Bulletin 7000 User Manual PowerFlex® 7000 Medium Voltage AC Drive Air-Cooled (“A” Frame)—ForGe Control (Using PanelView 550) Publication 7000A-UM151D-EN-P
Important User Information Solid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some important differences between solid-state equipment and hard-wired electromechanical devices.
Table of Contents Preface Overview Who should use this Manual ....................................................P-1 What is not in this Manual .......................................................P-1 Manual Conventions ................................................................P-2 General Precautions .................................................................P-3 Who to call for Commissioning ...............................................P-3 Chapter 1 Overview of Drive Introduction .....
ii Table of Contents Chapter 2 Drive Installation (cont.) Power Cabling Access ........................................................... 2-27 To access the customer power cable terminations .......... 2-27 Power Connections ................................................................ 2-28 Line/Motor Terminations ................................................ 2-28 Power Cabling Installation Requirements ....................... 2-28 Dimension Views: Cabling Cabinet for Config.
Table of Contents Chapter 3 7000 “A” Frame Operator Interface (cont.) Setting Time ............................................................. 3-16 Setting Date .............................................................. 3-17 Selecting Meters ....................................................... 3-17 Viewing Revision Levels .......................................... 3-20 Transfer Data in Memory ......................................... 3-21 Picking an Access Level ................................
iv Table of Contents Chapter 3 Chapter 4 Operator Interface (cont.) Operator Interface Menu Hierarchy Chart What does it show? ......................................................... 3-61 How do you read it? ........................................................ 3-61 Example ........................................................................... 3-62 PowerFlex 7000 “A” Frame Terminal Menu Tree .......... 3-63 PCMCIA Memory Card Installation Data Description .....................................
Table of Contents Chapter 4 Component Definition and Maintenance (cont.) Impeller Maintenance (DC Link/Fan Section) ...................... 4-31 Impeller Removal from Motor Shaft ............................... 4-31 Safety Notes .................................................................... 4-31 Installation of Impeller Assembly onto Motor Shaft ....... 4-32 Impeller Maintenance ........................................................... 4-34 Isolation Transformer Cooling Fan .......................
vi Table of Contents Appendix C Torque Requirements Torque Requirements for Threaded Fasteners ........................ C-1 Appendix D Meggering Drive Meggering ..................................................................... D-1 Meggering the PowerFlex 7000A ........................................... D-1 Equipment Required ......................................................... D-2 Procedure ..........................................................................
Preface Overview Who Should Use This Manual This User 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 the drive system. What Is Not in this Manual This manual is designed to provide only information specific to the PowerFlex 7000 “A” Frame drive. Therefore customer specific topics are not presented.
P-2 Preface Manual Conventions Symbols are used throughout this manual to indicate specific types of information. WARNING ATTENTION Warnings tell readers where people may be hurt if procedures are not followed properly. Cautions tell readers where machinery may be damaged or economic loss can occur if procedures are not followed properly.
Preface General Precautions Who to Call for Commissioning P-3 ATTENTION This drive contains ESD (Electrostatic Discharge) sensitive parts and assemblies. Static control precautions are required when installing, testing, servicing or repairing this assembly. Component damage may result if ESD control procedures are not followed. If you are not familiar with static control procedures, reference Allen-Bradley publication 8000-4.5.
P-4 Preface 7000A-UM151D-EN-P – March 2013 7000 “A” Frame
Chapter 1 Overview of Drive Introduction The PowerFlex® 7000 represents the third generation of medium voltage drives from Rockwell Automation, and 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 Drive Configurations – PowerFlex 7000 “A” Frame Configuration #1 Direct-to-Drive (AFE with DTC DC Link) Elimination of isolation transformer results in lower losses and saved space An integrated system solution for fewer connections and reduced installation costs New or existing motors Small system footprint 3 cables in/3 cables out on entire system for easy installation Low line harmonics and high power factor (typical current THD < 5%, PF > 0.
Overview of Drive Topology 1-3 The PowerFlex 7000 utilizes a Pulse Width Modulated (PWM) – Current Source Inverter (CSI) for the machine side converter as shown in Figure 1.1. This topology offers a simple, reliable, cost-effective power structure that is easy to apply to a wide voltage and power range. The power semiconductor switches used are easy-to-series for any medium voltage level. Semi-conductor fuses are not required for the power structure due to the current limiting DC link inductor.
1-4 Overview of Drive Rectifier Designs Active Front-End (AFE) Rectifier An Active Front-End rectifier is particularly attractive since it does not require an isolation transformer to meet IEEE 519-1992. Many competing technologies in today’s MV market require a multiwinding transformer to mitigate the unwanted harmonics through cancellation by phase shifting the transformer secondary windings. Depending on the topology, the transformer can have up to 15 sets of secondary windings.
Overview of Drive 1-5 a) b) a) Line current b) Line-to-line voltage at PCC Figure 1.2 – AFE rectifier and its input current/voltage waveforms The AFE rectifier can be used in conjunction with a rectifier duty isolation transformer or with an AC line reactor (as shown in Figure 1.2).
1-6 Overview of Drive Motor Compatibility 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 (5.4 °F) higher compared to across-the-line operation. Voltage waveform has dv/dt of less than 10 volts per microsecond.
Overview of Drive 1-7 Simplified Electrical Drawings – 2400V with AFE Rectifier LINE CONVERTER MACHINE CONVERTER DC LINK L+ M+ SGCTs SGCTs LR U (T1) L1 V (T2) L2 W (T3) L3 L- M- 2400 Volt – AFE Rectifier, Configuration #1 – Direct-to-Drive (Configurations without Integral Input Starter are available) LINE CONVERTER REMOTE ISTX L+ DC LINK MACHINE CONVERTER M+ SGCTs SGCTs 2U (X1) U (T1) 1V 2V (X2) V (T2) 1W 2W (X3) W (T3) 1U L- M- 2400 Volt – AFE Rectifier, Configuration
1-8 Overview of Drive Simplified Electrical Drawings – 3300/4160V with AFE Rectifier LINE CONVERTER MACHINE CONVERTER DC LINK L+ M+ SGCTs SGCTs LR U (T1) L1 V (T2) L2 W (T3) L3 L- M- 3300/4160 Volt – AFE Rectifier, Configuration #1 – Direct-to-Drive (Configurations without Integral Input Starter are available) LINE CONVERTER REMOTE ISTX DC LINK L+ SGCTs SGCTs 1U 2U (X1) U (T1) 2V (X2) V (T2) 2W (X3) W (T3) 1V 1W MACHINE CONVERTER M+ L- M- 3300/4160 Volt – AFE Rectifier, C
Overview of Drive 1-9 Simplified Electrical Drawings – 6600 V with AFE Rectifier LINE CONVERTER MACHINE CONVERTER DC LINK L+ M+ SGCTs SGCTs LR U (T1) L1 V (T2) L2 W (T3) L3 L- M- 6600 Volt – AFE Rectifier, Configuration #1 – Direct-to-Drive (Configurations without Integral Input Starter are available) LINE CONVERTER REMOTE ISTX DC LINK L+ SGCTs SGCTs 2U (X1) U (T1) 2V (X2) V (T2) 2W (X3) W (T3) 1U 1V 1W MACHINE CONVERTER M+ L- M- 6600 Volt – AFE Rectifier, Configuration #2
1-10 Overview of Drive Operator Interface Figure 1.4 – 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.
