PowerFlex® 7000 Medium Voltage AC Drive Air-Cooled (‘B’ Frame) – Classic Control Bulletin 7000 User Manual
Important User Information Read this document and the documents listed in the Additional Resources section about installation, configuration, and operation of this equipment before you install, configure, operate, or maintain this product. Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws, and standards.
Table of Contents Preface Overview Who should use this Manual .................................................... P-1 What is not in this Manual ....................................................... P-1 Manual Conventions ................................................................ P-1 General Precautions ................................................................. P-2 Who to call for Commissioning ...............................................
ii Table of Contents Chapter 2 Drive Installation (cont.) IEC Component and Device Designations ............................ 2-29 Power Wiring Selection ......................................................... 2-29 Cable Insulation .............................................................. 2-30 Wire Group Numbers ...................................................... 2-32 Power Cabling Access ...........................................................
Table of Contents Chapter 3 7000 “B” Frame Operator Interface (cont.) How to: Obtain Help ..................................................................... 3-12 Related Topics .......................................................... 3-12 Help On Help ............................................................ 3-13 Modify Operator Interface Operation (Utility) ............... 3-14 Changing Backlight Delay ........................................ 3-14 Changing Contrast .............................
iv Table of Contents Chapter 3 Operator Interface (cont.) Chapter 4 Commissioning 7000-UM150I-EN-P – June 2013 Starting the Trace ............................................................ 3-58 Flash Memory Transfers ................................................. 3-59 Format Flash Card .................................................... 3-61 View a Directory ....................................................... 3-62 Select a filename ................................................
Table of Contents Chapter 4 7000 “B” Frame Commissioning (cont.) Drive Application Review ..................................................... 4-13 Rockwell Automation Drive Line-up Drawings ............. 4-13 Electrical System One-line Diagram ............................... 4-14 Verify One-line Diagram on Site .................................... 4-14 Inspect Process ................................................................ 4-14 Safety Tests ....................................................
vi Table of Contents Chapter 4 Commissioning (cont.) 7000-UM150I-EN-P – June 2013 Control Power Transformer (CPT) ................................. 4-42 AC/DC Converter (PS1) .................................................. 4-43 DC/DC Converter (PS2) .................................................. 4-43 SGCT Power Supplies (IGDPS) ..................................... 4-46 Board LEDs ..................................................................... 4-47 Gating Tests ............................
Table of Contents Chapter 5 Functional Description Introduction .............................................................................. 5-1 Description of Operation ......................................................... 5-2 Speed Command ...................................................................... 5-3 Speed Reference ..................................................................... 5-4 Speed Control .........................................................................
viii Table of Contents Chapter 6 Component Definition Checking Clamping Pressure ................................................ 6-25 and Maintenance Clamping Pressure Adjustment ...................................... 6-25 (cont.) Temperature Sensing ............................................................. 6-26 Symmetrical Gate Commutated Thyristor Replacement ....... 6-28 Silicon Controlled Rectifier and SCR Self-Powered Gate Driver Board Replacement .....................................
Table of Contents Chapter 6 7000 “B” Frame Component Definition and Maintenance (cont.) Terminal/Connections Descriptions ................................ 6-69 Replacement Procedure ................................................... 6-71 UPS Option ............................................................................ 6-72 UPS Replacement Procedure .......................................... 6-73 Low Voltage Control Section ................................................ 6-74 DC/DC Power Supply .
x Table of Contents Chapter 6 Component Definition and Maintenance (cont.) Preventive Maintenance Check List .................................... 6-126 Operational Maintenance ..................................................... 6-126 Annual Maintenance ............................................................ 6-127 Initial Information Gathering ..................................... 6-127 Physical Checks ......................................................... 6-127 Control Power Checks ...........
Table of Contents 7000 “B” Frame 7000-UM150I-EN-P – June 2013 xi
Preface Overview Who Should Use This Manual This manual is intended for use by personnel familiar with medium voltage and variable speed solid-state drive equipment. The manual contains material that will allow the user to operate, maintain, and troubleshoot the drive system. What Is Not in this Manual This manual is designed to provide only general information on the PowerFlex 7000 drive. Therefore customer specific topics are not presented.
P-2 Preface Both of the above could indicate: • • • • A possible trouble spot Tell what causes the trouble spot Give the result of an improper action Tell the reader how to avoid trouble SHOCK HAZARD General Precautions 7000-UM150I-EN-P – June 2013 This symbol alerts the user to a potential electrical shock hazard that exists on a component or printed circuit board. ATTENTION This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies.
Preface Who to Call for Commissioning P-3 The Medium Voltage Support provides customer support for our product line. They may be contacted at 519-740-4747 and 519-740-4746. The support they offer includes, but is not limited to: – – – – 7000 “B” Frame Quoting and Managing Product On-site Start-ups. Ongoing Preventative Maintenance Planning for our products. Parts Management and on site inventory agreements. Customer in-house and on-site product training.
P-4 Preface 7000-UM150I-EN-P – June 2013 7000 “B” Frame
Chapter 1 Overview of Drive Introduction The PowerFlex™ 7000 represents the third generation of medium voltage drives at Rockwell Automation. The PowerFlex 7000 medium voltage AC drive is part of the PowerFlex family of AC drive products. The Allen-Bradley PowerFlex™ family of Drives incorporates leading-edge technology, embedded communications, and significant commonality across multiple platforms, networks, operator interface programming and hardware.
1-2 Overview of Drive The PowerFlex 7000 has the additional benefit of inherent regenerative braking for applications where the load is overhauling the motor, or where high inertia loads need to be slowed down quickly. Symmetrical Gate Commutated Thyristors (SGCTs) are used for machine converter switches. Silicon-controlled rectifiers (SCRs) (for 6/18 pulse) or SGCTs (for AFE rectifiers) are used for the line converter switches. LINE CONVERTER DC LINK MACHINE CONVERTER Figure 1.
Overview of Drive 1-3 The 6-pulse rectifier can be used in conjunction with a rectifier duty isolation transformer as shown or with an AC line reactor. A rectifier duty isolation transformer is required when the drive is being applied to existing or retrofit motors or when the supply voltage is higher than the drive rated voltage. (Refer to Specification 80001-005, Rectifier Duty Transformers for more details on transformer requirements and features.
1-4 Overview of Drive Sample line current and voltage are also shown in Figure 1.3. 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. a) b) Figure 1.
Overview of Drive 1-5 The small integral AC line reactor (see Fig. 1.4) provides additional filtering and current limiting features to a line side short circuit fault. The rectifier input current, the rectifier terminal voltage and the line current and voltage waveforms are shown in Figure 1.4. 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.
1-6 Overview of Drive “Direct-to-Drive” Technology (cont.) Rather than use an Isolation Transformer, the “Direct-to-Drive” Active Front End uses the semi-conductor switching pattern to reduce line current harmonics to levels that comply to the world’s most accepted harmonic standards. The Active Front End is the best method of harmonic cancellation because it does not suffer from complexity and high component count like multi-pulse drive topologies do.
Overview of Drive Motor Compatibility 1-7 The PowerFlex 7000 achieves near sinusoidal current and voltage waveforms to the motor, resulting in no significant additional heating or insulation stress. Temperature rise in the motor connected to the VFD is typically 3 °C (37 °F) higher compared to across the line operation. Dv/dt in the voltage waveform is less than 10 volts / microsecond. The peak voltage that the motor insulation will see is the rated motor RMS voltage divided by 0.707.
1-8 Overview of Drive SGCT Features and Benefits An SGCT is a Symmetrical Gate Commutated Thyristor with an integrated gate drive. Positioning the gate drive close to the SGCT as shown in Figure 1.6, creates a low inductance path that provides more efficient and uniform gating of the device. As a result, the device is better suited than a conventional GTO to handle the fluctuating levels of voltage and current while it is switching on and off during gating.
Overview of Drive Specifications Description Power Rating (Air Cooled) Motor Type Input Voltage Rating Input Voltage Tolerance Voltage Sag Power Loss Ride-Through Input Protection Input Frequency Input Short-circuit Current Withstand 2400 V – 6600 V Basic Impulse Level Power Bus Design Ground Bus Customer Control Wire Way Input Power Circuit Protection Input Impedance Device Output Voltage Inverter Design Inverter Switch Inverter Switch Failure Mode Inverter Switch Failure Rate (FIT) Inverter Switch C
1-10 Overview of Drive Specifications (cont.
Overview of Drive Description Control Power External I/O IEC Interlocking Corrosion Protection Ambient Temperature 208-575 V, 3 Phase, 50/60 Hz 16 Digital Inputs, 16 Digital Outputs 50-60 Hz AC or DC 120-240 V – 1 mA 50-60 Hz AC or DC 30-260 V – 1 Amp (1) Isolated, (1) Non-isolated, 4-20 mA or 0-10 V (250 ohm) • Analog input 12 Bit (4-20 mA) • Internal parameter 32 Bit resolution • Serial Communication 16 Bit resolution (.
1-12 Overview of Drive Simplified Electrical Drawings DC LINK L+ M+ LINE CONVERTER ISTX 4U (Z1) 4V (Z2) 4W (Z3) MACHINE CONVERTER SGCTs SCRs U (T1) 3U (Y1) 3V (Y2) 3W (Y3) V (T2) W (T3) 2U (X1) 2V (X2) 2W (X3) L- M- 2400 Volt – 18 Pulse LINE CONVERTER L+ DC LINK M+ SCRs MACHINE CONVERTER SGCTs 2U (X1) U (T1) 2V (X2) V (T2) 2W (X3) W (T3) L- M- 2400 Volt – 6 Pulse DC LINK LINE CONVERTER L+ M+ SGCTs MACHINE CONVERTER SGCTs 2U (X1) U (T1) 2V (X2) V (T2) 2W (X3) W (T3) L-
Overview of Drive DC LINK L+ M+ LINE CONVERTER ISTX 4U (Z1) 4V (Z2) 4W (Z3) 1-13 MACHINE CONVERTER SGCTs SCRs U (T1) 3U (Y1) 3V (Y2) 3W (Y3) V (T2) W (T3) 2U (X1) 2V (X2) 2W (X3) L- M- 3300 / 4160 Volt – 18 Pulse LINE CONVERTER L+ DC LINK M+ SCRs MACHINE CONVERTER SGCTs 2U (X1) U (T1) 2V (X2) V (T2) 2W (X3) W (T3) L- M- 3300 / 4160 Volt – 6 Pulse LINE CONVERTER L+ DC LINK M+ SGCTs MACHINE CONVERTER SGCTs 2U (X1) U (T1) 2V (X2) V (T2) 2W (X3) W (T3) L- M- 3300 / 41
1-14 Overview of Drive Simplified Electrical Drawings (cont.
Overview of Drive 1-15 Control Overview AC Line reactor Line filter cap Line Converter Machine Converter DC Link inductor Motor filter cap Motor Motor voltage Source Motor current Line current Machine Protection Alpha line Line Protection Flux angle Faults Alpha machine Sync Transfer Speed command Tach feedback Slip freq Idc Feedback Current Control Iy command Faults Ix command Line voltage Machine side feedback and gating Line side feedback and gating Motor Model Stator freq Speed
1-16 Overview of Drive Control Hardware The control hardware includes identical drive control boards for machine and line side complete with up to three fiber optic interface boards (depending on the voltage and number of switching devices), signal conditioning boards for machine and line side, customer interface board and external I/O board.
Overview of Drive 1-17 Operator Interface Figure 1.9 – PowerFlex 7000 Operator interface terminal The operator interface terminal features a 16-line, 40-character, pixel based LCD display that makes text and graphics easy to read. Bar chart meters are configurable for common process variables including speed, voltage and load. Everything is user friendly about the PowerFlex 7000 operator interface terminal including the greeting on the opening screen.
1-18 Overview of Drive 7000-UM150I-EN-P – June 2013 7000 “B” Frame
Chapter 2 Drive Installation Safety and Codes Unpacking and Inspection ATTENTION The Canadian Electrical Code (CEC), National Electrical Code (NEC), or local codes outline provisions for safely installing electrical equipment. Installation MUST comply with specifications regarding wire type, conductor sizes, branch circuit protection and disconnect devices. Failure to do so may result in personal injury and/or equipment damage.
2-2 Drive Installation 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 handling. Refer to “General Handling Procedures, publication 7000-IN002_-EN-P for a more detailed description.
Drive Installation 2-3 Overhead Lifting 1. Attach rigging to the lifting angles on the top of the cabinetry. ATTENTION Ensure that the load rating of the lifting device and rigging is sufficient to safely raise the drive. Refer to shipping weights on the packing slip enclosed with the shipment. 2. Do not pass ropes or cables through the support holes in the lifting angles. Use slings with safety hooks or shackles. 3.
2-4 Drive Installation Rod or Pipe Rollers This method is only suitable when there are no inclines and the drive is being moved on one floor level. 1. Boards 50.8 mm 152.4 mm (2 in. 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.
Drive Installation 2-5 Storage If it is necessary to store the drive, be certain to store in a clean dry dust free area. Storage temperature should be maintained between -20°C and 65°C (-4°F and 149°F). If storage temperature fluctuates or if humidity exceeds 85%, space heaters should be used to prevent condensation. The drive should be stored in a heated building having adequate air circulation. The drive must never be stored outdoors.
2-6 Drive Installation (F) The room in which the equipment is located must be large enough to accommodate the thermal losses of the equipment since air conditioning may be required; the ambient temperature must not exceed that for which the equipment is rated. The heat created by the drive is directly proportional to the power of the motor being driven and the efficiency of equipment within the room. If thermal load data is required contact the Rockwell Automation Sales office.
Drive Installation Installation 2-7 When the drive has been placed at its installation area, the lag bolts that fasten the shipping skid to the drive must be removed. The drive is moved off the shipping skid and the shipping skid can be discarded. Position the drive in its desired location. Verify that the drive is on a level surface and that the position of the drive will be vertical when the anchor bolts are installed.
2-8 Drive Installation Installation (cont.) If the indicators show that no shock was attained, full inspection and verification in accordance with the Commissioning process outlined in Chapter 4 is still essential. Red Plastic Housing 51 mm (2.0) Window Area appears Blue if subjected to shock 21 mm (0.8) Figure 2.3 – Shock Indicator Installation of Exhaust Air Hood On the top of the cabinet with the cooling fan, a sheet metal exhaust hood is to be installed.
Drive Installation 2-9 Flat plate (Quantity = 1) Exhaust hood panels (Quantity = 2) M6 thread forming screws (Quantity = 20) Figure 2.4 – Fan Hood Assembly Locate the exhaust hood on top of the cabinet per Figure 2.5 and reinstall 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 plate. Tighten all hardware.
2-10 Drive Installation Installation (cont.) Assembled Exhaust Hood M6 Screw (Quantity = 12) Ensure notch orientation to sides Figure 2.
Drive Installation Cabinet Layout and Dimensional Drawings of Drive 2-11 The following drawings are generic in nature and will not accurately detail your drive. They are provided here to give you a general overview of a typical drive. The Dimensional Drawings are order specific and will show the information outlined. The dimension drawing provides important information for the installation of the equipment.
2-12 Drive Installation PowerFlex 7000 Dimensional Drawings Note: Contact Factory for Seismic Mounting Information.
Drive Installation 2-13 Note: Contact Factory for Seismic Mounting Information.
2-14 Drive Installation Note: Contact Factory for Seismic Mounting Information.
Drive Installation 2-15 Note: Contact Factory for Seismic Mounting Information.
2-16 Drive Installation Note: Contact Factory for Seismic Mounting Information.
Drive Installation 2-17 Note: Contact Factory for Seismic Mounting Information.
2-18 Drive Installation Note: Contact Factory for Seismic Mounting Information.
Drive Installation 2-19 Note: Contact Factory for Seismic Mounting Information.
2-20 Drive Installation Note: Contact Factory for Seismic Mounting Information.
Drive Installation 2-21 Note: Contact Factory for Seismic Mounting Information.
2-22 Drive Installation Note: Contact Factory for Seismic Mounting Information.
Drive Installation 2-23 Note: Contact Factory for Seismic Mounting Information.
2-24 Drive Installation Control/Cabling Cabinet Shows the medium voltage area located in the control/cabling cabinet behind the low voltage compartment and with barriers removed. Note: The control/cabling cabinet comes in two different configurations: • 18-pulse rectifier (Figure 2.6) • 6-pulse/PWM (Figure 2.7) Major Components The following four diagrams are presented to show what the typical layout of each cabinet will be for the PowerFlex 7000 Drive.
Drive Installation 2-25 Hall Effect Sensors Sensing Boards Grounding Network (For use with Isolation Transformers) or Ground Filter (For use with Line Reactors) Power Terminals Current Transformers Motor Filter Capacitors Transient Suppression Network Figure 2.
2-26 Drive Installation Line Terminals Line Capacitors Motor Terminals Zero Sequence Current Transformer (if supplied) Line Reactor Motor Filter Capacitors Figure 2.
Drive Installation 2-27 Ground bus Differential Pressure sensor Inverter Modules Gate driver power supplies Rectifier Modules Figure 2.
2-28 Drive Installation Ground Bus AC/AC Converters “Hold up” Capacitor Fan Power Disconnect 3-phase fan power transformer DC Link Inductor (Barrier removed) Fan Power Cable Entry (bottom) Figure 2.
Drive Installation IEC Component and Device Designations 2-29 PowerFlex 7000 electrical drawings use conventions that are based on IEC (International Electrotechnical Commission) standards, while remaining basically compatible with North American ANSI (American National Standards Institute) standards. The symbols used to identify components on the drawings are international and a full listing of the symbols is given as part of each PowerFlex 7000 elementary drawing (ED) set.
2-30 Drive Installation Power Wiring Selection (cont.) Cable Insulation The cable insulation requirements for the PowerFlex 7000 drive are given in the tables below. 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 specified in the following tables.
Drive Installation 2-31 The following table identifies general wire categories that will be encountered when installing the PowerFlex 7000 Drive. Each category has an associated wire group number that is used in the following sections to identify the wire to be used. Application and signal examples along with the recommended type of cable for each group are provided. A matrix providing the recommended minimum spacing between different wire groups run in the same tray or separate conduit is also provided.
2-32 Drive Installation Power Wiring Selection (cont.) The wire sizes must be selected individually, observing all applicable safety and CEC or IEC / NEC regulations. The minimum permissible wire size does not necessarily result in the best operating economy. The minimum recommended size for the wires between the drive and the motor is the same as that used if a main voltage source connection to the motor was used. The distance between the drive and motor may affect the size of the conductors used.
Drive Installation 2-33 Latch Key interlock Handle Terminal blocks – Customer (TBC) Low voltage door Figure 2.
2-34 Drive Installation Low Voltage Compartment (Open) Power Terminals Low Voltage Door Figure 2.
Drive Installation Power Connections 2-35 The installer must ensure that interlocking with the upstream power source has been installed and is functioning. The installer is responsible for ensuring that power connections are made to the equipment in accordance with local electrical codes. The drive is supplied with provision for cable lugs.
2-36 Drive Installation 2314 [91.12] 900.0 [35.43] Figure 2.
Drive Installation Terminals U, V, W behind 2U, 2V, 2W 2-37 834.0 [32.84] 1417.2 [55.80] 1480.6 [58.19] 897.4 [35.27] 303.2 [11.92] 423.9 [16.66] 544.5 [21.40] 65.0 [2.56] 77.5 [3.05] 339.9 [13.36] 77.5 [3.05] 590.0 [23.19] 991.0 [38.95] Section X-X Figure 2.
2-38 Drive Installation The installer is responsible for ensuring that power connections are made with appropriate torque. (Refer to Appendix B "Torque Requirements" in back of manual.) The drive is supplied with provision for grounding of cable shields and stress cones near the power terminals. Power and Control Wiring Drive line-ups (i.e. Drive and Input Starter) which are delivered in two or more sections, for ease of handling, will require that the power and control wiring be re-connected.
Drive Installation 2-39 Information regarding termination of customer cables Customer termination assemblies can accommodate either top or bottom customer cable entry. The assemblies as provided are for bottom cable entry. 4-hole insulator Lug pad shown with bottom cable entry orientation Bolts M10 bus connection hardware Customer supplied lugs 4 lugs per phase maximum Figure 2.
2-40 Drive Installation Grounding Practices The purpose of grounding is to: • provide for the safety of personnel • limit dangerous voltages on exposed parts with respect to ground • facilitate proper over current device operation under ground fault conditions, and • provide for electrical interference suppression Generally, the means used for external grounding of equipment should be in accordance with the Canadian Electrical Code (CEC), C22.
Drive Installation 2-41 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 the power cables and/or conduit. The conduit or cable armor should be bonded to ground at both ends.
2-42 Drive Installation Grounding Practices (cont.) Grounding Requirements and Grounding Specification for Customers and Power Integrators An external ground must be attached to the main ground bus. The grounding means must comply with applicable local codes and standards.
Drive Installation Interlocking 2-43 Access to the medium voltage areas of the drive is restricted by the use of key interlocking for safety. At installation the key interlocking is set up so that access to the medium voltage compartments of the equipment can only be made when the upstream power is locked in the off position. Additionally, the key interlocking prohibits the upstream power being applied until the medium voltage drive’s access doors have been closed and locked shut.
