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Rockwell Automation Allen-Bradley PowerFlex 7000, User Manual

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Rockwell Automation Allen-Bradley PowerFlex 7000 User Manual Download Page 178

178

Rockwell Automation Publication 7000L-UM301F-EN-P - March 2020

Chapter 4

Commissioning

Key Steps to Commissioning 
a PowerFlex 7000 Drive

As a guide for a commissioning engineer, the major steps involved in the 
commissioning of medium voltage PowerFlex 7000 drives are outlined below in a 
sequential order. For detailed instructions, always refer to PowerFlex 7000 User 
Manual.

•

Review the drawings and identify all sources of energy that apply to the 
drive system and get better understanding of the application to which the 
drive system is applied.

•

Follow Safety Procedures and apply LOTO before working on the 
equipment

•

Complete all Power Off checks and note down motor and drive nameplate 
data

•

Apply control power and perform Power On checks

•

Perform Gating Test

•

Program the drive after verifying the information on EDs and DDs against 
the equipment nameplate data.

•

Perform System Test and verify operation of the drive and the associated 
controls

•

Remove any jumpers used during system test

•

Inspect the drive line-up and ensure that no tools are left inside the 
cabinets before closing them.

•

Apply medium voltage and complete incoming line phasing checks and 
take harmonic measurements

•

Perform DC Test. Ensure that the Diagnostic Trend is setup and ready 
before attempting the DC Test

•

Perform Stationary Autotune tests (first two autotune tests)

•

Bump the motor for rotation check

•

Complete Rotating Autotune tests (last autotune test) 

•

Save the parameters in NVRAM and also transfer them from Drive to 
Memory and also print the Drive Setup to your laptop

•

Start the drive in normal operation, print variables and capture waveforms

•

Complete commissioning documentation

IMPORTANT

If the commissioning datasheets submitted by the commissioning engineer are 
incomplete and/or the required commissioning data, such as harmonic 
waveforms, dc test waveforms, sync xfer waveforms etc., are not captured 
correctly or the required data is missing, then it can delay the processing of 
expense invoices submitted by the engineer. 

IMPORTANT

While the field service engineer is still at the site, they MUST send the 
following information to MV Tech Support for review via e-mail at 
[email protected].

•

Drive setup after completing the auto-tuning.

•

Drive variables captured in running condition (at load or no load or 
uncoupled or with load).

•

Line voltage and line current waveforms for harmonics on AFE drives when 
drive is energized.

Summary of Contents for Allen-Bradley PowerFlex 7000

Page 1: ...User Manual OriginalInstructions PowerFlex7000MediumVoltageACDriveLiquid Cooled C Frame ForGe Control Using PanelView 550 Bulletin Number 7000L ...

Page 2: ...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 Labels may also be on or inside the equipment to provide specific precautions WARNING Identifies informati...

Page 3: ...ect to Drive Technology 19 Motor Compatibility 21 SGCT Features and Benefits 22 Specifications 23 Simplified Electrical Drawings 27 Control Overview 29 Direct Vector Control 30 Control Hardware 30 Operator Interface 31 Chapter2 Drive Installation Safety and Codes 33 Unpacking and Inspection 33 Transportation and Handling 33 Overhead Lifting 34 Rod or Pipe Rollers 35 Fork Lift Trucks 36 Storage 36 ...

Page 4: ...ngers 75 Pipe Materials and Layout 76 External Piping to the Drive 77 External Piping Cleaning 77 Controlled Siphon into Open top Reservoir 78 Liquid to Liquid Heat Exchangers 80 Power and Control Wiring 83 Control Cables 83 Encoder Installation Guidelines 83 Information Regarding Termination of Customer Cables 86 Grounding Practices 87 Grounding Guidelines and Practices for Drive Signal and Safet...

Page 5: ...ting Date 105 Selecting Meters 106 Viewing Revision Levels 108 Transfer Data in Memory 109 Picking an Access Level 110 Select a Parameter 110 Via Groups 110 Via Name 111 Via Code 113 Edit Text 114 Configure the Drive 116 Enter Modify an Access Level 116 Drive Setup 120 Language Selection 121 Modify Parameters 122 Numerical Value 122 Enumerated Value 124 Bit Encoded Value 125 Analog Ports 126 Fault...

Page 6: ...ry Card 155 Parameter File Format 156 Loading Language Modules 156 System Programming 158 Advanced Screen Operations 158 Communications Statistics 158 Protocol Analyzer 159 Print Screen 160 Memory Dump 160 Database Download 162 Operator Interface Menu Hierarchy Chart 162 What Does It Show 162 How Do You Read It 163 Example 163 PCMCIA Memory Card Installation Data 167 Description 167 Installing the...

Page 7: ...Verify One line Diagram on Site 184 Inspect Process 184 Safety Tests 185 Lockout Tagout 185 Step Down Transformer Fusing 186 Fuse and O L Protection 186 Installation Review 186 Inspect for Shipping Damage 186 Inspect Cabinets for Debris 187 Protective Barriers 187 Component Grounding 187 Information on Splice Kits 188 Power Cabling 188 Control Wiring 188 Liquid Cooling Connections 189 Service Data...

Page 8: ...st Mode 220 SCR Firing Test 222 SGCT Firing Test 224 System Test 225 System Test Mode 225 Start Stop Control Circuit 226 Status Indicators 227 Analog I O 227 Configurable Alarms 231 18 Pulse Phasing Test 231 Line Terminal Resistance Measurements 232 Application of Medium Voltage 233 Input Phasing Check 233 DC Current Test 235 Tuning Procedure 238 1 Rectifier 238 2 Motor Impedance 243 3 FluxSpeed R...

Page 9: ...cement 280 Current Transformer Replacement 281 Filter Capacitor Cabinet 282 Filter Capacitors 282 Filter Capacitor Replacement 284 Testing Filter Capacitors 285 Converter Cabinet Components 287 Converter Cabinet 289 PowerCage 289 SGCT and Snubber Circuit 291 Checking Clamping Pressure 292 Clamping Pressure Adjustment 292 Symmetrical Gate Commutated Thyristor Replacement 293 Silicon Controlled Rect...

Page 10: ...5 Replacement Procedure 326 UPS Option 327 UPS Replacement Procedure 328 Cooling System 329 Cooling Circuit 330 Chill Blocks 330 Coolant Pumps 330 Pump Maintenance and Replacement 331 Pump Seal Replacement 331 Pump Replacement with Drive Running 332 Piping Tubing and Connectors 334 Non Return Valves 334 Pressure Indicator 335 Pressure Switch 335 Thermostatic Valve 335 Thermostatic Valve Replacemen...

Page 11: ...nalog Control Board Replacement 361 Tachometer Feedback Board 362 Encoder Options 362 Quadrature Encoder Operation 365 Positional Encoder Operations 366 Positional Encoder Guidelines 367 External Input Output Boards 368 External Input Output Board Replacement 369 Optical Interface Boards OIB 370 Optical Interface Board Replacement 371 Optical Interface Base Board OIBB 373 Optical Interface Base Bo...

Page 12: ...08 Final Power Checks before Restarting 408 Additional Tasks During Preventive Maintenance 409 Final Reporting 409 Time Estimations 410 Tool Parts Information Requirements 410 AppendixA Catalog Number Explanation PowerFlex 7000 Drive Selection Explanation 415 Service Duty Rating Continuous Current Rating Altitude Rating Code 415 When is an Encoder Required 416 PowerFlex 7000 Drive Performance Torq...

Page 13: ... documents for additional product detail or instruction relating to PowerFlex 7000 C Frame drives Drive specific Technical Specifications Transportation and Handling Procedures receiving and handling instructions for Medium Voltage variable frequency drive and related equipment Drive specific Technical Data additional troubleshooting parameters and specification information for MV variable frequen...

Page 14: ...ies 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 ...

Page 15: ... applications such as fans pumps compressors mixers conveyors kilns fan pumps and test stands Primary industries for these applications include petrochemical cement mining and metals forest products power generation and water waste water The PowerFlex 7000L is a global product that adheres to the most common standards from NEC IEC NEMA UL and CSA It is available with the world s most common supply...

Page 16: ...tom entry and exit of line and load cables 90 of drive losses are rejected outside the control room Integral liquid cooled DC link inductor reduces overall dimension and eliminates external interwiring Integral pumping panel includes Line supply c w disconnect and fusing Closed loop coolant system Iron and chloride free liquid ethyl glycol deionized water mixture Low conductivity coolant 1 2 micro...

Page 17: ...ent limiting DC link inductor With 6500VPIV rated power semiconductor devices the number of inverter components is kept to a minimum For example only six inverter switching devices are required at 2400V 12 at 3300 4160V and 18 at 6600V The PowerFlex 7000L has the additional benefit of inherent regenerative braking for applications where the load is overhauling the motor i e downhill conveyors etc ...

Page 18: ...rements and features Sample line current and voltage are also shown in Figure 2 The THD of line current is approximately 5 6 while the THD of line voltage line to line is approximately 2 0 THD of line voltage is a function of system impedance The 18 Pulse rectifier consists of one master bridge and two slave bridges and will always have a total of 18 SCR switching devices Figure 2 18 Pulse Rectifi...

Page 19: ... line current and voltage waveforms are shown in Figure 3 The line current THD is approximately 4 5 while line to line voltage THD is approximately 1 5 THD of line voltage is a function of system impedance Input power factor with the AFE rectifier is equal to or greater than 0 98 for the typical speed and load range when applied to variable torque loads Figure 3 Active rectifier PWM and its input ...

Page 20: ...xity and high component count like multi pulse drive topologies do Direct to Drive technology produces virtually no common mode voltage so it is suitable for new or existing motors and imposes no stress on the drive input The advantage of Direct to Drive technology over an Isolation Transformer is that no extra insulation is required in the motor in the motor cables or in the line cables In additi...

Page 21: ...ource inverter drives are a non issue with the PowerFlex 7000L Typical motor waveforms are shown in Figure 4 These motor friendly waveforms are achieved by utilizing a selective harmonic elimination SHE pattern in the inverter to eliminate major order harmonics in conjunction with a small output capacitor integral to the drive to eliminate harmonics at higher speeds Standard motors are compatible ...

Page 22: ...ward and reverse directions up to 6500 volts by a NPT Non Punch Through structure and nearly symmetrical pnp transistor in the wafer while the current is unidirectional Unlike many VSI topologies that use IGBTs the semiconductors used in the PowerFlex 7000L feature a non rupture non arc failure mode In the unlikely event of a device failure the fault would be contained within the device Implementi...

Page 23: ...ction 5 Vacuum Contactor with Fused Isolating Switch or CircuitBreaker OutputVoltage 0 2400V 0 3300V 0 4160V 0 6000V 0 6300V 0 6600V Inverter Design PWM Inverter Switch SGCT Inverter Switch Failure Mode Non rupture Non arc Inverter Switch Failure Rate FIT 100 per 1 Billion Hours Operation Inverter Switch Cooling Double Sided LowThermal Stress Inverter Switching Frequency 420 440 Hz Number of Inver...

Page 24: ...Torque Accuracy with HPTC optional 5 Speed Regulation 0 1 without Encoder Feedback 0 01 0 02 with Encoder Feedback Acceleration Deceleration Range Independent Accel Decel 4 x 30 s Acceleration Deceleration Ramp Rates 4 x Independent Accel Decel S Ramp Rate Independent Accel Decel 2 x 999 s Critical Speed Avoidance 3 x Independent with Adjustable bandwidth Stall Protection Adjustable time delay Loa...

Page 25: ...tion Analog input 12 Bit 4 20 mA Internal parameter 32 Bit resolution Serial Communication 16 Bit resolution 1Hz Digital Speed Reference Analog Outputs One Isolated Eight Non isolated 4 20 mA or 0 10V 600 Ω Communication Interface Ethernet IP DPI ScanTime Internal DPI 2 ms min 4 ms max Communications Protocols Optional DeviceNet ControlNet Ethernet I P LonWorks Dual port Ethernet I P Can Open Prof...

Page 26: ... Standards NEMA IEC CSA UL ANSI IEEE 1 Voltage Sag tolerance is reduced to 25 when control power is supplied from medium voltage via CPT 2 MOVs are used for 18 Pulse Surge arrestors are used for AFE Direct to Drive configurations 3 Short circuit fault rating based on input protection device contactor or circuit breaker 4 BIL rating based on altitudes 1000 m 3300 ft Refer to factory for derating on...

Page 27: ...ER L M DC LINK L M MACHINE CONVERTER U T1 V T2 W T3 4U Z1 4V Z2 4W Z3 ISTX SCRs 3U Y1 3V Y2 3W Y3 2U X1 2V X2 2W X3 SGCTs LINE CONVERTER L M DC LINK L M MACHINE CONVERTER U T1 V T2 W T3 SGCTs 2U X1 2V X2 2W X3 SGCTs LINE CONVERTER L M DC LINK L M MACHINE CONVERTER U T1 V T2 W T3 SGCTs 2U X1 2V X2 2W X3 SGCTs LINE CONVERTER L M DC LINK L M MACHINE CONVERTER U T1 V T2 W T3 4U Z1 4V Z2 4W Z3 ISTX SCR...

Page 28: ...2020 Chapter 1 Overview of Drive Figure 9 6000 6600Volt Active Front End LINE CONVERTER L M DC LINK L M MACHINE CONVERTER U T1 V T2 W T3 2U X1 2V X2 2W X3 SGCTs SGCTs LINE CONVERTER L M DC LINK L M MACHINE CONVERTER U T1 V T2 W T3 2U X1 2V X2 2W X3 SGCTs SGCTs ...

Page 29: ... Line Current Line Voltage Line Protection Faults Line Side Feedback and Gating Alpha Rectifier Motor Filter Cap Motor Motor Current Alpha Inverter Current Control InvTorque CurCmd Inv Flux CurCmd Flux Control Speed Feedback Flux Feedback Motor Model Motor Voltage Machine Protection Flux Range Faults Slip freq Stator freq Encoder Feedback Speed Command Speed Reference Speed Control Sync Transfer I...

Page 30: ...ts hertz type drives The speed bandwidth range is 5 25 rad s while the torque bandwidth range is 15 50 rad s Control Hardware The control hardware includes a processor board DPM with an interface to six fiber optic boards depending on the voltage and number of switching devices via OIBB an analog conditioning board ACB and an external IO board XIO The control hardware is used for rectifier and inv...

Page 31: ...nd troubleshooting The setup wizard helps the user to set the required parameter menus by asking questions or prompting selections for desired operation Warnings and comments appear complete with help text to keep the user on the right track The setup wizard combined with the auto tuning feature allows the drive to be tuned to the motor and load as quickly and accurately as possible resulting in f...

Page 32: ...32 Rockwell Automation Publication 7000L UM301F EN P March 2020 Chapter 1 Overview of Drive Notes ...

Page 33: ...ure sensitive components in the controller Transportation and Handling The PowerFlex 7000 drive is shipped on a wooden skid which is bolted to the underside of the cabinetry The drive should remain bolted to the shipping skid until it is delivered to its final installation area Lifting angles are supplied bolted to the top of the cabinetry The drive must be kept in an upright position during any h...

Page 34: ... and the compressive load on the lifting device do not allow the angle between the lifting cables chains and vertical to exceed 45 degrees ATTENTION Ensure that the load rating of the lifting device is sufficient to safely raise the controller sections Refer to the packing slip enclosed with shipment for shipping weights WARNING Care must be exercised when using either a forklift or the pipe rolli...

Page 35: ... moved on one floor level 1 Boards 50 8 mm x 152 4 mm 2 in x 6 in or equivalent and at least 300 mm 12 inches longer than the drive must be placed under the shipping skid 2 Carefully ease the shipping platform over the roller pipes until the drive weight is borne on the roller pipes 3 The drive can be rolled to its designated location Steady the load to prevent tipping Figure 14 Rod or Pipe Roller...

Page 36: ...rive should be stored in a heated building having adequate air circulation The drive must never be stored outdoors Siting of the Drive Site Considerations The standard environment in which the equipment is designed to operate is Elevation above sea level less than 1000 meters 3250 feet Ambient air temperature between 0 C 32 F and 40 C 104 F Relative humidity of the air not to exceed 95 non condens...

Page 37: ...cable lengths to the motor are virtually unlimited due to the near sinusoidal voltage and current waveforms Unlike voltage source drives there are no capacitive coupling dv dt or peak voltage issues that can damage the motor insulation system The CSI PWM topology utilized in the PowerFlex 7000 medium voltage AC drive has been tested with motors located up to 15 km 9 3 miles from the drive J Only p...

Page 38: ...mation provided in the dimension drawings and move the sections together Ground bus power and control connections are to be made per the electrical diagrams provided Side sheets of the enclosures are to be joined with thread forming screws using the available holes Liquid cooled Drives may require joining of the coolant pipes Some enclosure ratings may require the addition of silicone sealant wher...

Page 39: ...le ties Wire cutters Install CPVC Piping Splices Open doors of capacitor cabinet Cabinet 5 next to DC Link Choke cabinet Cabinet 6 Refer to Figure 16 Remove capacitor from position 3 if installed not all configurations have a capacitor in this location It is not necessary to remove capacitor from position 2 WARNING Heavy Magnetic DC Link Chokes up to 4600 kg 10 000 lb are shipped inside DC Link Ch...

Page 40: ...pe splices shipped in the capacitor cabinet Install and tighten the 4 CPVC unions with strap wrench 1 4 to 1 2 turn past hand tight Ensure O ring is seated inside male end of union Refer to Figure 17 Figure 18 and Figure 19 Do not use CPVC primer or cement Capacitor Position 1 Capacitor Position 2 Capacitor Position 3 CPVC Pipe Splices ...

Page 41: ...h 2020 41 Drive Installation Chapter 2 Figure 17 CPVC Pipe Splices Capacitor 2 not shown for clarity Figure 18 Typical StrapWrench not supplied used to tighten unions on CPVC pipe splices Pipe Splice 1 Capacitor Cabinet DC Link Choke Cabinet Pipe Splice 2 ...

Page 42: ...rdware required is pre attached to bus connections cabling and insulators in the cabinet where the power bus splice kit will attach Remove and attach as shown in Figure 20 to Figure 24 Torque M10 carriage bolts connecting bus to bus in the capacitor cabinet to 29 Nm 21 ft lb Torque M12 hardware supplied for cable to bus stab connections to 50 Nm 37 ft lb After cable connections have been made ensu...

Page 43: ...2020 43 Drive Installation Chapter 2 Figure 20 DC Link Choke Cabinet Power Bus 4 pieces Ground bus 1 shipped disassembled Figure 21 DC Link Choke Cabinet before field power bus connections MV Bus 4 pieces Ground Bus Link 1 piece Inside DC Link Choke Cabinet ...