Chapter 2 Drive Installation Safety and Codes WARNING 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 Siting of the Drive Site Considerations The standard environment in which the equipment is designed to operate is: • Elevation above sea level less than 1000 meters (3250 feet) • Ambient air temperature between 0°C (32°F) and 40°C (104°F) • Relative humidity of the air not to exceed 95% non-condensing For the equipment to operate in conditions other than those specified consult the local Rockwell Automation Sales office.
Drive Installation 2-3 (H) The equipment must be kept clean. Dust in the equipment decreases system reliability and inhibits cooling. (I) Power cable lengths to the motor are virtually unlimited due to the near sinusoidal voltage and current waveforms. Unlike voltage source drives, there are no capacitive coupling, dv/dt, or peak voltage issues that can damage the motor insulation system.
2-4 Drive Installation Installation 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.
Drive Installation 2-5 Flat plate (Quantity = 1) Exhaust hood panels (Quantity = 2) M6 thread forming screws (Quantity = 20) Figure 2.1 – Fan Hood Assembly All the components are shipped assembled. Figure 2.
2-6 Drive Installation Installation (cont.) Locate the exhaust hood on top of the cabinet per Figure 2.3 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. For drives with an acoustic hood (shown in Figure 2.2), locate the exhaust hood (refer to Figure 2.4).
Drive Installation 2-7 Assembled Acoustic Exhaust Hood Top Plate for Converter and Common Mode Choke/ DC Link Cabinet M6 Screw. Remove Existing Screw and reinsert with Hood. (Quantity = 11) Figure 2.
2-8 Drive Installation Installation (cont.) Installation of Integral Transformer Cooling Fan 1. Remove the protective plate covering the fan opening on the top of Isolation Transformer cabinet and discard. 2. Locate the cooling fan on top of the cabinet. Position it over the opening and align the mounting holes and wire harness connections. 3. Affix the fan to the drive top plate with the M6 thread forming screws provided. 4. Connect the fan wire harness to fan.
Drive Installation 2-9 Neutral Resistor Assembly Top Plate for Neutral Resistor Housing Ground Resistor Hood here 900 mm Converter – 800 mm Common Mode Choke Cabinet Top Plate for Converter and Common Mode Choke Cabinet Attach ground to top plate Line Filter Capacitors Neutral Resistor Assembly Refer to Electrical Drawings to verify cable rating to connect neutral resistor assembly. Motor Filter Capacitors Figure 2.
2-10 Drive Installation Assembled Acoustic Exhaust Hood Hood Ground Stud M6 Screw. Remove existing screw and reinsert with Hood. (Quantity = 11) M6 Screw (Quantity = 6) Ground Exhaust Hood here. (Use Green M6 Screw) Neutral Resistor Assembly Top Plate for Converter and Common Mode Choke/DC Link Cabinet Figure 2.
Drive Installation Cabinet Layout and Dimensional Drawings of Drive 2-11 The following dimension drawing is a sample and may not accurately detail your drive. It is 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 “A” Frame Dimensional Drawing SAMPLE Note: Contact Factory for Seismic Mounting Information.
Drive Installation Drive Layout 2-13 The following diagrams are presented to show the typical layout of the three main configurations of the PowerFlex 7000 “A” Frame Drive. Configuration #1 Direct-to-Drive (AFE with DTC DC Link) Line Reactor/Starter Cabling Catinet Converter Cabinet Control/DC Link/Fan Cabinet Figure 2.
2-14 Drive Installation Configuration #2 AFE Rectifier (Separate Isolation Transformer) Cabling Cabinet Converter Cabinet Control/DC Link/Fan Cabinet Figure 2.
Drive Installation 2-15 Configuration #3 AFE Rectifier (Integral Isolation Transformer) Isolation Transformer and Cabling Catinet Converter Cabinet Control/DC Link/Fan Cabinet Figure 2.
2-16 Drive Installation Cabling Cabinet #1 The cabling cabinet of the drive with integral line reactor and input starter is located in the left-hand section. The mounting and location of the line reactor and input starter are shown along with customer cable termination locations. The circulating fans for the cabinet are located on top. Note: This cabinet is also available without integral starter (see Figure 2.13). The width of the cabinet changes as a function of the drive voltage ratings.
Drive Installation 2-17 Cabling Cabinet #1 Low Voltage Compartment Line Cable Terminations Hall Effect Sensors Current Transformers Control Power Transformer Fuses Motor Cable Terminations AC Line Reactor Figure 2.
2-18 Drive Installation Cabling Cabinet #2 Cabling cabinet #2 is located in the left hand section and shows the medium voltage area for customer cable terminations, three phase fan power transformer, and fuse assemblies for transformer. Low Voltage Wireway Current Transformer Line Terminals Hall Effect Sensor Motor Cable Terminations Hall Effect Sensor Current Transformer Fan Control Power Transformer Control Power Transformer Fuses Figure 2.
Drive Installation Cabling Cabinet #3 2-19 The cabling cabinet of the drive with integral isolation transformer is located in the left-hand section. The mounting and location of the isolation transformer is shown along with customer cable termination locations. The cooling fan for the isolation transformer is located on top.
2-20 Drive Installation Converter Cabinet The converter cabinet for all configurations of the PowerFlex 7000 “A” Frame drive is located in the middle section. The mounting and location of Inverter / rectifier modules are shown along with gate drive power supplies and voltage sensing modules. Note: The width of the inverter / rectifier modules changes as a function of the drive voltage ratings (2400-6600V).