2-44 Drive Installation 7000-UM150I-EN-P – June 2013 7000 “B” Frame
Chapter 3 Operator Interface Chapter Objectives This chapter describes how you use the operator interface to modify and obtain information contained within the drive. In this chapter you will learn how to: Modify information associated with the initial drive setup. View: View & Reset Alarm Conditions. Request printouts of the information in the drive. Perform diagnostic trending. Modify the operation of the operator interface. - drive parameters, - drive status.
3-2 Operator Interface PowerFlex Operator interface – References to the operator interface refer to the product consisting of the PanelView 550 interface hardware and the unique software contained within it, which allows it to function with the Medium Voltage Drive. Editing Field – An area of a screen that is displayed in reverse video. When the field is in this state, data may be entered into it via the keypad.
Operator Interface Overview 3-3 The operator interface used on the PowerFlex 7000 Medium Voltage Drive is that of the PanelView 550 terminal (Figure 3.1). This terminal however does not behave as a PanelView, as only the hardware for the operator interface has been utilized. The PanelView software has been replaced with unique software to tailor it to the requirements of the Medium Voltage Drive, and its faceplate has been modified (Figure 3.1). 4 3 1 2 Figure 3.
3-4 Operator Interface Even though the upper row of Softkeys (i.e. F1-F5) may not be shown on some displays, the F1-HELP key is always active. (F2-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.
Operator Interface 3-5 While entering a value, the value may be edited using the [backspace] key. This key will remove the right most digit (or decimal point or negative). The help screen uses 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.
3-6 Operator Interface The upper left-hand corner contains the name of the screen (i.e. SELECT GROUP:). Knowing the name of the screen will assist you in the orientation of the menu system. On some screens to the right of the screen name, will be the name of the selected item from the previous screen as shown in Figure 3.3. Some screens have more than one page associated with them.
Operator Interface 3-7 Accessing/Writing to Drive When first powered up, the operator interface knows very little about the information in the drive. As each screen is activated, the operator interface requests information from the drive, which it will store within the operator interface for future reference. When the operator interface requests information from the drive, a window is used to display a message "Accessing Drive ...".
3-8 Operator Interface Figure 3.4 – Communications Error Figure 3.5 – Communications Error Language Changing When the language used by the drive changes, (either via the operator interface or an external device), the operator interface must do considerable work. The database strings are all invalidated, the character set for the server is changed and all strings used by the operator interface are linked to the new language. During this possibly lengthy process, the “Language Changing ...
Operator Interface 3-9 The operations for these latter keys will not be explained within the description of individual screen operations. They are explained here 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.
3-10 Operator Interface b) Obtaining Drive Database - During this phase, the database of information about the drive is obtained from the drive. Obtaining the database at this point in time is optional and may be aborted by pressing any key on the operator interface. Obtaining the entire database does however speed up subsequent operations since relevant portions of the database do not have to be obtained.
Operator Interface Top Level Menu 3-11 This screen (Figure 3.6) represents the main menu from which all other screens (and the operations which they perform) are activated. To activate an operation, simply press the function key corresponding to the 'Softkey' shown on the screen. A screen for that operation will be displayed. Refer to the section entitled "How To:" for information about the various operations which may be performed.
3-12 Operator Interface How To: The following sections describe how to perform the various operations on the drive, using the operator interface. 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.
Operator Interface 3-13 Press the [backspace] key to return to the previous level of help, (i.e. the previous related topic. To exit help completely press [F10] to return to the screen from which help was called. Figure 3.8 – Help on Related Topic (Softkey) Help on Help The previous sections described how you could access help for a particular screen, by pressing the [F1] key while on that screen. This also applies while in any of the help screens.
3-14 Operator Interface 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 the revision levels of all software in the drive line-up.
Operator Interface 3-15 To change the duration of the delay, press the [F2] key. The current backlight delay will be shown in reverse video (Figure 3.11). The value can be adjusted from 0 to 60 minutes. 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 10 minutes.
3-16 Operator Interface Figure 3.12 – Utility Contrast Setting Time 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 3.13). 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 of 10 units.
Operator Interface 3-17 Setting Date The calendar setting controls the date stamp that the drive uses on the information contained on the alarm summary screen. To change the date, press the [F4] key. The year position of the calendar will be in reverse video (Figure 3.14). 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 of 10 units.
3-18 Operator Interface Figure 3.15 – Utility Meter To change the tag attach to a meter, use the [cursor up] and [cursor down] keys to highlight the desired meter and press the [enter] key. (If nothing happens then you have not gained the required access to make changes.) Press the [F8] key in order to gain access and refer to the section entitled Enter/Modify an Access Level . This will begin the selection process of a tag as described in the section entitled "Select a Parameter".
Operator Interface 3-19 Figure 3.17 – Edit the Text When editing is complete, the screen will appear as in Figure 3.18. Figure 3.18 – Editing 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 3.15. The changes made do not take affect until you press [F10] and exit the screen.
3-20 Operator Interface Viewing Revision Levels For the purpose of maintenance or upgrading of software, the revision levels of all the software contained in the terminal and the drive may be viewed. To access this screen, press the [F9] key. A screen typical of Figure 3.
Operator Interface 3-21 Figure 3.21 – Edit the Drive Name Figure 3.22 – Editing Completed 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 drive. In order to transfer information from the two forms of memory, press the [F7] key.
3-22 Operator Interface The next level is 'Basic'. This level and all levels above it allow changes to be made to any parameter that can be viewed. The number of parameters viewable increases from the previous level. This level will be sufficient for configuring and maintaining the drive for the majority of applications. The last level intended for normal operation is the 'Advanced' level. From this level, the drive can be configured in its entirety.
Operator Interface 3-23 Figure 3.23 – Selecting a Group Figure 3.24 – Selecting a Member of a Group From the SELECT GROUP screen (Figure 3.23), 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 wish to select but do not know what group it belongs to or are unsure of the full name, this method of selection may be appropriate. Selecting via a name is initiated from the SELECT GROUP screen (Figure 3.23) by pressing the [F7] key.
3-24 Operator Interface All tags which begin with that letter, and are appropriate for the operation on which the selection is being performed, will be displayed as in Figure 3.26. 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.
Operator Interface 3-25 Use the data entry keys [0]-[9] to enter the desired code on the SELECT CODE screen (Figure 3.27). The entered code may be edited using the [backspace] key. Press the [enter] key. Figure 3.27 – 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 3.28). This allows you to verify that this was the tag that you intended to select with the code before proceeding.
3-26 Operator Interface When the [enter] key is pressed for a valid tag code (i.e. Figure 3.28) the selected tag will be used to continue the operation for which the selection process was being used if that tag is appropriate for the operation. For example: if you are performing a parameter modification operation, but have selected a read-only parameter tag code, you will be unable to exit the screen with this read-only parameter.
Operator Interface 3-27 The screen shown in Figure 3.31 is typical of all screens using the edit text operation. All screens have the F3, F4 and F5 keys in common (if applicable). Once in the 'editing field' all operations are performed on the character in reverse video. Pressing the [cursor left] and [cursor right] keys will move to the next character position in the string. Pressing the [cursor up] and [cursor down] keys will cycle through the characters contained in a set, each time the key is pressed.
3-28 Operator Interface Configure the Drive In order to tailor the drive to your motor and application, a number of elements must be defined in the drive. The section describes how you will set or 'configure' these elements of the drive, via this operator interface. You will learn how to: Change a parameter setting. Assign a parameter to an Analog Port. Selectively enable or disable (i.e. Mask) certain faults. Define your own faults attached to external inputs.
Operator Interface 3-29 The screen shown in Figure 3.32 is accessible from within a number of screens where the Access Level affects the operation of subsequent operations, such as: 1) [F10] key on the Top Level Menu, 2) [F8] key on the Modify Parameter screen, 3) [F8] key on the Setup Screen, 4) [F8] key on the Transfer Screen, 5) [F8] key on the Diagnostic Setup screen. Figure 3.32 – Access Screen The Current Access level is shown.
3-30 Operator Interface Figure 3.34 – Access Level Changed When the desired operations have been completed, the operator interface should be placed back to the 'Monitor' level in order to protect against unauthorized modifications. From this screen press the [F8] key. The level will change back to 'Monitor' as shown in Figure 3.32. The default value for the password (PIN) of the 'Basic' and 'Advanced' levels is zero (0), or simply pressing the [enter] key.
Operator Interface 3-31 Figure 3.36 – PIN Change Completed At the end of the operation you will see a status as shown in either Figures 3.36, 3.37 or 3.38 depending on whether you successfully changed the PIN, incorrectly entered the existing PIN or incorrectly verified the new PIN. Figure 3.37 – Invalid PIN Figure 3.38 – Invalid PIN Verification If you were not successful in changing the password, simply start over again by typing in the current password value.
3-32 Operator Interface Drive Setup This section describes how to: • select an alternate language • enter data to a drive parameter • assign a tag to an analog port • enable and disable a fault via a mask • assign text to be associated with optional external fault inputs • re-enter Setup Wizard • configure the XIO link • define the tags to be accessible by a PLC. You will access the "SETUP" screen from the Top Level Menu by pressing the [F8] key.
Operator Interface 3-33 Figure 3.40 – Basic Access Level Language Selection The drive is capable of supporting multiple languages. The operator interface supports these languages via language modules which must initially be loaded via the flash card (refer to the section Flash Memory Transfers). To select an alternate language, press the [F9] key on the SETUP screen. The screen will show all language modules currently loaded as in Figure 3.41. Associated with each language is a module revision level.
3-34 Operator Interface Modify Parameters To change a parameter, Use the up/down arrow keys on the SETUP screen to select the 'Parameters' option and press the [enter] key. This will begin the selection process of a parameter as described in the section entitled "Select a Parameter". The selection process to change a parameter can also be initiated while displaying the members of a parameter group on the DISPLAY screen (Figure 3.68) by pressing the [F7] key.
Operator Interface 3-35 Figure 3.43 – Modify Numerical Value To be allowed to make changes to the parameter, the operator 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 for further information on the operation to change the level.
3-36 Operator Interface Enumerated Value When the parameter is an enumerated value, the MODIFY PARAMETER screen typical of Figure 3.44 will be displayed. This screen shows: • the name of the parameter for which you are make the changes (i.e. Operating Mode) • the tag code for the parameter (i.e. 4) • the actual value of the parameter contained in the drive. Figure 3.44 – Modify Enumerated Value Figure 3.
Operator Interface 3-37 Use the up/down cursor keys to scroll onto these additional options. Press the [enter] key to accept the new value as shown in Figure 3.47. Figure 3.46 – Option List Viewed on Multiple Pages Figure 3.47 – Modification Completed The new 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.
3-38 Operator Interface Figure 3.48 – Modify Bit Encoded Value To be allowed to make changes to the parameter, the operator 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 for further information on the operation to change the level.
Operator Interface 3-39 Figure 3.49 – Analog Setup This will begin the selection process of a tag as described in the section entitled "Select a Parameter". 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.
3-40 Operator Interface Figure 3.50 – Fault Screen Figure 3.51 – Fault Mask OFF Figures 3.50 and 3.51 show all fault masks regardless of their current state. The fault masks can be viewed according to their state by pressing the [F7] key on the FAULTS SETUP screen. This will display the FAULTS OVERVIEW screen, typical of Figures 3.52 and 3.53. Figure 3.
Operator Interface 3-41 Figure 3.53 – Fault Overview, Enabled The state of the fault masks which you are currently viewing is defined to the right of the screen name, i.e. FAULTS OVERVIEW: DISABLED or FAULTS OVERVIEW: ENABLED. To change the state of fault masks currently displayed, press the [F7]. Each press of the [F7] key will toggle the screen to show the masks in the other state.
3-42 Operator Interface Figure 3.55 – AC O/V Now Enabled The changes to the fault masks do not take affect 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 3.56). Figure 3.
Operator Interface 3-43 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 to gain access). The first character position of the string will be in reverse video as shown in Figure 3.58.
3-44 Operator Interface These are shown on separate screens. The type of PLC word being viewed is defined to the 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.
Operator Interface 3-45 This will begin the selection process of a tag as described in the section entitled "Select a Parameter ". When selecting a tag for the output words, only parameters will be allowed. Both parameters and read-only parameters are allowed for the selection of input words. When you have completed the selection process, the selected tag will be assigned to the link. To remove an assignment to the highlighted link, press the [delete] (Backspace) key.
3-46 Operator Interface Figure 3.62 – Message Prompt Screen Figure 3.63 – NVRAM Screen Store/Retrieve Configuration (NVRAM) To access the memory functions, press [F5] on the Top Level Menu. Within this screen it is possible to perform three operations on the memory of the drive. To perform these operations you must have the proper access to the drive. Refer to the section entitled Enter/Modify an Access Level . Initialize The drive contains a default set of parameters and setup information.
Operator Interface 3-47 Figure 3.64 – Initialize Operation Save The changes that you have made to the drive data must be saved if you do not want to lose the data when the drive is powered off. To save the changes, press the [F5] key (Figure 3.65). Figure 3.65 – Save Operation To confirm the operation, press the [F8] key to proceed, or the [F9] key to abort. Saving the data will overwrite the previously stored data in the NVRAM.
3-48 Operator Interface Figure 3.66 – Load Operation To confirm the operation, press the [F8] key to proceed, or the [F9] key to abort. Loading the data will overwrite the data currently being used by the drive. Display Parameters The parameters of the drive can be displayed, continually showing the value contained in the drive. From the Top Level Menu, press the [F4] key. The DISPLAY GROUP screen of Figure 3.67 is displayed. The screen shows one or more pages of groups that can be displayed.
Operator Interface 3-49 Figure 3.69 – Bit Encoded Parameter Figure 3.70 – Bit Description for Local Outputs The DISPLAY screen, typical of Figure 3.68, is displayed. The screen shows the name of the group being displayed to the right of the screen name (“FEATURE SELECT”). One or more pages of the members in the group are displayed along with the value for this tag in the drive and its unit of measurement. Values that are bit encoded will show a hex value for the parameter value.
3-50 Operator Interface 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 DISPLAY GROUP screen. Refer to "Message Prompting" for further details. Custom Group From the DISPLAY GROUP screen (Figure 3.67) you can select a group which you have custom defined by pressing the [F7] key.
Operator Interface View Drive Status 3-51 The status of the drive is viewed by pressing the [F7] key from the Top Level Menu. This screen, shown in Figure 3.73, constantly displays the latest status of the drive. Figure 3.73 – Status Screen View & Reset Alarms All drive faults and warnings are logged to their respective queues. Collectively the faults and warnings are referred to as "Alarms". When a new alarm occurs, the F6 key on any screen will begin to flash in reverse video.
3-52 Operator Interface 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 Warning queues. If some faults still exist, they will return as new faults. Faults and Warnings are stored into separate queues. Both work similar, thus only the fault queue will be discussed. To access the fault queue, press the [F9] softkey from the ALARM SUMMARY screen. A screen typical of Figure 3.75 will be shown.
Operator Interface 3-53 Figure 3.77 – No Alarm Help Request Printouts When the drive contains the optional printer, you can obtain hard copies of the data that you are able to view on the terminal. The printouts are requested from the PRINTER screen. Press [F3] while displaying the Top Level Menu. The screen typical of Figure 3.78 is displayed. It shows the current status of the printer (A-B part #80025-290-01) and the type of reports that are available.
3-54 Operator Interface Perform Diagnostic Trending The diagnostic trending operation of screens allows you to capture the relationships of a number of parameters over a period of time. Within this operation you will: Define the Parameters to which the Trend Apply Define the Trigger Condition to Begin the Trend Define the Sampling Rate and position of the Trigger View the results of the Trend You will access the Diagnostic Trend operation from the Top Level Menu by pressing the [F9] key.
Operator Interface 3-55 Figure 3.80 – Diagnostic Setup Figure 3.81 – Assign A Trace From this screen, the tags to be monitored are assigned to a trace. The tag which you assign to the first trace 'Trace 1' is used as the trigger parameter. By default, when assigning a tag to Trace 1, the trigger value (i.e. data) will be set to the tag's minimum value and the trigger condition will be 'equal to'. A tag must be assigned to Trace 1 before the trigger value or condition can be set.
3-56 Operator Interface This will begin the selection process of a tag as described in the section entitled "Select a Parameter". When you have completed the selection process, the selected tag will be assigned to the trace, as in Figure 3.81. To remove a tag from the highlighted trace, press the [delete] (Backspace) key. Setting the Trigger Once you have assigned a tag to Trace 1, you may proceed to set the trigger value.
Operator Interface 3-57 The value (data) is set 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.
3-58 Operator Interface Starting the Trace 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 may cancel all the changes made after coming to the screen by pressing the [F7] key. When you exit the screen, the trend is started and the screen such as Figure 3.83 will show the trigger condition and the status. Pressing the [F7] key on the DIAGNOSTICS screen may also start the trend. Figure 3.83 – Diagnostic Armed Figure 3.
Operator Interface 3-59 Figure 3.85 – Diagnostic Stopped Figure 3.86 – View the Trend Buffer(s) A screen such as Figure 3.86 will be shown. Upon initial entry, the screen will be positioned to the trigger point, shown by the "T ->". To view data either side of the trigger point, press the [F8] and [F9] keys. Changes made to the diagnostic list setup are not permanent unless they are saved to the NVRAM in the drive. Upon exiting the DIAGNOSTICS screen (Figure 3.
3-60 Operator Interface - 28F010 - 28F020 - 28F008SA - 28F016SA. These chips are used in the following memory cards available from Rockwell Automation: 2711-NM11 2711-NM24 2711-NM12 2711-NM28 2711-NM14. 2711-NM216 This section describes how you will transfer information between these two forms of flash memory and the drive. You will learn how to: • Format a flash card. • Look at the directory of files on a flash card containing the DOS file format.
Operator Interface 3-61 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. Formatting erases all data on the card and creates a DOS file structure. To format a card press the [F2] key on the TRANSFER screen.
3-62 Operator Interface 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 3.89 will be shown. Figure 3.89 – Typical Directory Any screen or operation that requires a filename to be entered or picked from the directory uses this DIRECTORY screen. It is always obtainable from the [F7] key on any applicable screen.
Operator Interface 3-63 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 shown in Figure 3.90. Figure 3.90 – Typical File Selection An existing filename can be used as a basis for the new filename by first selecting that filename. Press the [F2] key. The filename can now be edited. Refer to the section entitled “Edit Text” for further details.
3-64 Operator Interface When the filename has been obtained, the TRANSFER: PROGRAM screen such as that in Figure 3.91 will be displayed, showing the filename, indicating the operation you are about to perform and showing the current status of the operation. Figure 3.91 – Load New Firmware The screen will then ask you to confirm the operation. Press the [F8] key to proceed, or the [F9] key to abort. Performing a DOWNLOAD FIRMWARE operation will overwrite the existing firmware that is currently running.
Operator Interface 3-65 WARNING: Any time the operator interface is powered up with a flash card inserted which contains a valid firmware *.FMW file, the operator interface will attempt to load new firmware (note item ‘a’ above). For this reason, it is not advisable to leave a memory card containing a firmware file in the operator interface, after the firmware has been downloaded. Parameter Transfers The parameters used by the drive are stored within the drive itself.
3-66 Operator Interface Upload to Operator Interface The parameters are read from the drive and stored in the operator interface by pressing the [F5] key. The screen will appear as in Figure 3.93, indicating the operation you are about to perform. The screen will then ask you to confirm the operation. Press the [F8] key to proceed, or the [F9] key to abort. Performing a “DRIVE TO MEMORY” transfer will overwrite any previous parameters stored within the operator interface. Figure 3.
Operator Interface 3-67 Figure 3.94 – Transfer File Parameters The screen will then ask you to confirm the operation. Press the [F8] key to proceed, or the [F9] key to abort. Pressing the [F4] key may 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.
3-68 Operator Interface a) First Line: – a revision number followed by a semi-colon (;). Number is not important. – the date followed by a semi-colon, i.e. 01/01/1996. Date is not important. – the time followed by a semi-colon, i.e. 12:01:01. Time is not important. b) Remaining Lines: – 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. i.e.
Operator Interface 3-69 Figure 3.96 – Transfer Language Module The screen will then ask you to confirm the operation. Press the [F8] key to proceed, or the [F9] key to 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.
3-70 Operator Interface Advanced Screen Operations A number of advanced functions have been incorporated into the operator interface. These operations are not required to operate the drive. They are meant as service tools for trained technicians and have been included here only for completeness. All operations are accessed via a two key sequence. Communications Statistics The screen, depicted in Figure 3.
Operator Interface 3-71 To reset the above counters, press the [F8] key. The BUFFERS show the current contents (in hexadecimal) of the Transmit (TX) and Receive (RX) 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.
3-72 Operator Interface Pressing the [F7] key changes the format of the displayed data. When data is shown as a mixture, a particular value is displayed based on the priority defined above, (control characters is highest). The RX row displays data received by the operator interface. The TX row displays the data transmitted by the operator interface. Print Screen The print screen operation allows a screen dump of the operator interface's display.
Operator Interface 3-73 To change the segment and/or offset being viewed, press the [F7] key. A display similar to Figure 3.102 will be shown. Each successive press of the [F7] key toggles between highlighting the segment and offset value. The highlighted value is the field that is currently being edited. Figure 3.102 – 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.
