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Allen-Bradley PowerFlex 7000 User Manual

Medium voltage ac drive air-cooled "b" frame-forge control
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User Manual
Original Instructions
PowerFlex 7000 Medium Voltage AC Drive Air-Cooled
("B" Frame)—ForGe Control
Catalog Number 7000
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Summary of Contents for Allen-Bradley PowerFlex 7000

  • Page 1 User Manual Original Instructions PowerFlex 7000 Medium Voltage AC Drive Air-Cooled (“B” Frame)—ForGe Control Catalog Number 7000...
  • Page 2 Important User Information 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.

  • Page 3: Table Of Contents

    Chapter 1 PowerFlex 7000 Drive Overview Topology ........... . . 15 Rectifier Designs .
  • Page 4 Table of Contents SGCT Anode-to-Cathode (Sharing) Resistance ....68 Snubber Resistance (SGCT Device)......70 Snubber Capacitance (SGCT Device) .
  • Page 5 Table of Contents Installing Impeller Assembly onto Motor Shaft ... . . 125 Replacing Air Filters ........127 Chapter 3 Control Component Definition Control Power Components .
  • Page 6 Appendix B Catalog Number Explanation PowerFlex 7000 Drive Selection Explanation ....181 Service Duty Rating, Continuous Current Rating and Altitude Rating Code ........181...
  • Page 7 When to use an Encoder ........209 PowerFlex 7000 Drive Performance (Torque Capabilities)..210...
  • Page 8 Table of Contents Notes: Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...

  • Page 9: Preface

    Preface Purpose This document provides procedural information for managing daily or recurring tasks involving the PowerFlex™ 7000 medium voltage “B” Frame drives (heatsink and heatpipe models). Summary of Changes This manual contains new and updated information as indicated in the following table.

  • Page 10: What Is Not In This Manual

    Preface What Is Not in This Manual This manual provides information specific to maintaining the PowerFlex 7000 “B” Frame drive. This document does not include topics such as: • Physically transporting or siting the drive cabinetry • Installing or commissioning procedures •...

  • Page 11: Commissioning Support

    Failure to do so voids the arc resistant structural integrity. After installation, Rockwell Automation medium voltage support is Commissioning Support responsible for commissioning support and activities in the PowerFlex 7000 product line. Phone: 519-740-4790 Option 1 for technical and option 4 for commissioning questions [email protected] or...

  • Page 12: Abbreviations

    Preface Abbreviations This table contains abbreviations used throughout this document. Table 1 - Abbreviations Abbreviation Description Analog Control Board Active Front End Adjustable Speed Drive Common Mode Choke Current Source Inverter Current Transformer Digital Multimeter Drive Processor Module HECS Hall Effect Current Sensor Human Machine Interface HPTC High Performance Torque Control...

  • Page 13: Product Certification

    Additional Resources These documents contain additional information concerning related products from Rockwell Automation. Resource Description PowerFlex 7000 Medium Voltage AC Drive (C Frame) - Provides troubleshooting, parameters, and specification information for MV variable frequency drives ForGe Control (Marine), publication 7000-TD002...
  • Page 14 Preface Notes: Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...

  • Page 15: Powerflex 7000 Drive Overview

    Topology The PowerFlex 7000 drive uses a pulse width modulated (PWM) – current source inverter (CSI) topology. This topology applies to a wide voltage and power range. The power semiconductor switches used are easy-to-series for any medium voltage level.

  • Page 16: Rectifier Designs

    Chapter 1 PowerFlex 7000 Drive Overview The PowerFlex 7000 drive 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.
  • Page 17 PowerFlex 7000 Drive Overview Chapter 1 A small integral line reactor and capacitor addresses the high harmonic orders (13th and above) and provides virtually sinusoidal input voltage and current waveforms back to the distribution system. This configuration delivers excellent line-side harmonic and power factor performance to meet IEEE 519- 1992 requirements and other global harmonic standards in virtually all cases.

  • Page 18: Cooling Technology

    Chapter 1 PowerFlex 7000 Drive Overview 18-pulse Rectifier with Separate Isolation Transformer For high power constant torque applications and/or when the line voltage is higher than the motor voltage, a transformer is required for voltage matching (indoor and outdoor transformer options are available). The 18-pulse rectifier uses SCRs instead of the SGCTs used for an AFE rectifier.

  • Page 19: Motor Compatibility

    PowerFlex 7000 Drive Overview Chapter 1 Motor Compatibility The PowerFlex 7000 drive 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.

  • Page 20: Simplified Electrical Diagrams

    Chapter 1 PowerFlex 7000 Drive Overview Simplified Electrical 2400V Diagrams Figure 6 - 2400V – Direct-to-Drive (Transformerless AFE Rectifier) LINE CONVERTER OMMON MODE CHOKE MACHINE CONVERTER SGCTs SGCTs U (T1) V (T2) W (T3) Figure 7 - 2400V – AFE Rectifier with Separate Isolation Transformer...

  • Page 21: 3300/4160V

    PowerFlex 7000 Drive Overview Chapter 1 3300/4160V Figure 9 - 3300/4160V – Direct-to-Drive (Transformerless AFE Rectifier) OMMON MODE CHOKE LINE CONVERTER MACHINE CONVERTER SGCTs SGCTs U (T1) V (T2) W (T3) Figure 10 - 3300/4160V – AFE Rectifier with Separate Isolation Transformer...

  • Page 22: 6600V

    Chapter 1 PowerFlex 7000 Drive Overview 6600V Figure 12 - 6600V – Direct-to-Drive (Transformerless AFE Rectifier) MACHINE CONVERTER LINE CONVERTER OMMON MODE CHOKE SGCTs SGCTs U (T1) V (T2) W (T3) Figure 13 - 6600V – AFE Rectifier with Separate Isolation Transformer...

  • Page 23: Functional Safety

    Safe Torque Off Safe Torque Off is a functional safety feature that is integrated into the PowerFlex 7000 drive, available for AFE and Direct-to-Drive configurations. The drive can receive a safety input signal (for example, from an optical sensor or a safety gate) and remove rotational power from the motor, allowing the motor to coast to a stop.

  • Page 24: Arcshield Technology

    ArcShield technology is available for AFE Direct-to-Drive configurations and is designed to help protect employees and minimize unplanned outages and downtime. The PowerFlex 7000 drive system with ArcShield option is a fully integrated Allen-Bradley™ CENTERLINE™ controller and PowerFlex 7000 drive combination. This safety feature redirects the energy from an arc flash event through the top of the enclosure.

  • Page 25: Operator Interface

    Chapter 1 Operator Interface The human-machine interface (HMI) board is an HMI-enabling device for the PowerFlex 7000 drive. The board lets you acquire all the necessary executable tools, documentation, and reports required to commission, troubleshoot, and maintain the drive. Via the HMI board, the user can choose the style and size of the desired Windows-based operator terminal to interact with the drive (for example, PanelView™...
  • Page 26 Chapter 1 PowerFlex 7000 Drive Overview This is ideal for non-PLC users wanting to control and monitor remotely (for example, at the driven machine or control room). This is also ideal if you, for example, have policies in place to control access to medium voltage equipment and the associated requirements of PPE when using the operator interface at the VFD.

  • Page 27: Power Component Definition And Maintenance

    Power Component Definition and Maintenance This section provides an overview of the control components and cabling of your PowerFlex 7000™ “B” Frame drive. This section also details a number of regular or recurring maintenance tasks that will keep your drive in peak operating condition.
  • Page 28 Chapter 2 Power Component Definition and Maintenance ATTENTION: Servicing energized industrial control equipment can be hazardous. Severe injury or death can result from electrical shock, burn, or unintended actuation of control equipment. Hazardous voltages can exist in the cabinet even with the circuit breaker in the off position. We recommend that you disconnect or lock out control equipment from power sources, and confirm discharge of stored energy in capacitors.