Drive Installation Control / DC Link / Fan Cabinet 2-21 The control / DC link / fan cabinet for all configurations of the PowerFlex 7000 “A” Frame drive is located in the right section. The mounting and location of the DC link inductor, line / load side capacitors, and main cooling fan are shown behind the low voltage control tub. Note: The control / DC link / fan cabinet has the same layout for all drives at 2400-6600 volt ratings.
2-22 Drive Installation Low Voltage Control Tub (Located in Control / DC Link / Fan Cabinet) The low voltage control tub is mounted in front of the DC link inductor in DC link / fan cabinet of the drive. Refer to Chapter 6, Component Definition and Maintenance, for complete content details of the low voltage section. Note: The low voltage control tub has the same layout for all PowerFlex 7000 “A” Frame drive ratings.
Drive Installation 2-23 AC to DC Cosel Power Supply Analog Control Board Fiber Optic Interface Boards Drive Processor Module Board DC to DC Power Supply Hinged Panel (Closed) Hinged Panel (Open) Figure 2.
2-24 Drive Installation IEC Component and Device Designations 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 electrical drawing (ED) set.
Drive Installation 2-25 Cable Insulation The cable insulation requirements for the PowerFlex 7000 “A” Frame 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.
2-26 Drive Installation The following table identifies general wire categories that will be encountered when installing the PowerFlex 7000 “A” Frame Drive. Each category has an associated wire group number that is used in the following sections to identify the wire to be used. Application and signal examples along with the recommended type of cable for each group are provided.
Drive Installation 2-27 The wire sizes must be selected individually, observing all applicable safety and CEC, IEC or 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 with an across-the-line starter. The distance between the drive and motor may affect the size of the conductors used.
2-28 Drive Installation Power Connections 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.
Drive Installation 2-29 411.9 [16.22] 284.9 [11.22] 157.9 [6.22] L1 L2 L3 242.5 [9.55] Note: To access line cables, fan housing and assembly must first be removed. Cable Entry Location (Top Load/Motor Entry) Line Cables L1, L2, L3 700.0 [27.56] 190.6 [7.50] Top Cable Entry Motor Cables U, V, W Removable Barrier for Cable Routing 2314.6 [91.12] 597.5 100.2 [23.52] [3.94] 214.5 [8.44] 2033.2 [80.05] 328.8 [12.94] 1324.8 [52.16] Bottom Cable Entry RH Side Sheet removed for clarity Figure 2.
2-30 Drive Installation Power Connections (cont.) Cable Entry Location (Top) 1000 [39.4] 700.00 [27.56] A B 209.6 [8.25] 480.5 [18.92] 480.5 [18.92] 366.2 [14.42] 1133.0 [44.61] 251.9 [9.92] 429.0 [16.89] 314.7 [12.39] 189.2 [7.45] 2314.6 [91.12] Line Cables L1,L2,L3 Motor Cables U,V,W SECTION B-B SECTION A-A A B Figure 2.
Drive Installation 400.0 [15.75] 112.8 [4.44] 2-31 1000.3 [39.38] 112.8 [4.44] 2314.6 [91.12] 1409.4 [55.49] 1180.8 [46.49] 952.2 [37.49] 412.9 [16.26] SECTION A-A Figure 2.
2-32 Drive Installation Power Connections (cont.) 1000.4 [39.39] 700.0 [27.56] 157.9 [6.22] 731.4 [28.79] 157.9 [6.22] 328.3 [12.92] 1U U 1V V 1W W 1998.0 [78.66] 1890.0 [74.41] 2314.6 [91.12] 1782.0 [70.16] Figure 2.
Drive Installation Power and Control Wiring 2-33 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. After the sections are brought together, the power and control wiring is to be re-connected as per the schematic drawings provided.
2-34 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 IMPORTANT Generally, the means used for external grounding of equipment should be in accordance with the Canadian Electrical Code (CEC), C22.
Drive Installation 2-35 Each power feeder from the substation transformer to the drive must be provided with properly sized ground cables. Utilizing the conduit or cable armor as a ground is not adequate. Note that if a drive isolation transformer is used, the WYE secondary neutral point should not be grounded. Each AC motor frame must be bonded to grounded building steel within 6 m (20 feet) of its location and tied to the drive's ground bus via ground wires within the power cables and/or conduit.
2-36 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 2-37 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.
2-38 Drive Installation 7000A-UM151D-EN-P – March 2013 7000 “A” 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 and Reset Alarm Conditions. • Request printouts of the information in the drive. • Perform diagnostic trending. • Modify the operation of the operator interface.
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 F1 - Help This operation is active on every screen, even if the 'Softkey' is not displayed. Help is context sensitive and will display help that relates to the screen that you are currently viewing. F6 - Alarms The F6 'Softkey' will always get you to the Alarm Summary Screen. A new alarm will cause this key to flash in reverse video. F8 - Next Page When a screen is capable of displaying data that requires more than one page, this 'Softkey' will be active.
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 The help for the additional topic will be displayed as in Figure 3.8 . As with the original help screen, the related topic help may also have related topics. 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.
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 Fault Masks A number of the faults within the drive may be selectively enabled or disabled by you. To view or modify the current fault mask settings, use the up/down arrow keys on the SETUP screen to select the 'Fault Masks' option and press the [enter] key. A typical screen as shown in Figure 3.50 shows all of the user maskable faults. Associated with each fault is the state of the mask. If OFF, it means the fault is disabled and will not occur. The normal state is ON or enabled.
Operator Interface 3-41 Figure 3.52 – AC O/V, Disabled 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 3.54 – AC O/V Removed From List Figure 3.55 – AC O/V Now Enabled The changes to the fault masks do not take effect until the screen is exited via the [F10] key, i.e. exiting the FAULTS OVERVIEW will change the masks in the drive as will exiting the FAULTS SETUP screen. In our example, exiting the FAULTS OVERVIEW screen and returning to the FAULTS SETUP screen now shows the “AC O/V” mask as being ON (Figure 3.56). Figure 3.
Operator Interface 3-43 User Definable External Text The drive contains a number of external fault inputs. You can custom define the text associated with these inputs, which will be used on the alarm screen and the fault mask screens. To define the text, use the up/down arrow keys on the SETUP screen to select the 'External Text' option and press the [enter] key. A screen typical of Figure 3.57 will be seen. Figure 3.
