Rockwell Automation Allen-Bradley PowerFlex 7000 User Manual
Rockwell Automation Allen-Bradley PowerFlex 7000 is an air-cooled medium-voltage AC drive that provides advanced control of AC induction motors. It is designed for a wide range of industrial applications, including: pumps, fans, compressors, and conveyors.
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User Manual
Original Instructions
PowerFlex 7000 Medium Voltage AC Drive Air-Cooled
(’A’ Frame)—ForGe Control
Bulletin Number 7000A
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.
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.
IMPORTANT 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).
Overview of Drive
Drive Installation
Table of Contents
Preface
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
What Is Not in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Chapter 1
Simplified Electrical Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Basic Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Chapter 2
Shock Indication Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Installation of Exhaust Air Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Installation of Redundant Fan Assembly. . . . . . . . . . . . . . . . . . . . . 27
Installation of Integral Transformer Cooling Fan. . . . . . . . . . . . . 29
Neutral Resistor Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Installation of Neutral Resistor Assembly (Direct-to-Drive). . . 31
Cabinet Layout and Dimensional Drawings of Drive . . . . . . . . . . . . . 32
IEC Component and Device Designations . . . . . . . . . . . . . . . . . . . . . . 37
Access the Customer Power Cable-terminations . . . . . . . . . . . . . 40
Line/Motor Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Installation Requirements for Power Cabling . . . . . . . . . . . . . . . . 41
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 3
Table of Contents
4
Power and Control Wiring. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Drive Signal and Safety Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
For Customers and Power Integrators . . . . . . . . . . . . . . . . . . . . . . . 48
Identification of Types of Electrical Supplies - Grounded and
Ungrounded Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Power Component Definition and
Maintenance
Chapter 3
Cabling Cabinet Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Hall Effect Sensor Replacements. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Current Transformer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Converter Cabinet Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Replacing the Voltage-sensing Circuit Board Assembly . . . . . . . . . . . 62
Surge Arrester Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
PowerCage Module Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
SGCT and Snubber Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
SGCT Anode-to-Cathode Sharing Resistance . . . . . . . . . . . . . . . 73
Snubber Capacitance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Replacing the SGCT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Replacing Snubber and Sharing Resistor . . . . . . . . . . . . . . . . . . . . . 80
Snubber Capacitor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Sharing Resistor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Maintain Uniform Clamping Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Adjusting the Clamping Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Replacing the Thermal Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Replacement of PowerCage Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . 89
Removal of Old Gasket Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
PowerCage Module Removal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Self-powered SGCT Power Supply - SPS . . . . . . . . . . . . . . . . . . . . . . . . 92
Equipment for Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Table of Contents
Control Component Definition and Maintenance
Air Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
D.C. Link / Fan / Control Components . . . . . . . . . . . . . . . . . . . . . . . . 97
Output Grounding Network Replacement . . . . . . . . . . . . . . . . . . 99
Ground Filter Component Replacement . . . . . . . . . . . . . . . . . . . 100
Replacing the Filter Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Testing the Filter Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
DC Link Reactor and CMC Replacement. . . . . . . . . . . . . . . . . . . . . . 107
Top of Integral Isolation Transformer Section . . . . . . . . . . . . . . 111
Top of Integral Line Reactor and Input Starter Section . . . . . . 112
Isolation Transformer Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . 112
Inlet Ring Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 112
DC Link / Fan Section. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Top of Integral Isolation Transformer Section . . . . . . . . . . . . . . 113
Chapter 4
Control Power Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Terminal / Connections Descriptions . . . . . . . . . . . . . . . . . . . . . . 126
Output Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Single Power Supply Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 128
Dual Power Supply Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Diode Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Replacing the UPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Low Voltage Control Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
DC/DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Terminal/Connections Descriptions . . . . . . . . . . . . . . . . . . . . . . . 136
Replacement Procedure for DC/DC Power Supply. . . . . . . . . . 137
Printed Circuit Board Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Drive Processor Module Replacement . . . . . . . . . . . . . . . . . . . . . . 141
Interface Module (IFM). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Analog Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Current Loop Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 5
Table of Contents
6
Catalog Number Explanation
Preventative Maintenance
Schedule
Isolated Process Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Non-Isolated Process Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Auxiliary +24V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Replacing the Analog Control Board . . . . . . . . . . . . . . . . . . . . . . . 151
Quadrature Encoder Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Positional Encoder Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Positional Encoder Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
External Input/output Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
External Input/output Board Replacement . . . . . . . . . . . . . . . . . 159
Optical Interface Board Replacement . . . . . . . . . . . . . . . . . . . . . . 162
Appendix A
PowerFlex 7000 Drive Selection Explanation . . . . . . . . . . . . . . . . . . . 167
Service Duty Rating, Continuous Current Rating and
Altitude Rating Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Appendix B
Preventative Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Initial Information Gathering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Control Power Checks (No Medium Voltage) . . . . . . . . . . . . . . 171
Final Power Checks before Restarting . . . . . . . . . . . . . . . . . . . . . . 172
Additional Tasks during Preventive Maintenance . . . . . . . . . . . 172
Time Estimations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Tool / Parts / Information Requirements. . . . . . . . . . . . . . . . . . . 174
Maintenance of Medium Voltage Equipment . . . . . . . . . . . . . . . 178
High-voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 179
Maintenance after a Fault Condition . . . . . . . . . . . . . . . . . . . . . . . 179
Operating Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Vacuum Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Power Cable and Control Wire Terminals. . . . . . . . . . . . . . . . . . 181
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Table of Contents
Torque Requirements
Locking and Interlocking Devices . . . . . . . . . . . . . . . . . . . . . . . . . . 182
Appendix C
Torque Requirements for Threaded Fasteners . . . . . . . . . . . . . . . . . . 183
Insulation Resistance Testing
Line and Load Cable Sizes
Appendix D
Drive Insulation Resistance Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Insulation Resistance Testing Procedures. . . . . . . . . . . . . . . . . . . . . . . 186
Appendix E
Maximum Line Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Maximum Load Cable Sizes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Appendix F
Environmental Considerations
Capacitor Dielectric Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Chromate Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Pre -Commissioning
Specifications
Appendix G
Start-up Commissioning Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Pre- Commissioning the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Appendix H
Index
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 7
Table of Contents
Notes:
8 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Summary of Changes
Preface
This document provides procedural information for managing the PowerFlex®
7000 medium voltage ‘A’ frame drives.
This manual contains new and updated information as indicated in the following table.
Topic
Added warning for motor filter capacitors and indicative fault codes
Changed input frequency to ±5%
Page
Who Should Use This Manual
This manual is intended for use by personnel familiar with medium voltage and solid-state variable speed drive equipment. The manual contains material that enables regular operation and maintenance of the drive system.
What Is Not in This Manual
This manual provides information specific to the maintenance of the
PowerFlex® 7000 ‘A’ frame drive. The manual excludes topics such as:
• Dimensional and electrical drawings that are generated for each customer order.
• Spare part lists compiled for each customer order.
• Human Machine Interface (HMI) operation and configuration.
Rockwell Automation provides the site- and installation-specific electrical and design information for each drive during the order process cycle. If they are not available on site with the drive, contact Rockwell Automation®.
General Precautions
ATTENTION: This drive contains ESD (electrostatic discharge) sensitive parts and assemblies. Static control precautions are required when this assembly is installed, tested, serviced, or repaired. Component damage can result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference Allen-Bradley publication 8000-4.5.2
, “Guarding
Against Electrostatic Damage” or any other applicable ESD protection handbook.
ATTENTION: An incorrectly applied or installed drive can result in component damage or a reduction in product life. Wiring or application errors, such as, an undersized motor, incorrect or inadequate AC supply, or excessive ambient temperatures can result in malfunction of the system.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 9
Preface
Additional Resources
ATTENTION: Only personnel familiar with the PowerFlex 7000 Adjustable
Speed Drive (ASD) and associated machinery can plan or implement the installation, start up, and subsequent maintenance of the system. Failure to comply can result in personal injury and/or equipment damage.
These publications contain additional information concerning “A” Frame drives and related products from Rockwell Automation.
Publication
7000-PP002
7000-TD002
7000-UM201
7000-QS002
7000-IN010
Industrial Automation Wiring and
Grounding Guidelines, publication
1770-4.1
Product Certifications website, rok.auto/certifications .
Description
PowerFlex 7000 Air-Cooled Drives Product Profile
PowerFlex 7000 Medium Voltage AC Drive (firmware revision 11or later) -
ForGe Control
PowerFlex 7000 HMI Offering with Enhanced Functionality
HMI Interface Board Software Updater and Firmware Download Procedure
Handling, Inspection, and Storage of Medium Voltage Line Filter Capacitors
Provides general guidelines for installing a Rockwell Automation industrial system.
Provides declarations of conformity, certificates, and other certification details.
You can view or download publications at http://www.rockwellautomation.com/global/literature-library/overview.page
.
To request paper copies of technical documentation, contact your local
Allen-Bradley distributor or Rockwell Automation sales representative.
10 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Introduction
Topology
Chapter
1
Overview of Drive
The PowerFlex® 7000 drive is a general-purpose, standalone, medium voltage drive. The drive controls speed, torque, direction, and the start and stops of standard asynchronous or synchronous AC motors. The PowerFlex 7000 works on numerous standard and specialty applications such as fans, pumps, compressors, mixers, conveyors, kilns, fan-pumps, and test stands. The
PowerFlex 7000 is used in industries such as petrochemical, cement, mining and metals, forest products, power generation, and water/waste water.
The PowerFlex 7000 drive meets most common standards from the National
Electrical Code (NEC), International Electrotechnical Commission (IEC),
National Electrical Manufacturers Association (NEMA), Underwriters
Laboratories (UL), and Canadian Standards Association (CSA). The
PowerFlex 7000 is available with most common supply voltages at medium voltage, from 2400...6600V.
The PowerFlex 7000 drive uses a pulse width modulated (PWM) – current source inverter (CSI) topology. This topology offers a simple, 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 6500V PIV rated power semiconductor devices, the number of inverter components is kept to a minimum. For example, only six inverter switchingdevices are required at 2400V, 12 at 3300...4160V, and 18 at 6600V.
The PowerFlex 7000 drive provides inherent regenerative-braking for applications where the load is overhauling the motor. Or where high inertia loads are slowed down quickly. Symmetrical gate-commutated thyristors
(SGCTs) are used for machine converter switches and line converter switches.
The PowerFlex 7000 drive provides a selectable option for enhanced torque control capabilities and increased dynamic control performance. This highperformance torque control (HPTC) feature delivers 100% torque at zero speed and provides torque control through zero speed with smooth direction transition.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 11
Chapter 1 Overview of Drive
Rectifier Designs
Configurations
The PowerFlex 7000 drive offers three rectifier configurations for "A" Frame drives:
• Direct-to-Drive™ (Active Front End [AFE] rectifier with integral line reactor and Common Mode Choke)
• AFE rectifier with separate isolation transformer
• AFE rectifier with integral isolation transformer
Direct-to-Drive
Direct-to-Drive technology does not require an isolation transformer or multiple rectifier bridges. Instead of multiple uncontrolled rectifiers, an AFE rectifier bridge is supplied. The rectifier semiconductors that are used are symmetrical gate commutated thyristors (SGCTs). Unlike the diodes that are used in VSI (voltage source inverter) rectifier bridges, SGCTs are turned on and off by a gating signal. A pulse-width modulation (PWM) gating-algorithm controls the firing of the rectifier devices, similar to the control philosophy of the inverter. The gating algorithm uses a specific 42 pulse switching-pattern
) called selective harmonic elimination (SHE) to mitigate the 5th,
7th, and 11th harmonic orders
Figure 1 - Typical PWM Switching-pattern, Line Voltage Waveform
12
An integral line reactor and capacitor addresses the high harmonic orders
(13th and above). The integral line reactor and capacitor also provide sinusoidal voltage and current waveforms back to the distribution system. The capacitor delivers excellent line-side harmonic and power factor performance to meet IEEE 519-1992 requirements and other global harmonic standards.
All while providing a simple, robust power structure that maximizes uptime by minimizing the number of discrete components and the number of interconnections required.
A common mode choke (CMC) mitigates the common mode voltage that is seen at the motor terminals. Standard (non-inverter duty rated) motors and motor cables can be used. This technology is ideal for motor retrofit applications.
An integral starter is offered as an option.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
LR
Overview of Drive Chapter 1
Figure 2 - 3300/4160V Direct-to-Drive (Transformerless AFE Rectifier)
Line Converter Common Mode Choke
L+ M+
Machine Converter
SGCTs SGCTs
U (T1)
V (T2)
W (T3)
1U
1V
1W
Remote ISTX
2U (X1)
2V (X2)
2W (X3)
LM-
AFE Rectifier with Separate Isolation Transformer
For applications when the line voltage is higher than the motor voltage, a transformer is required for voltage matching. In this case, providing an AFE rectifier with a separate isolation transformer is ideal (indoor and outdoor transformer versions are offered). The isolation transformer provides the input impedance (which replaces the integral line reactor) and addresses the common mode voltage (which replaces the CMC that is in the Direct-to-Drive rectifier configuration). However, the AFE rectifier, its operation, and advantages are the same as the Direct-to-Drive™ configuration.
Figure 3 - 3300/4160 AFE Rectifier with Separate Isolation Transformer
Line Converter
L+
DC Link
M+
Machine Converter
SGCTs SGCTs
U (T1)
V (T2)
W (T3)
LM-
AFE Rectifier with Integral Isolation Transformer
For applications that require a higher power rating than available with Directto-Drive, providing an AFE rectifier with an integral isolation transformer is ideal (indoor and outdoor transformer versions are offered). The isolation transformer provides the input impedance (which replaces the integral line reactor) and addresses the common mode voltage (which replaces the CMC in the Direct-to-Drive rectifier configuration). However, the AFE rectifier, its operation, and advantages are the same as the Direct-to-Drive configuration.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 13
Chapter 1 Overview of Drive
Internal ISTX
1U
1V
1W
2U (X1)
2V (X2)
2W (X3)
Figure 4 - 3300/4160 AFE Rectifier with Integral Isolation Transformer
Line Converter DC Link
L+ M+
Machine Converter
SGCTs SGCTs
LM-
U (T1)
V (T2)
W (T3)
Motor Compatibility
Motor Current
Motor Voltage
The PowerFlex 7000 achieves near sinusoidal current and voltage waveforms to the motor, with no significant additional heating or insulation stress. The motor that is connected to the VFD is typically 3 °C (5.4 °F) higher compared to across-the-line operation. Voltage waveform has dv/dt of less than 50V/μs.
Reflected wave and dv/dt issues that are often associated with VSI drives do not exist with the PowerFlex 7000. Typical motor waveforms are shown in
Figure 5 . These waveforms use a selective harmonic elimination (SHE) pattern
in the inverter to eliminate major order harmonics. And 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 unlimited. This technology can of control motors up to
15 km (9.3 miles) away from the drive.
Figure 5 - Motor Wave Forms at Full Load, Full Speed
300.00
Arms
200.00
100.00
0.00
-100.00
-200.00
-300.00
10.00K
7.50K
Vrms
5.00K
2.50K
0.00K
-2.50K
-5.00K
-7.50K
-10.00K
100.00
110.00
120.00
TIME (ms)
130.00
140.00
150.00
14 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Overview of Drive Chapter 1
Simplified Electrical
Drawings
2400V
Figure 6 - 2400V - Direct-to-Drive (Transformerless AFE Rectifier)
Line Converter Common Mode Choke
L+ M+
Machine Converter
SGCTs SGCTs
Optional Input Starter
L1
L2
L3
LR
U (T1)
V (T2)
W (T3)
Remote ISTX
LM-
Figure 7 - 2400 Volt – AFE Rectifier with Separate Isolation Transformer
Line Converter
DC Link
Machine Converter
L+ M+
SGCTs
SGCTs
1U
1V
1W
2U (X1)
2V (X2)
2W (X3)
U (T1)
V (T2)
W (T3)
1U
1V
1W
Integral ISTX
LM-
Figure 8 - 2400 Volt – AFE Rectifier with Integral Isolation Transformer
Line Converter
L+
DC Link
M+
Machine Converter
SGCTs SGCTs
2U (X1)
2V (X2)
2W (X3)
U (T1)
V (T2)
W (T3)
LM-
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 15
Chapter 1 Overview of Drive
3300/4160V
Figure 9 - Direct-to-Drive (Transformerless AFE Rectifier)
Line Converter Common Mode Choke Machine Converter
SGCTs SGCTs
Optional Input Starter
L1
L2
L3
LR
Remote ISTX
LM-
Figure 10 - AFE Rectifier with Separate Isolation Transformer
Line Converter
L+
%DC Link
M+
Machine Converter
SGCTs SGCTs
1U
1V
1W
2U (X1)
2V (X2)
2W (X3)
Integral ISTX
LM-
Figure 11 - AFE Rectifier with Integral Isolation Transformer
Line Converter
L+
DC Link
M+
Machine Converter
SGCTs SGCTs
1U
1V
1W
2U (X1)
2V (X2)
2W (X3)
LM-
U (T1)
V (T2)
W (T3)
U (T1)
V (T2)
W (T3)
U (T1)
V (T2)
W (T3)
16 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
6600V
Figure 12 - Direct-to-Drive (Transformerless AFE Rectifier)
LINE CONVERTER COMMON MODE CHOKE
L+ M+
MACHINE CONVERTER
SGCTs SGCTs
Overview of Drive Chapter 1
OPTIONAL INPUT STARTER
L1
L2
L3
LR
REMOTE
ISTX
1U
1V
1W
2U (X1)
2V (X2)
2W (X3)
LM-
Figure 13 - AFE Rectifier with Separate Isolation Transformer
LINE CONVERTER
L+
DC LINK
M+
MACHINE CONVERTER
SGCTs SGCTs
U (T1)
V (T2)
W (T3)
U (T1)
V (T2)
W (T3)
INTEGRAL
ISTX
1U
1V
1W
2U (X1)
2V (X2)
2W (X3)
LM-
Figure 14 - AFE Rectifier with Integral Isolation Transformer
LINE CONVERTER
L+
DC LINK
M+
MACHINE CONVERTER
SGCTs SGCTs
U (T1)
V (T2)
W (T3)
LM-
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 17
Chapter 1 Overview of Drive
18
Safe Torque Off
Safe Torque Off is a functional safety feature that is integrated into the
PowerFlex 7000, available for Active Front End (AFE) and Direct-to-Drive configurations. The drive can receive a safety input signal (for example, from an optical sensor or a safety gate). Then remove rotational power from the motor to allow the motor to coast to a stop. After the Safe Torque Off command is initiated, the drive will declare it's in the safe state. The drive itself remains powered and the safe state is reliably monitored to make sure that no rotational torque can be delivered to the motor. The drive can return rotational power to the motor after Safe Torque Off condition has been reset.
Speed
Figure 15 - Safe Torque Off
Stop Request
Stop Time
Time
Coast
Motor Power
Time
An internal safety relay provides for the safety input and reset circuits.
Safe Torque Off can be used in Active Front End (AFE) and Direct-to-Drive rectifier drive configurations for A, B, and C frames. Safe Torque Off cannot be used for parallel drives, N+1, N-1, synchronous transfer and 18 pulse drive configurations.
This feature TÜV certified for use in safety applications up to and including safety integrity level 3 (SIL3) and Category 3, Performance Level e (Cat 3,
PLe). More information on functional safety and SIL and PL ratings can be found in the following standards:
• EN 61508
• EN 62061
• EN 61800-5-2
• EN 13849-1
See publication 7000-UM203 for more information that is related to the functional safety option.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Operator Interface
Overview of Drive Chapter 1
The HMI Interface Board is an HMI-enabling device for the PowerFlex 7000 drive. The HMI Interface Board accesses all necessary executable tools, documentation, and reports required to commission, troubleshoot, and maintain the drive.
By way of the HMI Interface Board, you can choose the style and size of the desired Windows-based operator terminal to interact with the drive. For example, PanelView™ CE terminal, laptop, or desktop computer). The HMI
Interface Board removes past issues with compatibility between the drive and configuration tools, as all necessary tools are acquired from the drive.
The HMI Interface Board is well suited for applications that require remote placement of the operator terminal and remote maintenance.
Figure 16 - Operator Interface
Basic Configurations
There are three basic configurations for the HMI:
• Remote mounted
• Locally mounted
• No HMI supplied
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 19
Chapter 1 Overview of Drive
Remote-mounted HMI
The HMI is not mounted in the traditional location on the low voltage door of the Variable Frequency Drive (VFD). A remote mounting plate, complete with
E-stop push button, and HMI is supplied loose for the customer to mount wherever desired. The HMI connects to the VFD by way of a hardwired
Ethernet cable. There is no significant functional distance-limit, which is ideal for non-PLC users wanting to control and monitor remotely. For example, at the driven machine or control room. This usage is ideal for customers who have control policies in place. These policies must control the access to medium voltage equipment and the associated requirements of PPE when using the operator interface at the VFD.
Locally Mounted HMI
Similar to the previously offered PanelView™ 550, the HMI is mounted on the
LV door of the VFD. There is also a service access port (RJ45 connector) on the LV door.
No HMI Supplied
A service access port (RJ45 connector) is on the LV door of the VFD.
Customers use their own laptop as the HMI. All programs that are required to use the laptop as the HMI are stored in the VFD. The laptop is connected to the VFD by way of a hardwired Ethernet cable, when required. This connection is ideal for unmanned sites, where a dedicated HMI is not required.
See Publication 7000-UM201 for detailed instruction for the HMI.
See Publication 7000A-UM151 for detailed instruction for “A” Frame drives that use the PanelView 550 HMI.
20 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Chapter
2
Drive Installation
Safety and Codes
ATTENTION: The Canadian Electrical Code (CEC), National Electrical Code
(NEC), or local codes outline provisions for safely installing electrical equipment. Installation MUST comply with the specifications for wire type, conductor sizes, branch circuit protection, and disconnect devices. Failure to do so can result in personal injury and/or equipment damage.
Drive Storage
Siting of the Drive
If the drive must be stored, be certain to store the drive in a clean, dry, dust free area.
Storage temperature must be maintained between -40…+70 °C
(-40…+158 °F). If storage temperature fluctuates or if humidity exceeds 95%, use space heaters to minimize condensation. Store the drive in a heated building with adequate air circulation. Do not store the drive outdoors.
Site Considerations
The standard environment in which the equipment is designed to operate is:
• Elevation above sea level less than 1000 m (3250 ft).
• Ambient air temperature between 0…40 °C (32…104 °F).
• Relative humidity of the air not to exceed 95% noncondensing.
For the equipment to operate in conditions other than conditions specified consult the local sales office of Rockwell Automation.
The equipment requires the following site conditions:
• Indoor installation only, no dripping water, or other fluids.
• Clean air to cool equipment according to requirements.
• Level floor for anchoring the equipment. See dimension drawings for the location of the anchoring points.
• The room in which the equipment is located must allow for all equipment doors to be fully opened, typically 1200 mm (48 in.). Allow adequate clearance for over the drive for fan removal, greater than
700 mm (27.5 in.).
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 21
Chapter 2 Drive Installation
• Allow the air for cooling, to exit the drive freely at the top. The flow of air for cooling into and out the drive must be kept clear and uninhibited.
• The room in which the equipment is located must be large enough to accommodate the thermal losses of the equipment. The rated maximum air temperature must not be exceeded; air conditioning may be required.
The heat created by the drive is directly proportional to the power of the motor being driven and the efficiency of equipment within the room.
When thermal load data is required, contact the Rockwell Automation sales office.
• The area in which the drive is located must be free of radio frequency interference such as encountered with some welding units. Radio frequency interference can cause erroneous fault conditions and shut down the drive.
• The equipment must be kept clean. Dust in the equipment decreases system reliability and inhibits equipment cooling.
• Power cable lengths to the motor are unlimited due to the near sinusoidal voltage and current waveforms. Unlike voltage source drives, there are no capacitive coupling, dv/dt, or peak voltage issues that can damage the motor insulation system. The topology that is used in the
PowerFlex™ 7000 medium voltage AC drive does not produce dv/dt or peak voltage problems. PowerFlex 7000 has been tested with motors located up to 15 km (9.37 miles) from the drive.
• Only personnel familiar with the function of the drive must have access to the equipment.
• The drive is designed for front access and must be installed with adequate clearance to allow for total door opening. The back of the unit can be placed against a wall although some customers prefer back access also.
ATTENTION: An incorrectly applied or installed drive can result in component damage or a reduction in product life. Ambient conditions not within the specified ranges can result in malfunction of the drive.
Generator Note
ATTENTION: Verify that the load is not turning due to the process. A freewheeling motor can generate voltage that is back-fed to the equipment that is being worked on.
22 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Installation
Drive Installation Chapter 2
When the drive has been placed at its installation area:
1. Remove the lag bolts that fasten the shipping skid to the drive.
2. Move the drive off the shipping skid and discard the skid.
3. Position the drive in its desired location.
4. Verify that the drive is on a level surface and that the position of the drive is vertical when the anchor bolts are installed.
The location of the anchor points is provided with the dimension drawing of the drive.
5. Install and tighten the anchor bolts. (M12 or 1/2 in. hardware required). The engineering bolt systems are required for seismic requirements. Consult the factory.
6. Remove the top lifting angles, retain the hardware.
7. Install the hardware from the lifting angles in the tapped holes at the top of drive. The hardware blocks leakage of cool air and keeps dust out of the equipment.
Shock Indication Labels
Shock indication labels are devices that permanently record the physical shock to which equipment is subjected.
At the time of final preparation for shipment from the factory, a shock indication label is installed on the outside door of the converter cabinet.
During the shipping and installation process, drives can inadvertently be subjected to excess shock and vibration, which can impair its functionality.
When the drive has been placed in its installation area, inspect the shock indication labels on the outside of the door.
The drive is shipped with a label that records shock levels in excess of 10G. If these shock levels have been attained, the chevron shaped window appears blue in one of the two windows.
If the shock indicator is blue, contact Rockwell Automation® Product Support
Group in Cambridge, Ontario, Canada. The drive can have internal damage if physical shock was experienced during shipment or installation.
If the indicators show that no shock was attained, full inspection and verification in accordance with the Commissioning process that is outlined in
is still essential.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 23
Chapter 2 Drive Installation
Figure 17 - Shock Indicator
Red Plastic Housing
Window area appears black if subjected to shock.
51 mm
(2.0)
21 mm
(0.8)
Installation of Exhaust Air Hood
On the top of the cabinet, along with the cooling fan, a sheet-metal exhaust hood is installed. The components to compose the exhaust hood have been packaged and shipped with the drive. For drives with an acoustic hood, the components are shipped assembled. See Figure 19 .
1. Remove the protective plate that covers the fan opening on the drive.
The protective plate is a flat cover plate that is bolted to the top plate.
2. Remove the bolts and plate and set aside for reuse.
3. Loosely assemble the two L-shaped panel components that are shipped with the drive as per Figure 18 .
24 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Figure 18 - Fan Hood Assembly
Drive Installation Chapter 2
Flat Plate (1)
Exhaust Hood Panels (2)
M6 thread forming screws (20)
Figure 19 - Acoustic Fan Hood Assembly
All components are shipped assembled.
4. Locate the exhaust hood on top of the cabinet per Figure 20 and reinstall the original cover plate that was set aside.
Care must be taken that the notches on the bottom flange are oriented toward the sides of the drive.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 25
Chapter 2 Drive Installation
5. Affix assembly to the drive top plate.
6. Tighten all hardware.
For drives with an acoustic hood (shown in Figure 19 ), locate the exhaust hood
(refer to Figure 21 ).
ATTENTION: Any screws that are accidentally dropped in the equipment must be retrieved as damage or injury can occur.
Figure 20 - Fan Hood Installation
Assembled Exhaust Hood
M6 Screw (12)
Verify that notch orientation to sides
26 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Drive Installation Chapter 2
Figure 21 - Acoustic Fan Hood Installation
Assembled Acoustic
Exhaust Hood
M6 Screw (11)
Remove existing screw and reinsert with Hood.
Top Plate for Converter and
Common Mode Choke/DC
Link Cabinet
Installation of Redundant Fan Assembly
There are three redundant fan assemblies available. The redundant fan components are shipped assembled ( Figure 22 ).
Figure 22 - Redundant Fan Assemblies
Standard Design IP42 Design 14RD Design
1. Remove and discard the protective plate and associated hardware that covers the fan opening on the cabinet.
2. Remove the top cover of the fan housing and set the top cover aside.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 27
Chapter 2 Drive Installation
3. Remove the shipping cover plate on the bottom of the redundant fan assembly and discard.
4. Position the assembly over the opening, verify that the locating hole on the housing base aligns with the front right side of the cabinet.
5. Align the mounting holes and wire harness connections.
Figure 23 - Redundant Fan Assembly Orientation
Remove cover to install housing.
M8 Screw (12)
FRONT
6. Affix the redundant fan assembly to the drive top plate with the M6 thread screws provided.
7. Connect the fan wire harness to fan.
8. Reinstall the top cover onto the fan housing and tighten all hardware.
28 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Drive Installation Chapter 2
Installation of Integral Transformer Cooling Fan
1. Remove and discard the protective plate that is covering the opening for the fan on the top of Isolation Transformer cabinet.
2. Locate the cooling fan on top of the cabinet. Position the cooling fan over the opening and align the mounting holes and wire harness connections.
3. Affix the fan to the drive top plate with the M6 screws provided.
4. Connect the wire harness to fan.
Figure 24 - Fan Installation for Integral Isolation Transformer
Assembled Exhaust Hood
M6 Screw (6)
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 29
Chapter 2 Drive Installation
Neutral Resistor Assembly
Figure 25 - Hood Assembly for Neutral Resistor
Top Plate for Neutral
Resistor Housing
Ground resistor hood here
Attach ground to top plate.
Line filter capacitors
Top plate for converter and common mode choke cabinet
900 mm converter -
800 mm common mode choke cabinet
Neutral Resistor Assembly
See electrical drawings to verify cable rating and to connect neutral resistor assembly.
Motor filter capacitors
30 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Figure 26 - Acoustic Hood Assembly for Neutral Resistor
Hood Ground Stud
Remove existing
M6 Screws
(11)and reinsert with hood.