3-74 Operator Interface Database Download The database download operation allows the operator interface to obtain the majority of the information it requires on your command (instead of as needed). The operation is initiated from any screen by pressing the [F10] key and the [cursor up] key at the same time. Obtaining the entire drive database is a lengthy process.
Operator Interface Operator Interface Menu Hierarchy Chart 3-75 The screens of the operator interface are used to form a menu driven system to access the various operations in the drive. The hierarchy of this menu system is shown in Figures 3.104 and 3.105. What does it show? The chart shows the relationship between screens and a particular operation. It also shows the path to reach a particular screen.
3-76 Operator Interface 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 MAINMENU screen. This example assumes you have read the previous sections of this manual. The example will concentrate more on the flow of screens and how it relates to the chart, rather then the actual operations being performed by each screen. The symbols refer to those of the chart. Descriptions of movement, i.e.
7000 “B” Frame Select Code: F5-Code Select Letter: F7-List Select List: Select: Select Group: F7-Group D G S S F3-Lang'ge F7-Dir :Language F T F5-Lang'ge F3-Print Printer: F2-Utility F2-Format F8-Access T F2-Format :Format P Meters: F8-Meters Utility: Directory: F F F3-Program F7-Dir :Program F3-Program R Q Transfer: F7-Transfer Status: F7-Status MainMenu: F5-NVRAM Note: F F1-Help F2-Drv>Crd A F F7-Dir F6-Alarms Help: H G P F8-Access Help:Help: PF7000
7000-UM150I-EN-P – June 2013 Setup Wizard Parameters XIO Analog PLC Fault Masks S T S XIO Setup: T External Setup: F4-Display R Q P A F6-Alarms S D T T F10-Exit T T F8-D Setup F7-Overvw P Note: F10-Access Protocol Analyzer F7-Analyze Communications Obtain Database Memory Diag View: F9-View Password Change F9-Change Access: P Continued from Page 1 Page 2 of 2 All screens have access to the F1-Help and F6-Alarm key.
Operator Interface PCMCIA Memory Card Installation Data 3-79 Description The memory card slides into the card slot located on the backside of the PowerFlex 7000 operator interface. These instructions show how to insert the card in the Operator interface. ATTENTION The memory card should be kept free from moisture, extreme temperatures, and direct sunlight. Failure to observe this caution could result in damage to the card. ATTENTION Do not subject memory card to flexing or extreme shock.
3-80 Operator Interface 2. Position the card vertically so the key slot is facing the right side of the operator interface. KEY SLOT 3. Insert the card into the card slot and push until the card is firmly seated. ATTENTION 7000-UM150I-EN-P – June 2013 Do not force the card into the slot. Forcing the card into the slot may damage the connector pins.
Chapter 4 Commissioning Start-up Commissioning Services Start-up will be performed at the customer's site. Rockwell Automation requests a minimum of four- (4) weeks‟ notice to schedule each start-up. The standard Rockwell Automation work hours are between 8:00 AM to 5:00 PM EST, (8 hr/day) Monday through Friday, not including observed holidays. Additional working hours are available on a time and material basis. Rockwell Automation recommends the following: Drive Commissioning 7000 “B” Frame 1.
4-2 Commissioning 13. Apply medium voltage to the drive and perform operational checks. 14. Bump motor and tune drive to the system attributes. (If the load is unable to handle any movement in the reverse direction the load should be uncoupled prior to bumping the motor for directional testing). 15. Run the drive motor system throughout the operational range to verify proper performance. Please Note: Customer personnel will be required on-site to participate in the start-up of the system.
Commissioning ATTENTION 4-3 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 is to disconnect or lock out control equipment from power sources, and confirm discharge of stored energy in capacitors.
4-4 Commissioning Please print the following information: Medium Voltage Support Rockwell Automation Fax: 1 (866) 465-0103 or Fax: 1(519) 740-4756 Name: Company: Phone: Fax: Date: Pages: PowerFlex 7000 “B” Frame Pre-Commissioning Checklist 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 Support, along with the planned start-up date.
Commissioning 4-5 PowerFlex 7000 “B” Frame Pre-Commissioning Checklist 3. Safety Initials Date All mechanical interlocks and door Ram Interlocks are tested for proper functionality and are not defeated or damaged. All Kirk key interlocks are installed and tested for proper functionality. The grounding of the drive should be in accordance with CEC (Canadian Electrical Code), NEC (National Electrical Code), or IEC regulations.
4-6 Commissioning PowerFlex 7000 “B” Frame Pre-Commissioning Checklist 5. Power Wiring Initials Date The power cable connections to the drive, motor and isolation transformer adhere to CEC, NEC, IEC or appropriate local standards. The cable terminations, if stress cones are used, adhere to the appropriate standards. Appropriate cable insulation levels are adhered to, as per Rockwell Automation specifications (refer to tables on page 2-29 of User Manual for Cable Insulation Requirements).
Commissioning 4-7 PowerFlex 7000 “B” Frame Pre-Commissioning Checklist NOTES OR COMMENTS: 7000 “B” Frame 7000-UM150I-EN-P – June 2013
4-8 Commissioning Commissioning Preparation The following section identifies all the tools and resources required to successfully commission a PowerFlex 7000 “B” Frame drive lineup. In addition, it identifies how to obtain the required equipment in the event that it is not readily available prior to commissioning the drive. It is recommended that all items listed below be obtained prior to attempting to commission the drive.
Commissioning 4-9 Technical Publications Each drive is shipped with a service binder containing all technical publications required to commission and troubleshoot the drive lineup. This section describes how to determine what technical publications are required and how to obtain them in the event that the service binder is not available at the time of commissioning or additional information is required.
4-10 Commissioning PowerFlex 7000 “B” Frame Commissioning Checklist A commissioning checklist has been provided in this manual as a quick reference to assist in starting up the drive line-up. This checklist should not be used as a detailed instruction or in no way includes all necessary steps to commission every possible drive configuration.
Commissioning 4-11 PowerFlex 7000 “B” Frame Commissioning Checklist Service Data Control Power Off Tests Control Power On Tests Converter Tests 7000 “B” Frame Record customer name, location, date and drive ID number. Record drive nameplate data. Record motor nameplate data and compare it to the dimensional drawings. Record tachometer nameplate data, if applicable. Record harmonic filter nameplate data, if applicable.
4-12 Commissioning PowerFlex 7000 “B” Frame Commissioning Checklist Programming the Operator Interface Verify preliminary parameter settings. Calibrate signal conditioners Set analog outputs Fault masks / External faults Analog I/O PLC In/Out System Tests Perform a system test with low voltage control/test power. Prove all protection functions as desired. Verify that all emergency stop devices function. Calibrate the analog I/O. Verify that the fan is operating properly.
Commissioning Drive Application Review 4-13 In order to ensure trouble free commissioning, it is necessary for all involved in the start-up to familiarize themselves with the drive lineup and application. Service on the equipment should not be performed without a clear understanding of how the equipment has been designed to function and how the equipment has been applied.
4-14 Commissioning If the dimensional and electrical prints are not available, a copy can be sent from the factory. In addition, if the drawings require changes to accurately suit the installation and application of the system, please fax or e-mail them to the factory so they may be revised. Electrical System One-line Diagram Once the Rockwell Automation electrical and dimensional drawings are clearly understood, a copy of the electrical system one-line drawing should be obtained.
Commissioning Safety Tests 4-15 The information contained in this section of the commissioning chapter must be completed in order to ensure that the commissioning continues in an environment safe to all those involved in servicing the drive line-up. Every point included in this section must be completed prior to continuing with the drive commissioning. Ensure that commissioning of this drive line-up is performed in accordance with local safety standards.
4-16 Commissioning ATTENTION Ensure that the motor is not spinning due to a driven load. A spinning motor can generate a high potential into the drive‟s motor filter capacitors, which can result in severe injury or death. Refer to local safety guidelines for detailed procedures on how to safely isolate the equipment from hazards. The door to the medium voltage cabinets can only be opened after the lockout and tagout are successfully completed.
Commissioning Installation Review 4-17 Prior to commencing the commissioning of the drive line-up it is recommended that the installation of the equipment be re-inspected. Identifying errors in the drive installation prior to commencing the commissioning as opposed to mid way through the commissioning process will greatly reduce the amount of time required to commission the drive line-up.
4-18 Commissioning Information on Splice Kits The drive line-up may have been shipped in sections. Verify that the bus splice kits provided in this circumstance are installed and properly torqued at shipping split locations. Power Cabling All customer power and control wiring required for drive line-up installation have been identified on the electrical drawings by a dashed line (See electrical drawing – General Notes, for additional information).
Commissioning 4-19 Control Wiring Identify all customer-required control wiring detailed on the electrical diagram and located it within the terminal blocks in the drive. Examine it to verify that the cable insulation has not been tightened into the terminal. Verify that all connections have proper continuity. Ensure factory jumpers installed and marked with notes “to remove if remote equipment installed” have been removed.
4-20 Commissioning Service Data This section of the commissioning chapter has been included in this manual so that all of the system nameplate data and variable set points can be captured as commissioned. Why this Information is Needed When a PowerFlex 7000 “B” Frame medium voltage AC drive is commissioned, the start-up sometimes occurs in an artificial environment. There‟s usually no actual process being performed, and no load, at least not a full load.
Commissioning 4-21 Customer Information COMPANY ADDRESS CITY PROV/STATE/COUNTRY POSTAL/ZIP CODE SERVICE CONTACT TELEPHONE APPLICATION FAX E-MAIL SERIAL NO. DRIVE TAG ID NO.
4-22 Commissioning Drive Nameplate Data CATALOG NO. SCHEMATIC DIAGRAM Control Cell MAX VOLTS Hz Power Cell UNIT SERIES Hz MAX VOLTS BIL (kV) MVA CURENT (Amps) NEMA TYPE RECTIFIER TYPE SERVICE FACTOR Motor Filter Capacitors MANUFACTURER MODEL NO. CONFIGURATION: WYE VOLTS Hz KVAR Line Filter Capacitors (PWM Rectifier Only) MANUFACTURER MODEL NO. CONFIGURATION: WYE VOLTS Hz KVAR SERIAL NO.
Commissioning 4-23 Motor Nameplate Data Motor MOTOR TYPE: INDUCTION SYNCHRONOUS MANUFACTURER MODEL NO. SERIAL NO. HP/kW VOLTS CURRENT KVA POWER FACTOR CYCLES RPM SERVICE FACTOR EFFICIENCY CODE TYPE FRAME EXCITATION (Synchronous Only) EXCITER TYPE VOLTS: CURRENT: NEMA TYPE RTD TYPE: BEARING STATOR Tachometer/Encoder Nameplate Data Speed Feedback TACHOMETER MANUFACTURER PPR 7000 “B” Frame POSITION ENCODER MODEL NO. STATOR FEEDBACK (NONE) SERIAL NO.
4-24 Commissioning Miscellaneous Information Auxiliary Cooling Blower Motor (if any) HP/KW: VOLTS: PHASE: FLC: RPM: S.F.
Commissioning 4-25 DRIVE CIRCUIT BOARDS PART NUMBER DCB L 80190-239- DCB M 80190-239- FIO L (A,B,C) 80190-099- --- FIO M (A,B,C) 80190-099- --- SCB L 80190-279- --- SCB M 80190-279- --- CIB 80190-319- XIO 80190-299- --- VSB L 1 81000-199- --- VSB L 2 81000-199- --- VSB M 1 81000-199- --- Operator Interface 2711-KSASL11 TFB L 80190-639- --- TFB M 80190-639- --- SCR SPGDB 80190-219- --- IDGPS L (1-3) 80026-044- --- IDGPS M (1-3) 80026-044- --- 80026-172-
4-26 Commissioning SPARE DRIVE CONTROL BOARDS PART NUMBER DCB L 80190-239- DCB M 80190-239- FIO L or M 80190-099- --- SCB L 80190-379- --- SCB M 80190-379- --- CIB 80190-319- XIO 80190-299- VSB L or M 81000-199- SOFTWARE REVISION ----PV Firmware PV Software Operator Interface 2711-KSASL11- TFB L or M 80190-639- --- SCR SPGDB 80190-219- --- IDGPS L or M 80026-044- --- SGCT -- --- SCR -- --- PS1 [AC/DC Converter] PS2 [DC/DC Converter] PS4 [24V DC Power suppl
Commissioning Control Power Off Tests 4-27 The following checks listed in this section of the chapter should be performed prior to applying control power to the drive. It is recommended that these checks be completed in the sequence that they have been presented in this chapter. Interlocking When the input contactor option is purchased a key interlock is provided to prevent access to the medium voltage compartments of the drive unless the input isolation switch is locked in the open position.
4-28 Commissioning Grease marks from dead bolt pins Adjust dead bolt counterpart so that grease marks from pins hit here. Figure 4.1 – Dead bolt assembly mounted to door 1. Lock out and isolate the drive from medium voltage. Verify with a hot stick that there is no medium voltage present. 2. Determine that the key interlock is correctly aligned by securely bolting the medium voltage doors of the cabinet closed and removing the key from the lock.
Commissioning 4-29 4. Bolt the cabinet door closed so the pins on the dead bolt counterpart make contact with the dead bolt assembly. Doing so should leave two marks of torque sealant or grease on the assembly where the pins made contact (See Figure 4.1 – Dead bolt 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 dead bolt assembly.
4-30 Commissioning SGCT Testing The following steps outline how to verify SGCT semiconductors and all associated snubber components. A quick reference to the expected resistance and capacitance values as well as a simple schematic diagram is located in the table below. Table 4.A – SGCT Snubber Circuit Resistance and Capacitance Values SGCT Rating Sharing Resistor Snubber Resistor Snubber Capacitor 1500 Amp 80 kΩ 7 Ω (PWMR) 0.2 µf 1500 Amp 800 Amp 400 Amp 400 Amp 80 kΩ 80 kΩ 80 kΩ 80 kΩ 7.
Commissioning 4-31 SGCT Anode to Cathode Resistance Performing an Anode to Cathode resistance test not only tests the integrity of the SGCT but also the integrity of the sharing resistor. An abnormal device resistance measurement will indicate either a shorted device or damaged sharing resistor. Using an ohmmeter, measure the anode to cathode resistance each SGCT in the inverter bridge, looking for similar resistance values across each device.
4-32 Commissioning Damage to a sharing resistor is easily detected if the SGCT is replaced and the anode to cathode resistance remains abnormal. If the resistor is found to be out of tolerance, refer to Chapter 6 – Component Definition and Maintenance 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.
Commissioning 4-33 Snubber Capacitance (SGCT Device) Turn the multimeter from the resistance to capacitance measurement mode. Proceed to verify the snubber capacitor by measuring from the test point to the heatsink adjacent to the right. Measure capacitance between heatsink and test point. Snubber test point Figure 4.6 – Snubber Capacitor Test Refer to Table 4.A to determine the appropriate snubber capacitance value for the current rating of the SGCT used.
4-34 Commissioning Table 4.B – SCR Snubber Circuit Resistance and Capacitance Values Drive Rating Sharing Resistance Snubber Resistance Snubber Capacitance 2400V (6P), 6600V 80 kΩ 45 Ω 0.5 µf 3300V / 4160V 80 kΩ 60 Ω 0.5 µf 2400V (18P) 80 kΩ 60 Ω 0.68 µf Sharing Resistance Snubber Resistance Snubber Capacitor To Gate Driver Board Testpoint Heatsink Heatsink Figure 4.
Commissioning 4-35 SCR Anode to Cathode Resistance Performing an Anode to Cathode resistance test verifies the integrity of the SCR. Unlike the SGCT, the SCR uses the snubber circuit to power the self-powered gate driver boards. The resistance measurement taken across each SCR should be constant; an inconsistent value may indicate a damaged sharing resistor, selfpowered gate driver board or SCR.
4-36 Commissioning An SCR that has failed from anode to cathode will commonly produce a resistance 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 Chapter 6 – Component Definition and Maintenance for detailed instructions on how to replace the SCR assembly.
Commissioning 4-37 Gate to Cathode Resistance One test that can be performed on SCRs that cannot be performed on SGCTs is a Gate to Cathode Resistance Test. Performing a Gate to Cathode resistance measurement will identify damage to a SCR by revealing either an open or shorted gate to cathode connection.
4-38 Commissioning 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 heatsinks. For each device, there is one test point. To verify the resistance, measure the resistance between the test point and the heatsink above.
Commissioning 4-39 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). Sharing Resistance Snubber Resistance To Gate Snubber Capacitor Driver Board Testpoint Heatsink Heatsink Resistance between Test Point and white wire at 2-pole plug is snubber capacitance Figure 4.
4-40 Commissioning Control Power Tests Prior to energizing the drive, verify that the control power being fed into the input breakers are rated as designated on the electrical diagram.
Commissioning 4-41 Three Phase Input / Single Phase Input This configuration has two sources of control power: • • Three phase control power for fan operation and drive control Single-phase control power to operate the Interface, I/O and additional auxiliaries. Similar to the three-phase configuration, the input power for the fan and control must be verified at the primary of FDS1.
4-42 Commissioning Component AC/DC Converter Power Supply DC/DC Converter Power Supply SGCT Power Supplies SGCT Integrated Firing Card Drive Control Boards Customer Interface Board Digital I/O Remote I/O Adapter Operator Interface Terminal LED Activated NO Healthy LEDs Provided 1 Green LED on Case of Power Supply (No Label) 1 Green LED per section of Power Supply (No Label) LED 4 (Green) LED 3 (Green) LED 1 (Red) 1 Green LED – Healthy LED1 (Green) LED 2 (Green) LED 3 (Green) Various RED Surface Mounted
Commissioning 4-43 AC/DC Converter (PS1) Every PowerFlex 7000 “B” Frame drive will be supplied with at least one AC/DC converter. As the number of devices increases, so will the number of AC/DC converters installed. The electrical schematics provided by Rockwell Automation will identify how many AC/DC Converters have been installed in the application being commissioned. Ensure the output of the supply is 56V DC.
4-44 Commissioning Plug 1 (P1) – INPUT Terminal Numbers 12 Description Input Power (+56 V) Value Plug 2 (P2) – CONTROL Terminal Numbers Description 12 XIO PWR (+24 V 0.
Commissioning 4-45 If any values are out of the expected range, a bad DC/DC converter is suspect. For additional information on how to troubleshoot the DC/DC converter, refer to the troubleshooting section of the manual (Chapter 7). M4 (P.H.M.S.) and nylon shoulder washer Mounting plate Black insulation Part ID label DC/DC power supply VIEW “2” DC Power good indicator light M6 (H.H.T.R.S.) VIEW “1” Figure 4.
4-46 Commissioning SGCT Power Supplies (IGDPS) Note: Refer to Figure 4.16 for location of IGDPS. Ground bus Differential Pressure Sensor Inverter Modules Temperature Feedback Board (Inverter) Isolated Gate Driver Power Supplies Rectifier Modules Temperature Feedback Board (Rectifier) Figure 4.16 – Converter Cabinet Components The circuitry for the IGDPS is encapsulated in epoxy. As a result the module can not be field repaired and there are no test points or adjustments available on this board.
Commissioning 4-47 Board LEDs One operational green LED on each of the 6 outputs, visible from the input ends of the unit that detects failed 20V output. • • LED ON: output healthy LED OFF: output voltage is below 18Vdc If the HV IGDPS is healthy, then all six LEDs will be illuminated. If this in not true, this may indicate either a bad connection to the board or a defective output module. Record the following measurements to ensure all 6 outputs are functioning. They should be within ±1% of 20 V.
4-48 Commissioning Gating Tests Once the drive converters have been tested without Medium Voltage and all the power supply output values have been verified, it is necessary to test the SCRs and SGCTs under low voltage control power.
Commissioning 4-49 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. Press Enter and use the down arrow to get to Gating Test. Press Enter, and you will now be in gating test mode. ATTENTION 7000 “B” Frame Ensure that the drive is no longer running in test mode prior to applying medium voltage to the drive line-up. Failure to do so may result in equipment damage.
4-50 Commissioning SCR Firing Test In normal operation, the SCR firing cards derive their power from a voltage divider network that steps down the medium voltage to 20 volts maximum. As it is necessary to perform this test while isolated from medium voltage, a secondary source of power has to be provided to power the firing cards. Supplied with each drive is a power cable that supplies 20 V DC from the DC/DC Converter power supply to the firing cards (SPGDB).
Commissioning 4-51 Put the drive in Gating Test Mode and the rectifier will automatically go into Test Pattern gating mode. LED 1 – Gate Pulse (Orange) should light up and pulsate at the frequency that the device is firing. All the other LEDs will light up as the firmware sends a gating signal to every SCR. There is also a Gating Test that fires the individual devices one at a time, in what is described as a Z-pattern.
4-52 Commissioning SGCT SGCT LED 4 (Green) LED 3 (Green) LED 2 (Yellow) LED 1 (Red) Figure 4.18 – SGCT Healthy LEDs While the drive is sitting idle, without gating LEDs 4 (Green), 3 (Green), and 1 (RED) should be illuminated while LED 2 (Yellow) is off. If any other combinations of LEDs are illuminated, refer to Chapter 6 – Component Definition and Maintenance for instructions on how to troubleshoot the SGCT firing cards.