3-44 Operator Interface Figure 3.59 – Modification Completed The changes made do not take affect until you press [F10] and exit the screen. Any time prior to this you may cancel all of the changes made after coming to the screen by pressing the [F7] key. PLC The drive can be optionally connected to a PLC via a RIO (Remote Input/Output) adapter. The drive appears to the PLC as a rack of information. The tags that are associated with each of the words within a rack can be defined.
Operator Interface 3-45 Figure 3.60 – PLC Input Links Figure 3.61 – PLC Output Links 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.
3-46 Operator Interface Message Prompting All the changes you made while you were configuring the drive are stored in volatile memory of the drive. This means that when power to the drive is lost, so will be the changes. To permanently store the changes, the contents of the memory must be stored to NVRAM memory. When you exit a group of screens on which you have changed the drive data, you will be prompted as in Figure 3.62 to save the data.
Operator Interface 3-47 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. This can form a basis for configuring the drive.
3-48 Operator Interface 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. Load The changes that you stored in NVRAM are automatically used each time the drive is powered up. If you make changes to the data in the drive (without saving) and then wish to use the previously stored data, press the [F4] key (Figure 3.66). Figure 3.
Operator Interface 3-49 Figure 3.68 – Feature Select Group Chosen 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.
3-50 Operator Interface The left side of the pair shows the name of the bit, while the right side shows the current value of the bit within the parameter. All of these values are updated from the drive on a continual basis. From the DISPLAY screen, it is possible to modify a parameter. If the group you are currently viewing contains parameters, press the [F7] key. The operator interface then allows you to select the parameter you wish to modify.
Operator Interface 3-51 Figure 3.72 – V Line Assigned The changes take affect immediately, however are not saved until you press [F10] and exit the screen. Any time prior to this you may cancel all the changes made after coming to the screen by pressing the [F7] key. View Drive Status The status of the drive is viewed by pressing the [F7] key from the Top Level Menu. This screen, shown in Figure 3.73, constantly displays the latest status of the drive. Figure 3.
3-52 Operator Interface The screen shows the current status of the drive, as well as the last active Fault that tripped the drive and any pending warning. (The screen only shows a fault and/or warning if the drive is still in the fault and/or warning state. This is independent of the content of the queues.) Note: Terminal FRN > 4.005. To aid in troubleshooting, a time and date stamp is also provided, indicating the last time the drive was started and stopped for any reason.
Operator Interface 3-53 Help for Alarms When viewing the fault or warning queue, help text may be associated with the alarm entry. Use the up/down cursor keys to highlight the alarm in question and press the [enter] key. An ALARM HELP screen, typical of that shown in Figure 3.76 will be shown for that alarm. Not all alarms will have this additional help text. For those alarms the screen shown in Figure 3.77 is displayed. Figure 3.76 – Alarm Help Figure 3.
3-54 Operator Interface The printer can automatically print out the alarms as they occur. This feature is selected as one of the report formats. In the Figure 3.78, the "AUTO - ON" indicates that this feature is currently enabled. To disable the feature, use the [cursor down] key to select the text, and press the [enter] key. The text will change to "AUTO OFF" (if a printer is attached). The automatic alarm printout feature is now disabled.
Operator Interface 3-55 Figure 3.79 – 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. Pressing the [F3] key may restart an aborted download or one that failed prior to starting the download. To select or enter a different filename, press the [F7] key.
3-56 Operator Interface Parameter Transfers The parameters used by the drive are stored within the drive itself. The operator interface is used to review and modify these parameters. When a Drive Control Board is changed, it is necessary to re-enter the parameters into the new board. The operator interface can simplify this process by reading all the parameters from the old Drive Control Board and storing them either in the operator interface or on a flash card.
Operator Interface 3-57 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 3.81, 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.
3-58 Operator Interface Figure 3.82 – 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.
Operator Interface 3-59 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.
3-60 Operator Interface Figure 3.84 – 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.
Operator Interface Operator Interface Menu Hierarchy Chart 3-61 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 3.86 and 3.87. 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.
3-62 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 “A” Frame Select Code : F5 -Code Select Letter : F7 -List : F3 -Lang 'ge F7 -Dir Select Group F7 -Group S F T F5 -Lang 'ge :Language Printer : F3 -Print Select : D Select List : G S F2 -Format F8 -Access T F2 -Format :Format P Meters : F8 -Meters Utility : F2 -Utility Directory : F F3 -Program F7 -Dir :Program F3 -Program R Q Transfer : F7 -Transfer Status : F7 -Status MainMenu : F F5 -NVRAM F4 -Paramtr F F2 -Drv > Crd F1 -Help A F F7 -Dir F6- Alarms
7000A-UM151D-EN-P – March 2013 S T S XIO Setup : T External Setup : : P : F 8 -Access Modify Parameter M Analog Setup Display Custom F 7 -Custom : F 4 -Display R Q Display Group F 9 -Lang 'ge Setup : F 8 -Setup Language : F 8 -Access Setup Wizard Parameters XIO Analog PLC Fault Masks External Text P R Q S D T T S F 9 -Diags F 7 -Toggle : F 7 -Overvw P F 10 & F 10 & ^ F 10 & < F 8 -Access Diag Setup : F 8 -D Setup F 10 - Access Protocol Analyzer F 7 -Ana
Operator Interface PCMCIA Memory Card Installation Data 3-65 Description The memory card slides into the card slot located on the backside of the PowerFlex 7000 drive operator interface. These instructions show how to insert the card in the Operator interface. WARNING 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. WARNING Do not subject memory card to flexing or extreme shock.
3-66 Operator Interface 2. Position the card vertically so the key slot is facing the right side of the operator interface. KEY SLOT Figure 3.89 – Key Slot Orientation 3. Insert the card into the card slot and push until the card is firmly seated. WARNING 7000A-UM151D-EN-P – March 2013 Do not force the card into the slot. Forcing the card into the slot may damage the connector pins.
Chapter 4 Component Definition and Maintenance Cabling Cabinet Components Low Voltage Compartment Line Cable Terminations Hall Effect Sensors Current Transformers Control Power Transformer Fuses Motor Cable Terminations AC Line Reactor Figure 4.
4-2 Component Definition and Maintenance Line Cable Terminations (behind Disconnect Switch) Fused Disconnect Switch Disconnect Switch Operating Handle Vacuum Contactor Assembly Control Power Transformer Control Power Transformer Fuses Motor Cable Terminations (Hall Effect Sensors behind) AC Line Reactor Figure 4.