  • Page 29: Control / Cabling Cabinet Components

    Power Component Definition and Maintenance Chapter 2 Figure 19 - Deadbolt Counterpart Mounted to Cabinet 4. Bolt the cabinet door closed so the pins on the dead bolt counterpart make contact with the deadbolt assembly. Doing so should leave two marks of torque sealant or grease on the assembly where the pins made contact (see Figure 18 on page...
  • Page 30 Chapter 2 Power Component Definition and Maintenance Figure 20 - Cabling Cabinet for AFE Rectifier (Heatsink Model) Hall Effect Sensors Grounding Network (For use with Isolation Transformer) Ground Filter (For use with Line Reactor) Sensing Boards Line Terminals Motor Terminals Motor Filter Capacitors Current Transformers Surge Arresters...
  • Page 31 Power Component Definition and Maintenance Chapter 2 Figure 21 - Cabling Cabinet for AFE Rectifier (Heatpipe Model) Grounding Network (For use with Isolation Transformer) Ground Filter (For use with Line Reactor) Surge Arresters Motor Terminals Hall Effect Current Sensors Voltage Sensing Boards Line Terminals Current Transformers Zero Sequence Current...
  • Page 32 Chapter 2 Power Component Definition and Maintenance Figure 22 - Cabling Cabinet for AFE Rectifier (6600V Heatpipe Model) Motor Terminals Surge Arrestors Grounding Filter (for use with Line Reactor) Hall Effect Current Zero Sequence Sensors Current Transformer Current Transformer Voltage Sensing Boards Line Terminals Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...
  • Page 33 Power Component Definition and Maintenance Chapter 2 Figure 23 - Cabling Cabinet for 18-pulse Rectifier (Motor Filter Capacitors not shown) Motor Terminals Hall Effect Sensor Transient Voltage Sensing Suppression Boards Network Hall Effect Sensor Line Terminals Current Transformers Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...
  • Page 34 Chapter 2 Power Component Definition and Maintenance Figure 24 - AC line Reactor Cabinet with Connection Cabinet (Heatsink Model) Line Terminals Line Filter Motor Capacitors Terminals Zero Sequence Current Transformer (if supplied) Motor Filter Capacitors Line Reactor Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...
  • Page 35 Power Component Definition and Maintenance Chapter 2 Figure 25 - AC Line Reactor Cabinet (6600V Heatpipe Model) Fans Resistors Line Reactor Line Reactor Baffle Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...
  • Page 36 Chapter 2 Power Component Definition and Maintenance Figure 26 - AC Line Reactor with Connection Cabinet (Heatpipe Model) Fans Motor Filter Capacitors Line Filter Capacitors Resistors Line Reactor Baffle Line Reactor Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...

  • Page 37: Voltage-Sensing Assembly

    The voltage sensing board has six independent channels that convert voltages as high as 10,800V (7.2 kV x 1.5 pu) down to low voltage levels that the PowerFlex 7000 analog control board (ACB) can use. To measure up to twelve independent voltage channels, link two assemblies together, with one assembly acting as the master assembly and the second as the slave assembly.

  • Page 38: Replacing The Voltage-Sensing Circuit Board Assembly

    Chapter 2 Power Component Definition and Maintenance Replacing the Voltage-Sensing Circuit Board Assembly The number of sensing boards is dependent upon the drive rectifier configuration. To access the sensing boards in an arc resistant drive, remove the barriers behind the swing out LV compartment. 1.

  • Page 39: Input Transient Protection

    Power Component Definition and Maintenance Chapter 2 Input Transient Protection The drive provides input transient protection in one of two forms: • Transient suppression network (TSN), or • Surge arresters The TSN is optimized for 18-pulse rectifier designs. Surge arresters are optimized for AFE and Direct-to-Drive™...
  • Page 40 Chapter 2 Power Component Definition and Maintenance Figure 28 - Typical MOV V-I Characteristic Curve High Resistance Short Circuit Voltage Clamping Region Region Region VOLTAGE (VOLTS) 10 10 CURRENT (AMPERES) -log scale When the MOV clips the voltage transient, the MOV absorbs the transient energy.
  • Page 41 Power Component Definition and Maintenance Chapter 2 The fuses are E-rated, current-limiting fuses with a high interrupting rating. Because they are current-limiting, they limit both the magnitude and duration of fault currents. They are small dimension, ferrule-type fuses with a fiberglass body, and mount in standard fuse clips.
  • Page 42 Chapter 2 Power Component Definition and Maintenance Replacing Transient Suppression Network Fuses Two sizes of fuses (5 kV, 7.2 kV) are available within the TSN located inside the connection cabinet. The 18-pulse drive contains three TSNs. 1. Ensure there is no power to the equipment. ATTENTION: To prevent electrical shock, disconnect the main power before working on the drive.

  • Page 43: Surge Arresters

    Power Component Definition and Maintenance Chapter 2 Replacing Metal-Oxide Varistors Metal-oxide varistors (MOV) are part of the TSN located within the connection cabinet. 1. Ensure there is no power to the equipment. ATTENTION: To prevent electrical shock, disconnect the main power before working on the drive.
  • Page 44 Chapter 2 Power Component Definition and Maintenance Three Y-connected surge arresters attach to the incoming MV lines. The neutral point of the arresters connects to the ground bus. Figure 31 - Surge Arresters on Incoming MV Lines Drive Input from Line Terminals Heavy-duty Distribution Class Surge Arrestor...
  • Page 45 Power Component Definition and Maintenance Chapter 2 Replacing the Surge Arrester ATTENTION: To prevent electrical shock, disconnect the main power before working on the drive. Verify that all circuits are voltage-free using a hot stick or appropriate voltage-measuring device. Failure to do so may result in injury or death.
  • Page 46 Chapter 2 Power Component Definition and Maintenance Figure 33 - Surge Arresters (Heatpipe Model) Surge Arresters When you disconnect the surge arrester from drive, the arrester may retain a small amount of static charge. As a precautionary measure, install a temporary ground on the line-end of the arrester and discharge the stored energy.
  • Page 47 Verify that all circuits are voltage-free using a hot stick or appropriate voltage-measuring device. Failure to do so may result in injury or death. PowerFlex 7000 18-pulse and select AFE drives come with an installed grounding network. The number of capacitors varies depending on the system voltage.
  • Page 48 Chapter 2 Power Component Definition and Maintenance Replacing the Hall Effect Current Sensor (HECS) 1. Isolate and lock out all power to the drive. ATTENTION: To prevent electrical shock, disconnect the main power before working on the drive. Verify that all circuits are voltage-free using a hot stick or appropriate voltage-measuring device.
  • Page 49 Power Component Definition and Maintenance Chapter 2 Figure 35 - Hall Effect Current Sensor located within Cabinet Hall Effect M10 Hardware Current Sensor Bus Bar Figure 36 - Hall Effect Current Sensor (detail) Base Hardware Arrows must be oriented properly Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...

  • Page 50: Filter Capacitor Cabinet

    Chapter 2 Power Component Definition and Maintenance Replacing the Current Transformer (CT) 1. Isolate and lock out all power to the drive. ATTENTION: To prevent electrical shock, disconnect the main power before working on the drive. Verify that all circuits are voltage-free using a hot stick or appropriate voltage-measuring device.

  • Page 51: Replacing Filter Capacitors

    Power Component Definition and Maintenance Chapter 2 Figure 37 - Motor Filter Capacitor WARNING: Allow 5…10 minutes for motor capacitors to safely discharge voltage prior to opening cabinet doors. Replacing Filter Capacitors See Publication 7000-IN010, “Handling, Inspection, and Storage of Medium Voltage Line Filter Capacitors”.

  • Page 52: Testing Filter Capacitors

    Chapter 2 Power Component Definition and Maintenance ATTENTION: The porcelain bushings are extremely fragile and any force applied to the bushings can damage the seal between the bushing and the body causing potential leaks or chipping. 6. Install the new capacitor, sliding it back until it fits into the slot. Fasten the front bracket.
  • Page 53 Power Component Definition and Maintenance Chapter 2 ATTENTION: Capacitors that appear bulged or are leaking oil indicate potential problems with the internal elements. DO NOT USE. These units must be replaced. Failure to do so may lead to personal injury or death, property damage, or economic loss.

  • Page 54: Converter Cabinet Components

    Chapter 2 Power Component Definition and Maintenance 5. Connect a low voltage single-phase test power, for instance 110V or 220V, across a phase and the neutral of the capacitor. Switch on the test power and measure the test voltage and current drawn by the capacitor. Repeat the test for all three phases and note down the test voltage and current.
  • Page 55 Power Component Definition and Maintenance Chapter 2 Figure 38 - Converter Cabinet (Heatsink Model, 2400V) Ground Bus Differential Pressure Sensor Inverter Modules Isolated Gate Driver Power Supplies (IGDPS) Rectifier IGDPS not required in drives with SPS boards installed Rectifier Modules Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...
  • Page 56 Chapter 2 Power Component Definition and Maintenance Figure 39 - Converter Cabinet (Heatsink Model, 3300…4160V) Differential Pressure Ground Bus Sensor Isolated Gate Driver Power Supplies (IGDPS) Inverter Modules Rectifier IGDPS not required in drives with SPS boards installed Rectifier Modules Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...
  • Page 57 Power Component Definition and Maintenance Chapter 2 Figure 40 - Converter Cabinet (Heatsink Model, 6600V) Ground Bus Differential Pressure Sensor Isolated Gate Driver Power Supplies (IGDPS) Inverter Modules Rectifier Modules Rectifier IGDPS not required in drives with SPS boards installed Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...
  • Page 58 Chapter 2 Power Component Definition and Maintenance Figure 41 - Converter Cabinet, 3300…4160V (Heatpipe Model) Inverter modules Ground bus Isolated Gate Isolated Gate Driver Power Driver Power Supplies (IGDPS) Supplies (IGDPS) Rectifier modules Figure 42 - Converter Cabinet, 6600V (Heatpipe Model) Inverter modules Isolated Gate Isolated Gate...