Drive Installation Chapter 2
Assembled Acoustic
Exhaust Hood
Top Plate for Converter and Common
Mode Choke/DC Link Cabinet
M6 Screw (x6) Ground Exhaust
Hood (use Green
M6 Screw)
Neutral Resistor
Assembly
Installation of Neutral Resistor Assembly (Direct-to-Drive)
On top of the converter cabinet, install the sheet metal enclosure that contains power resistors.
1. Locate the resistor assembly on top of the cabinet as shown in Figure 25
(For acoustic hood assembly, refer to Figure 26 ).
2. Affix the assembly to the top plate using M6 screws provided.
3. Remove the top plate of the resistor assembly for access to the wiring connection points.
4. Connect the resistor wiring according to the electrical drawing that is provided with the drive. A typical connection diagram is shown in
Figure 25 .
5. Route the resistor wiring through the hole with a plastic bushing. Avoid damaging the wire insulation.
6. Connect the ground connection of the housing for the neutral resistor assembly to the top plate of the drive.
7. Reinstall the top plate of the neutral resistor housing.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 31
Chapter 2 Drive Installation
Cabinet Layout and
Dimensional Drawings of
Drive
The dimension drawing ( Figure 27
) is a sample and does not accurately detail your drive. The dimension drawing is provided here to give you a general overview of a typical drive.
The Dimensional Drawings are order-specific and shows the information that is outlined.
The dimension drawing provides important information for the installation of the equipment.
The FLOOR PLAN shows:
• The locations for anchoring the equipment to the floor (balloon D).
• Size and location of bottom openings for the power cable entry
(balloons A and B).
• Size and location of the bottom openings for the control wiring entry
(balloon C).
The ROOF PLAN shows:
• Size and location of the top openings for the power cable entry (balloons
A and B).
• Size and location of the top openings for the control wiring entry
(balloon C).
• Minimum aisle clearance in front of equipment (balloon M).
The FRONT VIEW shows:
• Minimum clearance that is required at top of drive for fan maintenance
(balloon K).
32 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Figure 27 - PowerFlex 7000 “A” Frame Dimensional Drawing
Drive Installation Chapter 2
SAMPLE
IMPORTANT Contact Factory for Seismic Mounting Information.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 33
Chapter 2 Drive Installation
Drive Layout
Figure 30 show the typical layout of the three main configurations
of the PowerFlex 7000 “A” frame drive.
Figure 28 - Direct-to-Drive™ (AFE with DTD DC Link)
34
Line Reactor/Starter
Cabling Cabinet
Converter Cabinet
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Control Link/Fan Cabinet
Figure 29 - AFE Rectifier (Separate Isolation Transformer)
Drive Installation Chapter 2
Cabling Cabinet
Converter Cabinet
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Control Link/Fan Cabinet
35
Chapter 2 Drive Installation
Figure 30 - AFE Rectifier (Integral Isolation Transformer)
36
Isolation Transformer and
Cabling Cabinet
Converter Cabinet
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Control Link/Fan Cabinet
Drive Installation Chapter 2
IEC Component and Device
Designations
PowerFlex 7000 MVD electrical drawings use conventions that are based on
IEC (International Electrotechnical Commission) standards, while remaining compatible with North American ANSI (American National Standards
Institute) standards. The symbols that are used to identify components on the drawings are international. A full listing of the symbols is given as part of each
PowerFlex 7000 electrical drawing (ED) set. The device designations that are used on the drawings and labels are also listed with explanations on each drawing set.
The identification of wiring uses a source/destination wire number convention on point-to-point multi-conductor wiring and in situations where the system is warranted. The wire-numbering system of unique, single numbers for multidrop and point-to-point wiring continues to be used for general control and power wiring. The wiring that connects between the sheets or that ends at one point and starts at another point on a drawing has an arrow and a reference to a drawing. The arrow and reference indicate the ongoing connection. The drawing reference indicates the sheet and the X/Y coordinates of the continuation point. The reference system is explained on a sheet in each drawing set. The system for unique wire numbers serves as confirmation that the correct wire is being traced from sheet to sheet or across a drawing.
Typically wires are identified with color rather than by number, in multiconductor cables. The abbreviations that are used to identify the colors on the drawings are fully identified on a sheet in the drawing set.
Selection of Power Wiring
The following tables identify general wire selections that are encountered when installing the PowerFlex 7000 “A” frame drive line-up.
General Notes
For proper start-up and operation, follow the recommendation for the medium voltage drive insulation-levels for field power cables. The cable insulation level must be increased over that which would be supplied for an Across-the-line application with the same rated line-to-line voltage.
Based on the distribution system design-criteria, either shielded or unshielded cable can be used. However, NEC requires shielded cables for installations above 2 kV.
Cable Insulation
The cable insulation requirements for the PowerFlex 7000 “A” frame drive are given in the following tables.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 37
Chapter 2 Drive Installation
38
ATTENTION: Voltage ratings that are shown in
are peak line-to-ground. Some cable manufacturers, rate voltage line-to-line RMS.
Verify that the cable meets the rating that is specified in the following tables.
Table 1 - Cable Insulation Requirements for AFE Drives with Separate Isolation Transformer
System Voltage (V, RMS)
2400
3000
3300
4160
6000
6300
6600
≥
4.1
≥
5.12
≥
5.63
≥
7.1
≥
10.8
≥
11.4
≥
11.8
Cable Insulation Rating (kV)
(Maximum Peak Line-to-Ground)
(1)
Machine Side
≥
2.2
≥
2.75
≥
3.0
≥
3.8
≥
5.5
≥
5.8
≥
6.0
(1) Cabling from the secondary side of isolation transformer to input of VFD
2400
3000
3300
4160
6000
6300
6600
Table 2 - Cable Insulation Requirements for “Direct-to-Drive” Technology or Integral Isolation
Transformer
System Voltage (V, RMS) Cable Insulation Rating (kV)
(Maximum Peak Line-to-Ground)
Line Side
≥
2.2
≥
2.75
≥
3.0
≥
3.8
≥
5.5
≥
5.8
≥
6.0
Machine Side
≥
2.2
≥
2.75
≥
3.0
≥
3.8
≥
5.5
≥
5.8
≥
6.0
Table 3 identifies general wire categories that are encountered when installing the PowerFlex 7000 “A” frame drive. Each category has an associated wire group number that is used in the following sections to identify the wire to be used. Application and signal examples along with the recommended type of cable for each group are provided. A matrix providing the recommended minimum spacing between different wire groups that are run in the same tray or separate conduit is also provided.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Drive Installation Chapter 2
Wire
Category
Power
Wire
Group
1
Control
Signal
2
3
4
5
6
Table 3 - Wire Group Numbers
Application Signal Example Recommended
Cable
AC Power
(> 600V AC)
2.3 kV, 3Ø
AC Lines
Per IEC / NEC
Local Codes and
Application
Requirements
For Tray: Recommended spacing between different wire groups in the same tray.
For Conduit: Recommended spacing for wire groups in separate conduit – mm (inches)
Wire
Group
In Tray
Power
1
228.6
(9.00)
Power
2
228.6
(9.00)
Control
3
228.6
(9.00)
Control
4
228.6
(9.00)
Signal
5
Signal
6
AC Power
(TO 600V AC)
480V, 3Ø Per IEC / NEC
Local Codes and
Application
Requirements
Between
Conduit
In Tray 228.6
(9.00)
76.2 (3.00)
Between Conduit
228.6
(9.00)
152.4
(6.00)
152.4
(6.00)
115V AC or
115V DC
Logic
Relay Logic
PLC I/O
Per IEC / NEC
Local Codes and
Application
Requirements
Between
Conduit
In Tray 228.6
(9.00)
76.2 (3.00)
Between Conduit
152.4
(6.00)
228.6
(9.00)
152.4
(6.00)
115V AC
Power
24V AC or
24V DC
Logic
Power Supplies
Instruments
PLC I/O Per IEC / NEC
Local Codes and
Application
Requirements
Between
Conduit
In Tray 228.6
(9.00)
76.2 (3.00)
Between Conduit
152.4
(6.00)
152.4
(6.00)
228.6
(9.00)
Between
Conduit
76.2 (3.00) Between Conduit
Analog Signals
DC Supplies
5-24V DC
Supplies
Belden 8760
Belden 8770
Belden 9460
Digital
(Low Speed)
Digital
(High Speed)
Power Supplies
TTL Logic Level
Pulse Train
Input Tachometer
PLC
Communications
Belden 8760
Belden 9460
Belden 9463
All signal wiring must be run in separate steel conduit.
A wire tray is not suitable.
The minimum spacing between conduits containing different wire groups is 76.2 mm (3 inches).
Belden 8760 - 18 AWG, twisted pair, shielded
Belden 8770 - 18 AWG, 3 conductor, shielded
Belden 9460 - 18 AWG, twisted pair, shielded
Belden 9463 - 24 AWG, twisted pair, shielded
Note 1: Steel conduit or cable tray can be used for all PowerFlex 7000 Drive power or control wiring, and steel conduit is required for all PowerFlex 7000 Drive signal wiring. All input and output power wiring, control wiring, or conduit must be brought through the entry holes for the drive conduit of the enclosure. Use appropriate connectors to maintain the environmental rating of the enclosure. The steel conduit is REQUIRED for all control and signal circuits, when the drive is installed in European Union countries. The connection of the conduit to the enclosure must be on full 360° and the ground bond at the junction must be less than 0.1 ohms. In EU countries, the usual practice is to install the control and signal wiring.
Note 2: The space between wire groups is the recommended minimum for parallel runs of 61 m (200 ft) or less.
Note 3: The customer is responsible for the grounding of shields. On drives that are shipped after November 28/02, the shields are removed from the drive boards. On drives that are shipped before November 28/02, all shields are connected at the drive end.
These connections must be removed before grounding the shield at the customer end of the cable. Shields for cables from one enclosure to another must be grounded only at the source end cabinet. If shielded cables must be spliced, the shield must remain continuous and insulated from ground.
Note 4: AC and DC circuits must be run in separate conduits or trays.
Note 5: Voltage drop in motor leads can adversely affect motor start and run performance. Installation and application requirements can dictate that larger wire sizes than indicated in IEC / NEC guidelines are used.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 39
Chapter 2 Drive Installation
Power Cabling Access
The wire sizes must be selected individually. Observe all applicable Safety and
CEC, IEC, or NEC regulations. The minimum wire-size allowed does not necessarily result in most economical operation. The minimum recommended size for the wires between the drive and the motor is the same as the one used with an across-the-line starter. The distance between the drive and motor can affect the size of the conductors used.
Consult the wiring diagrams and appropriate CEC, IEC, or NEC regulations to determine correct power wiring. If assistance is needed, contact your
Rockwell Automation Sales Office.
The drive is designed for the power cable to enter from either the top or bottom.
Cable access plates are on the top and bottom plates of the connection cabinet and identified by the customer-specific dimension drawing (DD).
Access the Customer Power Cable-terminations
Cable connections are located behind the medium voltage door of the
Connection/Cabling cabinet. Locations of power terminals for various drive configurations are indicated in
.
To facilitate the routing of line cables when cabling a cabinet with starter, remove internal barriers and duct covers on the left side of the cabinet.
1. Remove and retain the hardware from the barrier/cover.
2. Side barrier/cover toward the front of the cabinet for removal.
3. To allow routing and termination of line cables, remove the fan housing and cover plate (if installed) on the top of the cabinet,
4. Replace all barriers/covers by reversing the sequence, before applying medium voltage.
The installer is responsible for modifying the plate for power cable access, to suit their requirements.
Appropriate connectors must be used to maintain the environmental rating of the enclosure.
40 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Power Connections
Drive Installation Chapter 2
The installer must verify that interlocking with the upstream power source has been installed and is functioning.
The installer is responsible for verifying that power connections are made to the equipment in accordance with local electrical codes.
The drive is supplied with provision for cable lugs. The power terminals are identified as follows:
Line/Motor Terminations
• Drives with Connection to remote transformers: 2U, 2V, 2W
• Drives with integral transformers: 1U, 1V, 1W
• Drives with integral line reactor and input starter: L1, L2, L3
• Motor Connections: U, V, W
• Drives with integral line reactor, no input starter: 1U, 1V, 1W
Installation Requirements for Power Cabling
To determine cable distance from top or bottom of input cabinet to
termination points, refer to Figure 31
,
.
The installer is responsible for verifying that power connections are made with
appropriate torque (see page 183
).
The drive is supplied with provision for grounding of cable shields and stress cones near the power terminals.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 41
Chapter 2 Drive Installation
Cable Entry Location
(Top Load/Motor Entry)
Top Cable Entry)
190.6
[7.50]
700.0
[27.56]
Figure 31 - Dimension Views of Direct-to-Drive™ (AFE with DC Link) with Input Starter
411.9 [16.22]
284.9 [11.22]
157.9 [6.22]
L1 L2 L3
242.5 [9.55]
Note: To access line cable, the fan housing and assembly must first be removed.
Line Cables
Removeable Barrier for Cable Routing
2314.6
[91.12]
Motor Cables
U, V, W
100.2
[3.94]
597.5
[23.52]
214.5 [8.44]
328.8 [12.94]
1324.8
[52.16]
2033.2
[80.05]
Bottom Cable Entry)
Right-hand side sheet is removed for clarity.
42 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Section B-B
Cable Entry Location
(Top)
Drive Installation Chapter 2
Figure 32 - Dimension Views of Direct-to-Drive™ (AFE with DC Link) without Input Starter
700.00
[27.56]
1133.0
[44.61]
209.6
[8.25]
2314.6
[91.12]
480.5
[18.92]
Line Cables
L1,L2,L3
Motor Cables
Section A-A
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 43
Chapter 2 Drive Installation
Figure 33 - Dimension Views of AFE Rectifier with Separate Isolation Transformer
2314.6
[91.12]
112.8
[4.44]
1409.4
[55.49]
1180.8
[46.49]
952.2
[37.49]
44 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Section A-A
Drive Installation Chapter 2
Figure 34 - Dimension Views of AFE Rectifier with Integral Isolation Transformer
Section A-A
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 45
Chapter 2 Drive Installation
Power and Control Wiring
Drive line-ups (for example, a drive and input starter) that are delivered in two or more sections must be reconnected. After the sections are reassembled, the power and control wiring must be reconnected as per the schematic drawings provided.
Control Cables
Control cable entry/exit must be located near the terminal block 'TBC' – route the customer connections along the empty side of the TBC terminals.
These terminals are sized to accept a maximum #14 AWG. Connect the low voltage signals (includes 4...20 mA0). Use twisted shielded cable, with a minimum #18 AWG.
Of special concern is the tachometer signal. Two tachometer inputs are provided to accommodate a quadrature tachometer (senses motor direction).
The tachometer power supply is isolated and provides 15V and a ground reference. Many tachometer outputs have an open collector output, in which case a pull-up resistor must be added to make sure that proper signals are fed to
the system logic (see page 165
).
IMPORTANT To Connect Low voltage signals, use twisted shielded cable with the shield that is connected at the signal source end only. Wrap the shield at the other end with electrical tape and isolated. Make connections as shown on the electrical drawings (ED) provided.
Grounding Practices
The purpose of grounding is to:
• Provide for the safety of personnel.
• Limit dangerous voltages on exposed parts concerning ground.
• Facilitate proper over current device operation under ground fault conditions.
• Provide for electrical interference suppression.
IMPORTANT Generally, external grounding of equipment must be in accordance with the
Canadian Electrical Code (CEC), C22.1 or the National Electrical Code (NEC),
NFPA 70 and applicable local codes.
See the grounding diagrams that follow for ground connections. The main ground bus of the drive must be connected to the system ground. This ground bus is the common ground point for all grounds internal to the drive.
46 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Drive Installation Chapter 2
Figure 35 - Ground Connection Diagram with Isolation Transformer
Isolation Transformer
2U
2V
Output
Ground
Network
Connected to the neutral point of the capacitor
AC Motor
U (T1)
V (T2)
2W
W (T3)
Ground Bus
Figure 36 - Ground Connection Diagram with Line Reactor
Transformer
2U
AC Line Reactor
Converter
2V
2W
Inverter
Ground Bus
U (T1)
V (T2)
W (T3)
AC Motor
Each power feeder from the substation transformer to the drive must be provided with properly sized ground cables. Do Not use the conduit or cable armor as a ground.
If a drive isolation transformer is used, the WYE secondary neutral point must not be grounded.
Each AC motor frame must be bonded to grounded steel of a building, within
6 m (20 ft) of its location. Tied the motor frame to the drive ground bus by way of ground wires within the power cables and/or conduit. The conduit or cable armor must be bonded to ground at both ends.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 47
Chapter 2 Drive Installation
Drive Signal and Safety Grounds
When interface cables that carry signals (where the frequency does not exceed
1 MHz) are attached for communications with the drive, these general guidelines must be followed:
• Do not form a pigtail that is grounded at one point. Ground the mesh of a screen around its whole circumference.
• Coaxial cables with one conductor and a mesh screen that surrounds it, must have the screen that is grounded at both ends.
• Where a multi-layer screened cable is used (that is, a cable with both a mesh screen and a metal sheath or some form of foil), there are two alternative methods:
• The mesh screen can be grounded at both ends to the metal sheath.
The metal sheath or foil (known as the drain) must, unless otherwise specified, be grounded at one end only. Ground at the receiver end or the end that is physically closest to the main-equipment ground bus.
• The metal sheath or foil can be left insulated from ground and the other conductors and the mesh cable screen that is grounded at one end only.
For Customers and Power Integrators
An external ground must be attached to the main ground bus. The grounding means must comply with applicable local codes and standards. As general guidelines, for information only, the ground path must be of sufficiently low impedance and capacity that:
• The rise in potential of the drive ground point when subjected to a current of twice the rating of the supply must be no higher than 4V over ground potential.
• The current flowing into a ground fault is of sufficient magnitude to cause the protection to operate.
The main grounding conductor must be run separately from power and signal wiring so that faults:
• Do not damage the grounding circuit.
• Do not interfere with or damage, protection, or the metering systems.
Or cause undue disturbance on power lines.
48 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Interlocking
Drive Installation Chapter 2
Identification of Types of Electrical Supplies - Grounded and
Ungrounded Systems
With an ungrounded, three-phase electrical supply system, the cable insulation must handle the phase to phase voltage and the voltage to ground. This guideline is in case one of the other phases develops a ground fault. The cable insulation, at minimum, must be good for a continuous voltage of root three
(1.732) times (1.1) times the rated voltage of the supply.
(1.732 x 1.1 = 1.9 times the rated line-to-line voltage).
Ground Bus
The drive ground bus runs along the top of the drive at the front. The ground bus is at the top of each of the drive enclosures. The ground bus is accessible when the enclosure door is opened (and the low voltage compartment is hinged out in the case of the DC link/fan cabinet). The installer must verify that the drive is grounded properly, typically at the point on the ground bus in the cabling cabinet, close to the line cable terminations.
Key interlocking, is used for safety and to restrict access to the medium voltage areas of the drive. The upstream power must be locked in the off position for access to the medium voltage compartments of the equipment.
The key interlocking prohibits the upstream power being applied, until the access doors of the medium voltage drive are closed and locked shut.
It is the responsibility of the installer to verify that the key interlocking is installed properly to the upstream equipment.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 49
Chapter 2 Drive Installation
Notes:
50 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Chapter
3
Power Component Definition and Maintenance
Cabling Cabinet Components
Figure 37 - Direct-to-Drive with UPS Option
Line Cable Terminations
Low Voltage Compartment
UPS
Hall Effect Sensors
Current Transformers
Control Power
Transformer Fuses Motor Cable Terminations
AC Line Reactor
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Chapter 3 Power Component Definition and Maintenance
Figure 38 - Direct-to-Drive with Optional Input Starter
Line Cable Terminations
(Behind Disconnect Switch)
Fused Disconnect Switch
Disconnect Switch
Operating Handle
Vacuum Contactor Assembly
Control Power
Transformer
Motor Cable Terminations
(Hall Effect Sensors Behind)
Control Power
Transformer Fuses
AC Line Reactor
52 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Power Component Definition and Maintenance Chapter 3
Figure 39 - AFE Rectifier with Isolation Transformer
Low Voltage Wireway
Current Transformer
Line Cable Terminations
Current Transformer
Control Power Transformer Fuses
Hall Effect Sensor
Motor Cable Terminations
Hall Effect Sensor
Fan-control Power Transformer
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 53
Chapter 3 Power Component Definition and Maintenance
Figure 40 - AFE Rectifier with Integral Isolation Transformer
Fan Housing
Top Cable Entry and Exit Locations
Ground Bus
Hall Effect
Sensors
Line Cable
Terminations
Motor Cable
Terminations
Current
Transformers (CT)
Integral
Isolation
Transformer
A
54
SECTION A-A
Side View
Bottom Cable Entry and Exit Locations
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Front View
A
Hall Effect Sensor
Replacements
Power Component Definition and Maintenance Chapter 3
1. Verify that there is no power to the equipment.
ATTENTION: To avoid electrical shock, verify that the main power has been disconnected before working on the Hall Effect sensor. Verify that all circuits are voltage free. Use a hot stick or appropriate voltage-measuring device.
Failure to do so can result in injury or death.
2. Note the location of all wires and the orientation of the Hall Effect sensor. For quick reference when checking the orientation of the Hall
Effect sensor, look for the white arrow.
IMPORTANT The Hall Effect sensor and wires must be in the proper orientation. Note the position before disassembly.
3. The load cable must be disassembled to allow removal of the Hall Effect sensor. Remove the hardware and slide out the cable out.
4. Remove the plug that connects the sensing wire to the Hall Effect sensor.
5. Remove the four screws on the base of the Hall Effect sensor, and remove the Hall Effect sensor.
6. Replace the Hall Effect sensor. The arrow must be oriented as shown in
.
7. Slide the load cable back into place and secure the hardware.
8. Plug the connector back into the sensor. The plug is keyed to avoid incorrect connection.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 55
Chapter 3 Power Component Definition and Maintenance
Figure 41 - Hall Effect Sensor (Located Within Cabinet with Detail)
Hall Effect Sensor
(Detail A)
Detail A
Hall Effect Sensors
(Detail C)
Detail B
Hall Effect Sensor
(Detail B) Cabling Cabinet Detail C
Line Reactor /
Starter Cabinet
Current Transformer
Replacement
56
1. Verify that there is no power to the equipment.
ATTENTION: To avoid electrical shock, verify that the main power has been disconnected before working on the current transformer. Verify that all circuits are voltage free. Use a hot stick or appropriate voltage-measuring device. Failure to do so can result in injury or death.
2. Note the location of all wires and the orientation of the CT. For quick reference when checking the orientation of the CT, look for the white dot.
IMPORTANT The CT and wires must be in the proper orientation. Note the position before disassembly.
3. Disconnect the wires.
4. The line cable must be disassembled to allow removal of the CT.
5. Remove the hardware and slide the cable out.
6. Remove the two screws that are located in the base of the CT and remove the CT.
7. Replace the CT.
8. Verify the proper orientation.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Power Component Definition and Maintenance Chapter 3
9. Fasten the CT securely with the two screws in the base.
10. Reconnect the ring lugs.
11. Slide the line cable back into place
12. Secure the hardware.
Figure 42 - Replacement of Current Transformer
Current Transformer (CT)
Cabling Cabinet Line Reactor / Starter Cabinet
Current Transformer
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 57
Chapter 3 Power Component Definition and Maintenance
Converter Cabinet
Components
Figure 43 - Converter Cabinet Components (2400V Version)
Inverter Modules
Isolated Gate Driver
Power Supplies (IGDPS)
Rectifier Modules
58
Voltage Sensing Boards
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Rectifier IGDPS
(not required in drives with SPS boards installed)
Isolated Gate Driver
Power Supplies (IGDPS)
Power Component Definition and Maintenance Chapter 3
Figure 44 - Converter Cabinet Components (3300/4160V Version)
Inverter Modules
Rectifier IGDPS
(Not required in drives with SPS boards installed)
Voltage Sensing Boards
Rectifier Modules
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 59
Chapter 3 Power Component Definition and Maintenance
Figure 45 - Converter Cabinet Components (6600V Version)
Inverter
Modules
Isolated Gate Driver
Power Supplies
(IGDPS)
Rectifier
Modules
60
Voltage Sensing
Boards
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Rectifier IGDPS
Not required in drives with SPS boards installed)
Converter Cabinet
Power Component Definition and Maintenance Chapter 3
The converter cabinet contains three rectifier modules and three inverter
shows a 3300/4160V converter with a PWM Rectifier.
Isolated Gate Driver Power Supplies (IGDPS) are mounted on the right side of the cabinet for 6600V, 2400V Drives. On the left side of the cabinet for 3300V,
4160V Drives.
Thermal sensors are installed on the top module of the inverter and rectifier.
The exact location depends on the drive configuration.
Voltage-sensing Assembly
The voltage-sensing assembly consists of two voltage sensing boards, a mounting plate, and a protective cover. Every voltage sensing assembly has six independent channels. These channels convert voltages from up to 10,800V
(7.2 kV @ 1.5 pu) to lower voltage levels, which are used by the PowerFlex®
7000 control logic. For drives that require the synchronous transfer option, one extra assembly is used. This extra assembly uses a separate connector to output the transfer voltages directly to the ACB board.
Table 4 is a table of the input voltage ranges for each of the input terminals on the voltage-sensing board. There are four separate inputs taps for each of the six independent channels. This assembly has been designed to operate at a nominal input voltage of up to 7200V with a continuous 40% overvoltage. The output voltages are scaled to provide close to 10V peak for a 140% input voltage at the high end of each of the voltage ranges.
C
B
Tap
D
A
Each of the channels has only four taps. They are used to provide a range of input voltages and software. This range is used to provide a given amount of gain so that 140% corresponds to the maximum numerical value of the analog to digital converter.
Table 4 - Input Voltage Range
Voltage Range (V)
800…1449
1450…2499
2500…4799
4800…7200
ATTENTION: Grounds must be reconnected on the voltage sensing boards.
Failure to do so can result in injury, death, or damage to equipment.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 61
Chapter 3 Power Component Definition and Maintenance
Replacing the Voltagesensing Circuit Board
Assembly
1. Verify that there is no power to the equipment.
ATTENTION: To avoid electrical shock, verify that the main power has been disconnected before working on the sensing board. Verify that all circuits are voltage free. Use a hot stick or appropriate high voltage-measuring device.
Failure to do so can result in injury or death.
2. Remove clear plastic cover.
3. Mark the position of the ribbon cables and wires.
4. Remove the screws and lift the ring lugs from the terminals. To avoid electrical shock, verify that the main power is disconnected before working on the sensing board to remove the wires.
5. Release the locking mechanism that is on each side of the ribbon cable connector and pull the ribbon cable straight out to avoid bending the pins.
6. Remove the four nuts and washers that secure the assembly to the studs welded to the frame.
7. Remove the old VSB and replace the new VSB on the studs. To secure the assembly, use the existing hardware.
IMPORTANT Do not overtorque the connections or you can break the studs.
8. Replace all ring lugs on terminals. Plug in ribbon cables. Verify that cables are positioned properly and the fitting is secure (the locking mechanism is engaged).
9. For personnel and equipment safety, verify that both grounding connections are reconnected to the sensing board.
10. Replace clear plastic cover and refasten in place.
Figure 46 - Sensing Board with Mounting Hardware Placement
62 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Surge Arresters
Power Component Definition and Maintenance Chapter 3
Description
Heavy-duty distribution-class surge arresters are used for transient overvoltage protection in the drives with AFE rectifiers. The arresters are certified as per
ANSI/IEEE Std C62.11-1993.
The surge arresters are basically MOVs, with or without an air gap in series, packed in sealed housing. They provide overvoltage protection similar to what the TSN module does. They differ from the TSN as fusing is not required for the operation of surge arresters.
There are three types of surge arresters depending on the voltage class of the drive as shown in the following table:
3.3 kV 4.16, 4.8 kV Drive Voltage
Arrester Rating (RMS)
Arrester MCOV (RMS)
2.4 kV
3 kV
2.55
6 kV
5.10
6.0...6.9kV
9 kV
7.65
The most severe temporary overvoltage occurs when one phase is grounded in an ungrounded system. The full line-to-line voltage is applied to the arrester in this case. The arresters are designed to operate under this condition continuously without any problems as shown by their Maximum Continuous-
Operating Voltage (MCOV) rating.
There are three Y-connected surge arresters that are attached to the incoming
MV lines. The neutral point of the arresters is connected to the ground bus.
Figure 47 - Surge Arresters
Drive Input from Line Terminals
U V W
Heavy-duty
Distribution Class
Surge Arrester
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 63
Chapter 3 Power Component Definition and Maintenance
Operation
The operation of arresters without a gap is the same as the MOVs. Depending on design, the arrester can also be gapped. Both gapped and ungapped arresters provide adequate overvoltage protection.
The arresters are able to withstand or ride through most commonly seen bus transients within their capability. Caution must be taken if there is a harmonic filter on the MV bus to which PowerFlex 7000 is connected. The filter must satisfy relevant international or local standards, such as IEEE Std 1531—
Clause 6.4, to avoid high inrush currents.
The surge arrester is certified as per ANSI/IEEE Std C62.11-1993.
Certification tests include high-current short duration tests, low-current long duration tests, and fault current withstand tests. The fault current withstand tests consist of different combinations of kA and number of cycles. The test includes a 20-kA 10-cycle test, under which the arresters are non-fragmenting and without expelling any internal components.
The housing splits open to vent incoming energy when the handling capability of the arrester is exceeded and causes arrester failure. This design helps avoid damage to the adjacent components.
64
Surge Arrester Replacement
1. Verify that there is no power to the equipment. Isolate the drive by
Lockout/tagout.
ATTENTION: To avoid electrical shock, verify that the main power is disconnected before working on the surge arrester. Verify that all circuits are voltage free. Use a hot stick or appropriate voltage-measuring device. Failure to do so can result in injury or death.
2. Wait for a minimum of 10 minutes to allow the stored energy in the drive to be discharged.
3. Observe the location of the connecting leads.
4. Verify that the leads are at ground potential. Use temporary ground when necessary.
5. Detach the connecting leads.
6. Loosen the bolt that attaches the surge arrester to the ground bus.
Remove the arrester. Remove temporary ground when applicable.