Commissioning System Test 4-53 Prior to applying medium voltage, it is necessary to verify the entire low voltage control circuit to ensure the drive operates as desired. Failure to perform this test may result in damage to the drive or process in the event that the control does not operate as expected.
4-54 Commissioning Press Enter, and then use the down arrow to get to Operating Mode. Press Enter and use the down arrow to get to System Test. Press Enter, and you now will be in system test mode. From this point you can completely check the entire system without medium voltage. As long as you have test power to all your contactors, you can start, stop, E-Stop, trigger faults, check remote IO, check PLC inputs, and verify other functionality.
Commissioning 4-55 Start/Stop Control Circuit Once the drive 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.
4-56 Commissioning It is necessary to activate each status indicator used by the customer to ensure that they have connected their control to the drive correctly. This can be achieved by changing the drive status (ready, faulted, warning etc.). Analog I/O It is possible to configure all of the drive‟s analog inputs and outputs without running the motor.
Commissioning 4-57 Example: The customer 4-20mA speed input is coming to the Current Loop Receiver on the Customer Interface Board, and they want the maximum input to represent 60 Hz. 1. Reference Command Remote Maximum (Ref Cmd R Max) should be set for 60 Hz. 2. The Reference Select parameter should be set to „Remote 4-20a‟. 3. Have the source supply 20mA to the drive. This should be verified with a series Multimeter.
4-58 Commissioning Press EXIT [F10], go up to Parameters. Press Enter, and then scroll down the list until you reach Analog. Press Enter, and you will see the same list of available ports and the assigned parameter number, but not the name. If you scroll down, you will reach the scaling factors for the 4 Meter Port and the 3 CIB Port outputs.
Commissioning 4-59 The analog outputs from the customer interface boards are 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.
4-60 Commissioning Configurable Alarms Ensure that the configurable alarms have been programmed in the drive control. Instructions on where to locate the following External Fault related tasks in the manual are listed below: • • • Setting Fault Masks: Chapter 3 – Operator Interface, Fault Masks.
Commissioning 4-61 Line Terminal Resistance Measurements Measuring the resistance between the drive line cable terminals will quickly identify if there is interwiring between the 0, +20, and -20 bridges in the isolation transformer. 4U 4V 3U 3V 2U 2V 3W 4W 2W There are low resistances between phases through a transformer winding and a high resistance between transformer windings.
4-62 Commissioning Application of Medium Voltage Before running the drive on Medium Voltage, it is a good idea to set up the diagnostic trending feature to capture any information in the event of a fault during commissioning. REMEMBER TO RESET THE TRENDING BEFORE LEAVING THE DRIVE IN PRODUCTION. The diagnostic trending operation of the drive allows you to capture the relationships of 8 parameters over a period of time. Trending is a valuable tool for trouble shooting the drive.
Commissioning Trigger Cond Data 4-63 Defines whether you want a continuous or a singleshot trigger. Pressing this key will place an S or a C in front of the trigger parameter. You will almost always want a Single-Shot (S) trigger. S = Single shot>>the trigger occurs once and stops, trigger must be manually re-armed C = Continuous capture>>auto re-arm enabled to collect new trends until stopped by viewing contents of captured data Defines the Condition that will cause the trigger.
4-64 Commissioning 1. Press the Diagnostic Soft Key (DIAGS [F9]). 2. Press the Diagnostic Setup Soft Key (D_SETUP [F8]) to begin programming the diagnostic settings. 3. Cursor the backlit section to Trace 1 and press the enter key to begin programming. Scroll through the parameter list until Feedback – Status Flag2 (238) is located. Select this as Trace 1. 4. Select Trace 2 through 8 as described in the step above.
Commissioning 4-65 Input Phasing Check There are 9 voltage test points on the Line Signal Conditioning Board that will allow you to look at each voltage connection individually. These test points are labeled as follows: Table 4.
4-66 Commissioning Refer to Figure 4.19 for a visual representation of the phasing checks. 2U 2V 2W 3U 3V 3W 4U 4V 120° 4W -20° 0 240° +20° Figure 4.
Commissioning DC Current Test 4-67 The following test will assist in verifying the isolation transformer phasing, as well as verifying DC Link connections. It involves putting the drive in DC Current Test and monitoring variable Alpha Line and IDCP test point while increasing the DC current through the drive rectifier. The following instructions detail how to DC current test: Ensure that you have Advanced access.
4-68 Commissioning Press the start button and the drive should start running, pumping 0.1 pu (10%) of rated current through the DC link. Alpha Line should be approximately 90°-92°. We can also check the Idc Reference and Feedback. Press EXIT [F10], and scroll back down to Current Control and press Enter. Idc reference should be at 0.100 pu and Idc Feedback should be around that same number. Ensure that Idc error stays around 0. You can see the Idc waveform on the IDCP test point on the SCBL.
Commissioning Tuning Procedure 4-69 The PowerFlex 7000 “B” Frame medium voltage drive must be tuned to the motor and load to which it is connected. There are six drive functions that require tuning. These are listed below in the order in which they are usually performed: 1. 2. 3. 4. 5. 6.
4-70 Commissioning Parameter "Autotune Lc" in "Autotuning" is set to the measured value of commutation inductance, and parameter "Autotune select" is set to Off. If the test is successful, parameter "L commutation" in "Current Control" is set equal to "Autotune Lc". If the test fails, then parameter "L commutation" is not changed and a warning is issued indicating the cause of the failure: L comm low - indicates that the measured commutation inductance is less than 0.02 pu.
Commissioning 4-71 5. Start the drive. The dc link current will rise to 0.4 pu. Commutation notches will appear in the unfiltered line voltage VABI-OUT as shown in the figure. Some distortion will appear in the reconstructed voltage FAB1 around the zero crossings. 6. Measure the average width in degrees of the commutation notch nearest the peak of the VABI-OUT waveform as seen in the following figures. 7. Record the values of the parameters "V line average", and "Idc reference” in “Current control” 8.
4-72 Commissioning 12. Confirm that the commutation inductance is set to the correct value by increasing the horizontal and vertical magnification and observing the zero crossing of reconstructed voltage FAB1. Because the line converter firing angle is about 90 degrees, the commutation notch occurs near the zero crossing of the reconstructed voltage. The signal should be a straight line through the zero crossing with almost no visible distortion.
Commissioning 4-73 3. Start the drive. The step response of the current regulator is measured and the dc link time constant is adjusted to produce a critically damped response. This test may take up to two minutes to perform. When the desired response has been achieved, the drive shuts off. The current regulator bandwidth is set back to its normal value and parameter "Autotune select" is set to Off. Parameter "Autotune Tdc" indicates the results of the test.
4-74 Commissioning 3. Set parameter "Idc command test" in "Current Control" to 0.400 pu. 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 produce an underdamped response. 6.
Commissioning 4-75 CURRENT REGULATOR TUNED INCORRECTLY CURRENT REGULATOR TUNED INCORRECTLY 11. Set parameter "Curreg bandwidth" to the normal value of 200 rad/sec. Confirm that the rise time of the current feedback is now approximately 5 ms and that the overshoot is not excessive. 12. Set parameter "Idc ref step" to zero. The dc link current will return to a steady level of 0.4 pu. 13. Stop the drive. Set parameters Operating Mode to Normal, and Idc Command Test to 0.
4-76 Commissioning 3. Stator Resistance Parameter “R stator ” is used in the hardware reconstruction of the rotor flux. If this parameter is not adjusted correctly, the resulting distortion in the flux feedback may cause speed feedback or motor synchronization errors. Stator resistance must be tuned during commissioning because it is affected not only by motor parameters, but also by cable length. Stator resistance can be measured with the motor stationary.
Commissioning 4-77 4. Leakage Inductance Parameter "L total leakage" is used in the hardware reconstruction of the rotor flux. If this parameter is not adjusted correctly, the resulting distortion in the flux feedback may cause speed feedback or motor synchronization errors. Leakage inductance must be tuned during commissioning because it is affected not only by motor parameters, but also by cable length. Leakage inductance can be measured with the motor being stationary.
4-78 Commissioning 2. Because of the design 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, or if this is not possible, parameter "L total leakage" should be set to its default value of 0.20 pu. L leakage hi - indicates that the measured leakage inductance is greater than 0.30 pu. Possible causes are: 1.
Commissioning 4-79 In most applications, the motor runs at constant flux below rated speed and constant voltage above rated speed. The motor flux is normally set to a level that provides rated voltage at rated speed and full load. The flux level required to achieve this is a function of the motor parameters. The flux regulator Autotuning determines a value of rotor flux that should provide rated motor voltage at full load and rated speed, and sets the flux command parameter to this value.
4-80 Commissioning L magn high - indicates that the measured value of magnetizing inductance is greater than 10.0 pu. This warning is intended to draw attention to an unusually high value of magnetizing inductance. This may occur if the motor is much smaller than the drive, and the nameplate parameters do not correspond to the actual motor ratings. The flux regulator should be tuned using the manual method described below.
Commissioning 4-81 Synchronous Motor Flux Regulator This section applies only to firmware revision 3.001 and higher. Before the flux regulator can be tuned, the analog output for the field current reference must be set up. Configuring the Field Current Reference Excitation for 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.
4-82 Commissioning Tuning the Flux Regulator The tuning of the flux regulator for a synchronous machine is determined by four parameters: 1. Flxreg Bandwidth in "Flux Control" 2. L magnetizing in "Motor Model" 3. T rotor in "Motor Model" 4. Lmd in “Motor Model” "Flux Regulator Bandwidth" should be set to the default value for almost all applications. "L magnetizing", “Lmd”, and "T rotor" are usually unknown and must be measured.
Commissioning 4-83 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 parameter "Autotune Lm" is set to this value. The flux command is then set to a value that should produce rated voltage at rated speed and load. The resulting change in the flux level may cause the magnetizing inductance to change.
4-84 Commissioning T rotor low – indicates that the calculated value of rotor time constant is less than 0.1 seconds T rotor high – indicates that the calculated value of rotor time constant is greater than 5.0 seconds. 6. Speed Regulator The tuning of the speed regulator is determined by two parameters in the "Speed Control" group: 1. Spdreg bandwidth 2.
Commissioning 4-85 Parameter "Autotune inertia" is set to the measured inertia and parameter "Autotune select" is set to Off. If the test is successful, parameter "Total inertia" in "Speed Control" is set equal to "Autotune inertia", and the speed regulator gains are recalculated.
4-86 Commissioning 3. Assign parameter „Speed Error‟ in the "Current Control" group to a SCBL test point (Rect TP1 or 2). This can be done similarly to the way that the meter assignments were described earlier in the chapter. Then it can be displayed on your oscilloscope. Use the settings 2V/division and 1 sec/division. 4. Adjust the reference command to a value around the middle of the operating speed range. 5. Start the drive and wait for it to accelerate to the commanded speed. 6.
Commissioning 4-87 Calculating Total Inertia If the system inertia cannot be measured, it can be calculated if the moment of inertia of the motor and load are known. The value of parameter "Total inertia" is defined as the time required to accelerate the motor and load to rated speed when rated torque is applied. It can be calculated using the following formula: Total inertia = total inertia of motor & load in kg-m2 X ( rated speed in rad/ sec)2 rated power in watts or Total inertia = 6.
4-88 Commissioning Monitor the V Line Average (P135), and increase the tap setting on the drive feed if the measured value is less than 1.03 pu. It is desirable to have V Line Average read in the 1.03 to 1.07 pu range. Alpha Line (P327) should be greater than 15 while running at rated speed and load, indicating how far forward the rectifier is phased. The input voltage should be increased by tapping up the transformer. Fill in the following table with data from the various load points.
Commissioning 4-89 Figure 4.21 – Running Full Speed/Full Load: Line Side; Vab1_out (1) vs. Ia1_out (2) Figure 4.22 – Running Full Speed/Full Load: Line Side; Vab1_out (1) vs.
4-90 Commissioning Figure 4.23 – Running Full Speed/Full Load: Motor Side; Vab1_out (1) vs. Ia3_out (2) Figures 4.24 to 4.28: 18-pulse Rectifier, 6600V, 600 HP, 49A Figure 4.24 – Running DC Current Test Mode: .80 pu: Idcp (1) vs.
Commissioning 4-91 Figure 4.25 – – Running Full Speed, 90% Load: Line Side; Vab1_out (1) vs. Ia1_out (2) Figure 4.26 – Running Full Speed, 90% Load: Line Side; Vab1_out (1) vs.
4-92 Commissioning Figure 4.27 – Running Full Speed, 90% Load: Line Side; Vab1_out (1) vs. Idcp (2) Figure 4.28 – Running Full Speed, 90% Load: Motor Side; Vab1_out (1) vs.
Commissioning Capturing Data 4-93 When all of the final commissioning procedures are completed and the drive is running, it is VERY IMPORTANT TO CAPTURE ALL THE DRIVE DATA for future reference. The last step should be to PRINT --> DRIVE SETUP. This will print all the parameters (regardless of the user access level), the various firmware revisions, the exploded fault masks, the PLC links, and the Analog configuration. All of this information is required to address future customer issues.
Commissioning TEST # MOTOR/DRIVE OPERATING POINT %SPEED / RPM 1 25%/___ 2 50%/___ 3 75%/___ 4 100%/___ 5 ___%/___ 6 ___%/___ 7 ___%/___ 8 ___%/___ 9 ___%/___ 10 ___%/___ 11 ___%/___ 12 ___%/___ 7000 “B” Frame AMPS 4-94 DRIVE VARIABLES 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) 7000-UM150I-EN-P – June 2013
Commissioning 7000 “B” Frame 7000-UM150I-EN-P – June 2013 4-95
Chapter 5 PowerFlex 7000 Functional Description Introduction The PowerFlex 7000 is an adjustable speed ac drive in which motor speed control is achieved through control of the motor torque. The motor speed is calculated or measured and the torque is adjusted as required to make the speed equal to the speed command. The motor and load determine the stator frequency and the drive synchronizes itself to the motor.
Source AC Line reactor Line voltage Line side feedback and gating Faults Line Protection Line current Line filter cap Line Converter Alpha line Idc Feedback DC Link inductor Machine Converter Current Control Motor current Flux Control Speed Control Speed Reference Speed Command Motor Speed feedback Flux feedback Stator freq Slip freq Faults Machine Protection Motor voltage Motor Model Motor filter cap Machine side feedback and gating Alpha machine Iy command 7000-UM150I-EN-P –
Functional Description Speed Command 5-3 The function of Speed Command block is to select one of the 13 possible speed command inputs. Parameter Reference Select (2) in conjunction with Local/Remote selector switch is used to define the speed command input Speed Command In (276). When the selector switch is in Local position, the default speed command is the Analog Speed Potentiometer typically mounted on the LV panel.
5-4 Functional Description Speed Command (cont.) Three skip speeds Skip Speed 1(50), Skip Speed 2 (51), Skip Speed 3 (52) are provided to prevent the drive from continuously operating at a certain speed. This feature is sometimes needed to avoid mechanical vibrations occurring in a drive system at certain speeds.
Functional Description 0.005* S Curve Acc1 *S Curve Percent Non-Linear Portion S Curve Acc1 (481) Linear Portion 0.005* S Curve Acc1 *S Curve Percent 0.005* S Curve Dec1 *S Curve Percent Non-Linear Portion Non-Linear Portion S Curve Dec1 (479) Linear Portion 5-5 0.005* S Curve Dec1 *S Curve Percent Non-Linear Portion Figure 5.
5-6 Functional Description Speed Control The function of the speed control block is to determine the torqueproducing component (Isq) of the stator current (Is). The inputs to the block are the Speed Reference (278) from the speed ramp and the Stator Freq (448) and Slip Frequency (343) from the motor model. If drive is installed with an optional tachometer, then the motor speed is determined by counting the tach pulses.
7000 “B” Frame Isq Command (292) Flux Reference (305) MOTOR MODEL Slip Frequency (343) - Tach Feedback (348) Synch Reg Output (298) S Speed Feedback (289) + S: Sensorless T: Pulse Tach Speed Fdbk Mode (89) Stator Freq (448) Freq Close Loop SPEED REGULATOR OPEN LOOP START Trq Control Speed Fdbk Mode (90) Mode (89) S 2, 5 1,5,S,T TORQUE CONTROL MODE 4 0: Zero Torque 1: Speed Reg 2:Ext Trq Cmd 3:Spd Trq Pos 4: Spd Trq Neg 5: Spd Sum Trq Rate Limit(83) L Total Leakage (130) Motor Filter
5-8 Functional Description Flux Control The function of the flux control block (Figure 5.5) is to determine the magnetizing component (Isd) of the stator current (Is) needed to maintain the desired flux profile in the motor. The inputs are Flux Feedback (306) and Stator Freq (448) from the motor model, Speed Feedback (289) and Torque Reference (291) from the speed control block and the measured voltage at the input of the bridge Vline Bridge (696).
7000 “B” Frame FLUX COMMAND LIMIT Torque Reference 291) Flx Cmd No Load (103) Flx Cmd Base Spd (100) Speed Feedback (289) VLine Bridge (696) Rated Motor Volt (22) Base Speed (98) FLUX LIMIT Flux Cmd Limit (623) Rated Line Volts (18) Flux Reference (305) - Flux Feedback (306) + Isd Command 1 (309) + + Motor Filter Cap (128) R Stator (129) L Total Leakage (130) EXCITATION CURRENT LIMIT Stator Freq (448) -1.
5-10 Functional Description Flux Control for Synchronous Most of the magnetization for a synchronous motor is supplied by the rotor field winding, unlike an induction motor where all of the Motor magnetizing current is supplied through the stator. However, control of the motor flux through the field current is very slow because of the large time constant of the dc field winding and the current and voltage limitations of the field supply.
7000 “B” Frame Flux Reference (305) L Total Leakage (130) Isd command (310) Motor Filter Cap (128) L Magnetizing (130) CAP CURRENT CALCULATOR Stator Freq (448) + - Icd Command Gain (107) If Cmd Bandwidth (106) LOW PASS FILTER + L magnetizing (131) Lmd (418) + Ix command (312) I Field Command (314) + Functional Description 5-11 Figure 5.
5-12 Functional Description Current Control The function of the current control block (Figure 5.7) is to determine the firing angles for the converters Alpha Line (327) and Alpha Machine (328). The inputs are the torque (Iy Command) and flux producing (Ix Command) components of the dc link current command from the speed control and flux control blocks respectively, and the measured dc link current Idc Feedback (322).
7000 “B” Frame V Stator (344) Iy Command (294) Ix Command (312) Feedforward Fil (502) FEEDFORWARD FILTER x 2+y 2 tan -1 + - V line Average (135) cos Vdc Error (332) Curreg Bandwidth (113) Vdc Feedforward (333) Link Inductance (27) T DC link (115) Idc Error (323) Alpha Machine (328) Idc feedback (322) Idc Reference (321) DC LINK CURRENT REGULATOR + + Vdc Reference (326) Advance Rate Limit (121) Advance Limit =0.
5-14 Functional Description Line Converter Feedback The function of the line converter feedback block is to process (scale and filter) the line side voltage and current feedback signals before being sampled by the drive control software. It represents most of the analog portion of the line side Signal Conditioning Board (SCBL) and the Drive Control Board.
Functional Description Machine Converter Feedback 5-15 The function of the machine converter feedback block is to process (scale and filter) the raw voltage and current feedback signals to the form required by the drive control software. It represents most of the analog portion of the machine side Signal Conditioning Board (SCBM) and the Drive Control Board.
5-16 Functional Description Motor Model The function of the motor model block (Figure 5.8) is to determine the rotor flux position (Flux Angle), flux feedback (Flux Feedback), applied stator frequency (Stator Freq), slip frequency (Slip Frequency) and motor operating variables like stator current (I Stator), stator voltage (V Stator), torque (Torque), power (Motor Power) and power factor (Mtr Pwr Factor).
7000 “B” Frame 3 Motor Voltages 3 Motor Currents VECTOR ROTATOR Flux Angle (304) Flux Reference (305) V sq (691) V sd (690) I sq (339) Isd Command (310) T Rotor (132) I sd (338) MOTOR OPERATING VARIABLES Torque (345) Mtr Power Factor (692) Motor Power (346) V Stator (344) I Stator (340) Isq Command (292) Slip Frequency (343) Flx from Current (341) Stator Freq C (486) Speed Reference (278) Flux Angle V (489) Stator Freq V (485) Flux Angle C (492) CURRENT FLUX MODEL Rotor Angle (30
5-18 Functional Description Line/Machine Converter Protection Except for the dc link over-current, line side dc link over-voltage and machine side dc link over voltage, the drive protection is customer configurable in the software. Adjustable parameters specifying the trip level and time delay are provided for each fault (see Medium Voltage AC Drive Parameters, Publication 7000-TD001_-EN-P). A detailed list of all the faults and warnings (alarms) is provided in Chapter 7 (Troubleshooting).
Functional Description 5-19 For most Warnings no action is taken and drive maintains its normal operation. A warning could be an indication of a problem in drive e.g. an Air Filter warning is an indication of a blocked air filter. In addition there are a few warnings in the drive that may cause momentary interruption in the operation of the drive e.g. Master UV, Line Loss or Bus Transient.
