Allen-Bradley PowerFlex 7000 Medium Voltage AC Drive Air-Cooled (A Frame) - ForGe Control User Manual

PowerFlex 7000 Medium
Voltage AC Drive Air-Cooled
(’A’ Frame)—ForGe Control
Bulletin Number 7000A
User Manual
Original Instructions
PowerFlex 7000 Medium Voltage AC Drive Air-Cooled (’A’ Frame)—ForGe Control User Manual
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.
These 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).
The following icon may appear in the text of this document.
Identifies information that is useful and can help to make a process easier to do or easier to understand.
2
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Table of Contents
Preface
About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Download Firmware, AOP, EDS, and Other Files . . . . . . . . . . . . . . . . . . . . 9
Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
What Is Not in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Connect to Service and Support and Product Documentation . . . . . . . 11
Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 1
Overview of Drive
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Rectifier Designs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Motor Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Simplified Electrical Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
2400V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
3300/4160V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Safe Torque Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Basic Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Chapter 2
Drive Installation
Safety and Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Drive Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Siting of the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Site Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Generator Note. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Shock Indication Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Installation of Exhaust Air Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Installation of Redundant Fan Assembly . . . . . . . . . . . . . . . . . . . . . . . 29
Installation of Integral Transformer Cooling Fan . . . . . . . . . . . . . . . 30
Neutral Resistor Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Installation of Neutral Resistor Assembly (Direct-to-Drive) . . . . . . 32
Cabinet Layout and Dimensional Drawings of Drive . . . . . . . . . . . . . . . 32
Drive Layout. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
IEC Component and Device Designations . . . . . . . . . . . . . . . . . . . . . . . . . 37
Power Cabling Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Access the Customer Power Cable-terminations . . . . . . . . . . . . . . . . 37
Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Line/Motor Terminations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Installation Requirements for Power Cabling . . . . . . . . . . . . . . . . . . 38
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
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Table of Contents
Power and Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Grounding Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Drive Signal and Safety Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
For Customers and Power Integrators . . . . . . . . . . . . . . . . . . . . . . . . . 45
Identification of Types of Electrical Supplies - Grounded and
Ungrounded Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Ground Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Interlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Chapter 3
Power Component Definition
and Maintenance
4
Cabling Cabinet Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Hall Effect Sensor Replacements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Current Transformer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Converter Cabinet Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Converter Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Voltage-sensing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Replacing the Voltage-sensing Circuit Board Assembly . . . . . . . . . . . . . 56
Surge Arresters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
Surge Arrester Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Field Test and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
PowerCage Module Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Resistance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
SGCT and Snubber Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
SGCT Anode-to-Cathode Sharing Resistance . . . . . . . . . . . . . . . . . . . 67
Snubber Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Snubber Capacitance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Replacing the SGCT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70
Replacing Snubber and Sharing Resistor. . . . . . . . . . . . . . . . . . . . . . . 73
Snubber Capacitor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Sharing Resistor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Maintain Uniform Clamping Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Adjusting the Clamping Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Temperature Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Replacing the Thermal Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Heatsink Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
PowerCage Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Replacement of PowerCage Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Removal of Old Gasket Material . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
PowerCage Module Removal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Self-powered SGCT Power Supply - SPS . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Board Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Equipment for Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Fiber-optic Cabling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Air Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Air Pressure Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Table of Contents
D.C. Link / Fan / Control Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Output Grounding Network Replacement . . . . . . . . . . . . . . . . . . . . . 91
Ground Filter Component Replacement . . . . . . . . . . . . . . . . . . . . . . . 92
Filter Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Replacing the Filter Capacitors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Testing the Filter Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
DC Link Reactor and CMC Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Fan Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
DC Link Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Fan Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Top of Integral Isolation Transformer Section . . . . . . . . . . . . . . . . . 102
Top of Integral Line Reactor and Input Starter Section . . . . . . . . . 103
Impeller Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Isolation Transformer Cooling Fan . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Inlet Ring Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
DC Link / Fan Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Top of Integral Isolation Transformer Section . . . . . . . . . . . . . . . . . 104
Replacement of Air Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Fan Power Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Chapter 4
Control Component Definition
and Maintenance
Control Power Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Ride-through. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
AC/DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Terminal / Connections Descriptions . . . . . . . . . . . . . . . . . . . . . . . . . 115
Output Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Single Power Supply Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Dual Power Supply Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Diode Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
UPS Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Replacing the UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Low Voltage Control Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
DC/DC Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Terminal/Connections Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . 123
Replacement Procedure for DC/DC Power Supply . . . . . . . . . . . . . 124
Printed Circuit Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Drive Processor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Drive Processor Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . 128
Analog Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 130
Interface Module (IFM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Analog Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Current Loop Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Isolated Process Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Non-Isolated Process Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Auxiliary +24V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Replacing the Analog Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . 137
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Table of Contents
Encoder Feedback Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Encoder Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
Quadrature Encoder Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Positional Encoder Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Positional Encoder Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
External Input/output Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
External Input/output Board Replacement . . . . . . . . . . . . . . . . . . . . 145
Optical Interface Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Optical Interface Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 147
Appendix A
Preventative Maintenance
Schedule
Preventative Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Operational Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Annual Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Initial Information Gathering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Physical Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Control Power Checks (No Medium Voltage) . . . . . . . . . . . . . . . . . . 151
Final Power Checks before Restarting . . . . . . . . . . . . . . . . . . . . . . . . 151
Additional Tasks during Preventive Maintenance . . . . . . . . . . . . . . 151
Final Reporting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Time Estimations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Tool / Parts / Information Requirements. . . . . . . . . . . . . . . . . . . . . . 153
Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Maintenance of Medium Voltage Equipment. . . . . . . . . . . . . . . . . . 157
Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
High-voltage Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Maintenance after a Fault Condition . . . . . . . . . . . . . . . . . . . . . . . . . 158
Part-specific Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Cooling-fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Operating Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Vacuum Contactors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Power Cable and Control Wire Terminals . . . . . . . . . . . . . . . . . . . . . 159
Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Pilot Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Solid-state Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Locking and Interlocking Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Appendix B
PowerFlex 7000 Drive Spare
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 161
Part Storage Requirements and
Control Equipment and Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Recommendations
SGCT/SCR/SPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Signal Conditioners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Spare Parts Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
6
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Table of Contents
Spare Parts Connection Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Power Supply Connection Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Pioneer/Cosel Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
IGDPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
IntelliVAC Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Absopulse AC/DC Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Absopulse DC/DC Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168
1606 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Control Equipment and Boards Connection Guidelines. . . . . . . . . . . . 169
Analog Control Board (ACB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Power Components Connection Guidelines . . . . . . . . . . . . . . . . . . . . . . 170