7. Replace the surge arrester with an equivalent one (make sure that the voltage rating is the same).
8. Connect the leads to the surge arrester.
9. Surge arrester hardware to be torqued to 28 N•m (21 lb•ft).
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Figure 48 - Surge Arresters
Power Component Definition and Maintenance Chapter 3
Surge Arresters
When the surge arrester is disconnected from MV, the arrest can 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. Remove temporary ground before the arrester is reinstalled.
ATTENTION: To avoid electrical shock when removing the arrester from service, consider the arrester to be fully energized until both the line and ground leads are disconnected
Field Test and Care
A field test in not necessary. The arresters do not require special care. However at dusty sites, clean the arrester when the whole drive is cleaned.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 65
Chapter 3 Power Component Definition and Maintenance
PowerCage Module Overview
A PowerCage™ module is a converter module with these elements:
• Epoxy resin housing
• Power semiconductors with gate-driver circuit boards
• Heatsinks
• Clamp
• Snubber resistors
• Snubber capacitors
• Sharing resistors (2400V drives do not have a sharing resistor).
Each drive consists of three PowerCage rectifier modules and three PowerCage inverter modules.
AFE type rectifiers use SGCTs as semi-conductors.
All inverter modules use SGCTs as semi-conductors.
The size of the PowerCage module varies depending on the system voltage.
The power semi-conductor usage in the converter section is as follows:
Configuration
2400V, AFE
3300/4160V, AFE
6600V, AFE
12
18
Rectifier SGCTs
6
Inverter SGCTs
6
12
18
Some PowerFlex 7000 configurations contain Self-Powered SGCT Power
Supply (SPS) boards. These boards are applicable on all “A” frame drives and all
AFE “B” frame drives with heat sinks. See Self-powered SGCT Power Supply -
for more information.
ATTENTION: To help prevent electrical shock, disconnect the main power before working on the converter cabinet. Verify that all circuits are voltage free using a hot stick or appropriate voltage-measuring device. Failure to do so can result in injury or death
ATTENTION: The PowerCage module houses the SGCT circuit board, which is sensitive to static charges. Do not handle these boards without being properly grounded.
ATTENTION: Static charges can destroy some circuit boards. Use of damaged circuit boards can also damage related components. A grounding wriststrap is recommended for handling sensitive circuit boards.
66 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Resistance Checks
Power Component Definition and Maintenance Chapter 3
The inverter module is the module that contains the SGCT power device necessary for producing the motor voltages and currents. There are three inverter modules in each drive; the number of SGCTs per module depends on the voltage rating of the motor. To understand a module, a description of one
SGCT and its peripheral equipment is all that is required.
Before control power is applied to the drive, measurements must be taken of the power semiconductor and of snubber circuit resistance. These measures verify that the converter section was not damaged during shipment. The instructions that are provided below detail how to test these components:
• Inverter or AFE rectifier bridge:
– Snubber resistance test (snubber resistor).
– Snubber capacitance test (snubber capacitor).
– Anode-to-cathode resistance test (the sharing resistor and SGCT).
ATTENTION: Before attempting any work, verify that the system has been locked out and tested to have no potential.
Snubber Resistors
Snubber resistors connect in series with the snubber capacitors. Together they form a simple RC snubber that connects across each thyristor (SGCT). The snubber circuit reduces the dv/dt stress on the thyristors and reduces the switching losses. The snubber resistors connect as sets of various wire-wound resistors that are connected in parallel. The number of resistors in parallel depends on the type of the thyristor and the configuration and frame size of the drive.
Snubber Capacitors
Snubber capacitors are connected in series with the snubber resistors. Together they form a simple RC snubber that is connected across each thyristor
(SGCT). The purpose of the snubber circuit is to reduce the voltage stress (dv/ dt and peak) of the thyristor and to reduce the switching loss.
Sharing Resistors
The sharing resistors provide equal voltage sharing when using matched devices in series. SGCT PowerCage modules for 2400V systems do not need matched devices and have no sharing resistor.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 67
Chapter 3 Power Component Definition and Maintenance
SGCT and Snubber Circuit
As with all power semi-conductors or thyristors, the SGCT must have a snubber circuit. The snubber circuit for the SGCT is composed of a snubber resistor in series with a snubber capacitor.
The snubber circuit is shown in
Figure 49 . The physical locators of the same
circuit are shown in
Figure 57 . Measure the resistance across two adjacent
heatsinks. A value of 60...75 kΩ indicates a good sharing resistor.
Figure 49 - Snubber Circuit for SGCT Module
Cs-1
Rsn-2
Rsh
Cs-2
Rsn-1
Anode
Snubber
Resistor
Test Cathode
68
Heatsink
Figure 50 - Snubber Circuit for SGCT Module (with SPS Board)
Heatsink
Cs-1
Rsn-2
Rsh
Rsn-1
Anode
Snubber
Resistor
Test
Cs-2
Heatsink
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Heatsink
SPS Board
J1-1
J1-2
Cathode
Heatsink
Module
Housing
Pivot Plate
Power Component Definition and Maintenance Chapter 3
Figure 51 - 2400V Two Device PowerCage (Heat Sink Model)
SGCTs Heat Sink
Temperature
Feedback Board
Clamp Head
Pivot Plate
Heat sink
SGCT
Figure 52 - 2400V Two Device PowerCage Module (with SPS Boards Installed)
SPS Mounting Assembly with
Temperature Feedback Board
SGCT
Clamp Head
Module Housing
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
SPS Board
Mounting
Assembly without
Temperature
Feedback
Board
69
Chapter 3 Power Component Definition and Maintenance
Pivot Plate
Matched Set
Two SGCTs
Figure 53 - 3300/4160V Four Device PowerCage (Heat Sink Model)
Matched Set
Two SGCTs
Heat Sink
Pivot Plate
Module Housing
Temperature Feedback Board
Clamp Head
Matched Set
Two SGCTs
Figure 54 - 3300/4160V Four Device Rectifier PowerCage Module (with SPS Boards Installed)
SPS Mounting Assembly with
Temperature Feedback Board
Matched Set
Two SGCTs
Clamp Head
Heat sink
70
SPS Mounting Board Assembly without
Temperature Feedback Board
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Module Housing
Pivot Plate
Power Component Definition and Maintenance Chapter 3
Figure 55 - 6600V Six Device PowerCage Module
Matched Set
Three SGCTs
Matched Set
Three SGCTs Clamp Head
Module Housing
Pivot Plate
Heat Sink
Temperature Feedback Board
Figure 56 - 6600V Six Device PowerCage Module (with SPS Boards Installed)
Matched Set
Three SGCTs
Matched Set
Three SGCTs
Clamp Head
Heatsink
SPS Mounting Assembly with
Temperature Feedback Board
SPS Mounting Assembly without
Temperature Feedback Board
Module
Housing
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Chapter 3 Power Component Definition and Maintenance
Figure 57 - Snubber Circuit Assembly for SGCT Module
Rsh
Cs-1
Rsn-2
Rsn-1
Cs-2
Anode
Cathode
A sharing resistor is connected in parallel with the SGCT. The sharing resistor verifies that the voltage is shared equally among the SGCTs when connected in series. SGCTs are connected in series to increase the total reverse voltage blocking (PIV) capacity as seen by the electrical circuit. One SGCT has a PIV rating of 6500V. This single device provides sufficient design margin for electrical systems with 2400V medium voltage supply. At 4160V, two SGCTs must be connected in series to provide a net PIV of 13,000V to achieve the necessary design margin. Similarly, three SGCTs must be connected in series at
6600V, providing a net PIV of 19,500V to achieve the necessary design margin.
The SGCT is cooled by placing the SGCT between two forced air-cooled heatsinks, one heatsink on the anode and the other heatsink on the cathode.
The clamp assembly on the right-hand side of the inverter module generates these forces.
SGCT
400 A SGCT
800 A SGCT
1500 A SGCT
Device Diameter
38 mm (1.49 in.)
47 mm (1.85 in.)
63 mm (2.48 in.)
Clamp Force
8.6 kN
13.5 kN
20 kN
Pressure on the SGCTs must be uniform to avoid damage and to help maintain low thermal resistance. To achieve uniform pressure:
1. Loosen the heatsink mounting-bolts.
2. Tighten the clamp.
3. Tighten the heatsink mounting-bolts.
72 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Power Component Definition and Maintenance Chapter 3
External filtered air is directed through the slots of the heatsinks to carry away the generated heat from the SGCTs. The door filter is necessary to keep the slots on the heatsinks from getting plugged with dust particles.
SGCT Anode-to-Cathode Sharing Resistance
The anode-cathode resistance check measures the parallel combination of the sharing resistor and SGCT anode-cathode resistance. The sharing resistor has a resistance much lower than a good SGCT, thus the measurement is slightly less than the resistance of the sharing resistor. A measurement between 60…75 kΩ indicates that the SGCT is in good condition and that wiring to the SGCT is correct. If the SGCT fails, the SGCT is in the shorted mode, 0 Ω. The anode to cathode resistance check is 0 Ω.
A test point is provided inside the PowerCage module to measure the resistance of the snubber resistor and capacitance of the snubber capacitor. The test point is the electrical connection between the snubber resistor and snubber capacitor. The procedure is to place one probe of the multi-meter on the test point, and the other probe on the anode heatsink to measure the snubber
resistor value and the snubber capacitor ( Figure 58
). Remove the snubber terminal connection to TB1 of the SPGD board. Measure between the test point and the wire that is connected to pin 1 of the TB1 female connector.
Replace the snubber terminal connection once the measurement is complete.
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Chapter 3 Power Component Definition and Maintenance
Figure 58 - Resistance Measurements SGCT PowerCage Module
SPS board is removed for clarity
Resistance value between two heat sinks is sharing resistance in parallel with anodecathode resistance.
Resistance value between heat sink and test point is snubber resistance.
Snubber Resistance
Access to the snubber resistor is not required to test its resistance. Located within the PowerCage module under the heatsink is a snubber circuit testpoint. For each device, there is one test point. To verify the resistance, measure the resistance between the test point and the heat sink.
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Power Component Definition and Maintenance Chapter 3
Figure 59 - Testing the Snubber Resistor
Sharing Resistor
Snubber
Resistor
Snubber
Capacitor
Measure resistance between heat sink and test point.
Snubber Test Point Heatsink
Figure 60 - Snubber Resistor Test (with SPS Board)
Resistance Value between two heat sinks is sharing resistance in parallel with Anode-cathode
Resistance.
Sharing Resistor
Test Point
SGCT
Heatsink
Snubber
Resistor
Snubber
Capacitor
1
SPS Board
J1
2
Test Point
SGCT
Resistance value between heat sink and test point is snubber resistance.
Heatsink Heatsink
Snubber Capacitance
Turn the multimeter from the resistance to capacitance measurement mode.
Verify the snubber capacitor by measuring from the test point to the heat sink next to the right for standard rectifiers, or from heat sink to heat sink. For SPS rectifiers:
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Chapter 3 Power Component Definition and Maintenance
1. Disconnect the J1 connector from the SPS board.
2. Measure from the test point to pin 1 of the Phoenix connector (that plugs into J1 of the SPS board).
Figure 61 - Snubber Capacitor Test
Sharing Resistor
Measure capacitance between heat sink and test point (or heat sink to heat sink).
Snubber
Resistor
Test Point
SGCT
Snubber
Capacitor
Snubber
Test
Point
SGCT Cathode Wire
Snubber Test Point Heatsink
Figure 62 - Snubber Capacitor Test (Shown with SPS Board Installed)
Sharing Resistor
Heatsink
Snubber
Resistor
Snubber
Capacitor
1
SPS Board
J1
2
Test Point
SGCT
Heatsink
Snubber Capacitor Wire
Use connector terminal screw for testing the snubber capacitor.
Heatsink
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Power Component Definition and Maintenance Chapter 3
Replacing the SGCT
The Symmetrical Gate Commutated Thyristor (SGCT or device) with attached circuit board is located within the PowerCage module assembly.
SGCTs must be replaced in matched sets:
• 3300V and 4160V systems use sets of two.
• 6600V systems use sets of three.
The SGCT and associated control board are one component. The device or the circuit board is never changed individually. There are four status indicators on the SGCT; this table describes their functions:
Green Solid Green indicates that the Power Supply to the Card is OK.
Status
Indicator 4
Status
Indicator 3
Status
Indicator 2
Status
Indicator 1
Green
Yellow
Red
Solid Green indicates that the Gate-Cathode resistance is OK.
Status indicator ON indicates that the gate is ON, and flashes alternately with status indicator 1 while gating.
Status indicator ON indicates that the gate is OFF, and flashes alternately with status indicator 2 while gating.
1. Verify that there is no power to the equipment.
ATTENTION: To avoid electrical shock, verify that the main power has been disconnected before working on the drive. Verify that all circuits are voltage free. Use a hot stick or appropriate voltage-measuring device. Failure to do so can result in injury or death
Note the position of the fiber-optic cables for assembly.
2. To remove the SGCT, remove the power cable for the gate driver and the fiber-optic cables. If the minimum bend radius (50 mm [2 in.]) of the fiber-optic cables is exceeded, it can result in damage.
If installed, remove the SPS snubber connector ( J1 on the SPS board) and remove the SPS mounting-bracket with the SPS board.
ATTENTION: The fiber-optic cables can be damaged when struck or bent sharply. The minimum bend radius is 50 mm (2 in.). The connector has a locking feature that requires pinching the tab and gently pulling the connector out straight. The component on the printed circuit board must be held to avoid damage.
3. Remove the load on the clamp head assembly as described on
4. Two brackets secure the board to the heatsink. Loosen the captive screws until the circuit board is free. Adjust the position of the heatsinks, as required, to allow free movement of the SGCT.
5. Slide the circuit board straight out.
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Chapter 3 Power Component Definition and Maintenance
ATTENTION: Static charges can destroy or damage the SGCT. Personnel must be properly grounded before removing the replacement SGCT from the protective anti-static bag in which the SGCT is supplied in. Use of damaged circuit boards can also damage related components. A grounding wriststrap is recommended for handling sensitive circuit boards.
IMPORTANT Replacement SGCTs are supplied, grouped in matched sets. All SGCTs in a leg have been grouped based on their electrical performance. Grouping similarly matched devices helps ensure balanced load sharing of a leg of devices. When replacing the device, replace all SGCTs in a matched set, even if only one has failed.
6. Clean the heatsink with a soft cloth and rubbing-alcohol.
7. While grounded, remove the SGCT from the anti-static bag in which the SGCT is supplied in.
8. Apply a thin layer of Electrical Joint Compound (EJC No. 2 or approved equivalent) to the contact faces of the new SGCTs to be installed. The recommended procedure is to apply the compound to the pole faces with a small brush. Then gently wipe the pole face with an industrial wipe so that a thin film remains. Examine the pole face before proceeding to verify that no brush bristles remain.
IMPORTANT Too much joint compound can result in contamination of other surfaces and lead to system damage.
9. Slide the SGCT into place until the mounting brackets contact the surface of the heatsink.
10. Tighten the captive screws that are in the brackets.
11. Follow procedure Maintain Uniform Clamping Pressure on page 83
to verify that the heatsinks are clamped to a uniform pressure.
If equipped, reinstall the SPS board and mounting-bracket, and reconnect the snubber connection to J1 of the SPS board.
12. Connect the power cable and fiber-optic cables (verify that the bend radius is not exceeded).
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Figure 63 - Replacing the SGCT
Power Component Definition and Maintenance Chapter 3
SGCT Captive Screws
Clamp Head Block
DO NOT ADJUST outside nut.
Disk Springs
Inside nut for loosening and applying load to assembly.
Figure 64 - Replacing the SGCT (If SPS Board Is Installed)
SGCT Captive Screws
SPS board mounting- assembly captive screws.
Clamp Head Block
Inside nut for loosening and applying load to assembly.
DO NOT ADJUST outside nut.
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Chapter 3 Power Component Definition and Maintenance
Replacing Snubber and Sharing Resistor
The snubber and the sharing resistors are part of the resistor assembly that is located behind the PowerCage module.
1. Remove the PowerCage module as outlined in
Figure 65 - Removal of the PowerCage Module
Sharing Resistor Connection
Snubber Resistor Connection
Snubber Capacitor
Cathode Connection Anode Connection Common Snubber and
Sharing Resistor Connection
2. Note the connection of the leads for correct replacement.
3. Detach the leads that are on the bottom of the resistor assembly. See
Figure 66 .
4. Remove the push nuts on the end of the retaining rod. Pinch the clip together and pull off. Pull out the retaining rod. See Figure 66 .
5. Remove two bolts and swing out the PowerCage plug-in stab assembly.
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Detach leads of resistor assembly.
Power Component Definition and Maintenance Chapter 3
Figure 66 - Snubber and Sharing Resistor, Snubber Capacitor Replacement
Pinch and remove clips at end of the retaining rod
Extract the retaining rod.
Push Nut
Figure 67 - Removing the Resistor Bank from the PowerCage Module
Retaining Rod
Resistor Bank
6. Remove the resistor bank from the PowerCage module. See
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. Install the PowerCage module as outlined in
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Chapter 3 Power Component Definition and Maintenance
Snubber Capacitor
Replacement
The snubber capacitors are part of the capacitor assembly located behind the
PowerCage module.
IMPORTANT If the drive can be accessed from the rear, the snubber capacitors can be removed and replaced from the rear, with the PowerCage modules in place.
If the drive cannot be accessed from the rear, the PowerCage modules must be removed to access the snubber capacitors. See
Replace the capacitors one at a time. Do not remove all at once.
1. Using a 13 mm socket wrench, remove the M8 bolt on the end of the capacitor and retain hardware.
2. Hand rotate the capacitor counter-clockwise to unscrew it from the threaded stud connecting it to the PowerCage module.
3. Apply a drop of Loctite 425 to the thread of the 25 mm flange side of the replacement capacitor.
4. Hand-tighten the replacement capacitor onto the threaded stud.
ATTENTION: You must insert the capacitor in the correct orientation.
The 25 mm flange must be connected to the threaded stud on the PowerCage module.
17 mm (0.67 in.)
25 mm (0.98 in.)
5. Connect the electrical leads and hardware on the 17 mm flange side of the replacement capacitor.
Torque M8 hardware to 7 N•m (60 lb•in).
82
M8 Hardware Location
13 mm Socket
M8 Bolt
5/16 in. Lock Washer
5/16 in. Flat Washer
Electrical Lead
17 mm Flange
6. Bundle and secure the connecting wires using wire ties.
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Power Component Definition and Maintenance Chapter 3
Sharing Resistor Replacement
Normally the sharing resistor is part of the snubber resistor assembly. When the sharing resistor is replaced, also replace the snubber resistor.
The sharing and snubber resistors are normally on the backside of the
PowerCage module. See
Replacing Snubber and Sharing Resistor .
Maintain Uniform Clamping
Pressure
Always maintain proper pressure on the thyristors. Follow this procedure whenever a device is changed or the clamp is loosened completely.
1. Apply a thin layer of electrical joint compound (EJC No. 2 or approved equivalent) to the pressure pad face( Figure 69 ). To apply the compound, use a small brush and gently wipe the pad face with an industrial wipe until a thin film remains. Verify that no brush bristles remain.
2. Torque the heat sink bolts to 13.5 N•m (10 lb•ft.), then loosen each bolt two complete turns.
Figure 68 - Location of Heat Sink Bolts
Heat sink bolt location
3. Tighten the clamp to the proper force until you can turn the indicating washers by the fingers with some resistance.
4. Torque the heat sink bolts to 13.5 N•m (10 lb•ft.). Start with the center heat sink and move outward, alternate left to right.
5. Check the indicating washer of the clamp.
Checking the Clamping Pressure
Periodically, the clamping force in the PowerCage module must be inspected.
Verify that there is no power to the equipment.
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Chapter 3 Power Component Definition and Maintenance
ATTENTION: Main power must be disconnected before working on the drive.
Verify that all circuits are voltage free. Use a hot stick or appropriate voltagemeasuring device. Failure to do so can result in injury or death.
Figure 69 - Clamp Head Illustration
Calibration Nut- DO NOT ADJUST.
Indication Washer
Clamp Bar
Adjustment Nut
84
Disk Springs
Pressure Pad Face
If proper force (as designated on the clamp head block) is applied to the clamping assembly, the indicating washer is able to rotate with fingertip touch.
The indicating washer must not rotate freely. Turn the indicating washer using fingers until there is some resistance.
Adjusting the Clamping Pressure
1. Verify that all power to the drive is off.
2. Do not loosen the adjustment nut. If the clamping pressure is let off, the assembly procedure must be conducted to verify uniform pressure on the thyristors.
3. Tighten with a 21 mm (13/16 inch) wrench on the adjustment nut
(upward motion) until fingers can turn the indicating washer with some resistance. The indicating washer MUSTNOT ROTATE FREELY .
IMPORTANT Never rotate the calibration nut that is located outside the indicating washer at the end of the threaded rod. The rotation of the outer nut affects the torque calibration, which is factory set. Only adjust the inside nut (see
Figure 69 ).
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Temperature Sensing
Power Component Definition and Maintenance Chapter 3
Thermal sensors are on heatsinks in the converter. The thermal sensor is mounted on the heatsink with the temperature feedback board.
Replacing the Thermal Sensor
1. Verify that there is no power to the equipment.
ATTENTION: to avoid electrical shock, verify that the main power has been disconnected before working on the drive. Verify that all circuits are voltage free. Use a hot stick or appropriate voltage-measuring device. Failure to do so can result in injury or death.
2. Remove the SPS bracket first, if installed. The heatsink with the thermal sensor must be removed from the PowerCage module. Remove clamp load, refer to Figure 69 .
3. Remove the device (SGCT) that is secured to the heatsink with the thermal sensor.
4. Disconnect the fiber-optic cable to the temperature feedback board.
5. Remove two M8 screws that hold the heatsink in place.
6. Remove the heatsink with the temperature feedback board from the
PowerCage module. If SPS is equipped, the heatsink is on the SPS mounting bracket.
7. Disconnect the plug that connects the thermal sensor to the circuit board.
8. Remove the screw that attaches the thermal sensor to the heatsink.
9. Replace with the new thermal sensor and cable assembly.
10. There is a small voltage difference between the thermal sensor and its heatsink. For proper function, mount the small insulating pad between the thermal sensor and the heatsink, and the insulating bushing between the mounting screw and the thermal sensor (see
11. Replacement of the heatsink with the new thermal sensor is in the reverse order of removal.
12. Follow procedure Maintain Uniform Clamping Pressure on page 83
to verify that the heatsinks are clamped to a uniform pressure.
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Chapter 3 Power Component Definition and Maintenance
Figure 70 - Replacing the Thermal Sensor
Insulating
Bushing
Mounting Pad
Temperature Feedback
Circuit Board
Mounting Screw
Thermal Sensor and
Cable Assembly
Insulating
Bushing
Figure 71 - Replacing the Thermal Sensor (if SPS Board is Installed)
Mounting Pad
Temperature Feedback
Circuit Board
86
Mounting Screw
Thermal Sensor and
Cable Assembly
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Heatsink Replacement
Power Component Definition and Maintenance Chapter 3
There are three different styles of heat sinks in PowerFlex air-cooled drives, depending on thermal requirements:
• Aluminum Type W heat sinks have a plurality of short internal fins along the internal surfaces.
• Aluminum Type M heat sinks have internal fins with flat surfaces.
• Copper heat sinks have internal fins that are made from folded copper foil.
Figure 72 - Heatsinks
Aluminum Type W Aluminum Type M
1. Verify that there is no power to the equipment.
Copper
ATTENTION: To avoid electrical shock, verify that the main power has been disconnected before working on the drive. Verify that all circuits are voltage free. Use a hot stick or appropriate voltage-measuring device. Failure to do so can result in injury or death.
2. Remove the load from the clamp head per the procedure on
.
3. Remove the SGCT from the heatsink that is being replaced per the
.
4. There are two13 mm bolts that secure the heatsink to the PowerCage module. Remove the bolts using extenders so the socket wrench is past the sensitive gate driver boards.
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. See
Figure 56 for pivot plate location.
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Chapter 3 Power Component Definition and Maintenance
PowerCage Gasket
5. Loosen the two bolts and carefully remove the heatsink from the
PowerCage module.
6. Install the new heatsink and hand-tighten the bolts.
7. Replace the SGCT per the instructions on
to verify that the heatsinks are clamped to a uniform pressure.
To make sure that all air movement is through the slots of the heatsinks, all air leaks are sealed with a rubber gasket. This gasket is placed between the surface of the PowerCage module and heatsink module. The gasket must be in place to keep the SGCTs cool.
Figure 73 - PowerCage Gasket Location
Power Connection
Gasket
Resistors
Power Connection
PowerCage Housing
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Power Component Definition and Maintenance Chapter 3
Replacement of PowerCage Gaskets
The gaskets do not normally require replacement, but when they become damaged, they can require replacement.
Removal of Old Gasket Material
Pull off all material possible by hand. Scrape off as much material as possible with a sharp knife. Do not score the PowerCage module with the knife. All material cannot come off ! Remove as much as possible to leave an even surface to bond to. Clean away any loose pieces of gasket. Then proceed with installation of the gasket.
The PowerCage module must be cleaned with an all purpose household cleaner.
IMPORTANT Do not spray cleaner onto the PowerCage module. The spraying promotes electrical tracking.
Apply the cleaner to a paper towel and wipe the surface of the PowerCage module where the gasket is applied. Liberally spray the surface with distilled water. Wipe the surface with a clean paper towel.
Apply a thin bead of Loctite 454 adhesive (use the original nozzle size) to the
PowerCage module surface in a zigzag pattern. To spread the adhesive over 50% of the area, use the nozzle tip. Apply sufficient quantity of adhesive so that the adhesive remains wet long enough for the gasket to be applied. The adhesive uses the moisture in the air to cure. The higher the humidity the faster the adhesive cures.
IMPORTANT This adhesive will bond anything quickly, including fingers!
Position and orient the gaskets correctly, centered over the opening for the heatsinks with the narrow end positioned closest to the test points. Apply the porous surface of the gasket to the PowerCage module. The gasket bonds almost immediately. Apply some pressure to the gasket for 15...30 seconds.
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Chapter 3 Power Component Definition and Maintenance
PowerCage Module Removal
After all gaskets have been placed, check to see that the gasket has bonded properly. Repair any loose areas.
1. Verify that there is no power to the equipment.
ATTENTION: To avoid electrical shock, verify that the main power has been disconnected before working on the sensing board. Verify that all circuits are voltage free. Use a hot stick or appropriate voltage-measuring device. Failure to do so can result in injury or death.
2. Before removing the PowerCage module, all components that are located within the PowerCage module must be removed to avoid any damage to the components. To remove the clamping pressure, and remove the SGCT, circuit boards, and thermal sensor, consult the required sections.
ATTENTION: Static charges can damage or destroy the SGCT. Personnel must be properly grounded before circuit boards are removed from the PowerCage module. Use of damaged circuit boards can also damage related components. A grounding wriststrap is recommended for handling.
ATTENTION: Do NOT remove the pivot plate from the PowerCage. The pivot plate is 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. See
Figure 56 for pivot plate location.
3. Remove the M8 bolts in the two flanges that connect the heatsink to the
PowerCage module. To make the PowerCage module, easier to handle and reduce weight, remove the heatsink from the PowerCage module.
4. To detach the PowerCage module itself, remove the bolts on the outer flange. Carefully lift down the PowerCage module and place the forward face down. Do not over-torque these bolts when replacing the
PowerCage module.
IMPORTANT The PowerCage can be heavy. To avoid injury or damage to the module, two people are recommended to extract the PowerCage from the drive.
5. See appropriate section for component replacement.
6. When replacing the PowerCage module, place the bolts on the outer flange in loosely. Torque bolts alternately on one flange and then the opposite flange for tightening of the module. A suggested sequence for torquing PowerCage module bolts is shown in Figure 74 .
Note: The PowerCage module is shown with switching components, heatsinks, and clamps removed for ease of lifting.
90 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Figure 74 - Typical Torque Sequence
Power Component Definition and Maintenance Chapter 3
7. Replace interior assembly in the reverse order of removal.
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Chapter 3 Power Component Definition and Maintenance
Self-powered SGCT Power
Supply - SPS
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
SGCT snubber circuitry to provide the 20V DC required to power the SGCT device.
The SPS Board has two snubber connection inputs and two 20V DC outputs.
Snubber connection inputs are derived from opening the snubber capacitor to
SGCT cathode connection and bringing these connections to the SPS board
).
Figure 75 - Snubber Circuit for SGCT Module (with SPS Board)
Cs-1
Rsn-2
Rsh
Rsn-1
J1-1
J1-2
Cs-2
92
Board Calibration
This board requires no field calibration.
Test Points
TP4
TP6
TP15
TP14
300V DC bus
300V DC bus common
20V DC output
20V DC output common
The green Status Indicator (DS1) on the SPS board indicates that the 20V DC output is within operating specification range.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Figure 76 - SPS Board Test Points
J1 Snubber and
Test Power Harness
J2-20V DC
Output Power to SGCT and
TFB Board
DS1-20V DC
Good Status
Indicator
TP15 - 20V DC TP14 - 20V DC COM
TP4-300V DC
Power Component Definition and Maintenance Chapter 3
TP6-300V DC
Common
Terminal
J1 – 1
J1 – 2
J1 – 3
J1 – 4
J1 – 5
J1 – 6
Connections
Connection to the SGCT snubber capacitor at CS-2 location
Connection to SGCT cathode terminal
Connection to input attenuated feedback
(Short J1-3 to J1-4 to disable input SCR clamp stage for test power usage)
Connection to 300V DC common connection
(Short J1-3 to J1-4 to disable input SCR clamp stage for test power usage)
Connection to 300V DC internal bus
(Short J1-5 to J1-6 to allow input to operate from 90V AC)
Connection to TOPSwitch programming resistor
(Short J1-5 to J1-6 to allow input to operate from 90V AC)
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Chapter 3 Power Component Definition and Maintenance
Equipment for Testing
Verify that you have this equipment available to perform the testing tasks.