  • Page 59: Powercage Module Overview

    Power Component Definition and Maintenance Chapter 2 PowerCage Module Overview A PowerCage™ module is a converter module, consisting of the following elements: • Epoxy resin housing • Power semiconductors with gate driver circuit boards • Heatsinks or heatpipes • Clamp •...

  • Page 60: Resistance Checks

    Chapter 2 Power Component Definition and Maintenance Resistance Checks Prior to applying control power to the drive, power semiconductor and snubber circuit resistance measurements must be taken. Doing so will ensure that no damage has occurred to the converter section during shipment. The instructions provided below detail how to test the following components: •...

  • Page 61: Sgct And Snubber Circuit

    Power Component Definition and Maintenance Chapter 2 SGCT and Snubber Circuit With all power semiconductors or thyristors, the SGCT requires a snubber circuit. The snubber circuit for the SGCT consists of a snubber resistor in series with a snubber capacitor. Figure 43 shows the snubber circuit.
  • Page 62 Chapter 2 Power Component Definition and Maintenance Figure 45 - 2400V Two Device PowerCage Module (Heatsink Model) Pivot Plate SGCTs Heatsink Module Housing Temperature Feedback Board Clamp Head Figure 46 - 2400V Two Device PowerCage Module (with SPS Boards installed) SPS Mounting Assembly with SGCT SGCT...
  • Page 63 Power Component Definition and Maintenance Chapter 2 Figure 47 - 3300/4160V Four Device PowerCage Module (heatsink model) Pivot Plate Matched Set Matched Set Heatsink Two SGCTs Two SGCTs Clamp Head Module Housing Temperature Feedback Board Figure 48 - 3300/4160V Four Device Rectifier PowerCage Module (with SPS Boards installed) SPS Mounting Assembly with Pivot Plate Matched Set...
  • Page 64 Chapter 2 Power Component Definition and Maintenance Figure 49 - 6600V Six Device PowerCage Module (heatsink model) Matched Set Matched Set Pivot Plate Clamp Head Three SGCTs Three SGCTs Module Housing Heatsink Temperature Feedback Board Figure 50 - 6600V Six Device PowerCage Module (with SPS Boards installed) Matched Set Matched Set Pivot Plate...
  • Page 65 Power Component Definition and Maintenance Chapter 2 Figure 51 - 3300/4160V Four Device PowerCage Module (Heatpipe Model) End Position Module Housing Heatpipe Assembly Heatpipe Heatpipe Support Channel Assembly Matched Set Clamp Base Two SGCTs Matched Set Clamp Head Temperature Two SGCTs Feedback Board Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...
  • Page 66 Chapter 2 Power Component Definition and Maintenance Figure 52 - Snubber Circuit Assembly for SGCT module Cs-1 Rsn-2 Rsn-1 Cs-2 Anode Cathode Figure 53 - Snubber Circuit Assembly (Heatpipe Model) Rsn-2 Cs-1 Rsn-1 Cs-2 Anode Cathode Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...

  • Page 67: Sgct Testing

    Power Component Definition and Maintenance Chapter 2 In addition to the snubber circuit, a sharing resistor connects in parallel with the SGCT. The sharing resistor ensures the equal distribution of the voltage among the SGCTs connected in series. Connect SGCTs in series to increase the total reverse voltage blocking (PIV) capacity, as seen by the electrical circuit.

  • Page 68: Sgct Anode-To-Cathode (Sharing) Resistance

    Chapter 2 Power Component Definition and Maintenance Table 3 - SGCT/snubber resistance values SGCT Resistance Measurement Measured Resistance Inverter Rectifier (AFE only) SGCT Anode-Cathode Resistance (heatsink to heatsink) k-Ω (Lowest) (Highest) (Lowest) (Highest) Snubber Resistance (Test point: heatsink above) Ω (Lowest) (Highest) (Lowest)
  • Page 69 Power Component Definition and Maintenance Chapter 2 Figure 55 - Resistance Measurements SGCT PowerCage Module (with SPS Board Mounting Assembly) Resistance value between two heatsinks is sharing resistance in parallel with anode-cathode resistance Resistance value between heatsink and test point is snubber resistance Figure 56 - Resistance Measurements (Heatpipe Model) Snubber Test Point...

  • Page 70: Snubber Resistance (Sgct Device)

    Chapter 2 Power Component Definition and Maintenance Snubber Resistance (SGCT Device) Access to the snubber resistor is not required to test the resistance. The snubber circuit test point is located within the PowerCage module under the heatsinks. For each device, there is one test point. To verify the resistance, measure the resistance between the test point and the heatsink above.

  • Page 71: Snubber Capacitance (Sgct Device)

    Power Component Definition and Maintenance Chapter 2 Table 3 on page 68 to determine the appropriate snubber resistance value for the current rating of the SGCT used. If the resistor is found to be out of tolerance, see page page 76 for detailed instructions on replacing the snubber resistor assembly.
  • Page 72 Chapter 2 Power Component Definition and Maintenance Figure 60 - Snubber Capacitor Test (Shown with SPS Board Installed) Sharing Resistor Snubber Snubber SPS Board Capacitor Resistor Test Point SGCT Heatsink Heatsink Snubber Capacitor Wire Snubber Test Point Use Connector Terminal Screw for Testing Snubber Capacitor SGCT Cathode Wire Table 3 on page 68...

  • Page 73: Replacing The Sgct

    Power Component Definition and Maintenance Chapter 2 Replacing the SGCT The SGCT (“device”) with attached circuit board is located within the PowerCage module assembly. Replace SGCTs in matched sets (two sets for 4160V, three sets for 6600V). The SGCT and associated control board are a single component. Never change the device or the circuit board individually.
  • Page 74 Chapter 2 Power Component Definition and Maintenance 6. Slide the circuit board straight out. ATTENTION: Static charges can damage or destroy the SGCT. Properly ground yourself before removing the replacement SGCT from the protective anti- static bag. Using damaged circuit boards may also damage related components.
  • Page 75 Power Component Definition and Maintenance Chapter 2 Figure 61 - Replacing the SGCT Clamp head block SGCT captive screws DO NOT ADJUST outside nut Inside nut for loosening and Disc Springs applying load to assembly Figure 62 - Replacing the SGCT (if SPS board is installed) Inside nut for SGCT captive screws loosening and...

  • Page 76: Replacing Snubber And Sharing Resistor

    Chapter 2 Power Component Definition and Maintenance Figure 63 - Replacing the SGCT (Heatpipe Model) Clamp Head DO NOT ADJUST outside nut SGCT Disc Springs Captive Inside nut used for loosening Screws and applying load to assembly Replacing Snubber and Sharing Resistor The snubber and sharing resistors are part of the resistor assembly located behind the PowerCage module.
  • Page 77 Power Component Definition and Maintenance Chapter 2 Figure 64 - PowerCage Module Removal (Heatsink PowerCage) Sharing Resistor Push Nuts Snubber Resistor Connection Connection Snubber Capacitor Push Nuts Cathode Connection Common Snubber Anode Connection and Sharing Resistor Connection Figure 65 - PowerCage Module Removal (Heatpipe Model) Remove Hardware Make vertical cut on...
  • Page 78 Chapter 2 Power Component Definition and Maintenance 3. Remove the push nuts on the end of the retaining rod. 4. Pinch the clip together and pull off. 5. Pull out the retaining rod. Figure 66 - Snubber and Sharing Resistor Replacement (Heatsink Model) 2.
  • Page 79 Power Component Definition and Maintenance Chapter 2 6. Use silicone gel to secure the snubber resistor assembly to the PowerCage module. The gel minimizes possible damages to the resistor bank during transportation from the factory. You do not need to reapply any gel when inserting the new resistor bank.

  • Page 80: Replacing Snubber Capacitor

    Chapter 2 Power Component Definition and Maintenance 7. Place the new resistor bank assembly back into the PowerCage module. 8. Slide the retaining rod into place and push the clips back into place. 9. Connect the leads to the resistor bank 10.
  • Page 81 Power Component Definition and Maintenance Chapter 2 3. Remove the push nuts on the end of the retaining rod. Pinch the clip together and pull off. Pull out the retaining rod. 4. Remove two bolts and swing out the plug-in stab assembly. Figure 71 - Snubber Capacitor Replacement 2.

  • Page 82: Replacing Sharing Resistors

    Chapter 2 Power Component Definition and Maintenance Replacing Sharing Resistors Normally the sharing resistor is part of the snubber resistor assembly. Replacing the sharing resistor requires also replacing the snubber resistor. The sharing and snubber resistors are normally located on the backside of the PowerCage module.