SGCT – IGDPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
SGCT – SPS Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
SPS Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
SCR - SPGDB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Connection Wires Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Appendix C
Torque Requirements
Torque Requirements for Threaded Fasteners . . . . . . . . . . . . . . . . . . . . 175
Appendix D
Insulation Resistance Testing
Drive Insulation Resistance Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Insulation Resistance Testing Procedures . . . . . . . . . . . . . . . . . . . . . . . . 178
Appendix E
Environmental Considerations
Air Quality Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Hazardous Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Capacitor Dielectric Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Lithium Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Chromate Plating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
In Case Of Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Appendix F
Pre-Commissioning
Start-up Commissioning Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Pre-Commissioning the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Appendix G
History of Changes
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
7
Table of Contents
Notes:
8
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Preface
About This Publication
This document provides procedural information for managing daily or
recurring tasks involving the PowerFlex® 7000 medium voltage ‘A’ frame
drives.
Download Firmware, AOP,
EDS, and Other Files
Summary of Changes
Download firmware, associated files (such as AOP, EDS, and DTM), and access
product release notes from the Product Compatibility and Download Center at
rok.auto/pcdc.
This publication contains the following new or updated information. This list
includes substantive updates only and is not intended to reflect all changes.
Topic
Added warning around energizing isolation transformers
Updated section on how to connect to service and support
Changed torque value for replacing filter capacitors
Who Should Use This
Manual
Page
10
11
95
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®.
If you have multiple drive types or power ranges, ensure you have the correct
documentation for each specific PowerFlex 7000 product:
• ‘A’ frame for lower-power air-cooled, configurations (up to approximately
1250 hp/933 kW)
• ‘B’ frame for higher-power, air-cooled configurations (standard or heatpipe
models)
• ‘C’ frame for all liquid-cooled configurations
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
9
Preface
General Precautions
ATTENTION: This drive contains ESD (electrostatic discharge) sensitive parts
and assemblies. Static control precautions are required when installing,
testing, servicing or repairing this assembly. Component damage may result if
ESD control procedures are not followed. If you are not familiar with static
control procedures, reference Allen-Bradley publication 8000-4.5.2, “Guarding
Against Electrostatic Damage” or any other applicable ESD protection
handbook.
ATTENTION: An incorrectly applied or installed drive can result in component
damage or a reduction in product life. Wiring or application errors, such as,
undersizing the motor, incorrect or inadequate AC supply, or excessive
ambient temperatures may result in malfunction of the system.
ATTENTION: Only personnel familiar with the PowerFlex 7000 Variable
Frequency Drive (VFD) or Adjustable Speed Drive (ASD) and associated
machinery should plan or implement the installation, startup, and subsequent
maintenance of the system. Failure to comply may result in personal injury
and/or equipment damage.
ATTENTION: It is not recommended to repeatedly energize transformers.
Transformer energization results in high inrush current (10…15 times the rated
transformer current). Energizing a transformer multiple times in a short
period of time, may subject the transformer windings and winding insulation
to destructive thermal and electromechanical stress, due to the repetitive
high inrush current. This energization limitation is similar to limiting the
number of motor starts per hour to reduce thermal stress on a motor. The
typical inrush current for a motor is much lower (six times the motor full-load
current) making the energization limitation for an isolation transformer even
more important.
For applications where the motor must be started frequently, PowerFlex
medium voltage drives should be left in the 'Drive Ready' mode. The input
contactor/breaker remains closed in this mode (i.e., medium voltage remains
present on the transformer) and the drive will start, run, and stop the motor
when required, without the need to energize and deenergize the drive
isolation transformer.
ATTENTION: To keep arc resistant structural integrity, if applicable, the
following rules must be followed:
• The pressure relief vent may not be tampered with, and it is not to be used as
a step.
• No unapproved alterations can be made to the enclosure.
• All covers, plates, and hardware removed for installation or maintenance
purposes must be re-installed and properly secured. Failure to do so voids the
arc resistant structural integrity.
• Power cable entry points are to be treated as the boundary to a hazardous
location and must be sealed accordingly. Failure to do so voids the arc
resistant structural integrity.
• A plenum or chimney must be used to direct the arc flash energy to a suitable
location. Failure to do so voids the arc resistant structural integrity. See
publication 7000-IN007.
• All wiring between the low voltage panel and the power cell must be routed
through a suitable cable gland to ensure flames and gases are not transmitted
into this area (as fitted from factory).
• The medium voltage doors must be properly secured using the handle
mechanism (if provided), the key interlock (if provided), and the door bolts.
Failure to do so voids the arc resistant structural integrity.
10
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Preface
Connect to Service and
Support and Product
Documentation
Global
Customer Care
Technical
Documents
Scan the left QR code to get connected to your Regional Customer Care Group.
Scan the right QR code to get connected to the PowerFlex 7000 Medium
Voltage Drive product page, where you can access user manuals, technical
specifications, firmware manuals, and more.
Abbreviations
This table contains abbreviations used throughout this document.
Table 1 - Abbreviations
Abbreviation
Description
ACB
Analog Control Board
AFE
Active Front End
ASD
Adjustable Speed Drive
CMC
Common Mode Choke
CSI
Current Source Inverter
CT
Current Transformer
DMM
Digital Multimeter
DPM
Drive Processor Module
HECS
Hall Effect Current Sensor
HMI
Human Machine Interface
HPTC
High Performance Torque Control
IFM
Interface Module
IGDPS
Isolated Gate Driver Power Supply
LV
Low Voltage
MOV
Metal-oxide Varistor
MV
Medium Voltage
GN
Grounding Network
OIB
Optical Interface Board
OIBB
Optical Interface Base Board
PIV
Peak Inverse Rating
PLC
Programmable Logic Controller
PWM
Pulse Width Modulated
SCB
Signal Conditioning Board
SCR
Silicon-controlled Rectifier
SGCT
Symmetrical Gate Commutated Thyristor
SHE
Selective Harmonic Elimination
SIL
Safety Integrity Level
SPGDB
Self-powered Gate Driver Board
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
11
Preface
Table 1 - Abbreviations (Continued)
Additional Resources
Abbreviation
Description
SPS
Self-powered SGCT Power Supply
STO
Safe Torque Off
TSN
Transient Suppression Network
UPS
Uninterruptible Power Supply
VFD
Variable Frequency Drive
VSB
Voltage Sensing Board
VSI
Voltage Source Inverter
XIO
External Input/Output
These documents contain additional information concerning related products
from Rockwell Automation.
Resource
PowerFlex 7000 Medium Voltage AC Drives Technical Data,
publication 7000-TD010.
PowerFlex Medium Voltage AC Drives Selection Guide,
publication PFLEX-SG003
PowerFlex 7000 Medium Voltage AC Drive Transportation and Handling ForGe Control, publication 7000-IN008
PowerFlex 7000 HMI Offering with Enhanced Functionality,
publication 7000-UM201
HMI Interface Board Software Updater and Firmware Download Procedure,
publication 7000-QS002
Description
Provides technical specifications, standards and certifications, product selection tables,
cable considerations, torque capabilities and drive dimensions.
Provides information to correctly select the appropriate drive for your application. Includes
typical application load torque profiles, drive options, catalog number explanation, and
features.
Provides receiving and handling instructions for Medium Voltage variable frequency drive
and related equipment
Provides detailed information to configure, set up, operate, update and troubleshoot the
PowerFlex 7000 HMI Interface Board
Provides quick start information on updating HMI Interface Board software
Describes how to configure and use EtherNet/IP devices to communicate on the EtherNet/IP
network.
Describes basic Ethernet concepts, infrastructure components, and infrastructure features.
Ethernet Reference Manual, ENET-RM002
Provides guidance on how to conduct security assessments, implement Rockwell
Automation products in a secure system, harden the control system, manage user access,
System Security Design Guidelines Reference Manual, SECURE-RM001
and dispose of equipment.
UL Standards Listing for Industrial Control Products,
Assists original equipment manufacturers (OEMs) with construction of panels, to help ensure
publication CMPNTS-SR002
that they conform to the requirements of Underwriters Laboratories.
Provides an overview of American motor circuit design based on methods that are outlined
American Standards, Configurations, and Ratings: Introduction to
in the NEC.
Motor Circuit Design, publication IC-AT001
Provides a quick reference tool for Allen-Bradley industrial automation controls and
Industrial Components Preventive Maintenance, Enclosures, and Contact
assemblies.
Ratings Specifications, publication IC-TD002
Designed to harmonize with NEMA Standards Publication No. ICS 1.1-1987 and provides
Safety Guidelines for the Application, Installation, and Maintenance of
general guidelines for the application, installation, and maintenance of solid-state control in
Solid-state Control, publication SGI-1.1
the form of individual devices or packaged assemblies incorporating solid-state
components.
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.
Provides declarations of conformity, certificates, and other certification details.
Product Certifications website, rok.auto/certifications.
EtherNet/IP Network Devices User Manual, ENET-UM006
You can view or download publications at rok.auto/literature.
12
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Chapter
1
Overview of Drive
Introduction
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.
Topology
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.
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
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
13
Chapter 1
Overview of Drive
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
(Figure 1) called selective harmonic elimination (SHE) to mitigate the 5th, 7th,
and 11th harmonic orders
Figure 1 - Typical PWM Switching-pattern, Line Voltage Waveform
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.
Figure 2 - 3300/4160V Direct-to-Drive (Transformerless AFE Rectifier)
Line Converter
Common Mode Choke
L+
M+
Machine Converter
SGCTs
SGCTs
LR
U (T1)
V (T2)
W (T3)
L-
14
M-
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Chapter 1
Overview of Drive
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
DC Link
Line Converter
Remote ISTX
L+
SGCTs
SGCTs
1U
1V
1W
Machine Converter
M+
2U (X1)
U (T1)
2V (X2)
V (T2)
2W (X3)
W (T3)
L-
M-
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.
Figure 4 - 3300/4160 AFE Rectifier with Integral Isolation Transformer
Line Converter
Internal ISTX
DC Link
L+
Machine Converter
M+
SGCTs
SGCTs
1U
1V
1W
2U (X1)
U (T1)
2V (X2)
V (T2)
2W (X3)
W (T3)
L-
M-
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
15
Chapter 1
Overview of Drive
Motor Compatibility
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
Motor Current
100.00
0.00
-100.00
-200.00
-300.00
10.00K
Vrms
7.50K
Motor Voltage
5.00K
2.50K
0.00K
-2.50K
-5.00K
-7.50K
-10.00K
100.00
16
110.00
120.00
TIME (ms)
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
130.00
140.00
150.00
Chapter 1
Simplified Electrical
Drawings
Overview of Drive
2400V
Figure 6 - 2400V - Direct-to-Drive (Transformerless AFE Rectifier)
Line Converter
Common Mode Choke
L+
Optional Input Starter
Machine Converter
M+
SGCTs
SGCTs
LR
U (T1)
L1
V (T2)
L2
W (T3)
L3
L-
M-
Figure 7 - 2400 Volt – AFE Rectifier with Separate Isolation Transformer
Remote ISTX
Line Converter
DC Link
L+
Machine Converter
M+
SGCTs
SGCTs
2U (X1)
U (T1)
1V
2V (X2)
V (T2)
1W
2W (X3)
W (T3)
1U
L-
M-
Figure 8 - 2400 Volt – AFE Rectifier with Integral Isolation Transformer
Integral ISTX
Line Converter
DC Link
L+
SGCTs
1U
1V
1W