• SPS test power harness (80018-695-51).
• Digital multimeter.
1. Disconnect the snubber connection to J1 of the SPS board.
2. Connect one of the SPS test power harness connectors to the SPS J1 connector.
3. Plug the AC input end of the SPS test power harness into the appropriate drive receptacle.
The green status indicator (DS1) at the front of the board must be on.
4. Measure between the TP4 and TP6 on the SPS board. The measurement must be at a level of
√
2 x VIN
RMS
.
This value can range 120V (85V input) … 375V (265V input).
5. Measure between TP15 and TP14 on the SPS board. The measurement must be at a level of 20V DC, +/- 400 mV.
If these readings are not correct, replace the tested SPS board with a new board and return the faulty board to the factory.
ATTENTION: When the SPS test harness is installed and powered, there are lethal voltages on the SPS board. Always connect multimeter test leads to the SPS test points before input power is applied to the SPS test harness.
Always connect the SPS test harness connectors to the SPS board before input power is applied to the SPS test harness.
Some shorted components on the SPS board, cause the input breaker to the
SPS test power harness to trip. For example any of the input diode bridge diodes D10, D11, D13, or D14. In this situation, replace with a new unit and return the faulty board to the factory.
ATTENTION: When testing with the SPS harness is complete, remove the test harness from all SPS boards and remove the SPS test harness from the power converter cabinet. Do NOT leave the SPS test harness in the power converter cabinet. Reconnect all SGCT snubber connections to the J1 connectors on the SPS boards.
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Fiber-optic Cabling
Power Component Definition and Maintenance Chapter 3
The equipment is provided with fiber-optic cabling as a means of interfacing the low voltage control to the medium voltage circuits. The rerouting of the fiber-optic cables is not be required.
Each end of a fiber-optic cable is provided with a connector that plugs and latches into its respective location on a circuit board. To disconnect a fiberoptic cable, depress the ridged plastic tab at the end connector and pull. To install a fiber-optic cable, insert the fiber-optic port of the circuit board so that the plastic tab latches into place.
To replace fiber-optic cables, take care to avoid the cables from becoming strained or crimped as a resulting loss in light transmission results in loss in performance.
The minimum bend radius that is permitted for the fiber-optic cables is 50 mm
(2.0 in.).
When installing the fiber-optic cable, the color of the connector at the end of the cable must match the color of the connector socket on the circuit board.
Lengths of fiber-optic cables that are used in the product include:
Duplex
5.0 m (197 in.)
5.5 m (216.5 in.)
6.0 m (236.2 in.)
6.5 m (255.9 in.)
7.0 m (275.5 in.)
Simplex
5.0 m (197 in.)
6.0 m (236.2 in.)
10.0 m (292.7 in.)
There is one duplex fiber-optic for each thyristor, which manages gating and diagnostic functions. The circuitry on the respective driver boards determines the health status of the thyristor. This information is then sent to the main processor by way of a fail-safe light signal in the fiber-optic. The main processor initiates the firing command for the thyristor and transmits it to the appropriate gate driver board by way of the gating fiber-optic.
The color codes of the connectors are:
• BLACK or GREY – is the transmitting end of the fiber-optic.
• BLUE – is the receiving end of the fiber-optic.
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Chapter 3 Power Component Definition and Maintenance
Air Pressure Sensor
An air pressure sensor is in the converter cabinet and the integral rectifier transformer cabinet (if applicable). In both cases, the sensor is in the upper lefthand quadrant of the cabinet.
Figure 77 - Air Pressure Sensor
Flexible tube for low-pressure port
High-pressure Port
Mounting Screw
Wire Terminals
The air pressure sensor measures the difference in air pressure between the front and rear of the converter modules/integral rectifier transformer. A small direct current voltage signal is transmitted to the control circuits.
If reduced fan performance or air blockage occurs, for either the converter or the transformer, a message is sent. The measured differential pressure is reduced and a warning message appears on the console. A likely cause of the warning message would be blocked filters at the inlet.
If, as a result of blockage or fan failure, there is a risk of thermal damage for either the converter or transformer, a fault signal causes drive shutdown.
Air Pressure Sensor Replacement
1. Remove the wires at the sensor and note their designation.
2. Disconnect the clear tube on the low-pressure port. Remove the two mounting screws of the sensor.
3. Check the integrity of the sealant that has been applied where the clear tubing passed through the sheet metal barrier.
4. Installation of the replacement airflow sensor is in the reverse order of its removal.
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D.C. Link / Fan / Control
Components
Power Component Definition and Maintenance Chapter 3
Figure 78 - DC Link and Fan Cabinet, Low Voltage Control Tub Shown
Low Voltage
Control Tub
Retaining
Hardware
AC/DC Power Supply
(Dual Power Supply with Diode Shown)
Analog Drive
Control Board
Medium Voltage
Barrier (for access to Line/ Motor
Capacitors
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Chapter 3 Power Component Definition and Maintenance
Figure 79 - DC Link and Fan Cabinet, Low Voltage Control Tub Removed
Fan
Motor Filter
Capacitor
Line Filter
Capacitor
Inlet Ring
DC Link
Inductor
Grounding
Network/
Filter
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Power Component Definition and Maintenance Chapter 3
When the door is opened, control components are accessible. Behind the low voltage swing-out panel is the medium voltage compartment where the DC link and fan are located. The DC link is mounted on the floor plate of the cabinet above the capacitors.
Power connections are made to the inductor by way of its flexible leads. There are four power connection points that are labeled L+, L-, M+, and M-.
The DC link is equipped with thermal protection for the windings.
There is a current sensor on the M+ conductor.
The fan is located above the DC link; the primary elements of the fan are the inlet ring, impeller, and motor.
IMPORTANT The inlet ring is stationary and must not contact the rotating impeller.
Mounted on top of the cabinet is an air exhaust hood. The exhaust hood must be installed to avoid foreign objects from entering the drive.
Output Grounding Network Replacement
PowerFlex 7000 drives can have either a grounding network or a ground filter in place of the grounding network. The number of capacitors vary depending on the system voltage.
1. Verify that there is no power to the equipment.
ATTENTION: To avoid electrical shock, verify that the main power has been disconnected before working on the capacitor. Verify that all circuits are voltage free. Use a hot stick or appropriate voltage-measuring device. Failure to do so can result in injury or death.
2. Note the position of the leads.
3. Remove the 6.4 mm (¼ in.) hardware and disconnect the leads connected to the terminals.
4. Four brackets are used to secure the capacitor. Loosen the four screws at the base of the brackets and lift out the capacitor.
5. Place the new capacitor and tighten the screws securely.
6. Replace the ring lugs and 6.4 mm (¼ in.) hardware (
IMPORTANT The maximum torque for the capacitor terminal is 3.4 N•m (30 lb•in.).
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Chapter 3 Power Component Definition and Maintenance
Figure 80 - Output Grounding Network
Maximum torque on capacitor terminals
3.4 N•m (30 lb•in)
100
To release capacitor, loosen screws
Ground Filter Component Replacement
The number of capacitors vary depending on the system voltage.
1. Verify that there is no power to the equipment.
ATTENTION: To avoid electrical shock, verify that the main power has been disconnected before working on the capacitor. Verify that all circuits are voltage free. Use a hot stick or appropriate voltage-measuring device. Failure to do so can result in injury or death.
Note the position of the leads.
2. Disconnect the leads connected to the failed capacitor/resistor bank.
3. Loosen and remove the mounting screws as indicated in
Remove the failed component.
4. Assemble the new component in the reverse order of disassembly.
5. Reattach the leads strictly adhering to these torque requirements.
IMPORTANT The maximum torque for the capacitor terminal is 3.4 N•m (30 lb•in.).
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Reactor Transformer
Reactor Transformer Barrier
Power Component Definition and Maintenance Chapter 3
Figure 81 - Ground Filter Component Replacement
Resistor Bank
Filter Capacitors
Capacitors
Filter capacitors are used on the motor side for all drives. The AFE rectifier also
includes filter capacitors on the line side (see Figure 79
).
The filter capacitors units are three-phase four-bushing and “oil-filled”. The three-phase capacitors are composed of internal single-phase units that are connected in a Y configuration. The neutral point of the Y is connected to the fourth bushing, which is accessible and can be used measure neutral point voltage or other protection/diagnostics purposes. Depending on the drive configuration, the fourth bushing can or cannot be connected to circuitry. The metal cases of the capacitors are grounded through a stud on the capacitor housing.
The capacitors are equipped with internal “bleeding resistors” to discharge the capacitor and reduce its voltage below 50V in 5 minutes when left disconnected. A typical three-phase capacitor is shown in Figure 82 .
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Figure 82 - Motor Filter Capacitor
Motor Filter Capacitor
Line Filter Capacitor (with AFE rectifier only)
ATTENTION: Allow 5...10 minutes for motor capacitors to discharge voltage safely, before the cabinet doors are opened.
ATTENTION: Verify that the load is not turning due to the process. A freewheeling motor can generate voltage that is back-fed to the equipment being worked on.
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Power Component Definition and Maintenance Chapter 3
WARNING: The following fault codes may also indicate a non-operational
Motor Filter Capacitor (MFC):
F96 (Motor Overcurrent Fault)
F98 (Motor Neutral Overvoltage Fault)
F99 (Motor Flux Unbalance Fault)
F100 (Motor Current Unbalance Fault)
F103 (Motor Stall Fault)
F113 (DC Link Overcurrent Fault)
F114 (Ground Overcurrent Fault)
F115 (Neutral Resistor Overcurrent Fault)
F145 (Neutral Resistor Overload Fault)
Do not reset these faults until you have determined the root cause of the fault.
Operating a synchronous transfer system (specifically during the ‘Transfer to
Drive’ operation, also known as the de-sync operation) with a nonoperational MFC can lead to serious personal injury and/or property damage.
Replacing the Filter Capacitors
See Publication 7000-IN010 , “Handling, Inspection, and Storage of Medium
Voltage Line Filter Capacitors”.
1. Isolate and lockout all power to the drive.
ATTENTION: To avoid electrical shock, verify that the main power has been disconnected before working on the capacitor. Verify that all circuits are voltage free. Use a hot stick or appropriate voltage-measuring device. Failure to do so can result in injury or death.
ATTENTION: Verify that the load is not turning due to the process. A freewheeling motor can generate voltage that is back-fed to the equipment being worked on.
2. Remove medium voltage barrier below the low voltage panel to access capacitor (
3. Short all four bushings together and to ground on both capacitors before handling the connections. Note the location of all cables and mark them accordingly.
4. Remove the four power connections to the terminals, and the single ground connector from the drive to the capacitor frame.
5. Remove the grounding network and top bracket that holds the capacitor in place. At the bottom of the capacitor, there is no hardware securing the capacitor. The capacitor fits into a slot in the assembly.
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Chapter 3 Power Component Definition and Maintenance
6. Remove the capacitor from the drive. The capacitors can weigh up to
100 kg (220 lb); two people can be required to remove them.
IMPORTANT Do not lift capacitor by bushing as it can damage bushings and result in oil leakage.
ATTENTION: The porcelain bushings are fragile. Any force that is applied to the bushings can damage the seal, between the bushing and the body, and can cause potential leaks or chips.
7. Install the new capacitor. Slide the capacitor back into the slot. Fasten the top bracket and grounding network.
8. Reconnect all power cables and the ground connection. The connections use the M14 hardware, but must only be tightened to
30 N•m (22 lb•ft) due to capacitor mechanical constraints.
9. Remove any shorting/grounding conductors.
10. Reinstall the sheet metal that was removed, and verify that connections are secure and correct.
Testing the Filter Capacitors
There are two ways to test line filter capacitors. The first method is recommended, to reduce the chance of retorque issues, because the capacitors are not disconnected. If the readings are unsatisfactory, the second method is more accurate, but involves disconnecting and testing them individually.
First Method
1. Verify that there is no power to the equipment.
ATTENTION: To avoid electrical shock, disconnect the main power before working on the drive. Verify that all circuits are voltage-free. Use a hot stick or appropriate voltage-measuring device. Failure to do so can result in injury or death.
ATTENTION: Verify that the load is not running due to process. A freewheeling motor can generate voltage that feeds back to the equipment.
2. Isolate the equipment from medium voltage. Follow all safety steps.
3. Verify that there is no voltage present on the capacitor by using a hot stick or any other appropriate voltage-measuring device.
4. Verify that there is no oil leak or bulge in any of the capacitors.
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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 can lead to personal injury or death, property damage, or economic loss.
5. Using a DMM, measure the capacitance across each phase-to-neutral of capacitors without removing any connections.
If the difference between the highest and the lowest readings is below
15%, then all capacitors are in good condition. If the difference between the highest and the lowest readings is off by 15% or more, then a bad capacitor can be the cause. If multiple capacitors are used in the circuit, isolate each of them and check them separately to identify which one is defective.
6. Before disconnecting the capacitors, note the location of all cables and mark them accordingly.
7. Disconnect power cables from the capacitor terminals on all four
bushings and isolate them from the capacitor (see Replacing the Filter
).
8. Repeat step 5 to check each capacitor separately to confirm which is defective.
Second Method
1. Verify that there is no power to the equipment.
ATTENTION: To avoid electrical shock, disconnect the main power before working on the drive. Verify that all circuits are voltage-free. Use a hot stick or appropriate voltage-measuring device. Failure to do so can result in injury or death.
ATTENTION: Verify that the load is not running due to process. A freewheeling motor can generate voltage that feeds back to the equipment.
2. Verify that there is no oil leak or bulge in any of the capacitors.
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 can lead to personal injury or death, property damage, or economic loss.
3. Note the location of all cables and mark them accordingly.
4. Disconnect power cables from the capacitor terminals on all four
bushings and isolate them from the capacitor (see Replacing the Filter
).
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Chapter 3 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.
ATTENTION: The capacitor charges during this test. Use caution to avoid shock or injury. When moving the test connections from one phase to the next, wait a minimum of 5 minutes for the capacitor to discharge.
6. Calculate the capacitance from the measured values of test voltage and current. For a good capacitor, the calculated capacitance value for each of the three readings must be within ±15% of the capacitor nameplate micro-Farad. If the readings are outside this range, the capacitor must be replaced.
This example demonstrates the calculation for capacitance value.
Suppose that a capacitor under test is rated at 400 kVAR, 6600V, 50 Hz,
29.2 μF. Assume that you are using 200V, 50 Hz test power with the recorded voltage, and current values for each test as shown in this table.
Phase - Neutral
Test Voltage
Measured Current
L1-N
200V
1.87 A
L2-N
200V
1.866 A
Calculate the capacitance by using the first reading. In this case:
L3-N
200V
1.861 A
V = 200V, I = 1.87 for L1-N
Xc = V/I = 200/1.87 = 106.95
C= 1/ (2 π F
Xc)
C= 1/(2 x 3.14 x 50 x 106.95
C=29.7μ
F
Where:
F = frequency of the applied voltage.
Similarly, you can calculate the capacitance for the remaining two measurements for L2-N and L3-N.
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DC Link Reactor and CMC
Replacement
Power Component Definition and Maintenance Chapter 3
The DC Link maintains a low ripple current between the rectifier and the inverter.
ATTENTION: To avoid electrical shock, verify that the main power has been disconnected before working on the current transformer. Verify that all circuits are voltage free. The DC Link can be hot. Use a hot stick or appropriate voltage-measuring device. Failure to do so can result in injury or death.
The DC link reactor does not normally require service. If it is replaced,
Rockwell Automation must approve the replacement link. The link is cooled by air that is drawn through its coils.
To service the DC link, see
. For more information, see publication
7000-IN003 .
1. Verify that the power source to the drive is locked out and that the filter caps are fully discharged.
2. Open the door to the DC link cabinet and remove the screws that retain the sheet metal barrier and low voltage panel.
3. Swing the low voltage panel to the left and disassemble the closing barriers that are on the left and right-hand side of the panel. Remove the nuts and washers that secure them to the sides of the structure.
Depending on the size of the DC link, it might be necessary to remove the low voltage panel. Lift the panel off its hinges and shift or rotate the panel so it does not obstruct the opening to the DC link cabinet.
Confirm that the equipment that is used to lift the panel is adequate to do this.
4. Disconnect the four power connections. The DC link is equipped with flexible power leads.
5. Disconnect wires at terminal block on DC link for thermal switch.
6. Remove the hardware that secures the DC link.
7. Disconnect the ground connection.
The DC link is heavy and has provision for lifting with forks of a lift truck.
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Chapter 3 Power Component Definition and Maintenance
Figure 83 - DC Link Removal
Step 3: Unfasten DC Link leads and remove terminal assembly.
Disconnect ground wire and LV wires for thermal switch.
Step 1: Remove hardware and DC Link and fan barrier.
Fan Barrier
108
Step 2: Remove grounding filter/network assembly.
Installation of the replacement DC link is performed in the reverse order of its removal.
The installer must verify that the flexible DC link leads are connected to the appropriate terminal and routed so that electrical clearances are maintained.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Step 4: Remove DC Link hardware and lift link out of the front of the drive.
Fan Replacement
Power Component Definition and Maintenance Chapter 3
Verify that the nameplate ratings are the same or appropriate for the drive system. Another DC link requires different parameter settings.
Thermal protection of the DC link reactor is provided by two contacts
(normally closed) wired to the I/O module. These contacts open at 190 °C
(374 °F) and cause a fault/alarm message to be displayed.
There are several models of cooling fans that are used in PowerFlex drives.
Different fan types can be used in the various locations throughout the drive.
DC Link Section
The fan consists of a motor impeller assembly. To replace the fan, you must
remove the fan exhaust hood (see Fan Hood Installation on page 26
). Fan replacement requires work at a significant height from the floor. Make a suitable platform from which to work. The fan motor weighs approximately
45 kg (100 lb).
ATTENTION: To avoid electrical shock, verify that the main power has been disconnected before working on the current transformer. Verify that all circuits are voltage free. Use a hot stick or appropriate voltage-measuring device. Failure to do so can result in injury or death.
To replace the fan, follow these steps:
1. Open the DC Link cabinet, and swing out the LV panel ( Figure 79
).
2. Disconnect the power leads to the fan motor.
IMPORTANT Note the terminal locations so that proper fan rotation is maintained.
3. Remove and retain the four M8 nuts that secure the fan assembly to the mounting bracket ( Figure 84 ).
4. Using a crane, hoist, or similar lifting provision, affix tie straps around opposite vertical brackets of the fan assembly and carefully lift the fan assembly out of the cabinet.
ATTENTION: Do not support the assembly on the impeller or damage can result.
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Chapter 3 Power Component Definition and Maintenance
Figure 84 - Fan Removal
Fan Impeller
Fan Motor
Mounting Holes
Mounting Bracket
Z-Bracket for
Fan Mounting
Fan Installation
Handle the fan assembly with extreme caution. If handled improperly, the fan becomes unbalanced.
Fan installation is performed in the reverse order of its removal. Rotate the impeller by hand to make sure that there is no contact with the inlet ring.
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Power Component Definition and Maintenance Chapter 3
Top of Integral Isolation Transformer Section
Figure 85 - Isolation Transformer Fan Removal
Mounting
Holes
Cross Channel
Terminal Blocks
Fan
Inlet Ring
1. Remove the top plate of the ventilation housing and label fan supply leads before disconnecting.
2. Remove the bolts that retain the cross channel and withdraw the fan and channel from housing.
3. Disassemble and replace the fan.
4. Reassemble in the reverse order of removal.
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Chapter 3 Power Component Definition and Maintenance
Top of Integral Line Reactor and Input Starter Section
Figure 86 - Starter/Line Reactor Cabinet Fan Removal
Ventilator Cover
Terminal Blocks
Fans
Fan Mounting Blocks
Impeller Maintenance
Inlet Ring Removal and
Replacement
1. Remove the top ventilation cover from the exterior of the cabinet.
2. Expose the mounting hardware of the fan by removing the mounting screws. Invert the fan mounting bracket.
3. Unplug or disconnect fan leads from terminal blocks and replace fan.
4. Reassemble in the reverse order of removal.
Isolation Transformer Cooling Fan
The isolation transformer fan motor and impeller is an integral unit and cannot be serviced separately.
The inlet ring is the large circular part that is located beneath the fan impeller.
It is positioned such that the impeller sits outside but does not touch the ring.
The ring sits inside the impeller 10 mm (0.40 in.).
This procedure requires coming in contact with the internal electrical connectors and devices.
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ATTENTION: All power MUST be removed from the drive. Failing to do so can result in serious injury or death.
Precautions must be taken to keep the inlet ring from falling after all bolts have been removed.
ATTENTION: To avoid electrical shock, verify that the main power has been disconnected before working within the DC Link and Fan Area. Verify that all circuits are voltage free. Use a hot stick or appropriate high voltagemeasuring device. Failure to do so can result in injury or death.
DC Link / Fan Section
If rear panel access is possible, remove rear middle panel of the DC link / fan portion of the cabinet and remove the inlet ring from the back.
Procedure
If rear panel access is not possible, follow this procedure:
1. Remove bolts and swing-out low voltage panel (see
2. Remove bolts from the inlet ring being careful not to allow the ring to fall.
3. Remove inlet ring by way of the bottom access panel. Move the inlet ring around the DC link and diagonally out the door. Shifting of the DC link can be required.
4. To install the new ring, reverse steps 1…3. To verify that there is no contact with the inlet ring, rotate the fan impeller by hand. Move the ring and retighten bolts to help mitigate interference.
5. Replace all panels and barriers that are opened or removed during inlet ring replacement.
Top of Integral Isolation Transformer Section
1. Remove fan as described in “Fan Replacement”.
2. Disassemble bolts and remove inlet ring.
3. To install new ring, reverse the steps 1 and 2. To verify that there is no contact with the inlet ring rotate the fan impeller by hand. Move the ring and retighten bolts to help mitigate interference.
4. Replace all panels and barriers that are opened or removed during inlet ring replacement.
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Chapter 3 Power Component Definition and Maintenance
Replacement of Air Filters
ATTENTION: For arc resistant drives, equipment is not rated as arc resistant while the filter covers are open. Filter covers must be bolted closed to maintain arc resistant structural integrity
Air filters are at the cooling air intake grille that is mounted on the door in front of the converter, line reactor, and transformer cabinets.
Periodically, remove and clean, or remove and replace the filter material. If the air for cooling is dirty, renew filters frequently.
Filters can be renewed while the drive is running, but the procedure is easier to perform while the drive is shut down.
1. Use an 8 mm (5/16 in.) Hex key to loosen the ¼ turn fasteners and swing open the hinged grill assembly.
2. Remove filter material.
If the drive is running, replace the filter as soon as possible so foreign material is not drawn into the drive.
IMPORTANT Keep dirt that is accumulated on the inlet side of the filter from being sucked into the drive. To remove the filter material without tearing the filter is difficult, due to the suction at the air inlet
Recommended methods to clean the filter:
• Vacuum Clean – vacuum the inlet side of the filter to remove accumulated dust and dirt in seconds.
• Blow with Compressed Air – point compressed air nozzle in opposite direction of operating airflow. Blow from exhaust side toward intake side.
• Cold Water Rinse – normally the foam that is used in the filters require no oily adhesives. Use a standard hose with plain water to was collected dirt away. (Verify that filter is dry before reinstalling) .
• Immersion in Warm Soapy Water – Where stubborn air-borne dirt is present, the filter can be dipped in a solution of warm water and mild detergent. Rinse in clear clean water. (Verify that filter is dry before reinstalling).
Use only replacement filters that are provided, or approved for use by Rockwell
Automation Replacement of the filters is performed in the reverse order of its removal. Check that there are no openings that would allow foreign matter into the drive.
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Figure 87 - Filter Replacement
Power Component Definition and Maintenance Chapter 3
Retaining Hardware
Filter
Figure 88 - Airflow Through PowerCage Module
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Chapter 3 Power Component Definition and Maintenance
Figure 89 - Airflow Pattern for Drive Cooling
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Power Component Definition and Maintenance Chapter 3
Fan Power Transformer
Customersupplied
2.4…6.6 kV
PowerFlex A frame medium voltage drives have an optional fan power transformer (FPT).
• For PowerFlex A frame RPDTD drives with an integral starter:
– If an FPT is required (customer-supplied 380…480V is not available) : the FPT steps primary line voltage down to supply
380…480V power to the main and redundant fans. A control panel transformer (CPT) steps the same primary line voltage down the low voltage (LV) panel.
– If an FPT isn’t required : Customer-supplied 380…480V power directly feeds the main and redundant fans. A CPT steps this down to feed the LV panel.
• For PowerFlex A frame RPDTD drives without an integral starter, and
PowerFlex A frame RPDTX drives:
– If an FPT is required (customer-supplied 380…480V is not available) : the FPT steps primary line voltage down to supply
380…480V power to the main and redundant fans. Customersupplied 110…240V is supplied directly to the LV panel.
– If an FPT isn’t required : Customer-supplied 380…480V power feeds directly to the main and redundant fans. Customer-supplied
110…240V is supplied directly to the LV panel through the CPT.
Figure 90 - FPT Wiring Configurations
FPT is Required:
MPR
Main
Fan
380…480V
FPT
MPR
Redundant
Fan
CPT
110…240V
LV Panel
FPT is Not Required:
Customersupplied
380…480V
MPR
MPR
Main
Fan
Redundant
Fan
CPT
110…240V
LV Panel
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Chapter
4
Control Component Definition and
Maintenance
Control Power Components
There are two configurations in which control power is distributed for the drive. The different methods are dependent on what drive option the customer has chosen:
1. Direct-to-Drive™ (transformerless AFE rectifier) ( Figure 91 )
2. AFE rectifier with separate isolation transformer (
3. AFE rectifier with integral isolation transformer ( Figure 93
).
Ride-through
Standard controls with 5 cycle ride-through – The drive main control boards will remain energized for a total of 5 cycles after control power is interrupted. If control power is not restored during the 5 cycles, a controlled shutdown occurs.
Figure 91 illustrates the control power distribution for AFE drives with
integral starter/line reactor.
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Chapter 4 Control Component Definition and Maintenance
Figure 91 - Direct-to-Drive (Transformerless AFE Rectifier)
- Operator Interface
- Relays
Customer
Supplied
120V 1 PH
Line
Filter
AC/DC Converter
600 W/ 1000W/ 1500 W
C Hold-up
DC/DC Converter
Sense Cable
VFD
Line
Reactor
Fan
DC Fail
380V 50 Hz or
460V 60 Hz
3 PH
5V-Logic
+/-15V Logic
+/-24V-HECS
24V-Isolators
24V-XIO
20V Isolated Gate
Driver Power Supply
Inverter only for SPS Drives
20V
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Control Component Definition and Maintenance Chapter 4
Figure 92 illustrates the control power distribution for AFE drives with remote
transformer/starter (A) or integrated line reactor with remote starter (B).
Figure 92 - AFE Rectifier with Separate Isolation Transformer
-Operator Interface
-Relays
Customer Supplied
120V
1 PH
AC/DC Converter
600 W/ 1000W/1500 W
DC Fail
VFD
A
Tx Fan
Fan
OR
VFD
Line
Reactor
Fan
380V 50 Hz
Or
460V 60 HZ
3 PH
B
C Hold-up
DC/DC Converter
Sense Cable
20V Isolated
Gate Driver
Power Supply
Inverter only for SPS Drives
+5V-LOGIC
+/- 15V-LOGIC
+/- 24V-HECS
+24V-ISOLATORS
+24-XIO
20V
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Chapter 4 Control Component Definition and Maintenance
Figure 93 illustrates the control power distribution for AFE drives with
integral transformer and remote starter.
Figure 93 - AFE Rectifier with Integral Isolation Transformer
-Operator Interface
-Relays
Customer Supplied
120V
1 PH
AC/DC Converter
600 W/ 1000W/ 1500 W
VFD
Tx Fan
380V, 50 Hz
Or
460V, 60 HZ
3 PH
Fan
C Hold-up
DC/DC Converter
+5V-LOGIC
+/- 15V-LOGIC
+/- 24V-HECS
+ 24V-ISOLATORS
+24-XIO
Sense Cable
20V Isolated
Gate Driver
Power Supply
Inverter only for SPS Drives
20V
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AC/DC Power Supply
Control Component Definition and Maintenance Chapter 4
The load demands on the AC/DC converters are the DC/DC converter and up to six IGDPS modules (up to three IGDPS modules for SPS drives). The
DC/DC is a fixed load; however, the quantity of IGDPS modules vary depending upon the drive configuration and whether SPS modules are used.
Description
The AC/DC power supply accepts single phase voltage and produces a regulated output
(1)
for the DC/DC power supply and the HV IGDPS modules that power the SGCTs. The input and output voltages are monitored and fail signals are announced when either voltage goes below a preset level.
Figure 94 - AC/DC Converter Power Supply
DC/DC
Power
Supply Single Phase
95…265V ac
47…63 Hz
0.98PF @ 1000 W or
0.98PF @ 1500 W
AC.DC Power Supply
Cosel PS Output 57V DC
600 W/ 1000W/ 1500 W
HV IGDPS
Power
Supply
DC FAIL : Upon loss of DC output (V outputs ≤ 49V DC) this output goes from low to high.
(1) Cosel power supply output 57V DC, Pioneer power supply output is56V DC.
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Chapter 4 Control Component Definition and Maintenance
Location
The AC/DC power supply is located in the low voltage panel at the top righthand section of the drive, see
Figure 95 - Location of AC/DC Cosel (single) Power Supply on Low Voltage Panel
AC/DC Power Supply
(Cosel)
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Control Component Definition and Maintenance Chapter 4
Figure 96 - Location of AC/DC Cosel (Dual) Power Supply on Low Voltage Panel
AC/DC Power
Supply (Cosel)
Diode
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Chapter 4 Control Component Definition and Maintenance
Terminal / Connections Descriptions
The terminal connections are shown in
Figure 97 - Terminal locations on 1000W AC/DC Power Supply (Cosel)
Single Phase
Input
Control Signals
Adjustment Pot
DC Outputs
Figure 98 - Terminal Locations on 600 W AC/DC Power Supply (Cosel)
Terminal/Connections
Descriptions
(600W Cosel Power Supply)
126
Single Phase Input
DC Outputs
Control Signals
Adjustment Pot
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Control Component Definition and Maintenance Chapter 4
P1-AC Input
P2-DC Output
P3-Fail Output
+
–
FG
PIN#
PIN#
AC (L)
AC (N)
NC
PIN#
CN1
CN2
CN3
LABEL
Live
Neutral
No Connection
Earth
LABEL
+57V
+57V COMM
LABEL
1-2 Connected
3-4 Connected
5, 6, 7, 8, 9, 10 N/C
N/C
7 - Alarm
8 - Alarm GND
Output Calibration
Verify that the output of the supply is 56V DC
(1)
.