Page 44: ...on Publication 7000L UM301F EN P March 2020 Chapter 2 Drive Installation Figure 22 DC Link Choke Cabinet after field connections of power bus Figure 23 Capacitor Cabinet after field connections of power bus M M L L M L L M ...

Page 45: ...s pieces with M10 hardware Connect cables from DC Link Choke to MV Bus pieces using supplied M12 hardware Figure 25 DC Link Choke Cabinet after connection of cables from DC Link Choke to red insulators Connection points are labeled on bus and DC Link Choke Connect cables from labeled stabs M L L L on DC Link Choke to corresponding labeled stabs M L M L on bus ...

Page 46: ...allation Figure 26 DC Link Choke Cabinet Typical Cable Connection Connect Ground Bus Link from top left of DC Link Choke cabinet to ground bus in adjacent capacitor cabinet by sliding underneath wire duct Use supplied hardware Figure 27 Ground Bus Link Figure 28 Install Ground Bus Link ...

Page 47: ...esentative for assistance Final wiring connections to be performed by Rockwell Automation field service representative 1 Remove the wireway covers located on top of the line and motor filter capacitor sections and the DC Link section 2 If drive has strip heater wiring it will be coiled up in the top wireway Route these wires down through the grommeted cutout for connection on the terminal blocks l...

Page 48: ...ommeted cutouts back into the wireway There is a fiber optic cable in this bundle and care must be taken not to damage it The fiber optic cable control power wires and the XIO link cable will be required in the pump control cabinet Figure 31 Control Wiring 4 Route the 8 gauge black and red twisted pairs of wire and the Belden shielded cables down through the grommeted cutout into the AC DC power s...

Page 49: ...ugh the grommeted cutout into the center of the DC choke section Figure 33 Figure 33 Fan Thermostat ControlWires 6 Route the control wires down through the grommeted cutout into the control power disconnect section Figure 34 7 Connect the numbered wires to the corresponding numbered terminal blocks Figure 35 to Figure 38 Figure 34 Route control wires through grommeted cutout ...

Page 50: ...Publication 7000L UM301F EN P March 2020 Chapter 2 Drive Installation 8 Refer to the electrical drawing and make the above control wiring connections Figure 35 56V DC Connections Figure 36 AC DC fails Belden Cable Connection ...

Page 51: ... been made and neatly routed in each section the excess control wires can be looped up in the top wireways 10 Swing out the control section in the pump control cabinet 11 Route the XIO link cable control power wires and the fiber optic cable down through the wire ways grommeted cutout 12 Route the XIO link cable the control power wires into the pump control cabinet through the upper side grommeted...

Page 52: ...de grommeted cutout Figure 39 120V and XIO cables through upper cutout 14 Connect the XIO link cable to the XIO board XIO link A connector Figure 40 15 Connect the control power wires to the control power terminal blocks Refer to Electrical Drawings for corresponding wire numbers and terminal blocks 16 Connect the fiber optic cable to the TFB board Figure 40 XIO link Cable ...

Page 53: ...tallation Chapter 2 Figure 41 TFB Fiber Optic connected Use supplied silicone see Figure 42 to seal between cabinets to prevent moisture or dirt from entering Join sidesheets with M6 Taptite thread forming screws in holes provided Figure 42 Capacitor Cabinet Silicone sealant ...

Page 54: ...arefully remove turnbuckles Retain for future use Figure 43 Choke Cabinet Re install any capacitors that were removed Proceed with Removal of Lifting Angles Removal of Lifting Angles Lifting angles should be removed only when the Drive is in its final location The lifting angles are retained with 5 8 11 hardware The 5 8 bolts need to be re installed in their holes in the top of the Drive to preven...

Page 55: ...ed The drive is shipped with a label that records shock levels in excess of 10G If these shock levels have been attained the chevron shaped window will appear blue in one of the two windows If these shock levels have been attained record the values There is a greater possibility of the drive having sustained internal damage if it has been subjected to physical shock during the shipping and install...

Page 56: ...the top plate Remove the bolts and plate and set aside for reuse Secondly loosely assemble the two L shaped panel components shipped with the drive Locate the exhaust hood on top of the cabinet per Figure 46 and re install the original cover plate previously set aside Care must be taken that the notches on the bottom flange are oriented toward the sides of the drive Affix assembly to the drive top...

Page 57: ...nally mounted fans Capacitor cabinets have internally mounted fans which are installed and wired by Rockwell Automation refer to Figure 46 The customer only needs to install the fan hood Figure 46 Fan Hood Installation Internally Mounted Fans Fan Hood to be installed on site Internally mounted fans ...

Page 58: ...e fans mounted and wired to terminal blocks On site the fan assembly is to be mounted on the top plate of the converter cabinet as shown in Figure 47 Wiring for fan power is to be routed through the hole near the terminal blocks The plate is fastened to the cabinet with M6 hardware Connect wires to the terminal blocks per the electrical diagram Position the fan hood over the fan assembly and faste...

Page 59: ...ge area located in the control cabling cabinet behind the low voltage compartment and with barriers removed Major Components The following seven diagrams show the typical layout of each cabinet for PowerFlex 7000 C Frame Drives Control and Cabling Cabinet Converter Cabinet Capacitor Cabinet DC Link Inductor Cabinet Pump Cabinet TIP The control cabling cabinet comes in two different configurations ...

Page 60: ...P March 2020 Chapter 2 Drive Installation Figure 49 Control and Cabling Cabinet AFE Rectifier version shown with Control Panel removed Hall effect Sensor MotorTerminals LineTerminals Voltage Sensing Hall effect Sensor Surge Arrestors Current Transformer ...

Page 61: ...020 61 Drive Installation Chapter 2 Figure 50 Control and Cabling Cabinet 18 Pulse version shown with Control Panel removed Current Transformers Voltage Sensing Hall Effect Sensor Hall Effect Sensor LineTerminals Transient Suppression Networks MotorTerminals ...

Page 62: ...000L UM301F EN P March 2020 Chapter 2 Drive Installation Figure 51 Low Voltage Tub Compartment ANALOG CONTROL BOARD Analog Control Board Drive Processor Module DPM Tach Feedback CircuitBoard DC DC Power Supply Fiber Optic Interface Boards ...

Page 63: ...blication 7000L UM301F EN P March 2020 63 Drive Installation Chapter 2 Figure 52 Converter Cabinet Components 4160V AFE shown Ground Bus IsolatedGateDrive Power Supplies IGDPS Inverter Modules Rectifier Modules CoolantPiping ...

Page 64: ...ation Publication 7000L UM301F EN P March 2020 Chapter 2 Drive Installation Figure 53 Converter Cabinet Components 6600V AFE shown Isolated Gate Driver Power Supplies IGDPS Ground Bus Inverter Modules Rectifier Modules ...

Page 65: ...Rockwell Automation Publication 7000L UM301F EN P March 2020 65 Drive Installation Chapter 2 Figure 54 Capacitor Cabinet Grounding Network Line Capacitors Motor Line Capacitors Cooling Fan ...

Page 66: ...l Automation Publication 7000L UM301F EN P March 2020 Chapter 2 Drive Installation Figure 55 DC Link Inductor Cabinet Liquid cooled DC Link Reacotr Fuse Blocks Power Transformer AC DC Power Supplies Cooling Pipes ...

Page 67: ...omation Publication 7000L UM301F EN P March 2020 67 Drive Installation Chapter 2 Figure 56 Pump Cabinet showing swing out low voltage panel Coolant Pumps Deionizer Cartridge Pumping Panel Swingout LowVoltage Panel ...

Page 68: ... on a drawing has an arrow and drawing reference to indicate the ongoing connection The drawing reference indicates the sheet and the X Y coordinates of the continuation point The reference system is explained on a sheet in each drawing set The unique wire numbering system serves as confirmation that the correct wire is being traced from sheet to sheet or across a drawing Wires in multi conductor ...

Page 69: ...ion and signal examples along with the recommended type of cable for each group are provided A matrix providing the recommended minimum spacing between different wire groups run in the same tray or separate conduit is also provided ATTENTION Voltage ratings shown in the following tables are peak line to ground Some cable manufacturers rate voltage line to line RMS Ensure the cable meets the rating...

Page 70: ... continuous and insulated from ground Note 4 AC and DC circuits must be run in separate conduits or trays Note 5 Voltage drop in motor leads may adversely affect motor starting and running performance Installation and application requirements may dictate that larger wire sizes than indicated in IEC NEC guidelines are used ForTray Recommended spacing between different wire groups in the same tray F...

Page 71: ...e access plates are provided on the top and bottom plates of the connection cabinet identified by the customer specific dimension drawing Access the Customer Power CableTerminations Open the door of the low voltage control compartment The low voltage control compartment is hinged on its left side The power terminals are behind the low voltage control compartment Note that there is a key interlock ...

Page 72: ...72 Rockwell Automation Publication 7000L UM301F EN P March 2020 Chapter 2 Drive Installation Figure 57 Swing out of LowVoltage Compartment Latch Key Interlock Handle Terminal Blocks Customer TBC ...

Page 73: ...Rockwell Automation Publication 7000L UM301F EN P March 2020 73 Drive Installation Chapter 2 Figure 58 Access to PowerTerminals LowVoltage Door LowVoltage Compartment Open ...

Page 74: ...e drive is supplied with provision for cable lugs The power terminals are identified as follows Incoming Connections Drives with AFE Rectifiers 2U 2V 2W Drives with 18 Pulse Rectifiers Secondary d0 2U 2V 2W Secondary d 20 3U 3V 3W Secondary d 20 4U 4V 4W Motor Connections U V W The installer is responsible for ensuring that power connections are made with appropriate torque Refer to Torque Require...

Page 75: ...gh bottom plate of cabinet Pipes through right side of cabinet Removable plates are provided in each of these locations Figure 59 Connection to Liquid to Air Heat Exchanger rear of pumping cabinet shown with back plates removed Piping to Heat Exchanger through top of cabinet Outlet Coolant Connection Warm Fluid to Heat Echaanger Inlet Coolant Connection Fluid Return from heat Exchanger Piping to H...

Page 76: ...s of 110 psi Schedule 80 CPVC piping may be installed within a climate controlled building with any outside pipe of stainless steel Shield CPVC from direct sunlight to prevent UV damage Use expansion loops for long pipe runs See document CTS 3 CPVC CTS Products Design and Installation Manual from Spears Manufacturing Company www spearsmfg com for more information Figure 60 Plan View of Piping to H...

Page 77: ...capped piping and valves to maintain cleanliness before welding or assembly Parts must be stored in a clean dry area All external piping must be cleaned and flushed before installation to ensure proper coolant system and drive pump operation 98 4 3 9 98 4 3 9 14 2 0 560 Dimensions in mm in UseM12 0 5in boltwith washer Torque to 27 41 N m 20 30 lb ft Torque in a cross pattern slowly working toward ...

Page 78: ...Reservoir Rockwell Automation recommends this method of pipe routing for pipes and heat exchangers higher than the reservoir coolant level The reservoir is located in the VFD pump cabinet This method controls the siphoning of coolant into the open top reservoir when the coolant pumps are off for maintenance It prevents the siphoning of all pipes higher than the reservoir liquid level causing reser...

Page 79: ...as damage may occur Follow priming and valve operation instructions located on pump cabinet door before operating pumps Figure 63 Controlled Siphon Method Drain Fill 2 or 3 in piping BallCheck Valve 1 5 or 2 in piping VentValve x4 ARV100VS Plastomatic Mounting Notes 2 ft max section of horizontal piping for vent valve mounting Horizontalventvalvepiping for exit and return must be mounted at the sa...

Page 80: ...anger to the supply and return coolant Pipes through top plate of cabinet Pipes through bottom plate of cabinet Pipes through right side of cabinet Removable plates are provided in each of these locations Drain Fill 2 or 3 in piping BallCheck Valve 1 5 or 2 in piping VentValve x4 ARV100VS Plastomatic Mounting Notes 2 ft max section of horizontal piping forvent valve mounting Horizontalventvalvepip...

Page 81: ...tion to Liquid to Liquid Heat Exchanger rear of pumping cabinet shown with back plates removed Access for connections through top of cabinet Access for connections to heat exchanger through right side of cabinet Liquid to Liquid Heat Exchanger Access for connections to heat exchanger through bottom of cabinet ...

Page 82: ...ture C Rectifier Voltage Amps US Gpm 1 L m 2 Min Max 18 Pulse 4160 375 19 5 72 435 7 0 32 430 21 5 80 435 8 0 32 495 26 5 100 435 13 0 32 575 29 0 109 435 15 0 32 657 37 5 142 435 25 0 32 6600 375 33 0 125 435 18 0 32 430 44 5 167 435 34 0 32 495 48 5 184 435 40 0 32 575 54 5 206 435 43 0 32 657 62 6 237 435 49 0 32 AFE 4160 375 19 5 74 435 7 0 32 430 24 0 90 435 10 0 32 495 26 5 100 435 13 0 32 5...

Page 83: ...istor must be added to ensure that proper signals are fed to the system logic Refer to When is an Encoder Required on page 416 Appendix A to see if one needs to be supplied Encoder Installation Guidelines The most frequent problems encountered when transmitting an encoder s signal s to the drive are signal distortion and electrical noise Either of these problems can result in a gain or loss of enc...

Page 84: ...ring Use low capacitance wires 40pf ft with 100 shield coverage for long cable runs and connect the shield only at the drive end Figure 67 Detail Power Terminal Dimensions For more protection against electrical noise specify an encoder with complementary outputs and connect with twisted pair cable With this type of cabling the induced currents will self cancel As a final precaution ground the shie...

Page 85: ...er if the frequency can be kept so that the cable s characteristic impedance is around 348ohms this will improve the surge currents and may increase the maximum distance to 100m 330 ft b For the Universal Encoder Interface the distance can be extended out to 200 m 650 ft 100 Khz This distance can be increased to 500m at frequencies below 55 Khz It is not recommended to exceed this distance since t...

Page 86: ...ds and re orient them as shown in Figure 69 To remove the lug pads disconnect the M10 bus connection hardware 17 mm hex tooling required Remove the two bolts that secure the lug pad to the 4 hole insulator Refer to Torque Requirements for Threaded Fasteners on page 421 Appendix B for Torque Values of electrical connections Figure 69 Typical Line Cable Terminal Assembly modified for top cable entry...

Page 87: ...d on its own is not adequate Note that if a drive isolation transformer is used the WYE secondary neutral point should not be grounded Each AC motor frame must be bonded to grounded building steel within 6 m 20 feet of its location and tied to the drive s ground bus via ground wires within IMPORTANT Generally the means used for external grounding of equipment should be in accordance with the Canad...

Page 88: ...therwise specified be grounded at one end only again as specified above at the receiver end or the end which is physically closest to the main equipment ground bus or The metal sheath or foil may be left insulated from ground and the other conductors and the mesh cable screen grounded at one end only as stated above Grounding Requirements and Grounding Specification for Customers and Power Integra...

Page 89: ...ccessible at the top of each of the drive enclosures when the enclosure door is opened and the low voltage compartment hinged out in the case of the incomer cabinet It is the responsibility of the installer to ensure that the drive is grounded properly typically at the point on the ground bus in the incomer cabinet close to the incoming power terminations Interlocking Access to the medium voltage ...

Page 90: ...90 Rockwell Automation Publication 7000L UM301F EN P March 2020 Chapter 2 Drive Installation Notes ...

Page 91: ... or read Setting a parameter i e writing to it will modify how the drive behaves Prior to using the drive a number of parameters must be set Additional parameters may be changed while the drive is in use in order to adjust its operation i e the speed could be changed via a parameter Read only Parameter A memory location which can only be read A read only parameter contains real time data and is us...

Page 92: ...at is not affected by loss of power It is used for long term storage of data such as parameters and alarm queues Flash A type of memory technology which will indefinitely store information and is unaffected by power loss It is used for storage of firmware parameters and data files PCMCIA A standard for flash memory cards Personal Computer Memory Card International Association Overview The operator...

Page 93: ...own on some displays the F1 HELP key is always active F2 through F5 are only active if shown Cursor Selection Keys The cursor keys are normally used to select an item on the display When an item on the display is selected that item will be displayed in reverse video To change the selection press the key in the desired direction On selection screens having more than one page the page will automatic...

Page 94: ...ses the backspace key to return to the previous level of help The enter key varies depending on the screen If you are in the process of a selection operation the enter key will accept the selection and proceed to a different screen based on the selection in order to complete the operation If you are in the process of entering data the enter key will accept the edited data What is a Screen The oper...

Page 95: ... The current page number and the number of pages which make up the data currently being displayed on the screen is shown in the upper right hand corner e g showing page 1 of 2 pages Along the bottom of the screen are one or two rows of Softkeys which represent the assignment to the actual function keys In Figure 73 Softkeys F6 through F10 are shown Pressing F8 will display the next page of data In...

Page 96: ... a window is used to display a message Accessing Drive During this time the operator interface will not respond to any user input until the task at hand is completed You will notice that subsequent activation of the same screen for the same data will be much quicker since the operator interface already has most or all of its required information You can selectively choose to download the complete ...

Page 97: ...ing a box around the Communication Error Two examples of this are shown in Figure 75 and Figure 76 In both cases once communications has been re established the information window will be removed and the operator interface will return to normal operation Figure 75 Communications Error Figure 76 Communications Error Languange Changing When the language used by the drive changes either via the opera...

Page 98: ...and apply equally to all screens F1 Help This operation is active on every screen even if the Softkey is not displayed Help is context sensitive and will display help that relates to the screen that you are currently viewing F6 Alarms The F6 Softkey will always get you to the Alarm Summary Screen A new alarm will cause this key to flash in reverse video F8 NextPage When a screen is capable of disp...

Page 99: ...ata are not affected Aborting the download will not affect portions of the database already obtained Once the database has been obtained the operator interface will start up in one of two modes depending on to what degree the drive has previously been configured 1 On an unconfigured drive the operator interface will enter the Setup Wizard mode Until the user has gone through the entire Setup Wizar...

Page 100: ...erface Throughout the discussion a number of screens will be used to achieve the desired operation In many cases the same screen will be used for more than one operation however with possibly different data from the drive Throughout the section you want to focus on how the operation is performed The operator interface will take care of what screens are needed to perform the operation Obtain Help H...

Page 101: ...just above the Softkeys Additional topics are selected via the cursor left and cursor right keys Figure 78 shows the additional topic of SOFTKEYS selected To access this information press the enter key The help for the additional topic will be displayed as in Figure 79 As with the original help screen the related topic help may also have related topics Press the backspace key to return to the prev...

Page 102: ...inally accessed press the F10 key Figure 80 Help on Help Modify Operator Interface Operation Utility The utility operation of screens change the characteristics of the operator interface Within this operation you will Set the clock and calendar Change the delay for the display backlight shutoff Change the contrast of the display Define the meters that will be displayed on the Top Level Menu View t...