Machine Converter
M+
SGCTs
U (T1)
2U (X1)
2V (X2)
V (T2)
2W (X3)
W (T3)
L-
M-
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
17
Chapter 1
Overview of Drive
3300/4160V
Figure 9 - Direct-to-Drive (Transformerless AFE Rectifier)
Line Converter
Optional Input Starter
Common Mode Choke
Machine Converter
SGCTs
SGCTs
LR
U (T1)
L1
V (T2)
L2
W (T3)
L3
L-
M-
Figure 10 - AFE Rectifier with Separate Isolation Transformer
Line Converter
Remote ISTX
M+
SGCTs
SGCTs
1U
1V
1W
Machine Converter
%DC Link
L+
2U (X1)
U (T1)
2V (X2)
V (T2)
2W (X3)
W (T3)
L-
M-
Figure 11 - AFE Rectifier with Integral Isolation Transformer
Integral ISTX
Line Converter
DC Link
L+
M+
SGCTs
SGCTs
1U
1V
1W
2U (X1)
U (T1)
2V (X2)
V (T2)
2W (X3)
W (T3)
L-
18
Machine Converter
M-
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Chapter 1
Overview of Drive
6600V
Figure 12 - Direct-to-Drive (Transformerless AFE Rectifier)
LINE CONVERTER
L+
M+
SGCTs
SGCTs
OPTIONAL INPUT STARTER
MACHINE CONVERTER
COMMON MODE CHOKE
LR
U (T1)
L1
V (T2)
L2
W (T3)
L3
L-
M-
Figure 13 - AFE Rectifier with Separate Isolation Transformer
LINE CONVERTER
REMOTE
ISTX
M+
SGCTs
SGCTs
1U
1V
1W
MACHINE CONVERTER
DC LINK
L+
2U (X1)
U (T1)
2V (X2)
V (T2)
2W (X3)
W (T3)
L-
M-
Figure 14 - AFE Rectifier with Integral Isolation Transformer
INTEGRAL
ISTX
LINE CONVERTER
M+
SGCTs
SGCTs
1U
1V
1W
MACHINE CONVERTER
DC LINK
L+
2U (X1)
U (T1)
2V (X2)
V (T2)
2W (X3)
W (T3)
L-
M-
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19
Chapter 1
Overview of Drive
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.
Figure 15 - Safe Torque Off
Speed
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.
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Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Chapter 1
Operator Interface
Overview of Drive
The human-machine interface (HMI) board is an HIM-enabling device for the
PowerFlex 7000 drive. The board lets you acquire all the necessary executable
tools, documentation, and reports required to commission, troubleshoot, and
maintain the drive.
IMPORTANT
Any references to HIM can refer to PanelView™ Plus 6 (shipped
prior to 2022), or eHIM (shipped from 2022) terminal.
Via the HMI board, the user can choose the style and size of the desired
Windows®-based operator terminal to interact with the drive (for example,
PanelView Plus 6 Windows CE terminal, eHIM Windows 10 terminal, laptop,
or desktop computer). The HMI board removes past issues with compatibility
between the drive and configuration tools, as all the necessary tools are
acquired from the drive.
The HMI board is well suited for applications that require remote placement of
the operator terminal and remote maintenance.
Figure 16 - Operator Interface
eHIM
PanelView Plus 6(1)
(1) The PanelView Plus 1000 is PanelView Plus 6 with a 10 in. screen.
Basic Configurations
There are three basic configurations for the HIM.
Locally-mounted HIM
IMPORTANT
This configuration applies to both the eHIM and PanelView Plus 6
terminal.
The HIM is mounted on the LV door of the VFD. There is also a service access
port (RJ-45 connector) on the LV door.
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21
Chapter 1
Overview of Drive
Remote-mounted HIM
IMPORTANT
This configuration only available with PanelView Plus 6 HIM.
The HIM is not mounted in the traditional location on the low voltage door of
the VFD. A remote mounting plate, complete with E-Stop push button, and
HIM is supplied loose for you to mount wherever desired. The HIM connects to
the VFD via a hardwired ethernet cable. There is no significant functional
distance limitation.
This is ideal for non-PLC users wanting to control and monitor remotely (for
example, at the driven machine or control room). This is also ideal if you, for
example, have policies in place to control access to medium voltage equipment
and the associated requirements of PPE when using the operator interface at
the VFD.
No HIM supplied
IMPORTANT
This configuration only available with PanelView Plus 6 HIM.
A service access port (RJ-45 connector) is located on the LV door of the VFD.
You can use your own laptop as the HIM. All programs required to use the
laptop as the HIM are stored in the VFD. Their laptop is connected to the VFD
via a hardwired Ethernet cable, when required. This is ideal for unmanned
sites, where a dedicated HIM is not required.
See publication 7000-UM201 for detailed instruction for the HIM.
See publication 7000-UM151 for detailed instruction for ‘B’ frame drives using
the PanelView 550 HIM.
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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
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.
Siting of the Drive
Site Considerations
The standard environment in which the equipment is designed to operate is:
• Elevation above sea level less than 1000 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.).
• 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.
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Chapter 2
Drive Installation
•
•
•
•
•
•
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.
Installation
24
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.
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Chapter 2
Drive Installation
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
page 187 is still essential.
Figure 17 - Shock Indicator
Red Plastic Housing
51 mm
(2.0)
Window area appears black
if subjected to shock.
21 mm
(0.8)
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25
Chapter 2
Drive Installation
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.
Figure 18 - Fan Hood Assembly
Flat Plate (1)
Exhaust Hood Panels (2)
M6 thread forming screws (20)
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Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Chapter 2
Drive Installation
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.
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.
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27
Chapter 2
Drive Installation
Figure 20 - Fan Hood Installation
Assembled Exhaust Hood
M6 Screw (12)
Verify that notch
orientation to sides
Figure 21 - Acoustic Fan Hood Installation
Assembled Acoustic
Exhaust Hood
Top Plate for Converter and
Common Mode Choke/DC
Link Cabinet
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Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
M6 Screw (11)
Remove existing screw
and reinsert with Hood.
Chapter 2
Drive Installation
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.
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
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29
Chapter 2
Drive Installation
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.
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)
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Chapter 2
Drive Installation
Neutral Resistor Assembly
Figure 25 - Hood Assembly for Neutral Resistor
Top Plate for Neutral
Resistor Housing
Ground
resistor
hood here
900 mm converter 800 mm common mode
choke cabinet
Top plate for converter and
common mode choke cabinet
Attach
ground to
top plate.
Line filter
capacitors
Neutral Resistor Assembly
See electrical drawings to
verify cable rating and to
connect neutral resistor
assembly.
Motor filter
capacitors
Figure 26 - Acoustic Hood Assembly for Neutral Resistor
Hood Ground Stud
Remove existing
M6 Screws (11)and
reinsert with hood.
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
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31
Chapter 2
Drive Installation
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.
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).
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Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Chapter 2
Drive Installation
SAM
PLE
Figure 27 - PowerFlex 7000 “A” Frame Dimensional Drawing
IMPORTANT
Contact Factory for Seismic Mounting Information.
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
33
Chapter 2
Drive Installation
Drive Layout
Figure 28 … 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)
Line Reactor/Starter
Cabling Cabinet
34
Converter Cabinet
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Control Link/Fan Cabinet
Chapter 2
Drive Installation
Figure 29 - AFE Rectifier (Separate Isolation Transformer)
Cabling Cabinet
Converter Cabinet
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Control Link/Fan Cabinet
35
Chapter 2
Drive Installation
Figure 30 - AFE Rectifier (Integral Isolation Transformer)
Isolation Transformer and
Cabling Cabinet
36
Converter Cabinet
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Control Link/Fan Cabinet
Chapter 2
IEC Component and Device
Designations
Drive Installation
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 multi-drop 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
multi-conductor cables. The abbreviations that are used to identify the colors on
the drawings are fully identified on a sheet in the drawing set.
Power Cabling Access
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 Figure 31 through Figure 34.
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.
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Chapter 2
Drive Installation
Power Connections
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, Figure 33 and Figure 34.
The installer is responsible for verifying that power connections are made with
appropriate torque (see page 175).
The drive is supplied with provision for grounding of cable shields and stress
cones near the power terminals.
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Chapter 2
Drive Installation
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.
Cable Entry Location
(Top Load/Motor Entry)
Line Cables
700.0
[27.56]
L1, L2, L3
190.6
[7.50]
Top Cable Entry)
Motor Cables
U, V, W
Removeable Barrier
for Cable Routing
2314.6
[91.12]
597.5
100.2
[23.52]
[3.94]
214.5 [8.44]
2033.2
[80.05]
328.8 [12.94]
1324.8
[52.16]
Bottom Cable Entry)
Right-hand side sheet is removed for clarity.
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
39
Chapter 2
Drive Installation
Figure 32 - Dimension Views of Direct-to-Drive™ (AFE with DC Link) without Input Starter
Cable Entry Location
(Top)
1000 [39.4]
700.00
[27.56]
A
B
209.6
[8.25]
480.5 [18.92]
480.5
[18.92]
366.2 [14.42]
1133.0
[44.61]
251.9 [9.92]
429.0 [16.89]
314.7 [12.39]
189.2 [7.45]
2314.6
[91.12]
Line Cables
L1,L2,L3
Motor Cables
U,V,W
Section A-A
Section B-B
A
B
Figure 33 - Dimension Views of AFE Rectifier with Separate Isolation Transformer
40
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Chapter 2
400.0 [15.75]
112.8
[4.44]
Drive Installation
1000.3 [39.38]
112.8 [4.44]
2314.6
[91.12]
1409.4
[55.49]
1180.8
[46.49]
952.2
[37.49]
412.9 [16.26]
Section A-A
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41
Chapter 2
Drive Installation
Figure 34 - Dimension Views of AFE Rectifier with Integral Isolation Transformer
Section A-A
42
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Chapter 2
Power and Control Wiring
Drive Installation
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.
IMPORTANT
Grounding Practices
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.
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.
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Chapter 2
Drive Installation
Figure 35 - Ground Connection Diagram with Isolation Transformer
AC Motor
Connected to
the neutral point U (T1)
of the capacitor
Isolation Transformer
2U
2V
V (T2)
Output
Ground
Network
2W
W (T3)
Ground Bus
Figure 36 - Ground Connection Diagram with Line Reactor
AC Line Reactor
Transformer
2U
Converter
2V
U (T1)
AC Motor
V (T2)
Inverter
2W
W (T3)
Ground Bus
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.
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.
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Chapter 2
Drive Installation
• 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.
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.
Interlocking
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.
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45
Chapter 2
Drive Installation
Notes:
46
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Chapter
3
Power Component Definition and Maintenance
Cabling Cabinet
Components
Figure 37 - Direct-to-Drive with UPS Option
Low Voltage Compartment
Line Cable Terminations
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
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Chapter 3
Power Component Definition and Maintenance
Figure 39 - AFE Rectifier with Isolation Transformer
Low Voltage Wireway
Current Transformer
Hall Effect Sensor
Line Cable Terminations
Motor Cable Terminations
Hall Effect Sensor
Current Transformer
Control Power Transformer Fuses
Fan-control Power Transformer
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Chapter 3
Power Component Definition and Maintenance
Figure 40 - AFE Rectifier with Integral Isolation Transformer
A
Fan Housing
Top Cable Entry
and Exit Locations
Ground Bus
Hall Effect
Sensors
Line Cable
Terminations
Motor Cable
Terminations
Current
Transformers
(CT)
(Back)