There is a potentiometer on the top of the power supply that adjusts the
56V DC
output for the power supply. Isolate the output of the power supplies;
multiple supplies in parallel affect your measurements. With the control power on and the output of the AC/DC Converter that is isolated from the drive control,
adjust the potentiometer until the output equals 56V DC
each power supply. When all adjustments are complete, reconnect the power supply to the circuit and remeasure the output. Readjust if necessary.
cannot be maintained, the power supply can be faulty. In multiple power supply configurations, the final output voltage after the diodes can be in the range of 56…57V DC.
(1) 56V DC for Cosel model numbers -XRWAC and earlier. 57V DC for Cosel model numbers -XRWAD and newer.
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Chapter 4 Control Component Definition and Maintenance
Single Power Supply Replacement
The single power supply (see Figure 95 on page 124
) is replaced using the following procedure. Retain all hardware for re-installation.
1. Verify that control power has been isolated and locked out.
2. Disconnect the terminals at the unit.
3. Remove the four M6 bolts from the bracket holding the power supply.
M6 Bolts
4. Extract the power supply complete with bracket from the drive.
5. Remove the brackets from the failed power supply (four M4 screws and nylon shoulder washers).
Power Supply
Polypropylene Sheet
Power Supply
Mounting Bracket
Nylon Shoulder Washer
M4 Screw
6. Attach the bracket to the replacement power supply. The black polypropylene sheet must be between the AC/DC power supply and the mounting plate of the bracket.
7. Repeat steps 6...1 in this order to replace the unit.
8. Reapply control power and verify voltage levels.
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Control Component Definition and Maintenance Chapter 4
Dual Power Supply Replacement
If there are two power supplies (see Figure 96 on page 125
) follow these steps to replace one or both of the power supply units. Retain all hardware for reinstallation.
1. Verify that control power has been isolated and locked out.
2. Disconnect the terminals at the unit.
3. Remove the M6 screws from the diode safety cover.
M6 Head Screw
M6 Hex Screw
(Phillips Head)
Low Voltage
Swing-out Tub
Diode Safety Cover
Diode
Bracket
M6 Bolts
4. Remove the diode cover from the diode.
5. Remove the M6 Hex screws from diode.
6. Remove the diode from the panel.
7. Remove the four M6 bolts from the bracket holding the power supply.
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Chapter 4 Control Component Definition and Maintenance
M6 Bolts
Low Voltage
Swing-out Tub
Bracket
8. Extract the power supply complete with bracket from the drive.
9. Remove the brackets from the failed power supply (four M4 screws and nylon shoulder washers).
Power Supply
Polypropylene Sheet
Power Supply
Mounting Bracket
Nylon Shoulder Washer
M4 Screw
10. Attach the bracket to the replacement power supply. The black polypropylene sheet must be between the AC/DC power supply and the mounting plate of the bracket.
11. Clean the diode contact area and apply thermal grease to the area.
12. Repeat Steps 10...1 in this order to replace the unit.
13. Reapply control power and verify voltage levels.
130 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Low Voltage
Swing-out Tub
Control Component Definition and Maintenance Chapter 4
Diode Replacement
To replace of diode follow these instructions.
1. Verify that control power has been isolated and locked out.
2. Disconnect the terminals at the unit.
3. Remove the M6 screws from the diode safety cover.
4. Remove the diode cover from the diode.
5. Remove the M6 Hex screws from diode.
6. Remove the diode from the panel.
7. Clean the diode contact area and apply thermal grease to the area.
8. Reinstall the unit following the steps 6…1 in reverse.
M6 Head Screw
M6 Hex Screw
(Phillips Head)
Diode Safety Cover
Diode
Bracket
M6 Bolts
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Chapter 4 Control Component Definition and Maintenance
UPS Option
The PowerFlex™ 7000 “A” Frame drive has the option for internal and external
UPS power. This keeps the control power active within the drive in the event of a control power loss. The following diagram shows the current configuration of the internal UPS option.
Figure 99 - 300 W AC/DC Power Supply
300 W AC/DC
Power Supply
The Holding Bracket
Hold-up Capacitor
132
UPS
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Control Component Definition and Maintenance Chapter 4
The UPS is installed in the incoming cabling section in the UPS LV control section.
The UPS maintains control power to all critical 120V AC loads and an extra
AC/DC power supply that feeds the DC/DC power supply for powering all drive control components. The main drive cooling fan is not powered from this UPS.
The UPS uses the AS400 communication protocol, and feeds several status signals back to the ACB to control responses to various conditions. These conditions include low batteries, loss of input power, UPS Okay, and UPS on bypass.
If the customer has an external UPS, the firmware does not expect any of the signals that are mentioned in the previous section. No information that is related to the UPS status is displayed. The firmware operates in the same manner regarding the operation of the drive with an internal or external UPS.
The output of the UPS feeds a 300 W AC/DC power supply. This supply is
20% of the standard AC/DC power supply that is used in the drive. The load that is represented by the DC/DC power supply is much smaller than the load of the IGDPS boards, and the size is reduced accordingly. The standard AC/
DC power supply is used to feed the IGDPS boards. The 300 W AC/DC power supply has an AC input that is monitored by the UPS, and the DC output that is monitored by the ACB board for fault conditions.
A hold-up capacitor on the output of the 300 W AC/DC power supply maintains the 56V DC
(1)
if there is a failure of the power supply.
Replacing the UPS
IMPORTANT To replace the UPS battery, refer to the UPS user manual that was shipped with the drive.
1. Isolate and lockout the control power.
2. Remove the hardware that fastens the holding bracket to the cabinet assembly and remove the holding bracket.
3. Disconnect the input and output wiring that is connected to and from the UPS.
4. Disconnect the 15-pin status plug and remove the UPS.
ATTENTION: Before installing the new UPS, check the battery recharge date on the shipping carton label. If the date has passed and the batteries were never recharged, do not use the UPS. Contact Rockwell Automation.
(1) 56V DC for Cosel model numbers -XRWAC and earlier. 57V DC for Cosel model numbers -XRWAD and newer.
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Chapter 4 Control Component Definition and Maintenance
5. Before installing the new UPS, the internal battery must be connected.
(1) a. Remove the UPS front cover. Push down on the top of the cover and pull the cover towards you to unclip the cover from the cabinet.
b. Connect the white connectors together, connecting red to red, and black to black. Verify that there is a proper connection.
c. Remove and retain the two screws from the screw mounts.
d. Place the battery connector between the screw mounts. Reinstall the two screws that hold the connector in place.
e. Replace the UPS front cover.
Figure 100 - Connect the Internal UPS Battery
134
6. Reconnect all connections that are removed in the previous steps.
7. Before reconnecting the mounting bracket, apply control power to the unit and verify that the UPS is configured for the AS400 communication protocol. See the manual that comes with the UPS for instructions.
8. When the configuration has been confirmed, install the mounting bracket.
(1) Reprinted from 700-3000 VA User’s Guide by permission of Eaton Corporation.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Control Component Definition and Maintenance Chapter 4
Low Voltage Control Section
The low voltage control section houses all control circuit boards, relays,
Operator Interface Terminal, DC/DC power supply, and most other low voltage control components.
Figure 101 - Low Voltage Tub Compartment (Cosel Power Supply)
Analog
Control
Board
Optical
Interface
Boards
Drive
Processor
Module
DC to DC
Power
Supply
Hinged
Panel
(Closed)
Hinged
Panel
(Closed)
DC/DC Power Supply
Description
The DC/DC power supply is used as a source of regulated DC voltages for various logic control boards and circuits. The input to this power supply is from a regulated 56V DC
(1)
source.
Figure 102 - DC/DC Converter Power Supply
+
56…57V DC
-
C hold-up
DC/DC
Power Supply
+5V-LOGIC
+/- 15V-LOGIC
+/- 24V-HECS
+/- 24V-ISOLATORS
+24-XIO
Sense Cable
(1) 56V DC for Cosel model numbers -XRWAC and earlier. 57V DC for Cosel model numbers -XRWAD and newer.
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Chapter 4 Control Component Definition and Maintenance
The capacitor at the input terminals enables the equipment to ride through power dips. If the capacitor (C hold-up) loses the 56V
(1)
input, it maintains the voltage level for a period of time to enable a controlled shut-down. This component is not required in all configurations.
Due to the critical nature of the ACB/DPM Logic power source, the DC/DC power supply provides redundancy for the 5V rail. There are two separate 5V outputs, each capable of powering the logic boards. In the event of one failing, the drive switches to the other power supply automatically to provide the output power.
Terminal/Connections Descriptions
P1 – DC Input
2
3
PIN NO.
LABEL
1 +56V
+56V COMM
EARTH
DESCRIPTION ONLY
+56V input
+56V common
Earth ground
P2 – SENSE (To ACB) PIN NO.
LABEL
1 +56V
2
3
+56V RTN
NC
6
7
4
5
NC
+24V
+24V RTN
NC
12
13
14
10
11
8
9
NC
+5VA
DGND (com1)
+5VB
DGND (com1)
ID0
ID1
DESCRIPTION ONLY
+56V input supply
+56V input supply return
Not Connected
Not Connected
Isolated +24V Supply
Isolated +24V Supply return
Not Connected
Not Connected
Primary +5V supply, before OR’ing diode
+5V, +/-15V Common
Secondary +5V supply, before OR’ing diode
+5V, +/-15V Common
Power Supply ID Pin 0
Power Supply ID Pin 1
P3 – ISOLATOR
(To Isolator Modules)
PIN NO.
LABEL
1
2
3
ISOLATOR (+24V, 1 A)
ISOL_COMM (com4)
EARTH
DESCRIPTION ONLY
+24V, 1A/com4
0V/com4
EARTH
136
(1) 56V DC for Cosel model numbers -XRWAC and earlier. 57V DC for Cosel model numbers -XRWAD and newer.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Control Component Definition and Maintenance Chapter 4
P4 – PWR
(To ACB)
PIN NO.
LABEL
7
8
5
6
3
4
1
2
9
10
11
DESCRIPTION ONLY
+24V_XIO (+24V, 2 A)
XIO_COMM (com3)
+24V, 2 A/com3
0V/com3
+HECSPWR (+24V, 1 A) +24V, 1 A/com2
LCOMM (com2) 0V/com2
–HECSPWR (-24V,1 A) -24V, 1 A/com2
+15V_PWR (+15V,1 A) +15V, 1 A/com1
ACOMM (com1)
-15V_PWR (-15V,1 A)
0V/com1
-15V, 1 A/com1
+5V_PWR (+5V,5 A)
DGND (com1)
EARTH
+5V, 10 A/com1
0V/com1
Earth ground
Replacement Procedure for DC/DC Power Supply
1. With the drive energized, check that all output voltages are present
(View 1,
2. De-energize the drive, isolate, and lockout the control power, and
remove all wire connections from the unit (View 1, Figure 103
).
3. Remove quantity of four M6 (H.H.T.R.S.) that allows the DC/DC
Power Supply Assembly to be removed from the low voltage panel.
(View 1,
).
4. Remove quantity of four M4 (P.H.M.S.) and nylon shoulder washers
from the back of the mounting plate (View 2, Figure 103
).
5. Replace old DC/DC Power Supply with the new one.
Verify that the black insulation is between the DC/DC power supply and the mounting plate. Repeat steps 4...1 in this order to replace unit
(View 2,
).
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Chapter 4 Control Component Definition and Maintenance
6. Verify that the ground wire of P4 plug is connected to the ground by
M10 bolt.
Figure 103 - Replacement of DC/DC power supply
M4 (P.H.M.S.) and nylon shoulder washer
Mounting Plate
Black insulation
Printed Circuit Board
Replacement
Part ID label
DC/DC
Power Supply
View “2”
View “1”
M6 (H.H.T.R.S)
The replacement of printed circuit boards must be handled in a careful manner.
IMPORTANT Remove all power to the drive.
Do not remove the replacement board from the anti-static bag until necessary.
Use anti-static wriststrap, which is grounded in the Low Voltage Control
Section.
There are no direct screw/terminal connections on any of the low voltage circuit boards. All wire/terminal connections are made with plugs that plug into the circuit boards. Changing boards only requires the removal of the plugs, which minimizes the chance of mistakes when reconnecting the wiring.
138 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Drive Processor Module
Control Component Definition and Maintenance Chapter 4
This board contains the control processors responsible for all drive control processing and stores all parameters that are used for the drive control.
Figure 104 - Drive Processor Module (DPM)
Test Points
Primary Secondary
Battery
Inverter
Gating
Signals
HMI
Interface
Module
Rectifier
Gating
Signals
DPM Data Port
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Primary Secondary
139
Chapter 4 Control Component Definition and Maintenance
Diagnostic test points on the DPM have a voltage output range of -5…+5V.
The following is the list of test points on the DPM:
Table 5 - Test Points on Drive Processor Module
DPM-TP9
DPM-TP10
DPM-TP7
DPM-TP11
DPM-TP12
DPM-TP13
DPM-TP14
Test Points
DPM-TP1
DPM-TP2
DPM-TP3
DPM-TP4
DPM-TP5
DPM-TP6
DPM-TP8
ITP2
ITP3
ITP4
RTP4
RTP3
RTP2
RTP1
Name
+1.2V
+1.8V
+2.5V
+3.3V
+5V
DGND
ITP1
Description
+1.2V DC power supply
+1.8V DC power supply
+2.5V DC power supply
+3.3V DC power supply
+5V DC power supply
Digital ground
Digital to Analog output – Assignable diagnostic test point
Digital to Analog output – Assignable diagnostic test point
Digital to Analog output – Assignable diagnostic test point
Digital to Analog output – Assignable diagnostic test point
Digital to Analog output – Assignable diagnostic test point
Digital to Analog output – Assignable diagnostic test point
Digital to Analog output – Assignable diagnostic test point
Digital to Analog output – Assignable diagnostic test point
This table defines the states of status indicators D9 and D11 on the DPM board. D9 is used for the inverter side processor and D11 is for the rectifier side processor. The other two status indicators (D6 and D7) are the watchdogs for the inverter and rectifier code respectively.
Red
Red
Red
Table 6 - Description of D9 and D11 Function
Red
Red
Red
Red
Red
Red
Color
Green
Red
Green
Green
Green
Green
Green
Solid
2 count
3 count
4 count
8 count
9 count
Rate of Count (Pulse)
10 count
0.25 Hz
0.25 Hz
0.5 Hz
2 Hz
1 Hz
Solid
10 count
11 count
14 count
Meaning
Pre-execution OK
No bootcode
No application
Downloading by way of serial port
Serial port active – (terminal)
Waiting/loading application
Operation running or successful
Operation failed
POST – RAM failed
POST – NVRAM failed
POST – DPRAM failed
FPGA Loading failed
POST – USART failed:
1 Green Count = Port 1
2 Green Count = Port 2
End of code reached
Download – CRC error
Download – Overflow error
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Control Component Definition and Maintenance Chapter 4
Drive Processor Module Replacement
Before replacing the drive processor module, record all programmed drive parameters and settings. Specifically, the parameters, fault masks, fault descriptions, and PLC links are critical. This information is stored in NVRAM on each, and as a result you can lose your settings with a new board.
To record parameters, use the memory on the terminal. Other options include a Flashcard, HyperTerminal, the door-mounted printer, or DriveTools
™ software to record the parameters to a file.
To print all drive setup information, use the printer and HyperTerminal. In the situation where a board has failed, you probably will not be able to save parameters after the failure. In this case, contact the customer to see if they have a copy of the last parameters, or contact Product Support to check if they have a copy.
IMPORTANT Save all parameters when you are finished commissioning or servicing the drive.
1. Record all drive setup information using any of the previously mentioned options.
2. Verify that all medium voltage and control voltage power to the drive is isolated and locked out.
3. It is required to first remove the transparent sheet on top of the drive processor module by removing the four screws.
4. Use static strap before removing any connectors.
5. Remove the connectors J4, J11, and J12 after proper identification and marking if necessary. Use the electrical drawing as the reference.
6. Remove the four screws on the corners of the board fastening the board to the standoffs on the analog control board ACB.
7. Gently remove the drive processor module from the four, 34-pin female connectors and one, 16-pin female connector on the ACB.
IMPORTANT Remove the DIM module from the DPM. Plug DIM module on the new DPM before the replacement of DPM.
8. Follow steps 7...3 in this order to reinstall the boards back into the low voltage control cabinet.
9. Apply control power to the drive. The DPMs are shipped with no firmware installed, so the drive automatically goes into download mode.
Install firmware in the drive following the guidelines in publication
7000-UM201A .
10. Program the drive. See publication 7000-TD002 .
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Chapter 4 Control Component Definition and Maintenance
Figure 105 - ACB and DPM Replacement
142 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Analog Control Board
Analog Control Board
Control I/O
Status and
Control
Power
Monitoring
Line Current
Inputs
Control Component Definition and Maintenance Chapter 4
The Analog Control Board (ACB) is the hub for all control-level signals external to the drive. Analog I/O, External Fault signals (through the XIO board), SCANport/DPI communication modules, Remote I/O, terminal interface, printers, modem, and other external communication devices are routed through this board.
Figure 106 - Analog Control Board
Encoder
Interface
Motor andLine
AC Voltage
Feedback Inputs
Motor and
Line DC Link and Neutral
Point Voltage
Motor Current
Inputs
DC Link
Current
Inputs
Ground Fault and CMC
Neutral Current
Inputs
Comms
Connections
Air
Pressure
Inputs
Meter Inputs &
Speed Pot Input
Comms Connections
Terminal (PanelView)
DC Power Supply
Monitoring
XIO-PWR(+24V,+/-15V, +/-24V,
+5V DIG, DC Power Supplies)
DC -ABUS +56V
Monitoring (in UPS option)
DC Fail
Signal
Monitoring
DPI™
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 143
Line Voltage
Sync. Transfer
Feedback
Inputs
UPS Fail
Signal
Monitoring
Comms
Connections
DCSL
Comms
Connections
XIO Board
Chapter 4 Control Component Definition and Maintenance
The ACB receives all Analog Signals from the internal components of the drive including the current and voltage feedback signals. The boards also have isolated Digital I/O for fan status, E-stops, and contactor control and status feedback. All test points for the currents, system voltages, control voltages, and flux are on these boards.
ACB-J17
ACB-J18
ACB-J19
ACB-J20
ACB-J21
ACB-J22
ACB-J23
ACB-J24
ACB-J9
ACB-J10
ACB-J11
ACB-J12
ACB-J13
ACB-J14
ACB-J15
ACB-J16
ACB-J25
ACB-J26
ACB-J27
ACB-J28
ACB-J30
ACB-J31
ACB-J32
ACB-J33
ACB-J34
Table 7 - Connectors on Analog Control Board
ACB Connectors
ACB-J1
ACB-J2
ACB-J3
ACB-J4
ACB-J5
ACB-J6
ACB-J7
ACB-J8
Description
Control I/O and control power monitor
Line current inputs, CT2U, CT2W
Line current inputs, CT3U,CT3W
Line current inputs, CT4U,CT4W
Motor current inputs, HECSU, HECSW
DC Link current inputs, HECSDC1, HECSDC2
Ground fault and CMC Neutral current inputs, GFCT, INN
Isolated and non-isolated analog inputs, AIN1,AIN2,AIN3 and Non-isolated outputs,
AOUT1, AOUT2, AOUT3, AOUT4
Air pressure inputs, AP0, AP1
Meter outputs, AOUT5, AOUT6, AOUT7, AOUT8, and Speed Pot input, AIN0
Communication connections, printer outputs
Communication connections, Terminal
DC power supplies, XIO(+24V),+/-15V,+/-24V,+5V
DC power supply monitoring, 5V1, 5V2, DC-BUS
DC-ABUS +56V output monitoring (UPS option)
DPI interface
Communication connections, scan port
DC fail signal monitoring
DC fail signal monitoring
DC fail signal monitoring
DC fail signal monitoring
Communication connection, XIO link CAN interface
Communication connection, parallel drive
UPS fail signal monitoring
Line-voltage synchronous transfer feedback voltage inputs VSA,VSB,VSC
Motor and line DC link and Neutral Point Voltage inputs
AC Motor and Line-voltage feedback inputs
Encoder interface
DPM connection, A/D SUB system
DPM connection, DACs serial data
DPM power supply, +5V
DPM connection, Faults & other I/O
DPM connection, Encoder
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Control Component Definition and Maintenance Chapter 4
Table 8 - Test Points on Analog Control Board
ACB-TP23
ACB-TP24
ACB-TP25
ACB-TP26
ACB-TP27
ACB-TP28
ACB-TP29
ACB-TP30
ACB-TP15
ACB-TP16
ACB-TP17
ACB-TP18
ACB-TP19
ACB-TP20
ACB-TP21
ACB-TP22
ACB-TP7
ACB-TP8
ACB-TP9
ACB-TP10
ACB-TP11
ACB-TP12
ACB-TP13
ACB-TP14
Test points
ACB-TP1
ACB-TP2
ACB-TP3
ACB-TP4
ACB-TP5
ACB-TP6
ACB-TP31
ACB-TP32
ACB-TP33
ACB-TP34
ACB-TP35
ACB-TP36
ACB-TP37
ACB-TP38
ACB-TP39
ACB-TP40
ACB-TP41
ACB-TP42
V3uv
V3vw
V3wu
I3u
I3w
Vzs3
Vn2
V3_pk
I2u
I2w
Vzs2
Vn1
V2_pk
Vdcr1
Idc1
Vvws
Vn
V_pk
Vdci1
Vdci2
Vuvs
V2uv
V2vw
V2wu
Name
Vuv
Vvw
Vwu
Iu
Iw
Vzs
Vzs4
Vnn
Inn
Ignd
Vdcr2
Idc2
Vwus
V4uv
V4vw
V4wu
I4u
I4w
Description
Motor voltage feedback, UV
Motor voltage feedback, VW
Motor voltage feedback, WU
Motor current, HECSU
Motor current, HECSW
Zero sequence generation motor-side, VZS
Motor side filter CAP neutral voltage, MFCN
Motor over voltage detection for UVW
Motor side DCLINK voltage for bridge #1, VMDC1
Motor side DCLINK voltage for bridge #2, VMDC2
Line voltage synchronous feedback, VSAB
Line voltage feedback, 2UV
Line voltage feedback, 2VW
Line voltage feedback, 2WU
Line current, CT2U
Line current, CT2W
Zero sequence generation line-side, VZS2
Line filter CAP neutral voltage for bridge #1, LFCN1
AC over voltage detection for 2UVW
Line side DCLINK voltage for bridge#1,VLDC1
DCLINK current, HECSDC1
Line voltage synchronous feedback, VSBC
Line voltage feedback, 3UV
Line voltage feedback, 3VW
Line voltage feedback, 3WU
Line current, CT3U
Line current, CT3W
Zero sequence generation line side, VZS3
Line filter CAP neutral voltage for bridge #2, LFCN2
AC over voltage detection for 3UVW
Line side DCLINK voltage for bridge#2, VLDC2
DCLINK current, HECSDC2
Line voltage synchronous feedback, VSCA
Line voltage feedback, 4UV
Line voltage feedback, 4VW
Line voltage feedback, 4WU
Line current, CT4U
Line current, CT4W
Zero sequence generation line-side, VZS4 (spare one)
CMC neutral voltage, VNN
CMC neutral current, INN
Ground fault current, GFCT
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Chapter 4 Control Component Definition and Maintenance
Table 8 - Test Points on Analog Control Board (Continued)
ACB-TP66
ACB-TP67
ACB-TP68
ACB-TP69
ACB-TP70
ACB-TP71
ACB-TP72
ACB-TP73
ACB-TP58
ACB-TP59
ACB-TP60
ACB-TP61
ACB-TP62
ACB-TP63
ACB-TP64
ACB-TP65
ACB-TP74
ACB-TP75
ACB-TP76
ACB-TP77
ACB-TP78
ACB-TP79
ACB-TP80
ACB-TP81
ACB-TP82
ACB-TP83
ACB-TP50
ACB-TP51
ACB-TP52
ACB-TP53
ACB-TP54
ACB-TP55
ACB-TP56
ACB-TP57
ACB-TP43
ACB-TP44
ACB-TP45
ACB-TP46
ACB-TP47
ACB-TP48
ACB-TP49
AIN1
AIN2
AIN0
AIN3
DGND
AGND
AP1
AP0
AGND
AGND
+5V
+15V
-15V
+24V
-24V
24VCOM
OPCS
OP
BPIS
BPCS
IPIS
IPCS
IP
OPIS
BP
DGND
Z-
CP1
CP2
CP3
CP4
Vltrp
AGND
AGND
A-
B-
B+
Z+
Vspr
Vmtrp
A+
Spare channel for inputs
Motor over voltage detection set point
Encoder A+ input
Encoder B+ input
Encoder Z+ input
Encoder A-input
Encoder B- input
Encoder Z- input
Control power monitoring for channel 1
Control power monitoring for channel 2
Control power monitoring for channel 3
Control power monitoring for channel 4
AC over voltage detection set point for 2UVW and 3UVW
Analog ground
Analog ground
Analog ground
Analog ground
+5V DC power supply
+15V DC power supply
-15V DC power supply
+24V DC power supply
-24V DC power supply
+/- 24V common
Digital ground
Analog ground
Analog control Inputs, air pressure input, AP1
Analog control Inputs, air pressure input, AP0
Analog control Input, AIN1
Analog control Input, AIN2
Analog control Input, AIN0
Analog control Input, AIN3
Input isolating switch
Input contactor status
Input contactor command
Output isolating switch
Output contactor status
Output contactor command
Bypass isolating switch
Bypass contactor status
Bypass contactor command
Digital ground return
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Interface Module (IFM)
The interface module is used to make all customer useable connections to the
ACB. The pin numbers that are listed on the following pages refer to IFM pin numbers.
Figure 107 - Interface Module
Even pin Numbers
Odd pin Numbers
Connection to ACB (J8)
Analog Inputs and Outputs
The PowerFlex 7000 drive offers one isolated process current-loop transmitter and three isolated process current-loop receivers, which are embedded into the control. They are accessible on the ACB.
The isolated process output is configured as 4...20 mA. The three isolated process inputs are individually configurable for either a range of -10/0/+10V or
4...20 mA (Refer to Programming Manual).
The following information shows the connections for each input and output.
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Chapter 4 Control Component Definition and Maintenance
Current Loop Transmitter
The current loop transmitter transmits 4...20 mA output to an external receiver. The loop compliance on the transmitter is 12.5V. Loop compliance is the maximum voltage at which a transmitter can generate to achieve the maximum current and is usually a function of the power supply voltage.
Therefore, the PowerFlex 7000 transmitter can drive a receiver with an input resistance up to 625
Ω
shows a block diagram of the transmitter.
Figure 108 - Process Loop Transmitter Block Diagram
+15V
+15V
Isolated
DC/DC
Converter
5V
DSP
FPGA
Optical
Interface
#
D/A ŀ Current
Boost
IFM
20
18
19
21
This type of transmitter is known as a 4-wire transmitter, and will “sink” current from a receiver. The receiver is connected by two wires only from pins
20 (+ connection) and either pins 18, 19, 21 (- connection).
The recommended connection is shown in Figure 108
. The type of shielded cable that is used is application-specific. The type is determined by the length of the run, the characteristic impedance, and the frequency content of the signal.
148 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
1,5,9
Control Component Definition and Maintenance Chapter 4
-
+
Isolated Process Receiver
+
These inputs are individually configurable to accept either a -10/0/+10V input signal or a 4...20 mA signal. When configured for voltage input, each channel has an input impedance of 75 kΩ. When used as a current loop input, the transmitter must have a minimum loop compliance of 2V to satisfy the 100 Ω input impedance. Regardless of input configuration, each input is individually isolated to ± 100V DC or 70V RMS AC.
Figure 109 shows a block diagram of the receiver.
Figure 109 - Process Loop Receiver Block Diagram
Buffer
A/D
X1 ŀ /#
U1
FPGA
DSP
-
Isolation Amplifier
1s1st I/P pins
2nd I/P pins
2,6,10
3,7,11
4,8,12
DC
3rd I/P pins
The receiver can accept 4-wire transmitters. Figure 110 shows the recommended connections. Again, the type of shielded cable that is used is application-specific as per the transmitter. Pin numbers that are shown are for connection to the first of three isolated process receivers.
Figure 110 - Process Loop Receiver Connections
VPP
GND
4-Wire Transmitter
Out
RTN
2
1
3
4
IFM
User-supplied power
(Sinking)
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Chapter 4 Control Component Definition and Maintenance
Non-Isolated Process Outputs
The drive supplies four non-isolated -10/0/+10V outputs for customer use.
These outputs can drive loads with impedances as low as 600 Ω. These outputs are all referenced to the drive AGND and therefore must be isolated if they are required to drive outside the PowerFlex ‘A’ frame enclosure.
Figure 111 - Non-isolated Configurable Analog Outputs on ACB
DSP
FPGA
A2D
Buffer
IFM Pin Number
27, 31,35,39
Analog
Output
25,29,33,37
28,32,36,40
150
Auxiliary +24V Power Supply
An Isolated 24V Power Supply is built into the DC/DC converter (Connector
P3). This supply can be used for any customer supplied equipment that requires up to 24 W at 24V. This supply can also be used to power any custom drive options, such as isolation modules for additional Process Control
Outputs. The health of this power supply is monitored in the drive.
2
3
PIN NO.
1
DESCRIPTION
ISOLATOR (+24V, 1 A)
ISOL_COMM (com4)
EARTH
The ACB is common for both the line and motor-side current feedbacks.