Page 103: ...e the duration of the delay press the F2 key The current backlight delay will be shown in reverse video Figure 82 The value can be adjusted from 0 60 min A value of zero 0 will disable the delay keeping the light on indefinitely Press the cursor up or cursor down keys to change the value by a resolution of 1 minute Press the cursor left and cursor right keys to change the value by a resolution of ...

Page 104: ...SettingTime The clock setting controls the time stamp that the drive uses on the information contained on the alarm summary screen To change the time press the F5 key The hour s position of the clock will be in reverse video Figure 84 Press the cursor up or cursor down keys to change the value by a resolution of 1 unit Press the cursor left and cursor right keys to change the value by a resolution...

Page 105: ...nge the month press the F4 key again and repeat the procedure Likewise to change the day press the F4 key again Each press of the F4 key will highlight the next position of the calendar The highlighted position may be modified via the cursor keys To abort the change press the backspace key and the calendar will return to its original date To accept the change press the enter key The new calendar s...

Page 106: ...cess and refer to Enter Modify an Access Level on page 116 This will begin the selection process of a tag as described in the section entitled Select a Parameter on page 110 When you have completed the selection process the selected tag will be assigned to the meter i e V Line The name of the meter will have been changed to a default string as shown in Figure 87 for meter 2 Figure 87 Utility Meter...

Page 107: ...ting Completed The operator interface contains a default set of meters This default set is selected by pressing the F2 key any time the Meters screen is displayed This results in the default text and tags as shown in Figure 86 The changes made do not take affect until you press F10 and exit the screen Any time prior to this you may cancel all of the changes made after coming to the screen by press...

Page 108: ... of Figure 91 shows the type of drive a 16 character user definable string to uniquely identify a drive revision level of the terminal software and its part number revision level of the bootcode contained in the terminal revision level of various boards contained in the drive These are identified by name Figure 91 Utility Rev Level To modify the user definable text string press the F8 key If nothi...

Page 109: ...ssing the F7 key Figure 92 Edit the Drive Name Figure 93 Editing Complete Transfer Data in Memory The operator interface contains long term storage in two forms Flash memory contained in the operator interface is used to store the firmware and optionally language modules and parameters used in the drive This information can also be stored on a removable flash card that can be taken to another driv...

Page 110: ... are made to the drive Individual PIN numbers protects all levels except the first Use the up down cursor keys to select the desired access level Then enter the PIN value for the given access level and press enter If the correct PIN was entered the access level will change Refer to Enter Modify an Access Level on page 116 for complete information on the use of Access Levels Select a Parameter Vari...

Page 111: ...keys to change the page select the desired tag Press the enter key and the selected tag will be used to continue the operation for which the selection process was being used Figure 94 Selecting a Group Figure 95 Selecting a Member of a Group From the SELECT GROUP screen Figure 94 the tag can also be selected via its name by pressing the F7 key Via Name When you know the name of the tag that you wi...

Page 112: ...ration on which the selection is being performed will be displayed as in Figure 97 Using the cursor up or cursor down keys and if required the F8 and F9 keys to change the page select the desired tag Press the enter key and the selected tag will be used to continue the operation for which the selection process was being used From either of these two screens SELECT LETTER or SELECT LIST you can ret...

Page 113: ...se the data entry keys 0 9 to enter the desired code on the SELECT CODE screen Figure 98 The entered code may be edited using the backspace key Press the enter key Figure 98 Select via Code Step 1 The screen will display one of two formats If the code you entered was valid it will show the name of the tag associated with the code Figure 99 This allows you to verify that this was the tag that you i...

Page 114: ...en with this read only parameter The screen will display this information along with the tag s current value such as shown in Figure 101 Re enter a tag code for a parameter or press F10 to return to the previous screen without making a selection Figure 101 SelectedTag Inappropriate Edit Text Various operations require a text string to be entered Operations requiring this are setting external fault...

Page 115: ...f the set There are four sets of characters available Press the F3 key to cycle among the sets The sets consist of the upper case letters A through Z the lower case letters a through z the numbers 0 9 and the characters and the characters space _ Note these character set may vary depending on the language selected A special set consisting of A through Z 0 9 and the underscore character are used fo...

Page 116: ...s the more complete method to configure the drive for any application The drive may also be configured for the majority of applications by using the Setup Wizard The Setup Wizard can be entered from the SETUP screen by selecting the Setup Wizard from the list of options and pressing enter Regardless of the method used for configuration the default factory parameters will be obtained from the Drive...

Page 117: ...ect a different access level use the up down cursor keys to select the desired the level Then enter the password value PIN for that level using the data entry keys The value can be any number between 0 through 65 535 As the number is entered via the keys 0 9 the value will be shown by a placeholder e g in the editing field as shown in Figure 104 Figure 104 Pin Entry The value may be edited by usin...

Page 118: ...the ACCESS screen First use the up down cursor keys to select the level for which you wish to modify the PIN Press the F9 key The typical PASSWORD CHANGE screen shown in Figure 106 is displayed showing the Access Level for which the new PIN will be applied to Figure 106 PIN Change Enter the current PIN value via the data keys 0 9 and press the enter key As in the ACCESS screen the entered value is...

Page 119: ...e a status as shown in either Figure 107 Figure 108 or Figure 109 depending on whether you successfully changed the PIN incorrectly entered the existing PIN or incorrectly verified the new PIN Figure 108 Invalid PIN Figure 109 Invalid PIN Verification If you were not successful in changing the password simply start over again by typing in the current password value ...

Page 120: ...e typical screen shown in Figure 110 The Current Access level is shown If it states Monitor then you are restricted to only viewing the basic drive setup You cannot make any changes You must be in at least the Basic access level in order to modify any of the drive parameters and you may only modify the parameters for which you can view at the given access level At power up the operator interface a...

Page 121: ... alternate language press the F9 key on the SETUP screen The screen will show all language modules currently loaded as in Figure 112 Associated with each language is a module revision level Use the cursor up and cursor down keys to select the desired language and press the enter key The operator interface will switch to the new language selected It is possible for other devices attached to the dri...

Page 122: ...LAY screen Figure 138 by pressing the F7 key When you have successfully selected a parameter one of three possible screens will be displayed depending on the type of parameter Numerical Value When the parameter is a numerical value the MODIFY PARAMETER screen typical of Figure 113 will be displayed This screen shows the name of the parameter for which you are making the changes e g Rated motor vol...

Page 123: ...the backspace key This key will delete the right most character e g number decimal point or negative sign shown on the screen Press the enter key to accept the new value as shown in Figure 114 If the new value that you entered is outside the limits defined the new value will not change For example If you entered 900 when the minimum value was 4000 the new value will still show 4100 Some data must ...

Page 124: ...tor interface must be set to an Access Level other than Monitor You will be able to view the screen however pressing the data entry keys will have no effect If you are not in the correct level press the F8 key in order to gain access to the parameter Refer to the section entitled Enter Modify an Access Level on page 116 for further information on the operation to change the level Having gained acc...

Page 125: ... the F10 key Prior to this you can modify the new value by repeating the above procedure or you can cancel the change by pressing the F7 key The CANCEL operation returns the new value to that of the actual value Bit EncodedValue When the parameter is a bit encoded value the MODIFY PARAMETER screen typical of Figure 119 will be displayed This screen shows the name of the parameter for which you are...

Page 126: ...ew value is not sent to the drive until you exit the screen with the F10 key Prior to this you can modify the new value by repeating the above procedure or you can cancel the change by pressing the F7 key The CANCEL operation returns the new value to that of the actual value Analog Ports The drive contains a number of external analog ports to which you can assign any parameter To setup an analog p...

Page 127: ...titled Select a Parameter on page 110 When you have completed the selection process the selected tag will be assigned to the port To remove an assignment to the highlighted port press the delete Backspace key The changes made do not take affect until you press F10 and exit the screen Any time prior to this you may cancel all of the changes made after coming to the screen by pressing the F7 key ...

Page 128: ...The normal state is ON or enabled To change the state of the mask use the cursor up or cursor down keys to select the desired fault and press the enter key Each press of the enter key will toggle the state of the mask as shown in Figure 122 If nothing happens you do not have proper access to the drive Exit to the SETUP screen and refer to the section entitled Enter Modify an Access Level on page 1...

Page 129: ...ow the masks in the other state To change the state of a mask on the FAULTS OVERVIEW screen use the cursor up and cursor down keys to select the desired mask and press the enter key In the example of Figure 123 the AC O V is currently disabled and is selected When enter is pressed its mask is enabled thus removing the fault from this screen as shown in Figure 125 Pressing F7 toggles the screen to ...

Page 130: ... changes to the fault masks do not take effect until the screen is exited via the F10 key i e exiting the FAULTS OVERVIEW will change the masks in the drive as will exiting the FAULTS SETUP screen In our example exiting the FAULTS OVERVIEW screen and returning to the FAULTS SETUP screen now shows the AC O V mask as being ON Figure 127 Figure 127 AC O V Mask is ON ...

Page 131: ...Figure 128 will be seen Figure 128 External Setup Text To modify the text attached to a particular fault input use the cursor up and cursor down keys to select the desired input To modify the text press the cursor right key If nothing happens then you have not gained the required access to make changes Exit to the SETUP screen and refer to the section entitled Enter Modify an Access Level on page ...

Page 132: ...e right of the screen name i e PLC SETUP INPUTS or PLC SETUP OUTPUTS To switch to the other screen press the F8 key Each press of the F8 key will toggle the screen to show the other set of words The layout of the PLC rack is dependent on the DIP switch settings on the RIO adapter refer to the appropriate manual for information on the following adapters and their use 1203 GD1 1203 GK1 1203 CN1 1203...

Page 133: ...y The changes made do not take affect until you press F10 and exit the screen Any time prior to this you may cancel all of the changes made after coming to the screen by pressing the F7 key XIO The drive uses XIO adapters to hardwire to discrete inputs and outputs Each drive contains one or more of these modules Each module contains a unique address that is assigned automatically according to wher...

Page 134: ...ch you have changed the drive data you will be prompted as in Figure 133 to save the data If you wish to save the data press F8 Yes and the NVRAM screen refer to Store Retrieve Configuration NVRAM on page 135 will be entered Figure 134 If you wish the data to reside as temporary data in RAM only press F9 No Pressing F10 Exit will return you to the screen from which you previously exited Note that ...

Page 135: ...d setup information This can form a basis for configuring the drive To initialize the drive with the default set of data press the F3 key The screen will appear as in Figure 135 indicating the operation you are about to perform The screen then will ask you to confirm the operation Press the F8 key to proceed or the F9 key to abort Performing an initialization will overwrite the data currently in t...

Page 136: ...sly stored data in the NVRAM Load The changes that you stored in NVRAM are automatically used each time the drive is powered up If you make changes to the data in the drive without saving and then wish to use the previously stored data press the F4 key Figure 137 Figure 137 Load Operation To confirm the operation press the F8 key to proceed or the F9 key to abort Loading the data will overwrite th...

Page 137: ... Level Menu press the F4 key The DISPLAY GROUP screen of Figure 138 is displayed The screen shows one or more pages of groups that can be displayed The number of groups displayed depends on the current access level Using the cursor up and cursor down keys select the group you wish to display and press the enter key Figure 139 Figure 138 Display Screen Figure 139 Feature Select Group Chosen Figure ...

Page 138: ...sible to modify a parameter If the group you are currently viewing contains parameters press the F7 key The operator interface then allows you to select the parameter you wish to modify Refer to the section entitled Modify Parameters for further details If you have modified any parameters in the drive you will be prompted to make the changes permanent This prompt will occur upon exiting the DISPLA...

Page 139: ...iately however are not saved until you press F10 and exit the screen Any time prior to this you may cancel all the changes made after coming to the screen by pressing the F7 key View Drive Status The status of the drive is viewed by pressing the F7 key from the Top Level Menu This screen shown in Figure 144 constantly displays the latest status of the drive Figure 144 Status Screen ...

Page 140: ... and stopped for any reason To acknowledge the alarm s press the F6 key This will cause the F6 key to cease flashing and return to normal video If a new alarm were to occur the F6 key would again flash in reverse video To reset the drive press the F7 key This operation will reset any latched faults in the drive This has no action upon either the Fault or Warningqueues Ifsomefaults still exist they...

Page 141: ...p text may be associated with the alarm entry Use the up down cursor keys to highlight the alarm in question and press the enter key An ALARM HELP screen typical of that shown in Figure 147 will be shown for that alarm Not all alarms will have this additional help text For those alarms the screen shown in Figure 148 is displayed Figure 147 Alarm Help Figure 148 No Alarm Help ...

Page 142: ...omatically print out the alarms as they occur This feature is selected as one of the report formats In Figure 149 the AUTO ON indicates that this feature is currently enabled To disable the feature use the cursor down key to select the text and press the enter key The text will change to AUTO OFF if a printer is attached The automatic alarm printout feature is now disabled Pressing the enter key a...

Page 143: ... displayed If data has already been captured a time stamp indicating the last time the given trigger has occurred This captured data can be viewed by pressing the F9 softkey When a trigger has been defined and is currently Stopped it can be re started by pressing the F7 key If the status is Running the user can force the trigger to occur by pressing the F2 key Note that in doing so that the trigge...

Page 144: ...nd press the enter key Since there are more traces then can be seen on a single screen use the up down arrow keys to extend the list to the additional traces on the screen If nothing happens then you have not gained the required access to make changes Press the F8 key and refer to the section entitled Enter Modify an Access Level on page 116 to gain access This will begin the selection process of ...

Page 145: ... through the use of the numerical keypad Use the data entry keys 0 9 to enter the new value The key can be typed at any time to enter a negative value The key is used to enter a decimal point for fractional values The entered new value can be edited by pressing the backspace key This key will delete the right most character i e number decimal point or negative sign shown on the screen Press the en...

Page 146: ...r will store values after the trigger Pressing the F5 key will allow you to set the percentage of the trend buffer allocated to values collected after the trigger has occurred This data field is modified in the same manner as the trigger data is entered Starting theTrace The changes do not take affect and the trend is not started until you press F10 and exit the screen Any time prior to this you m...

Page 147: ...Figure 156 The time and date at which the trigger occurred is displayed The trend buffers may only be viewed when their status is stopped If in continuous mode the capture will stop when the buffers are viewed To view the trend buffers press the F9 key Figure 156 Diagnostic Stopped Figure 157 View the Trend Buffer s A screen such as Figure 157 will be shown Upon initial entry the screen will be po...

Page 148: ...ws the data from one drive to be physically transferred to another drive for loading All files on the flash card use a DOS format thus can be read or written by any PC that contains a PCMCIA drive Flash memory cards which are supported are those that contain the following memory chips from INTEL 28F010 28F020 28F008SA 28F016SA These chips are used in the following memory cards available from Rockw...

Page 149: ...level press the F8 key Refer to the section Enter Modify an Access Level on page 116 Format Flash Card Flash card files have a characteristic unlike normal DOS files They can not be modified once written New files can be added to the card however they cannot be selectively removed When a new flash card is to be used or all the files removed from an existing card the card must first be formatted Fo...

Page 150: ...creen by pressing the F2 key View a Directory The directory of a flashcard is shown by pressing the F7 key on the TRANSFER screen The directory shows the filename and extension along with a date and time stamp of when the file was created A screen typical of Figure 160 will be shown Figure 160 Typical Directory Any screen or operation that requires a filename to be entered or picked from the direc...

Page 151: ... the desired file Pressing Enter will select the file and proceed with the operation Press the F10 key to abort the selection operation and return to the previous screen without continuing with the operation Enter a Filename When a new file is being created the DIRECTORY screen is used to enter the new filename Upon entering the screen all existing files relevant to the operation are shown as show...

Page 152: ...u have not gained the required access to modify the flash memory Exit to the TRANSFER screen and refer to the section entitled Enter Modify an Access Level on page 116 to gain access When the filename has been obtained the TRANSFER PROGRAM screen such as that in Figure 162 will be displayed showing the filename indicating the operation you are about to perform and showing the current status of the...

Page 153: ...s been installed the previously stored parameters are then downloaded to the new board The flash card provides an added benefit when more than one drive is using the same set of parameters Parameters can be entered on the first drive then uploaded and stored on the flash card The flash card may then be taken to the remaining drives and the parameters downloaded to those drives Note This feature do...

Page 154: ...meters stored within the operator interface Figure 164 Transfer Stored Parameters Download from Operator Interface The parameters stored in the operator interface are downloaded to the drive by pressing the F3 key A screen similar to that shown in Figure 164 will be shown except the operation will show MEMORY TO DRIVE To confirm the operation press the F8 key to proceed or the F9 key to abort Perf...

Page 155: ...ay restart an aborted transfer or one that failed To select or enter a different filename press the F7 key Download from Memory Card The parameters are read from a memory card and written to the drive by pressing the F2 key The operator interface will enter the DIRECTORY screen from which an existing parameter filename can be selected or entered Refer to the sections entitled Select a Filename on ...

Page 156: ...emaining Lines a each line contains one parameter The line consists of the linear parameter number followed by a semi colon and the parameter value followed by a semi colon For example 1 0 2 0 5 2 Loading Language Modules In order to use a language in the operator interface it must first be loaded into the operator interface from the flash card From the TRANSFER screen press the F5 key The operato...

Page 157: ... abort If an attempt to download a language module that already exists is made the transfer will fail In order to download a newer version of a language all languages in the operator interface must first be cleared this is a characteristic of flash memory by pressing the F2 key on the TRANSFER LANGUAGE screen The screen as in Figure 168 will then ask you to confirm the operation Press the F8 key t...

Page 158: ...via a two key sequence Communications Statistics The screen depicted in Figure 169 shows statistics involving the serial communications between the operator interface and the drive as well as the contents of the transmit and receive buffers It is called from any screen except the PRINTER screen by pressing the F10 key and the cursor down key at the same time Figure 169 Communications Statistics Bu...

Page 159: ...X buffers contained in the operator interface These buffers are circular in nature The Psh push and Pop values indicate the location in the buffer where the next character will be loaded or unloaded respectively If the values are equal then the buffer is empty To aid in viewing the buffer locations the cursor keys can be used to highlight the buffer contents The current location of the cursor is s...

Page 160: ...his requires the use of a second RS232 port communicating at 9600 Baud to an external computer Special software is required in the computer to receive the data and to interpret the data The operation is initiated from any screen by pressing the F10 key and the cursor right key at the same time The screen will clear and a message will indicate that the screen is being printed as well as the percent...

Page 161: ...t value The highlighted value is the field that is currently being edited Figure 173 Edit the Segment Offset The segment offset address is edited via the numeric keypad and the arrow keys All values of 0 9 can be entered directly via the numeric keypad To enter a value of A F the cursor up and cursor down keys must be used to cycle through the possible values Note that the value 0 9 can also be en...