(Front)
Integral
Isolation
Transformer
SECTION A-A
Side View
50
Bottom Cable Entry
and Exit Locations
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
A
Front View
Chapter 3
Hall Effect Sensor
Replacements
Power Component Definition and Maintenance
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
Figure 41.
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.
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
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Line Reactor /
Starter Cabinet
51
Chapter 3
Power Component Definition and Maintenance
Current Transformer
Replacement
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.
4.
5.
6.
Disconnect the wires.
The line cable must be disassembled to allow removal of the CT.
Remove the hardware and slide the cable out.
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.
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)
Current Transformer
Cabling Cabinet
52
Line Reactor / Starter Cabinet
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Chapter 3
Converter Cabinet
Components
Power Component Definition and Maintenance
Figure 43 - Converter Cabinet Components (2400V Version)
Isolated Gate Driver
Power Supplies (IGDPS)
Inverter Modules
Rectifier Modules
Rectifier IGDPS
(not required in
drives with SPS
boards installed)
Voltage Sensing Boards
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Chapter 3
Power Component Definition and Maintenance
Figure 44 - Converter Cabinet Components (3300/4160V Version)
Inverter Modules
Isolated Gate Driver
Power Supplies (IGDPS)
Rectifier IGDPS
(Not required in
drives with SPS
boards installed)
Rectifier Modules
Voltage Sensing Boards
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Chapter 3
Power Component Definition and Maintenance
Figure 45 - Converter Cabinet Components (6600V Version)
Isolated Gate Driver
Power Supplies
(IGDPS)
Inverter
Modules
Rectifier
Modules
Rectifier IGDPS
Not required in
drives with SPS
boards installed)
Voltage Sensing
Boards
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Chapter 3
Power Component Definition and Maintenance
Converter Cabinet
The converter cabinet contains three rectifier modules and three inverter
modules. Figure 43 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 2 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.
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 2 - Input Voltage Range
Tap
D
C
B
A
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.
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.
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Power Component Definition and Maintenance
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
Surge Arresters
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:
Drive Voltage
2.4 kV
3.3 kV
Arrester Rating (RMS)
3 kV
6 kV
9 kV
Arrester MCOV (RMS)
2.55
5.10
7.65
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4.16, 4.8 kV
6.0...6.9kV
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Chapter 3
Power Component Definition and Maintenance
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 ContinuousOperating 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
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.
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Chapter 3
Power Component Definition and Maintenance
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).
Figure 48 - Surge Arresters
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
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Chapter 3
Power Component Definition and Maintenance
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.
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
Rectifier SGCTs
6
12
18
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 SPS on page 84 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.
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.
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Chapter 3
Resistance Checks
Power Component Definition and Maintenance
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.
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.
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61
Chapter 3
Power Component Definition and Maintenance
Figure 49 - Snubber Circuit for SGCT Module
Cs-1
Rsn-2
Rsh
Cs-2
Rsn-1
Snubber
Resistor
Test
Anode
Heatsink
Cathode
Heatsink
Figure 50 - Snubber Circuit for SGCT Module (with SPS Board)
Cs-1
Rsn-2
Rsh
SPS Board
Rsn-1
Snubber
Resistor
Test
Anode
J1-1
J1-2
Cs-2
Cathode
Heatsink
Heatsink
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Heatsink
Chapter 3
Power Component Definition and Maintenance
Figure 51 - 2400V Two Device PowerCage (Heat Sink Model)
Pivot Plate
SGCTs
Heat Sink
Module
Housing
Temperature
Feedback Board
Clamp Head
Figure 52 - 2400V Two Device PowerCage Module (with SPS Boards Installed)
SPS Mounting Assembly with
Temperature Feedback Board
SGCT
SGCT
Clamp Head
Pivot Plate
Heat sink
SPS Board
Mounting
Assembly
without
Temperature
Feedback
Board
Module Housing
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Chapter 3
Power Component Definition and Maintenance
Figure 53 - 3300/4160V Four Device PowerCage (Heat Sink Model)
Pivot Plate
Matched Set
Two SGCTs
Matched Set
Two SGCTs
Module Housing
Temperature Feedback Board
Heat Sink
Clamp Head
Figure 54 - 3300/4160V Four Device Rectifier PowerCage Module (with SPS Boards Installed)
Pivot Plate
Heat sink
64
Matched Set
Two SGCTs
SPS Mounting Assembly with
Temperature Feedback Board
SPS Mounting Board Assembly without
Temperature Feedback Board
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Matched Set
Two SGCTs
Clamp Head
Module Housing
Chapter 3
Power Component Definition and Maintenance
Figure 55 - 6600V Six Device PowerCage Module
Matched Set
Three SGCTs
Pivot Plate
Matched Set
Three SGCTs
Module Housing
Clamp Head
Heat Sink
Temperature Feedback Board
Figure 56 - 6600V Six Device PowerCage Module (with SPS Boards Installed)
Pivot Plate
Heatsink
Matched Set
Three SGCTs
SPS Mounting Assembly with
Temperature Feedback Board
Matched Set
Three SGCTs
SPS Mounting Assembly without
Temperature Feedback Board
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Clamp Head
Module
Housing
65
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.
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.
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Power Component Definition and Maintenance
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.
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.
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Chapter 3
Power Component Definition and Maintenance
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.
Figure 59 - Testing the Snubber Resistor
Sharing Resistor
Snubber
Capacitor
Snubber
Resistor
Test Point
SGCT
Measure resistance
between heat sink
and test point.
Snubber Test Point
Heatsink
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
Snubber
Capacitor
Snubber
Resistor
Test Point
SGCT
Resistance value between
heat sink and test point is
snubber resistance.
68
Heatsink
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Heatsink
SPS Board
1
J1
2
Chapter 3
Power Component Definition and Maintenance
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:
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
Snubber
Capacitor
Snubber
Resistor
Measure capacitance
between heat sink and
test point (or heat sink
to heat sink).
Test Point
SGCT
Heatsink
Heatsink
Snubber Test Point
Figure 62 - Snubber Capacitor Test (Shown with SPS Board Installed)
Sharing Resistor
Snubber
Capacitor
Snubber
Resistor
Snubber
Test
Point
1
SPS Board
J1
2
Test Point
SGCT
Heatsink
Heatsink
Snubber Capacitor Wire
SGCT Cathode Wire
Use connector terminal screw for
testing the snubber capacitor.
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Chapter 3
Power Component Definition and Maintenance
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:
Status Indicator 4
Status Indicator 3
Green
Green
Status Indicator 2
Yellow
Status Indicator 1
Red
Solid Green indicates that the Power Supply to the Card is OK.
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 page 77.
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.
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5. Slide the circuit board straight out.
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 76 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
Clamp Head Block
SGCT Captive Screws
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)
Inside nut for
loosening and
applying load to
assembly.
SGCT Captive Screws
DO NOT ADJUST outside nut.
Clamp Head Block
SPS board mountingassembly captive screws.
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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 PowerCage Module
Removal on page 82.
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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Figure 66 - Snubber and Sharing Resistor, Snubber Capacitor Replacement
Pinch and remove clips at
end of the retaining rod
Extract the
retaining rod.
Detach leads of
resistor assembly.
Figure 67 - Removing the Resistor Bank from the PowerCage Module
Push Nut
Retaining Rod
Resistor Bank
6. Remove the resistor bank from the PowerCage module. See Figure 67.
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 PowerCage Module
Removal on page 82.
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Snubber Capacitor
Replacement
Power Component Definition and Maintenance
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 PowerCage
Module Removal on page 82.
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).
13 mm Socket
M8 Bolt
5/16 in. Lock Washer
5/16 in. Flat Washer
Electrical Lead
17 mm Flange
M8 Hardware Location
6. Bundle and secure the connecting wires using wire ties.
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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.
ATTENTION: Main power must be 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.
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Figure 69 - Clamp Head Illustration
Calibration Nut- DO NOT ADJUST.
Clamp Bar
Indication Washer
Adjustment Nut
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
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 Figure 70).
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 76 to
verify that the heatsinks are clamped to a uniform pressure.
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Figure 70 - Replacing the Thermal Sensor
Temperature Feedback
Circuit Board
Insulating
Bushing
Mounting Pad
Mounting Screw
Thermal Sensor and
Cable Assembly
Figure 71 - Replacing the Thermal Sensor (if SPS Board is Installed)
Mounting Pad
Temperature Feedback
Circuit Board
Insulating
Bushing
Mounting Screw
Thermal Sensor and
Cable Assembly
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Heatsink Replacement
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
Copper
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 load from the clamp head per the procedure on page 77.
3. Remove the SGCT from the heatsink that is being replaced per the
instructions on page 70.
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 51 through Figure 56 for pivot plate location.
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 page 70.
See page 76 to verify that the heatsinks are clamped to a uniform
pressure.
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PowerCage Gasket
Power Component Definition and Maintenance
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
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.
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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.
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 51 through 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
82
The PowerCage can be heavy. To avoid injury or damage to the module,
two people are recommended to extract the PowerCage from the drive.
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Power Component Definition and Maintenance
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.
Figure 74 - Typical Torque Sequence
7. Replace interior assembly in the reverse order of removal.
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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).
Figure 75 - Snubber Circuit for SGCT Module (with SPS Board)
Cs-1
Rsn-2
Rsh
Rsn-1
Cs-2
J1-1
J1-2
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.
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Figure 76 - SPS Board Test Points
J1 Snubber and
Test Power Harness
TP6-300V DC
Common
J2-20V DC
Output Power
to SGCT and
TFB Board
DS1-20V DC
Good Status
Indicator
TP15 - 20V DC
TP14 - 20V DC COM
TP4-300V DC
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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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 VINRMS.
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
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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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