Different scaling resistors are mounted on the terminal block for line side and machine side
There are two status indicators on the ACB labeled D7 and D9. D9 is the
±15V DC voltage-OK signal, and D7 is the +5V DC voltage-OK signal.
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Control Component Definition and Maintenance Chapter 4
Replacing the Analog Control Board
To replace the analog control boards,
1. Verify that all medium voltage and control voltage power to the drive is isolated and locked out.
2. It is required to remove the transparent sheet on top of the drive processor module and the drive processor module also before removing the ACB. Remove the transparent sheet on top of the DPM by removing the four screws.
3. Use static strap before removing any connectors.
4. Mark, identify, and remove the connectors J4, J11, and J12 on DPM.
Use the electrical drawing as the reference. Remove the four screws holding the DPM on the standoffs above the ACB.
5. Gently remove the DPM mounted on the four, 34-pin connectors.
6. Remove the screws that hold the encoder interface board and gently remove the board that is mounted on the 8-pin connector.
7. Mark, identify, and remove the connectors J1, J2, J3, J4, J5, J6, J7, J8, J9,
J10, J12, J13, J14, J16, J22, J24, J25, J26, J27 on ACB. Use the electrical drawing as the reference.
8. Remove the ACB board by removing the four screws, and six standoffs screwed to support the DPM and encoder interface board.
9. , Reinstall the boards into the low voltage control cabinet by following steps 8...2, in that order.
10. Apply low-voltage power and complete a system test and medium voltage tests. These tests verify that the new board functions properly.
Encoder Feedback Board
Encoder Options
There are two positional encoder interface boards that can be used with the
PowerFlex 7000 ForGe control. The encoder interface boards do not have any test points that are accessible. However, buffered and isolated versions of each of the signals A+, A-, B+, B-, Z+ and Z- are available on the ACB at test points
TP45-TP50.
Regardless of which type of encoder board, follow these conditions:
1. Do not attach encoders with open collector outputs to the drive.
Acceptable outputs are analog line driver or push pull.
2. The drive does not operate properly with single ended quadrature encoders. Rockwell Automation recommends using differential inputs only for these types of encoders. Single ended outputs are only acceptable for Positional Encoders.
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Chapter 4 Control Component Definition and Maintenance
+5V
J3
Output
Config.
20B-ENC-1 & 20B-ENC-1-MX3 Encoder Interface
This encoder interface allows the drive to be connected to a standard quadrature encoder. The 20B-ENC encoder interface provides three optically isolated differential encoder inputs for A and B phases and a Z track. These inputs cannot be configured for use with single ended encoder. Differential encoders only are supported. The board also provides a galvanized, isolated
12V/3 W supply to power the attached encoder. The 20B-ENC-1 Encoder interface can be configured for 5V operation, however Rockwell Automation recommends operation at 12V.
Figure 112 - Encoder Interface (20B-ENC-1 and 20B-ENC-1-MX3)
+12V
+12V
+5V
J2
Input
Config
152
Must be configured for 12V operation.
Operation at 5V does not allow for long cable lengths as the power must be regulated within 5% at the encoder. Due to the resistance and capacitance of the cable, there would be difficultly keeping the power regulated at the encoder to 4.75V. With longer runs of cable, power could drop below the 4.75V and the encoder would not operate properly. Generally, 18 Avg cabling is used with a Rdc of 19.3 Ω/km. The longest cable distance from the board to the encoder is limited to 12 m (42 ft).
The 20B-ENC-1-MX3 encoder option is functionally identical to the 20B-
ENC-1 encoder with the addition of conformal coating. Figure 112 shows the recommended jumper positions for use with the PowerFlex 7000 drive.
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Control Component Definition and Maintenance Chapter 4
Input Connections
All encoder interface connections are made to J1. The connections are as follows:
• J1 Pin 1 A+
• J1 Pin 2 A-
• J1 Pin 3 B+
• J1 Pin 4 B-
• J1 Pin 5 Z+
• J1 Pin 6 Z-
• J1 Pin 7 encoder power return
• J1 Pin 8 encoder power (+12V @ 3 watts)
80190-759-01, 80190-759-02 Universal Encoder Interface
The Universal Encoder Interface allows the drive to be connected to an absolute position encoder or a standard quadrature encoder. The interface also provides the option for dual or redundant quadrature encoders. The universal encoder interface provides 12 single ended or 6 differential, optically isolated inputs, and a 12V/3 W galvanized, isolated encoder power source. When using absolute encoders, the 12 single ended inputs are used. For quadrature encoders, the six differential inputs are used.
Either type of encoder with frequencies up to 200 kHz, can be interfaced to the universal encoder interface.
The 80190-759-02 universal encoder interface is functionally identical to the
80190-759-01 with the addition of conformal coating. Jumpers that are installed on the 12-position header J4 configure the universal encoder interface. The header has three positions that are labeled ‘Park’ and used to store the jumpers when indicated as “Removed” in Table 9 . If labeled
“Installed” each function is selected by moving its corresponding jumper from the ‘park’ location to the selected function location. The following table describes the functions available.
ATTENTION: Removing the Universal Encoder Interface while control power is applied can result in damage to the board. Only remove the board when the control power is off.
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Chapter 4 Control Component Definition and Maintenance
Table 9 - Encoder Configurations
ENC_TYPE
Installed
Installed
POL_QRDNTS
Installed
Installed
CD_DQUAD
Installed
Removed
Installed
Installed
Removed
Removed
Removed
Installed
Removed
Removed
Removed
Removed
Installed
Installed
Installed
Removed
Removed
Installed
Figure 113 - Universal Encoder Board
Installed
Removed
Installed
Removed
Installed
CONFIGURATIONS
Single-quadrature encoder option (factory default)
Dual-quadrature encoder option without redundancy
Dual-quadrature encoder option with redundancy
Single-quadrature option (CDSEL/DQUAD) must be removed for redundancy
Gray-code absolute encoder low-true
Natural-binary absolute encoder low-true
Gray-code absolute encoder high-true
Natural-binary absolute encoder high-true
Single-quadrature encoder option (factory default)
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Connections to the universal encoder interface are made by way of a 1492-
IFM20F interface module. The connections to the IFM are as follows:
Table 10 - Encoder Functions
14
15
12
13
10
11
8
9
18
19
16
17
20
6
7
4
5
2
3
IFM Pin #
1
Quadrature Encoder Function
A1+
A1-
B1+
B1-
ENC_COM
Z1+
Z1-
A2+ (redundant or dual ENC)
A2- (redundant or dual ENC)
ENC_COM
B2+ (redundant or dual ENC)
E6
E7
ENC_COM
E8
B2- (redundant or dual ENC)
Z2+ (redundant or dual ENC)
E9
E10
Z2- (redundant or dual ENC) E11
ENC_COM ENC_COM
ENC_COM
ENC_COM
ENC PWR (+12V)
ENC PWR (+12V)
ENC PWR (+12V)
E1
E2
Absolute Encoder Function
E0
E4
E5
E3
ENC_COM
ENC_COM
ENC_COM
ENC PWR (+12V)
ENC PWR (+12V)
ENC PWR (+12V)
Figure 114 - 20-pin Interface Module (IFM)
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Chapter 4 Control Component Definition and Maintenance
Quadrature Encoder Operation
The universal encoder interface accepts either single or dual quadrature encoders. Configuration of the board to accept the encoders is done through jumpers on J4.
Boards that are shipped from the factory come defaulted to a quadrature encoder configuration (consult factory for availability of dual quadrature encoder options).
For dual encoder configurations, the primary encoder is wired to pins 1…7 on the 1492-IFM20 module.
To select the dual encoder option, remove the CD_QUAD jumper and place the jumper in PARK. This action configures the board to accept two individual quadrature encoders. In this mode, the drive can switch between encoders for applications such as Synchronous Transfer between two motors with each having their own encoder.
For redundant encoder option, remove both the CD_QUAD and
POL_QRDNT jumpers and place them in PARK. With this configuration, the drive switches over to the redundant encoder when a problem is detected with the primary encoder.
ATTENTION: When the drive switches over to the redundant encoder, the drive cannot switch back without recycling the control power.
156
Positional Encoder Operations
(1)
Besides quadrature encoders, the universal encoder interface also accepts positional (absolute) encoders. Parallel positional data is converted to a serial stream and transmitted to the DPM when requested by the drive. The board also generates “pseudo” quadrature differential signals, including a zero position mark, which is derived from the binary data to the DPM.
There are three different positional encoder configurations available. For all of these configurations remove the ENC_TYPE jumper. The other jumpers configure the board for the type of positional data (Gray Code or Natural
Binary) set by CD_DQUAD and high or low true data set by POL_QRDNT.
1.
Gray code, Low True . In this configuration, the board inverts the incoming gray code data and then converts the data to binary for transmission to the DPM.
2.
Natural Binary, Low True . No conversion is done on the incoming data but the data is inverted.
(1) Consult factory for availability of Positional Encoders.
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Control Component Definition and Maintenance Chapter 4
3.
Gray code, High True . In this configuration, the incoming gray code data is converted to binary. No inversion is done on the input data.
4.
Natural Binary, High True . The positional data is converted to the serial stream. No inversion or conversion is done on the data.
Positional Encoder Guidelines
When selecting a positional encoder, certain guidelines must be followed for optimal performance.
1.
Code Selection: Absolute encoders can be purchased with either gray code or Binary output format. Gray code is a form of binary code where only one-bit changes at a time for each sequential number or position.
The fact that only one-bit changes at a time make reading valid positional data and not ambiguous data, easier for the universal encoder interface. If we compare the Natural Binary code to Gray code for the transition from 255 to 256, here is what we get:
255
256
Binary Code
011111111
100000000
Gray Code
010000000
110000000
All 9 bits changed in the Binary Code while only the MSB of the gray code changed. In the universal encoder interface, the frequency filter components and input hysteresis create delays. Differences in these delays could cause errors due to reading a bit as ON when the bit is actually transitioning to OFF or vice versa. In the case of gray code, since only 1 bit ever changes, the ambiguity error is never multiple counts. For this reason and to reduce inrush currents, Rockwell Automation recommends using gray code positional encoders.
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 must assume the output to be High True. In a 10bit High True encoder, the zero position is 0000000000. In a Low/True encoder, the zero position is 1111111111. On the universal encoder interface, the position data is inverted in hardware. A ‘1’ turns on an optocoupler and produces a ‘0’. Therefore a High True encoder would produce 1111111111 for the zero position. With the POL_QRDNT jumper, you can control the polarity of the input. With the jumper installed (factory default), the jumper is designed to accept High True encoders and an extra inversion is done in the Universal Encoder
Interface. If you are using a Low True encoder, remove the jumper. The optocouplers alone invert the zero position.
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Chapter 4 Control Component Definition and Maintenance
The other role of the POL_QRDNT jumper is to correct the data, in the event the encoder was mounted so that a CCW rotation produced decremented counts. If so the POL_QRDNT jumper must be configured to the opposite of what, the jumper must normally be for the data polarity. For example if the universal encoder interface is configured to operate with High True encoders (POL_QRDNT installed), remove the jumper to correct for encoder mounting.
External Input/output
Boards
The external input/output (XIO) boards are connected through a network cable (CAN Link) to the Analog Control Board (ACB). This cable can be connected to 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. There are 16 isolated inputs and 16 isolated outputs on the card, and they are used for Runtime I/O including Start, Stop, Run,
Fault, Warning, Jog, and External Reset signals. The boards also handle the standard drive fault-signals (for example transformer/line reactor overtemperature, DC link overtemperature) and several spare fault inputs that are configurable. There is an option in software to assign each XIO a specific function (General I/O, External I/O, or liquid cooling).
Figure 115 - XIO Board
OUTPUTS
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
Status
Indicators
1 2 3 4 5 6 7 8
INPUTS
9 10 11 12 13 14 15 16
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Control Component Definition and Maintenance Chapter 4
The standard drive comes with one XIO board. Additional boards (up to five) can be daisy chained together. From XIO Link B ( J5) on the first board to XIO
Link A (J4) on the second board, for a total of six XIO cards. However, currently the drive only supports the use of addresses 1 to 3, depending on the features and application of the drive. U6 on the XIO board displays the address of the board, which is automatically calculated from position of the XIO board in the network.
XIO Link A and B ports are interchangeable. To make wiring easier to follow use:
• Link A for “upstream”, that is, closest to the ACB.
• Link B for “downstream” or farthest from the ACB.
Status indicator D1 and display U6 indicate the status of the board. See
Table 11 for the possible status for D1.
Table 11 - D1 Display Status
Status Indicator Status
Solid Green
Solid Red
Alternate Flashes of Red and
Green
Description
Normal operation
Board failure
No communication available to ACB board
(Normal during start up or not programmed)
Table 12 - U6 Display Status
Display
—
Description
No valid address found
0 Card in “Master” mode
Explanation
• More than six XIO cards on network
• XIO cable failure
• XIO card failure
• ACB failure
• Rockwell Automation use only
• Remove connection to J3 and recycle power
Decimal point ON
Decimal point OFF
Indicates network activity • Normal
No activity on the network • Normal at Power-on, during firmware download and with unprogrammed drive
External Input/output Board Replacement
1. Verify that all medium voltage and control voltage power to the drive is isolated and locked out.
2. Note and Mark the location and orientation of all plugs, cables, and connectors into the XIO board. Use the electrical drawing as a reference.
3. Use your static strap, disconnect all connections.
4. Remove the XIO board assembly from the low-voltage control cabinet. The XIO board mounts on a DIN rail. A 3-piece assembly is used to secure the board. Remove the old board and install the new board in its place.
5. Install the new XIO board assembly in the low-voltage control cabinet.
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Chapter 4 Control Component Definition and Maintenance
6. Reconnect all connections and verify the locations.
7. To verify that the new board functions properly, apply Low Voltage power and complete a System Test and Medium Voltage test.
Optical Interface Boards
The Optical Interface (OIB) Boards are the interface between the DPM and the Gate Driver circuitry. The drive control decides which device to fire, and sends an electrical signal to the OIB boards. The OIB board converts that electrical signal to an optical signal. The signal is sent fiber-optically to the gate driver cards. Typically, the Transmit ports are gray and the Receive ports are blue. The gate driver accepts that signal and turns the device on and off accordingly. The diagnostic fiber-optic signals work the same way, but the source is the gate driver boards and the destination is the drive control boards.
Each OIB contains one extra fiber-optic receiver (RX7), which is used for temperature measurement.
Figure 116 - Optical Interface Board
160
The OIB boards are mounted directly on the Optical Interface Base Board
(OIBB) by two parallel 14-pin connectors for the electrical connection, and plastic clips to provide the mechanical strength. There is one OIBB for the inverter, and one OIBB for the rectifier device. The OIBBs are interfaced to the DPM with two ribbon cables to connect to J11 and J12.
Each OIB board can handle the Firing and Diagnostic duplex fiber-optic connector for six devices. Physically, on the OIBBs, there is provision for 18 devices for the inverter and the rectifier. This capacity is enough to handle the
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Control Component Definition and Maintenance Chapter 4 highest rated drive that we currently produce. The top OIB board on the
OIBB is for the ‘A’ devices. The middle OIB board is for the ‘B’ devices. The bottom OIB board is for the ‘C’ devices.
Figure 117 - Optical Interface Base Board (OIBB)
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Chapter 4 Control Component Definition and Maintenance
Each OIB 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 in the ‘A’ position. However some drive configurations only require one thermistor feedback connection. The temperature feedback connection on OIBC is not implemented on the OIBB and is never used. For more information, see the drawings that are supplied with your drive. The alarm and trip set points for each of these signals is programmable in software.
There are three status indicators on the OIB. This table describes the status and description for the status indicator states:
Status Indicator Status
D1 Red – On
D2
D3
Yellow – On
Green – On
Description
Run – The OIB has received an Enable signal. The drive control software is in control of all gating.
Ready –The OIB power supply is sufficient for proper operation.
Power – The OIB has received a voltage signal greater than 2V.
162
Optical Interface Board Replacement
IMPORTANT If the drive is equipped with the Safe Torque Off option, the drive uses OIBBS boards. See publication 7000-UM203 to replace the OIBBS.
1. Isolate and locked out all power to the drive.
2. Note and mark the location and orientation of all fiber-optic cables. Use the electrical drawing for reference.
IMPORTANT Use a static strap when performing this procedure.
3. Disconnect all fiber-optic cables.
4. Remove the OIB board from the OIBB.
Carefully handle the four standoffs, which snap into place on the OIB, when disconnecting the boards.
Carefully handle the 28-pin connection between the boards. Avoid bending the pins.
5. Remove the 60-pin cable connector on the OIBB and the ground connection.
6. Remove the ground nut that holds the OIBB in place.
7. Carefully handle the five standoffs that snap into place on the OIBB, when removing the boards.
8. Install the new OIBB. Verify that the standoffs snap into place.
9. Reinstall the ground nut that holds the OIBB in place.
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Control Component Definition and Maintenance Chapter 4
10. Reconnect all connections and verify the locations.
ATTENTION: Reconnect the fiber-optic cables in their proper location.
Failure to do so can result in injury or damage to equipment.
Figure 118 - OIB Replacement (Mounting Plate Accessible)
Optical
Interface
Boards
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Chapter 4 Control Component Definition and Maintenance
Notes:
164 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Appendix
A
Catalog Number Explanation
1
7000A
a
Code
7000A
7000
7000L
Code
A
B
C
D
E
F
G
J
L
N
Z b
2
A
3
40
c a
Bulletin Number
“A” Frame (Air-cooled)
“B” Frame (Air-cooled)
“C” Frame (Liquid-cooled)
Description b
Service Duty/Altitude Code
Description
Normal Duty, 0...1000 m Altitude. Maximum 40 °C (104 °F)
Ambient
Normal Duty, 1001...5000 m Altitude
Reduced Ambient (from 40 °C (104 °F) offering)
1001...2000 m = 37.5 °C (99.5 °F)
2001...3000 m = 35 °C (95 °F)
3001...4000 m = 32.5 °C (90.7 °F)
4001...5000 m = 30 °C (86 °F)
Heavy Duty, 0...1000 m Altitude. Maximum 40 °C (104 °F)
Ambient
Heavy Duty, 1001...5000 m Altitude. Reduced Ambient
(from 40 °C (104 °F) offering) – same as “B” code
Normal Duty, 0...1000 m Altitude. Maximum 35 °C (95 °F)
Ambient
Normal Duty, 1001...5000 m Altitude
Reduced Ambient (from 35 °C (95 °F) offering)
1001...2000 m = 32.5 °C (90.5 °F)
2001...3000 m = 30 °C (86 °F)
3001...4000 m = 27.5 °C (81.5 °F)
4001...5000 m = 25 °C (77 °F)
Heavy Duty, 0...1000 m Altitude. Maximum 35 °C (95 °F)
Ambient
Normal Duty, 0...1000 m Altitude. Maximum 50 °C (140 °F)
Ambient
Heavy Duty, 0...1000 m Altitude. Maximum 50 °C (122 °F)
Ambient
Normal Duty, 0...1000 m Altitude. Maximum 20 °C (68 °F)
Ambient
Custom Configuration (Contact Factory)
Position d
4
D
5
A
e
6
RPDTD
f
7
1...etc.
81
93
61
70
Code
40
46
53
105
120
140
160
185
Description
40 A
46 A
53 A
61 A
70 A
81 A
93 A c
Drive Current Rating
(1)
105 A
120 A
140 A
160 A
185 A
325
375
430
495
Code
215
250
285
575
625
657
720
(1) Not all amperages are available at all ambient/altitude configurations.
Description
215 A
250 A
285 A
325 A
375 A
430 A
495 A
575 A
625 A
657 A
720 A
Code
D
T
K
U d
Enclosure Type
Description
Type 1 w/gasket (IP21)
Type 1 w/gasket (IP21) – Seismic rated
IP42
IP42 – Seismic rated
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 165
Appendix A Catalog Number Explanation
1
7000A
a b
2
A
3
40
c
Frame
Size
“A” Frame
“B” and “C”
Frames
(3) e
Supply Voltage/Control Voltage/Frequency/CPT Selection
Voltage
Nominal
Line
Control
Frequency
(Hz)
With a
C.P.T
(1)
Code
Without a
C.P.T
(2)
2400
3300
120
120...240
110
220
60
50
A
AA
CY
CP
AD
—
CDY
CDP
4160
6600
110
220
120
120...240
110
220
110...220
120
50
60
50
60
JY
JP
JAY
J
JA
EY
EP
E
EA
JDY
JDP
—
JD
—
EDY
EDP
ED
—
2400
3300
230
380
400
230
240
208
480
600
60
50
AHD
ABD
ACD
CPD
CND
CKD
EPD
50
4160
6600
600
230
380
400
380
400
208
480
208
480
600
60
50
60
ECD
JPD
JND
JKD
END
EKD
EHD
EBD
JHD
JBD
JCD
(1) A Control Power Transformer-modification must be selected (6, 6B, and so on) to size the transformer.
(2) Control Circuit Power is supplied from separate/external source.
(3) Three-phase Control Circuit Power is supplied from separate/external source.
Position d
4
D
5
A
e
6
RPDTD
f
7
1–...etc.
Code
RPDTD
RPTX
RPTXI
R18TX f
Rectifier Configuration/Line Impedance Type
Description
AFE Rectifier with Integral Line Reactor and
Direct-to-Drive DC Link
AFE Rectifier with provision for connection to separate
Isolation Transformer (standard DC Link)
AFE Rectifier with integral Isolation Transformer
(standard DC Link)
(1)
18 Pulse Rectifier with provision for connection to separate
Isolation Transformer (standard DC Link)
(2)
(1) RPTXI configuration is only available for “A” Frame configurations.
(2) R18TX configuration is only available for “B” and “C” Frame configurations.
166 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
PowerFlex 7000 Drive
Selection Explanation
Catalog Number Explanation Appendix A
The PowerFlex 7000 medium voltage AC drive selection tables are based on two rating types for drive service:
1.
Normal Duty (110% overload for 1 minute, once every 10 minutes) – used for Variable Torque (VT) applications only.
Drives with this rating are designed for 100% continuous operation, with 110% overload for 1 minute, once every 10 minutes.
2.
Heavy Duty (150% overload for 1 minute, once every 10 minutes) – used for Constant Torque (CT) applications only.
Drives with this rating are designed for 100% continuous operation with
150% overload for 1 minute, once every 10 minutes.
Service Duty Rating, Continuous Current Rating and
Altitude Rating Code
There are different codes that define service duty and altitude in the drive
catalog number (see Catalog Number Explanation on page 165
).
EXAMPLE Catalog number 7000A – A105DED-RPDTD, has a continuous current rating of 105 A, with a “normal duty” service rating up to 1000 m altitude.
Catalog number 7000A – B105DED-RPDTD has a continuous rating of 105 A with a “normal duty” service rating up to 5000 m altitude.
The ambient temperature rating is reduced at higher altitudes. If 40 °C
(104 °F) ambient is required at 1001...5000 m altitude, a rating code of Z is required.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 167
Appendix A Catalog Number Explanation
Notes:
168 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Preventative Maintenance Schedule
Appendix
B
Preventative Maintenance
Checklist
The preventive maintenance activities on the PowerFlex® 7000 “A” Frame can be broken down into two categories:
• Operational Maintenance – can be completed while the drive is running.
• Annual Maintenance – must be completed during scheduled downtime.
See the Tools/Parts/Information Requirements at the end of this section for a list of documentation and materials that are required to complete the preventive maintenance documents.
Operational Maintenance
This process requires the changing or the cleaning the air filters. The
PowerFlex 7000 drives require consistent, unrestricted airflow to keep the power devices cool. The air filter is the main source of blockage in the air path.
The drive provides an air filter alarm whenever the pressure differential across the devices drops to a drive-specific level. By referring to the Air-Filter Block parameter, this differential can be anywhere from 7…17% blocked, depending on the heat sink and device configuration. This percentage can seem small, but it takes significant blockage to begin to lower the voltage from the pressure sensor. The percentage is a measure of voltage drop, and must not be viewed as a percentage of the opening that is covered. They are not related linearly.
If you receive an Air Filter Warning, change or clean the filter. If the drive reaches an Air Filter Fault is dependent on site-specific particle conditions.
Annual Maintenance
These maintenance tasks must be performed on an annual basis. These tasks are recommended, and depending on the installation conditions and operating conditions, you can find that the interval can be lengthened. For example, we do not expect that the tightening of torqued power connections is required every year. Due to the critical nature of the applications that are run on MV drives, the key word is preventive. By spending approximately 8.0 hr/yr on these tasks, unexpected downtime can be reduced.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 169
Appendix B Preventative Maintenance Schedule
Initial Information Gathering
Some of the important information to be recorded includes:
• Print Drive Setup.
• Print Fault/Warning Queues.
• Save Parameters to NVRAM.
• Save Parameters to Operator Interface.
• Circuit Board Part Numbers / Serial Numbers / Revision Letters
(record only if parts have been modified or changed since Preventive
Maintenance was last performed).
ATTENTION: To avoid electrical shock, verify that the main power has been disconnected before working on the drive. Use a hot stick or appropriate voltage-measuring device to verify that all circuits are voltage free. Failure to do so can result in injury or death.
Physical Checks
Ensure there is no medium voltage and control power when performing these physical checks.
1. Power Connection Inspection a. Inspect PowerFlex 7000A drive, input/output/bypass contactor sections, and all associated drive components for power cable and ground cable connections that are loose. Torque them to specifications.
b. Inspect the bus bars and check for any signs of discoloration from overheating. Toque the bus connections to specifications.
c. Clean all cables and bus bars that exhibit dust build-up.
d. Use torque sealer on all connections.
2. Conduct the integrity checks on the signal ground and safety grounds.
3. Check for any visual or physical evidence of damage or degradation of components in the low voltage compartments.
a. Inspect relays, contactors, timers, terminal connectors, circuit breakers, ribbon cables, control wires for corrosion, excessive temperature, or contamination.
b. Clean all contaminated components by using a vacuum cleaner (DO
NOT use a blower). Wipe clean components where appropriate.
4. Check for any visual or physical evidence of damage or degradation of components in the medium voltage compartments. For example inverter/rectifier, cabling, DC Link, contactor, load break, and harmonic filter.
170 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Preventative Maintenance Schedule Appendix B a. Inspect main cooling-fan, power devices, heatsinks, circuit boards, insulators, cables, capacitors, resistors, current transformers, potential transformers, fuses, wiring. Causes could be corrosion, excessive temperature, or contamination.
b. Verify torque on heatsink bolts (electrical connections to bullet assemblies) is within specifications (13.5 N•m [10.0 lb•ft]).
c. Clean all contaminated components by using a vacuum cleaner and wipe clean components where appropriate.
IMPORTANT Do not use a blower.
IMPORTANT An important component to check for contamination is the heatsink. The fine grooves in the aluminum heatsinks can capture dust and debris.
5. Physically inspect and verify for the proper operation of the contactor/ isolator interlocks, and door interlocks.
a. Inspect and verify the proper operation of the key interlocks.
b. Verification the additional cooling fans are mounted in the AC Line
Reactor cabinet, Harmonic Filter cabinet for mounting and connections.
c. Clean the fans and verify that the ventilation passages are not blocked and the impellers are freely rotating without any obstruction.
d. Do the insulation resistance test of the drive, motor, isolation transformer/line reactor, and the associated cabling. See
the insulation resistance test procedure.
e. Check indicator washers of the clamp head for proper clamp
pressure, and adjust as necessary. See page 83
for details on proper clamp pressure.
Control Power Checks (No Medium Voltage)
1. Apply Control power to the PowerFlex drive. Test power to all vacuum contactors (input, output, and bypass) in the system. Verify that all contactors can close and seal in.
2. See Publication 1502-UM050 for a detailed description of all contactor maintenance.
3. Verify all single-phase cooling-fans for operation, including the cooling fans in the AC/DC Power supplies and the DC/DC converter.
4. Verify the proper voltage levels at the CPT (if installed), AC/DC Power
Supplies, DC/DC converter, isolated gate power-supply boards.
for appropriate procedures/voltage levels for the previously referenced checks.
5. Verify the gate pulse patterns by using the Gate Test Operating Mode.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 171
Appendix B Preventative Maintenance Schedule
172
For drives with SPS boards installed, use the Test Power Harness
(80018-695-51) to power the rectifier SGCT boards.
6. 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.
Final Power Checks before Restarting
1. Verify that all cabinets are cleared of tools, and all component connections are back in place and in the running state.
2. Put all equipment in normal operating mode, and apply medium voltage.
3. If there were any input or output cables that are removed, verify the input-phasing, and bump the motor for rotation.
4. If there were any changes to the motor, input transformer, or their associated cabling, retune the drive to the new configuration using
Autotuning.
5. Save all parameter changes (if any) to NVRAM.
6. Run the application up to full speed/full load, or to customer satisfaction.
7. Capture the drive variables while running, in the highest access level if possible.
Additional Tasks during Preventive Maintenance
1. Investigation of customer concerns that relate to drive performance.
Relate any problems that are found during maintenance procedures to customer issues.
2. Informal instruction on drive operation and maintenance for plant maintenance personnel a. Reminder of safety practices and interlocks on MV equipment, and on specific operating concerns.
b. Reminder of the need to identify operating conditions properly.
3. Recommendation for critical spare parts, which can be stocked in-plant to reduce production downtime.
a. Gather information on all spare parts on site, and compare that with factory-recommended critical spares. Evaluate that levels are sufficient.
b. Contact MV Spare Parts group for more information.
4. Vacuum Bottle Integrity Testing by using a Vacuum Checker or AC high potential. See Publication 1502-UM050 for a detailed description of all contactor maintenance.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Preventative Maintenance Schedule Appendix B
Final Reporting
1. A complete, detailed report on all steps in the Preventive Maintenance procedures must be recorded to identify changes.
• A completed copy of this checklist must be included.
• Make an addendum with detailed descriptions of all adjustments and measurements that were made include Interlock Adjustments, Loose
Connections, Voltage Readings, Insulation Resistance Results,
Parameters, and so forth.
2. This information must be communicated to MV Product Support so future support activities have the latest site information available.
