
1V
1W
LR
– 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
DC LINK
Figure 7 - 3300 / 4160 Volt – Active Front End
Overview of Drive Chapter 1
Figure 8 - 6000-6600 Volt – 18 Pulse
DC LINK
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
SGCTs
LINE CONVERTER
L- M-
L+ M+
MACHINE CONVERTER
U (T1)
V (T2)
W (T3)
2U (X1)
2V (X2)
2W (X3)
SGCTs
SGCTs
Figure 9 - 6000-6600 Volt – Active Front End
DC LINK
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
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
OIB
OIB
OIB
OIB
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
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