left-hand quadrant of the cabinet.
Figure 77 - Air Pressure Sensor
Flexible tube for lowpressure 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
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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Figure 79 - DC Link and Fan Cabinet, Low Voltage Control Tub Removed
Fan
Inlet Ring
DC Link
Inductor
Grounding
Network/
Filter
Motor Filter
Capacitor
Line Filter
Capacitor
When the door is opened, control components are accessible. Behind the low
voltage swing-out panel is the medium voltage compartment where the DC
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Power Component Definition and Maintenance
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 (Figure 80).
IMPORTANT
The maximum torque for the capacitor terminal is 3.4 N•m (30 lb•in.).
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Figure 80 - Output Grounding Network
Maximum torque on
capacitor terminals
3.4 N•m (30 lb•in)
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 Figure 81.
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
92
The maximum torque for the capacitor terminal is 3.4 N•m (30 lb•in.).
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Figure 81 - Ground Filter Component Replacement
Reactor Transformer
Resistor Bank
Reactor Transformer Barrier
Capacitors
Filter 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.
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 non-operational
MFC can lead to serious personal injury and/or property damage.
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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 (Figure 78).
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.
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 25 N•m (19 lb•ft) due
to capacitor mechanical constraints.
IMPORTANT
Use two wrenches to tighten the nuts to prevent damage to the
capacitor.
9. Remove any shorting/grounding conductors.
10. Reinstall the sheet metal that was removed, and verify that connections
are secure and correct.
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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.
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
Capacitors on page 95).
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.
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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.
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
Capacitors on page 95).
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
L3-N
200V
1.861 A
Calculate the capacitance by using the first reading. In this case:
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
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 Figure 83. 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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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
Step 4: Remove DC Link
hardware and lift link out
of the front of the drive.
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.
Verify that the nameplate ratings are the same or appropriate for the drive
system. Another DC link requires different parameter settings.
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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.
Fan Replacement
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 Installation of Exhaust Air Hood 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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Figure 84 - Fan Removal
Fan Motor
Fan Impeller
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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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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Top of Integral Line Reactor and Input Starter Section
Figure 86 - Starter/Line Reactor Cabinet Fan Removal
Ventilator Cover
Terminal Blocks
Fan Mounting Blocks
Fans
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.
Impeller Maintenance
Isolation Transformer Cooling Fan
The isolation transformer fan motor and impeller is an integral unit and
cannot be serviced separately.
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Inlet Ring Removal and
Replacement
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.
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 Figure 78).
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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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
Retaining Hardware
Filter
Figure 88 - Airflow Through PowerCage Module
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Figure 89 - Airflow Pattern for Drive Cooling
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Fan Power Transformer
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. Customer-supplied 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:
Customersupplied 2.4…6.6
kV
FPT
CPT
MPR
Main
Fan
MPR
Redundant
Fan
380…480V
110…240V
LV Panel
FPT is Not Required:
MPR
Main
Fan
MPR
Redundant
Fan
Customersupplied
380…480V
CPT
108
110…240V
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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 (Figure 92).
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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Figure 91 - Direct-to-Drive (Transformerless AFE Rectifier)
- Operator Interface
- Relays
Customer
Supplied
120V 1 PH
5V-Logic
C Hold-up
+/-15V Logic
AC/DC Converter
600 W/ 1000W/ 1500 W
Line
Filter
DC/DC Converter
+/-24V-HECS
24V-Isolators
24V-XIO
Sense Cable
DC Fail
380V 50 Hz
or
460V 60 Hz
3 PH
Line
Reacto
Fan
20V Isolated Gate
Driver Power Supply
20V
VFD
Inverter only for SPS Drives
Figure 92 illustrates the control power distribution for AFE drives with remote
transformer/starter (A) or integrated line reactor with remote starter (B).
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Figure 92 - AFE Rectifier with Separate Isolation Transformer
-Operator Interface
-Relays
C Hold-up
+5V-LOGIC
+/- 15V-LOGIC
Customer Supplied
120V
1 PH
AC/DC Converter
600 W/ 1000W/1500 W
DC/DC Converter
+/- 24V-HECS
+24V-ISOLATORS
+24-XIO
DC Fail
Sense Cable
380V 50 Hz
Or
460V 60 HZ
3 PH
Tx Fan
Line
Reactor
OR
VFD
A
Fan
VFD
Fan
20V Isolated
Gate Driver
Power Supply
20V
Inverter only for SPS Drives
B
Figure 93 illustrates the control power distribution for AFE drives with integral
transformer and remote starter.
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Figure 93 - AFE Rectifier with Integral Isolation Transformer
-Operator Interface
-Relays
C Hold-up
Customer Supplied
120V
1 PH
+5V-LOGIC
+/- 15V-LOGIC
AC/DC Converter
600 W/ 1000W/ 1500 W
DC/DC Converter
+/- 24V-HECS
+ 24V-ISOLATORS
+24-XIO
Sense Cable
Tx Fan
20V Isolated
Gate Driver
Power Supply
380V, 50 Hz
Or
460V, 60 HZ
3 PH
VFD
AC/DC Power Supply
Fan
20V
Inverter only for SPS Drives
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(a) 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
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
DC/DC
Power
Supply
HV IGDPS
Power
Supply
DC FAIL: Upon loss of DC output (V outputs ≤ 49V DC) this output goes from low to
high.
(a) Cosel power supply output 57V DC, Pioneer power supply output is 56V DC.
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Location
The AC/DC power supply is located in the low voltage panel at the top righthand section of the drive, see Figure 95.
Figure 95 - Location of AC/DC Cosel (single) Power Supply on Low Voltage Panel
AC/DC Power Supply
(Cosel)
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Figure 96 - Location of AC/DC Cosel (Dual) Power Supply on Low Voltage Panel
AC/DC Power
Supply (Cosel)
Diode
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Terminal / Connections Descriptions
The terminal connections are shown in Figure 97.
Figure 97 - Terminal locations on 1000W AC/DC Power Supply (Cosel)
Adjustment Pot
DC Outputs
Control Signals
Cosel
PBA600F-60-XRWAD
Single Phase
Input
Figure 98 - Terminal Locations on 600 W AC/DC Power Supply (Cosel)
Terminal/Connections
Descriptions
(600W Cosel Power Supply)
Single Phase Input
Control Signals
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PBA600F-60-XRWAD
Adjustment Pot
DC Outputs
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P1-AC Input
P2-DC Output
PIN#
AC (L)
AC (N)
NC
FG
PIN#
+
–
PIN#
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
CN1
P3-Fail Output
CN2
CN3
Output Calibration
Verify that the output of the supply is 56V DC(a).
There is a potentiometer on the top of the power supply that adjusts the
56V DC(a) 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(a). Perform this test on
each power supply. When all adjustments are complete, reconnect the power
supply to the circuit and remeasure the output. Readjust if necessary.
If 56V DC(a) 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.
Single Power Supply Replacement
The single power supply (see Figure 95 on page 113) 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.
(a) 56V DC for Cosel model numbers -XRWAC and earlier. 57V DC for Cosel model numbers -XRWAD and newer.
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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.
Dual Power Supply Replacement
If there are two power supplies (see Figure 96 on page 114) 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)
Diode Safety Cover
Diode
Low Voltage
Swing-out Tub
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.
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Control Component Definition and Maintenance
7. Remove the four M6 bolts from the bracket holding the power supply.
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.
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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
Low Voltage
Swing-out Tub
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
Hold-up Capacitor
The Holding Bracket
UPS
The UPS is installed in the incoming cabling section in the UPS LV control
section.
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Control Component Definition and Maintenance
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(a) 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.
5. Before installing the new UPS, the internal battery must be connected.(b)
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.
(a) 56V DC for Cosel model numbers -XRWAC and earlier. 57V DC for Cosel model numbers -XRWAD and newer.
(b) Reprinted from 700-3000 VA User’s Guide by permission of Eaton Corporation.
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Figure 100 - Connect the Internal UPS Battery
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.
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)
122
Hinged
Panel
(Closed)
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Chapter 4
DC/DC Power Supply
Control Component Definition and Maintenance
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(a) source.
Figure 102 - DC/DC Converter Power Supply
+5V-LOGIC
+/- 15V-LOGIC
DC/DC
Power Supply
+
56…57V DC
+/- 24V-HECS
-
+/- 24V-ISOLATORS
C hold-up
+24-XIO
Sense Cable
The capacitor at the input terminals enables the equipment to ride through
power dips. If the capacitor (C hold-up) loses the 56V(b) 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
PIN NO.
1
2
3
LABEL
+56V
+56V COMM
EARTH
DESCRIPTION ONLY
+56V input
+56V common
Earth ground
P2 – SENSE (To ACB)
PIN NO.
1
2
3
4
5
6
7
8
9
10
11
12
13
14
LABEL
+56V
+56V RTN
NC
NC
+24V
+24V RTN
NC
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
(a) 56V DC for Cosel model numbers -XRWAC and earlier. 57V DC for Cosel model numbers -XRWAD and newer.
(b) 56V DC for Cosel model numbers -XRWAC and earlier. 57V DC for Cosel model numbers -XRWAD and newer.
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Control Component Definition and Maintenance
P3 – ISOLATOR
(To Isolator Modules)
PIN NO.
1
2
3
P4 – PWR
(To ACB)
PIN NO.
1
2
3
4
5
6
7
8
9
10
11
LABEL
ISOLATOR (+24V, 1 A)
ISOL_COMM (com4)
EARTH
LABEL
+24V_XIO (+24V, 2 A)
XIO_COMM (com3)
+HECSPWR (+24V, 1 A)
LCOMM (com2)
–HECSPWR (-24V,1 A)
+15V_PWR (+15V,1 A)
ACOMM (com1)
-15V_PWR (-15V,1 A)
+5V_PWR (+5V,5 A)
DGND (com1)
EARTH
DESCRIPTION ONLY
+24V, 1A/com4
0V/com4
EARTH
DESCRIPTION ONLY
+24V, 2 A/com3
0V/com3
+24V, 1 A/com2
0V/com2
-24V, 1 A/com2
+15V, 1 A/com1
0V/com1
-15V, 1 A/com1
+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, Figure 103).
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,
Figure 103).
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, Figure 103).
6. Verify that the ground wire of P4 plug is connected to the ground by
M10 bolt.
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Control Component Definition and Maintenance
Figure 103 - Replacement of DC/DC power supply
M4 (P.H.M.S.) and nylon
shoulder washer
Mounting Plate
Black insulation
Part ID label
DC/DC
Power Supply
View “2”
M6 (H.H.T.R.S)
View “1”
Printed Circuit Board
Replacement
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.
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Control Component Definition and Maintenance
Drive Processor Module
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