  • Page 83: Scr Testing

    Power Component Definition and Maintenance Chapter 2 Figure 73 - Snubber Circuit Assembly for SCR Rectifier Module Rsn-2 Cs-1 Cs-2 Rsn-1 Anode Cathode SCR Testing The following section verifies SCR semiconductors and all associated snubber components. For quick reference to the expected resistance and capacitance values, see Table 4.
  • Page 84 Chapter 2 Power Component Definition and Maintenance Figure 74 - SCR snubber Circuit Connections Sharing Resistor Snubber To Gate Driver Board Snubber Capacitor Resistor Test Point Heatsink Heatsink Heatsink Heatsink SCR Resistance Measurement Measured Resistance Inverter Rectifier (SCR only) SCR Anode-Cathode Resistance (heatsink to heatsink) k-Ω...

  • Page 85: Scr Anode-To-Cathode Resistance

    Power Component Definition and Maintenance Chapter 2 SCR Anode-to-Cathode Resistance Performing an anode-to-cathode resistance test verifies the integrity of the SCR. The SCR uses the snubber circuit to power the self-powered gate driver boards. The resistance measurement taken across each SCR should be constant;...

  • Page 86: Scr Sharing Resistance Test

    Chapter 2 Power Component Definition and Maintenance SCR Sharing Resistance Test To test the sharing resistor of an SCR module, disconnect the 2-pole plug of the self-powered gate driver board labeled SHARING and SNUBBER on the circuit board. The red wire of the plug is the sharing resistor. Measure the resistance between the red wire of the plug and the heatsink to the left.

  • Page 87: Scr Gate-To-Cathode Resistance

    Power Component Definition and Maintenance Chapter 2 SCR Gate-to-Cathode Resistance One test that can be performed on SCRs that cannot be performed on SGCTs is a Gate-to-Cathode Resistance Test. Performing a Gate-to- Cathode resistance measurement will identify damage to an SCR by revealing either an open or shorted gate to cathode connection.

  • Page 88: Snubber Resistance (Scr Device)

    Chapter 2 Power Component Definition and Maintenance Snubber Resistance (SCR Device) Access to the snubber resistor is not required to test the resistance. The snubber circuit test point is located within the PowerCage module under the heatsinks. For each device, there is one test point. To verify the resistance, measure the resistance between the test point and the heatsink above.

  • Page 89: Snubber Capacitance (Scr Device)

    Power Component Definition and Maintenance Chapter 2 Snubber Capacitance (SCR Device) Turn the multimeter from the resistance to capacitance measurement mode. Proceed to verify the snubber capacitor by measuring from the test point and the white wire at the 2-pole device snubber plug (labeled snubber). Figure 79 - Snubber Capacitance Test Sharing Resistor Snubber...

  • Page 90: Replacing Scr And Scr Self-Powered Gate Driver Boards

    Chapter 2 Power Component Definition and Maintenance Replacing SCR and SCR Self-Powered Gate Driver Boards (SPGDB) Replacing the SCR is similar to replacing the SGCT, except that you can replace the SCR and circuit board independently of one another. 1. Isolate and lock out all power to the drive. ATTENTION: To prevent electrical shock, disconnect the main power before working on the drive.
  • Page 91 Power Component Definition and Maintenance Chapter 2 8. Loosen the tie wrap holding the gate-cathode wire in place, and remove the device from the assembly. 9. Install the new device in the same position and using the same orientation as the original SCR, and firmly secure the gate-cathode wires with the same tie wrap.

  • Page 92: Uniform Clamping Pressure

    Chapter 2 Power Component Definition and Maintenance Figure 80 - SCR and SPGDB Assembly Always maintain proper pressure on the thyristors. Follow this procedure Uniform Clamping Pressure whenever changing devices or loosening the clamp completely. 1. Apply a thin layer of electrical joint compound (Alcoa EJC No. 2 or approved equivalent) to the clamp head pressure pad face (Figure 82).

  • Page 93: Checking Clamping Pressure

    Power Component Definition and Maintenance Chapter 2 4. Torque the heatsink bolts to 13.5 N•m (10 lb•ft) starting with the center heatsink and moving outward alternating left to right. 5. Check the clamp indicating washer. Checking Clamping Pressure Periodically inspect the clamping force in the PowerCage module. Ensure there is no power to the equipment.

  • Page 94: Temperature Sensing

    Chapter 2 Power Component Definition and Maintenance Temperature Sensing Thermal sensors are available on one heatsink in the rectifier and one heatsink in the inverter. The thermal sensors are mounted on the heatsink with the temperature feedback board, or on the SPS mounting bracket which is mounted to the heatsink, if equipped.
  • Page 95 Power Component Definition and Maintenance Chapter 2 Figure 83 - Thermal sensor replacement (Heatsink Model) Temperature Feedback Circuit Board Mounting Pad Insulating Bushing Mounting Screw Thermal Sensor and Cable Assembly Figure 84 - Thermal Sensor Replacement (SPS Board Model) Temperature Feedback Mounting Pad Circuit Board Insulating...
  • Page 96 Chapter 2 Power Component Definition and Maintenance Figure 85 - Thermal Sensor Replacement (Heatpipe Model) Thermal sensor plugs into Temperature feedback air flow circuit board Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...

  • Page 97: Replacing Heatsinks/Heatpipes

    Chapter 2 Replacing Heatsinks/ There are three different styles of heatsinks and one type of heatpipe used in PowerFlex 7000 air-cooled drives, depending on thermal requirements: Heatpipes • Aluminum type W heatsinks have a plurality of short internal fins along the internal surfaces •...

  • Page 98: Replacing Heatsinks

    Chapter 2 Power Component Definition and Maintenance Replacing Heatsinks The copper heatsinks can weigh about 9 kg (20 lb), while the aluminum heatsinks will weigh approximately 4 kg (9 lb). 1. Isolate and lock out all power to the drive. ATTENTION: To prevent electrical shock, disconnect the main power before working on the drive.

  • Page 99: Replacing Heatpipes

    Power Component Definition and Maintenance Chapter 2 Replacing Heatpipes For the largest power ratings of AFE rectifiers, heatpipes are used. Heatpipes weigh approximately 13 kg (28 lb). To replace a heatpipe: 1. Loosen heatpipe locking nuts on top of heatpipe horizontal fin support (center nut at each sink).

  • Page 100: Powercage Gasket

    Chapter 2 Power Component Definition and Maintenance b. Tighten the clamp to the proper force until you can turn the indicating washers by the fingers with some resistance. 17. Once clamp force has been re-applied, tighten heatpipe locking nuts on top of horizontal fin support (center nut at each sink) to 8 N•m (6 lb•ft).
  • Page 101 Power Component Definition and Maintenance Chapter 2 Figure 88 - PowerCage Gasket Location (Heatsink Model) Power Connection Gasket Resistors Power Connection Housing Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...

  • Page 102: Replacing Powercage Gaskets

    Chapter 2 Power Component Definition and Maintenance Figure 89 - PowerCage Gasket Location (Heatpipe Model) Resistors Gasket PowerCage Housing Replacing PowerCage Gaskets The gaskets do not normally require replacement, but in the event that they become damaged, you may have to replace them. Remove Old Gasket Material Remove as much material as possible by hand to leave an even, bondable surface.

  • Page 103: Removing The Powercage Module

    Power Component Definition and Maintenance Chapter 2 Clean the PowerCage module with a general purpose household cleaner. Do not spray onto the PowerCage module as this promotes electrical tracking. Apply the cleaner to a paper towel and wipe the surface of the PowerCage module where you will apply the gasket.
  • Page 104 Chapter 2 Power Component Definition and Maintenance ATTENTION: Do NOT remove the pivot plate from the PowerCage. The pivot plate is located on the opposite end of the PowerCage from the clamp head. If the pivot plate is removed from the PowerCage, it must be replaced in the original orientation.

  • Page 105: Self-Powered Sgct Power Supply - Sps

    Power Component Definition and Maintenance Chapter 2 Self-powered SGCT Power This board is a component in drives that does not use the IGDPS module to power the rectifier SGCTs. The SPS board extracts energy from the associated Supply - SPS SGCT snubber circuitry to provide the 20V DC required to power the SGCT device.
  • Page 106 Chapter 2 Power Component Definition and Maintenance Figure 92 - SPS Board Test Points J1 Snubber and Test Power Harness TP6-300V DC common J2-20V DC Output Power to SGCT and TFB Board DS1-20V DC Good LED TP15 - 20V DC TP14 - 20V DC COM TP4-300V DC Terminal...

  • Page 107: Testing Equipment

    Power Component Definition and Maintenance Chapter 2 Testing Equipment Ensure you have the following equipment available in order to perform testing tasks. • SPS test power harness (part no. 80018-695-51) • Digital multimeter 1. Disconnect the snubber connection to J1 of the SPS board. 2.