5-20 Functional Description Power Semiconductor Diagnostics (cont.) Off line Detection of Failed SCRs/SGCTs • Line Converter – 6P-SCR, 18P-SCR and PWM The rectifier diagnostics are performed when medium voltage is first applied by closing the input contactor and when the drive receives a start command. From 4.001 onwards, the drive also performs off line diagnostics when a drive reset command is issued.
Functional Description 5-21 Voltage across a thyristor when medium voltage is applied Diagnostic feedback for a healthy SCR Diagnostic feedback high Diagnostic feedback low Diagnostic feedback for a shorted SCR Figure 5.9 – Voltage across a thyristor when MV is applied Typical SGCT Gating pattern 1 0 LIGHT NO LIGHT Healthy Diagnostic Feedback 1 0 NO LIGHT LIGHT Gate Cathode shorted or PS problem 1 0 LIGHT NO LIGHT No gating received 1 0 1 0 LIGHT No diagnostic feedback NO LIGHT Figure 5.
5-22 Functional Description Power Semiconductor Diagnostics (cont.) SCR Rectifier Active Off-Line Diagnostics In the active diagnostic test, each device is gated at maximum blocking voltage. For a healthy SCR, the feedback will normally change from high to low when gated. However the drive will receive a high state both before and after gating if the device is open-circuited, there is an incomplete gating fiber-optic path or a damaged gate driver.
Functional Description 5-23 On-line detection of Failed SCRs/SGCTs When the gating is enabled for both converters, the feedback from the gate drivers is constantly switching on and off, usually several times per cycle. The diagnostics feedback signals from each device are monitored and the protective measures are performed. SCR On-Line Diagnostics For SCR rectifier drives, the drive detects both open and shorted devices while running.
5-24 Functional Description Test Modes The PowerFlex 7000 AC drive is provided with test modes to check the functionality of the drive during commissioning. These test modes are selected using the parameter Operating Mode in the Feature Select group. When Test Mode is set to the default value of Normal, the drive is in the normal operating mode. The parameter cannot be changed while the drive is running.
Functional Description ATTENTION 5-25 Application of medium voltage to the drive input or output when it is operating in gate test mode may cause severe damage to the drive. To test the line converter and to tune the dc link current regulator and the line commutating impedance, the drive Operating Mode is selected as DC Current.
5-26 Functional Description ATTENTION Open circuit test mode should not be used when the drive is connected to a load unless an output contactor is provided. Setting Operating Mode to Open Loop selects a diagnostic mode in which the drive is run in an open loop manner without closing any of the feedback loops on the motor side (Speed and Flux regulators). Parameters Trq Command 0 and Trq Command 1 are used to inject motor current at a small stator frequency (typically 10% of Rated Line Frequency).
Functional Description 5-27 1. The motor has pulled out and stalled during starting due to insufficient torque. The remedy for this is to increase the value of some or all of the parameters Trq Command 0, Trq Command 1 and Accel Time 1. 2. The motor was already rotating but the flying start failed because the drive passed through the low slip region too quickly to allow the motor flux to build up. The solution to this problem is to increase the value of parameter Accel Time 1.
5-28 Functional Description Flying Start (Synch Motor) With a synchronous motor, flying start is much quicker and more reliable because a detectable stator voltage is produced whenever the field is applied and the motor is rotating, even with zero stator current. When the drive is started, rated field current is applied to the motor but the stator current remains at zero until the end of the ramp start delay to allow the rotor flux to build up.
Functional Description 5-29 The slip frequency required to provide the desired flux and torque is calculated by the motor model. The slip frequency is integrated to get the slip angle and added to the measured rotor angle to obtain the flux angle. Indirect control can be used at any speed, but its weakness is that the calculated slip is sensitive to errors in the motor parameters.
5-30 Functional Description Input contactor Input bus Output contactor PF7000 MOTOR Bypass contactor PF7000 CONTROL Bypass bus Figure 5.11 – A typical synchronous transfer set up using PF7000 For single motor applications, the drive is capable of performing synchronous transfer without the need for a Programmable Logic Controller (PLC).
Functional Description 5-31 For all multiple motor synchronizing applications, a PLC is used for overall control of the synchronous transfer operation. Typically, the PLC gives control of the bypass contactor to the drive before performing the transfer, and takes back control after the transfer is completed. Note: The following note applies only to applications using PLCs.
5-32 Functional Description Synchronous Transfer (cont.) 3. When the phase error between the motor voltage and bypass voltage has remained less than the value specified by parameter Sync Error Max (228) for the time interval specified by parameter Sync Time (229) the drive activates its bp contactor close output. 4. After a time delay specified by Sync Off Delay (227) the drive shuts off. It is important that this parameter is set to the correct value.
7000 “B” Frame Motor voltage angle Bypass voltage angle + Sync Reg Error (297) Sync Lead Angle (226) _ + Sync Reg Gain (225) SYNCXFER REGULATOR -3 Hz 0 Disabled Enable Warn or Enable Fault TIME DELAY To Speed Control Shut off drive Close Bypass Contactor Sync Off Delay (227) Sync Reg Output (298) Sync Time (229) Sync Xfer Option (419) 3 Hz Sync Error max (228) TIME DELAY Functional Description 5-33 Figure 5.
5-34 Functional Description Synchronous Transfer (cont.) Transfer to Drive To transfer a motor running on the bypass back to the drive a Transfer to Drive command is requested. Following sequence of events take place: 1. The drive is given a Transfer to Drive command. After a normal start command is given, the drive closes the output contactor.
Functional Description Analog Outputs 5-35 A total of thirteen programmable analog outputs are provided on various boards. There are two analog outputs on each SCB and 1 on the CIB, which are intended for diagnostic purposes and are available as test points for connection to an oscilloscope or chart recorder. These analog outputs are 8-bit, non-isolated, with a range of -10V to +10V.
5-36 Functional Description 7000-UM150I-EN-P – June 2013 7000 “B” Frame
Chapter 6 Component Definition and Maintenance Control / Cabling Cabinet Components Motor Terminals Hall-Effect Current Sensor (HECS) Voltage Sensing Transient Suppression Networks (TSN) Hall-Effect Current Sensor (HECS) Line Terminals Current Transformers (CT) Figure 6.
6-2 Component Definition and Maintenance Hall Effect Current Sensors (HECS) Grounding Network (For use with Isolation Transformers) or Ground Filter Voltage Sensing (For use with Line Reactors) Power Terminals Motor Filter Capacitors (MFC) Current Transformers (CT) Transient Suppression Network (TSN) Figure 6.
Component Definition and Maintenance 6-3 Line Terminals Line Capacitors Line Filter Capacitors (LFC) Motor Terminals Zero Sequence Current Transformer (if supplied) Line Reactor Motor Filter Capacitors (MFC) Figure 6.
6-4 Component Definition and Maintenance Voltage-Sensing Assembly The voltage-sensing assembly consists of the voltage sensing board and the mounting plate. The voltage sensing board has six independent channels which convert voltages up to 10800V (7.2kV x 1.5 pu) down to low voltage levels which can be used by the PowerFlex 7000 control logic (i.e. Signal Conditioning Board - SCB).
Component Definition and Maintenance Voltage-Sensing Assembly Replacement 6-5 The number of sensing boards is dependent upon the drive rectifier configuration. 1. Ensure there is no power to the equipment. ATTENTION To prevent electrical shock, ensure the main power has been disconnected before working on the sensing board. Verify that all circuits are voltage free using a hot stick or appropriate high voltage-measuring device. Failure to do so may result in injury or death. 2.
6-6 Component Definition and Maintenance Description Transient Suppression Network – TSN The Transient Suppression Network Module consists of an assembly of suppressors that are connected to each of the three phase input lines and the structure‟s ground bus. There is a separate assembly for each set of three phase input voltages: three assemblies for an 18-pulse drive. A transient voltage spike in excess of the semiconductor rating will destroy or shorten the lifespan of the device.
Component Definition and Maintenance 6-7 When the MOV is clipping the voltage transient, the energy of the transient is being absorbed by the MOV. The varistor has a limited energy absorbing capability and generally there is not enough time for the heat generated to be conducted out of the device. The MOV is sized based on the steady-state voltage rating, the energy in the transient, and the repetition rate of the transients.
6-8 Component Definition and Maintenance Drive Input Power from Line Terminals U V W Transient Suppression Network Medium Voltage Input Fuses Phase MOV Suppressor Ground MOV Suppressor Figure 6.6 – Simplified Wiring Diagram Transient Suppression Network Fuse Replacement Two sizes of fuses (5 kV, 7.2 kV) are available within the Transient Suppression Network (TSN) located inside the connection cabinet. The 18-pulse drive contains three TSNs. 1. Ensure there is no power to the equipment.
Component Definition and Maintenance 6-9 2. Fuses are held in a place with a fuse clip. To remove the 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. I MPORTANT Make sure to replace the fuse with another of the same rating. (See Figure 6.7 for location.) Connecting links Location of ground Varistors Varistors 5 kV fuses Location for 5 kV fuses 7.2 kV fuses Location for 7.
6-10 Component Definition and Maintenance Metal-Oxide Varistor Replacement Metal-oxide varistors (MOV) are part of the Transient Suppression Network located within the connection cabinet. The PWMR drive contains one varistor panel while the 18-pulse drive contains three. 1. Ensure there is no power to the equipment. ATTENTION 2. 3. 4. 5. 6. Observe the locations of the connecting links. Detach the connecting links by removing the screws. Using a screwdriver remove the screws at the base.
Component Definition and Maintenance 6-11 6. Replace the ring lugs and 6.4-mm (¼ inch) hardware. (See Figure 6.9) I MPORTANT The maximum torque for the capacitor terminal is 3.4 Nm (30 lb-in). Reactor Transformer Capacitors Resistor Bank Figure 6.8 – Location of Notch Filter in “B” Frame Drive Important: Important: Torqueon oncapacitor terminals capacitor terminals Torque 3.4Nm Nm(30 lb-in) (30lb-in) 3.4 Loosenscrews screwsto to release capacitor Loosen release capacitor Figure 6.
6-12 Component Definition and Maintenance Ground Filter Component Replacement The number of capacitors will vary depending on the system voltage. 1. Ensure there is no power to the equipment. ATTENTION To prevent electrical shock, ensure the main power has been disconnected before working on the capacitor. Verify that all circuits are voltage free using a hot stick or appropriate voltage-measuring device. Failure to do so may result in injury or death. 2. Note the position of the leads. 3.
Component Definition and Maintenance Hall Effect Current Sensor Replacement 6-13 1. Ensure there is no power to the equipment. ATTENTION To prevent electrical shock, ensure the main power has been disconnected before working on the Hall Effect current sensor. Verify that all circuits are voltage free using a hot stick or appropriate voltage-measuring device. Failure to do so may result in injury or death. 2. Note the location of all wires and the orientation of the Hall Effect current sensor.
6-14 Component Definition and Maintenance Current Transformer Replacement 1. Ensure there is no power to the equipment. ATTENTION To prevent electrical shock, ensure the main power has been disconnected before working on the current transformer. Verify that all circuits are voltage free using a hot stick or appropriate voltage-measuring device. Failure to do so may result in injury or death. 2. Note the location of all wires and the orientation of the CT.
Component Definition and Maintenance Filter Capacitor Cabinet 6-15 Filter Capacitors Filter capacitors are used on the motor side for all 18-pulse and PWM rectifier drive options. The PWM rectifier option also includes filter capacitors on the line side. Refer to Figure 2.6 (Cabling Cabinet for 18-pulse Rectifier) and Figure 2.7 (Cabling Cabinet for 6-pulse/PWM Rectifier). The filter capacitors are three-phase four-bushing units and “oilfilled”.
6-16 Component Definition and Maintenance Filter Capacitor Replacement 1. Ensure there is no power to the equipment. ATTENTION To prevent electrical shock, ensure the main power has been disconnected before working on the capacitor. Verify that all circuits are voltage free using a hot stick or appropriate voltagemeasuring device. Failure to do so may result in injury or death. 2. Note the location of all the cables and mark them accordingly. 3.
Component Definition and Maintenance 6-17 Testing Filter Capacitors 1. Ensure there is no power to the equipment before testing the capacitor. ATTENTION ATTENTION To prevent electrical shock, ensure the main power has been disconnected before working on the capacitor. Verify that all circuits are voltage free using a hot stick or appropriate voltagemeasuring device. Failure to do so may result in injury or death. Verify the load is not running due to process.
6-18 Component Definition and Maintenance 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 replaced. Example: An example is given below to illustrate how the capacitance value is calculated. Suppose a capacitor under test is rated at 400kVAR, 6600V, 50Hz, 29.2F.
Component Definition and Maintenance 6-19 Converter Cabinet Components Ground bus Differential Pressure Sensor Inverter Modules Temperature Feedback Board (Inverter) Isolated Gate Driver Power Supplies Rectifier Modules Temperature Feedback Board (Rectifier) Figure 6.
6-20 Component Definition and Maintenance Converter Cabinet The converter cabinet contains three rectifier modules and three inverter modules. Figure 6.14 shows a 2300-volt converter with a Pulse Width Modulation Rectifier (PWMR). Isolated Gate Driver Power Supplies (IGDPS) are mounted on the cabinet‟s right side sheet. Thermal sensors are installed on the top module of the inverter and rectifier. The exact location depends on the drive configuration.
Component Definition and Maintenance 6-21 The power semi-conductor usage in the converter section is as follows: Configuration Inverter SGCTs Rectifier SGCTs Rectifier SCRs 2300V, 6P 6 0 6 2300V, 18P 6 0 18 2300V, PWM 6 6 0 3300/4160V, 6P 12 0 12 3300/4160V, 18P 12 0 18 3300/4160V, PWM 12 12 0 6600V, 6P 18 0 18 6600V, 18P 18 0 18 6600V, PWM 18 18 0 ATTENTION 7000 “B” Frame To prevent electrical shock, ensure the main power has been disconnected before working on t
6-22 Component Definition and Maintenance SGCT SGCT Heatsink Clamp Base Module housing Clamp head Temperature Feedback Board Figure 6.15 – 2-Device PowerCage Matched set 2 SGCTs Matched set 2 SGCTs Clamp Base Module housing Temperature Feedback board Clamp head Figure 6.
Component Definition and Maintenance Matched set 3 SGCTs 6-23 Matched set 3 SGCTs Clamp Base Module housing Temperature Temperature Feedback board sensing board Clamp head Figure 6.17 – 6-Device PowerCage SGCT and Snubber Circuit With all power semi-conductor or thyristors, the SGCT must have a snubber circuit. The snubber circuit for the SGCT is comprised of a snubber resistor in series with a snubber capacitor. Figure 6.
6-24 Component Definition and Maintenance In addition to the snubber circuit, a sharing resistor is connected in parallel with the SGCT. The function of the sharing resistor is to ensure the voltage is shared equally among the SGCTs when connected in series. SGCTs are connected in series to increase the total reverse voltage blocking (PIV) capacity as seen by the electrical circuit. A single SGCT has a PIV rating of 6.5 kV.
Component Definition and Maintenance Checking Clamping Pressure 6-25 Periodically, the clamping force in the PowerCage should be inspected. Ensure there is no power to the equipment. ATTENTION To prevent electrical shock, ensure the main power has been disconnected before working on the drive. Verify that all circuits are voltage free using a hot stick or appropriate voltage-measuring device. Failure to do so may result in injury or death.
6-26 Component Definition and Maintenance I MPORTANT Never rotate the lock nut located outside the indicating washer at the end of the threaded rod. The rotation of the outer nut will affect the torque calibration, which is factory set. Only adjust the inside nut. (See Figure 6.20.) Clamp head block SGCT captive screws Disc springs Inside nut used for loosening and applying load to assembly DO NOT ADJUST outside nut. Figure 6.
Component Definition and Maintenance 6-27 2. To replace a thermal sensor, refer to page P-2 regarding electrostatic discharge. 3. The heatsink with the thermal sensor must be removed from the PowerCage. Remove clamp load (refer to Figure 6.19). 4. Remove the device (SGCT or SCR) that is secured to the heatsink with the thermal sensor. (Refer to Figure 6.15., 6.16 or 6.17). 5. Disconnect the fiber optic cable to the temperature feedback board. 6. Remove two M8 screws holding the heatsink in place. 7.
6-28 Component Definition and Maintenance Symmetrical Gate Commutated Thyristor Replacement The Symmetrical Gate Commutated Thyristor (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 The SGCT and associated control board are a single component. There will never be a time when the device or the circuit board will be changed individually.
Component Definition and Maintenance 6-29 1. Ensure there is no power to the equipment. ATTENTION To prevent electrical shock, ensure the main power has been disconnected before working on the drive. Verify that all circuits are voltage free using a hot stick or appropriate voltagemeasuring device. Failure to do so may result in injury or death. 2. Note the position of the fiber optic cables for assembly. 3.
6-30 Component Definition and Maintenance I MPORTANT SGCTs come in matched sets in systems with more than one device per leg. When replacing the device, it is necessary to replace both SGCTs in the pair even if only one has failed. The devices are arranged from left to right in pairs (i.e. pairs 1+2, 3+4, 5+6). 7. While grounded, remove the SGCT from the anti-static bag it is supplied in. 8. Clean the heatsink with a soft cloth and rubbing alcohol. 9.
Component Definition and Maintenance Silicon Controlled Rectifier and SCR Self-Powered Gate Driver Board Replacement 6-31 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 independently of one another. 1. Ensure there is no power to the equipment. ATTENTION To prevent electrical shock, ensure the main power has been disconnected before working on the drive.
6-32 Component Definition and Maintenance ATTENTION The SCR and SCR SPGD Board can be destroyed or damaged by static charges. Personnel must be properly grounded before removing the replacement SCR and SCR SPGD Board from the protective anti-static bag that it is supplied in. Use of damaged circuit boards may also damage related components. A grounding wrist strap is recommended for handling sensitive circuit boards. I MPORTANT Never adjust the orientation of the SCR using the Gate and Cathode Leads.
Component Definition and Maintenance 6-33 12. While grounded, use a long Phillips screwdriver to remove the 2 screws that hold the SCR SPGD Board to the metal bracket on the red glastic assembly. Retain the hardware. 13. Pull the 4 plastic clips that secure the SCR SPGD Board to the glastic assembly. Retain the hardware. 14. Install the new SCR SPGD Board in the assembly with the 4 plastic clips and use the screws to secure the board to the metal bracket. 15.
6-34 Component Definition and Maintenance Heatsink Replacement There are 2 different styles of heatsinks used in the PowerFlex drive depending on current ratings and thermal requirements. The lighter aluminum heatsink has a very fine ventilation pattern through the heatsink. The heavier copper heatsink has a basic ventilation pattern with larger openings for airflow, and will often have a grill mounted on the front of the heatsink to help restrict the flow.
Component Definition and Maintenance 6-35 2. Remove the load from the clamp head per the procedure on page 6-23 under „Checking Clamping Pressure‟. 3. Completely remove the SGCT or SCR from the heatsink that is being replaced per the instructions on pages 6-24 to 6-27. 4. There are 2 bolts that secure the heatsink to the PowerCage. They are 13-mm bolts, and should be removed using several extenders to get the socket wrench out past all the sensitive gate driver boards. 5.
6-36 Component Definition and Maintenance PowerCage Gasket To ensure all air movement is through the slots of the heatsinks, all possible air leaks have been sealed with a rubber gasket. This gasket is placed between the surface of the PowerCage and heatsink module. It is necessary to have the gasket in place to ensure proper cooling of the SGCTs or SCRs are maintained. Power Connection Resistors Gasket Power Connection PowerCage Housing Figure 6.
Component Definition and Maintenance 6-37 Apply a thin bead of Loctite 454 adhesive to the PowerCage surface in a zigzag pattern using the original nozzle size. Use the tip to spread the adhesive around to cover at least 50% of the area. There should be sufficient quantity of adhesive to remain wet long enough for the gasket to be applied. The adhesive uses the moisture in the air as it cures. The higher the humidity the faster the adhesive will cure.
6-38 Component Definition and Maintenance PowerCage Removal (cont.) 3. Remove the 13-mm bolts in the two flanges that connect the heatsink to the PowerCage, then remove the heatsink from the PowerCage. This will reduce the weight of the PowerCage making it easier to handle. 4. To detach the PowerCage itself, the bolts on the outer flange need to be removed. Carefully lift the PowerCage down, placing the forward face down. Do not overtorque these bolts when replacing the PowerCage.
Component Definition and Maintenance Snubber Resistors 6-39 Snubber resistors are connected in series with the snubber capacitors. Together they form a simple RC snubber that is connected across each thyristor (SCR or SGCT). The purpose of the snubber circuit is to reduce the dv/dt stress on the thyristors and to reduce the switching losses. The snubber resistors are connected as sets of various wirewound resistors connected in parallel.
6-40 Component Definition and Maintenance Snubber and Sharing Resistor Replacement The snubber and sharing resistors are part of the resistor assembly located behind the PowerCage. 1. Remove the PowerCage as outlined in “PowerCage Removal”. 2. Note the connection of the leads for correct replacement. 3. Detach the leads located on the bottom of the resistor assembly.