Inverter
Gating
Signals
Battery
Rectifier
Gating
Signals
HMI
Interface
Module
DPM Data Port
126
Secondary
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Primary
Secondary
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 3 - Test Points on Drive Processor Module
Test Points
DPM-TP1
DPM-TP2
DPM-TP3
DPM-TP4
DPM-TP5
DPM-TP6
DPM-TP8
DPM-TP9
DPM-TP10
DPM-TP7
DPM-TP11
DPM-TP12
DPM-TP13
DPM-TP14
Name
+1.2V
+1.8V
+2.5V
+3.3V
+5V
DGND
ITP1
ITP2
ITP3
ITP4
RTP4
RTP3
RTP2
RTP1
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.
Table 4 - Description of D9 and D11 Function
Color
Green
Red
Green
Green
Green
Green
Green
Red
Red
Red
Red
Red
Rate of Count (Pulse)
10 count
0.25 Hz
0.25 Hz
0.5 Hz
2 Hz
1 Hz
Solid
Solid
2 count
3 count
4 count
8 count
Red
9 count
Red
Red
Red
10 count
11 count
14 count
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
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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Chapter 4
Control Component Definition and Maintenance
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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Figure 105 - ACB and DPM Replacement
Analog Control Board
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Control Component Definition and Maintenance
Analog Control Board
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
Control I/O
Status and
Control
Power
Monitoring
Motor and Line
AC Voltage
Feedback Inputs
Line Current
Inputs
Motor and Line
DC Link and
Neutral Point
Voltage Inputs
Line Voltage
Sync. Transfer
Feedback
Inputs
Motor Current
Inputs
DC Link
Current
Inputs
UPS Fail
Signal
Monitoring
Ground Fault
and CMC
Neutral Current
Inputs
Comms
Connections
DCSL
Comms
Connections
Comms
Connections
XIO Board
Air
Pressure
Inputs
DC Fail
Signal
Monitoring
DPI™
Meter Inputs &
Speed Pot Input
130
Comms Connections
Terminal (PanelView)
DC Power Supply
Monitoring
XIO-PWR(+24V,+/-15V, +/-24V, +5V DC -ABUS +56V Monitoring
(in UPS option)
DIG, DC Power Supplies)
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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.
Table 5 - Connectors on Analog Control Board
ACB Connectors
ACB-J1
ACB-J2
ACB-J3
ACB-J4
ACB-J5
ACB-J6
ACB-J7
ACB-J8
ACB-J9
ACB-J10
ACB-J11
ACB-J12
ACB-J13
ACB-J14
ACB-J15
ACB-J16
ACB-J17
ACB-J18
ACB-J19
ACB-J20
ACB-J21
ACB-J22
ACB-J23
ACB-J24
ACB-J25
ACB-J26
ACB-J27
ACB-J28
ACB-J30
ACB-J31
ACB-J32
ACB-J33
ACB-J34
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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Table 6 - Test Points on Analog Control Board
Test points
ACB-TP1
ACB-TP2
ACB-TP3
ACB-TP4
ACB-TP5
ACB-TP6
ACB-TP7
ACB-TP8
ACB-TP9
ACB-TP10
ACB-TP11
ACB-TP12
ACB-TP13
ACB-TP14
ACB-TP15
ACB-TP16
ACB-TP17
ACB-TP18
ACB-TP19
ACB-TP20
ACB-TP21
ACB-TP22
ACB-TP23
ACB-TP24
ACB-TP25
ACB-TP26
ACB-TP27
ACB-TP28
ACB-TP29
ACB-TP30
ACB-TP31
ACB-TP32
ACB-TP33
ACB-TP34
ACB-TP35
ACB-TP36
ACB-TP37
ACB-TP38
ACB-TP39
ACB-TP40
ACB-TP41
ACB-TP42
ACB-TP43
ACB-TP44
ACB-TP45
ACB-TP46
ACB-TP47
ACB-TP48
ACB-TP49
ACB-TP50
ACB-TP51
132
Name
Vuv
Vvw
Vwu
Iu
Iw
Vzs
Vn
V_pk
Vdci1
Vdci2
Vuvs
V2uv
V2vw
V2wu
I2u
I2w
Vzs2
Vn1
V2_pk
Vdcr1
Idc1
Vvws
V3uv
V3vw
V3wu
I3u
I3w
Vzs3
Vn2
V3_pk
Vdcr2
Idc2
Vwus
V4uv
V4vw
V4wu
I4u
I4w
Vzs4
Vnn
Inn
Ignd
Vspr
Vmtrp
A+
B+
Z+
ABZCP1
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
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
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Chapter 4
Control Component Definition and Maintenance
Table 6 - Test Points on Analog Control Board (Continued)
ACB-TP52
ACB-TP53
ACB-TP54
ACB-TP55
ACB-TP56
ACB-TP57
ACB-TP58
ACB-TP59
ACB-TP60
ACB-TP61
ACB-TP62
ACB-TP63
ACB-TP64
ACB-TP65
ACB-TP66
ACB-TP67
ACB-TP68
ACB-TP69
ACB-TP70
ACB-TP71
ACB-TP72
ACB-TP73
ACB-TP74
ACB-TP75
ACB-TP76
ACB-TP77
ACB-TP78
ACB-TP79
ACB-TP80
ACB-TP81
ACB-TP82
ACB-TP83
CP2
CP3
CP4
Vltrp
AGND
AGND
AGND
AGND
+5V
+15V
-15V
+24V
-24V
24VCOM
DGND
AGND
AP1
AP0
AIN1
AIN2
AIN0
AIN3
IPIS
IPCS
IP
OPIS
OPCS
OP
BPIS
BPCS
BP
DGND
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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Control Component Definition and Maintenance
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.
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 . Figure 108 shows a block diagram of the transmitter.
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Control Component Definition and Maintenance
Figure 108 - Process Loop Transmitter Block Diagram
+15V
Isolated
DC/DC
Converter
+15V
5V
DSP
D/A
FPGA
#
IFM
ŀ
Optical
Interface
Current
Boost
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.
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
+
1,5,9
+
A/D
Buffer
ŀ/#
X1
-
2,6,10
FPGA
DSP
U1
Isolation Amplifier
-
3,7,11
4,8,12
1s1st I/P pins
2nd I/P pins
3rd I/P pins
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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
IFM
VPP
Out
GND
RTN
1
3
2
DC
User-supplied power
(Sinking)
4
4-Wire Transmitter
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
Buffer
FPGA
IFM Pin Number
27,31,35,39
A2D
Analog
Output
25,29,33,37
28,32,36,40
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Control Component Definition and Maintenance
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.
PIN NO.
1
2
3
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.
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.
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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.
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
1
2
3
12 11
2
+12V
1
1
2
3
+5V
+5V
12 11
2
1
J3
Output
Config.
+12V
+5VREF
J2
Input
Config.
J3
1
2
3
J2
2
12
1
11
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).
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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.
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 7. 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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Control Component Definition and Maintenance
Table 7 - Encoder Configurations
ENC_TYPE
Installed
POL_QRDNTS
Installed
CD_DQUAD
Installed
Installed
Installed
Removed
Installed
Removed
Removed
Installed
Removed
Installed
Removed
Removed
Removed
Removed
Installed
Installed
Installed
Removed
Removed
Installed
Installed
Removed
Installed
Removed
Installed
Figure 113 - Universal Encoder Board
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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)
Chapter 4
Control Component Definition and Maintenance
Connections to the universal encoder interface are made by way of a 1492IFM20F interface module. The connections to the IFM are as follows:
Table 8 - Encoder Functions
IFM Pin #
1
Quadrature Encoder Function
A1+
Absolute Encoder Function
E0
2
A1-
E1
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
B1+
B1ENC_COM
Z1+
Z1A2+ (redundant or dual ENC)
A2- (redundant or dual ENC)
ENC_COM
B2+ (redundant or dual ENC)
B2- (redundant or dual ENC)
Z2+ (redundant or dual ENC)
Z2- (redundant or dual ENC)
ENC_COM
ENC_COM
ENC_COM
ENC PWR (+12V)
ENC PWR (+12V)
ENC PWR (+12V)
E2
E3
ENC_COM
E4
E5
E6
E7
ENC_COM
E8
E9
E10
E11
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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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.
Positional Encoder Operations(a)
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.
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.
(a) Consult factory for availability of Positional Encoders.
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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 10-bit 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.
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 faultsignals (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).
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Figure 115 - XIO Board
OUTPUTS
16
15
14
13
12
11
10
9
8
7
6
5
4
3
2
1
atus Indicators
1
2
3
4
5
6
7
9
8
10
11
12
13
14
15
16
INPUTS
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 9
for the possible status for D1.
Table 9 - 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 10 - U6 Display Status
144
Display
Description
—
No valid address found
0
Card in “Master” mode
1…6
Decimal point ON
Valid address
Indicates network activity
Decimal point OFF
No activity on the network
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
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
• Normal
• Normal
• Normal at Power-on, during firmware download
and with unprogrammed drive
Chapter 4
Control Component Definition and Maintenance
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.
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
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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
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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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.
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.
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.
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Figure 118 - OIB Replacement (Mounting Plate Accessible)
Optical
Interface
Boards
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Appendix
A
Preventative Maintenance Schedule
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.
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).
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Appendix A
Preventative Maintenance Schedule
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.
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.
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Preventative Maintenance Schedule
d. Do the insulation resistance test of the drive, motor, isolation
transformer/line reactor, and the associated cabling. See Insulation
Resistance Testing Procedures on page 178 for the insulation
resistance test procedure.
e. Check indicator washers of the clamp head for proper clamp pressure,
and adjust as necessary. See page 76 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.
See page 187 for appropriate procedures/voltage levels for the previously
referenced checks.
5. Verify the gate pulse patterns by using the Gate Test Operating Mode.
For drives with SPS boards installed, use the Test Power Harness (80018695-51) 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.
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Appendix A
Preventative Maintenance Schedule
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.
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].
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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
(1)
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)
1.0 hour
0.5 hours
2.0 hours(1)
0.5 hours
– Phasing Check
1.5 hours(1)
– Autotuning(1)
– Operation to Maximum Load
2.0 hours(1)
Site Dependent
• Additional Tasks(1)
– Investigation
– Informal Training/Refresher
– Spare Parts Analysis
– Vacuum Bottle Integrity Check
• Final Report
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.
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.
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Preventative Maintenance Schedule
•
•
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
•
•
•
Maintenance Schedule
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).
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 on page 47 of this user manual.
I – Inspection
M – Maintenance
R – Replacement
C – Cleaning
Rv – Review
RFB/R – Refurbishment/Replacement
154
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.
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.
The parts can be refurbished at lower cost or the parts can be replaced
with new ones.
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Appendix A
Preventative Maintenance Schedule
5
7
Table 11 - PowerFlex 7000 Drive Preventative Maintenance Schedule (Years 0…10)
0
Period Interval (Years)
(1) (2)
Air-Cooling
System
Enhancements
Operational
Conditions
Spare Parts
3
4
6
8
9
10
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
I
I
I
I
I
R
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
R
I
I
I
I
I
I/R (4)
I
I
I
I/R(4)
I
Rv/R(4)
I
I
I
I
I
I
I
I
I
R
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
R
I
I
I
I
I
I
I
I
RFB/R
RFB/R
M
M
M
RFB/R
I
I
I
I
I
I
I
I
I
R
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
R
RFB/R
RFB/R
M
M
M
RFB/R
I
I
Battery Module (UPS)(7)
Low Voltage Terminal Connections/
Plug-in Connections
Medium Voltage Connections
Heatsink Bolted Connections
I
I
I
I
R
I
I
I
I
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
Medium Voltage Connections (Rectifier)(3)
–
–
–
I(3)
–
–
–
I(3)
–
I(3)
Medium Voltage Connections (Inverter)(5)
–
–
–
–
–
–
–
–
–
I
Firmware
Hardware
Parameters
Variables
Application Concerns
Inventory/Needs
–
–
I
I
I
I
–
–
I
I
I
I
Rv
Rv
Rv
Rv
Rv
Rv
–
–
I
I
I
I
–
–
I
I
I
I
Rv
Rv
Rv
Rv
Rv
Rv
–
–
I
I
I
I
–
–
I
I
I
I
Rv
Rv
Rv
Rv
Rv
Rv
–
–
I
I
I
I
(3)(4)
Power Switching Rectifier Snubber Capacitors
Components
Inverter Snubber Capacitors(5)(6)