Page 162: ...ss from you If unsuccessful it will immediately return to the screen from which this call was made The download may be aborted at any time by pressing any key on the operator interface The portion of the database already obtained will be valid A subsequent request to download the database will continue from where the previous download had terminated This screen will always return to the screen fro...

Page 163: ...represents the same flow as previously defined For sake of clarity the soft function key calls to the HELP operation and the ALARMS screen have not been shown It is implied that all screens have this ability via the F1 and F6 keys respectively Example As an example of using the chart we will modify a parameter while displaying it starting from the Top Level Menu referred to in the chart as the MAI...

Page 164: ...ill return you to the DISPLAY screen via the symbol D Successive presses of the F10 key will return you to the DISPLAY GROUP and finally to either the MAINMENU or the MESSAGE screens If you have changed any data in the drive the F10 Exit key will bring up the MESSAGE screen The message will remind you that the changes made in the drive are only temporary unless saved to NVRAM If you desire the dat...

Page 165: ...F1 Help Format Program F2 Format F3 Program F F3 Program F7 Dir Directory G Parameters F4 Paramtr F2 Crd Drv F F2 Drv Crd F F F7 Dir G F8 Access P F7 Dir F Language F5 Lang ge F F3 Lang ge F7 Dir G Q R F2 Format Status F7 Status NVRAM F5 NVRAM E Select Group Select Select Letter Select Code F7 List F5 Code Select List S D T PowerFlex 7000 Terminal Menu Tree Note All screens have access to the F1 H...

Page 166: ... Fault Help Display Group Display View Parameter F4 Display Q R Display Custom F7 Custom S T T D M F 7 Modify Language F 9 Lang ge P F8 Access Modify Parameter P F8 Access M S T Parameters External Setup External Text Fault Masks PLC Analog Memory Obtain Database Communications Protocol Analyzer F 7 Analyze Faults Setup Faults Overview F7 Overvw F7 Toggle F10 F 10 F10 PLC Setup F 8 Toggle T S Anal...

Page 167: ...ry Card 1 Locate the vertical card slot on the back of the operator interface See Figure 177 Figure 177 Rear View of Operator Interface 2 Position the card vertically so the key slot is facing the right side of the operator interface WARNING The memory card should be kept free from moisture extreme temperatures anddirectsunlight Failuretoobservethiscautioncouldresultin damage to the card WARNING D...

Page 168: ... P March 2020 Chapter 3 Operator Interface Figure 178 Key Slot Orientation 3 Insert the card into the card slot and push until the card is firmly seated WARNING Donotforcethecardintotheslot Forcingthecardintotheslotmay damage the connector pins KEY SLOT ...

Page 169: ...al 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 all inter sectional wiring is connected properly 7 Re verify control wiring from any external control devices such as PLCs etc 8 Confirm cooling system is operational 9 Verification of proper phasing fro...

Page 170: ...nce that they have been presented Failure to do so may result in equipment failure or personal injury Notwithstanding the safety references here all local codes and safety practices are to be utilized when working on this product TIP Customer personnel will be required on site to participate in the start up of the system ATTENTION Servicing energized industrial control equipment can be hazardous S...

Page 171: ...ist Once all points of the checklist are complete initial each check box and provide the date Photocopy the checklist and fax the copy to Medium Voltage Center of Expertise MV COE along with the planned start up date Upon receiving this checklist the MV COE will contact the site to finalize arrangements for a start up engineer to travel to site if so desired by the end user Receiving and Unpacking...

Page 172: ...ns If the drive has an isolation transformer the wye secondary neutral point must not be grounded If shipping splits exist in the line up the ground bus between cabinets has been installed Based on your local regulation an ARC Flash study has been completed Initials Date All low voltage wiring entering the drive is labeled appropriate wiring diagrams are available and all customer interconnections...

Page 173: ...safety and CEC NEC IEC regulations All power connections are torqued as per Rockwell Automation Specifications See page 421 AllcustomerpowercablinghasbeenMeggeredorHi Pottestedbeforeconnectingtodrive system Powerwiringphaserotationhasbeenverifiedperthespecificelectricaldiagramssupplied by Rockwell Automation Initials Date The medium voltage and low voltage power is available for startup activities...

Page 174: ...174 Rockwell Automation Publication 7000L UM301F EN P March 2020 Chapter 4 Commissioning NOTES ...

Page 175: ... 740 4790 Recommended Tools and Equipment HandTools Metric and Imperial wrenches sockets and Hex keys Torque wrench Assortment of screw drivers Assortment of electrical tools wire strippers electrical tape crimpers etc ElectricalEquipment High voltage gloves 10 kV insulation rating minimum Approved high voltage potential tester 10 kV rating minimum Anti static strap Test Equipment 100 MHz oscillos...

Page 176: ...ffice PowerFlex 7000 Parameters The PowerFlex 7000 Technical Data publication for Parameters is also required for Commissioning and Troubleshooting Refer to 7000 TD002_ EN P for the latest firmware revision Additional Manuals Any additional manual required to configure the drive line up can be identified on the Electrical Schematics The Schematic titled General Notes identifies all required Rockwe...

Page 177: ...within one week after leaving the site The items listed below MUST be included when submitting the commissioning package 1 All checklists and tables in this document commissioning checklist customer data motor data daily service summary etc 2 Harmonics waveforms must be captured on AFE drives under drive not running and full load conditions 3 DC current test waveforms dc voltage and dc current and...

Page 178: ...edium voltage and complete incoming line phasing checks and take harmonic measurements Perform DC Test Ensure that the Diagnostic Trend is setup and ready before attempting the DC Test Perform Stationary Autotune tests first two autotune tests Bump the motor for rotation check Complete Rotating Autotune tests last autotune test Save the parameters in NVRAM and also transfer them from Drive to Memo...

Page 179: ...leted documents along with the Field Service Report The Field Service Engineer must endeavor to fill these forms out as accurately and legibly as possible Please refer to the PowerFlex 7000 User Manual for the Commissioning Procedure and necessary guidelines POWERFLEX 7000 MEDIUM VOLTAGE DRIVE ROCKWELL AUTOMATION CANADA 135 Dundas Street Cambridge Ontario N1R 5X1 Canada MV Support Contact Info Off...

Page 180: ...ntial in the cabinet with appropriate safety equipment Remove step down CPT or PT fuses and place them in a safe place outside of the drive cabinet Control power must be off Check fuse and O L values and compare them to the values specified on the schematic diagrams Installation Review Examine the drive for shipping damage Inspect cabinets for debris Ensure that protective barriers removed for dri...

Page 181: ...ions Verify the AC DC output is 56V DC at the input of the DC DC converter and at the input to gate driver power supplies Adjust if necessary Verify the 20V output of SGCT IGDPS boards Verify that all of the DC outputs in the DC DC converter are at rated value Verify that healthy lights are on for all control boards and firing boards Use wireharness with power supply adapter to test SCR gate drive...

Page 182: ...ers settings for operating the drive with unloaded motor Program the drive for operation at full load Run the drive at rated load and rated speed and record variables Capture line side and load side voltage and current waveforms under running condition Paperwork Print DRIVE SETUP which gives all parameters firmware revisions PLC links etc Complete the Commissioning Datasheets Mark up EDs with modi...

Page 183: ...ded with the equipment must be studied and understood Within these drawings is detailed information and instructions required for commissioning and installation of the equipment including the following DimensionalDrawings Power cable termination locations Ground bus locations Shipping split locations Control and medium voltage power ratings Drive options Remote I O protocol PLC options Motor and l...

Page 184: ...ive line up is required While referencing the one line diagram and Rockwell Automation prints identify all the locations of the components within the drive line up by their Tag Identification name or number Trace the power cables from point to point while following the electrical diagrams Any discrepancy between the physical installation and the electrical prints should be reviewed prior to commen...

Page 185: ...d after the lockout and tagout are successfully completed ATTENTION Servicing energized industrial control equipment can be hazardous Severe injury or death can result from electrical shock burn or unintended actuation of control equipment Hazardous voltages may exist in the cabinet even with the circuit breaker in the off position Recommended practice isto disconnector lock out control equipmentf...

Page 186: ...s are also identified by stickers located on the cabinet structure in close proximity to the fuse or overload Ensure the settings match the rating identified on the sticker Replacement fuses have been shipped with the drive in the event that a fuse opens during commissioning Installation Review Prior to commencing the commissioning of the drive line up it is recommended that the installation of th...

Page 187: ...le for the installation to remove protective barriers to allow for more space within the cabinets Ensure that all protective barriers removed during the installation have been re installed Failure to re install a protective barrier may result in equipment damage or personal injury Component Grounding Verify that the drive and all its associated equipment have system power ground cabling installed ...

Page 188: ...ated on each end and are sufficiently torqued refer to Torque Requirements for Threaded Fasteners on page 421 Appendix B Verify that the cable installed meets the recommended power rating outlined in the electrical drawings and installation section of the manual Ensure that the cable terminations are stress coned if required Verify that the customer power cables have been Hi Potted or Meggered and...

Page 189: ...yout on page 76 Figure 61 and Figure 62 show the drive flange connections and required bolt torque Use the 1 8 in Elastomer gasket supplied The rear view of the cooling cabinet shown in Figure 59 shows the location of the inlet and outlet for the drive cooling system It is very important to connect the outlet of the drive to the inlet of the heat exchanger and the outlet of the heat exchanger to t...

Page 190: ...pleted in a detailed and accurate manner and that immediately after their completion the following data sheets are submitted to the customer and to the factory They will be required to perform modifications on the drive line up once production commences It is common for modifications to be made to the drive s program some time during the two month period following the drive commissioning This is d...

Page 191: ...ing Engineer Commissioning Date Motor Nameplate Data MotorType Induction OR Synchronous Manufacturer Model No Serial No HP KW Volts Current KVA Power Factor Frequency RPM Service Factor Efficiency Code Type Frame NEMAType RTDType Bearing Stator Excitation For Synchoronous Motors only ExciterType Volts Current Tachometer Encoder Nameplate Data Tachometer Position Encoder Stator Feedback None Manufa...

Page 192: ... Number of Capacitors Each Cap KVAR Volts Hz Line Filter Capacitors AFE Rectifier Only Manufacturer Model No Number of Capacitors Eac Cap KVAR Volts Hz DC Link Manufacturer Serial No Model Current Amp Inductance mH Insulation Class Temp Rise Input Reactor Configuration Manufacturer Model No Serial No Line Reactor____ IsolationTransformer___ Voltage mH KVA Current Temp Rise Impedance Primary____ Se...

Page 193: ...iscellaneous Information Auxiliary Cooling Blower Motor if any HP KW Volts Phase FLC RPM S F Manufacturer Model Frame Size Drives Source of Control Power UPS Lighting Panel Number Other Specify Environmental Conditions Air Conditioned Fan Forced Air Other Specify Other Pertinent Information ...

Page 194: ...VSB M 1 81000 199 Operator Interface 2711 KSASL11 PV Firmware 2 PV Software 3 TFB L 80190 639 or 80190 539 TFB M 80190 639 or 80190 539 SCR SPGDB 1 80190 219 SPS 1 80190 799 IGDPS L 1 3 80026 044 IGDPS M 1 3 80026 044 PS1 A F 1 AC DC Converter 80026 520 or524 PS2 DC DC Converter 81002 440 PS4 24V DC Power supply CPT 80022 069 UPS Printer 1 The drive can have more than one of this circuit board 2 P...

Page 195: ...th all medium voltage equipment are aligned in the factory they often move out of position during shipping or are often misaligned when the cabinet is set down on an uneven floor The following instructions will assist the field engineers in quickly and accurately aligning the deadbolt key interlock with its counterpart Figure 179 Deadbolt Assembly Mounted to Door 1 Lock out and isolate the drive f...

Page 196: ...e 179 Deadbolt Assembly 5 Slightly loosen the adjustment bolts on the counterpart and make the necessary movements on the counterpart to ensure that the pins align with the landing plates on the deadbolt assembly As the amount of counterpart movement required is an estimate it may take a couple attempts to properly align the assembly 6 Clean the torque seal grease from the key interlock once finis...

Page 197: ...ing SGCT semiconductors and all snubber components Expected SGCT Snubber Circuit Resistance and Capacitance values are listed in Table 6 Table 6 SGCT Snubber Circuit Resistance and Capacitance Values Figure 181 SGCT Snubber Circuit Connections ATTENTION Before attempting any work verify that the system has been locked out and tested to have no potential Drive Rating Sharing Resistance Snubbe Resis...

Page 198: ...milar resistance values across each device Easy access from the anode to cathode is available by going from chill block to chill block as shown in Figure 182 Figure 182 Anode to Cathode Resistance Test Points An SGCT when not gated on is an open circuit A healthy device resistance value should be close to the value sharing resistor however due to parallel resistances in the firing card the resista...

Page 199: ...the resistor is found to be out of tolerance refer to Component Definition and Maintenance on page 265 Chapter 5 for detailed instructions on how to replace the snubber sharing resistor assembly Snubber Resistance SGCT Device Access to the snubber resistor is not required to test the resistance The snubber circuit test point is located within the PowerCage under the chill blocks For each device th...

Page 200: ...ally looking for a consistent reading for all devices If the capacitor is found to be out of tolerance refer to Component Definition and Maintenance on page 265 Chapter 5 for detailed instructions on how to replace the snubber capacitor SCRTesting The following steps outline how to verify SCR semiconductors and all associated snubber components A quick reference to the expected resistance and capa...

Page 201: ...istance measurement taken across each SCR should be consistent an inconsistent value may indicate a damaged sharing resistor self powered gate driver board or SCR Anode Chillblock Cathode Chilblock Disconnect Points Rsh 1 Rsn 1 Cs 1 Cs 2 Rsn 2 To Gate Driver Board TP Rsh 2 SCR Resistance Measurement Measured Resistance SCR Anode Cathode Resistance Heatsink to Heatsink k Ω Lowest Highest SCR Gate C...

Page 202: ... value of 0 for a shorted device or Ω for an opened device Unlike the SGCT it is highly irregular for an SCR to have a partially shorted device If an SCR is found to be out of tolerance refer to Component Definition and Maintenance on page 265 Chapter 5 for detailed instructions on how to replace the SCR assembly SCR Sharing ResistanceTest To test the sharing resistor of an SCR module disconnect t...

Page 203: ...e Test Performing a Gate to cathode resistance measurement will identify damage to a SCR by revealing either an open or shorted gate to cathode connection To test an SCR from gate to cathode disconnect the SCR gate leads from the self powered gate driver board and measure the gate to cathode resistance on the SCR firing card Phoenix connector as shown in Figure 188 Red Wire at 2 pole connector Snu...

Page 204: ... procedure is located in Chapter 5 refer to Component Definition and Maintenance on page 265 Snubber Resistance SCR Device Access to the snubber resistor is not required to test the resistance The snubber circuit test point is located within the PowerCage under the chill blocks For each device there is one test point To verify the resistance measure the resistance between the test point and the ch...

Page 205: ...ition and Maintenance on page 265 Chapter 5 for detailed instructions on how to replace the snubber resistor assembly Snubber Capacitance SCR Device Turn the multimeter from the resistance to capacitance measurement mode Proceed to verify the snubber capacitor by measuring from the test point and the white wire at the 2 pole device snubber plug labeled snubber Measure resistance between chill bloc...

Page 206: ...tual snubber capacitor value shown in the table If the capacitor is found to be out of tolerance refer to Component Definition and Maintenance on page 265 Chapter 5 for detailed instructions on how to replace the snubber capacitor Control Power Tests Although there are a variety of options available to customers that will effect the control power distribution within the drive the input will always...

Page 207: ...s not meet the design specifications Three Phase Input Single Phase Input This configuration has one source of control power Three phase control power for fan operation which is also converted to single phase control power to operate the Interface power supplies I O and additional auxiliaries Similar to the three phase configuration the input power for the fan and control must be verified at the p...

Page 208: ...er up self test Refer to Publication 7000 TD002_ EN P for information on troubleshooting Control Power Transformer CPT A control power transformer CPT is supplied only in certain drive configurations If there is no control transformer supplied in the drive being commissioned please disregard the following information on setting the control voltage output level Component LED Activated AC DC Convert...

Page 209: ...werFlex 7000 C Frame drive will be supplied with at least one AC DC power supply As the number of devices increases OR to provide a redundant power supply the number of AC DC power supplies installed may be more than one The electrical schematics provided by Rockwell Automation will identify how many AC DC power supplies have been installed in the application being commissioned Ensure the output o...

Page 210: ...imeter measure each of the outputs of the DC DC converter to ensure that they meet the values specified on the electrical schematics Compare these measured values to those displayed on the Operator Terminal under the Metering group Table 8 Plug 1 P1 INPUT Table 9 Plug 2 P2 SENSE SIGNAL Table 10 Plug 3 P3 ISOLATOR Terminal Numbers Description Value 1 2 Input Power 56V Terminal Numbers Description V...

Page 211: ...s IGDPS Note Refer to Figure 194 and Figure 195 for location of IGDPS Terminal Numbers Description Value 1 2 24V_XIO 24V 2A XIO_COMM COM3 5 3 4 HECSPWR 24V 1A LCOMM COM2 1 5 4 HECSPWR 24V 1A LCOMM COM2 1 6 7 15V_PWR 15V 1A ACOMM COM1 0 5V 8 7 15V PWR 15V 1A ACOMM COM1 0 5V 9 10 5V PWR 5V 5A DGND COM1 5 1 5 5V M4 P H M S and nylon shoulder washer Mounting Plate Black Insulation DC DC power supply P...

Page 212: ...ation Publication 7000L UM301F EN P March 2020 Chapter 4 Commissioning Figure 194 Converter Cabinet Components 3300 4160V Ground Bus IsolatedGateDrive Power Supplies IGDPS Inverter Modules Rectifier Modules CoolantPiping ...

Page 213: ...utomation Publication 7000L UM301F EN P March 2020 213 Commissioning Chapter 4 Figure 195 Converter Cabinet Components 6600V Isolated Gate Driver Power Supplies IGDPS Ground Bus Inverter Modules Rectifier Modules ...

Page 214: ...ll 6 outputs in each IGDPS are functioning The output voltage should be within 20V 1 There may be more than one IGDPS in the drive Commissioning the Cooling System The liquid cooling system is tested for leaks at the factory but shipping damage can create leaks in the liquid cooling system All leaks must be repaired prior to start up Test Points ExpectedValue Measured Value IGDPS 1 IGDPS 2 IGDPS 3...

Page 215: ... inlet of reservoir This allows the drive to remove any trapped air in the system If the heat exchanger is at a higher elevation then air release valves should be installed at the highest point Figure 196 Typical Liquid to air Heat Exchanger The tubing to the heat exchanger should have been cleaned by the installation personnel If they are still in the process of installation you should verify tha...