Component Definition and Maintenance 4-3 Low Voltage Wireway Current Transformer Line Terminals Hall Effect Sensor Motor Cable Terminations Hall Effect Sensor Current Transformer Fan Control Power Transformer Control Power Transformer Fuses Figure 4.
4-4 Component Definition and Maintenance Fan Housing Top Cable Entry and Exit locations Ground Bus Hall Effect Sensors Line Terminals Load Terminals Current Transformers (CT) (Back) (Front) Integral Isolation Transformer Side View Bottom Cable Entry and Exit locations Front View Figure 4.
Component Definition and Maintenance 4-5 Converter Cabinet Components Inverter Modules Isolated Gate Drive Power Supplies (IGDPS) Rectifier Modules Voltage Sensing Boards Figure 4.
4-6 Component Definition and Maintenance Converter Cabinet The converter cabinet contains three rectifier modules and three inverter modules. Figure 4.5 shows a 3300/4160 V converter with a PWM Rectifier. Isolated Gate Driver Power Supplies (IGDPS) are mounted on the cabinet’s right side sheet (6600 V, 2400 V Drives) and on the cabinet’s left side sheet (3300 V, 4160 V Drives). Thermal sensors are installed on the top module of the inverter and rectifier.
Component Definition and Maintenance 4-7 Drive input power from line terminals U V W Heavy duty distribution class surge arrester Figure 4.6 – Surge Arresters Operation The operation of arresters without a gap is the same as that of MOVs. Depending on design, the arrester may also be gapped. Both gapped and ungapped arresters provide adequate overvoltage protection. The arresters are able to withstand or ride through most commonly seen bus transients within their capability.
4-8 Component Definition and Maintenance PowerCage™ A PowerCage is a converter module, consisting of the following elements: • epoxy resin housing • power semi-conductors with gate driver circuit boards • heatsinks • clamp • snubber resistors • snubber capacitors • sharing resistors Each drive consists of three PowerCage rectifier modules and three PowerCage inverter modules. AFE type rectifiers use SGCTs as semi-conductors. All inverter modules use SGCTs as semi-conductors.
Component Definition and Maintenance ATTENTION The SGCT circuit board is sensitive to static charges. It is important that these boards should not be handled without proper grounding. ATTENTION Some circuit boards can be destroyed by static charges. Use of damaged circuit boards may also damage related components. A grounding wrist strap is recommended for handling sensitive circuit boards.
4-10 Component Definition and Maintenance PowerCage™ (cont.) Matched set 2 SGCTs Clamp Base Matched set 2 SGCTs Temperature Feedback Board Module housing Heatsink Clamp head Figure 4.8 – 4-Device PowerCage Matched set 3 SGCTs Matched set 3 SGCTs Clamp Base Heatsink Clamp head Module housing Temperature Feedback board Figure 4.
Component Definition and Maintenance SGCT and Snubber Circuit 4-11 As 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. SHARING RESISTOR SNUBBER RESISTOR SNUBBER CAPACITOR TEST POINT SGCT HEAT SINK HEAT SINK Figure 4.10 – SGCT and snubber circuit In addition to the snubber circuit, a sharing resistor is connected in parallel with the SGCT.
4-12 Component Definition and Maintenance SGCT Device Diameter Clamp Force 400 A SGCT 38 mm 8.6 kN 800 A SGCT 47 mm 13.5 kN 1500 A SGCT 63 mm 20 kN Pressure on the SGCTs must be uniform to prevent damage and to ensure low thermal resistance. Uniform pressure can be achieved by loosening the heatsink mounting bolts, tightening the clamp and then tightening the heatsink bolts. See section “Uniform Clamping Pressure” for instructions.
Component Definition and Maintenance Checking Clamping Pressure 4-13 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 voltagemeasuring device. Failure to do so may result in injury or death.
4-14 Component Definition and Maintenance IMPORTANT Never rotate the calibration 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 Figures 4.11 and 4.12.) Clamp head block DO NOT ADJUST outside nut. SGCT captive screws Disc springs Inside nut used for loosening and applying load to assembly Figure 4.
Component Definition and Maintenance Symmetrical Gate Commutated Thyristor Replacement 4-15 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: • 3300V and 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.
4-16 Component Definition and Maintenance Symmetrical Gate Commutated Thyristor Replacement (cont.) 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.
Component Definition and Maintenance 4-17 7. Clean the heatsink with a soft cloth and rubbing alcohol. 8. While grounded, remove the SGCT from the anti-static bag it is supplied in. 9. Apply a thin layer of Electrical Joint Compound (Alcoa EJC No. 2 or approved equivalent) to the contact faces of the new SGCTs to be installed. The recommended procedure is to apply the compound to the pole faces using a small brush, and then gently wipe the pole face with an industrial wipe so that a thin film remains.
4-18 Component Definition and Maintenance Snubber Resistors Snubber resistors are connected in series with the snubber capacitors. Together they form a simple RC snubber that is connected across each thyristor (SGCT). The purpose of the snubber circuit is to reduce the voltage stress (dv/dt and peak) on the thyristors and to reduce the switching losses. The snubber resistors are connected as sets of various wire-wound resistors connected in parallel.
Component Definition and Maintenance Fiber Optic Cabling 4-19 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.
4-20 Component Definition and Maintenance D.C. Link / Fan / Control Components Low voltage Control Tub Retaining Hardware Fan AC/DC Power Supply Inlet Ring M+ L+ Analog Drive Control Board L- M- DC Link Inductor Grounding Network/ Filter Motor Filter Capacitor Medium Voltage Barrier (for access to Line/Motor Capacitors) Figure 4.16 – DC Link and Fan cabinet with low voltage control tub shown Line Filter Capacitor Figure 4.
Component Definition and Maintenance 4-21 Filter Capacitors Filter capacitors are used on the motor side for all drives. The AFE rectifier option also includes filter capacitors on the line side. Refer to Figure 4.17 (DC Link and Fan Cabinet with control panel removed). The filter capacitors are three-phase four-bushing units and “oil-filled”. The three-phase capacitors are comprised of internal single-phase units that are connected in a Y configuration.
4-22 Component Definition and Maintenance D.C. Link / Fan / Control Components (cont.) Generator Note: WARNING Verify that the load is not turning due to the process. A freewheeling motor can generate voltage that will be back-fed to the equipment being worked on. Filter Capacitor Replacement 1. Ensure there is no power to the equipment. ATTENTION ATTENTION To prevent electrical shock, ensure the main power has been disconnected before working on the capacitor.