Integrated Gate Driver Power Supply
Self-Powered SGCT Power Supply (SPS)
Isolation Transformer/Line Reactor
Integral
Magnetics/Power DC Link/CMC
Filters
Line/Motor Filter Capacitors
AC/DC and DC/DC Power Supplies
Control Cabinet Control Boards
Components
Batteries (DCBs and CIB)
Connections
2
I
I
I
I
I
Door Mounted Air Filters
Main Cooling Fan Motor
Redundant Cooling Fan Motor (if supplied)
Small Aux. Cooling Fans “Caravel”
Power Devices (SGCTs/SCRs)
Snubber Resistors/Sharing Resistors/ HECS
C/R
1
(1)
(2)
(3)
(4)
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).
These components may be serviced while the VFD is running.
When rectifier snubber capacitors are replaced, the MV connections for the rectifier need to be inspected.
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.
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Appendix A
Preventative Maintenance Schedule
Table 12 - PowerFlex 7000 Drive Preventative Maintenance Schedule (Years 11…20)
11
Period Interval (Years)
(1) (2)
Air-Cooling
System
Enhancements
Operational
Conditions
Spare Parts
13
14
15
16
17
18
19
20
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
R
I
I
I
I
I
I
RFB/R
RFB/R
I
I
I
I
I
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/R (4)
I
I
I
I/R (4)
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
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
RFB/R
RFB/R
M
M
M
RFB/R
I
R
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
R
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
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
Medium Voltage Connections (Rectifier)(3)
–
I(3)
–
–
–
I(3)
–
–
–
–
(5)
–
–
–
–
–
–
–
–
–
–
–
–
I
I
I
I
Rv
Rv
Rv
Rv
Rv
Rv
–
–
I
I
I
I
–
–
I
I
I
I
Rv
Rv
Rv
Rv
Rv
Rv
–
–
I
I
I
I
–
–
I
I
I
I
Rv
Rv
Rv
Rv
Rv
Rv
–
–
I
I
I
I
–
–
–
–
–
–
Door Mounted Air Filters
Main Cooling Fan Motor
Redundant Cooling Fan Motor (if supplied)
Small Aux. Cooling Fans “Caravel”
Power Devices (SGCTs/SCRs)
Snubber Resistors/Sharing Resistors/ HECS
(3)(4)
Power Switching Rectifier Snubber Capacitors
Components
Inverter Snubber Capacitors(5)(6)
Integrated Gate Driver Power Supply
Self-Powered SGCT Power Supply (SPS)
Isolation Transformer/Line Reactor
Integral
Magnetics/Power DC Link/CMC
Filters
Line/Motor Filter Capacitors
AC/DC and DC/DC Power Supplies
Control Cabinet Control Boards
Components
Batteries (DCBs and CIB)
Connections
12
Battery Module (UPS)(7)
Low Voltage Terminal Connections/
Plug-in Connections
Medium Voltage Connections
Heatsink Bolted Connections
Medium Voltage Connections (Inverter)
Firmware
Hardware
Parameters
Variables
Application Concerns
Inventory/Needs
(1)
(2)
(3)
(4)
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).
These components may be serviced while the VFD is running.
When rectifier snubber capacitors are replaced, the MV connections for the rectifier need to be inspected.
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.
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Appendix A
General Notes
Preventative Maintenance Schedule
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.
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.
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Preventative Maintenance Schedule
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 medium-voltage 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.
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, the procedure is specified in their individual product instructions or
User Manual.
IMPORTANT
158
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.
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Appendix A
Preventative Maintenance Schedule
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.
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.
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Appendix A
Preventative Maintenance Schedule
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.
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 157
and Cooling-fans on page 158. 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.
160
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Appendix
B
PowerFlex 7000 Drive Spare Part Storage
Requirements and Recommendations
Overview
If equipment containing electrolytic capacitors (for example, power supplies)
is stored (unpowered) under normal storage temperatures and conditions, it
can be kept for up to 15 years. After 15 years, the electrolyte inside of the
capacitors dries because the rubber seals of the capacitor starts to deteriorate.
During the storage period (of up to 15 years) it’s required to maintain the
electrolytic capacitors (to preserve the aluminum oxide dielectric).
To maintain the health of the electrolytic capacitors, the equipment must be
energized annually.
Power Supplies
The following reconditioning procedures are applicable for the following
components:
• Pioneer/Cosel power supply
• IGDPS
• IntelliVAC™ module
• Absopulse AC/DC converter
• Absopulse DC/DC converter
Energize the components with nominal input voltage for 1…2 hours every year
of storage. If the power supplies were stored for a longer than three years
without energizing, perform the reconditioning procedure as described below.
Reconditioning for AC/DC Power Supply
1. Connect the power supply through an AC autotransformer. The voltage
range (120/240V) is adapted to the nominal voltage of the energized item.
2. Feed the power supply with 25% of the nominal voltage of the energized
item for 15 minutes.
3. Increase voltage to 50% of the nominal voltage of the energized item,
feed the power supply for another 15 minutes.
4. Increase voltage to 75% of the nominal voltage of the energized item, feed
the power supply for another 15 minutes.
5. Increase voltage to 100% of nominal voltage of energized item, feed
power supply for another 15 minutes.
Reconditioning for DC/DC power supply
1. Connect the power supply to a variable DC source with current limiting
functionality (limit the current to 200 mA). The voltage range is adapted
to nominal voltage of energized part.
2. Feed the power supply with 25% of the nominal voltage of the energized
item for 15 minutes.
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
161
Appendix B
PowerFlex 7000 Drive Spare Part Storage Requirements and Recommendations
3. Increase voltage to 50% of the nominal voltage of the energized item,
feed the power supply for another 15 minutes.
4. Increase voltage to 75% of the nominal voltage of the energized item, feed
the power supply for another 15 minutes.
5. Increase voltage to 100% of the nominal voltage of the energized item,
feed the power supply for another 15 minutes.
1606 Power Supply
If an average storage temperature of 25 °C (77 °F) is maintained, energize the
power supply for approximately 10 minutes with nominal input voltage.
With adequate storage temperatures, this procedure should be performed at
least every five years. At higher temperatures, this procedure should be
performed every three years.
UPS Batteries
If the batteries are stored for a long period, recharge then every 6 months by
connecting the UPS to utility power. The internal batteries charge to 90%
capacity in less than 3 hours.
However, the UPS manufacturer recommends that the batteries charge for
48 hours after long-term storage. Check the battery recharge date on the
shipping carton label.
ATTENTION: If the recharge date has passed and the batteries were never
recharged, do not use them.
Control Equipment and Boards
Energize control equipment up once per year to achieve power supply
capacitor integrity.
• Power up the ACB board once a year
• Replace the lithium battery in the DPM every 3 years
162
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Appendix B
PowerFlex 7000 Drive Spare Part Storage Requirements and Recommendations
SGCT/SCR/SPS
Energize with nominal input voltage for 1…2 hours every year of storage.
To energize these components:
SGCT
•
•
•
Use the AC power source, PS1, and IGDPS power supplies to power up
the SGCT boards.
Alternatively, use a variable DC source with current limiting
functionality and the IGDPS power supplies.
Or, use the assembly of variable AC power source (120V or 240V), SPS,
and SPS wire harness that are provided with the drive.
SPGDB
•
Use a variable DC power source with current limiting functionality.
SPS
•
Use an assembly of variable AC power source (120V or 240V) and
provided with the drive SPS wire harness.
If the boards were not energized for longer than 3 years, perform the following
reconditioning procedures:
• SGCT
- Apply 20V DC voltage (from an IGDPS or a variable DC power source)
through a current limiting resistor (around 300 Ohms/1 Watt
minimum) for one hour.
• SPGDB
- Apply 20V DC voltage (from an IGDPS or a variable DC power source)
through a current limiting resistor (around 300 Ohms/1 Watt
minimum) for a period of one hour.
Cooling Fans
Rotated by hand (10…20 spins) every 3 months to ensure circulation of
lubricant in bearings and to help prevent brinelling of the bearings.
Signal Conditioners
These components have a 3 year lifetime storage period.
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
163
Appendix B
PowerFlex 7000 Drive Spare Part Storage Requirements and Recommendations
Spare Parts Maintenance
Schedule
Use the following table to determine the appropriate action per the spare parts
maintenance schedule below.
Ch Charging
E Energizing
R Recondition/
Reforming
Re Replacement
Ro Rotating
3
6
9
12
15
18
21
24
Period Interval (Months)
27 30 33 36 39
Pioneer/Cosel
power supply
—
—
—
E
—
—
—
E
—
—
—
E/R(1)
IGDPS
—
—
—
E
—
—
—
E
—
—
—
Component Type
IntelliVAC module
Power Supplies
This indicates that the component should be charged to maintain component integrity.
This indicates that the component should be energized to maintain component integrity.
This indicates that the component should be reconditioned/reformed to maintain
component integrity.
This indicates that the component has reached its mean storage life, and should be
replaced.
This indicates that the component should be rotated to maintain component integrity.
—
—
—
E
—
—
—
E
—
—
42
45
48
51
54
57
60
—
—
—
E
—
—
—
E
E/R(1)
—
—
—
E
—
—
—
E
—
E/R(1)
—
—
—
E
—
—
—
E
Absopulse AC/DC Conv.
—
—
—
E
—
—
—
E
—
—
—
E/R(1)
—
—
—
E
—
—
—
E
Absopulse DC/DC Conv.
—
—
—
E
—
—
—
E
—
—
—
E/R(1)
—
—
—
E
—
—
—
E
1606 Power Supply
—
—
—
-
—
—
—
-
—
—
—
—
—
—
—
—
—
—
UPS battery
ACB
Control Equipment
Lithium battery for
and Boards
DPM
—
—
Ch
—
—
—
Ch
E
—
—
Ch
—
—
—
Ch
E
—
—
Ch
—
—
—
E(2)
Ch
E
—
—
Ch
—
—
—
Ch
E
—
—
Ch
—
—
—
E(2)
Re
E
—
—
—
—
—
—
—
—
—
—
—
Re
—
—
—
-
—
—
—
-
—
—
—
E
—
—
—
E
—
—
—
E/R(1)
—
—
—
E
—
—
—
E
—
E/R(1)
—
—
—
E
—
—
—
E
—
E/R(1)
SGCT
Power Components SCR SPGDB
SPS board
Air-cooling system Cooling fans
Additional Devices Signal conditioner
—
—
E
—
—
—
E
—
—
—
E
—
—
—
E
Ro
—
Ro
—
Ro
—
Ro
—
Ro
—
Ro
—
Ro
—
Ro
—
—
—
—
—
—
—
—
E
—
—
—
E
Ro
—
Ro
—
Ro
—
Ro
—
Ro
—
Ro
—
Ro
—
102 105
108
111
114
117
120
63
66
69
72
75
78
81
Ro Ro Ro Ro Ro
— — —
Re
—
Period Interval (Months)
84 87 90 93 96 99
Pioneer/Cosel
power supply
—
—
—
E/R(1)
—
—
—
E
—
—
—
E
—
—
—
E/R(1)
—
—
—
E
IGDPS board
—
—
—
E/R(1)
—
—
—
E
—
—
—
E
—
—
—
E/R(1)
—
—
—
E
—
E/R(1)
—
E/R(1)
—
—
—
E
—
E/R(1)
—
E/R(1)
—
—
—
E
—
E/R(1)
—
E/R(1)
—
—
—
E
—
—
—
—
—
—
—
—
—
—
—
E(2)
—
—
—
Component Type
IntelliVAC module
Power Supplies
—
Absopulse AC/DC Conv.
Absopulse DC/DC Conv.
—
—
—
—
—
—
—
—
—
—
—
—
—
—
—
E
E
E
—
—
—
—
—
—
—
—
—
E
E
E
—
—
—
—
—
—
1606 Power Supply
—
—
—
E(2)
UPS battery
ACB
Control equipment
Lithium battery for
and boards
DPM
—
—
Ch
—
—
—
Ch
E
—
—
Ch
—
—
—
Ch
E
—
—
Ch
—
—
—
Ch
E
—
—
Ch
—
—
—
Ch
E
—
—
Ch
—
—
—
E(2)
Re
E
—
—
—
Re
—
—
—
-
—
—
—
-
—
—
—
Re
—
—
—
—
—
—
—
E/R(1)
—
—
—
E
—
—
—
E
—
—
—
E/R(1)
—
—
—
E
Power Components SCR SPGDB
—
—
—
E/R(1)
—
—
—
E
—
—
—
E
—
—
—
E/R(1)
—
—
—
E
SPS board
—
—
—
—
—
—
E
—
—
—
E
—
—
—
—
—
E
Ro
—
Ro
—
Ro
—
Ro
—
Ro
—
Ro
—
Ro
—
Ro
—
Ro
—
Ro
—
Ro
—
Ro
—
Ro
—
E/R(1)
Ro
Re
—
Ro
—
E/R(1)
Ro
Re
Ro
—
Ro
—
Ro
—
Ro
—
SGCT
Air-cooling system Cooling fans
Additional devices Signal conditioner
(1) Recommended energizing item up for 1…2 hours every year of storage. If the item was stored for a longer time without energizing (longer than 3 years), then the reconditioning procedure
must be applied.
(2) With an average storage temperature of 25 °C (77 °F) the energizing procedure should be performed at least every five years, and at higher temperatures every three years.
164
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Appendix B
Spare Parts Connection
Matrix
PowerFlex 7000 Drive Spare Part Storage Requirements and Recommendations
Use this matrix to determine the appropriate supporting device for each
component type.
Table 13 - Spare Parts Connection Matrix
IGDPS Board
SPS Board
SPS Wire Harness
2 Pole Connector
80174-014-01-R
3 Pole Connector
80174-014-02-R
2 Pole Euro Style Plug
80026-131-10
AC
Autotransformer
(120/240V)(2)
Control equipment
and Boards
PowerFlex 7000
Power Supply 1
(Pioneer/Cosel)
Power Supplies
Variable DC Source
with Current Limiting
Function
Component Category
Variable AC Source
(120/240V)
Supporting Device(1)
Pioneer/Cosel
power supply