Page 216: ...ered to the pumping control cabinet This determines the direction of rotation of the pumps There will be arrows on the pump showing the proper direction of rotation and it can be visually verified by looking at the non drive end shaft Manually activate the pump control relays and verify the rotation Manually activate the fan control relays and ensure each of the fans on the heat exchanger is rotat...

Page 217: ... approximately 170 L 45 U S gallons to fill the system The drum SHOULD NEVER BE DISCARDED In the event that you need to drain the system you will want to have this handy to store the coolant so that it can be reused Figure 197 Cooling Cabinet Overview showing Valve Locations 1 V8 V9 if provided V2 hidden if provided V12 P3 V7 drain fill if provided P2 V6 drain fill P1 STR2 V11 STR1 if provided ...

Page 218: ... Locations 2 System Fill and AirVenting 1 Attach transfer pump to drain fill line see drain fill pump in Figure 2 Ensure flow arrow on pump is in correct direction Figure 199 Drain Fill Pump V11 V4 Pump 1 Pump 2 V5 V12 V3 V1 WARNING Do not allow main pumps P1 and P2 to turn when dry Damage to seals can result Flow Direction Transfer Pump ...

Page 219: ...r electrical connections if not clockwise 8 Start Pump 2 to circulate coolant and eliminate air in the system If the pump is noisy and sounds like gravel is being pumped the pump may be cavitating Ensure V2 and V3 are open and strainer STR1 if provided is not plugged 9 Continue to fill system to maintain level in reservoir Eliminate air by running Pump 2 for several hours Air in the system can be ...

Page 220: ...st the SCRs and SGCTs under low voltage control power The following procedures will describe how to perform the next level of device testing Gating Test Mode SCR Firing Test SGCT Firing Test If the results of the tests are not as described in the section below refer to Component Definition and Maintenance on page 265 Chapter 5 for detailed information on how to troubleshoot problems in the convert...

Page 221: ...ess the ACCESS F10 key and use the down arrow until you highlight ADVANCED Press Enter and then EXIT F10 Figure 201 Access Advanced Screen Now press SETUP F8 to get to Parameters and then Enter You should be on Feature Select the first group Press Enter and then use the down arrow to get to Operating Mode ATTENTION Ensure that the drive is isolated from medium voltage prior to starting this test ...

Page 222: ...rds Supplied with each drive is a power cable which supplies 15 V DC from an AC DC power supply to the firing cards SPGDB This cable has one input to be connected to an AC source 120 240V 50 60 Hz and 18 sets of outputs that can be connected to the SCR self powered gate driver boards The procedure is as follows Plug the AC power connector on the test cable into an appropriate AC source The other e...

Page 223: ...ice will turn on for 2 seconds then turn off The next device to the right will turn on for 2 seconds and the pattern will continue When you reach the end of the first stack of devices the right device in the middle stack down will fire and the pattern continues right to left until the end of the middle stack is reached Then the left device in the bottom stack will fire and the pattern will continu...

Page 224: ...shoot the SGCT firing cards Put the drive in Gating Test Mode and the inverter will automatically go into the Test Pattern gating mode Monitor the SGCT LEDs and ensure that LEDs 4 Green and 3 Green remain illuminated while LEDs 1 Red and 2 Yellow toggle on an off alternately at the frequency that the converter is operating at There is also a Gating Test that fires the individual devices one at a t...

Page 225: ...ol does not operate as expected This section of the manual provides instruction for the following five tests System Test Mode Start Stop Contactor Control Status Indicators Analog I O Configurable Alarms SystemTest Mode The following procedure explains how to enter System Test Mode This allows the drive to operate the drive s low voltage control circuit without medium voltage present Drive status ...

Page 226: ...is in System Test mode ensure that the stop start circuit functions as desired It may be necessary to study the electrical schematic drawings prior to performing this test in order to understand the control circuit Start the drive in local control while observing the system vacuum contactors or customer supplied circuit breakers If troubleshooting is required in Rockwell Automation medium voltage ...

Page 227: ...modifications at this time and re test the system if necessary Status Indicators Drive status is often feedback to a plant s process control either digitally through the PLC input output feature see Chapter 3 Operator Interface PLC page 3 43 or through relay logic The following relays are provided with the drive as standard It is necessary to activate each status indicator used by the customer to ...

Page 228: ...ally have to be increased above the desired maximum value to compensate for the loading down of their 10 volt input rails by the attached potentiometer or isolator Example SpdCmd Anlg Inp 4 20mA Reference command Input Scaling The customer 4 20 mA speed input is coming to the Current Loop Receiver on the ACB and they want the maximum input to represent 60 Hz 1 Reference Command Remote Maximum Ref ...

Page 229: ...arrow to highlight the output you wish to assign When you press Enter you will be brought to the entire list of parameters in the Select Group screen Use the arrow and enter keys to find the parameter you wish to assign and press Enter This will take you back to the Analog screen and you will see the new parameter name beside your selected output Press EXIT F10 go up to Parameters Press Enter and ...

Page 230: ...e stated as 0 to 10 volts but in actual fact their outputs are typically 0 025 to 9 8 or 9 9 V This is due to the rails being loaded down by an attached speed potentiometer or signal conditioner impedance Incorporated signal conditioners usually have 0 to 10 volt inputs and 4 to 20 mA outputs An additional error is incorporated in the signal conditioners so if they are calibrated for 0 to 10 volts...

Page 231: ...ks in the manual are listed below Setting Fault Masks Refer to Fault Masks on page 128 Chapter 3 Setting External Fault Text Refer to User Definable External Text on page 131 Chapter 3 Setting Fault Classes Refer to Drive Commissioning on page 169 The external faults can be tested by lifting the wires to all external warning fault inputs while running in system test mode These wires are terminated...

Page 232: ...ing between the 0 20 and 20 bridges in the isolation transformer Figure 204 18 Pulse Terminals There are low resistances between phases through a transformer winding and a high resistance between transformer windings Therefore the expected resistance measurements are listed in the table below If the measurement results are not as described above the interwiring between the isolation transformer an...

Page 233: ...e been re installed before continuing Ensure that you have taken the drive out of System Test mode and have returned to Normal operating mode Input Phasing Check There are 9 voltage test points on the ACB board that will allow you to look at each voltage level individually These test points are labeled as follows Table 12 ACBTest Points and Associated Voltage Signals All of these test points can b...

Page 234: ...y 120 and 240 respectively 2 3U 3V and 3W should be lagging 2U 2V and 2W by 20 20 respectively 3 4U 4V and 4W should be leading 2U 2V and 2W by 20 20 respectively Figure 205 CH1 is 2Vuv CH2 is 2Vvw CH3 is 2Vwu For 60 Hz systems 360 16 7 ms For 50 Hz systems 360 20 ms Refer to Figure 206 for a visual representation of the phasing checks ...

Page 235: ...the drive in DC Current Test and monitoring variable Alpha Line and Idc feedback while increasing the DC current through the drive rectifier The following instructions detail how to DC current test The PV550 display screens are given as an example The actual screen data may differ Ensure that you have Service access From the main screen press SETUP F8 then press Enter and press Enter again to acce...

Page 236: ...EXIT F10 until you make it out to the main screen There is no need to save to NVRAM when the prompt appears Press DISPLAY F4 and scroll down until you reach the group Current Control Press Enter and then press MODIFY F7 Scroll down to Idc Test Command and press Enter Enter the number 0 1 pu and then press Enter Press EXIT F10 twice and press PREV PG The value of Alpha Rectifier will be displayed o...

Page 237: ...ch 0 1pu of Idc Test Command The waveform should also never have any of the low points between ripples go to 0V This would indicate a problem with the DC Link cabling See the troubleshooting section for sample waveforms Press MODIFY F7 and increase Idc to 2 pu and repeat the process Go as high as 0 7 pu in 0 1p u steps for 18 Pulse and 0 3 pu in 0 1pu steps for AFE verifying each level as you incr...

Page 238: ...nce It is also used in the calculation of the line converter retard limit for SCR rectifiers to ensure proper operation under all conditions of line voltage and load current If the Input Impedance parameter is not correctly adjusted the resulting error in the reconstructed line voltage may cause line synchronization faults and incorrect reading of the incoming line voltage The Input Impedance para...

Page 239: ...et to Autotune Idc BW 212 3 Start the drive The dc current will increase to 0 2pu and stay at that level for couple of seconds The drive records the data under this condition and then ramps up to approximately rated current After staying at the level for couple of seconds the drive will again record the measured data and then ramp the current to zero The current regulator bandwidth is set back to ...

Page 240: ... rectifier input voltage by looking at parameter Rec Input Voltage P696 Let this value be Vin0 5 For SCR drives set parameter Idc Command Test in Current Control to 0 800 pu For AFE drives set the parameter to 0 300 pu Let this value be Idc 6 Start the drive and wait for a few seconds for steady state conditions to be established 7 Record the value of the rectifier input voltage by looking at para...

Page 241: ...ter Screen 3 Set parameter Idc Test Command in Current Control to 0 225 pu for AFE rectifier drives and 0 400 pu for SCR drives 4 Set parameter CurReg Bandwidth in Current Control to 100 rad sec A lower than the normal bandwidth makes the step response easier to measure 5 Set parameter T DC Link in Current Control to 0 020 sec which is at the low end of the normal range of values and should produc...

Page 242: ...nk causes the rise time to increase Since the desired step response is slightly under damped T DC Link should not be increased beyond the value at which the overshoot disappears Figure 209 Current Regulator Tuned Incorrectly Figure 210 Current Regulator Tuned Correctly 10 Set parameter CurReg Bandwidth to the normal value of 200 rad sec Confirm that the rise time of the current feedback is now app...

Page 243: ...zero 4 In the second half of the step the output frequency ramps up to rated frequency with the dc current equal to 1 0pu for a few seconds This test may produce a small amount of motor torque and some rotation may occur This step will calculate the L Total Leakage The current is ramped down and parameter Autotune Select is set to Off Parameter Autotune RStator 219 is set to the measured Stator re...

Page 244: ... of the motor this method of measuring leakage inductance does not produce a valid result The leakage inductance will have to be obtained from the motor data sheet If this is not possible parameter L Total Leakage should be set to its default value of 0 20 pu 3 FluxSpeed Regulator INDUCTION MOTORS This method combines the auto tuning of the Flux and Speed regulator in a single step It calculates p...

Page 245: ...ed motor voltage at full load and rated speed and sets the flux command parameter to this value SpeedRegulator The tuning of the speed regulator is determined by two parameters in the Speed Control group 1 SpdReg Bandwidth 2 Total Inertia Parameter SpdReg Bandwidth is set to a value determined by the requirements of the application but parameter Total Inertia is usually unknown and must be measure...

Page 246: ...ves the rated slip If the auto tuning is successful then parameter Lm Rated 131 in Motor Model is set equal to Autotune L Magn parameter T Rotor P132 in Motor Model is set equal to Autotune T Rotor and the flux regulator gains are recalculated parameter Total Inertia 82 in Speed Control is set equal to Autotune Inertia and the regulator gains are calculated If the auto tuning fails then a warning ...

Page 247: ...o Autotune Inertia However a high inertia measurement could also be produced by a value of Autotune Trq Stp which is too low FluxRegulatorManualTuning InductionMotor 1 Adjust the reference command to a value between 20 and 30 Hz 2 Start the drive and wait for it to accelerate to the commanded speed 3 Record the value of parameter Lm Measured 134 in Motor Model 4 Stop the drive 5 Set parameter Lm R...

Page 248: ...iddle of the operating speed range 5 Start the drive and wait for it to accelerate to the commanded speed 6 Set parameter Speed Ref Step in Speed Control to 0 8 Hz The drive speed will step up and down by this amount at regular intervals The step of 0 8 Hz corresponds to 0 8V or 800mV on the test point To capture the error set the scope at 200mV division and 200msec division Trigger the scope on n...

Page 249: ...or the synchronous motor is provided by a current regulated field supply either a dc supply for a slip ring or dc brushless machine or a three phase ac supply for an ac brushless machine The drive provides an analog current reference as an input to the field supply The analog current reference has a range of 0 10V where 0V corresponds to zero field current and 10V corresponds to maximum field curr...

Page 250: ...Rated in Motor Model 3 T Rotor in Motor Model 4 Lmd in Motor Model 5 SpdReg Bandwidth in Speed Control 6 Total Inertia in Speed Control The FluxSpeed Regulator tuning function calculates parameters Lm Rated 131 T Rotor 132 in Motor Model Group and Total Inertia 82 in Speed Control group This is combined Auto tuning for Flux and Speed regulator FluxRegulator Flux Regulator Bandwidth should be set t...

Page 251: ...rent has been set up as described previously and that parameter L Total Leakage has been set to the correct value 2 Set parameter Autotune Select in Autotuning to FluxSpeed Reg 3 Start the drive The motor accelerates normally up to the speed specified by parameter Autotune Spd Cmd The motor magnetizing inductance is calculated from the magnetizing current reference and the flux feedback and parame...

Page 252: ...et equal to Autotune Lmd Parameter Total Inertia 63 in Speed Control is set equal to Autotune Inertia If the flux regulator auto tuning fails a warning is issued indicating the cause of the failure L Magnetize Low indicates that the measured value of magnetizing inductance is less than 1 0 pu This warning is intended to draw attention to an unusually low value of magnetizing inductance The most li...

Page 253: ...o have to increase starting torque and ensure Motor Stall faults during initial operation Reaching Specific Load Points Verify the drive can reach rated speed and load Monitor the Torque Reference P291 and the displayed value of the motor current If you are running into a torque limit the Torque Reference will be running near the Torque Limit Motoring P84 limit If you are not realizing rated motor...

Page 254: ...E VARIABLES SPEED RPM AMPS VOLTS Vline Speed Ref Hz Speed Fdbk Hz Flux Ref pu Torque Ref pu I DC Ref pu I DC Fdbk pu Alpha Machine degrees Alpha Line degrees Inverter Heatsink Temp C Rectifier Heatsink Temp C 1 25 ___ 2 50 ___ 3 75 ___ 4 100 ___ 5 ___ ___ 6 ___ ___ 7 ___ ___ 8 ___ ___ 9 ___ ___ 10 ___ ___ 11 ___ ___ 12 ___ ___ ...

Page 255: ...ence purpose Drive InputVoltage Phasing Checks After applying medium voltage to the drive perform an input voltage phasing check Summary Drive input contactor should be closed If the drive input contactor configuration is set to NOT RUNNING you will have to temporarily change it to ALL FAULTS Ensure that the drive is not running when capturing these waveforms Capture the three line voltage wavefor...

Page 256: ...ptured on ACB test points showing 20 deg Phase Shift between Master and two Slave Bridges Ch1 Master V2uv red Ch2 Slave 1 V3uv yellow Ch3 Slave 2 V4uv blue TIP Use the same settings on the oscilloscope when capturing waveforms for the two Slave bridges If you are using a 2 channel oscilloscope then first capture two waveforms and move them onto a wavestar worksheet and after that capture the remai...

Page 257: ...e Setting Figure 214 SampleWaveforms Sample waveforms captured on SCBL test points under Drive Not Running Condition Ch1 V2uv red Ch2 I2u yellow TIP Please refer to tech note PowerFlex 7000_GEN 15 to compare the waveforms for harmonic distortion Ifyounotice considerable distortion in the waveforms then you MUST send those waveforms to MV Support via e mail at mvsupport_technical ra rockwell com an...

Page 258: ... current regulation by monitoring Idc Error P323 and Alpha Line P327 3 Capture DC link voltage waveform at ACB test point Vdcr1 and DC link current waveform at ACB test point Idc1 at 0 3pu for AFE drives or at 0 7pu for 18 Pulse drives 4 Label the waveforms as Vdcr1 and Idc1 5 Save the worksheet as DC Test 0 3pu for AFE drives or DC Test 0 7pu for 18 Pulse drives Table 15 Oscilloscope Setting Figu...

Page 259: ...ve at Also print variables at 50 and 100 load points Before printing variables make sure the drive Access Level is at SERVICE 1 Capture line voltage current waveforms at ACB test points V2uv I2u 2 Label the waveforms as V2uv and I2u 3 Capture motor voltage current waveforms at ACB test points Vuv Iu 4 Label the waveforms as Vuv and Iu 5 Save the worksheet as Line and Load Voltage and Current Wavef...

Page 260: ...e 216 SampleWaveforms Sample waveforms recorded on a AFE Drive running under full load condition Ch1 LineVoltage Ch2 Line Current Ch3 MotorVoltage Ch4 Motor Current Sample waveforms recorded on 18 Pulse Drive running at 75 load Ch1 LineVoltage Ch2 Line Current Ch3 MotorVoltage Ch4 Motor Current ...

Page 261: ... refer to the tech note PowerFlex 7000_GEN 78 for details Label the waveforms as BP_Close_Cmd and Actual_Closure Save the worksheet as Bypass Contactor Close Delay Table 17 Oscilloscope Setting Figure 217 SampleWaveforms Ch1 Bypass Contactor Close Command BPC output at ACB J1 12 402 Ch2 Actual Closure of Bypass Contactor using 9V battery across contactor vacuum bottles While simulating a synchrono...

Page 262: ...performing a live synchronous transfer Capture motor voltage at ACB test point Vuv bypass voltage at ACB test point Vuvs Capture and trigger on falling edge of the DC Link current waveform at ACB test point Idc1 Label the waveforms as Vuv Vuvs and Idc1 Save the worksheet as Synch on Motor 01 for example Table 19 Oscilloscope Setting Oscilloscope Time Base Waveform Test Point Waveform Label Ch 1 10...

Page 263: ...Rockwell Automation Publication 7000L UM301F EN P March 2020 263 Commissioning Chapter 4 Figure 219 SampleWaveforms Live SynchronousTransfer Capture 50Hz System Ch1 Idc1 yellow Ch2 Vuv blue Ch3 Vuvs red ...

Page 264: ...264 Rockwell Automation Publication 7000L UM301F EN P March 2020 Chapter 4 Commissioning Notes ...

Page 265: ... 7000L UM301F EN P March 2020 265 Chapter 5 Component Definition and Maintenance Control Cabling Cabinet Components Figure 220 Control and Cabling Cabinet showing LV Control Panel AFE Rectifier version shown LowVoltage Control Panel ...

Page 266: ...20 Chapter 5 Component Definition and Maintenance Figure 221 AFE Control and Cabling Cabinet with LV Control Panel removed Motor Terminals Line Terminals Hall Effect Sensor Voltage Sensing Hall Effect Sensor Surge Arresters Current Transformer Current Transformer ...

Page 267: ...67 Component Definition and Maintenance Chapter 5 Figure 222 18 Pulse Control and Cabling Cabinet with LV Control Panel removed Motor Terminals Transient Suppression Networks Line Terminals Current Transformers Hall Effect Sensor Voltage Sensing Hall Effect Sensor ...

