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PowerFlex® 7000 Medium Voltage AC Drive

Air-Cooled (‘A’ Frame) – Fourth Generation (ForGe) Control

Bulletin 7000A

Reference Manual

Summary of content (412 pages)

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PowerFlex® 7000 Medium Voltage AC Drive Air-Cooled (‘A’ Frame) – Fourth Generation (ForGe) Control Bulletin 7000A Reference Manual
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Important User Information Solid-state equipment has operational characteristics differing from those of electro-mechanical 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://literature.rockwellautomation.com describes some important differences between solid-state equipment and hard-wired electromechanical devices.
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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 .....
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ii Table of Contents Chapter 2 Drive Installation (cont.) Cabling Cabinet #1 (with Input Starters) ...............................2-21 Cabling Cabinet #1 (without Input Starters) ......................... 2-22 Cabling Cabinet #2 ................................................................2-23 Cabling Cabinet #3 ................................................................2-24 Converter Cabinet ..................................................................2-25 Control/DC Link/Fan Cabinet .....
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Table of Contents Chapter 3 7000 “A” Frame Operator Interface (cont.) What is a Screen? ..............................................................3-5 Components ................................................................3-5 Information Windows .................................................3-6 Accessing/Writing to Drive ..................................3-7 Communication Error ...........................................3-7 Language Changing .............................................
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iv Table of Contents Chapter 3 Operator Interface (cont.) View Drive Status ...........................................................3-51 View and Reset Alarms ...................................................3-51 Help for Alarms ........................................................3-52 Request Printouts ............................................................3-53 Perform Diagnostic Trending ..........................................3-54 Assigning a Trace .....................................
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Table of Contents Chapter 4 7000 “A” Frame Commissioning (cont.) Service Manual ....................................................................... 4-9 Reference Manual ................................................................... 4-9 Important Note for Commissioning Engineer ...................... 4-10 Key Steps to Commissioning a PowerFlex 7000 Drive ........ 4-11 Commissioning Datasheets ................................................... 4-12 Commissioning Check List ......................
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vi Table of Contents Chapter 4 Chapter 5 Commissioning (cont.) Converter Cabinet Components (6600V) .................4-43 IGDPS Board LEDs ..................................................4-44 Gating Tests ...........................................................................4-45 Gating Tests Mode ..........................................................4-45 SGCT Firing Test ............................................................4-47 System Test .............................................
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Table of Contents Chapter 5 Component Definition Surge Arresters ..................................................................... 5-10 and Maintenance Description ..................................................................... 5-10 (cont.) Operation ........................................................................ 5-11 Surge Arrester Replacement ........................................... 5-11 Field Test and Care ........................................................ 5-12 PowerCage™ ..
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viii Table of Contents Chapter 5 Component Definition and Maintenance (cont.) 7000A-RM001A-EN-P – January 2011 Impeller Maintenance ...........................................................5-54 Isolation Transformer Cooling Fan .................................5-54 Inlet Ring Removal and Replacement ...................................5-54 Safety Notes ....................................................................5-54 DC Link / Fan Section .....................................................
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Table of Contents Chapter 5 Component Definition and Maintenance (cont.) Appendix A Catalog Number Explanation Downloading Firmware .......................................................5-101 Introduction ...................................................................5-101 Overview .......................................................................5-101 Preparation for Downloading Firmware ..............................5-102 PF7000 in Download Mode ..........................................
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x Table of Contents Appendix D Preventative Maintenance Appendix E Specifications 7000A-RM001A-EN-P – January 2011 Preventive Maintenance Check List ....................................... D-1 Operational Maintenance ........................................................ D-1 Annual Maintenance ............................................................... D-2 Initial Information Gathering ........................................... D-2 Physical Checks (NO Medium Voltage and NO Control Power) ......
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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 information specific to the PowerFlex 7000 “A” Frame drive. Therefore customer specific topics are not presented.
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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.
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Preface General Precautions 7000 “A” Frame 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 8000-4.5.2, “Guarding Against Electrostatic Damage” or any other applicable ESD protection handbook.
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P-4 Preface Who to Call for Commissioning Rockwell Automation Medium Voltage Support group is responsible for Commissioning Support and activities in our product line. They may be contacted at 519-740-4100, request Medium Voltage Support – Project Manager. The support they offer includes, but is not limited to: – – – 7000A-RM001A-EN-P – January 2011 Quoting and Managing Product On-site Start-ups. Quoting and Managing Field Modification projects.
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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.
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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.
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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.
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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.