—
—
—
—
—
—
—
—

IGDPS board
—

—
—
—
—

—
—
—
IntelliVAC module(3)


—
—
—
—
—
—
—

Absopulse AC/DC Conv.

—
—
—
—
—
—
—
—

Absopulse DC/DC Conv.
—

—
—
—
—
—
—
—
—
1606 power supply

—
—
—
—
—
—
—
—

ACB board
—

—
—
—
—
—
—

—






—
—
—
—
SCR SPGDB
—

—
—
—
—
—

—
—
SPS board

—
—
—
—

—
—
—

Component/Item
SGCT(4)
Power Components
(1)
(2)
(3)
(4)
(4)
The nominal voltage of supporting device/s must be adapted to nominal voltage of energized item.
The AC transformer is used only for the reconditioning procedure instead of variable AC source.
The IntelliVAC module can be energized with AC or DC input voltage.
Energize the SGCT boards using one of the methods below.
a. Assembly of AC power source, PowerFlex 7000 PS1 and IGDPS power supply.
b. Assembly of variable DC power source with current limiting function, SPS board, and wire harness provided with the drive.
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
165
Appendix B
PowerFlex 7000 Drive Spare Part Storage Requirements and Recommendations
Power Supply Connection
Guidelines
Pioneer/Cosel Power Supply
1. Connect the AC source to the AC input terminals of Pioneer/Cosel power
supply via 13 A circuit breaker.
2. Use 10 AWG (5.3 mm2) wire to connect the devices.
Figure 119 - Pioneer/Cosel Power Supply
AC Input Terminals
AC(L)
1500W
COSEL
AC_IN
AC(N)
FG
DC_OUT
8
DC_FAIL
+
-
-GND_PE
CN1
8
CN2
8
CN3
Old Style Drawing
Cosel Power Supply
Old Style Drawing
Pioneer Power Supply
New Style Drawing
IGDPS
There are two methods to connect the IGDPS.
First Method
1. Connect the variable DC source with current limiting function
(56V DC/200mA) to the DC input terminals of IGDPS.
2. Use 14 AWG (2.1 mm2 wire) to connect the devices.
Second Method
1. Connect the AC source to the AC input terminals of Pioneer/Cosel power
supply via 13 A circuit breaker.
2. Connect the Pioneer/Cosel power supply 56V DC output terminals to the
DC input terminals of IGDPS.
3. Use 14 AWG (2.1 mm2 wire) to connect the devices.
Figure 120 - IGDPS
DC Input Terminals
New Style Drawing
166
Old Style Drawing
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Appendix B
PowerFlex 7000 Drive Spare Part Storage Requirements and Recommendations
IntelliVAC Control Module
1. Connect the AC or DC source (120…240V) to the power input terminals of
IntelliVAC control module via 2 A circuit breaker.
2. Use 12 AWG (3.3 mm2) wire to connect the devices.
Figure 121 - IntelliVAC Control Module
Power Input Terminals
INTELLIVAC
PWR_IN
L1
L2/N
GND
-GND_PE
1
2
3
EC
TCO
7
8
OPEN
9
10
CLOSE
CCO
11
12
AUX
7 +
OPEN
-
9 +
CLOSE
- 10
16
CONTACTOR
STATUS
15
4
8
14
MODULE
STATUS
13
6
1 EC
2 +
TCO
4
3
5
11
AUX
12
CCO
6
5
MOD_STAT
13
14
CNT_STAT
15
16
New Style Drawing
CONFIGURATION
DIP SWITCHES
INPUT POWER
L1
G
L2/N
Old Style Drawing
Absopulse AC/DC Converter
1. Connect the AC source to the AC input terminals of Absopulse AC/DC
converter.
2. Use 12 AWG (3.3 mm2) wire to connect the devices.
Figure 122 - Absopulse AC/DC Converter
AC Input Terminals
New Style Drawing
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Old Style Drawing
167
Appendix B
PowerFlex 7000 Drive Spare Part Storage Requirements and Recommendations
Absopulse DC/DC Converter
There are two methods to connect the Absopulse DC/DC converter.
First Method
1. Connect the variable DC source with current limiting function
(56V DC/200mA) to the DC input terminals of DC/DC converter.
2. Use 12 AWG (3.3 mm2) wire to connect the devices.
Second Method
1. Connect the AC source to the AC input terminals of Pioneer/Cosel power
supply via 13 A circuit breaker
2. Connect the Pioneer/Cosel power supply 56V DC output terminals to the
DC input terminals of DC/DC converter.
3. Use 12 AWG (3.3 mm2) wire to connect the devices.
Figure 123 - Absopulse DC/DC Converter
DC Input Terminals
New Style Drawing
168
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Old Style Drawing
Appendix B
PowerFlex 7000 Drive Spare Part Storage Requirements and Recommendations
1606 Power Supply
1. Connect the variable AC source to the AC input terminals of 1606 power
supply via 2 circuit breaker.
2. Use 12 AWG (3.3 mm2) wire to connect the devices.
Figure 124 - 1606 Power Supply
AC Input Terminals
Old Style Drawing
New Style Drawing
Control Equipment and
Boards Connection
Guidelines
Analog Control Board (ACB)
1. Connect the variable DC source with current limiting function (5V DC/
200mA) to the +5V and DGND pin to the +5V pin of ACB DC input
connector J13.
2. Use 18 AWG (0.8 mm2) wire to connect the devices.
Figure 125 - Analog Control Board
AC Input Terminals
New Style Drawing
Old Style Drawing
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
169
Appendix B
PowerFlex 7000 Drive Spare Part Storage Requirements and Recommendations
Power Components
Connection Guidelines
SGCT – IGDPS
There are two connection methods for the IGDPS.
First Method
1. Connect the AC source to the AC input terminals of Pioneer/Cosel power
supply via 13 A circuit breaker.
2. Connect the Pioneer/Cosel power supply 56V DC output terminals to the
DC input terminals of IGDPS.
3. Connect the IGDPS 20V DC output terminals with SGCT DC input
terminals.
4. Use 12 AWG (3.3 mm2) wire to connect the power supply devices.
5. Use 16 AWG (1.3 mm2) to connect the IGDPS with SGCT.
Second Method
1. Connect the variable DC source with current limiting function
(56V DC/200mA) to the 56V DC input terminals of IGDPS.
2. Connect the IGDPS 20V DC output terminals with SGCT DC input
terminals.
3. Use #14 AWG (2.1 mm2)wire to connect the DC source with IGDPS.
4. Use #16 AWG (1.3 mm2) to connect the IGDPS with SGCT.
Figure 126 - IGDPS
DC Input Terminals
New Style Drawing
170
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Old Style Drawing
Appendix B
PowerFlex 7000 Drive Spare Part Storage Requirements and Recommendations
SGCT – SPS Board
1. Connect the variable AC power source 120V or 240V to the test plug of the
SPS board.
2. Connect the SPS DC output terminals with the DC input terminals of
SGCT.
3. Connect the AC power source to the SPS board using the SPS wire
harness.
4. Use 16 AWG/1.3 mm2 to connect the SPS with SGCT board.
Figure 127 - SGCT - SPS Board
DC Input Terminals
Old Style Drawing
New Style Drawing
SPS Board
1. Connect the AC source 120V or 240V to the test plug of SPS board.
2. Use SPS wire harness provided with the drive to connect the SPS with AC
source.
Figure 128 - SPS Board
AC Input Terminals
New Style Drawing
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Old Style Drawing
171
Appendix B
PowerFlex 7000 Drive Spare Part Storage Requirements and Recommendations
SCR - SPGDB
1. Connect the variable DC source with current limiting function
(20V DC/100mA) to the test plug.
2. Use 14 AWG (2.1 mm2) wire to connect the devices.
Figure 129 - SCR - SPGDB
Input Terminals
1
2
+
+
3
-
1
+
2
-
New Style Drawing
172
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
TB1
SPGDB2U4A
TB4
SPGD_
TST_PWR
1
2
3
4
5
6
TB3
N
AC_IN
3
3
3
3
3
3
TB2
L
GND
2
1
1
2
VS
SN
G
C
OT1
OF1
Old Style Drawing
2U4A-LA4
Appendix B
PowerFlex 7000 Drive Spare Part Storage Requirements and Recommendations
Connection Wires Size
Table 14 - PowerFlex 7000 Drive Connection Wire Sizes
AWG orMCM
Diameter (in.)
Diameter (mm)
Cross-SectionalArea (mm2)
750
700
600
500
450
400
350
300
250
0000 (4/0)
000 (3/0)
00 (2/0)
0 (1/0)
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
0.8660
0.8370
0.7750
0.7070
0.6710
0.6320
0.5920
0.5480
0.5000
0.4600
0.4096
0.3648
0.3249
0.2893
0.2576
0.2294
0.2043
0.1819
0.1620
0.1443
0.1285
0.1144
0.1019
0.0907
0.0808
0.0720
0.0641
0.0571
0.0508
0.0453
0.0403
0.0359
0.0320
0.0285
0.0254
0.0226
0.0201
0.0179
22.00
21.25
19.67
17.96
17.04
16.06
15.03
13.91
12.70
11.68
10.40
9.27
8.25
7.35
6.54
5.83
5.19
4.62
4.11
3.67
3.26
2.91
2.59
2.30
2.05
1.83
1.63
1.45
1.29
1.15
1.02
0.91
0.81
0.72
0.65
0.57
0.51
0.45
380.031
354.695
304.025
253.354
228.018
202.683
177.348
152.012
126.677
107.160
84.970
67.400
53.460
42.390
33.610
26.650
21.140
16.760
13.290
10.550
8.360
6.630
5.260
4.170
3.310
2.630
2.080
1.650
1.310
1.040
0.820
0.650
0.520
0.410
0.330
0.260
0.200
0.160
26
0.0159
0.40
0.130
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
173
Appendix B
PowerFlex 7000 Drive Spare Part Storage Requirements and Recommendations
Notes:
174
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Appendix
C
Torque Requirements
Torque Requirements for
Threaded Fasteners
Unless otherwise specified, use these values of torque to maintain the
equipment.
Table 15 - Torque Requirements
Diameter
M2.5
M4
M5
M6
M8
M10
M12
M14
Pitch
0.45
0.70
0.80
1.00
1.25
1.50
1.75
2.00
Material
Steel
Steel
Steel
Steel
Steel
Steel
Steel
Steel
Torque (N•m)
0.43
1.8
3.4
6.0
14
29
50
81
Torque (lb•ft)
0.32
1.3
2.5
4.4
11
21
37
60
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-UM200I-EN-P - October 2023
175
Appendix C
Torque Requirements
Notes:
176
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
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 phaseto-phase 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-UM200I-EN-P - October 2023
177
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.
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.
178
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Appendix D
Insulation Resistance Testing
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-UM200I-EN-P - October 2023
179
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 16 on page 180.
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.
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 16 - Test Readings
Type of Drive
Liquid-cooled Drive
Air-cooled Drive
Drive with input/output Caps Disconnected
Isolation Transformer
Motor
180
Minimum Insulation Resistance Value
200 M
1k M
5k M
5k M
5k M
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Appendix D
Insulation Resistance Testing
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.
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.
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
181
Appendix D
Insulation Resistance Testing
Notes:
182
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Appendix
E
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(a) as being less than 0.2 mg/m3 of dust.
If outside air does not meet the conditions described above (0.2 mg / m3), 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.
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.
(a) 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-UM200I-EN-P - October 2023
183
Appendix E
Environmental Considerations
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.
Chromate Plating
Some sheet steel and fasteners are plated with zinc and sealed with a
chromate-based 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
self-contained breathing apparatus to help protect against any inhalation of
toxic gases.
184
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Appendix E
Environmental Considerations
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-UM200I-EN-P - October 2023
185
Appendix E
Environmental Considerations
Notes:
186
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Appendix
F
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.
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.
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
187
Appendix F
Pre-Commissioning
Notes:
188
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Appendix
G
History of Changes
This appendix contains the new or updated information for each revision of
this publication. These lists include substantive updates only and are not
intended to reflect all changes. Translated versions are not always available for
each revision.
7000A-UM200H-EN-P - April 2022
Change
Removed the following sections:
• Technical specifications
• Catalog number explanation
• Line and load cable sizes
• Cable considerations
These sections moved to PowerFlex 7000 Medium Voltage AC Drives Technical Data,
publication 7000-TD010.
Updated operator interface section to account for eHIM
Added appendix detailing spare part storage requirements
7000A-UM200G-EN-P - February 2020
Change
Added warning for motor filter capacitors and indicative fault codes
Changed input frequency to ±5%
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
189
Appendix G
History of Changes
Notes:
190
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
Index
A
abbreviations 11
AC/DC power supply 112
cosel power supply 115
location 113
output calibration 116
replacement 116, 117
air filters 105
location 106
air pressure sensor 88
replacement 88
air quality requirements 183
analog control board 130
components 130
connectors 131
current loop transmitter 134
disposal 184
interface module 134
isolated process receiver 135
non-isolated process outputs 136
replacement 137
test points 132
auxiliary +24V power supply 137
C
cabinet layout 32
cabling cabinet components 47
clamping pressure 76
adjustment 77
check pressure 76
clamp head 77
commissioning 187
control power components
ride-through 109
converter cabinet
2400V 53
3300/4160V 54
6600V 55
components 53
cosel power supply 115
current loop transmitter 134
current transformer
replacement 52
D
D.C. link 89
reactor replacement 98
removal 99
DC/DC power supply 123
replacement 124
terminal/connections 123
device designations 37
dimensional drawings 32
DPM. See drive processor module
drive processor module 126
components 126
disposal 184
test points 127
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
drive storage 23
siting 23
temperature 23
E
encoder feedback board 138
20B-ENC-1 & 20B-ENC-1-MX3 encoder
interface 138
80190-759-01, 80190-759-02 universal
encoder interface 139
components 138
configurations 140
input connections 139
options 138
positional encoder 142
quadrature encoder 142
environmental considerations 183
air quality requirements 183
hazardous materials 183
exhaust air hood
assembly 26
installation 26
external input/output boards 143
D1 display status 144
disposal 184
replacement 145
F
fan 89
components 101
impeller maintenance 103
inlet ring replacement 104
location 89
redundant fan assembly 29
removal 101
replacement 100
fiber optic cable 87
bend radius 87
color code 87
length 87
filter capacitors 93
replacement 95
testing 96
G
gasket 81
replacement 81
ground filter component 92
replacement 92
grounding 43
electrical supplies 45
ground bus 45
isolation transformer diagram 44
line reactor diagram 44
safety 44
191
Index
H
hall effect sensor
replacement 51
hazardous materials 183
heatsink
replacement 80
I
IEC component 37
IFM. See interface module
impeller assembly 104
maintenance 103
inlet ring 104
replacement in isolation transformer 104
inlet ring replacemenet 104
integral isolation transformer
fan replacement 102
interface module 134
components 134
interlocking 45
isolated process receiver 135
L
line terminations 38
low voltage control 122
M
maintenance 149
annual 149
checklist 149
control power checks 151
final power checks 151
operational maintenance 149
physical checks 150
reporting 152
motor compatibility 16
motor terminations 38
N
neutral resistor
direct-to-drive 32
hood assembly 31
non-isolated process outputs 136
O
OIB. See optical interface boards
operational maintenace 149
operator interface 21
configurations 21
optical interface 184
optical interface boards 145
componenets 146
LEDs 147
location 148
replacement 147
output grounding network 91
replacement 91
192
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
P
positional encoder 142
guidelines 143
power
cable terminations 37
cabling access 37
power cabling terminations 37
power connections 38
Line terminations 38
motor terminations 38
power cabling installation 38
powercage 60
2400V 63
3300/4160V 64
6600V 65
air flow 106
clamp head 77
gasket 81
removal 82
torque sequence 83
Q
quadrature encoder 142
R
rectifier designs 13
redundant fan assembly 29
resistance checks 61
SGCT 61
SGCT anode-to-cathode 67
snubber capacitance 69
snubber circuit 61
snubber resistance 68
S
self-powered SGCT power supply. See SPS
board
SGCT
LEDs 70
replacement 70
resistance test 67
snubber circuit assembly 66
test points 67
sharing resistors 61
replacement 73, 76
resistance test 67
test points 67
shock indicator 25
simplified electrical drawings 17
2400V 17
3300/4160V 18
6600V 19
site consideration 23
snubber capacitors 61
replacement 75
resistance test 69
test points 69
snubber resistors 61
replacement 73
resistance test 68
test points 68
Index
SPS board 84
calibration 84
components 85
disposal 184
test equipment 86
test points 84
surge arresters 57
certification 58
operation 58
replacement 59
testing and care 60
symmetrical gate commutated thyristor. See
SGCT
T
test points
analog control board 132
thermal sensors 78
replacement 78
topology 13
torque requirements 175
torque sequence 83
transformer cooling fan 30
U
uninterruptible power supply. See UPS
UPS 120
connect battery 121
location 120
replace 121
V
voltage sensing assembly 56
input voltage range 56
replacement 56
X
XIO. See external input/output boards
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
193
Index
Notes:
194
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
PowerFlex 7000 Medium Voltage AC Drive Air-Cooled (’A’ Frame)—ForGe Control User Manual
Rockwell Automation Publication 7000A-UM200I-EN-P - October 2023
195
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