Page 268: ...te 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 thus they must be used to provide a range of input volta...

Page 269: ...ds using the existing hardware to secure the assembly Do not overtorque the connections or you may break the studs 7 Replace ring lugs on terminals Plug in ribbon cables making sure that cables are positioned properly and fitting is secure locking mechanism is engaged 8 For personnel and equipment safety ensure both grounding connections are re connected to the sensing board Figure 223 Sensing Boa...

Page 270: ... transient suppressors used in the module are heavy duty metal oxide varistors or MOVs Varistors are voltage dependent nonlinear resistors They have symmetrical voltage current characteristics similar to back to back connected Zener Diodes The varistor has very high resistance below its voltage rating and appears as an open circuit The leakage current through the device would be very small in this...

Page 271: ...ine which assembly you should have in your case The fuses provide overload protection for the conductors feeding the suppression network and overcurrent protection if a short circuit occurs on the downstream side of the fuse These conductors will normally have a much smaller current carrying capacity than the drive input conductors and thus will not be protected by the drive input fuses The fuses ...

Page 272: ... fuse pull firmly 3 To replace the fuse hold it in position and push firmly until the fuse is seated within the fuse clip Install fuses so that the rating is visible U V W Drive Input Power from Line Terminals Transient Suppression Network Medium Voltage Input Fuses Phase MOV Suppressor Ground MOV Suppressor ATTENTION To prevent electrical shock ensure the main power has been disconnected before w...

Page 273: ...he locations of the connecting links 3 Detach the connecting links by removing the screws 4 Using a screwdriver remove the screws at the base 7 2 kV fuses 5 kV fuses Varistors Location of ground Connecting links Varistors Location for 7 2 kV fuses Location for 5 kV fuses ATTENTION To prevent electrical shock ensure the main power has been disconnected before working on the transient suppression ne...

Page 274: ...for the operation of surge arresters There are 3 types of surge arresters depending on the voltage class of the drive as shown in the table below 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 prob...

Page 275: ...fy 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 incl...

Page 276: ...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 Nm 21ft lb Figure 228 Surge Arresters ATTENTION To prev...

Page 277: ...of the brackets and lift the capacitor out 5 Place the new capacitor and tighten the screws securely 6 Replace the ring lugs and 6 4 mm 1 4 inch hardware See Figure 229 TIP When the surge arrester is disconnected from MV it is possible that a small amount of static charge is retained by the arrester As a precautionary measure install a temporary ground on the line end of the arrester and discharge...

Page 278: ...r 5 Component Definition and Maintenance Figure 229 Capacitor in Grounding Network Figure 230 Location of Ground Filter in C Frame Drive Loosen screws to release capacitor Important Torque on capacitor terminals 3 4 N m 30 lb in Capacitors Reactor Transformer Resistor Bank ...

Page 279: ...mble the new component in the reverse order of disassembly 6 Reattach the leads strictly adhering to the torque requirements outlined in Figure 229 Loosen screws to release capacitors Remove screws for replacing resistor bank Important Torque on capacitor terminals 3 4 Nm 30 lb in maximum Important Torque on resistor bank assembly 1 2 Nm 11 0 lb in maximum ATTENTION To prevent electrical shock ens...

Page 280: ...ct sensor Note the arrow must be oriented as shown in Figure 233 7 Slide the bus bar back into place and secure with the M10 hardware 8 Fasten the ring lugs on the wires back into place in the correct position Do not overtighten or you will break the threaded stud Important Torque on Resistor Bank Assembly 1 2 Nm 11 0 lb in maximum Loosen screws to release capacitors Remove screws for replacing re...

Page 281: ...located in the base of the CT and remove 6 Replace the CT ensuring the proper orientation Fasten the CT securely with the four screws in the base Customer Terminals Hall Effect Sensors TIP Arrows on Hall Effect sensors indicate direction of current flow CustomerTerminals shown for bottom cable entry Customer must remove and re orient terminals if top entry is required ATTENTION To prevent electric...

Page 282: ...ternal 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 for neutral point voltage measurement or other protection diagnostics purposes Depending on the drive configuration the fourth bushing may or may not be connected to circuitry The metal cases of the capacitors are grounded through a stu...

Page 283: ...t 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 specifica...

Page 284: ...nt bracket 7 Reconnect all the power cables and the ground connection These use M14 hardware but should only be tightened to 30 Nm 22 ft lb due to capacitor mechanical constraints You may want to fasten these connections before fully sliding the capacitor into place depending on the available space 8 There are instruction labels on each capacitor detailing how to tighten the terminal connections P...

Page 285: ...and current drawn by the capacitor Repeat the test for all three phases and note down the test voltage and current 8 Now 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 should be within 10 of the capacitor nameplate micro Farad If it is outside this range then the capacitor must be r...

Page 286: ...00V 50Hz test power and have recorded the values of voltage and current for each test as given in the table below Let us calculate the capacitance using the first reading In this case Where f frequency of the applied voltage Similarly you can calculate the capacitance for the remaining two measurements for L2 N and L3 N Phase Neutral L1 N L2 N L3 N TestVoltage 200V 200V 200V Measured Current 1 87A...

Page 287: ...P March 2020 287 Component Definition and Maintenance Chapter 5 Converter Cabinet Components Figure 236 Converter Cabinet Components 4160V AFE shown Ground Bus IsolatedGateDriver Power Supplies IGDPS Inverter Modules Rectifier Modules Coolant Piping ...

Page 288: ...blication 7000L UM301F EN P March 2020 Chapter 5 Component Definition and Maintenance Figure 237 Converter Cabinet Components 6600V AFE shown IsolatedGateDriver Power Supplies IGDPS Ground Bus Inverter Modules Rectifier Modules ...

Page 289: ...ks Clamp Snubber resistors Snubber capacitors Sharing resistors Piping for coolant to flow to each chill block All drives have six PowerCages three rectifiers and three inverter modules The liquid cooled drive has two types of rectifiers the 18 Pulse SCR and the PWM rectifier All inverter modules use SGCTs as semi conductors The size of the PowerCage will vary depending on the system voltage and t...

Page 290: ...s It is important that these boards should not be handled without proper grounding ATTENTION Some circuit boards can be destroyed by static charges Use of damaged circuit boards may also damage related components A grounding wrist strap is recommended for handling sensitive circuit boards Matched Set 2 SGCTs Module Housing Outlet Manifold Clamp Base Matched Set 2 SGCTs Clamp Head Inlet Manifold Ma...

Page 291: ...nected in series to increase the total reverse voltage blocking PIV capacity as seen by the electrical circuit A single SGCT has a PIV rating of 6 5 kV At 4 16 kV 2 SGCTs must be connected in series to provide a net PIV of 13 kV to achieve the necessary design margin Similarly three SGCTs must be connected in series at 6 6 kV The cooling requirements of the SGCT are achieved by placing the SGCT be...

Page 292: ...ot loosen the adjustment nut completely 3 Tighten with a 21 mm 13 16 inch open ended wrench on the adjusting nut upward motion until the indicating washer can be turned by fingers with some resistance IT SHOULD NOT SPIN FREELY ATTENTION To prevent electrical shock ensure the main power has been disconnectedbeforeworkingonthedrive Verifythatallcircuitsarevoltagefree using a hot stick or appropriate...

Page 293: ...yristor SGCT or device with attached circuit board is located within the PowerCage assembly SGCTs must be replaced in matched sets 4160V systems use sets of 2 6600V systems use sets of 3 SGCTs can be removed and replaced without interrupting the cooling fluid path To remove SGCTs the following procedure is to be employed Clamp Head DO NOT ADJUST calibration nut Adjusting Nut used for loosening and...

Page 294: ...cables Exceeding the minimum bend radius 50 mm 2 in of the fiber optic cables may result in damage Adjusting Nut DO NOT ADJUST calibration nut SGCT Retaining Screws Indicating Washer LED 4 Green Solid Green indicates that the Power Supply to the Card is OK LED 3 Green Solid Green indicates that the Gate Cathode resistance is OK LED 2 Yellow LED ON indicates the gate is ON and Flashes alternately w...

Page 295: ...re Figure 244 Replacing the SGCT Brace Angle ATTENTION The fiber optic cables can be damaged if struck or bent sharply The minimum bend radius is 50 mm 2 inches The connector has a locking feature that requires pinching the tab and gently pulling straightout Thecomponentontheprintedcircuitboardshouldbeheld to prevent damage ATTENTION The SGCT can be destroyed or damaged by static charges Personnel...

Page 296: ...cribed in Checking Clamping Pressure on page 292 12 Connect the control power cable and fiber optic cables ensure the bend radius is not exceeded Silicon Controlled Rectifier and SCR Self Powered Gate Driver Board Replacement The method for replacing the Silicon Controlled Rectifier SCR is almost identical to that of the SGCT The one exception is that the SCR and circuit board can be replaced inde...

Page 297: ...brush and then gently wiping the pole face with an industrial wipe so that a thin film remains Examine the pole face before proceeding to ensure that no brush bristles remain ATTENTION The fiber optic cables can be damaged if struck or bent sharply The minimum bend radius is 50 mm 2 inches The connector has a locking feature that requires pinching the tab and gently pulling straightout Thecomponen...

Page 298: ...embly with the 4 plastic clips and use the screws to secure the board to the metal bracket 15 Connect the Gate Cathode phoenix connector to the Gate Driver Board 16 Slide the SCR and SCRGD Board back into place until the mounting bracket makes contact with the chill block Use the Phillips screwdriver to tighten the assembly to the chill block 17 Readjust the clamping load as described in Checking ...

Page 299: ...e drive using the following technique 1 Ensure that power has been disconnected 2 Ensure all pumps have been turned off Allow the system to cool down before servicing any components in the coolant system 3 Remove all SCR SGCT devices and their circuit boards as outlined in Silicon Controlled Rectifier and SCR Self Powered Gate Driver Board Replacement on page 296 and Symmetrical Gate Commutated Th...

Page 300: ... included in spare parts kit and four 4 M10 bolts with a length from 10 to 30 mm for use as plugs in the 3 8 hose not included See Figure 248 M10 bolts must be clean Figure 248 Flow Stopper for Servicing 2 required 6 Insert the 2 clamps per Figure 249 on the 3 4 inch 19 mm silicon hoses to isolate flow between the vertical manifolds and the horizontal manifolds of the converter modules ...

Page 301: ...ed Slide the hose clamp toward the chill block 7 Have a hose plug assembly and a M10 bolt ready Per Figure 250 pull the hose from the upper manifold hose barb and collect the fluid in a container Figure 250 Converter PowerCage Module Service per Step 7 8 Per Figure 251 insert the hose plug on the hose barb of the upper manifold Insert a M10 bolt in the end of the chill block hose Note that there m...

Page 302: ...PowerCage Module Service per Step 8 Repeat this procedure for the lower manifold connection point The chill block can be extracted from the PowerCage per Chill Block Removal and Replacement on page 303 Figure 252 Cooling System Matched Set 2 SGCTs Module Housing Outlet Manifold Clamp Base Matched Set 2 SGCTs Clamp Head Inlet Manifold ...

Page 303: ...acement on page 293 6 Check coolant levels to ensure there is still enough coolant in the system If coolant must be added refer to Fluid Top up on page 341 Chill Block Removal and Replacement Instructions for removing Chill Block assembly 1 Ensure all Power has been disconnected 2 Remove SCR SCGT s and circuit board s outlined in Symmetrical Gate Commutated Thyristor Replacement on page 293 and Si...

Page 304: ...owerCage Ensure that the stabs are aligned with their connectors at the back of the PowerCage This is difficult to see When the stabs are properly aligned and in place the chill block assembly will be seated squarely and the support bracket should be resting on the PowerCage base when positioned correctly ATTENTION The chill block assembly is heavy and it is recommended that two people pull the as...

Page 305: ...ards detachment of cooling system and chill block removal 3 With all the components removed detach the manifold assembly by removing the bolts on the outer flange Carefully lift the PowerCage down placing the front face down Do not overtorque these bolts when replacing the PowerCage 4 When replacing the PowerCage it is important to place the bolts on the outer flange loosely Torque bolts alternate...

Page 306: ...edure is to place one probe of the multi meter on the test point and the other probe on the appropriate chill block to determine the value of the resistor or capacitor Snubber resistors are connected in series with the snubber capacitors Together they form a simple RC snubber that is connected across each semiconductor SCR or SGCT The purpose of the snubber circuit is to reduce the dv dt stress on...

Page 307: ...he sharing resistor and SGCT anode cathode resistance The sharing resistor has a resistance much lower than a good SGCT thus the measurement will be slightly less than the resistance of the sharing resistor A measurement between 60 kΩ and 75 kΩ indicates the SGCT is in good condition and that wiring to the SGCT is correct If the SGCT fails it may be shorted The anode to cathode resistance check wi...

Page 308: ...ower Cage SCRPowerCages To obtain the sharing resistor value disconnect the 2 pole plug of the self powered gate driver board labeled SHARING and SNUBBER on the circuit board The red wire of the plug is the sharing resistor Measure the resistance between the red wire of the plug and the chill block to the left the anode chill block A value of approximately 80 kΩ indicates a healthy sharing resisto...

Page 309: ...mbly Servicing of resistors requires that the chill block be removed from the PowerCage Refer to Chill Block Removal and Replacement on page 303 1 Remove the chill block outlined in Chill Block Removal and Replacement on page 303 2 Note all connections for correct replacement 3 Remove the screws holding the bus bars to the resistor terminals The position of the sharing resistor is common on all dr...

Page 310: ...e pole faces using a small brush and then gently wiping the pole face with an industrial wipe so that a thin film remains Examine the pole face before proceeding to ensure that no brush bristles remain 6 Install the new resistor s on the chill plate and replace the M4 mounting screws 7 When all damaged snubber resistors have been replaced re assemble the bus bars with the original hardware 8 Re co...

Page 311: ...ware on the 17 mm flange side of the replacement capacitor Torque M8 hardware to 7 N m 60 lb in Figure 259 Rear View of 7000L PowerCage 6 Bundle and secure the connecting wires using wire ties 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 Pow...

Page 312: ...alth of the SCR It has the hardware necessary to diagnose the condition of the SCR This status is relayed to the processor via a fail safe light signal transmitted through a fiber optic cable Board Calibration No field calibration is required for this board Test points description TP1 SCR gate output attach oscilloscope between TP1 and TP2 to see gating pulses TP2 SCR cathode output TP3 Common ref...

Page 313: ...ower to temperature sensor board TB2 2 Common connection of positive 20V power supply to temperature sensor board TB3 1 Positive 15V power supply connection for test power used when commissioning drive or testing SPGDB TB3 2 Provides artificial sense voltage signal to allow SPGDB to gate the SCR when in test mode When the appropriate test power cable is used P N 81001 262 51 this input is shorted ...

Page 314: ...P03D6500 SCR to the gate cathode leads of the SPGDB board TB4 1 TB4 2 2 Attach a temperature sensor board to the TB2 1 TB2 2 terminals 3 Apply 15V test power to terminals TB3 1 and TB3 3 TB3 1 is at 15V while TB3 3 is the 15V return Leave TB3 2 open 4 Measure TP4 to TP3 which should be 14 4V 100mV 5 Measure TP5 to TP3 which should be 5 0V 250mV 6 Measure TB2 1 to TB2 2 which should be 14 4V 100mV ...

Page 315: ...e 261 19 Verify that the signal between TP1 and TP2 is as shown in Figure 262 and Figure 263 20 Remove the jumper between TB3 1 and TB3 2 21 Apply a constant fiber optic signal to the OP1 input 22 Apply a 60 Hz 33 duty cycle signal at a 0 to 2V level between the TB1 2 input and COM Verify the signals in Figure 264 and Figure 265 Note that in Figure 265 there should be a 220 μS 20 μS time between t...

Page 316: ...316 Rockwell Automation Publication 7000L UM301F EN P March 2020 Chapter 5 Component Definition and Maintenance Figure 262 SCR gating pulse Figure 263 Expanded SCR gating pulse ...

Page 317: ...l Automation Publication 7000L UM301F EN P March 2020 317 Component Definition and Maintenance Chapter 5 Figure 264 V SenseTrigger to SCR gating pulse Figure 265 Expansion of V SenseTrigger to SCR gating pulse ...

Page 318: ...a resulting loss in light transmission will result in loss in performance The minimum bend radius permitted for the fiber optic cables is 50 mm 2 0 inches When installing the fiber optic cable the colour of the connector at the end of the cable must match the colour of the connector socket on the circuit board Lengths of fiber optic cables used in the product include Duplex Simplex 5 0 meter 5 0 m...

Page 319: ...former and the AC DC power supplies are accessible This is the section where the customer 3 phase power is brought into the drive The DC Link is mounted on the floor beneath the control power section The larger door is interlocked with the rest of the system and cannot be opened unless the MV power is locked out The DC Link is part of the cooling circuit for the PowerFlex 7000L C Frame drive and h...

Page 320: ...eactor does not normally require service To replace the DC Link refer to Figure 267 and complete the following steps 1 Ensure the MV source power to the drive is locked out 2 Drain the coolant from the drive system 3 Lock out the control power 4 Access the DC Link cabinet and remove the cooling connections to the DC Link 5 Disconnect the 4 power connections to the DC Link Remember to note the loca...

Page 321: ...s go to the proper locations You must also ensure that they are routed the same way so that electrical clearances are not compromised The nameplate data must be compared to the old DC Link to ensure that the ratings are appropriate for the drive system Any changes in the nameplate should be noted since the parameters within the drive will need to be changed Liquid Cooled DC Link Reactor Cooling Pi...

Page 322: ...es after control power is interrupted If control power is not restored during the 5 cycles a controlled shutdown will occur Figure 268 illustrates the control power distribution for 6 pulse and PWM drives with integral starter line reactor Figure 268 AFE Line Reactor Drives Figure 269 illustrates the control power distribution for 6 pulse and AFE drives with remote transformer starter or integrate...

Page 323: ...V DC output for the DC DC power supply and the HV IGDPS modules for the SGCTs The input and output voltages are monitored and fail signals are annunciated upon either voltage going below a pre set level Figure 270 AC DC Converter Power Supply Printer Operator Interface Relays DC DC CONVERTER AC DC Converter 56V DC 1000W 1500W 5V LOGIC 15V LOGIC 24V HECS 24V ISOLATORS 24 XIO SENSE CABLE 20V C Hold ...

Page 324: ... of DC output V outputs 49 VDC this output goes from low to high Location The AC DC power supply is located in the low voltage panel in the far right hand section of the drive A typical low voltage compartment is shown in Figure 271 Figure 271 Location of AC DC Pioneer Power Supply on LowVoltage Panel AC DC Power Supplies Pioneer ...