Faxed to (519) 740-4756 or
E-mailed to [email protected].
Time Estimations
Operational Maintenance
Annual Maintenance
• Initial Information Gathering
• Physical Checks
– Torque Checks
– Inspection
– Cleaning
(1)
– Insulation Resistance
• Control Power Checks
– Contactor Adjustments
(1)
– Voltage Level Checks
– Firing Check
– System Test
(1)
• Medium Voltage Checks
– Final Inspection
– Phasing Check
(1)
– Autotuning
(1)
– Operation to Maximum Load
• Additional Tasks
(1)
– Investigation
– Informal Training/Refresher
– Spare Parts Analysis
– Vacuum Bottle Integrity Check
• Final Report
0.5 hours per filter
0.5 hours
2.0 hours
2.0 hours
2.5 hours
(1)
1.5 hours
2.0 hours
1.0 hour
0.5 hours
2.0 hours
0.5 hours
(1)
(1)
1.5 hours
(1)
2.0 hours
(1)
Site Dependent
Varies with nature of Problem
2.0 hours
1.0 hour
3.0 hours
3.0 hours
(1) Time cannot be required depending on the nature of the maintenance and the condition of the drive system. These times are only estimations.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 173
Appendix B Preventative Maintenance Schedule
Tool / Parts / Information Requirements
The following is a list of the tools that are recommended for proper maintenance of the PowerFlex 7000 drives. Not all tools are required to perform a specific procedure for drive preventive. To complete all tasks that are listed above, these tools would be required.
Tools
• 100 MHz Oscilloscope with a minimum 2 Channels and memory.
• 5 kV DC insulation resistance tester.
• Digital Multimeter.
• Torque Wrench.
• Laptop Computer with Relevant Software and Cables.
• Assorted Hand Tools (Screwdrivers, Open Ended Metric Wrenches,
Metric Sockets, and so forth).
• 8 mm Allen Keys.
• Speed Wrench.
• Feeler Gauge.
• Vacuum Bottle Checker or AC-high potential.
• Minimum of 15 kV Hotstick / Potential Indicator.
• Minimum of 10 kV Safety Gloves.
• Vacuum Cleaner with anti-static hose.
• Anti-static Cleaning Cloth.
• No. 30 Torx Driver.
Documentation
• PowerFlex 7000 Parameters Manual – Publication 7000-TD002 .
• 400 A Vacuum Contactor Manual – Publication 1502-UM050 .
• Drive-Specific Electrical and Mechanical Prints.
• Drive-Specific Spare Parts List.
Materials
• Torque Sealer (Yellow) Part number --- RU6048.
• Electrical Joint Compound ALCOA EJC No. 2 or approved equivalent
(For Power Devices).
• Aeroshell no. 7 Part number 40025-198-01 (for Vacuum Contactors).
174 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Maintenance Schedule
Preventative Maintenance Schedule Appendix B
By rigorously following this maintenance schedule, the Customer can expect to have peak product availability and the highest possible uptime. This Annual,
Preventative Maintenance Program 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.
For more details, see Chapter 3 Power Component Definition and
Maintenance of this User Manual.
I – Inspection
M – Maintenance
R – Replacement
C – Cleaning
The component must be inspected for signs of excessive accumulation of dust, dirt, and so forth, or external damage. For example, examine the
Filter Capacitors for bulges in the case, inspect the heatsinks for debris that can clog the Airflow path.
A maintenance task that is not normally a preventative maintenance task and can include the inductance testing of Line Reactors/DC Links, or the full testing of an isolation transformer.
The component has reached its mean operational life. To decrease the chance of failure, replace the component. It is likely that components exceed the design life in the drive, and that is dependent on many factors such as usage, heat.
The cleaning of a part that can be reused, and refers specifically to the door-mounted air filters in the liquid-cooled drives and some air-cooled drives.
Rv – Review A discussion with Rockwell Automation to determine whether any of the enhancements/changes made to the Drive Hardware and Control would be valuable to the application.
RFB/R – Refurbishment/Replacement The parts can be refurbished at lower cost or the parts can be replaced with new ones.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 175
Appendix B Preventative Maintenance Schedule
Rockwell Automation PowerFlex 7000 Drive Preventative Maintenance Schedule
Period Interval (Years)
Air-Cooling
System
Door Mounted Air Filters
(1) (2)
Main Cooling Fan Motor
Redundant Cooling Fan Motor (if supplied)
Small Aux. Cooling Fans “Caravel”
Power Switching
Components
Power Devices (SGCTs/SCRs)
Snubber Resistors/Sharing Resistors/ HECS
Rectifier Snubber Capacitors
(3)(4)
Inverter Snubber Capacitors
(5)(6)
Integral
Magnetics/Power
Filters
Control Cabinet
Components
Connections
Enhancements
Operational
Conditions
Spare Parts
Integrated Gate Driver Power Supply
Self-Powered SGCT Power Supply (SPS)
Isolation Transformer/Line Reactor
DC Link/CMC
Line/Motor Filter Capacitors
AC/DC and DC/DC Power Supplies
Control Boards
Batteries (DCBs and CIB)
Battery Module (UPS)
(7)
Low Voltage Terminal Connections/
Plug-in Connections
Medium Voltage Connections
Heatsink Bolted Connections
Medium Voltage Connections (Rectifier)
(3)
Medium Voltage Connections (Inverter)
(5)
Firmware
Hardware
Parameters
Variables
Application Concerns
Inventory/Needs
0 1 2 3 4 5 6 7 8 9 10
C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R
I
I I
I
I
I
I
I
I
I
I
I
RFB/R
RFB/R
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
–
–
I
I
–
–
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
–
–
–
–
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
R
–
–
Rv
Rv
Rv
Rv
Rv
Rv
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I/R
(4)
I
(3)
–
–
–
I
I
I
I
I
I
I
I
I
I
I
I
I
R
RFB/R
RFB/R I
M
M
M
RFB/R I
R
–
–
–
–
I
I
I
I
I
I
I
I
I
I
I
I
I
I
R
–
–
Rv
Rv
Rv
Rv
Rv
Rv
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
–
–
–
–
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I/R
(4)
I
(3)
–
–
–
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
R
–
–
Rv
Rv
Rv
Rv
Rv
Rv
I
I
M
M
I
RFB/R
R
RFB/R
RFB/R
M
I
R
I
Rv/R
(4)
R
(1) If filter supplied is not a washable type, replace filter. If filter supplied is a washable type, wash or replace (depending on state of filter).
(2) These components may be serviced while the VFD is running.
(3) When rectifier snubber capacitors are replaced, the MV connections for the rectifier need to be inspected.
(4) A 4-year rectifier snubber capacitor replacement interval applied only to drives with 6-pulse or 18-pulse rectifiers shipped before 2012 (rectifier snubber capacitors are blue). However, current enhanced replacement rectifier snubber capacitors extend this to a 10-year replacement interval (replacement rectifier snubber capacitors are black). A 10-year rectifier snubber capacitor replacement interval has always applied to drives with AFE rectifiers.
(5) When inverter snubber capacitors are replaced, the MV connections for the inverter need to be inspected.
(6) A 10-year inverter snubber capacitor replacement interval applies to all drive configurations.
(7) Replace UPS batteries annually for 50°C rated VFDs.
I
–
I
–
I
I
I
(3)
I
I
I
176 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Preventative Maintenance Schedule Appendix B
Rockwell Automation PowerFlex 7000 Drive Preventative Maintenance Schedule
Period Interval (Years)
Air-Cooling
System
Door Mounted Air Filters
(1) (2)
Main Cooling Fan Motor
Redundant Cooling Fan Motor (if supplied)
Small Aux. Cooling Fans “Caravel”
Power Switching
Components
Power Devices (SGCTs/SCRs)
Snubber Resistors/Sharing Resistors/ HECS
Rectifier Snubber Capacitors
(3)(4)
Inverter Snubber Capacitors
(5)(6)
Integral
Magnetics/Power
Filters
Control Cabinet
Components
Connections
Enhancements
Operational
Conditions
Spare Parts
Integrated Gate Driver Power Supply
Self-Powered SGCT Power Supply (SPS)
Isolation Transformer/Line Reactor
DC Link/CMC
Line/Motor Filter Capacitors
AC/DC and DC/DC Power Supplies
Control Boards
Batteries (DCBs and CIB)
Battery Module (UPS)
(7)
Low Voltage Terminal Connections/
Plug-in Connections
Medium Voltage Connections
Heatsink Bolted Connections
Medium Voltage Connections (Rectifier)
(3)
Medium Voltage Connections (Inverter)
(5)
Firmware
Hardware
Parameters
Variables
Application Concerns
Inventory/Needs
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
–
–
I
I
–
–
I
I
11
C/R
I
I
I
I
I
I
I
I
I
I
I
I
I
R
I
I
12
C/R
I
I/R
(4)
R
I
(3)
–
Rv
Rv
Rv
Rv
Rv
Rv
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
13
C/R
–
–
–
–
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
14
C/R
RFB/R I
RFB/R I
15
C/R
–
–
–
–
I
I
I
I
I
I
R
M
M
I
RFB/R I
I
RFB/R I
M I
I
RFB/R I
I
R
R
–
–
Rv
Rv
Rv
Rv
Rv
Rv
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
16
C/R
I
I/R
(4)
I
(3)
–
–
–
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
17
C/R
–
–
–
–
I
I
–
–
Rv
Rv
Rv
Rv
Rv
Rv
I
I
I
I
I
I
–
–
–
–
–
–
–
–
–
–
–
–
I
I
(1) If filter supplied is not a washable type, replace filter. If filter supplied is a washable type, wash or replace (depending on state of filter).
(2) These components may be serviced while the VFD is running.
(3) When rectifier snubber capacitors are replaced, the MV connections for the rectifier need to be inspected.
(4) A 4-year rectifier snubber capacitor replacement interval applied only to drives with 6-pulse or 18-pulse rectifiers shipped before 2012 (rectifier snubber capacitors are blue). However, current enhanced replacement rectifier snubber capacitors extend this to a 10-year replacement interval (replacement rectifier snubber capacitors are black). A 10-year rectifier snubber capacitor replacement interval has always applied to drives with AFE rectifiers.
(5) When inverter snubber capacitors are replaced, the MV connections for the inverter need to be inspected.
(6) A 10-year inverter snubber capacitor replacement interval applies to all drive configurations.
(7) Replace UPS batteries annually for 50°C rated VFDs.
I
I
I
I
I
I
I
I
I
I
R
I
I
I
I
I
I
18
C/R
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
19
C/R
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
20
C/R
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 177
Appendix B Preventative Maintenance Schedule
General Notes
Maintenance of Medium Voltage Equipment
ATTENTION: The servicing of energized Medium-Voltage Motor Control
Equipment can be hazardous. Severe injury or death can result from electrical shock, bump, or unintended actuation of controlled equipment.
Recommended practice is to disconnect and lockout control equipment from power sources, and release stored energy, if present.
For countries following NEMA standards, refer to:
• National Fire Protection Association Standard No. NFPA70E, Part II and (as applicable).
• OSHA rules for Control of Hazardous Energy Sources (Lockout/
Tagout).
• OSHA Electrical Safety Related Work Practices including:
• Procedural requirements for lockout-tagout.
• Appropriate work practices, personnel qualifications, and required training.
• Where it is not feasible to de-energize and lockout or tagout electric circuits and equipment before working on or near exposed circuit parts.
• For countries following IEC standards, refer to local codes and regulations.
Periodic Inspection
Medium-Voltage Motor control equipment must be inspected periodically.
Inspection intervals must be based on environmental and operating conditions and adjusted as indicated by experience. An initial inspection within 3 to 4 months after installation is suggested. See the following standards for general guidelines for setting-up a periodic maintenance program.
For countries following NEMA standards, refer to:
• National Electrical Manufacturers Association (NEMA) Standard
• No. ICS 1.1 (Safety Guidelines for the Application, Installation, and
Maintenance of Solid-Sate Control) for MV Drives.
• ICS 1.3 (Preventive Maintenance of Industrial Control and Systems
Equipment) for MV Controllers.
178 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Preventative Maintenance Schedule Appendix B
For countries following IEC standards, refer to:
• IEC 61800-5-1 Sec. 6.5 for MV Drives.
• IEC 60470 Sec. 10.
• IEC 62271-1 Sec. 10.4 for MV Controllers.
Contamination
If inspection reveals that dust, dirt, moisture, or other contamination has reached the control equipment, the cause must be mitigated. Contamination could indicate unsealed enclosure openings (conduit or other) or incorrect operating procedures. Replace any damaged or embrittled seals and repair or replace any other damaged or malfunctioning parts (for example, hinges, fasteners). Dirty, wet, or contaminated control devices must be replaced unless they can be cleaned effectively by vacuuming or wiping. Do not clean with compressed air. The compressed air can displace dirt, dust, or debris into other parts or equipment, or damage delicate parts.
High-voltage Testing
High-voltage insulation resistance (IR) or dielectric withstanding voltage
(insulation resistance) tests must not be used to check solid-state control equipment. When insulation resistance testing electrical equipment such as transformers or motors, solid-state devices must be bypassed before performing the test. Even though no damage can be readily apparent after a insulation resistance test, the solid-state devices are degraded and repeated application of high voltage can lead to failure.
Maintenance after a Fault Condition
Opening of the short circuit protective device (such as fuses or circuit breakers) in a properly coordinated motor branch circuit indicates a fault condition in excess of operating overload. Such conditions can damage medium-voltage motor control equipment. Before power, is restored the fault condition must be corrected and any repairs or replacements must be made to the mediumvoltage motor control equipment. See NEMA Standards Publication No. ICS-
2, Part ICS2-302 for procedures. To maintain the integrity of the equipment, use only Allen-Bradley recommended replacement parts and devices. Verify that the parts are properly matched to the model, series, and revision level of the equipment. After maintenance or repair of the equipment, always test the control system for proper functioning under controlled conditions (that avoid hazards if a control malfunction). For additional information, see NEMA ICS
1.3, PREVENTIVE MAINTENANCE OF INDUSTRIAL CONTROL
AND SYSTEMS EQUIPMENT. Published by the National Electrical
Manufacturers Association, Also NFPA70B, ELECTRICAL EQUIPMENT
MAINTENANCE, published by the National Fire Protection Association.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 179
Appendix B Preventative Maintenance Schedule
Part-specific Notes
Cooling-fans
Inspect fans that are used for forced air cooling. Replace any that have bent, chipped, or missing blades, or if the shaft does not turn freely. Apply power momentarily to check operation. If unit does not operate, check and replace wiring, fuse, or fan motor as appropriate. Clean or change air filters as recommended in the Users Manual.
Operating Mechanisms
Check for proper functioning and freedom from sticking or binding. Replace any broken, deformed or badly worn parts or assemblies according to the product User Manuals. Check for and securely tighten any loose fasteners.
Lubricate, if specified in individual product instructions. Many devices are factory-lubricated. If lubrication during use or maintenance of these devices is needed,is specified in their individual product instructions or User Manual.
IMPORTANT Allen-Bradley® magnetic starters, contactors, and relays are designed to operate without lubrication. Do not lubricate these devices, because oil or grease on the pole faces (the mating surfaces) of the operating magnet can cause the device to stick in the ‘ON’ mode.
Contacts
Check contacts for excessive wear and dirt accumulations. Vacuum or wipe contacts with a soft cloth if necessary to remove dirt. Discoloration and slight pitting do not harm Contacts. Do not file contacts, as dressing only shortens contact life. Do not use spray cleaners on contacts, as their residues on magnet pole faces or in operating mechanisms can cause sticking and can interfere with electrical continuity. Contacts must only be replaced after contact face material has become badly worn. To avoid misalignment and uneven contact pressure always replace contacts in complete sets.
Vacuum Contactors
Contacts of vacuum contactors are not visible, so contact wear must be checked indirectly. Vacuum bottles must be replaced when:
• The contactor wear indicator line shows need for replacement.
• The vacuum bottle integrity-tests show need for replacement.
Replace all vacuum bottles in the contactor simultaneously to avoid misalignment and uneven contact wear. If the vacuum battles do not require replacement, check and adjust over-travel to the value listed in the product user manual.
180 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Preventative Maintenance Schedule Appendix B
Power Cable and Control Wire Terminals
A loose connection in a power circuit can cause overheating that can lead to equipment malfunction or failure. A loose connection in a control circuit can cause control malfunctions. Loose bonding or grounding connections can increase hazards of electrical shock and contribute to electromagnetic interference (EMI). Check the tightness of all terminals and bus bar connections and tighten any loose connections. Replace any parts or wiring that is damaged by overheating, and any broken wires or the bonding straps.
See the User Manual for torque values that are required for power cable and bus hardware connections.
Coils
If a coil exhibits evidence of overheating (cracked, melted or burned insulation), it must be replaced. In that event, check for and correct overvoltage or undervoltage conditions, which can cause coil failure. Be sure to clean any residue of melted coil insulation from other parts of the device or replace such parts.
Batteries
Replace batteries periodically as specified in product manual or if a battery shows signs of electrolyte leakage. Use tools to handle batteries that have leaked electrolyte; most electrolytes are corrosive and can cause burns. Dispose of the old battery in accordance with instructions that are supplied with the new battery or as specified in the product manual.
Pilot Lights
Replace any burned out lamps or damaged lenses. Do not use solvents or cleaning- agents on the lenses.
Solid-state Devices
ATTENTION: Use of unrecommended test equipment for solid-state controls can result in damage to the control or test equipment or unintended actuation of the controlled equipment. See paragraph titled HIGH VOLTAGE
TESTING.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 181
Appendix B Preventative Maintenance Schedule
Solid-state devices require a periodic visual inspection. Discolored, charred, or burned components can indicate the need to replace the component or circuit board. Replacements must be made only at the Personal Computer board or plug-in component level. Inspect printed circuit boards to determine that they are properly seated in the edge board connectors. Board locking tabs must also be in place. Solid-state devices must also be protected from contamination, and
provisions for cooling must be maintained – see Contamination on page 179
and Cooling-fans on page 180 . Do not use solvents on printed circuit boards.
Locking and Interlocking Devices
Check these devices for proper working-condition and capability of performing their intended functions. Make any necessary replacements only with Allen-Bradley® renewal parts or kits. Adjust or repair only in accordance with Allen-Bradley instructions found in the product user manuals.
182 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Appendix
C
Torque Requirements
Torque Requirements for
Threaded Fasteners
Unless otherwise specified, use these values of torque to maintain the equipment.
Table 13 - Torque Requirements
M6
M8
M10
M12
M14
Diameter
M2.5
M4
M5
1.00
1.25
1.50
1.75
2.00
Pitch
0.45
0.70
0.80
Steel
Steel
Steel
Steel
Steel
Material
Steel
Steel
Steel
29
50
6.0
14
81
Torque (N•m)
0.43
1.8
3.4
21
37
4.4
11
60
Torque (lb•ft)
0.32
1.3
2.5
¼ in.
3/8 in.
20
16
Steel S.A.E. 5
Steel S.A.E. 2
12
27
9.0
20
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 183
Appendix C Torque Requirements
Notes:
184 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Appendix
D
Insulation Resistance Testing
Drive Insulation Resistance
Testing
When a ground fault occurs, there are three zones in which the problem can appear: input to the drive, the drive, and output to the motor. The ground fault condition indicates that a phase conductor has found a path to ground. A current with a magnitude that ranges from leakage to fault level exists that is dependent on the resistance of the path to ground. The drive itself rarely is a source of a ground fault when it is properly installed. Ground fault problems that are associated with the drive rarely occur. Normally the source of the fault exists in either the input or output zone.
Since the procedure for insulation resistance testing the drive is more complex, is recommended to first insulation resistance test the input and output zones when encountering a ground fault. If the location of the ground fault cannot be located outside the drive, insulation resistance test the drive.
ATTENTION: Insulation resistance testing the drive must be performed with due care as the hazards to drive exist if safety precautions are not followed.
The
Insulation Resistance Testing Procedures apply high voltage to ground.
All control boards in the drive are grounded and if not isolated, the high potential that is applied to them can cause immediate damage.
ATTENTION: Use caution when performing an insulation resistance test.
High-voltage testing is potentially hazardous and can cause severe burns, injury, or death. Where appropriate, connect the test equipment to Ground.
Check that the insulation levels before power equipment is energized.
Insulation resistance tests provide a resistance measurement from the phase-tophase and phase-to-ground by applying a high voltage to the power circuitry.
Perform this test to detect Ground faults without damaging any drive equipment.
Remove (temporarily) any existing paths to ground that are necessary for normal operation of the drive, and all connected equipment to a high potential while measuring the leakage current to ground.
ATTENTION: There are risks of serious or fatal injury to personnel if you do not follow safety guidelines.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 185
Appendix D Insulation Resistance Testing
Insulation Resistance Testing
Procedures
To perform insulation resistance testing tests on the PowerFlex® 7000A, follow this procedure.
ATTENTION: Failure to comply with this procedure can result in a poor insulation resistance test reading and damage to drive control boards.
Required equipment
• Torque wrench and 10 mm socket
• Phillips screwdriver
• 2500/5000V insulation resistance tester.
1. Isolate and lockout the drive system from any high-voltage source.
a. Disconnect any incoming power sources. b. Isolate and lockout medium-voltage sources. c. Turn off all control power sources at their respective circuit breakers.
d. Verify with a potential indicator that power sources are disconnected, and that the control power in the drive is de-energized.
2. Isolate the power circuit from system ground (“float the drive”).
Remove the grounds on these components within the drive (refer to the electrical schematics provided with the equipment to determine the points to disconnect):
• Voltage Sensing Boards (VSB)
• Output Grounding Network (OGN)
Voltage Sensing Boards
3. Remove all ground connections, at the screw terminals on the VSB, from all VSBs in the drive. There are two grounds on each board marked
“GND 1”, and “GND 2”.
ATTENTION: Disconnect the terminals on the boards rather than from the ground bus as the grounding cable is only rated for 600V. The Injection of a high voltage on the ground cable degrades the cable insulation. Do not disconnect the white medium-voltage wires from the VSBs. They must be included in the test.
The number of VSBs installed in each drive varies depending on the drive configuration.
Disconnect Output Grounding Network
4. Remove the ground connection on the OGN (if installed). Lift this connection at the OGN capacitor rather than the grounding bus, as the grounding cable is only rated for 600V.
186 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Insulation Resistance Testing Appendix D
ATTENTION: The Injection of a high voltage on the ground cable during an insulation resistance test degrades the cable insulation.
5. Disconnect connections between power circuit and low voltage control.
Disconnect Voltage Sensing Boards
The connections between the low voltage control and the power circuit are made through ribbon cable connectors. The cables are plugged into connectors on the voltage sensing board that is marked “J1”, “J2”, and “J3”, and terminate on the signal conditioning boards. Every ribbon cable connection that is made on the VSBs is marked for identification.
6. Confirm the marking matches the connections, and disconnect the ribbon cables and move them clear of the VSB. If the ribbon cables are not removed from the VSB, then high potential applies directly to the low voltage control through the SCBs and damages those boards.
ATTENTION: The VSB ribbon cable insulation is not rated for the potential that is applied during an insulation resistance test. You must disconnect the ribbon cables at the VSB rather than the SCB to avoid exposing the ribbon cables to high potential.
Removing Potential Transformer Fuses
A insulation resistance test can exceed the rating of potential transformer fusing. To avoid damage:
7. Remove the primary fuses from all potential and control power transformers in the system. This step removes a path from the power circuit back to the drive control.
Isolate Transient Suppression Network
A path to ground exists through the TSN network as it has a ground connection that dissipates high energy surges in normal operation. This ground path must be isolated. If this ground connection is not isolated, the insulation resistance test indicates a high leakage current through this path and falsely indicates a problem in the drive.
8. Remove all fuses on the TSN before proceeding with the insulation resistance test.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 187
Appendix D Insulation Resistance Testing
Surge Arrestors
Drives that are supplied after 2009 have surge arrestors instead of a TSN. Surge arrestors can remain in the circuit during the insulation resistance test procedure.
9. Insulation resistance test the drive.
10. All three phases on the line and machine sides of the drive connect through the DC Link and snubber network. A test from any one of the input or output terminals to ground sufficiently tests the drive.
IMPORTANT Verify the drive and any connected equipment is clear of personnel and tools before starting the insulation resistance test . Barricade any open or exposed conductors. Conduct a walk-around inspection before commencing the test.
ATTENTION: Discharge the insulation resistance tester before it is disconnected from the equipment.
a. Connect the insulation resistance tester to the drive. Follow the specific instructions for that drive model. b. If the insulation resistance tester has a lower voltage setting (normally
500V or 1000V), apply that voltage for 5 seconds. Do the test as a precursor for a higher voltage rating. If you forgot to remove any grounds, can limit the damage. If the reading is high, apply 5 kV from any drive input or output terminal to ground. c. Perform an insulation resistance test at 5 kV for 1 minute and record the result.
The test readings must be greater than the minimum values listed in
Table 14 on page 189 .
Low Test Results
11. If the test results are lower than the listed values, segment the drive system into smaller components. Repeat the test on each segment until the source of the ground fault is identified. a. Isolate the line side of the drive from the machine side by removing the appropriate cables on the DC Link reactor. b. Isolate the DC Link reactor from the drive by disconnecting the four power cables. c. Verify that all electrical components being insulation resistance tested are electrically isolated from ground.
188 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Insulation Resistance Testing Appendix D
Items that produce lower than expected readings are surge capacitors at the motor terminals and motor filter capacitors at the output of the drive. The insulation resistance testing procedure must follow a systematic segmentation of electrical components to isolate and locate a ground fault.
Table 14 - Test Readings
Type of Drive
Liquid-cooled Drive
Air-cooled Drive
Drive with input/output Caps Disconnected
Isolation Transformer
Motor
Minimum Insulation Resistance Value
200 M
Ω
1k M
Ω
5k M
Ω
5k M
Ω
5k M
Ω
The motor filter capacitors and line filter capacitors (if applicable) can skew the insulation resistance test result as being lower than expected.
The capacitors have internal discharge resistors that discharge the capacitors to ground. If the insulation resistance test results are skewed, disconnect the output capacitors.
IMPORTANT Humidity and dirty standoff insulators can cause leakage to ground because of tracking. Clean a 'dirty' drive before starting the insulation resistance test.
12. Reconnect connections between power circuit and low voltage control.
Reconnect the ribbon cables “J1”, “J2” and “J3” in all VSBs. Do not cross the cable connections.
ATTENTION: Incorrect placement of the feedback cables can result in serious damage to the drive. Make sure that they are connected to the proper location
13. Reconnect the power circuit to the system ground.
Reconnect Voltage Sensing Boards
14. Reconnect the two ground conductors on the VSBs.
The conductors provide a reference point for the VSB and enable the low voltage signal to be fed to the SCBs. If the ground conductors are not connected, the monitored low voltage signal rises to medium voltage potential, which is a serious hazard.
Make sure that the ground conductors on the VSB are securely connected before applying medium voltage to the drive.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 189
Appendix D Insulation Resistance Testing
ATTENTION: Failure to connect both ground connections on the voltage sensing board can result in high potential in the low voltage cabinet within the drive. This result damages the drive control and can cause injury or death to personnel
Reconnect Output Grounding Network
15. Reconnect the ground connection on the OGN capacitor. Torque the bolt connection to 3.4 N•m (30 lb•in.). Do Not Exceed the torque rating of this connection as it can result in damage to the capacitor.
ATTENTION: Failure to reconnect the OGN ground can result in the neutral voltage offset being impressed on the motor cables and stator, which can result in equipment damage.
For drives that did not originally have the OGN connected (or installed), there is no need for concern.