  • Page 108: Self-Powered Gate Driver Board - Spgdb

    Chapter 2 Power Component Definition and Maintenance Self-Powered Gate Driver This board is a component in drives using SCRs as the rectifying device on the input of the drive. The SCRs require a gating pulse to turn on, and this is Board –...

  • Page 109: Terminal/Connections

    Power Component Definition and Maintenance Chapter 2 Figure 93 - Self-Powered Gate Driver Board TB3 - Test Power Connection OP1, OT1 - Fiber Optic Transmitter and Receiver TB2 - Temperature Sensor Power Connection TB4 - Gate and Cathode Thyristor Connection Status Indicator TB1 - Snubber Connection Terminal/Connections...

  • Page 110: Testing Procedure For Scr Self-Powered Gate Driver Board

    Chapter 2 Power Component Definition and Maintenance Testing Procedure for SCR Testing Equipment Self-Powered Gate Driver Ensure you have the following equipment available in order to perform testing Board tasks. • Digital oscilloscope • Function generator w/duty cycle control • DC power supply (+15V @ 300 mA required) •...
  • Page 111 Power Component Definition and Maintenance Chapter 2 20. Remove the jumper between TB3-1 and TB3-2. 21. Apply a constant fiber optic signal to the OP1 input. 22. Apply a 60 Hz, 33% duty cycle signal, at a 0 to +2V level, between the TB1-2 input and COM.
  • Page 112 Chapter 2 Power Component Definition and Maintenance Figure 96 - Expanded SCR Gating Pulse Figure 97 - V-Sense Trigger to SCR Gating Pulse Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...

  • Page 113: Fiber Optic Cabling

    Power Component Definition and Maintenance Chapter 2 Figure 98 - Expansion of V Sense Trigger to SCR Gating Pulse The equipment uses fiber optic cabling between the low voltage control and Fiber Optic Cabling the medium voltage circuits. You should never need to change the routing of the fiber optic cables.

  • Page 114: Air Pressure Sensor

    Chapter 2 Power Component Definition and Maintenance The product uses the following fiber optic cable lengths. Duplex Simplex 5.0 m 5.0 m 5.5 m 6.0 m 6.0 m 10.0 m 6.5 m 7.0 m There is one duplex fiber optic for each thyristor, which manages gating and diagnostic functions.

  • Page 115: Replacing The Air Pressure Sensor

    DC Link and Fan Cabinet This section describes the DC link and fan cabinet components of your PowerFlex 7000 “B” Frame drive. This section also details a number of regular Components or recurring maintenance tasks that will keep your drive in peak operating condition.
  • Page 116 Chapter 2 Power Component Definition and Maintenance Figure 100 - DC Link/Fan Cabinet with Fan Control Panel (Heatsink Model) Ground Bus AC/DC Converters Fan Power Disconnect Single Phase Control Power Transformer DC Link Inductor or CMC (Barrier Removed) Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...
  • Page 117 Power Component Definition and Maintenance Chapter 2 Figure 101 - DC Link/Fan Cabinet with Panel Removed to Show CMC (Heatpipe Model) Fans Common Mode Choke Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...
  • Page 118 Chapter 2 Power Component Definition and Maintenance Figure 102 - DC Link/Fan Cabinet with Panel Removed to show Main Cooling Fan Inlet Ring Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...

  • Page 119: Dc Link Reactor

    Power Component Definition and Maintenance Chapter 2 The door of the cabinet interlocks to remain closed until you disconnect the fan power. The fan power disconnect handle is on the right-hand side of the cabinet. The DC link and fan are behind the fixed fan control panels in the medium voltage compartment.
  • Page 120 Chapter 2 Power Component Definition and Maintenance Figure 103 - DC Link Removal (Heatsink Model) 2. Unfasten DC links leads 3. Remove DC link hardware and slide DC link forward 1. Remove hardware and DC link barrier Figure 104 - DC Link Removal (Heatpipe Model) 2.

  • Page 121: Removing And Replacing Fans

    Power Component Definition and Maintenance Chapter 2 Install the replacement DC link in the reverse order of its removal. You must connect the flexible DC link leads to the appropriate terminal and route them to maintain electrical clearances. You must also verify that the nameplate ratings are the same or appropriate for the drive system.
  • Page 122 Chapter 2 Power Component Definition and Maintenance Figure 105 - Fan Removal (Heatsink Model) Fan Motor Mounting Holes Fan Impeller Mounting Bracket Inlet Ring Figure 106 - Fan Removal (Heatpipe Model) Fan Assembly Back of Fan Housing slides under Retaining Bracket M6 Taptite (4x) Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...

  • Page 123: Fan Installation

    Power Component Definition and Maintenance Chapter 2 Fan Installation Take care when handling the fan as poor handling can adversely affect its balance. Install the fan in the reverse order of its removal. IMPORTANT After installation, rotate the impeller by hand to verify it is clear of the inlet ring.

  • Page 124: Impeller Maintenance

    Chapter 2 Power Component Definition and Maintenance Impeller Maintenance The fan impeller connects to the motor shaft with a split tapered bushing. This bushing is positioned on the motor shaft and through the center of the impeller. Two cap screws, when tightened to 10.2 N•m (7.5 lb•ft), lock the bushing onto the motor shaft and the impeller to the bushing.

  • Page 125: Installing Impeller Assembly Onto Motor Shaft

    Power Component Definition and Maintenance Chapter 2 4. Tighten each bolt part of a turn successively, to push the impeller off the bushing. Screwing down the cap screws into these holes will force the bushing away from the impeller hub, releasing the compression on the shaft.
  • Page 126 Chapter 2 Power Component Definition and Maintenance 6. Tighten the cap screws progressively with a wrench. Do this evenly as though mounting an automobile wheel. Turn one a quarter turn, then the next a quarter turn, then go back and turn the other a quarter turn and so on.

  • Page 127: Replacing Air Filters

    Power Component Definition and Maintenance Chapter 2 If rear panel access is not possible, follow this procedure: 1. Remove the DC Link barrier and impeller access panel (Figure 105 on page 122). Remove electrical components in front of the inlet ring access panel.
  • Page 128 Chapter 2 Power Component Definition and Maintenance Recommended cleaning method of filters: • Vacuum – A few passes of a vacuum cleaner on the inlet side of the filter will remove accumulated dust and dirt in seconds. • Blow with compressed air – point compressed air nozzle in opposite direction of operating air flow (Blow from exhaust side toward intake side) •...
  • Page 129 Power Component Definition and Maintenance Chapter 2 Figure 110 - Air Flow Pattern for Snubber Cooling Figure 111 - Air Flow through PowerCage Module Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...
  • Page 130 Chapter 2 Power Component Definition and Maintenance Notes: Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...

  • Page 131: Control Component Definition And Maintenance

    Chapter Control Component Definition and Maintenance Control Power Components There are two configurations for distributing control power for the drive, dependent on your selected drive option. • Direct-to-Drive™ (transformerless AFE rectifier) (see Figure 112) • AFE/18-pulse rectifier with separate isolation transformer (see Figure 113 on page 133) Ride-through...
  • Page 132 Chapter 3 Control Component Definition and Maintenance Figure 112 - Direct-to-Drive (transformerless AFE Rectifier) - Operator Interface - Relays 5V-Logic Customer C Hold-up Supplier +/-15V Logic 120V 1 PH AC/DC Converter Line DC/DC Converter 600 W/ 1000W/ +/-24V-HECS Filter 1500 W 24V-Isolators 24V-XIO Sense Cable...

  • Page 133: Ac/Dc Power Supply

    Control Component Definition and Maintenance Chapter 3 Figure 113 - AFE/18-pulse Remote Transformer / Starter - Operator Interface - Relays Customer C Hold-up 5V-Logic Supplier +/-15V Logic 120V 1 PH AC/DC Converter Line DC/DC Converter +/-24V-HECS 600 W/ 1000W/ Filter 24V-Isolators 1500 W 18-pulse...
  • Page 134 Chapter 3 Control Component Definition and Maintenance Figure 115 - Location of AC/DC Pioneer Power Supply on LV Panel (Heatsink Model) AC/DC Power Supply Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...

  • Page 135: Terminal / Connections Descriptions

    Control Component Definition and Maintenance Chapter 3 Figure 116 - Location of AC/DC Power Supply on LV Panel (Heatpipe Model) AC/DC Power Supply in LV compartments above converter section Terminal / Connections Descriptions (Pioneer Power Supply) The terminal connections are shown in Figure 117.