Page 325: ... measurements With the control power on and the output of the AC DC Converter isolated from the drive control adjust the potentiometer until the output equals 56 volts DC 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 it is not possible to maintain 56 V DC the power supply may be f...

Page 326: ...t from the drive 5 Remove the bracket from the failed power supply four M4 screws and nylon shoulder washers 6 Attach bracket to replacement power supply 7 Repeat Steps 5 4 3 2 and 1 in this order to replace the unit see Figure 273 8 Reapply control power and verify voltage levels Figure 273 Replacement of AC DC Power Supply on LowVoltage Panel TIP MakesuretheBlackInsulationisbetweentheAC DCpowers...

Page 327: ...DC DC Power Supply for powering all the drive control components The main drive cooling fan and the AC DC Power Supply that feeds the IGDPS boards are not powered from this UPS The UPS is configured for the AS400 communication protocol and has several status signals that are fed back to the Customer Interface Board to allow the control to respond to various conditions including low batteries loss ...

Page 328: ...old up capacitor on the output of the 300W AC DC Power Supply to maintain the 56VDC in the event of a failure of the power supply UPS Replacement Procedure 1 Ensure Control Power has been isolated and locked out 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 connected to and from the UPS 4 Disco...

Page 329: ...Rockwell Automation Publication 7000L UM301F EN P March 2020 329 Component Definition and Maintenance Chapter 5 Cooling System Figure 275 Generic Cooling System Overview ...

Page 330: ...ted of highly conductive copper machined parts that are silver soldered together The parts are machined to a fine surface finish The copper chill block provides good heat transfer from the electrical device to the chillblock The coolant system is connected to each chill block with flexible 10 mm 3 8 in hose which fits onto stainless steel hose barbs which are part of the chill block assembly Figur...

Page 331: ...lacement Pump Seal Replacement Refer to pump nameplate for manufacturer s model information Typical pump seal replacement information is provided at manufacturers websites Figure 277 Pump Cabinet ATTENTION Do not run the pumpFs withoutcoolant Ensure coolantis present in the system Damage to the pump seals may result V4 V12 V5 P1 P2 V11 ...

Page 332: ... one of the pumps must be running Two pumps run alternately switching from one pump to another after a preset time This switching time is dependent on the Control Program setup A pump may be replaced during drive operation by following the instruction sheet PowerFlex 7000C LIQUID COOLED SYSTEM OPERATION attached to the inside of the pump cabinet door V12 V11 P1 P2 Note V4 andV5 on vertical section...

Page 333: ...foot plate and remove 9 Repair pump as per manufacturers repair procedure supplied with the drive PumpInstallation 1 Isolate power to pump motor wires ensuring no voltage at pump motor leads 2 Install pump and reattach wires to motor 3 Open V1 if provided 4 Open V4 for pump P1 or V5 for pump P2 5 To prime pump carefully unscrew vent plug on top of pump casing Close vent plus when coolant is seen 6...

Page 334: ... inch 50 mm diameter The coolant hose connecting chill blocks to manifolds and Common Mode Chokes or DC Links to piping is made of 10 mm 3 8 EPDM The hose is pushed onto hose barbs of stainless steel or CPVC Hose clamps are used at the hose barbs Non ReturnValves The non return valves NV1 NV2 shown in Figure 279 are ball type valves made from CPVC These can not be changed with the drive on line Al...

Page 335: ...e circulate within the drive As the fluid increases in temperature the valve gradually opens letting a trickle of fluid flow through the heat exchanger The thermostatic element is set to begin opening at 29ºC 85ºF and is fully open at 38ºC 100ºF All flow then travels to the heat exchanger The thermostatic valve keeps the semiconductor devices from getting too cold and it keeps the near room temper...

Page 336: ...d over travel spring can be felt as it is pushed down To determine if the element will close at a specific temperature place the element in a bath of water approximately 3 C 5 F below the start to open temperature This is the number stamped on the element Due to the effect of hysteresis the element will close 3 C 5 F below the start to open temperature Element Replacing Refer to Figure 281 1 Remov...

Page 337: ...The heat exchanger HTX1 is normally a liquid to air unit made of copper tubing and copper headers There are primary and secondary fans to cool the unit The fans are controlled by temperature sensor TS1 shown in Figure 283 A stainless steel liquid to liquid plate type exchanger is also available If the temperature is less than 32 C 90 F the fans will not run The primary fan will start when the temp...

Page 338: ...ses to the warning level Figure 283 Temperature and Conductivity Sensors Temperature Sensor This temperature sensor TS1 shown in Figure 283 triggers the drive to shut down when the fluid temperature entering the converter cabinet is too high This situation could occur if the air cooling of the heat exchanger is cut off due to fan failure plugging of the air paths or failure of the thermostatic val...

Page 339: ...ters and de ionizes coolant at a rate of about 19 L minute 5 gpm Valve V14 may be closed only if the coolant mixture in the drive has a freeze temperature colder than 40 C This allows a decreased flow to 5 3 L minute 1 4 gpm This stream can be isolated for cleaning and maintenance by closing the incoming valve V8 The filter is a 500 micron fine mesh type which can be cleaned many times by rinsing ...

Page 340: ...filters the de ionization cartridge should be replaced Note that if the filters are clogged coolant conductivity will increase even if the de ionization cartridge is still functioning properly The filters and the de ionization cartridge can be changed while the drive is running 1 Close valves V8 and V9 if provided and unscrew the housing see Figure 2 Drain some of the coolant by loosening the drai...

Page 341: ... up of the fluid and the other indicates a very low coolant level LSDL trip and triggers a shut down of the drive De ionized water and chloride free ethylene glycol or a mixture of the two may be added to the reservoir Use the 200 L 55 gal barrel to mix coolant and or to premix the de ionized water and glycol Check the freeze protection concentration with a glycol tester and add fluid accordingly ...

Page 342: ...um Ca 2 and chloride Cl are stripped from rocks and soil by water Also found in water are organic molecules from decaying debris bacteria and microbes that normally grow in water and dissolved ionized gases such as chlorine Cl2 and carbon dioxide CO2 Conductivity is primarily the result of ionized solids and gases in water The other materials in water contribute very little to electric current flo...

Page 343: ...rive During operation the concentration of pure ethylene glycol and de ionized water may change due to fluid leakage or evaporation therefore the freezing point of the coolant may not be correct The following instruction detail the steps required to record and correct the freezing point of the coolant mixture Required items Glycol and battery tester Part No 80025 862 01 De ionized water 19 L 5 gal...

Page 344: ...he first 30 minutes and once the system begins to fill and pressurize you should be constantly inspecting all fittings and connections for drips It is best to have help in checking the inverter and rectifier section and the DC Link cabinet An absorbent cloth is ideal for checking that the coolant is actually leaking and is not just remnants of the repair If a leak is a visible at the threaded join...

Page 345: ...at the flow arrow on pump is in the correct direction Open valve V6 and V7 if provided to pump coolant out Low Voltage Control Section The low voltage control section panel houses all of the control circuit boards relays Operator Interface Terminal DC DC power supply and most other low voltage control components Refer to Figure 287 for a generic representation of a low voltage tub arrangement Figu...

Page 346: ...als is for power dip ride through purposes Upon loss of the 56V input the capacitors C hold up will maintain the voltage level 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 has been designed to provide redundancy for the 5V rail There are two separate 5V outputs each capable of powering the logic boards In t...

Page 347: ...C Not Connected 9 5VA Primary 5V supply before OR ing diode 10 DGND com1 5V 15V Common 11 5VB Secondary 5V supply before OR ing diode 12 DGND com1 5V 15V Common 13 ID0 Power Supply ID Pin 0 14 ID1 Power Supply ID Pin 1 P3 ISOLATOR To Isolator Modules PIN NO LABEL DESCRIPTION ONLY 1 ISOLATOR 24V 1A 24V 1A com4 2 ISOL_COMM com4 0V com4 3 EARTH EARTH P4 PWR To ACB PIN NO LABEL DESCRIPTION ONLY 1 24V_...

Page 348: ...ly Assembly to be removed from the Low Voltage Panel View 1 4 Remove quantity of four M4 P H M S and Nylon Shoulder Washers from the back of the Mounting Plate View 2 5 Replace old DC DC Power Supply with the new one NOTE Make sure the Black Insulation is between the DC DC Power Supply and the Mounting Plate Repeat Steps 4 3 2 1 in this order to replace unit View 2 6 Ensure the ground wire of P4 p...

Page 349: ...rds J2 J3 J4 J5 J6 J7 J8 LINE CURRENT INPUTS MOTOR CURRENT INPUTS DCLINK CURRENT INPUTS GROUND FAULT CMC NEUTRAL CURRENT INPUTS ISOLATED NON ISOLATED ANALOG INPUTS AND NON ISOLATED OUTPUTS J9 J10 AIR PRESS URE INPUTS METER OUTPUTS SPEE D POT INPUT J12 J11 COMMS CONNECTIONS TERMINAL PANEL VIEW J14 J16 DC POWER SUPPLY MONITORING 5V1 5V2 DC BUS DPI INTERFACE J17 COMMS CONNECTIONS DPI SCANPORT J15 J13...

Page 350: ...Chapter 5 Component Definition and Maintenance Drive Processor Module This module contains the control processors It is responsible for all the drive control processing and stores all of the parameters used for the drive control Figure 291 Drive Processor Module DPM ...

Page 351: ...tput Assignable diagnostic test point DPM TP9 ITP2 Digital to Analog output Assignable diagnostic test point DPM TP10 ITP3 Digital to Analog output Assignable diagnostic test point DPM TP7 ITP4 Digital to Analog output Assignable diagnostic test point DPM TP11 RTP4 Digital to Analog output Assignable diagnostic test point DPM TP12 RTP3 Digital to Analog output Assignable diagnostic test point DPM ...

Page 352: ... case you should 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 Instructions to Replace the Drive Processor Module 1 Record all drive setup information using any of the options above if possible 2 Ensure that all medium voltage and control voltage power to the drive is isolated and locked out 3 It is required to first ...

Page 353: ...omatically go into download mode Install firmware in the drive following the guidelines on page 383 11 Program the drive Refer to Technical Data Medium Voltage AC Drive Parameters Publication 7000 TD002_ EN P The parameters should also be saved to NVRAM and then externally to the drive using the options described earlier in this section Figure 292 ACB and DPM Replacement Analog Control Board ACB A...

Page 354: ... 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 DPI communication modules Remote I O terminal interface printers modem and other external communication devices are routed through this board Figure 293 ACB Analog Control Board ...

Page 355: ...OUT1AOUT2 AOUT3 AOUT4 ACB J9 Air pressure inputs AP0 AP1 input fromTSP ACB J10 Meter outputs AOUT5 AOUT6 AOUT7 AOUT8 and Speed Pot input AIN0 ACB J11 Communication connections printer outputs ACB J12 Communication connections PanelView ACB J13 DC power supplies XIO 24V 15V 24V 5V ACB J14 DC power supply monitoring 5V1 5V2 DC BUS ACB J15 DC ABUS 56V output monitoring in UPS option ACB J16 DPI inter...

Page 356: ...2w Line current CT2W TP17 Vzs2 Zero Sequence Generation Line side VZS2 TP18 Vn1 Line Filter CAP NeutralVoltage for Bridge 1 LFCN1 TP19 V2_pk AC over voltage detection for 2UVW TP20 Vdcr1 Line side DCLINKVoltage for Bridge 1 VLDC1 TP21 Idc1 DCLINK current HECSDC1 TP22 Vvws LineVoltage Synchronous Feedback VSBC TP23 V3uv LineVoltage Feedback 3UV TP24 V3vw LineVoltage Feedback 3VW TP25 V3wu LineVolta...

Page 357: ... AC OverVoltage Detection set point for 2UVW 3UVW TP56 AGND Analog ground TP57 AGND Analog ground TP58 AGND Analog ground TP59 AGND Analog ground TP60 5V 5V DC power supply TP61 15V 15V DC power supply TP62 15V 15V DC power supply TP63 24V 24V DC power supply TP64 24V 24V DC power supply TP65 24VCOM 24V common TP66 DGND Digital ground TP67 AGND Analog ground TP68 AP1 Analog Control Inputs Air pres...

Page 358: ...o the ACB The pin numbers listed on the following pages refer to IFM pin numbers Figure 294 Interface Module IFM Analog Inputs and Outputs The PowerFlex 7000 C Frame offers one isolated process current loop transmitter and three isolated process current loop receivers embedded into the control These are accessible on the ACB TP80 BPIS Bypass Isolating Switch TP81 BPCS Bypass Contactor Status TP82 ...

Page 359: ...sistance up to 625 ohms Figure 295 shows a block diagram of the transmitter Figure 295 Process Loop Transmitter Block Diagram 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 above The type of shielded cable used ...

Page 360: ...ss Outputs The drive supplies four non isolated 10 0 10 V outputs for customer use These outputs can drive loads with impedances as low as 600 ohms These outputs are all referenced to the Drive AGND and therefore should be isolated if they are required to drive outside the PowerFlex C frame enclosure Figure 297 Non Isolated Configurable Analog Outputs on ACB 4 8 12 3 7 11 ŀ X1 U1 FPGA DSP 1 st I P...

Page 361: ...op of the DPM by removing the 4 screws 3 Use static strap before removing any connectors 4 Remove the connectors J4 J11 and J12 on DPM after proper identification and marking if necessary Use the electrical drawing as the reference Remove the 4 screws holding it on the standoffs above the ACB 5 Gently remove the DPM mounted on the four 34 pin connectors 6 Remove the screws holding encoder interfac...

Page 362: ...ders 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 MX3EncoderInterface This encoder interface allows the drive to be connected to a standard Quadrature Encoder The 20B ENC encoder interface provides 3 optically isolated differential encoder inputs for A and B phases as w...

Page 363: ...erface The Universal Encoder Interface allows the drive to be connected to an absolute position encoder or a standard quadrature encoder and also provides the option for dual or redundant quadrature encoders The Universal Encoder Interface provides 12 single ended or 6 differential optically isolated inputs as well as a 12V 3Watt galvanically isolated encoder power source When using absolute encod...

Page 364: ...ved Dual Quadrature Encoder Option without Redundancy Installed Removed Removed Dual Quadrature Encoder Option with Redundancy Installed Removed Installed Single Quadrature Option CDSEL DQUAD must be removed for Redundancy Removed Installed Installed Gray Code Absolute Encoder LowTrue Removed Installed Removed Natural Binary Absolute Encoder LowTrue Removed Removed Installed Gray Code Absolute Enc...

Page 365: ...ctory come defaulted to single quadrature encoder configuration 1 For dual encoder configurations the primary encoder is wired to pins 1 to 7 on the 1492 IFM20 module See Table 26 11 B2 Redundant or Dual ENC E8 12 B2 Redundantor Dual ENC E9 13 Z2 Redundant or Dual ENC E10 14 Z2 Redundant or Dual ENC E11 15 ENC_COM ENC_COM 16 ENC_COM ENC_COM 17 ENC_COM ENC_COM 18 ENC PWR 12V ENC PWR 12V 19 ENC PWR ...

Page 366: ...will also generate pseudo quadrature differential signals including a zero position mark 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 se...

Page 367: ...nds 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 should assume it to be High True In the case of a 10bit High True encoder the zero position is represented by 0000000000 Whereas a Low True encoder the zero position is 1111111111 On the Universal Encoder Inte...

Page 368: ...an option in software to assign each XIO a specific function General IO External IO or Liquid Cooling Figure 301 XIO Board The standard drive comes with one XIO board additional boards up to 5 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 6 XIO cards However at this time the drive only supports the use of addresses 1 to 3 de...

Page 369: ... the old board needs to be removed from the assembly and the new board installed 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 Apply Low Voltage power and complete a System Test and Medium Voltage tests to ensure the new board functions properly LED Status Description Solid Red Board Failure Alternate Fla...

Page 370: ...erface Board The OIB boards are mounted directly on the Optical Interface Base Board OIBB using 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 using two ribbon cables to connect to J11 and J12 Each OIB board can handle the F...

Page 371: ...the fiber optic cables Use the electrical drawing for reference 3 Using your static strap disconnect all of the connections It may be necessary to remove the 60 core cable connectors on the Optical interface base and the ground connection for access to the standoffs 4 Remove the OIB board from the OIBB There are four standoffs that snap into place on the OIB and they need to be carefully handled w...

Page 372: ...372 Rockwell Automation Publication 7000L UM301F EN P March 2020 Chapter 5 Component Definition and Maintenance Figure 303 OIB Replacement Mounting Plate Accessible Optical Interface Boards OIB ...

Page 373: ...interconnections between the OIBs and the DPM It connects to either J11 or J12 on the DPM via a 60 Conductor shielded ribbon cable The drain wire for this cable must be attached to the screw terminal J8 The remaining connectors on the board complete the electrical connection of the installed OIBs to the DPM Each OIB can support from one to three OIBs Figure 304 Optical Interface Base Board OIBB ...

Page 374: ...ing Command Signal TP10 DIAG_4 OIB A RX5 Diagnostic Feedback TP11 CMD_4 OIB A TX5 Firing Command Signal TP12 DIAG_5 OIB A RX6 Diagnostic Feedback TP13 CMD_5 OIB A TX6 Firing Command Signal TP14 TFB_A OIB ATemperature Feedback Signal TP15 GND Ground Reference forTP1 TP14 TP16 DIAG_6 OIB B RX1 Diagnostic Feedback TP17 CMD_6 OIB B TX1 Firing Command Signal TP18 DIAG_7 OIB B RX2 Diagnostic Feedback TP...

Page 375: ...a download mode In the download mode the system is waiting to receive a firmware download via the serial data port J4 on the DPM The system may also be placed into download mode from the Drive Terminal This can only be accomplished if you have obtained a minimum of ADVANCED level access Once that has been obtained from the main screen selecting UTILITY TRANSFER SYSTEM will place the drive into dow...

Page 376: ...assword required and you should have Advanced level access Figure 305 Advanced Screen Hit F10 to Exit and then F5 for NVRAM Press F5 for SAVE and F8 for YES The parameters should now be saved to NVRAM Press F10 again to EXIT Figure 306 Save to NVRAM To save to the Operator Interface Terminal and Flash Card Press F2 UTILITY F7 TRANSFER and F4 PARAMETERS You should now be on the following screen ...

Page 377: ...ert the card in the slot on the terminal It can only go in one way Then press F4 DRV CRD Saving to the card means that you will have to choose a file name Use the Up and Down arrows to select the character and then use the Right arrow to go to the next character Press the Enter key when finished Figure 308 Transfer pending Press F8 for YES and the parameters will be transferred to the card Press F...