Enable Transient Suppression Network
16. Reinstall the fuses on the TSN.
190 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Appendix
E
Line and Load Cable Sizes
Maximum Line Cable Sizes
Table 15 - Maximum Line Cable Sizes
(1)
Product
Voltage/Frequency/
Rectifier
2400V / 60 Hz / RPDTD
2400V / 60 Hz / RPDTD
3300V / 50 Hz / RPDTD
3300V / 50 Hz / RPDTD
4160V / 50 Hz / RPDTD
4160V / 50 Hz / RPDTD
4160V / 60 Hz / RPDTD
4160V / 60 Hz / RPDTD
6600V / 50 Hz / RPDTD
6600V / 50 Hz / RPDTD
2400V / 60 Hz / RPTX
3300V / 50 Hz / RPTX
4160 / 50 Hz / RPTX
4160 / 60 Hz / RPTX
6600 / 50 Hz / RPTX
2400V / 60 Hz / RPTXI
3300V / 50 Hz / RPTXI
4160V / 50 Hz / RPTXI
4160V / 60 Hz / RPTXI
6600V / 50 Hz / RPTXI
Drive Rating
(A)
46…140
46…140
46…140
46…140
46…140
46…140
46…140
46…140
40…93
40…93
Drive
Structure
Code
71.9
(2)
71.13, 71.18
(3)
71.13, 71.18
71.13, 71.18
71.13, 71.18
71.10
71.14, 71.19
46…160
46…160
46…160
46…160
40…105
46…160
46…160
46…140
46…160
40…105
71.7
71.7
71.7
71.7
71.8
71.3
71.3
71.3
71.3
71.6, 71.15
Input (Line Side)
Drive Enclosure
Opening Inches
(mm)
(4)
4.00 x 4.00 (102 x 102)
4.00 x 4.00 (102 x 102)
4.00 x 4.00 (102 x 102)
4.00 x 4.00 (102 x 102)
4.00 x 4.00 (102 x 102)
4.00 x 4.00 (102 x 102)
4.00 x 4.00 (102 x 102)
4.00 x 4.00 (102 x 102)
4.00 x 4.00 (102 x 102)
4.00 x 4.00 (102 x 102)
4.00 x 8.00 (102 x 204)
4.00 x 8.00 (102 x 204)
4.00 x 8.00 (102 x 204)
4.00 x 8.00 (102 x 204)
4.00 x 8.00 (102 x 204)
4.00 x 4.00 (102 x 102)
4.00 x 4.00 (102 x 102)
4.00 x 4.00 (102 x 102)
4.00 x 4.00 (102 x 102)
4.00 x 4.00 (102 x 102)
Maximum Size and Number of
Incoming Cables: NEMA
(5)(6)(7)(8)(9)
One #4/0 / phase (5 kV or 8 kV)
One #4/0 / phase (5 kV or 8 kV)
One #4/0 / phase (5 kV or 8 kV)
One #4/0 / phase (5 kV or 8 kV)
One #4/0 / phase (5 kV or 8 kV)
One #4/0 / phase (5 kV or 8 kV)
One #4/0 / phase (5 kV or 8 kV)
One #4/0 / phase (5 kV or 8 kV)
One #4/0 / phase (8 kV or 15 kV)
One 350 MCM / phase (8 kV or 15 kV)
One 350 MCM / phase (8 kV or 15 kV)
One 350 MCM / phase (8 kV or 15 kV)
One 350 MCM / phase (8 kV or 15 kV)
One 350 MCM / phase (8 kV or 15 kV)
One 350 MCM / phase (15 kV)
One 350 MCM / phase (8 kV or 15 kV)
One 350 MCM / phase (8 kV or 15 kV)
One 350 MCM / phase (8 kV or 15 kV)
One 350 MCM / phase (8 kV or 15 kV)
One #4/0 / phase (8 kV or 15 kV)
Maximum Size and Number of
One 107 mm2 /phase (5 kV or 8 kV)
One 107 mm2 / phase (5 kV or 8 kV)
One 107 mm2 / phase (5 kV or 8 kV)
One 107 mm2 / phase (5 kV or 8 kV)
One 107 mm2 / phase (5 kV or 8 kV)
One 107 mm2 / phase (5 kV or 8 kV)
One 107 mm2 / phase (5 kV or 8 kV)
One 107 mm2 / phase (5 kV or 8 kV)
One 107 mm2 / phase (5 kV or 8 kV)
One 177 mm2 / phase (5 kV or 8 kV)
One 177 mm2 / phase (5 kV or 8 kV)
One 177 mm2 / phase (8 kV or 15 kV)
One 177 mm2 / phase (8 kV or 15 kV)
One 177 mm2 / phase (8 kV or 15 kV)
One 177 mm2 / phase (15 kV)
One 177 mm2 / phase (5 kV or 8 kV)
One 177 mm2 / phase (5 kV or 8 kV)
One 177 mm2 / phase (5 kV or 8 kV)
One 177 mm2 / phase (5 kV or 8 kV)
One 177 mm2 / phase (8 kV or 15 kV)
Space for Stress
Cones [in. (mm)]
18.8 (478)
17.1 (435)
33.8 (860)
33.8 (860)
33.8 (860)
33.8 (860)
33.8 (860)
20.0 (508)
(10)
20.0 (508)
20.0 (508)
20.0 (508)
20.0 (508)
18.8 (478)
17.1 (435)
18.8 (478)
17.1 (435)
18.8 (478)
17.1 (435)
18-3/8 (467)
17.1 (435)
(1) This data is informative only; do not base final design criteria solely on this data. Follow national and local installation codes, industry best practices, and cable manufacturer recommendations.
(2) With starter.
(3) Without starter.
(4) Some ‘A’ frame drives have one enclosure opening for both line and load cables. Most ‘A’ frame drives have separate provisions for line and load cable openings. All cabling capacities that are shown in this table are “worst case” conditions when both line and load cables enter and exit in the same direction.
(5) Cable sizes are based on overall dimensions of compact-stranded three-conductor shielded cable (common for industrial-cable tray installations). Maximum sizes stated accounts for minimum rated cable insulation requirements. The next higher-rated cable (8 kV is not commercially available in many areas of the world. Rockwell Automation provides an 8 kV (minimum rating) and a 15 kV rating, when applicable. Enclosure openings accommodate the thicker insulation on the higher-rated cable. IEC ratings show the equivalent to the NEMA sizes. The exact cable mm
2
size that is shown is not commercially available in many cases; use the next smaller standard size.
(6) Minimum cable bend radius recommendations vary by national codes, cable type, and cable size. Consult local codes for guidelines and requirements. General relationship of cable diameter to bend radius is typically between 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]).
(7) For minimum requirements for cable insulation, see the user manual for your frame. Stated voltages are peak line-to-ground. Some cable manufacturers rate cabling based on RMS line-to-line.
(8) Ground lug capabilities: two mechanical range lugs for ground cable connections. Mechanical range lugs can accommodate cable size #6-250MCM (13.3...127 mm
2
).
(9) As methods for cabling can vary, the maximum cable sizes that are shown do not account for the size of the conduit hub. Verify size of conduit hubs against the “Drive enclosure openings” shown.
(10) Cable enters termination point horizontally in this case, therefore orient space for the stress cones horizontally also.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 191
Appendix E Line and Load Cable Sizes
Maximum Load Cable Sizes
Table 16 - Maximum Load Cable Sizes
(1)
PRODUCT
Voltage/Frequency/
Rectifier
2400V / 60 Hz / RPDTD
2400V / 60 Hz / RPDTD
3300V / 50 Hz / RPDTD
3300V / 50 Hz / RPDTD
4160V / 50 Hz / RPDTD
4160V / 50 Hz / RPDTD
4160V / 60 Hz / RPDTD
4160V / 60 Hz / RPDTD
6600V / 50 Hz / RPDTD
6600V / 50 Hz / RPDTD
2400V / 60 Hz / RPTX
3300V / 50 Hz / RPTX
4160 / 50 Hz / RPTX
4160 / 60 Hz / RPTX
6600 / 50 Hz / RPTX
2400V / 60 Hz / RPTXI
3300V / 50 Hz / RPTXI
4160V / 50 Hz / RPTXI
4160V / 60 Hz / RPTXI
6600V / 50 Hz / RPTXI
Drive Rating
(A)
Drive
Structure
Code
46…140
46…140
46…140
71.9
(2)
71.13, 71.18
(3)
46…140
46…140
46…140
46…140
46…140
40…93
40…93
46…160
46…160
46…160
46…160
40…105
46…160
46…160
46…140
46…160
40…105
71.13, 71.18
71.13, 71.18
71.13, 71.18
71.10
71.14, 71.19
71.7
71.7
71.7
71.7
71.8
71.3
71.3
71.3
71.3
71.6, 71.15
OUTPUT (MOTOR SIDE)
Drive Enclosure
Opening
Inches (mm)
(4)
4.00 x 4.00 (102 x 102)
4.00 x 4.00 (102 x 102)
4.00 x 4.00 (102 x 102)
4.00 x 4.00 (102 x 102)
4.00 x 4.00 (102 x 102)
4.00 x 4.00 (102 x 102)
4.00 x 4.00 (102 x 102)
4.00 x 4.00 (102 x 102)
4.00 x 4.00 (102 x 102)
4.00 x 4.00 (102 x 102)
4.00 x 8.00 (102 x 204)
4.00 x 8.00 (102 x 204)
4.00 x 8.00 (102 x 204)
4.00 x 8.00 (102 x 204)
4.00 x 8.00 (102 x 204)
4.00 x 4.00 (102 x 102)
4.00 x 4.00 (102 x 102)
4.00 x 4.00 (102 x 102)
4.00 x 4.00 (102 x 102)
4.00 x 4.00 (102 x 102)
Maximum Size and Number of
Incoming Cables: NEMA
(5)(6)(7)(8)(9)
One #4/0 / phase (5 kV or 8 kV)
One #4/0 / phase (5 kV or 8 kV)
One #4/0 / phase (5 kV or 8 kV)
One #4/0 / phase (5 kV or 8 kV)
One #4/0 / phase (5 kV or 8 kV)
One #4/0 / phase (5 kV or 8 kV)
One #4/0 / phase (5 kV or 8 kV)
One #4/0 / phase (5 kV or 8 kV)
One #4/0 /phase (8 kV or 15 kV)
One 350 MCM /phase (8 kV or 15 kV)
One 350 MCM /phase (8 kV or 15 kV)
One 350 MCM /phase (8 kV or 15 kV)
One 350 MCM /phase (8 kV or 15 kV)
One 350 MCM /phase (8 kV or 15 kV)
One 350 MCM /phase (15 kV)
One 350 MCM /phase (8 kV or 15 kV)
One 350 MCM /phase (8 kV or 15 kV)
One 350 MCM /phase (8 kV or 15 kV)
One 350 MCM /phase (8 kV or 15 kV)
One #4/0 /phase (8 kV or 15 kV)
Maximum Size and Number of
One 107 mm2 / phase (5 kV or 8 kV)
One 107 mm2 / phase (5 kV or 8 kV)
One 107 mm2 / phase (5 kV or 8 kV)
One 107 mm2 / phase (5 kV or 8 kV)
One 107 mm2 / phase (5 kV or 8 kV)
One 107 mm2 / phase (5 kV or 8 kV)
One 107 mm2 / phase (5 kV or 8 kV)
One 107 mm2 / phase (5 kV or 8 kV)
One 107 mm2 / phase (8 kV or 15 kV)
One 177 mm2 / phase (8 kV or 15 kV)
One 177 mm2 / phase (5 kV or 8 kV)
One 177 mm2 / phase (8 kV or 15 kV)
One 177 mm2 / phase (8 kV or 15 kV)
One 177 mm2 / phase (8 kV or 15 kV)
One 177 mm2 / phase (15 kV)
One 177 mm2 / phase (5 kV or 8 kV)
One 177 mm2 / phase (5 kV or 8 kV)
One 177 mm2 / phase (5 kV or 8 kV)
One 177 mm2 / phase (5 kV or 8 kV)
One 177 mm2 / phase (8 kV or 15 kV)
Space for Stress
Cones [in. (mm)]
18.4 (467)
16.7 (424)
18.4 (467)
16.7 (424)
18.4 (467)
16.7 (424)
18.4 (467)
16.7 (424)
18.4 (467)
20.6 (524)
33.8 (860)
33.8 (860)
33.8 (860)
33.8 (860)
33.8 (860)
20.6 (524)
(10)
20.6 (524)
20.6 (524)
20.6 (524)
20.6 (524)
(1) This data is informative only; do not base final design criteria solely on this data. Follow national and local installation codes, industry best practices, and cable manufacturer recommendations.
(2) With starter.
(3) Without starter.
(4) Some ‘A’ frame drives have one enclosure opening for both line and load cables. Most ‘A’ frame drives have separate provisions for line and load cable openings. All cabling capacities that are shown in this table are “worst case” conditions when both line and load cables enter and exit in the same direction.
(5) Cable sizes are based on overall dimensions of compact-stranded three-conductor shielded cable (common for industrial cable tray installations). Maximum sizing stated accounts for minimum rated cable insulation requirements and the next higher-rated cable. 8 kV is not commercially available in many areas of the world. Rockwell Automation provides an 8 kV (minimum rating) and a 15 kV rating, when applicable. Enclosure openings accommodate the thicker insulation on the higher-rated cable. IEC ratings show the equivalent to the NEMA sizes. The exact cable mm2 size that is shown is not commercially available in many cases; use the next smaller standard size.
(6) Minimum cable bend radius recommendations vary by national codes, cable type, and cable size. Consult local codes for guidelines and requirements. General relationship of cable diameter to bend radius is typically between 7x...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]).
(7) For minimum requirements for cable insulation, see the user manual for your frame. Stated voltages are peak line-to-ground. Some cable manufacturers rate cabling based on RMS line-to-line.
(8) Ground lug capabilities: two mechanical range lugs for ground cable connections. Mechanical range lugs can accommodate cable size #6-250 MCM (13.3...127 mm2).
(9) As methods for cabling can vary widely, maximum cable sizes that are shown do not account for the size of the conduit hub. Verify size of conduit hubs against the “Drive enclosure openings” shown.
(10) Cable enters termination point horizontally in this case, therefore orient space for the stress cones horizontally also.
192 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Appendix
F
Environmental Considerations
Air Quality Requirements
Air cleanliness for PowerFlex® 7000 drives is important for two reasons:
1. Airborne particulate that settles on heat sinks and heat-producing components increases the thermal resistance of the components. This resistance results in an increase in the temperature of the part. The internal fins of the hockey-puck thyristor heat sinks must be kept clean.
The dust on the surface of the heat sinks interferes with the boundary layer airflow, which inhibits the cooling of the part.
2. Particulate can decrease the tracking insulation of electrical insulation materials within the drive. Electrically conductive dusts (such as coal dust and metallic dusts) can be severe. However other particulates such as cement dust, moist from high levels of ambient relative humidity, can prove destructive as well. Dusts that coat the low voltage circuit boards can cause failures too.
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. This is defined by IEC
60721
(1)
as being less than 0.2 mg/m
3
of dust.
If outside air does not meet the conditions described above (0.2 mg / m
3
), the site air handling system must filter the air to ASHRAE (American Association of Heating, Refrigeration and Air-Conditioning Engineers) Standard 52.2
MERV 11 (Minimum Efficiency Reporting Value). This filtration eliminates from 65…80% of the particulate in Range 2 (1.0…3.0 μm) and 85% of the particulate in Range 3 (3.0…10.0 μm). This filter system must be cleaned or changed regularly.
This environment is accomplished by placing the drive in a pressurized room with adequate air conditioning to maintain the ambient temperature. The drive exhaust air is circulated within the control room. Five to ten percent cooled/heated and filtered make-up air is provided to keep the room pressurized.
(1) IEC 60721-3-3 “Classification of Environmental Conditions - Part 3: Classification of Groups of Environmental Parameters and their Severities - Section 3: Stationary Use at Weather Protected Locations”.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 193
Appendix F 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 make sure that environmentally inert materials were used wherever feasible. A final review has found this product to be substantially free of hazardous material.
Rockwell Automation is actively seeking alternatives to potentially hazardous materials for which no feasible alternatives exist today in the industry. In the interim, the following precautionary information is provided for your protection and for the protection of the environment. Contact the factory for any environmental information on any material in the drive or with any questions about environmental impact.
Capacitor Dielectric Fluid
The fluids that are used in the filter capacitors and the snubber capacitors are considered safe and are fully sealed within the capacitor housings.
Environmental regulations typically do not restrict the shipping and the handling of this fluid. In the unlikely event that capacitor fluid leaks out, avoid ingestion or contact with skin or eyes as slight irritation could result. Rubber gloves are recommended for handling.
To clean up, soak into an absorbent material and discard into an emergency container, or, if significant leakage occurs, pump fluid directly into the container. Do not dispose into any drain or into the environment in general or into general landfill refuse. Dispose of according to local regulations. If of an entire capacitor is disposed of, the same disposal precautions must be taken.
Printed Circuit Boards
Printed circuit boards can contain lead in components and materials. Circuit boards must be disposed of according to local regulations and must not be disposed of with general landfill refuse.
Lithium Batteries
This drive contains four small lithium batteries. Three are mounted on the printed circuit boards and one is located in the PanelView™ user interface. Each battery contains less than 0.05 g of lithium, which is fully sealed within the batteries. Environmental regulations typically do not restrict the shipping and the handling of these batteries, however, lithium is considered a hazardous substance. Lithium batteries must be disposed of according to local regulations and must not be disposed of with general landfill refuse.
194 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Environmental Considerations Appendix F
Chromate Plating
Some sheet steel and fasteners are plated with zinc and sealed with a chromatebased dip. Environmental regulations typically do not restrict the shipping and the handling of the chromate plated parts, however, chromate is considered a hazardous substance. Dispose of chromate plated parts according to local regulations, not with general landfill refuse.
In Case Of Fire
This drive is highly protected against arc faults and therefore unlikely the drive would be the cause of a fire. In addition, the materials in the drive are selfextinguishing (that is they cannot burn without a sustained external flame). If, however, the drive is subjected to a sustained fire from some other source, some of the polymer materials in the drive produce toxic gases. Individuals that are involved in the extinguishing of the fire or anyone near must wear a selfcontained breathing apparatus to help protect against any inhalation of toxic gases.
Disposal
When disposing of the drive, it must be disassembled and separated into groups of recyclable material as much as possible (that is steel, copper, plastic, wire). Send these materials to local facilities for recycling. Follow all previously mentioned disposal precautions.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 195
Appendix F Environmental Considerations
Notes:
196 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Appendix
G
Pre -Commissioning
Start-up Commissioning
Services
Start-up is performed at the customer site. Rockwell Automation requests a minimum of four weeks notice to schedule each start-up.
The Rockwell Automation standard work hours are between 9:00 a.m. to 5:00
PM EST (8 hr/day) Monday through Friday, not including observed holidays.
Additional work hours are available on a time and material basis.
Pre- Commissioning the Drive
Rockwell Automation manages the start-up service for each installed drive at the customer site. There are a number of tasks that must be completed before
Rockwell Automation personnel are scheduled for drive commissioning.
Rockwell Automation recommends the following:
1. A pre-installation meeting/conference call with the customer to review:
• The Rockwell Automation Start-up Plan.
• The Start-up Schedule.
• The Drive installation requirements.
2. Inspect the mechanical and electrical devices of the drive.
3. Perform a tug test on all internal connections within the drive and verify wiring.
4. Verify critical mechanical connections for proper torque requirements.
5. Verify and adjust mechanical interlocks for permanent location.
6. Confirm that all inter-sectional wiring is connected properly.
7. Verify control wiring from any external control devices such as PLCs.
8. Confirm that the cooling system is operational.
9. Verify the proper phasing from the isolation transformer to the drive.
10. Confirm cabling of drive to motor, isolation transformer, and line feed.
11. Collect test reports that indicate the insulation resistance/hipot test has been performed on line and motor cables.
12. Control power checks to verify all system inputs such as starts/stops, faults, and other remote inputs.
13. Apply medium voltage to the drive and perform operational checks.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 197
Appendix G Pre -Commissioning
14. Bump motor and tune drive to the system attributes. If the load is unable to handle any movement in the reverse direction, uncouple the load before bumping the motor for a directional test.
15. Verify proper performance, run the drive motor system throughout the operational ranges.
Customer personnel are required on-site to participate in the start-up of the system.
198 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Appendix
H
Specifications
ATTENTION: In the event of discrepancies between information in generic manual specifications and your specific design or electrical drawings, take the DD or EE ratings as correct values.
Drive Specifications
Table 17 - General Design Specifications
Description
Motor Type
Input Voltage Rating
Input Voltage Tolerance
Voltage Sag
(1)
Control Power Loss Ride-through
Induction or Synchronous
2400V, 3300V, 4160V, 6600V
± 10% of Nominal
-30%
5 Cycles (Std)
> 5 Cycles (Optional UPS)
Surge Arrestors (AFE/Direct-to-Drive)
50/60 Hz, ±5%
25 kA RMS SYM, 5 Cycle
Input Protection
(2)
Input Frequency
Power Bus Input Short-circuit
Current Withstand
(2400…6600V
(3)
)
Basic Impulse Level
(4)
Power Bus Design
Ground Bus
Customer Control Wireway
Input Power Circuit Protection
(5)
Output Voltage
Inverter Design
Inverter Switch
Inverter Switch Failure-Mode
Inverter Switch Failure-Rate (FIT)
Inverter Switch Cooling
Inverter Switching Frequency
45 kV (0…1000 m)
Copper - Tin plated
Copper - Tin plated 6 x 51 mm (¼ x 2 in.)
Separate and Isolated
Vacuum Contactor with Fused Isolating Switch or Circuit Breaker
0…2400V
0…3300V
0…4160V
0…6000V, 0…6300V, 0…6600V
PWM
SGCT
Non-rupture, Non-arc
100 per 1 Billion Hours Operation
Double Sided, Low Thermal Stress
420…440 Hz
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 199
Appendix H Specifications
200
Table 17 - General Design Specifications (Continued)
Description
Number of Inverter SGCTs
Inverter PIV Rating
(Peak Inverse Voltage)
Rectifier Designs
Voltage
2400V
3300V
4160V
6600V
Voltage
2400V
3300V
4160V
6600V
SGCTs (per phase)
4
6
2
4
PIV (each device)
Total PIV
6500V
6500V
6500V
6500V
Direct-to-Drive™ (transformerless AFE rectifier)
AFE with separate isolated transformer
AFE with integrated transformer
6500V
13,000V
13,000V
19,500V
Rectifier Switch
Rectifier Switch Failure-Mode
SGCT (AFE Rectifier)
Non-rupture, Non-arc
Rectifier Switch Failure-Rate (FIT) 50 (SGCT) per 1 Billion Hours Operation
Rectifier Switch Cooling Double Sided, Low Thermal Stress
Number of Rectifier Devices per phase
Voltage
2400V
3300V
4160V
6600V
AFE
2
4
4
6
Output Current THD (1 st
…49 th
)
Output Waveform to Motor
Medium Voltage Isolation
< 5%
Sinusoidal Current / Voltage
Modulation techniques
Fiber-optic
Selective Harmonic Elimination (SHE)
Synchronous Trapezoidal PWM
Asynchronous or Synchronous SVM (Space Vector Modulation)
Control Method
Tuning Method
Speed Regulator Bandwidth
Digital Sensorless Direct Vector
Full Vector Control with Encoder Feedback (Optional)
Autotuning with Setup Wizard
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)
+/- 5% Torque Accuracy with HPTC
(optional)
Speed Regulation 0.1% without Tachometer Feedback
0.01...0.02% with Tachometer Feedback
Independent Accel/Decel – 4 x 30 s
4 x Independent Accel/Decel
Acceleration/Deceleration Range
Acceleration/Deceleration Ramp
Rates
S Ramp Rate
Critical Speed Avoidance
Stall Protection
Independent Accel/Decel – 2 x 999 s
3 x Independent with Adjustable bandwidth
Adjustable time delay
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Specifications Appendix H
Table 17 - General Design Specifications (Continued)
Description
Load Loss Detection
Control Mode
Current Limit
Output Frequency Range
Service Duty Rating
Typical VFD Efficiency
Input Power Factor
IEEE 519 Harmonic Guidelines
(6)
VFD Noise Level
Regenerative Braking Capability
Flying Start Capability
Operator Interface
Languages
Control Power
External I/O
External Input Ratings
External Output Ratings
Analog Inputs
Analog Resolution
Analog Outputs
Communication Interface
Scan Time
Adjustable level, delay, speed set points
Speed or Torque
Adjustable in Motoring and Regenerative
0.2 Hz...75 Hz (Standard)
75 Hz...90 Hz (Optional - need specific Motor Filter Capacitor [MFC])
Normal Duty
110% Overload for 1 min. every 10 min.
(Variable Torque Load)
Heavy Duty
150% Overload for 1 min. every 10 min.
(Constant Torque Load)
> 97.5% (AFE)
Contact Factory for Guaranteed Efficiency of Specific Drive Rating
AFE Rectifier
0.95 minimum, 10...100% Load
IEEE 519 - 1992 Compliant
< 85 dB (A)) per OSHA Standard 3074
Inherent – No Additional Hardware or Software Required
Yes – Able to Start into and Control a Spinning Load in Forward or Reverse
Direction
10 in. Color Touch Screen – Cat# 2711P-T10C4A9 (VAC)
Built-in PDF viewer
Redesigned PanelView™ Plus 6 Logic Module with 512 Mb of memory
English, French, Spanish, Portuguese, German, Chinese, Italian, Russian, and Polish
220/240V or 110/120V, Single phase - 50/60 Hz (20 A)
16 Digital Inputs, 16 Digital Outputs
50…60 Hz AC or DC
120…240 V – 1 mA
50…60 Hz AC or DC
30…260V – 1 A
Three Isolated, 4…20 mA or 0…10V (250 Ω)
Analog input 12 Bits (4…20 mA)
Internal parameter 32-Bit resolution
Serial Communication 16-Bit resolution (.1 Hz)
(Digital Speed Reference)
One Isolated, Eight Non-isolated,
4…20 mA or 0…10V (600 Ω)
EtherNet IP™/DPI™
Internal DPI – 2 ms … 4 ms.
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 201
Appendix H Specifications
Table 17 - General Design Specifications (Continued)
Description
Communications Protocols
(Optional)
Enclosure
Lifting Device
Mounting Arrangement
Structure Finish
Interlocking
Corrosion Protection
Ambient Temperature
Fiber-Optic Interface
Door Filter
Door Filter Blockage
Storage and Transportation
Temperature Range
Relative Humidity
Altitude (Standard)
Altitude (Optional)
DeviceNet®
EtherNet/IP
ControlNet®
Lon Works
Dual-port EtherNet/IP Can Open
PROFIBUS RS-485 HVAC
Modbus
Interbus
USB
RS-485 DF1
RS-232 DF1
Type 1 (standard) IP21 (IEC)
IP42 (IEC) (optional)
Standard / Removable
Mounting Sill Channels
Epoxy Powder – Paint
Exterior Sandtex Light Grey (RAL 7038) – Black (RAL 8022)
Internal – Control Sub Plates – High Gloss White (RAL 9003)
Key provision for customer input Disconnecting Device
Unpainted Parts (Zinc Plated / Clear Chromate)
0…40 °C (32…104 °F) / 0…50 °C (32…122 °F) - optional
Rectifier – Inverter – Cabinet (Warning / Trip)
Painted Diffuser with Matted Filter or Washable Foam Media
Airflow Restriction Trip / Warning
-40…+70 °C (-40…+158 °F)
Max. 95%, Noncondensing
0…1000 m (0…3300 ft)
Up to 4160V: 1001...5000 m (3301...16,400 ft)
>6000V: 1001…2000 m (3301…6600 ft)
1, 2, 3, 4
NEMA, IEC, CSA, UL, ANSI, IEEE
Seismic (UBC Rating)
Standards
(1) Voltage Sag tolerance is reduced to -25% when control power is supplied from medium voltage by way of CPT.
(2) Surge arrestors are used for AFE/Direct-to-Drive configurations.
(3) Short-circuit fault rating that is based on input protection device (contactor or circuit breaker).
(4) BIL rating that is based on altitudes < 1000 m (3300 ft). See factory for derating on altitudes >1000 m (3281 feet).
(5) Optional.
(6) Under certain conditions, power system analysis is required.
202 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
Index
A
AC/DC power supply
cosel power supply
location
output calibration
replacement
additional resources
air filters
location
air pressure sensor
replacement
air quality requirements
altitude rating code
analog control board
components
connectors
current loop transmitter
disposal
interface module
isolated process receiver
non-isolated process outputs
replacement
test points
auxiliary +24V power supply
C
cabinet layout
cable insulation
AFE requirements
direct-to-drive
wire group numbers
cabling cabinet components
catalog number explanation
clamping pressure
adjustment
check pressure
clamp head
commissioning
continuous current rating
control power components ride-through
converter cabinet
2400V
3300/4160V
6600V
components
cosel power supply
current loop transmitter
current transformer replacement
D
D.C. link
reactor replacement
removal
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
DC/DC power supply
replacement
terminal/connections
device designations
dimensional drawings
See drive processor module drive processor module
components
disposal
test points
drive storage
siting
temperature
E
encoder feedback board
20B-ENC-1 & 20B-ENC-1-MX3 encoder interface
80190-759-01, 80190-759-02 universal encoder interface
components
configurations
input connections
options
positional encoder
quadrature encoder
environmental considerations
air quality requirements
hazardous materials
exhaust air hood assembly
installation
external input/output boards
D1 display status
disposal
replacement
F
fan
components
impeller maintenance
inlet ring replacement
location
redundant fan assembly
removal
replacement
fiber optic cable
bend radius
color code
length
filter capacitors
replacement
testing
G
gasket
replacement
general precautions
203
Index
204 ground filter component
replacement
grounding
electrical supplies
ground bus
isolation transformer diagram
line reactor diagram
safety
H
hall effect sensor replacement
hazardous materials
heatsink replacement
I
IEC component
interface module impeller assembly
maintenance
inlet ring
replacement in isolation transformer
inlet ring replacemenet
integral isolation transformer fan replacement
interface module
components
interlocking
isolated process receiver
L
line terminations
low voltage control
M
maintenance
annual
checklist
control power checks
final power checks
operational maintenance
physical checks
reporting
motor compatibility
motor terminations
N
neutral resistor direct-to-drive
hood assembly
non-isolated process outputs
O
optical interface boards operational maintenace
operator interface
basic configurations
optical interface
optical interface boards
componenets
LEDs
location
replacement
output grounding network
replacement
P
positional encoder
power guidelines
cable terminations
cabling access
power cabling terminations
power connections
Line terminations
motor terminations
power cabling installation
power wiring selection
cable insulation
powercage
2400V
3300/4160V
6600V
air flow
clamp head
gasket
removal
torque sequence
Q
quadrature encoder
R
rectifier designs
redundant fan assembly
resistance checks
SGCT
SGCT anode-to-cathode
snubber capacitance
snubber circuit
snubber resistance
S
self-powered SGCT power supply. See
SPS board service duty rating
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
SGCT
LEDs
replacement
resistance test
snubber circuit assembly
test points
sharing resistors
replacement
resistance test
test points
shock indicator
simplified electrical drawings
2400V
3300/4160V
6600V
site consideration
snubber capacitors
replacement
resistance test
test points
snubber resistors
replacement
resistance test
test points
SPS board
calibration
components
disposal
test equipment
test points
surge arresters
certification
operation
replacement
testing and care
symmetrical gate commutated thyristor.
See
SGCT
V
voltage sensing assembly
input voltage range
replacement
W
wire group numbers
X
external input/output boards
T
test points analog control board
thermal sensors
replacement
topology
torque requirements
torque sequence
transformer cooling fan
U
uninterruptible power supply. See
UPS
UPS
connect battery
location
replace
Index
Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020 205
Index
Notes:
206 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020
.
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Allen-Bradley, Direct-to-Drive, DPI, PanelView, PowerCage, PowerFlex, Rockwell Automation, and Rockwell Software are trademarks of Rockwell Automation, Inc.
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Publication 7000A-UM200G-EN-P - February 2020
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Key features
- Advanced control algorithms for precise motor control
- Built-in safety features to protect personnel and equipment
- Flexible configuration options to meet specific application requirements
- Rugged construction for reliable operation in harsh environments
- Easy-to-use interface for quick and easy setup and operation
- Compact design to save space in your control panel
- High efficiency to reduce energy consumption
- Support for a wide range of motor types and sizes
- Versatile communication options for easy integration into control networks
- Built-in diagnostics to simplify troubleshooting