Component Definition and Maintenance Retaining Rod 6-41 Detach the leads of the resistor assembly Pinch and remove clips at ends of retaining rods Extract retaining rod Figure 6.
6-42 Component Definition and Maintenance Snubber and Sharing Resistor Replacement (cont.) 5. Silicon gel is used to secure the snubber resistor assembly to the PowerCage. It is also used to minimize possible damages to the resistor bank during transportation from the factory. It does not need to be re-applied when inserting the new resistor bank. Remove the resistor bank from the PowerCage. Retaining Rod Push Nut Resistor Bank Figure 6.29 – Removing resistor bank from PowerCage 6.
Component Definition and Maintenance 6-43 SGCT PowerCages The snubber circuit is shown in Figure 6.30. Measure the resistance across two adjacent heatsinks. A value between 60 kΩ and 75 kΩ indicates a good sharing resistor. Rsn -2 Cs-1 Rsh Cs-2 Rsn -1 Anode Cathode Snubber Resistor Test Point Rsh Rsn-2 Cs-1 Cs-2 Anode Rsn-1 Cathode Figure 6.
6-44 Component Definition and Maintenance Sharing Resistors (cont.) Replacing Sharing Resistor Normally the sharing resistor is part of the snubber resistor assembly. Replacement of the sharing resistor will require replacing the snubber resistor also. The sharing and snubber resistors are normally located on the backside of the PowerCage. See the instructions for removing and replacing snubber resistors. SCR PowerCages The snubber circuit is shown in Figure 6.31.
Component Definition and Maintenance 6-45 Resistance measurements The anode-cathode resistance check will measure the parallel combination of the sharing resistor and SGCT anode-cathode resistance. The sharing resistor has a resistance much lower than a good SGCT, thus the measurement 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.
6-46 Component Definition and Maintenance Self-Powered Gate Driver Board – SPGDB Description This board is used in drives where SCRs are used as the rectifying device on the input of the drive. The SCRs require a gating pulse in order to turn on, and this is achieved by using the SPGDB. The SPGDB receives its command from the drive processor, via a light signal, which is transmitted through a fiber optic cable.
Component Definition and Maintenance TB3: 6-47 Test power connection Fiber optic transmitter and receiver TB2: Thermal sensing power connection TP9 TP8 TP7 TB4: Gate and cathode thyristor connection TP6 TP5 TP4 TP3 LED TB1: TP2 Snubber connection TP1 Figure 6.
6-48 Component Definition and Maintenance Testing procedure for SCR self-powered gate driver board Equipment needed: • • • • • Digital oscilloscope Function generator w/duty cycle control DC power supply (+15V @ 300 mA required) Digital multimeter Temperature sensor board (80190-639-02) Procedure: 1. Connect a clamped ABB #5STP03D6500 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.
Component Definition and Maintenance 6-49 Figure 6.34 – Gating pulses Figure 6.
6-50 Component Definition and Maintenance Figure 6.36 – Expanded SCR gating pulse Figure 6.
Component Definition and Maintenance 6-51 Figure 6.
6-52 Component Definition and Maintenance Fiber Optic Cabling The equipment is provided with fiber optic cabling as a means of interfacing the low voltage control to the medium voltage circuits. The user of the equipment should never need to change the routing of the fiber optic cables. Each end of a fiber optic cable is provided with a connector that plugs and latches into its respective location on a circuit board.
Component Definition and Maintenance Air Pressure Sensor 6-53 An air pressure sensor is located in the converter cabinet. It is located in the upper left area near the uppermost inverter module. Flexible tube for low pressure port High pressure port Mounting screw Wire terminals Figure 6.39 – Air Pressure Sensor The air pressure sensor compares the air pressure in front of the converter modules with the air pressure behind the converter modules.
6-54 Component Definition and Maintenance D.C. Link and Fan Cabinet Components Ground Bus AC/AC Converters “Hold up” Capacitor Fan Impeller Access Panel 3-phase fan power transformer Inlet Ring DC Link Inductor (Barrier removed) Fan Power Cable Entry (bottom) Figure 6.40 – DC Link and Fan cabinet with control panel shown Figure 6.41 – DC Link and Fan Cabinet with fan control panel removed The door of the cabinet is interlocked such that it cannot be opened unless the fan power is disconnected.
Component Definition and Maintenance 6-55 There is a current sensor on the M+ conductor. Above the D.C. link is the main drive cooling fan. The primary elements of the fan are the inlet ring, impeller and motor. The inlet ring is stationary and must not contact the rotating impeller. Mounted on top of the cabinet is an air exhaust hood. The exhaust hood must be installed to prevent foreign objects entering the drive.
6-56 Component Definition and Maintenance Step 2: Unfasten DC links leads. Step 3: Remove DC link hardware and slide DC link forward. Step 1: Remove hardware and DC link barrier. Figure 6.42 – DC link removal Installation of the replacement DC link is performed in the reverse order of its removal. The installer must ensure that the flexible DC link leads are connected to the appropriate terminal and routed so that electrical clearances are maintained.
Component Definition and Maintenance Fan Removal and Replacement 6-57 The fan consists of a motor and impeller assembly. To replace the fan it is necessary to remove the fan exhaust hood and top plate of its cabinet. Safety notes Fan replacement requires working at a significant height from the floor. Care should be taken to make a suitable platform from which to work. The fan motor is heavy and will require suitable lifting provision. Ensure that fan power is locked out during fan maintenance.
6-58 Component Definition and Maintenance Fan Installation Care must be taken in handling of the fan as its balance could be affected by poor handling. Fan installation is performed in the reverse order of its removal. Upon completion of installation, rotate the impeller by hand to ensure that there is no contact with the inlet ring. Impeller Maintenance Impeller Removal from Motor Shaft The fan impeller is held onto the motor shaft with a split tapered bushing.
Component Definition and Maintenance Impeller Maintenance (cont.) 6-59 1. Record the distance from the end of the motor shaft to the bushing. The new impeller must be installed in the same location. Failure to do so will result in gaps between the impeller and the intake ring resulting in loss of air flow, or rubbing of the impeller against the inlet ring or motor assembly during operation. 2. Remove both capscrews from the bushing. The impeller or bushing may fall as screws are loosened. 3.
6-60 Component Definition and Maintenance To Assemble: 1. Make sure the shaft and keyway are clean and smooth. Clean the shaft and bore with rubbing alcohol or non oily solvent. Check the key size with both the shaft and bushing keyways. 2. Put the capscrews through the clearance holes in the bushing and put the bushing loosely into the impeller, lining up the screws with the threaded holes on the impeller hub. Do not press, drive or hammer the bushing into the bore. 3.
Component Definition and Maintenance Inlet Ring Removal and Replacement 6-61 The inlet ring is the large circular part located on the underside of a horizontal barrier beneath the fan impeller. It is positioned such that the impeller sits inside but does not touch the ring. The ring sits inside the impeller 10 mm (0.40 inches). Safety Notes This procedure will require coming in contact with the internal electrical connectors and devices.
6-62 Component Definition and Maintenance Replacement of Air Filters Air filters are located at the cooling air intake grille mounted on the door in front of the converter, line reactor and transformer cabinets. It is necessary to periodically remove and clean, or remove and replace the filter material. The frequency with which the filters are renewed depends on the cleanliness of the supplied cooling air.
Component Definition and Maintenance Replacement of Air Filters (cont.) 6-63 When replacing with a new filter, the filter must be provided by Rockwell Automation or approved for use by Rockwell Automation. Replacement of the filters is performed in the reverse order of its removal. Check that there are no openings that would allow foreign matter to enter the drive. Retaining Hardware Filter Figure 6.
6-64 Component Definition and Maintenance Figure 6.46 – Air Flow Pattern for Snubber Cooling Figure 6.
Component Definition and Maintenance Control Power Components 6-65 There are two configurations in which control power will be distributed for the drive. The different methods are dependent on what drive option the customer has chosen: 1. Standard control with 5 cycle ride-through, or 2. Standard control with extended ride-through capabilities.
6-66 Component Definition and Maintenance Printer Terminal relays 120V, single phase (Optional) 3phase TX, XXXV/208V XXX = 380, 480, 600 XXXVAC 3 phase, 4 wire AC FAIL +5V - LOGIC +/-15V - LOGIC +/-24V - LEM +12V - SCANport +15V - TACH +24V I/O +15V - SPGDB TEST C hold-up AC/DC Converter 56 V DC 1500 W DC/DC Converter DC FAIL DC/DC FAIL DC/DC WARN SPGDB P/S FAIL Fan Fan supply is XXXV, 3 phase 20 V Isolated Gate Driver Power Supply 6 20V Figure 6.
Component Definition and Maintenance 6-67 Printer Terminal Relays/contactor AC/DC CONVERTER 56 VDC @ 300W 120V, single phase UPS 2kVA bypass UPS on on batt AC FAIL DC FAIL C hold-up DC/DC CONVERTER DC/DC FAIL DC/DC WARN +5V - LOGIC +/-15V - LOGIC +/-24V - LEM +12V - SCANPORT +15V - TACH +24V - I/O +15V - SPGDB TEST SPGDB P/S FAIL batt low (Optional) 3 phase transformer XXXV/208V XXXVAC 3 phase,4 wire Fan supply is XXXV, 3 phase Fan AC/DC CONVERTER 56V DC @ 1500W AC FAIL 20 V ISOLATED GATE
6-68 Component Definition and Maintenance AC/DC Power Supply Each AC/DC converter is rated for 1500W at 50°C and 1525 m (5000 feet). Above these two limits, de-rating factors are used to reduce the capacity of the converter. The converter must always have a minimum 20% margin; that is, its power output must not exceed 80% of its maximum rating. The load demands on the AC/DC converters are the DC/DC converter and up to six IGDPS modules.
Component Definition and Maintenance AC/DC Power Supply (cont.) 6-69 Location The AC/DC power supply is located on the low voltage incoming compartment. A typical low voltage compartment is shown in Figure 6.51. AC/DC Power Supply Fan Disconnect Fan Power Fuses Contactor / Overload Control Power Transformer Figure 6.51 – Location of AC/DC power supply on low voltage panel Terminal / Connections descriptions The terminal connections are shown in Figure 6.52.
6-70 Component Definition and Maintenance P1-AC input P2-DC output PIN# LABEL 1 2 3 4 EARTH LINE 1 LINE 2 LINE 3 PIN# LABEL 1 2 3 4 P3-FAIL output PIN# 3 14 15 16 +56V +56V COMM +56V +56V COMM LABEL DC POWER FAIL (OUTPUT POWER GOOD) AC/DC FAIL COMM (LOGIC RETURN) CURRENT SHARING AC POWER FAIL (POWER FAIL) Ensure the output of the supply is 56V DC. There is a potentiometer on the top of the power supply that adjusts the 56 Volt DC output for the power supply.
Component Definition and Maintenance AC/DC Power Supply (cont.) 6-71 Replacement procedure 1. Ensure 3-phase control power has been isolated and locked out. 2. Disconnect the terminals at the top of the unit. 3. Remove the two M6 bolts per Figure 6.53. 4. Extract the power supply complete with left-side mounting bracket from the drive. 5. Remove the mounting bracket from the failed power supply (four M4 screws). Retain the insulation sheet. 6. Attach mounting bracket to replacement power supply.
6-72 Component Definition and Maintenance UPS Option The PowerFlex 7000 „B‟ Frame drive has the option for internal and external UPS power to keep the control power active within the drive in the event of a control power loss. The following diagram shows the current configuration of the internal UPS option: 300W AC/DC Power Supply Hold-up Capacitor Holding Bracket UPS Figure 6.54 – 300W AC/DC Power Supply The UPS is installed in the incoming cabling section, below the LV control section.
Component Definition and Maintenance UPS Option (cont.) 6-73 If the customer has an external UPS, the firmware will essentially not expect any of the signals mentioned in the above section, and will not display any information relating to the UPS status. The firmware will operate in the same manner with respect to the operation of the drive with an internal or external UPS. The output of the UPS feeds a 300W AC/DC Power Supply.
6-74 Component Definition and Maintenance 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 6.55 for a generic representation of a low voltage tub arrangement.
Component Definition and Maintenance DC/DC Power Supply 6-75 Description The DC/DC power supply is used as a source of regulated DC voltage for various logic control boards and circuits. The input to this power supply is from a regulated 56Vdc source. +5V - DCB LOGIC +/-15V - DCB LOGIC + 56 Vdc Chold-up +/-24V - LEM DC/DC Power Supply - DC/DC FAIL DC/DC WARN +12V +15V - REM I/O TACH +15V - SPGDB TEST +24V - PRINTER,I/O SPGDB TEST POWER ON Figure 6.
6-76 Component Definition and Maintenance LEDs Green operational LED on front of unit detects DC FAIL output.
Component Definition and Maintenance P6-SCBM PIN# 1 2 3 4 5 6 7 8 9 10 11 LABEL +LEMPWR (+24V,1A) LCOMM (com2) –LEMPWR (-24V,1A) +15V_PWR (+15V,1A) ACOMM (com1) –15V_PWR (-15V,1A) +5V_PWR (+5V,10A) DGND (com1) +15V_ENC (+15V,1A) ENC_COMM (com3) DGND (com1) DESCRIPTION ONLY +24V,1A/com2 0V/com2 -24V,1A/com2 +15V,1A/com1 0V/com1 -15V,1A/com1 +5V,10A/com1 0V/com1 +15V,1A/com3 0V/com3 0V/com1 P7-CIB PIN# 1 2 3 4 5 6 7 8 9 10 LABEL XIO_PWR (+24V,3A) XIOCOMM (com5) +15V_PWR (+15V,1A) ACOMM (com1) –15V_PWR
6-78 Component Definition and Maintenance M4 (P.H.M.S.) and nylon shoulder washer Mounting plate Black insulation Part ID label DC/DC power supply VIEW “2” DC Power good indicator light M6 (H.H.T.R.S.) VIEW “1” Figure 6.57 – Replacement of DC/DC power supply Printed Circuit Board Replacement The replacement of printed circuit boards should be handled in a careful and deliberate manner. There are some basic precautions that should be taken. They include the following: Remove all power to the drive.
Component Definition and Maintenance Drive Control Boards 6-79 There are two Drive Control Boards (DCBs) in the Low Voltage Control Section. There is one board to control the Rectifier or LineSide devices (DCB-L) and one board to control the Inverter or Machine-Side devices (DCB-M). These boards in their unprogrammed state are the same and are interchangeable. The DCB-M is the top board. The DCB-L is the middle board, directly connected to the Customer Interface Board (CIB). Figure 6.
6-80 Component Definition and Maintenance LED STATUS Solid Green Flashing Green @ 0.25 Hz Flashing Green @ 0.50 Hz Flashing Green @ 1.0 Hz Flashing Green @ 2.0 Hz 1 Green Pulse 2 Green Pulses 3 Green Pulses 10 Green Pulses Off Solid Red Flashing Red @ 0.25 Hz Flashing Red @ 0.50 Hz Flashing Red @ 1.
Component Definition and Maintenance Drive Control Boards (cont.) 6-81 Drive Control Board Replacement Before replacing the DCB-L or the DCB-M, it is important to record all of the programmed drive parameters and settings. Specifically, the parameters, fault masks, fault descriptions, and PLC links are critical. This information is stored in NVRAM on each, and as a result you may lose your settings with a new board. The best method to record parameters is to use the memory on the terminal.
6-82 Component Definition and Maintenance Drive Control Board (Machine) Fiber Optic Interface Boards Drive Control Board (Line) Customer Interface Board Figure 6.
Component Definition and Maintenance Drive Control Boards (cont.) 6-83 6. Remove the Fiber Optic Interface (FOI) Boards from the DCBs. There are standoffs and pins from the DCB that slide into the FOI boards, but they are physically attached only using the standoff connectors, and you have to be firm, but CAREFUL, in freeing the FOI boards. 7. There are numerous plastic clips holding all 3 boards to the plate. Loosen the connectors and remove all 3 boards as one unit.
6-84 Component Definition and Maintenance Customer Interface Board The Customer Interface Board (CIB) is the hub for all control-level signals external to the drive. Analog I/O, External Fault signals (through the XIO board), SCANport/DPI communication modules, Remote I/O, terminal interface, printers, modem, Drive Identity Module, and other external communication devices are routed through this board. LEDs Figure 6.
Component Definition and Maintenance 6-85 Analog Inputs and Outputs The PowerFlex 7000 “B” Frame offers one isolated process current loop transmitter and one isolated process current loop receiver, embedded into the control. These are accessible on the CIB. Each of these can be configured independently as either 0-20mA or 4-20mA. (Refer to Programming Manual). The following information will show the connections for each.
6-86 Component Definition and Maintenance Customer Interface Board (cont.) Shielded Twisted Pair CIB Ia J4A 1 2 3 4 SHLD Process Loop Receiver Figure 6.62 – Recommended Connection to CIB Transmitter Current Loop Receiver The receiver can accept either 0-20mA or 4-20mA inputs from an external transmitter. The transmitter must have a minimum loop compliance of 5V to satisfy the input impedance of 250 ohms. A block diagram of the receiver is shown below.
Component Definition and Maintenance 6-87 The receiver can accept either 2-wire or 4-wire transmitters, and therefore the connections to this port are dependent on the type of external transmitter used. The figure below shows the recommended connections. Again, the type of shielded cable used is application specific as per the transmitter.
6-88 Component Definition and Maintenance Customer Interface Board (cont.) Customer Interface Board Replacement The DCB-L, DCB-M, and CIB are all connected together using solid plug connections. This means that the best way to change any of the boards without physically stressing the connections and boards is to remove all 3 from the drive and change the board externally. Instructions to replace the Customer Interface Board 1.
Component Definition and Maintenance 6-89 10. Apply control power to the drive. The CIBs are shipped with no firmware installed, so the drive will automatically go into download mode. Install firmware in the drive following the guidelines in „Installing Firmware‟. 11. Program the drive. Refer to Technical Data “Medium Voltage AC Drive Parameters” – publication 7000-TD001_-EN-P.
6-90 Component Definition and Maintenance Customer Interface Board (cont.) The following table illustrates the most commonly used test points.
Component Definition and Maintenance Signal Conditioning Boards (cont.) 6-91 There is a separate SCB for each DCB, and they are labeled SCB-L and SCB-M. These boards are NOT the same and therefore not interchangeable. They are separate part numbers. The main reasoning for the difference is that Current Feedback from the Line-Side Current Transformers and Current Feedback from the Machine-Side Hall Effect sensors requires different scaling resistors.
6-92 Component Definition and Maintenance External Input/Output Boards The External Input/Output (XIO) Boards are connected through a network cable (CAN Link) to the Customer Interface Board. This cable should be connected to XIO Link A (J4). The XIO board handles all external Digital Input and Output signals and sends them to the CIB through the cable.
Component Definition and Maintenance External Input/Output Board (cont.) 6-93 The standard drive comes with one XIO board, although additional boards can be paralleled through the same type of CAN Link connection, from XIO Link B (J5) on the first board to XIO Link A (J4) on the second board, and so on. Specific applications may require the additional inputs and outputs. There is a component on the XIO board that will display the XIO board number.
6-94 Component Definition and Maintenance Fiber Optic Interface Boards The Fiber Optic Interface (FOI) Boards are the interface between the Drive Control Boards and the Gate Driver circuitry. The drive control decides which device to fire, and sends an electrical signal to the FOI boards. The FOI board converts that electrical signal to an optical signal, which is transmitted via fiber optics to the gate driver cards. Typically, the Transmit ports are Black and the Receive ports are Blue.
Component Definition and Maintenance Fiber Optic Interface Boards (cont.) 6-95 Each FOI board also has an input for a signal from a Thermistor Feedback Board. On the standard offering, there is one thermistor from the Line Converter and one thermistor from the Machine Converter, each going into the respective FOI board in the „A‟ position. There is capability in the control for 2 thermistors per converter. The alarm and trip setpoints for each of these signals is programmable in software.
6-96 Component Definition and Maintenance Downloading the Drive Firmware Introduction With the introduction of the PowerFlex 7000 Medium Voltage Drive, all drive control functions are loaded on the Drive Control Boards (DCBs) with firmware via a serial connection on the Customer Interface Board (CIB). The firmware for all participating boards in the system is packaged into a single file (with the extension .XFW) and downloaded to the drive using the XMODEM protocol.
Component Definition and Maintenance Preparation for Downloading Firmware 6-97 Required Laptop loaded 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 the CIB Communication Port (J8). (A serial cable with pins 2-3 swapped at one end will also work) Latest copy of the drive firmware file (filename.XFW) Drive Access level must be at least „Advanced‟ or higher (Service or Rockwell).
6-98 Component Definition and Maintenance 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. 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: In order to save parameters to the Operator Interface Terminal, press F5 (DRV>MEM). To save to the Flash Card, you must first insert the card in the terminal.
Component Definition and Maintenance 6-99 To place the drive in firmware download mode, you need to obtain a minimum of „ADVANCED‟ access level. Once that has been obtained, then from the main screen select UTILITY (F2) -> TRANSFER (F7) -> SYSTEM (F9). This will place the drive into firmware download mode. When the system is in download mode, the status of LEDs on CIB board labeled OBP1 (D1), and on two DCBs labeled D1, provide indication of the firmware download process.