  • Page 136: Terminal / Connections Descriptions

    Chapter 3 Control Component Definition and Maintenance PIN# LABEL P1-AC input EARTH LINE NEUTRAL P2-DC output +56V +56V COMM +56V +56V COMM P3-FAIL output DC POWER FAIL (OUTPUT POWER GOOD) CURRENT SHARING DC POWER FAIL COMMON Terminal / Connections Descriptions (Cosel Power Supply) The terminal connections are shown in Figure 118.

  • Page 137: Output Calibration

    Control Component Definition and Maintenance Chapter 3 Figure 119 - Terminal Locations on 600W AC/DC Power Supply (Cosel) Terminal/Connections Descriptions (600W Cosel Power Supply) Single Phase Input Air Flow Control Signals FRONT VIEW DC Outputs P1-AC Input PIN# LABEL AC (L) Live AC (N) (1500 W only) Neutral (1500 W only)

  • Page 138: Power Supply Replacement

    Chapter 3 Control Component Definition and Maintenance Power Supply Replacement Follow these steps to replace a power supply. 1. Ensure control power is isolated and locked out. 2. Disconnect all the wiring terminals from the power supply unit. 3. Remove the four M6 bolts (Figure 120).
  • Page 139 Control Component Definition and Maintenance Chapter 3 Figure 120 - Replacing AC/DC Power Supply on LV Panel (Heatsink Model) 10 mm 5.0 N•m (44 in•lb) Figure 121 - Replacing AC/DC Power Supply on LV Panel (Heatpipe Model) Power supply is secured by a mounting bracket held by four M6 taptites to LV mounting plate Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...

  • Page 140: Power Supply Diode Replacement

    Chapter 3 Control Component Definition and Maintenance Power Supply Diode Replacement IMPORTANT If there are at least two power supplies, the drive is equipped with a power supply diode. IMPORTANT Depending on watt rating and number of power supplies, the location of the diode will differ depending on your configuration.

  • Page 141: Ups Option

    Control Component Definition and Maintenance Chapter 3 8. Install the new power supply diode cover. The drive has the option for internal and external UPS power to keep the UPS Option control power active within the drive in the event of a control power loss. Figure 122 shows the current configuration of the internal UPS option.
  • Page 142 Chapter 3 Control Component Definition and Maintenance Figure 123 - 300W AC/DC Power Supply (Heatpipe Model) 300W AC/DC EMI Filter Power Supply Hold-up Capacitor Holding Bracket The UPS is installed in the incoming cabling section, below the LV control section. The UPS will maintain control power to all the critical 120VAC loads and an extra AC/DC power supply that feeds the DC/DC power supply for powering all the drive control components.

  • Page 143: Replacing The Ups

    Control Component Definition and Maintenance Chapter 3 Replacing the UPS IMPORTANT To replace the UPS battery, see the UPS user manual that was shipped with the drive. 1. Isolate and lock out the control power. 2. Remove the hardware that fastens the holding bracket to the cabinet assembly and remove the holding bracket.

  • Page 144: Low Voltage Control Section

    Chapter 3 Control Component Definition and Maintenance 6. Reconnect all the connections removed in the previous steps. 7. Before reconnecting the mounting bracket, apply control power to the unit and ensure the UPS is configured for the AS400 communication protocol. See the manual that comes with the UPS for instructions. 8.

  • Page 145: Dc/Dc Power Supply

    Control Component Definition and Maintenance Chapter 3 DC/DC Power Supply The DC/DC power supply provides a source of regulated DC voltages for various logic control boards and circuits., using a regulated 56V DC source. Figure 126 - DC/DC Converter Power Supply 5V-Logic +/-15V Logic DC/DC Power Supply...

  • Page 146: Terminal/Connections Descriptions

    Chapter 3 Control Component Definition and Maintenance Terminal/Connections Descriptions P1 – DC Input PIN NO. LABEL DESCRIPTION ONLY +56V +56V input +56V COMM +56V common EARTH earth ground P2 – SENSE PIN NO. LABEL DESCRIPTION ONLY (To ACB) +56V +56V input supply +56V RTN +56V input supply return Not connected...

  • Page 147: Replacing A Dc/Dc Power Supply

    Control Component Definition and Maintenance Chapter 3 Replacing a DC/DC Power Supply Figure 127 - Replacing a DC/DC Power Supply M4 Hardware and Nylon Shoulder Washer Mounting Plate Black Insulation Part ID Label DC/DC Power M6 Hex Head Supply Cap Screw 1.

  • Page 148: Drive Processor Module

    Chapter 3 Control Component Definition and Maintenance Drive Processor Module This board contains control processors, which are responsible for all the drive control processing and stores the parameters used for the drive control. Figure 128 - Drive Processor Module (DPM) Secondary Test Points Primary...
  • Page 149 Control Component Definition and Maintenance Chapter 3 Diagnostic test points on the DPM have a voltage output range of -5…+5V. Table 5 identifies test points on the DPM. Table 5 - Test Points on Drive Processor Module Test points Name Description DPM-TP1 +1.2V...

  • Page 150: Replacing The Drive Processor Module

    Chapter 3 Control Component Definition and Maintenance Table 7 - Description of D9 and D11 Function: Boot Code Status (Continued) Color Rate or Count (Pulse) Meaning 8 count FPGA Loading failed 9 count POST – USART failed: 1 Green Count = Port 1 2 Green Count = Port 2 10 count End of code reached...
  • Page 151 Control Component Definition and Maintenance Chapter 3 7. Remove the drive processor module from the four, 34-pin female connectors and one, 16-pin female connector on the ACB. 8. Remove the DIM module from the DPM and plug it on the new DPM before replacing the DPM.

  • Page 152: Analog Control Board (Acb)

    Chapter 3 Control Component Definition and Maintenance Analog Control Board (ACB) The ACB is the hub for all control-level signals external to the drive. The drive routes analog I/O, external fault signals (through the XIO board), DPI communication modules, remote I/O, terminal interface, printers, modem, and other external communication devices through this board.
  • Page 153 Control Component Definition and Maintenance Chapter 3 The analog control board receives all of the analog signals from the internal components of the drive. This includes the current and voltage feedback signals. The board also has isolated digital I/O for e-stops, contactor control and status feedback.
  • Page 154 Chapter 3 Control Component Definition and Maintenance Table 10 - Test Points on Analog Control Board Test points Name Description ACB-TP1 Motor voltage feedback, UV ACB-TP2 Motor voltage feedback, VW ACB-TP3 Motor voltage feedback, WU ACB-TP4 Motor current, HECSU ACB-TP5 Motor current, HECSW ACB-TP6 Zero sequence generation motor side, VZS...
  • Page 155 Control Component Definition and Maintenance Chapter 3 Table 10 - Test Points on Analog Control Board (Continued) Test points Name Description ACB-TP40 CMC neutral voltage, VNN ACB-TP41 CMC neutral current, INN ACB-TP42 Ignd Ground fault current, GFCT ACB-TP43 Vspr Spare channel for inputs ACB-TP44 Vmtrp Motor over voltage detection set point...

  • Page 156: Status Indicators

    Chapter 3 Control Component Definition and Maintenance Table 10 - Test Points on Analog Control Board (Continued) Test points Name Description ACB-TP79 Output contactor command ACB-TP80 BPIS Bypass isolating switch ACB-TP81 BPCS Bypass contactor status ACB-TP82 Bypass contactor command ACB-TP83 DGND Digital ground return Status Indicators...

  • Page 157: Analog Inputs And Outputs

    Therefore, the PowerFlex 7000 transmitter can drive a receiver with an input resistance up to 625 Ω.

  • Page 158: Isolated Process Receiver

    Chapter 3 Control Component Definition and Maintenance The recommended connection is shown above. The type of shielded cable used is application specific and is determined by the length of the run, the characteristic impedance and the frequency content of the signal. Isolated Process Receiver These inputs are individually configurable to accept either a -10/0/+10V input signal or a 4-20 mA signal.

  • Page 159: Non-Isolated Process Outputs

    Control Component Definition and Maintenance Chapter 3 Non-Isolated Process Outputs The drive supplies four non-isolated -10/0/+10 V outputs for your use. These outputs can drive loads with impedances as low as 600 Ω. These outputs are referenced to the Drive AGND; isolate them if you require them to drive outside the frame enclosure.

  • Page 160: Replacing The Analog Control Board

    Chapter 3 Control Component Definition and Maintenance Replacing the Analog Control Board To replace the analog control boards: 1. Isolate and lock out all power to the drive. 2. Remove the transparent sheet on top of the drive processor module and the drive processor module itself before removing the ACB.