Component Definition and Maintenance 4-23 8. Install the new capacitor, sliding it back until it fits into the slot. Fasten the top bracket and grounding network. 9. Reconnect all the power cables and the ground connection. These use M14 hardware, but should only be tightened to 30 Nm (22 ft-lbs.) due to capacitor mechanical constraints. 10. Remove any shorting/grounding conductors. 11. Reinstall the sheet metal that was removed, and complete one final check to ensure connections are secure and correct.
4-24 Component Definition and Maintenance D.C. Link / Fan / Control Components (cont.) 2. Follow appropriate safety steps to isolate the equipment from medium voltage. 3. Verify that there is no voltage present on the capacitor by using a hot stick or any other appropriate voltage-measuring device. 4. Perform visual inspection to ensure there is no oil leak or bulge in any of the capacitors. 5.
Component Definition and Maintenance ATTENTION 4-25 Verify the load is not running due to process. A freewheeling motor can generate voltage that will be back-fed to the equipment being worked on. 2. Follow appropriate safety steps to isolate the equipment from medium voltage. 3. Verify that there is no voltage present on the capacitor by using a hot stick or any other appropriate voltage-measuring device. 4. Perform visual inspection to ensure there is no oil leak or bulge in any of the capacitors. 5.
4-26 Component Definition and Maintenance D.C. Link / Fan / Control Components (cont.) e.g. - the capacitor under test is rated at 400 kVAR, 6600V, 50Hz, 29.2 µF. You are using 200V, 50Hz test power and have recorded the values of voltage and current for each test as given in the table below. Phase - Neutral Test Voltage Measured Current L1-N 200V 1.87A L2-N 200V 1.866A L3-N 200V 1.861A Let us calculate the capacitance using the first reading. In this case: V = 200V, I = 1.
Component Definition and Maintenance 4-27 Recommended Digital Multimeters (DMM) to be used for checking filter capacitors BK Precision LCR/ESR Meter, Model 885 Fluke 179 Fluke 12 Fluke 29 Fluke 87V Figure 4.
4-28 Component Definition and Maintenance Fan Replacement There are several models of cooling fans used in PowerFlex drives. Differing fan types may be used in the various locations throughout the drive. DC Link Section The fan consists of a motor impeller assembly. To replace the fan, it is necessary to remove the fan exhaust hood. See Figure 4.20. To prevent electrical shock, ensure the main power has been disconnected before working on the current transformer.
Component Definition and Maintenance 4-29 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. Top of Integral Isolation Transformer Section Cross Channel Mounting Holes Terminal Blocks Fan Inlet Ring Figure 4.21 – Isolation Transformer Fan Removal 1.
4-30 Component Definition and Maintenance Fan Replacement (cont.) Top of Integral Line Reactor and Input Starter Section Ventilator Cover Terminal Blocks Fan Mounting Bracket Fans Figure 4.22 – Starter/Line Reactor Cabinet Fan Removal 1. Remove the top ventilation cover from the exterior of the cabinet. 2. Remove mounting screws and invert fan mounting bracket to expose fan mounting hardware. 3. Unplug or disconnect fan leads from terminal blocks and replace fan. 4.
Component Definition and Maintenance Impeller Maintenance (DC Link / Fan Section) 4-31 Impeller Removal from Motor Shaft The fan impeller is held onto the motor shaft with a split tapered bushing. This bushing is positioned on the motor shaft and through the center of the impeller. Two cap screws, when tightened to 10.2 N-m (7.5 ft-lbs.), lock the bushing onto the motor shaft and the impeller to the bushing. Safety notes The impeller is fragile.
4-32 Component Definition and Maintenance Impeller Maintenance (DC Link / Fan Section) (cont.) 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 cap screws from the bushing.
Component Definition and Maintenance 4-33 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 cap screws 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.
4-34 Component Definition and Maintenance Impeller Maintenance Isolation Transformer Cooling Fan The isolation transformer fan motor and impeller is an integral unit and cannot be serviced separately. Inlet Ring Removal and Replacement The inlet ring is the large circular part located beneath the fan impeller. It is positioned such that the impeller sits outside but does not touch the ring. The ring sits inside the impeller 10 mm (0.40 inches).
Component Definition and Maintenance 4-35 4. To install the new ring, reverse the above procedure. Rotate the fan impeller by hand to ensure that there is no contact with the inlet ring. Move the ring and retighten bolts to eliminate interference. 5. Replace all panels and barriers opened or removed during inlet ring replacement. Top of Integral Isolation Transformer Section 1. Remove fan as described in “Fan Replacement”. 2. Disassemble bolts and remove inlet ring. 3.
4-36 Component Definition and Maintenance Replacement of Air Filters (cont.) Recommended cleaning method of filters: 1. Vacuum Clean – A few passes of a vacuum cleaner on the inlet side of the filter will remove accumulated dust and dirt in seconds. 2. Blow with Compressed Air – point compressed air nozzle in opposite direction of operating air flow (Blow from exhaust side toward intake side) 3. Cold Water Rinse – Under normal conditions the foam media used in the filters, require no oily adhesives.
Component Definition and Maintenance 4-37 Figure 4.25 – Air Flow Pattern for Drive Cooling Figure 4.
4-38 Component Definition and Maintenance Control Power Components 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. AFE Rectifier with DTD DC Link – Conf. #1 (refer to Figure 4.27) 2. AFE Rectifier with Separate Isolation Transformer – Config. #2 (refer to Figure 4.28) 3. AFE Rectifier with Integral Isolation Transformer – Config. #3 (refer to Figure 4.
Component Definition and Maintenance 4-39 Figure 4.28 illustrates the control power distribution for AFE drives with remote transformer/starter (A) or integrated line reactor with remote starter (B).
4-40 Component Definition and Maintenance Control Power Components (cont.) Figure 4.29 illustrates the control power distribution for AFE drives with integral transformer and remote starter.
Component Definition and Maintenance AC/DC Power Supply 4-41 The load demands on the AC/DC converters are the DC/DC converter and up to six IGDPS modules. The DC/DC is a fixed load; however, the quantity of IGDPS modules will vary depending upon the drive configuration. Description The AC/DC power supply accepts single phase voltage and produces a regulated 56V DC output for the DC/DC power supply and the HV IGDPS modules that power the SGCTs.