6-100 Component Definition and Maintenance - 7000-UM150I-EN-P – June 2013 From „Connect to‟ window, select COM1 from the dropdown list as shown below, and then click OK. - At the „COM1 Properties‟ window, set port settings as shown below and then click OK. - Now, close HyperTerminal program. A message box will pop as shown below. Click Yes.
Component Definition and Maintenance - 6-101 You will be prompted to save the connection that you just created. Click Yes. This will close the HyperTerminal program. The first step is complete. Now, you are ready to download the firmware into the drive. For this you need to follow the steps as outlined below. Step-2: 7000 “B” Frame Downloading the Firmware - Connect the null-modem cable between your laptop‟s serial port and the serial port „J8‟ on the CIB.
6-102 Component Definition and Maintenance 7000-UM150I-EN-P – June 2013 - From the File menu, click Open… The Open window will appear. Locate the HyperTerminal Connection that you created earlier, and then click Open. - If the drive is in download mode, the character C will appear every 3 seconds inside the HyperTerminal window. - At the HyperTerminal window, click on Transfer menu and select „Send file…‟.
Component Definition and Maintenance 6-103 - Under Protocol, click the arrow on the right to open the dropdown list. Select Xmodem from the list and then click on Send button. This will start the download process, and a window similar to the one shown below will appear showing download progress. - After the download is complete, the “Download Successful” message will appear inside the HyperTerminal window. At this point the system is still in download mode.
6-104 Component Definition and Maintenance For major revision level upgrades, the 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. IT IS IMPORTANT TO REFER TO THE RELEASE NOTES BEFORE UPGRADING FIRMWARE.
Component Definition and Maintenance Setting Elapsed Time 6-105 The drive firmware download process resets the operating hours displayed on the Terminal back to zero. You can restore the actual operating hours using a utility program (Sethobb.exe) supplied with the firmware package. To set the elapsed time, follow the steps described below: - Turn off control power to the drive control boards and the Terminal. - Remove the Terminal connector from CIB (Port-J7).
6-106 Component Definition and Maintenance Power off the Terminal and insert the 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.
Component Definition and Maintenance 6-107 5. When you see the screen similar to one shown below then at that moment turn on control power to the Terminal. 6. As soon as control power is applied to the Terminal, the firmware download will start automatically, and the following message will appear on your laptop screen. 7. The screens shots copied below show the progress status of firmware file transfer. 8.
6-108 Component Definition and Maintenance Setting up Diagnostic Trending The diagnostic trending is a valuable tool for troubleshooting faults in the drive. It is a method of capturing the variation in the values of different variables over a period of time prior to and after a fault or warning condition. In a classic drive, the maximum number of parameters that can be assigned for trending is 8. The length of the trend buffer is 100 samples.
Component Definition and Maintenance Data 6-109 Defines the trigger value with respect to the read-only parameter in Trace 1. Setting up the Trend The Access level must be Basic or higher level before programming the drive‟s trending feature. To change Access level to Basic, press F10 [Access] key on the main screen. The display will change to „Access‟ screen. Select Basic by pressing down-arrow key and then press Enter key. The Access level will change to Basic.
6-110 Component Definition and Maintenance 3. With Trace-1 selected, press Enter key as shown in the picture below. 4. The display will change to „Select Group‟ screen as shown in the picture below.
Component Definition and Maintenance 5. 6-111 Press F7 [LIST]. The display will change to „Select Letter‟ screen as shown in the picture below. 6. Press F5 [CODE]. The display will change to „Select Code‟ screen as shown in the picture below.
6-112 Component Definition and Maintenance 7. Enter the parameter linear number (in our example we 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. 8. Press Enter key again. The display will change to the „Diagnostics Setup‟ screen and the desired parameter gets assigned to Trace 1.
Component Definition and Maintenance 6-113 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. 12. Press F3 [DATA] key. The cursor moves to the data field. In our example we will enter 18 and then press Enter key. 13. Press F4 [RATE] key. The cursor moves to the rate field.
6-114 Component Definition and Maintenance 14. Press F5 [POST] key and enter 10 (this is the percentage of post-trigger samples) and then press the Enter key. 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 „Stopped‟ then press F7 [Re-Arm] key. This will change the Status to Running. 16.
Component Definition and Maintenance Printing (Uploading) Data from the Drive 6-115 Overview The data from the drive; such as drive setup, parameters, variables, trend data, fault masks, alarm queues etc., can be uploaded and saved into laptop using HyperTerminal program. When using the HyperTerminal program to upload the data, you will be prompted to select a file to store this data.
6-116 Component Definition and Maintenance Method Step-1: Creating an empty notepad (.txt) file 7000-UM150I-EN-P – June 2013 - Run NotePad Program (Start Program Accessories Notepad ) - A blank Notepad window will appear as shown below. - From the File menu select Save As, as shown below.
Component Definition and Maintenance 6-117 - On the Save As window, enter 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. - An empty notepad file has been created. So, now close the Notepad program.
6-118 Component Definition and Maintenance 7000-UM150I-EN-P – June 2013 - Now, the „Connect to‟ window will appear. Select COM1 from the dropdown list next to „Connect Using‟ and then click OK, as shown below. - Now, the „COM1 Properties‟ window will appear. Set the port settings as shown below and then click OK.
Component Definition and Maintenance 6-119 - Now, close the HyperTerminal program. Following message box will appear. - Click Yes. At this point, you will be prompted to save the session. - Click Yes to terminate the HyperTerminal program. Step-3: Uploading the Data from the drive Now, that you have created an empty notepad file and setup HyperTerminal connection, you are ready to upload the data from the drive.
6-120 Component Definition and Maintenance - - 7000-UM150I-EN-P – June 2013 From the File menu, click Open….At the Open dialog box, locate the HyperTerminal connection you just created in step-2, (eg. Parameters) and then click Open. From the Transfer menu, select Capture Text… as shown below. - The Capture Text dialog box will appear. Click on Browse button and search the file Example.txt that you created in Step-1 above. - Now click Start button.
Component Definition and Maintenance 6-121 - HyperTerminal will now act as a dummy printer and is waiting for the information to be transmitted from the drive to the laptop. From the drive Terminal, hit F3 (PRINT) at the main screen as shown below: - The Terminal screen will change and display Printer options, as shown below. - Now, using Up or Down () arrow keys on the Terminal keypad select the item you want to print (ie., upload the info into laptop) and press Enter key ().
6-122 Component Definition and Maintenance It is important to note that while the data is being transferred, the Printer Status will show Transfer in Process. Once the data transfer is complete, the Printer Status changes to either Auto-Off or Auto-On. - 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 shown in the screenshot below.
Component Definition and Maintenance Setting up the PowerFlex 7000 “B” Frame Trending Feature 6-123 The trending setup is best illustrated through an example: Trend Read-Only Parameters: 1 – Status Flag (569) 2 – Alpha Line (327) 3 – Speed Feedback (289) 4 – Torque Reference (291) 5 – IDC Reference (321) 6 – IDC Feedback (322) 7 – I Stator (340) 8 – V Stator (344) The sample rate is to be set at 0 msec. This will default to the fastest sample rate. 20% of the samples should be recorded after the trigger.
6-124 Component Definition and Maintenance Environmental Considerations Hazardous materials Environmental protection is a top priority for Rockwell Automation. The facility that manufactured this medium voltage drive operates an environmental management system that is certified to the requirements of ISO 14001. As part of this system, this product was reviewed in detail throughout the development process to ensure that environmentally inert materials were used wherever feasible.
Component Definition and Maintenance • 6-125 Lithium Batteries This drive contains 4 small lithium batteries. 3 are mounted to printed circuit boards and 1 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 regulations, however, lithium is considered a hazardous substance.
6-126 Component Definition and Maintenance Preventive Maintenance Check List The preventive maintenance activities on the PF7000 Air-Cooled Drive (A-Frame or B-Frame) can be broken down into two categories: • Operational Maintenance – can be completed while the drive is running. • Annual Maintenance – should be completed during scheduled downtime.
Component Definition and Maintenance Annual Maintenance 6-127 As the name implies, these maintenance tasks should be performed on an annual basis. These are recommended tasks, and depending on the installation conditions and operating conditions, you may find that the interval can be lengthened. For example, we do not expect that torqued power connections will require tightening every year. Due to the critical nature of the applications run on MV drives, the key word is preventive.
6-128 Component Definition and Maintenance Annual Maintenance (cont.) Check for any visual/physical evidence of damage and/or degradation of components in the low voltage compartments. This includes Relays, Contactors, Timers, Terminal connectors, Circuit breakers, Ribbon cables, Control Wires, etc.; Causes could be corrosion, excessive temperature, or contamination. Clean all contaminated components using a vacuum cleaner (DO NOT use a blower), and wipe clean components where appropriate.
Component Definition and Maintenance 6-129 Control Power Checks (No Medium Voltage) Apply 3 Phase Control power to the PF7000 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.
6-130 Component Definition and Maintenance Annual Maintenance (cont.) Additional Tasks During Preventive Maintenance Investigation of customer‟s concerns relating to drive performance Relate any problems found during above procedures to customer issues.
Component Definition and Maintenance 6-131 Time Estimations Operational Maintenance 0.5 hours per filter Annual Maintenance Initial Information Gathering 0.5 hours Physical Checks – Torque Checks – Inspection – Cleaning ** – Meggering 2.0 hours 2.0 hours 2.5 hours ** 1.5 hours Control Power Checks – Contactor Adjustments ** – Voltage Level Checks – Firing Check – System Test ** 2.0 hours ** 1.0 hours 0.5 hours 2.
6-132 Component Definition and Maintenance Annual Maintenance (cont.) Tool / Parts / Information Requirements The following is a list of the tools recommended for proper maintenance of the PF7000 drives. Not all of the tools may be required for a specific drive preventive procedure, but if we were to complete all of the tasks listed above the following tools would be required.
Chapter 7 Troubleshooting (Firmware 5.xxx) Documenting Shutdowns 7000 “B” Frame All faults, warnings, or messages displayed on the Operator Interface should be thoroughly documented by the user prior to resetting those messages. This will assist maintenance personnel in correcting problems and ensuring they do not recur.
7-2 Troubleshooting Acronyms and Abbreviations Used in this Manual Acronym/ Abbreviation A/D AC ADC Cap Ch Chn CIB Cmd CT Ctctr Cur DAC DC DCB DD DIM DO DPI DrvIn ED Fbk Flt Fltr FO FOB FOI FPGA GND Gnrl HCS Hi HW I Init Inv IO Isoltn Sw L L LED Liq Description Analog/Digital Alternating Current Analog to Digital Converter Capacitor Channel Channel Customer Interface Board Command Current Transformer Contactor Current Digital to Analog Converter Direct Current Drive Control Board Dimensional Drawings Dri
Troubleshooting 7-3 FAULT MESSAGES FAULT MESSAGE AC/DC#1 DC Fail AC/DC#2 DC Fail AC/DC#3 DC Fail AC/DC#4 DC Fail AC/DC#5 DC Fail AC/DC#6 DC Fail FAULT CODE 143 144 145 146 147 148 DESCRIPTION RECOMMENDED ACTIONS The output of the specified AC/DC Power Supply has seen the 56VDC output voltage drop below the hardwired trip level. The trip level is fixed in hardware as 52VDC ± 1.7VDC, depending on hardware tolerances..
7-4 Troubleshooting FAULT MESSAGE Air Filter FAULT CODE 73 Auxiliary Prot’n 141 Standard External Fault/Warning Input included to allow the end-user to install a protective relay/system status contact that can activate a drive fault or warning, depending on configuration of Aux Prot Class (P445) Bad Reference 246 Cab Temp High (C-Frame Only) 229 The CIB verifies a 2.5VDC reference in the A-D converters during initial power up.
Troubleshooting 7-5 FAULT MESSAGE Conductivity Hi (C-Frame Only) FAULT CODE 227 Coolant Level Lo (C-Frame Only) 228 The measured coolant level within the reservoir has dropped below the second (lowest) level sensor and the drive has faulted. This sensor is set for the minimum level required to ensure there will be no air drawn into the system through the reservoir. Coolant Temp Hi (C-Frame Only) 226 The measured coolant temperature has exceeded 54°C (129°F).
7-6 Troubleshooting FAULT MESSAGE FAULT CODE DESCRIPTION RECOMMENDED ACTIONS – If you have the Cap/CT Error code, this only occurs for PWM rectifiers when energized and not running. The line current measured by the CTs does not match the expected line current based on the capacitor parameters and measured voltage. Possible causes are incorrect capacitor, CT or burden resistor parameters, and in some cases, blown TSN fuses. DAN Comm 45 Drive Area network communication fault.
Troubleshooting FAULT MESSAGE DC Link OC SW 7-7 FAULT CODE 171 DESCRIPTION RECOMMENDED ACTIONS The Measured I DC Link Feedback (P322) has exceeded DC Overcurrent Trip (P169) for the duration set in DC Overcurrent Delay (P170). This fault should never occur on it‟s own, but only after a DC Link OC HW fault.
7-8 FAULT MESSAGE DPI Interface Troubleshooting FAULT CODE 243 DESCRIPTION RECOMMENDED ACTIONS This fault typically occurs when you have the Communication Type (P147) set for 500k (DPI only), and you have a SCANPort adapter connected to the CIB. SCANPort operates at 125k, and the DPI can operate at both speeds. This can also occur if the SCANPort network attempts to access Port 5, which is internally assigned to DPI.
Troubleshooting FAULT MESSAGE 7-9 FAULT CODE DESCRIPTION Ext Cooling Loss (C-Frame only) 224 will appear if the specific input (1-16) is configured in Fault Config as a Class 1 or Class 2 fault. The drive has detected the loss of the ability to provide cooling for the drive. This is detected through feedback from the Heat Exchanger Cooling fans contactors and overloads.
7-10 Troubleshooting FAULT MESSAGE FAULT CODE DESCRIPTION configuration of InputProt2 Class (P444). Input Xfmr/LR OT 136 The temperature switch in the drive Input Isolation Transformer or Line Reactor has detected an over-temperature and opened. There is a thermal switch in each phase winding, and they are connected in series.
Troubleshooting 7-11 FAULT MESSAGE Inv HS Sensor FAULT CODE 38 Inv ChB Sensor 39 Inv HCS Power 28 IsoTx Air Filter (A-Frame Only) 71 The Pressure sensed by the pressure transducer in the Integral Isolation Transformer section (as a voltage) has dropped below the value set in Pressure Value Transformer Trip (P654). Line DC Link OV 172 The DC Link Voltage measured on the Line side of the DC Link has exceeded Line DC Overvoltage Trip (P173) for the duration set in Line DC Overvoltage Delay (P174).
7-12 FAULT MESSAGE Line Fltr Cap OV Troubleshooting FAULT CODE 176 DESCRIPTION RECOMMENDED ACTIONS The measured line voltage Vline Bridge (P696) has exceeded Line Overvoltage Trip (P165) for the duration set in Line Overvoltage Delay (P166). This is the only uncompensated voltage, representing the voltage on the input to the bridge. All other voltages in the line-side are compensated using L commutation.
Troubleshooting FAULT MESSAGE Line OC 7-13 FAULT CODE 166 DESCRIPTION RECOMMENDED ACTIONS The measured Line Current has exceeded Line Overcurrent Trip (P161) for the duration set in Line Overcurrent Delay (P162).
7-14 Troubleshooting FAULT MESSAGE Master CurrentUB FAULT CODE 163 Master VoltageUB 160 The measured phase voltages in the Master Bridge have exceeded the value set in Line Voltage Unbalance Trip (P271) for the duration set in Line Voltage Unbalance Delay (P272). Motor Current UB 33 The measured current unbalance on the drive output has exceeded Mtr I UB Trip (P208) for the duration set in Mtr I UB Delay (P214).
Troubleshooting FAULT MESSAGE Motor DC Link OV 7-15 FAULT CODE 17 DESCRIPTION RECOMMENDED ACTIONS DC Link Voltage on the motor side, measured through the Voltage Sensing Board, has exceeded Motor DC Overvoltage Trip (P193) for the duration set in Motor DC Overvoltage Delay (P194).
7-16 FAULT MESSAGE Motor Neutral OV Troubleshooting FAULT CODE 67 DESCRIPTION RECOMMENDED ACTIONS The Neutral-to-Ground voltage measured from the Output Filter Capacitor Neutral point has exceeded Ground Fault Overvoltage Trip (P189) for the duration set in Ground Fault Overvoltage (P190). This value is displayed in V Motor Neutral (P347).
Troubleshooting 7-17 FAULT MESSAGE Motor Overspeed FAULT CODE 66 Motor Protection 138 Standard External Fault/Warning Input included to allow the end-user to install a protective relay (IE Bulletin 825 Motor Protection Relay) auxiliary contact that can activate a drive fault or warning, depending on configuration of Motor Prot Class (P443). Motor Stall 23 The drive has detected a motor stall condition, with a delay set by Motor Stall Delay (P191).
7-18 FAULT MESSAGE Mstr Xfr Err Troubleshooting FAULT CODE 46 DESCRIPTION Master transfer Error This is applicable to parallel drive only Mtr Cap OV 44 Motor filter capacitor Over Voltage fault. This is for ESP application MV in Gate Test 26 The drive has Medium Voltage applied and the user attempted to place the drive in Gating Test mode. MV in System Test 27 The drive has Medium Voltage applied and the user attempted to place the drive in System Test mode.
Troubleshooting 7-19 FAULT MESSAGE Pressure Loss (C-Frame Only) FAULT CODE 223 Printer USART 242 Pump/Fan Pwr Off (C-Frame Only) 230 The control power to the pumping system and the heat exchanger fans is not present. R Neutral OC 206 Neutral Resistor Over Current.
7-20 Troubleshooting FAULT MESSAGE Rect HeatSink OT FAULT CODE 193 Rect ChannelB OT 194 Rec HS Sensor 201 Rec ChB Sensor 202 RNeutral OL 203 SCB Incompat 177 FAULT MESSAGE 7000-UM150I-EN-P – June 2013 FAULT CODE DESCRIPTION RECOMMENDED ACTIONS The temperature detection on the Rectifier Heatsink, connected to Channel A fiber optic receiver RX7 on FOI-L-A, has exceeded Rectifier Heatsink Temperature Trip (P315).
Troubleshooting 7-21 FAULT MESSAGE Slave1 CurrentUB FAULT CODE 164 Slave2 CurrentUB 165 The measured and calculated phase currents in the Slave2 Bridge have exceeded the value set in Line Current Unbalance Trip (P108) for the duration set in Line Current Unbalance Delay (P109). Slave1 Phasing 168 The voltage phasing on the Slave1 bridge is not phased the same as the voltages on the Master bridge.
7-22 FAULT MESSAGE Sync Xfer Failed Troubleshooting FAULT CODE 75 DESCRIPTION RECOMMENDED ACTIONS A Synchronous Transfer was not completed in the time specified in Synchronous Transfer Time (P230) and the drive has faulted. This fault will only occur if the parameter Sync Xfer Option (P419) is configured as Enable Fault. If the parameter is set as Enable Warn, the drive will go back to last speed command and issue a warning. Tach Loss fault This fault occurs only if the drive is not running.