Page 378: ...ure the drive is stopped and the E Stop is pressed This is just a precaution as all versions of firmware 7 xxx and later will not allow you to attempt a download while running Figure 310 Current Access Advanced This time press F9 for SYSTEM and a screen will appear telling you that you are in download mode and to recycle control power once the download is complete There are two status LEDs D9 and ...

Page 379: ... is 1 005 then only D9 will be flashing and D11 will stay solid But if the bootcode is 1 005 then both LEDs will be flashing After putting the drive in download mode the following is the display on the drive terminal Figure 311 System in Download Mode If you press any Key after this message the PanelView will show Communication Error Connect your PC to the DPM data port J4 Locate the PowerFlex 700...

Page 380: ... following screen Figure 312 Modules Available for DownloadWindow The DPM are preloaded with Bootcode and select the Firmware by clicking in the checkbox against Firmware and click OK This will start the process of the downloading of firmware attempting connection to the drive The following screen is displayed Figure 313 FORGE Download Utility ...

Page 381: ...majority of the parameters that were stored in the Operator Interface or other external means can still be used but there may be things such as new parameters changed scaling on an existing parameter or added functionality to existing parameters that may have to be addressed To reload the parameters from the Operator Interface once again obtain ADVANCED level access Then follow the same steps to g...

Page 382: ...dcopy This will provide a record of the new settings Setting ElapsedTime When you replace the existing DPM board in the drive with a new board the operating hours counter will start from zero Therefore if you want to keep the actual operating hours in the drive you can restore them by running a utility program Sethobb exe which is usually supplied with the firmware package A copy of the program ca...

Page 383: ...memory card Apply power to the terminal The terminal on power up will sense new firmware and download it from the card You will see a series of codes on the screen 2 20 21 and then the drive application firmware will start The process may take several minutes When the download is finished remove the card from the Terminal If you leave the card in the terminal it will reload the firmware each time ...

Page 384: ...ownloadTerminal Firmware As soon as control power is applied to the Terminal the firmware download will start automatically 6 Once the firmware download is complete the message Download successfully completed will appear on your laptop screen Press any key to close the DOSFWDL program 7 Remove the serial cable from the laptop and connect it to ACB board port J12 The Terminal will now start communi...

Page 385: ...til you print upload the trend data into your laptop Print the Alarm Queue as well so that you know which alarm or fault condition was detected by the drive Trace The Read Only Parameter which is assigned to a particular list The item linked to Trace 1 is used as the trigger value There are 16 traces in total although not all have to be active Rate The time delay between sample periods Any value b...

Page 386: ...key on the main screen to display Diagnostics screen as shown in the picture below Figure 317 Diagnostics screen 2 Press F8 D_SETUP The display will change to Diagnostics Setup screen as shown in the picture below Figure 318 Diagnostics Setup 3 With Trace 1 selected press Enter key as shown in the picture below Figure 319 Trace 1 ...

Page 387: ...by Alphabetical order press F7 key to move to the letters screen from there you can search the parameter by highlighting the first letter of the parameter and then pressing the Enter key iii by entering the parameter linear number press F7 and then F5 for the Code In the following example we will select the parameter by using a Linear number i e we will enter the Code For this follow the steps out...

Page 388: ... have entered 569 and then press Enter key Once you press the Enter key the parameter description will appears on the screen as shown in the picture below Figure 323 Parameter Description 8 Press Enter key again The display will change to the Diagnostics Setup screen and the desired parameter gets assigned to Trace 1 Now press the down arrow key to move the cursor to Trace 2 and repeat steps 3 8 a...

Page 389: ...ine on the screen will toggle between C and S The letter C stands for Continuous and S stands for Single shot Select S for single shot 11 Press F2 CONDITION key The cursor will move to the equal sign This defines the trigger condition Press up or down arrow keys to select sign as the trigger condition for our example Figure 325 Trigger Condition 12 Press F3 DATA key The cursor moves to the data fi...

Page 390: ... 327 Rate Option 14 Press F5 POST key and enter 10 this is the percentage of post trigger samples and then press the Enter key Figure 328 Post Option 15 Now press F10 EXIT key to exit to Diagnostic screen On the Diagnostics screen verify that the Status is Running which means the Diagnostic Trend is ready and will capture the data whenever the trigger condition is satisfied If the Status shows Sto...

Page 391: ...be prompted to select a file to store this data Therefore you need to open an empty Notepad file and then save that file on your pc before uploading the data from the drive The following example illustrates the method to create an empty txt file example1 txt and upload or print the data from drive into laptop Required Laptop with Windows HyperTerminal program A null modem cable with a 9 pin female...

Page 392: ...pter 5 Component Definition and Maintenance Figure 330 Null modem Cable Creating an empty notepad txt file 1 Run NotePad Program Start Program Accessories Notepad Figure 331 Opening Notepad 2 From the File menu select Save As as shown below Figure 332 Saving in Notepad ...

Page 393: ...r a filename for instance example txt in the field next to File name and select the directory from the dropdown list next to Save in at the top of the window In this example the selected directory is C temp Now click on Save button Figure 333 Enter Filename in Notepad 4 An empty notepad file has been created So now close the Notepad program ...

Page 394: ...ection 1 Run HyperTerminal program 2 On the Connection Description window enter a name for instance Parameters for the New Connection under the Name field as shown below and then click OK Figure 334 Connection Description 3 Select COM1 from the dropdown list next to Connect Using and then click OK as shown below Figure 335 Connect Using Com1 ...

Page 395: ...ear Set the port settings as shown below and then click OK Figure 336 COM1 Properties 5 Close the HyperTerminal program The following message box will appear Figure 337 Disconnect from HyperTerminal 6 Click Yes At this point you will be prompted to save the session Figure 338 Save Session Parameters 7 Click Yes to terminate the HyperTerminal program ...

Page 396: ...the data from the drive 1 Connect a null modem cable between your computer s serial port and the serial port J11 on the Analog Control Board ACB 2 Restart HyperTerminal program On the Connection Description window click Cancel Figure 339 Connection Description New Connection 3 From the File menu click Open At the Open dialog box locate the HyperTerminal connection you just created in step 2 e g Pa...

Page 397: ...t 5 The Capture Text dialog box will appear Click on Browse button and search the file Example txt that you created in step 1 above Figure 342 Open Text File 6 Click Start HyperTerminal now acts as a dummy printer and is waiting for the information to be transmitted from the drive to the laptop 7 From the drive Terminal hit F3 PRINT at the main screen as shown below Figure 343 Terminal Screen ...

Page 398: ...able selections are Drive Setup for complete setup which include Parameters Fault Masks and Revisions Trend Data for analyzing the drive trending Variables snapshot of real time data while the drive running 8 The last step is to stop the communication between your laptop and the drive and close the file Example txt At your laptop click on Transfer menu and select Stop option under Capture Text as ...

Page 399: ...es the data of 8 most recent faults is always available The data can be retrieved for analysis The method of retrieving Control Data is explained below Required Laptop with Windows HyperTerminal program A null modem cable with a 9 pin female connector for the laptop serial port and a 9 pin male connector for Drive Processor Module DPM data port J4 A serial cable with pins 2 3 swapped at one end wi...

Page 400: ...Run HyperTerminal program 2 At the Connection Description window enter any name for new connection under the Name field as shown below and then click OK Figure 347 Enter Name for New Connection 3 The Connect to window will appear as shown below Select COM1 from the dropdown list next to Connect using and then click OK Figure 348 Connect toWindow ...

Page 401: ...ill appear Set the port settings as shown below and then click OK Figure 349 Select Port Settings 5 Close HyperTerminal program Click Yes to disconnect and Yes again to save Printing Control Data 1 Restart HyperTerminal program 2 At the Connection Description window as shown below click Cancel Figure 350 Connection Description New Connection ...

Page 402: ... this example and then click Open 4 Press the ENTER key This should bring up the following options menu in the HyperTerminal window Figure 351 HyperTerminalWindow 5 From the above menu select the desired option by pressing the corresponding number to upload print the data To upload Control Data select option 4 6 After selecting the desired option you need to start the transfer by selecting Receive...

Page 403: ...n the HyperTerminal program and unplug the null modem cable from the DPM board Environmental Considerations Hazardous Materials Environmental protection is a top priority for Rockwell Automation The facility that manufactured this medium voltage drive operates an environmental management system that is certified to the requirements of ISO 14001 As part of this system this product was reviewed in d...

Page 404: ...and must not be disposed of with general landfill refuse LithiumBatteries This drive contains four small lithium batteries Three are mounted to printed circuit boards and one is located in the PanelView user interface Each battery contains less than 0 05g of lithium which is fully sealed within the batteries Shipping and handling of these batteries is typically not restricted by environmental regu...

Page 405: ...itions the time between maintenance should not exceed three months Annual Maintenance should be completed during scheduled downtime Refer to Tool Parts Information Requirements on page 410 at the end of this section for a list of documentation and materials needed to properly complete the preventive maintenance documents Operational Maintenance The PowerFlex 7000 C frame drive uses a mixture of de...

Page 406: ...poration Significant change in coolant levels could be sign of leak in the drive or heat exchanger and should be checked thoroughly Percentage of Glycol in coolant should also be checked periodically Since Water will evaporate faster than Glycol the percentage could change as the liquid evaporates The heat transfer quality changes as the percentages changes A correct Glycol content should be maint...

Page 407: ...or contamination Clean all contaminated components using a vacuum cleaner DO NOT use a blower and wipe clean components where appropriate Check for any visual physical evidence of damage and or degradation of components in the medium voltage compartments inverter rectifier cabling DC Link contactor load break harmonic filter etc This includes main cooling fan power devices heatsinks circuit boards...

Page 408: ...ks No Medium Voltage Apply 3 Phase Control power to the PowerFlex 7000 drive and test power to all of the vacuum contactors input output and bypass in the system verifying all contactors can close and seal in Refer to Publication 1502 UM050_ EN P for a detailed description of all contactor maintenance Verify all single phase cooling fans for operation This includes the cooling fans in the AC DC Po...

Page 409: ...ions Recommendation for critical spare parts which should be stocked in plant to reduce production downtime Gather information on all spare parts on site and compare that with factory recommended critical spares to evaluate whether levels are sufficient Contact MV Spare Parts group for more information Vacuum Bottle Integrity Testing using a Vacuum Checker or AC Hipot Refer to Publications 1502 UM...

Page 410: ...te Dependent Additional Tasks Investigation Depends on Nature of the Problem Informal Training Refresher 2 0 hours Spare Parts Analysis 1 0 hours Vacuum Bottle Integrity Check 3 0 hours Final Report 3 0 hours indicates that the time may not be required depending on the nature of the maintenance and the condition of the drive system These times are only estimations Tool Parts Information Requiremen...

Page 411: ...x Driver Documentation PowerFlex 7000 User Manual Publication 7000 UM151_ EN P PowerFlex Technical Data Parameters Troubleshooting Publication 7000 TD002_ EN P PowerFlex MV Drives Transportation and Handling Procedures Publication 7000 IN008_EN P MV 400A Vacuum Contactor Series D User Manual Publication 1502 UM050_ EN P MV 400A Vacuum Contactor Series E User Manual Publication 1502 UM052_ EN P Dri...

Page 412: ...412 Rockwell Automation Publication 7000L UM301F EN P March 2020 Chapter 5 Component Definition and Maintenance ...

Page 413: ...5 C 2001 3000 m 30 C 3001 4000 m 27 5 C 4001 5000 m 25 C G Heavy Duty 0 1000 m Altitude Maximum 35 C Ambient J Normal Duty 0 1000 m Altitude Maximum 50 C Ambient L Heavy Duty 0 1000 m Altitude Maximum 50 C Ambient N Normal Duty 0 1000 m Altitude Maximum 20 C Ambient Z Custom Configuration Contact Factory c Drive Current Rating 1 1 Not all amperages are available at all ambient altitude configurati...

Page 414: ...is supplied from separate external source 2400 208 60 AHD 480 ABD 600 ACD 3300 230 50 CPD 380 CND 400 CKD 4160 230 50 EPD 380 END 400 EKD 208 60 EHD 480 EBD 600 ECD 6600 230 50 JPD 380 JND 400 JKD 208 60 JHD 480 JBD 600 JCD f Rectifier Configuration Line ImpedanceType Code Description RPDTD AFE Rectifier with Integral Line Reactor and Direct to Drive DC Link RPTX AFE Rectifier with provision for c...

Page 415: ... Rating Code There are five different codes that define service duty and altitude in the drive catalog number per the table on page 413 For example Catalog number 7000 A105DEHD R18TX has a continuous current rating of 105 amps with a normal duty service rating up to 1000 meters altitude Catalog number 7000 B105DEHD R18TX has a continuous rating of 105 amps with a normal duty service rating up to 5...

Page 416: ...ation is based on of motor synchronous speed Tachometer to be mounted on the AC machine Operational 15 V DC Power Supply mounted in drive to power the encoder as a standard option with the encoder feed back card Customer is responsible for providing and mounting of encoder Sleeve bearing motors require the encoder to have an axial movement tolerance Recommended encoders are shaft mounting type Mag...

Page 417: ...nimum Tach PPR RecommendedTach PPR 3600 1024 1024 3000 1024 1024 1800 1024 2048 1500 1024 2048 1200 2048 2048 1000 2048 2048 900 2048 4096 720 4096 4096 600 4096 4096 450 4096 8192 360 8192 8192 300 8192 8192 Standard Control Mode 3600 600 3000 600 1800 1024 1500 1024 1200 2048 1000 2048 900 2048 720 2048 600 2048 Parameter 7000TorqueCapability without Encoder of Motor RatedTorque 7000Torque Capab...

Page 418: ...mit An electronic method of limiting the maximum torque available from the motor The software in a drive typically sets the torque limit to 150 of motor rated torque Table 33 Typical Application LoadTorque Profiles 1 Application LoadTorque Profile LoadTorque as Percent of Full Load DriveTorque Required Drive Service Duty Rating EncoderRequiredfor Extra Starting Torque Break away Accelerating Peak ...

Page 419: ...avy Yes Solids CT 175 125 175 Contact factory Yes PULPER VT 40 100 150 Contact factory No PUMPS Centrifugal discharge open VT 40 100 100 Normal No Oil field Flywheel CT 150 200 200 Contact Factory Yes Propeller VT 40 100 100 Normal No Fan Pump VT 40 100 100 Norma No Reciprocating Positive Displacement CT 175 30 175 Contact factory Yes Screw type started dry VT 75 30 100 Normal No Screwtype primed ...

Page 420: ...420 Rockwell Automation Publication 7000L UM301F EN P March 2020 Appendix A Catalog Number Explanation Notes ...

Page 421: ...cified the following values of torque are to be used in maintaining the equipment Diameter Pitch Material Torque N m Torque lb ft M2 5 0 45 Steel 0 43 0 32 M4 0 70 Steel 1 8 1 3 M5 0 80 Steel 3 4 2 5 M6 1 00 Steel 6 0 4 4 M8 1 25 Steel 14 11 M10 1 50 Steel 29 21 M12 1 75 Steel 50 37 M14 2 00 Steel 81 60 1 4 20 Steel S A E 5 12 9 0 3 8 16 Steel S A E 2 27 20 ...

Page 422: ...422 Rockwell Automation Publication 7000L UM301F EN P March 2020 Appendix B Torque Requirements forThreaded Fasteners Notes ...

Page 423: ...e meggered This procedure must be performed with due care as the hazards to drive exist if the safety precautions in the procedure are not followed This is due to the fact the megger procedure applies high voltage to ground all the control boards in the drive have been grounded and if not isolated they will have high potential applied to them causing immediate damage Meggering the PowerFlex 7000 I...

Page 424: ...o the electrical diagrams provided with the equipment to assist in determining the points which need to be disconnected Voltage Sensing Boards VSB Output Grounding Network OGN Voltage Sensing Boards Remove all ground connections from all of the VSBs in the drive This has to be done at the screw terminals on the VSB rather than the ground bus There are two grounds on each board marked GND 1 and GND...

Page 425: ...n Network A path to ground exists through the TSN network as it has a ground connection to dissipate high energy surges in normal operation If this ground connection is not isolated the Megger test will indicate a high leakage current reading through this path falsely indicating a problem in the drive To isolate this ground path all fuses on the TSN must be removed before proceeding with the Megge...

Page 426: ...r capacitors at the output of the drive The meggering procedure must follow a systematic segmentation of electrical components to isolate and locate a ground fault 5 Reconnecting Connections between Power Circuit and Low Voltage Control Reconnect the ribbon cables J1 J2 and J3 in all the VSBs Do not cross the cable connections Mixing the feedback cables may result in serious damage to the drive 6 ...

Page 427: ... torque down to 3 4 Nm 30 lb in Exceeding the torque rating of this connection may result in damage to the capacitor Transient Suppression Network Re install the fuses on the TSN ATTENTION Failuretoconnectbothgroundconnectionsonthevoltage sensing board will result in high potential in the LowVoltage cabinet within the drive which will result in damage to the drive control and possible injury or de...

Page 428: ...428 Rockwell Automation Publication 7000L UM301F EN P March 2020 Appendix C Meggering Notes ...

Page 429: ...e case or inspecting the heatsinks for debris clogging the air flow path M Maintenance This indicates a maintenance task that is outside the normalpreventativemaintenancetasks andcaninclude theinductance testing of Line Reactors DC Links or the full testing of an isolation transformer R Replacement This indicates that the component has reached its mean operational life and should be replaced to de...

Page 430: ...R I I R I Battery Module UPS 7 I I I I R I I I I R Connections LowVoltageTerminal Connections Plug in Connections I I I I I I I I I I MediumVoltage Connections I I I I I I I I I I Chillblock Bolted Connections I I I I I I I I I I MediumVoltage Connections Rectifier 3 I 3 I 3 I 3 MediumVoltage Connections Inverter 5 I Enhancements Firmware Rv Rv Rv Hardware Rv Rv Rv Operational Conditions Parameter...

Page 431: ...Battery Module UPS 7 I I I I R I I I I I Connections LowVoltageTerminal Connections Plug in Connections I I I I I I I I I I MediumVoltage Connections I I I I I I I I I I Chillblock Bolted Connections I I I I I I I I I I MediumVoltage Connections Rectifier 3 I 3 I 3 MediumVoltage Connections Inverter 5 Enhancements Firmware Rv Rv Rv Hardware Rv Rv Rv Operational Conditions Parameters I Rv I I Rv I ...

Page 432: ...432 Rockwell Automation Publication 7000L UM301F EN P March 2020 Appendix D Preventative Maintenance Schedule Notes ...

Page 433: ......

Page 434: ...codetorouteyourcalldirectlytoatechnicalsupport engineer http www rockwellautomation com global support direct dial page Literature Library Installation Instructions Manuals Brochures and Technical Data http www rockwellautomation com global literature library overview page Product Compatibility and Download Center PCDC Get help determining how products interact check features and capabilities and ...

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