4-42 Component Definition and Maintenance AC/DC Power Supply (cont.) Location The AC/DC power supply is located in the low voltage panel at the top right-hand section of the drive. A typical low voltage compartment is shown in Figure 4.31. AC/DC Power Supply (Pioneer) Figure 4.
Component Definition and Maintenance 4-43 AC/DC Power Supply (Cosel) Figure 4.
4-44 Component Definition and Maintenance Low Voltage Control Section The low voltage control section 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 4.33 for a generic representation of a low voltage tub arrangement.
Component Definition and Maintenance 4-45 AC to DC Cosel Power Supply Analog Control Board Fiber Optic Interface Boards Drive Processor Module DC to DC Power Supply Hinged Panel (Closed) Hinged Panel (Open) Figure 4.
4-46 Component Definition and Maintenance DC/DC Power Supply Description The DC/DC power supply is used as a source of regulated DC voltages for various logic control boards and circuits. The input to this power supply is from a regulated 56V DC source. +5V - LOGIC + 56VDC - C hold-up DC/DC Power Supply +/-15V - LOGIC +/- 24V - HECS +24V - ISOLATOR +24 - XIO Sense Cable Figure 4.35 – DC/DC converter power supply The capacitor at the input terminals is for power dip ride-through purposes.
Component Definition and Maintenance 4-47 IO Connectors on Control Boards MOTOR & LINE AC VOLTAGE FEE DBA CK INPUTS MOTOR &LINE DC LINK AND NEUTRAL POINT VOLTAGE INTPUTS J27 LINE VOLTAGE SY NC .
4-48 Component Definition and Maintenance Drive Processor Module This board contains the control processors. It is responsible for all the drive control processing and stores all of the parameters used for the drive control. Figure 4.
Component Definition and Maintenance ACB Analog Control Board 4-49 The Analog Control Board (ACB) is the hub for all control-level signals external to the drive. Analog I/O, External Fault signals (through the XIO board), ScanPort/DPI communication modules, Remote I/O, terminal interface, printers, modem, and other external communication devices are routed through this board. Figure 4.
4-50 Component Definition and Maintenance ACB Analog Control Board (cont.) Interface Module (IFM) The Interface Module is used to make all customer useable connections to the ACB. The pin numbers listed on the following pages refer to IFM pin numbers. Even pin numbers Odd pin numbers Connection to ACB (J8) Figure 4.
Component Definition and Maintenance External Input/Output Boards 4-51 The External Input/Output (XIO) Boards are connected through a network cable (CAN Link) to the Analog Control Board (ACB). This cable may be connected to either XIO Link A (J4) or XIO Link B (J5). The XIO board handles all external Digital Input and Output signals and sends them to the ACB through the cable.
4-52 Component Definition and Maintenance LED D1 and display U6 indicate the status of the board. The following table illustrates the possible states for D1.
Component Definition and Maintenance Optical Interface Boards 4-53 The Optical Interface (OIB) Boards are the interface between the DPM and the Gate Driver circuitry. The drive control decides which device to fire, and sends an electrical signal to the OIB boards. The OIB board converts that electrical signal to an optical signal, which is transmitted via fiber optics to the gate driver cards. Typically, the Transmit ports are Grey and the Receive ports are Blue.
4-54 Component Definition and Maintenance Optical Interface Boards (cont.) Figure 4.
Component Definition and Maintenance 4-55 Each OIB also has input RX7 for a signal from a Temperature Feedback Board. The quantity and location of thermistor connections is dependant on the drive configuration. Typically there is one temperature sensor from the Line Converter and one temperature sensor from the Machine Converter, each going into the respective OIB in the ‘A’ position. However some drive configurations only require one thermistor feedback connection.
4-56 Component Definition and Maintenance Environmental Consideration (cont.) • Capacitor Dielectric Fluid The fluids used in the filter capacitors and the snubber capacitors are generally considered very safe and are fully sealed within the capacitor housings. Shipping and handling of this fluid is not restricted under any regulations. In the unlikely event that capacitor fluid leaks out, avoid ingestion or contact with skin or eyes as slight irritation could result.
Component Definition and Maintenance • 4-57 In Case Of Fire This drive is highly protected against arcing faults and therefore it is very unlikely the drive would be the cause of a fire. In addition, the materials in the drive are self-extinguishing (i.e. they will not burn without a sustained external flame). If, however, the drive is subjected to a sustained fire from some other source, some of the polymer materials in the drive will produce toxic gases.
4-58 Component Definition and Maintenance 7000A-UM151D-EN-P – March 2013 7000 “A” Frame
Appendix A 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 9:00 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 “A” Frame 1.
A-2 Commissioning Start-up Commissioning Services (cont.) 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.
Appendix B Catalog Number Explanation for PowerFlex 7000 Variable Frequency Drives First Position 7000 Bulletin Number Second Position – A Service Duty/ Altitude Code Third Position Fourth Position Fifth Position 40 D A Current Rating Enclosure Type Line and Control Voltages Code 7000A Description “A” Frame (Air Cooled) Code D 7000 “B” Frame (Air Cooled) T 7000L “C” Frame (Liquid Cooled) Description Type 1 w/gasket (IP21) Type 1 w/gasket (IP21) – Seismic rated Type 12 w/vents and fi
B-2 Catalog Number Explanation – Drive Selection Table B-1 – Supply Voltage, Control Voltage, Frequency and Control Power Transformer Selection Voltage Nominal Line 2400 3300 4160 6600 Frequency Control 120 120-240 110 220 110 220 120 120-240 110 220 110-220 (Hz) 60 50 50 60 50 Modification Number With a Without a C.P.T. C.P.T. A AD AA — CY CDY CP CDP EY EDY EP EDP E ED EA — JY JDY JP JDP JAY — A Control Power Transformer modification must be selected (6, 6B ...etc.) to size the transformer.
Catalog Number Explanation – Drive Selection PowerFlex 7000 Drive Selection Explanation B-3 The PowerFlex 7000 medium voltage AC drive selection tables are based on two (2) types of drive service duty ratings: 1) 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.
B-4 Catalog Number Explanation – Drive Selection When When is is aa tachometer tachometer required? 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.
Catalog Number Explanation – Drive Selection PowerFlex 7000 Performance (Torque Capabilities) B-5 The PowerFlex 7000 drives have been tested on a dynamometer to verify performance under locked rotor, accelerating, and low speedhigh torque conditions. Table B-4 below shows the PowerFlex 7000 drive torque capabilities as a percent of motor rated torque, independent of the drive’s momentary overload conditions.