  • Page 161: 20B-Enc-3 Encoder Interface

    Control Component Definition and Maintenance Chapter 3 20B-ENC-3 Encoder Interface This encoder interface enables connecting the drive to a standard quadrature encoder. The 20B-ENC encoder interface provides three optically isolated differential encoder inputs for A and B phases as well as a Z track. You cannot configure these inputs for use with a single ended encoder.
  • Page 162 Chapter 3 Control Component Definition and Maintenance 80190-759-01, 80190-759-02 Universal Encoder Interface The universal encoder interface enables connections between the drive and to an absolute position encoder or a standard quadrature encoder, providing the option for dual or redundant quadrature encoders. The universal encoder interface provides 12 single ended or 6 differential, optically isolated inputs as well as a 12V/3W galvanically isolated encoder power source.
  • Page 163 Control Component Definition and Maintenance Chapter 3 Figure 137 - Universal Encoder Board Connections to the universal encoder interface occur via a 1492-IFM20F interface module. The connections to the IFM are detailed below. Table 12 - Encoder Functions IFM Pin # Quadrature Encoder Function Absolute Encoder Function ENC_COM...

  • Page 164: Quadrature Encoder Operation

    Chapter 3 Control Component Definition and Maintenance Figure 138 - 20-pin Interface Module (IFM) Quadrature Encoder Operation The universal encoder interface accepts either single or dual quadrature encoders. Configure the board to accept the encoders through jumpers on J4. Boards shipped from the factory come default to single quadrature encoder configuration.

  • Page 165: Positional Encoder Operations

    Control Component Definition and Maintenance Chapter 3 Positional Encoder Operations Besides quadrature encoders, the universal encoder interface also accepts positional (absolute) encoders. The interface converts parallel positional data to a serial stream and transmits it to the DPM. The board also generates “pseudo”...
  • Page 166 Chapter 3 Control Component Definition and Maintenance 2. Data Polarity: Absolute encoders typically have a High True output. If the encoder model does not have a High/True (or Non Inverted/ Inverted) option, you should assume it to be High True. In the case of a 10bit High True encoder, the zero position is represented by 0000000000.

  • Page 167: External Input/Output Boards

    Control Component Definition and Maintenance Chapter 3 External Input/Output The external input/output (XIO) boards connect through a network cable (CAN Link) to the analog control board (ACB). You can connect this cable to Boards either XIO Link A ( J4) or XIO Link B ( J5). The XIO board handles all external digital input and output signals and sends them to the ACB through the cable.

  • Page 168: Replacing The External Input/Output Board

    Chapter 3 Control Component Definition and Maintenance LED D1 and display U6 indicate the status of the board. Table 13 illustrates the possible states for D1. Table 13 - Color Status Explanation for LED D1 LED Status Description Solid Green Normal operation Solid Red Board failure...

  • Page 169: Optical Interface Boards (Oib)

    Control Component Definition and Maintenance Chapter 3 Optical Interface Boards The optical interface boards are the interface between the DPM and the gate driver circuitry. The drive control decides which device to fire, and signals the (OIB) OIB boards. The OIB board converts that electrical signal to an optical signal that it transmits via fiber optics to the gate driver cards.

  • Page 170: Replacing The Optical Interface Board

    Chapter 3 Control Component Definition and Maintenance Each OIB board also has input RX7 for a signal from a temperature feedback board. The quantity and location of thermistor connections is dependent on the drive configuration. Typically, there is one temperature sensor from the line converter and one temperature sensor from the machine converter, each going into the respective OIB board in the ‘A’...
  • Page 171 Control Component Definition and Maintenance Chapter 3 Figure 141 - OIB Replacement (Mounting Plate Accessible) Optical Interface Boards (OIB) Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...
  • Page 172 Chapter 3 Control Component Definition and Maintenance This board provides the mechanical and electrical interconnections between the OIBs and the DPM. The board connects to either J11 or J12 on the DPM via a 60-conductor shielded-ribbon cable. Attach the cable drain wire to the screw terminal J8.

  • Page 173: Replace The Optical Interface Base Board

    Control Component Definition and Maintenance Chapter 3 Replace the Optical Interface Base Board IMPORTANT If the drive is equipped with the Safe Torque Off option, the drive will use OIBBS boards. See publication 7000-UM203 to replace the OIBBS. 1. Isolate and lock out all power to the drive. IMPORTANT Use a static strap when performing this procedure.
  • Page 174 Chapter 3 Control Component Definition and Maintenance Test Point Signal Name Description DIAG_3 OIB A, RX4 Diagnostic Feedback CMD_3 OIB A, TX4 Firing Command Signal TP10 DIAG_4 OIB A, RX5 Diagnostic Feedback TP11 CMD_4 OIB A, TX5 Firing Command Signal TP12 DIAG_5 OIB A, RX6 Diagnostic Feedback...

  • Page 175: Specifications

    Appendix Specifications ATTENTION: See the customer drawings if when there is a discrepancy between the generic manual specifications and the specific design or electrical drawings. “B” Frame Drive Specifications Table 17 - General Design Specifications Description Motor Type Induction or Synchronous Input Voltage Rating 2400V, 3300V, 4160V, 6600V Input Voltage Tolerance...
  • Page 176 Appendix A Specifications Table 17 - General Design Specifications (Continued) Description Number of Inverter SGCTs Voltage SGCTs (per phase) 2400V 3300V 4160V 6600V Inverter PIV Rating Voltage PIV (each Total PIV device) (Peak Inverse Voltage) 2400V 6500V 6500V 3300V 6500V 13,000V 4160V 6500V...
  • Page 177 Specifications Appendix A Table 17 - General Design Specifications (Continued) Description Adjustable time delay Stall Protection Load Loss Detection Adjustable 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) 75 Hz…90 Hz (Optional - need specific Motor Filter Capacitor [MFC]) Service Duty Rating...
  • Page 178 Appendix A Specifications Table 17 - General Design Specifications (Continued) Description Communication Protocols DeviceNet ControlNet (Optional) Ethernet I/P Lon Works Dual-port Ethernet I/P Can Open Profibus RS485 HVAC Modbus RS485 DF1 Interbus RS232 DF1 Enclosure Type 1 IP21 (with door gaskets) IP42 (optional) Lifting Device Standard / Removable...
  • Page 179 Appendix Catalog Number Explanation Position 7000 RPDTD 1–…etc. Bulletin Number Drive Current Rating Code Description Code Description Code Description 40 A 215 A 7000A “A” Frame (Air-cooled) 46 A 250 A 7000 “B” Frame (Air-cooled) 53 A 285 A 7000L “C”...
  • Page 180 Appendix B Catalog Number Explanation Position 7000 RPDTD 1–…etc. Supply Voltage/Control Voltage/Frequency/CPT Selection Rectifier Configuration/Line Impedance Type Voltage Code Code Description Frequency Frame Nominal With a Without a Size (Hz) Control AFE Rectifier with Integral Line Reactor and C.P.T C.P.T Line RPDTD Direct-to-Drive™...

  • Page 181: Powerflex 7000 Drive Selection Explanation

    Catalog Number Explanation Appendix B PowerFlex 7000 Drive The PowerFlex 7000 medium voltage AC drive selection tables are based on two types of drive service duty ratings: Selection Explanation 1. Normal Duty (110% overload for one minute, once every ten minutes) –...
  • Page 182 Appendix B Catalog Number Explanation Notes: Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...

  • Page 183: Preventative Maintenance Checklist

    This process really involves only one task: changing or cleaning the air filters. The PowerFlex 7000 drive requires consistent, unrestricted airflow to keep the power devices cool. The air filter is the main source of blockage in the air path.

  • Page 184: Initial Information Gathering

    Physical Checks (NO Medium Voltage and NO Control Power) 1. Power connection inspection • Inspect PowerFlex 7000 drive, input/output/bypass contactor sections, and all associated drive components for loose power cable connections and ground cable connections: torque them to the required torque specifications.

  • Page 185: Control Power Checks (No Medium Voltage)

    Preventative Maintenance Schedule Appendix C • Verify torque on heatsink bolts (electrical connections to bullet assemblies) is within specifications (13.5 N•m). • Clean all contaminated components using a vacuum cleaner and wipe clean components where appropriate. IMPORTANT Do not use a blower. •...

  • Page 186: Final Power Checks Before Restarting

    Appendix C Preventative Maintenance Schedule 6. Verify the proper gate pulse patterns using gate test operating mode. For drives with SPS boards installed, use the test power harness (80018- 695-51) to power the rectifier SGCT boards. 7. If there have been any changes to the system during the outage, place the drive in system test operating mode and verify all functional changes.

  • Page 187: Final Reporting

    Preventative Maintenance Schedule Appendix C Final Reporting 1. A complete, detailed report on all steps in the Preventive Maintenance procedures should be recorded to identify changes. • A completed copy of this checklist should be included. • A detailed description of all adjustments and measurements that were taken during the process should be included in an addendum (interlock adjustments, loose connections, voltage readings, insulation resistance results, parameters, and so on).