Troubleshooting 7-23 FAULT MESSAGE U1A Fbk FO Loss U1B Fbk FO Loss U1C Fbk FO Loss U4A Fbk FO Loss U4B Fbk FO Loss U4C Fbk FO Loss V3A Fbk FO Loss V3B Fbk FO Loss V3C Fbk FO Loss V6A Fbk FO Loss V6B Fbk FO Loss V6C Fbk FO Loss W2A Fbk FO Loss W2B Fbk FO Loss W2C Fbk FO Loss W5A Fbk FO Loss W5B Fbk FO Loss W5C Fbk FO Loss FAULT CODE 93 99 468 96 102 471 95 101 470 98 104 473 94 100 469 97 103 472 U1A Gat FO Loss U1B Gat FO Loss U1C Gat FO Loss U4A Gat FO Loss U4B Gat FO Loss U4C Gat FO Loss V3A Gat FO Lo
7-24 FAULT MESSAGE U1A Online Flt U1B Online Flt U1C Online Flt U4A Online Flt U4B Online Flt U4C Online Flt V3A Online Flt V3B Online Flt V3C Online Flt V6A Online Flt V6B Online Flt V6C Online Flt W2A Online Flt W2B Online Flt W2C Online Flt W5A Online Flt W5B Online Flt W5C Online Flt 2U1A Device Flt 2U1B Device Flt 2U1C Device Flt 2U4A Device Flt 2U4B Device Flt 2U4C Device Flt 2V3A Device Flt 2V3B Device Flt 2V3C Device Flt 2V6A Device Flt 2V6B Device Flt 2V6C Device Flt 2W2A Device Flt 2W2B Device F
Troubleshooting 7-25 FAULT MESSAGE 2U1A Fbk FO Loss 2U1B Fbk FO Loss 2U1C Fbk FO Loss 2U4A Fbk FO Loss 2U4B Fbk FO Loss 2U4C Fbk FO Loss 2V3A Fbk FO Loss 2V3B Fbk FO Loss 2V3C Fbk FO Loss 2V6A Fbk FO Loss 2V6B Fbk FO Loss 2V6C Fbk FO Loss 2W2A Fbk FO Loss 2W2B Fbk FO Loss 2W2C Fbk FO Loss 2W5A Fbk FO Loss 2W5B Fbk FO Loss 2W5C Fbk FO Loss FAULT CODE 267 273 324 270 276 327 269 275 326 272 278 329 268 274 325 271 277 328 2U1A Gat FO Loss 2U1B Gat FO Loss 2U1C Gat FO Loss 2U4A Gat FO Loss 2U4B Gat FO Loss
7-26 FAULT MESSAGE 2U1A Online Flt 2U1B Online Flt 2U1C Online Flt 2U4A Online Flt 2U4B Online Flt 2U4C Online Flt 2V3A Online Flt 2V3B Online Flt 2V3C Online Flt 2V6A Online Flt 2V6B Online Flt 2V6C Online Flt 2W2A Online Flt 2W2B Online Flt 2W2C Online Flt 2W5A Online Flt 2W5B Online Flt 2W5C Online Flt 2U1A Offline OC 2U1B Offline OC 2U1C Offline OC 2U4A Offline OC 2U4B Offline OC 2U4C Offline OC 2V3A Offline OC 2V3B Offline OC 2V3C Offline OC 2V6A Offline OC 2V6B Offline OC 2V6C Offline OC 2W2A Offlin
Troubleshooting FAULT MESSAGE 4V3C Offline OC 4V6C Offline OC 4W2C Offline OC 4W5C Offline OC 2U1A Offline SC 2U1B Offline SC 2U1C Offline SC 2U4A Offline SC 2U4B Offline SC 2U4C Offline SC 2V3A Offline SC 2V3B Offline SC 2V3C Offline SC 2V6A Offline SC 2V6B Offline SC 2V6C Offline SC 2W2A Offline SC 2W2B Offline SC 2W2C Offline SC 2W5A Offline SC 2W5B Offline SC 2W5C Offline SC 3U1B Offline SC 3U4B Offline SC 3V3B Offline SC 3V6B Offline SC 3W2B Offline SC 3W5B Offline SC 4U1C Offline SC 4U4C Offline SC 4
7-28 FAULT MESSAGE 2U1A Online OC 2U1B Online OC 2U1C Online OC 2U4A Online OC 2U4B Online OC 2U4C Online OC 2V3A Online OC 2V3B Online OC 2V3C Online OC 2V6A Online OC 2V6B Online OC 2V6C Online OC 2W2A Online OC 2W2B Online OC 2W2C Online OC 2W5A Online OC 2W5B Online OC 2W5C Online OC 3U1B Online OC 3U4B Online OC 3V3B Online OC 3V6B Online OC 3W2B Online OC 3W5B Online OC 4U1C Online OC 4U4C Online OC 4V3C Online OC 4V6C Online OC 4W2C Online OC 4W5C Online OC 7000-UM150I-EN-P – June 2013 Troubleshoo
Troubleshooting FAULT MESSAGE 2U1A Online SC 2U1B Online SC 2U1C Online SC 2U4A Online SC 2U4B Online SC 2U4C Online SC 2V3A Online SC 2V3B Online SC 2V3C Online SC 2V6A Online SC 2V6B Online SC 2V6C Online SC 2W2A Online SC 2W2B Online SC 2W2C Online SC 2W5A Online SC 2W5B Online SC 2W5C Online SC 3U1B Online SC 3U4B Online SC 3V3B Online SC 3V6B Online SC 3W2B Online SC 3W5B Online SC 4U1C Online SC 4U4C Online SC 4V3C Online SC 4V6C Online SC 4W2C Online SC 4W5C Online SC 7000 “B” Frame 7-29 FAULT CO
7-30 Troubleshooting WARNING MESSAGES WARNING MESSAGE AC/DC#1 DC Fail AC/DC#2 DC Fail AC/DC#3 DC Fail AC/DC#4 DC Fail AC/DC#5 DC Fail AC/DC#6 DC Fail WARNING CODE 95 96 97 98 99 100 DESCRIPTION RECOMMENDED ACTIONS The output of the specified AC/DC Power Supply has seen the 56VDC output voltage drop below the hardwired trip level. The trip level is fixed in hardware as 52VDC ± 1.7VDC, depending on hardware tolerances.
Troubleshooting WARNING MESSAGE Air Filter 7-31 WARNING CODE 29 DESCRIPTION RECOMMENDED ACTIONS The Pressure drop at the input to the converter section sensed by the pressure transducer (as a voltage) has dropped below the value set in Pressure Value Alarm (P320). This is dependent on the operation of the Main Cooling Fan.
7-32 Troubleshooting WARNING MESSAGE Bypass UV WARNING CODE 185 Bypass Volt UB 186 The measured Line-Side Bypass Voltage has exceeded the value set in Line Voltage Unbalance Trip (P271) for the duration set in Line Voltage Unbalance Delay (P272). CIB Battery Low 159 Conductivity Hi (C-FRAME ONLY) 147 The battery on the CIB that powers the NVRAM has reached a preset low level of 2.6VDC. The measured conductivity is greater than 1 μS/cm3.
Troubleshooting 7-33 WARNING MESSAGE DI Contctr Fdbk WARNING CODE 118 DI Contctr Open 18 DI Contctr Clsd 19 DO Contctr Open 20 DO Contctr Clsd 21 OP Contctr Open 46 OP Contctr Clsd 47 BP Contctr Open 37 BP Contctr Clsd 38 7000 “B” Frame DESCRIPTION RECOMMENDED ACTIONS This warning indicates that the drive has sensed MV on the front end, but there is no input contactor status coming back to the drive – Verify the contactor is closed – Confirm the feedback path from the contactor to th
7-34 Troubleshooting WARNING MESSAGE DI IsoSw Open WARNING CODE 42 DI IsoSw Clsd 324 DO IsoSw Open 43 DO IsoSw Clsd 325 OP IsoSw Open 45 OP IsoSw Clsd 326 BP IsoSw Open 44 BP IsoSw Clsd 327 DC/DC Redundant 101 DC Link OT 67 DC Link OC 115 7000-UM150I-EN-P – June 2013 DESCRIPTION RECOMMENDED ACTIONS The Drive Input Isolation Switch is Open when it is expected to be closed, which is in Normal mode, DC Current test mode, Open Loop test mode, and Open Circuit test mode, The Drive Inpu
Troubleshooting WARNING MESSAGE DC Link Range 7-35 WARNING CODE 126 DESCRIPTION RECOMMENDED ACTIONS The value entered for the parameter Link Inductance (P27) is below a minimum value for the programmed Drive/Motor ratings. 6P Rectifier – 0.85 pu 18P Rectifier – 0.42 pu PWM Rectifier – 0.
7-36 WARNING MESSAGE External 1-16 Troubleshooting WARNING CODE 1-16 DESCRIPTION These are the optional additional External Faults available when there is an additional XIO board installed. This is configured with XIO Ext Faults (P593), and this message will appear if the specific input (1-16) is configured in Fault Config as a Warning. The drive control is receiving a hardwired fan feedback even though the fan has not been commanded to run.
Troubleshooting WARNING MESSAGE HeatExchnger Fan (C-FRAME ONLY) 7-37 WARNING CODE 144 DESCRIPTION The drive has detected a problem from the Liquid-to-Air heat exchanger fans. – Verify the Fan O/L settings and conditions – Verify the Fan Control Relay status and auxiliary contact signals.
7-38 Troubleshooting WARNING MESSAGE Inv Heatsink OT WARNING CODE 24 Inv ChannelB OT 25 Inv HS Sensor 195 DESCRIPTION The temperature detection on the Inverter Heatsink, connected to Channel A fiber optic receiver RX7 on FOI-M-A, has exceeded Inverter Heatsink Temperature Warning (P316). Not Normally Used – The temperature detection on an Inverter Heatsink, connected to fiber optic receiver RX7 on FOI-M-B, has exceeded Inverter Temperature Warning Channel B (P571).
Troubleshooting WARNING MESSAGE Iso Fn2 Cntr 7-39 WARNING CODE 330 DESCRIPTION Isolation Transformer Fan 2 contactor Iso Fn1 Loss 331 Isolation Transformer Fan 1 Loss Iso Fn2 Loss 332 Isolation Transformer Fan 2 Loss IsoTx Air Filter (A-Frame Only) 26 The Pressure sensed by the pressure transducer in the integral Isolation Transformer section (as a voltage) has dropped below the value set in Pressure Value Transformer Warning (P655).
7-40 WARNING MESSAGE Line DC Link OV Troubleshooting WARNING CODE 116 Line Loss 120 Liq IO Config (C-Frame Only) 131 Liq IO Conflict (C-Frame Only) 132 Logx IO Config 133 Logx IO Conflict 134 Master UV 112 Motor Cap Range 23 7000-UM150I-EN-P – June 2013 DESCRIPTION The measured Line DC voltage has exceeded Line DC Overvoltage Trip (P173), and instantaneously causes a warning. The drive has detected a loss of input voltage from losing the frequency (PLL) lock on the input voltage.
Troubleshooting 7-41 WARNING MESSAGE Motor DC Link OV WARNING CODE 192 Motor Load Loss 41 Motor OL 17 Motor OV 193 Motor Protection 68 Mtr Cap OV W 334 No DO/OP Ctctr 190 7000 “B” Frame DESCRIPTION RECOMMENDED ACTIONS DC Link Voltage on the motor side, measured through the Voltage Sensing Board, has exceeded Motor DC Overvoltage Trip (P193), and instantaneously causes a warning.
7-42 Troubleshooting WARNING MESSAGE No PLL Lock WARNING CODE 117 No Tach Installd 36 The drive has sensed that there is no tachometer/encoder connected, but the Speed Feedback Mode (P89) has been set to Pulse Tach. NVRAM Cleared 87 The parameters stored in the NVRAM of the DCB are corrupt and have been set to default values. This can occur if new firmware has been loaded into the DCB or Power Capacitors are low.
Troubleshooting 7-43 WARNING MESSAGE Pump Failure (C-FRAME ONLY) WARNING CODE Queues Cleared 91 This means that the drive had to clear the fault and warning queues after an upgrade of the firmware R Stator High 52 Autotune Rs (P219) measured during the autotune test was higher than 0.20 pu, indicating the presence of extremely long motor leads.
7-44 WARNING MESSAGE Rec HS Sensor Troubleshooting WARNING CODE 201 Rec ChB Sensor 202 Reg in Limit 51 Slip Range 189 Slave 0-7 OffL 348-355 Slave1 UV 113 Slave2 UV 114 Slv RfsdMstr 343 7000-UM150I-EN-P – June 2013 DESCRIPTION While Running, the drive has detected a missing temperature sensor connected to the TFB on the rectifier heatsink.
Troubleshooting 7-45 WARNING MESSAGE Speed Cmd Loss WARNING CODE 183 SpdProfile Limit 92 Sync Xfer Failed 40 T DC Link High 58 T DC Link Low 57 T Rotor Low 63 T Rotor High 64 Tach Loss W 33 Tach Power 35 7000 “B” Frame DESCRIPTION RECOMMENDED ACTIONS The drive has lost communication with the device responsible for providing the speed command to the drive. This has been set to annunciate as a warning.
7-46 WARNING MESSAGE Tach Reversed Temp Feedback Ls (C-Frame Only) Troubleshooting WARNING CODE 34 152 DESCRIPTION The drive has sensed that the 2 channels (generally A and B) are reversed. While Running, the drive has detected a missing temperature feedback. A missing sensor can be interpreted as either 0°C or over 100°C, and both are unrealistic values.
Troubleshooting WARNING MESSAGE XIO Card #1-6 Loss 7-47 WARNING CODE 81-86 DESCRIPTION RECOMMENDED ACTIONS An XIO card has dropped off the communications link between the XIO cards and the CIB. – Reset the board in an attempt to reestablish communications. – Check all connections between the Customer Interface Board and the jumpers between individual adapters – Verify the status of all XIO adapters by comparing the LED status to the table in the manual.
7-48 WARNING MESSAGE U1A Online Wrn U1B Online Wrn U1C Online Wrn U4A Online Wrn U4B Online Wrn U4C Online Wrn V3A Online Wrn V3B Online Wrn V3C Online Wrn V6A Online Wrn V6B Online Wrn V6C Online Wrn W2A Online Wrn W2B Online Wrn W2C Online Wrn W5A Online Wrn W5B Online Wrn W5C Online Wrn Troubleshooting WARNING CODE 216 222 240 219 225 243 218 224 242 221 227 245 217 223 241 220 226 244 DESCRIPTION INVERTER SGCT WARNING FOR REDUNDANT DEVICES or N-1 CAPABILITY ONLY This warning will occur during operat
Troubleshooting 7-49 WARNING MESSAGE 2U1A Device Wrn 2U1B Device Wrn 2U1C Device Wrn 2U4A Device Wrn 2U4B Device Wrn 2U4C Device Wrn 2V3A Device Wrn 2V3B Device Wrn 2V3C Device Wrn 2V6A Device Wrn 2V6B Device Wrn 2V6C Device Wrn 2W2A Device Wrn 2W2B Device Wrn 2W2C Device Wrn 2W5A Device Wrn 2W5B Device Wrn 2W5C Device Wrn WARNING CODE 264 270 282 267 273 285 266 272 284 269 275 287 265 271 283 268 274 286 2U1A Online Wrn 2U1B Online Wrn 2U1C Online Wrn 2U4A Online Wrn 2U4B Online Wrn 2U4C Online Wrn 2V
7-50 Troubleshooting WARNING MESSAGE 2U1A Offline SC 2U1B Offline SC 2U1C Offline SC 2U4A Offline SC 2U4B Offline SC 2U4C Offline SC 2V3A Offline SC 2V3B Offline SC 2V3C Offline SC 2V6A Offline SC 2V6B Offline SC 2V6C Offline SC 2W2A Offline SC 2W2B Offline SC 2W2C Offline SC 2W5A Offline SC 2W5B Offline SC 2W5C Offline SC WARNING CODE 300 306 318 303 309 321 302 308 320 305 311 323 301 307 319 304 310 322 2U1A Online SC 2U1B Online SC 2U1C Online SC 2U4A Online SC 2U4B Online SC 2U4C Online SC 2V3A Onl
Appendix A Catalog Number Explanation for PowerFlex 7000 MV Drives 7000 - A105 D EHD - R18TX - 1 – 1DD – 3LL – 760A First Position Second Position Third Position Fourth Position Fifth Position Sixth Position Bulletin Number Service Duty / Continuous Current Rating / Altitude Rating Code Enclosure Type Nominal Line Voltage Control Voltage System Frequency Rectifier Type Code Options D = NEMA Type 1 w/gaskets and vents (IEC IP42) (Reference TABLE A-3) (Refer to TABLE A-1) (Refer to TABLE A-
A-2 Catalog Number Explanation – Drive Selection Table A-2 Service Duty Rating, Continuous Current Rating and Altitude Rating Code Continuous Current Capability Service Duty Rating and Altitude Rating Code Code Rating A = Normal Duty 40 40 Amp 0-1000 m Altitude (@ 40°C Ambient) 46 46 Amp 53 53 Amp B = Normal Duty 61 61 Amp 1001-5000 m Altitude 70 70 Amp (2000 m Altitude @ 37.5°C Ambient) 81 81 Amp (3000 m Altitude @ 35.0°C Ambient) 93 93 Amp (4000 m Altitude @ 32.
Catalog Number Explanation – Drive Selection PowerFlex 7000 Drive Selection Explanation A-3 The PowerFlex 7000 medium voltage AC drive selection tables are based on two types of drive service duty ratings: • Normal Duty (110% overload for one (1) Minute, once every 10 minutes) – used for Variable Torque (VT) applications only. Drives with this rating are designed for 100% continuous operation, with 110% overload for one (1) minute, once every 10 minutes.
A-4 Catalog Number Explanation – Drive Selection When is a tachometer required? A tachometer is required under the following conditions: 1. When speed regulation accuracy must be between 0.01 – 0.02% of nominal speed. 2. When the zero speed breakaway torque needed is greater than 90% of continuous running torque. 3. When continuous running speed is greater than or equal to 0.1 Hz, but less than 6 Hz. 4. For minimizing restart times using the flying start capability in forward or reverse direction.
Catalog Number Explanation – Drive Selection PowerFlex 7000 Drive Performance (Torque Capabilities) A-5 The PowerFlex 7000 drives have been tested on a dynamometer to verify performance under locked rotor, accelerating, and low speedhigh torque conditions. Table A-5 below shows the PowerFlex 7000 drive torque capabilities as a percent of motor rated torque, independent of the drive’s momentary overload conditions.
A-6 Catalog Number Explanation – Drive Selection Table A-6 Typical Application Load Torque Profiles Application Load Torque Profile Load Torque as Percent of Full-Load Drive Torque Break-away Accelerating Peak Running Required Drive Tachometer Service Required for Extra Duty Rating Starting Torque? Agitators Liquid Slurry CT CT 100 150 100 100 100 100 Heavy Heavy Yes Yes Blowers ( Centrifugal) Damper Closed Damper Open VT VT 30 40 50 110 40 100 Normal Normal No No Chipper ( Wood) Startin
Appendix B Torque Requirements for threaded fasteners Unless otherwise specified the following values of torque are to be used in maintaining the equipment. 7000 “B” Frame 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 ¼“ 20 Steel S.A.E. 5 12 9.0 3/8” 16 Steel S.A.E.
B-2 Torque Requirements 7000-UM150I-EN-P – June 2013 7000 “B” Frame
Appendix C Drive Logic Command Drive Logic Command Word – Database 2.001 The following is the Logic Command from the output of the Parser. It is a READ only variable in the Drive.
C-2 Logic Status Word Logic Status Word – Database 2.001 The following is the Logic Status word from the Drive. It is common for all SCANport/DPI product specific peripherals. Bit Function Value Description Notes 0 Ready 1 Drive is Ready 1 Running 1 Drive is Running 2 Commanded Direction 1 Drive has been commanded to run forward 0 = Reverse Command 3 Rotating Direction 1 Drive is rotating in the forward direction 0 = Reverse Rotation.
Logic Status Word C-3 Product Specific Logic Command – Database 2.001 To be used with gateway adapters such as RIO or DeviceNet.
C-4 Logic Status Word Drive Logic Command Word – Database 3.001 and later The following is the Logic Command from the output of the Parser. It is a READ only variable in the Drive.
Logic Status Word C-5 Logic Status Word – Database 3.001 and later The following is the Logic Status word from the Drive. It is common for all SCANport/DPI product specific peripherals. Bit Function Value Description Notes 0 Ready 1 Drive is Ready 1 Running 1 Drive is Running 2 Commanded Direction 1 Drive has been commanded to run forward 0 = Reverse Command 3 Rotating Direction 1 Drive is rotating in the forward direction 0 = Reverse Rotation.
C-6 Logic Status Word Product Specific Logic Command – Firmware 3.001 and 3.002 To be used with gateway adapters such as RIO or DeviceNet.
Logic Status Word C-7 Product Specific Logic Command – Firmware 3.004 to 5.003 To be used with gateway adapters such as RIO or DeviceNet.
C-8 Logic Status Word 7000-UM150I-EN-P – June 2013 7000 “B” Frame
Appendix D Meggering Drive Meggering When a ground fault occurs, there are three zones in which the problem may appear: input to the drive, the drive, output to the motor. When a ground fault occurs, it indicates a phase conductor has found a path to ground. Depending on the resistance of the path to ground, a current with magnitude ranging from leakage to fault level exists.
D-2 Meggering ATTENTION There exists the possibility of serious or fatal injury to personnel if safety guidelines are not followed. The following procedure details how the Megger test on the PowerFlex 7000 is to be performed. Failure to comply to this procedure may result in poor Megger reading and damage to drive control boards. Equipment Required Torque Wrench and 7/16 inch socket Phillips Screwdriver 2500/5000 Volt Megger Procedure 1.
Meggering D-3 Note: It is important to disconnect the terminals on the boards rather than from the ground bus as the grounding cable is only rated for 600 V. Injecting a high voltage on the ground cable will degrade the cable insulation. Do not disconnect the white medium voltage wires from the VSBs. They must be included in the test. The number of VSBs installed in each drive varies depending on the drive configuration. Output Grounding Network Remove the ground connection on the OGN (if installed).
D-4 Meggering Potential Transformer Fuses A Megger test may exceed the rating of potential transformer fusing. Removing the primary fuses from all potential and control power transformers in the system will not only protect them from damage but remove a path from the power circuit back to the drive control. Transient Suppression Network A path to ground exists through the TSN network as it has a ground connection to dissipate high energy surges in normal operation.
Meggering D-5 The test should produce a reading greater than the minimum values listed below. If the test results produced a value lower than these values start segmenting the drive system down into smaller components and repeat the test on each segment to identify the source of the ground fault. This implies isolating the line side of the drive from the machine side by removing the appropriate cables on the DC Link reactor.
D-6 Meggering 6. Re-Connect the Power Circuit to the System Ground Voltage Sensing Boards Securely re-connect the two ground conductors on the VSBs. The two ground connections on the VSB provide a reference point for the VSB and enable the low voltage signal to be fed to the SCBs. If the ground conductor was not connected, the monitored low voltage signal could then rise up to medium voltage potential which is a serious hazard that must be avoided at all times.