B-6 Catalog Number Explanation – Drive Selection Table B-5 – Typical Application Load Torque Profiles * Application Load Torque Profile Load Torque as Percent Required Drive Tachometer of Full-Load Drive Torque Service Required for Extra Duty Rating Starting Torque? Break-away Accelerating Peak Running 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) Star
Appendix C Torque Requirements for threaded fasteners Unless otherwise specified the following values of torque are to be used in maintaining the equipment. 7000 “A” 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.
C-2 Torque Requirements 7000A-UM151D-EN-P – March 2013 7000 “A” 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. The ground fault condition indicates a phase conductor has found a path to ground. Depending on the resistance of the path to ground, a current with magnitude ranging from leakage to fault level exists.
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 7000A is to be performed. Failure to comply with 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. Reconnect the Power Circuit to the System Ground Voltage Sensing Boards Securely reconnect 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.
Appendix E Preventative Maintenance Schedule 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.
E-2 Preventative Maintenance Schedule Annual Maintenance 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. Investing approximately 8.
Preventative Maintenance Schedule E-3 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.
E-4 Preventative Maintenance Schedule Annual Maintenance (cont.) Control Power Checks (No Medium Voltage) Apply Control power to the PowerFlex 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.
Preventative Maintenance Schedule E-5 Additional Tasks During Preventive Maintenance Investigation of customer’s concerns relating to drive performance Relate any problems found during above procedures to customer issues.
E-6 Preventative Maintenance Schedule Annual Maintenance (cont.) 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.
Preventative Maintenance Schedule E-7 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.
E-8 Preventative Maintenance Schedule Rockwell recognizes that following a defined maintenance schedule will PowerFlex 7000 Maintenance Schedule deliver the maximum product availability. By rigorously following this maintenance schedule, the Customer can expect the highest possible uptime.
E-9 Preventative Maintenance Schedule Rockwell Automation PowerFlex 7000 Preventative Maintenance Service Schedule Interval Period (in years) Commissioning Activities Air-Cooling System Liquid-Cooling System Power Switching Components Integral Magnetics/Power Filters Control Cabinet Components Connections Enhancements Operational Conditions Spare Parts Door Mounted Air Filters Main Cooling Fan Motor Redundant Cooling Fan Motor (if supplied) Small Aux.
E-10 Preventative Maintenance Schedule Rockwell Automation PowerFlex 7000 Preventative Maintenance Service Schedule (cont.
Preventative Maintenance Schedule General Notes E-11 Maintenance of Medium Voltage Motor Control Equipment ATTENTION Servicing energized Medium Voltage Motor Control Equipment can be hazardous. Severe injury or death can result from electrical shock, bump, or unintended actuation of controlled equipment. Recommended practice is to disconnect and lockout control equipment from power sources, and release stored energy, if present.
E-12 Preventative Maintenance Schedule General Notes (cont.) Contamination If inspection reveals that dust, dirt, moisture or other contamination has reached the control equipment, the cause must be eliminated. This could indicate unsealed enclosure openings (conduit or other) or incorrect operating procedures. Replace any damaged or embrittled seals and repair or replace any other damaged or malfunctioning parts (e.g., hinges, fasteners, etc.).
Preventative Maintenance Schedule Part-specific Notes E-13 Cooling Fans Inspect fans used for forced air cooling. Replace any that have bent, chipped, or missing blades, or if the shaft does not turn freely. Apply power momentarily to check operation. If unit does not operate, check and replace wiring, fuse, or fan motor as appropriate. Clean or change air filters as recommended in the Users Manual. Operating Mechanisms Check for proper functioning and freedom from sticking or binding.
E-14 Preventative Maintenance Schedule Part-specific Notes (cont.) Power Cable and Control Wire Terminals Loose connections in power circuits can cause overheating that can lead to equipment malfunction or failure. Loose connections in control circuits can cause control malfunctions. Loose bonding or grounding connections can increase hazards of electrical shock and contribute to electromagnetic interference (EMI).
Preventative Maintenance Schedule E-15 Solid-State Devices ATTENTION Use of other than factory recommended test equipment for solid-state controls may result in damage to the control or test equipment or unintended actuation of the controlled equipment. Refer to paragraph titled HIGH VOLTAGE TESTING. Solid-state devices require little more than a periodic visual inspection. Discolored, charred or burned components may indicate the need to replace the component or circuit board.
E-16 Preventative Maintenance Schedule 7000A-UM151D-EN-P – March 2013 7000 “A” Frame
Appendix F Specifications Specifications Description Power Rating (Air Cooled) Motor Type Input Voltage Rating Input Voltage Tolerance Voltage Sag Control Power Loss Ride-Through Input Protection Input Frequency Power Bus Short-circuit Current Withstand 3300 V – 6000 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
F-2 Specifications Specifications (cont.
Specifications Description Control Power External I/O External Input Ratings External Output Ratings Analog Inputs Analog Resolution Analog Outputs Communication Interface Scan Time Communications Protocols (Optional) Enclosure Lifting Device Mounting Arrangement Structure Finish Interlocking Corrosion Protection Fiber Optic Interface Door Filter Door Filter Blockage Ambient Temperature Storage and Transportation Temperature Range Relative Humidity Altitude (Standard) Altitude (Optional) Seismic (UBC Rat
F-4 Specifications Dimensions / Weights Nominal Line Voltage 2400V 60 Hz or 3300V 50 Hz or 4160V 50/60 Hz 6600V 50/60 Hz Note: Drive Type Configuration #1 – Direct-to-Drive Configuration #2 – AFE Rectifier with separate isolation transformer Configuration #3 – AFE Rectifier with Integral isolation transformer Configuration #1 – Direct-to-Drive Configuration #2 – AFE Rectifier with separate isolation transformer Configuration #3 – AFE Rectifier with integral isolation transformer VFD Maximum Current 14
Medium Voltage Products, 135 Dundas Street, Cambridge, ON, N1R 5X1 Canada, Tel: (1) 519.740.4100, Fax: (1) 519.623.8930, www.ab.com/mvb Publication 7000A-UM151D-EN-P – March 2013 Supersedes 7000A-UM151C-EN-P – October 2010 Copyright © 2010 Rockwell Automation, Inc. All rights reserved. Printed in Canada.