  • Page 188: Time Estimations

    The following is a list of the tools recommended for proper maintenance of the PowerFlex 7000 drive. Not all of the tools may be required for a specific drive preventive procedure, but to complete all of the tasks listed above the following tools would be required.
  • Page 189 • No. 30 Torx driver Documentation • PowerFlex 7000 Technical Data (Parameters, Troubleshooting) – Publication 7000-TD002 • PowerFlex 7000 MV Drives Transportation and Handling Procedures – Publication 7000-IN008 • MV 400A Vacuum Contactor, Series D User Manual – publication 1502-UM050 •...

  • Page 190: Overview

    Appendix C Preventative Maintenance Schedule Overview Rockwell Automation recognizes that following a defined maintenance schedule improves drive performance and operational lifespan. By following this maintenance schedule, you can expect the highest possible uptime. Annual maintenance includes a visual inspection of all drive components visible from the front of the unit, resistance checks on the power components, power supply voltage level checks, general cleaning and maintenance, checking of all accessible power connections for tightness, and other tasks.
  • Page 191 Preventative Maintenance Schedule Appendix C Rockwell Automation PowerFlex 7000 Drive Preventative Maintenance Schedule Period Interval (Years) (1) (2) Air-Cooling Door Mounted Air Filters System Main Cooling Fan Motor RFB/R I Redundant Cooling Fan Motor (if supplied) RFB/R I Small Aux. Cooling Fans “Caravel”...
  • Page 192 Appendix C Preventative Maintenance Schedule Rockwell Automation PowerFlex 7000 Drive Preventative Maintenance Schedule Period Interval (Years) (1) (2) Air-Cooling Door Mounted Air Filters System Main Cooling Fan Motor RFB/R Redundant Cooling Fan Motor (if supplied) RFB/R Small Aux. Cooling Fans “Caravel”...

  • Page 193: Torque Requirements For Threaded Fasteners

    Appendix Torque Requirements Torque Requirements for Unless otherwise specified, use the following values of torque in maintaining the equipment. Threaded Fasteners • • Diameter Pitch Material Torque (N Torque (lb M2.5 0.45 Steel 0.43 0.32 0.70 Steel 0.80 Steel 1.00 Steel 1.25 Steel...
  • Page 194 Appendix D Torque Requirements Notes: Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...

  • Page 195: Overview

    Appendix Insulation Resistance Test Overview When a ground fault occurs, there are three zones in which the problem may appear: input to the drive, the drive, output to the motor. The ground fault condition indicates a phase conductor has found a path to ground. Depending on the resistance of the path to ground, a current with magnitude ranging from leakage to fault level exists.

  • Page 196: Insulation Resistance Test Procedure

    Appendix E Insulation Resistance Test Follow this procedure to perform insulation resistance tests on the drive. Failure to comply with this procedure may result in poor test readings and damage to drive control boards. Insulation Resistance Test Required Equipment Procedure •...
  • Page 197 Insulation Resistance Test Appendix E Grounding Network b. Remove the ground connection on the GN (if installed). Lift this connection at the GN capacitor rather than the grounding bus, as the grounding cable is only rated for 600V. IMPORTANT Injecting a high voltage on the ground cable during an insulation resistance test will degrade the cable insulation.
  • Page 198 Appendix E Insulation Resistance Test 4. Test the drive. IMPORTANT Verify the drive and any connected equipment is clear of personnel and tools prior to commencing the insulation resistance test. Barricade off any open or exposed conductors. Conduct a walk-around inspection before commencing the test All three phases on the line and machine sides of the drive connect through the DC Link and snubber network.
  • Page 199 Insulation Resistance Test Appendix E Type of Drive Minimum Insulation Resistance Value Ω Drive with input/output capacitors disconnected 5k M Ω Isolation transformer 5k M Ω Motor 5k M The motor filter capacitors and line filter capacitors (if applicable) may result in the test results being lower than expected.
  • Page 200 Appendix E Insulation Resistance Test Notes: Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...

  • Page 201: Maximum Line Cable Sizes

    Appendix Line and Load Cable Sizes Maximum Line Cable Sizes The data provided in Table 18 Table 19 is for informational purposes only. Final design criteria should not be based solely on this data. National and local installation codes, industry best practices, and cable manufacturer recommendations must be followed.
  • Page 202 7…12x (for example, if the cable diameter is 1 in. [2.54 cm] the minimum bend radius could range between 7…12 in. [18.8…30.48 cm]). (4) For minimum cable insulation requirements, see the PowerFlex 7000 user manual for your particular frame. Stated voltages are peak line-to-ground. Some cable manufacturers rate cabling based on RMS line-to-line.

  • Page 203: Maximum Load Cable Sizes

    Line and Load Cable Sizes Appendix F Maximum Load Cable Sizes Table 19 - Maximum Load Cable Sizes Product Output (Motor Side) Voltage/Frequency/ Drive Drive Structure Load Cable No. and Max. Size of Outgoing No. and Max. Size of Outgoing Space for Rectifier Rating (A)
  • Page 204 7…12x (for example, if the cable diameter is 1 in. [2.54 cm] the minimum bend radius could range between 7…12 in. [18.8…30.48 cm]). (4) For minimum cable insulation requirements, see the PowerFlex 7000 user manual for your particular frame. Stated voltages are peak line-to-ground. Some cable manufacturers rate cabling based on RMS line-to-line.

  • Page 205: Air Quality Requirements

    Dust coating low voltage circuit boards can also cause failures. Air presented to the PowerFlex 7000 drive must be of a cleanliness expected in a typical industrial control room environment. The drive is intended to operate in conditions with no special precautions to minimize the presence of sand or dust, but not in close proximity to sand or dust sources.

  • Page 206: Hazardous Materials

    Appendix G Environmental Considerations Hazardous Materials Environmental protection is a top priority for Rockwell Automation. The facility that manufactured this medium voltage drive operates an environmental management system that is certified to the requirements of ISO 14001. As part of this system, this product was reviewed in detail throughout the development process to ensure that environmentally inert materials were used wherever feasible.

  • Page 207: Chromate Plating

    Environmental Considerations Appendix G Chromate Plating Some sheet steel and fasteners are plated with zinc and sealed with a chromate- based dip. Shipping and handling of the chromate plating parts is typically not restricted by environmental regulations, however, chromate is considered a hazardous substance.
  • Page 208 Appendix G Environmental Considerations Notes: Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...
  • Page 209 • If possible, use encoders without Marker, Index, Z, or sig. C signals, as these are not used on the PowerFlex 7000 drive. • When installing, the encoder body and electronics must be isolated from ground (options available from the encoder manufacturer to accomplish this).
  • Page 210 Performance (Torque conditions. Table 22 shows the PowerFlex 7000 drive torque capabilities as a Capabilities) percent of motor rated torque, independent of the momentary overload conditions of the drive. Table 22 - PowerFlex 7000 Drive Torque Capabilities...
  • Page 211 Encoder Use and Torque Capabilities Appendix H Table 23 - Typical Application Load Torque Profiles Application Load Load Torque as Percent of Full-Load Drive Required Encoder Torque Torque Drive Service Required for Profile Duty Rating Extra Break- Accelerating Peak Starting away Running Torque?
  • Page 212 Appendix H Encoder Use and Torque Capabilities Table 23 - Typical Application Load Torque Profiles (Continued) Application Load Load Torque as Percent of Full-Load Drive Required Encoder Torque Torque Drive Service Required for Profile Duty Rating Extra Break- Accelerating Peak Starting away Running...
  • Page 213 Index Cosel power supply 136 terminal locations on 1000W AC/DC 136 abbreviations 12 terminal locations on 600W AC/DC 137 AC/DC power supply 133 current loop transmitter 157 location 134 current transformer location (heatpipe model) 135 replace 50 output calibration 137 replace 138 ACB.
  • Page 214 Index hazardous materials 206 capacitor dielectric fluid 206 fuse 40 chromate plating 207 replace 43 circuit boards 206 simplified wiring diagram 41 drive disposal 207 suppressor 39 fire 207 lithium batteries 206 heatpipe converter cabinet 58 non-isolated process outputs 159 PowerCage components 65 PowerCage gasket components 102 remove fan 122...
  • Page 215 Index resistance checks 60 SPS board 105 SCR anode-to-cathode resistance 85 board components 106 SCR gate-to-cathode 87 calibration 105 SCR sharing resistance 86 snubber circuit schematic 61 SGCT and snubber circuit 61 test equipment 107 SGCT anode-to-cathode 68 test points 105 SGCT testing 67 surge arresters 43 snubber capacitance (SCR) 89...
  • Page 216 Index Notes: Rockwell Automation Publication 7000-UM202D-EN-P - May 2018...
  • Page 218 Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page. Allen-Bradley, ArcShield, CENTERLINE, Direct-to-Drive, DriveTools, PanelView, PowerCage, PowerFlex, Rockwell Automation, and Rockwell Software are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

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