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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).
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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.
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Overview of Drive SGCT Features and Benefits 1-7 An SGCT is a thyristor with an integrated gate drive. Positioning the gate drive close to the SGCT as shown in Figure 1.4, creates a low inductance path that provides more efficient and uniform gating of the device. As a result, the device is better suited to handle the fluctuating levels of voltage and current while it is switching on and off during gating.
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1-8 Overview of Drive Simplified Electrical Drawings – 2400V with AFE Rectifier LINE CONVERTER DC LINK L+ M+ SGCTs MACHINE CONVERTER 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 DC LINK L+ MACHINE CONVERTER M+ SGCTs SGCTs 2U (X1) U (T1) 1V 2V (X2) V (T2) 1W 2W (X3) W (T3) 1U L- M- 2400 Volt – AFE Rectifier, Configuration
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Overview of Drive 1-9 Simplified Electrical Drawings – 3300/4160V with AFE Rectifier LINE CONVERTER DC LINK L+ M+ MACHINE CONVERTER 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 MACHINE CONVERTER DC LINK L+ M+ SGCTs SGCTs 1U 1V 1W 2U (X1) U (T1) 2V (X2) V (T2) 2W (X3) W (T3) L- M- 3300/4160 Volt – AFE Rectifier, Co
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1-10 Overview of Drive Simplified Electrical Drawings – 6600 V with AFE Rectifier LINE CONVERTER DC LINK L+ M+ MACHINE CONVERTER 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 1U 1V 1W MACHINE CONVERTER M+ 2U (X1) U (T1) 2V (X2) V (T2) 2W (X3) W (T3) L- M- 6600 Volt – AFE Rectifier, Configuration #
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Overview of Drive 1-11 Control Overview Line Converter Machine Converter DC Link Inductor Faults Line Synch Current Control Machine gating and diagnostic feedback Machine Side Control Idc ref. Ref. Current and phase shift calculator Machine Converter Feedback Machine Converter Protection (HW) Faults Machine Converter Protection (SW) Tach. Feedback Line Converter Protection Line Side Control Motor Faults Line gating and diagnostic feedback Sync.
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1-12 Overview of Drive Control Hardware The control hardware includes a Drive Processor Module (DPM) with an interface to six Optical Interface Boards (OIB) (depending on the voltage and number of switching devices) via the Optical Interface Base Board (OIBB), an Analog Control Board (ACB) and an external IO board (XIO). The control hardware is used for rectifier and inverter, induction or synchronous drive control and all configurations.
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Overview of Drive 1-13 Operator Interface Figure 1.7 – 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.
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1-14 Overview of Drive 7000A-RM001A-EN-P – January 2011 7000 “A” Frame
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Chapter 2 Drive Installation Safety and Codes Unpacking and Inspection 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.
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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.
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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.
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2-4 Drive Installation Transportation and Handling (cont.) 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 mm x 150 mm (2 in. x 6 in.) or equivalent and at least 300 mm (12 inches) longer than the drive must be placed under the shipping skid. 2. Carefully ease the shipping platform over the roller pipes until the drive weight is borne on the roller pipes. 3. The drive can be rolled to its designated location.
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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 -40°C and 70°C (-40°F and 185°F). If storage temperature fluctuates or if humidity exceeds 95%, 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.
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2-6 Drive Installation Siting of the Drive (cont.) (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.
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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.
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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.
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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 All the components are shipped assembled. Figure 2.
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2-10 Drive Installation Installation (cont.) Locate the exhaust hood on top of the cabinet per Figure 2.6 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 2.5), locate the exhaust hood (refer to Figure 2.7).
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Drive Installation 2-11 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.
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2-12 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.
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Drive Installation 2-13 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.
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2-14 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.
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Drive Installation External Ducting The PowerFlex 7000’s design allows for its exhaust air to be ducted outside of the control room. In this case, consideration must be given to the conditions present in the atmosphere outside the control room.
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2-16 Drive Installation Cabinet Layout and Dimensional Drawings of Drive 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.
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Drive Installation 2-17 PowerFlex 7000 “A” Frame Dimensional Drawing SAMPLE Note: Contact Factory for Seismic Mounting Information.
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2-18 Drive Installation Drive Layout 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 Cabinet Converter Cabinet Control/DC Link/Fan Cabinet Figure 2.
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Drive Installation 2-19 Configuration #2 AFE Rectifier (Separate Isolation Transformer) Cabling Cabinet Converter Cabinet Control/DC Link/Fan Cabinet Figure 2.
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2-20 Drive Installation Configuration #3 AFE Rectifier (Integral Isolation Transformer) Isolation Transformer and Cabling Cabinet Converter Cabinet Control/DC Link/Fan Cabinet Figure 2.
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Drive Installation Cabling Cabinet #1 2-21 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 2.16). The width of the cabinet changes as a function of the drive voltage ratings.
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2-22 Drive Installation 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.
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Drive Installation Cabling Cabinet #2 2-23 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 Hall Effect Sensor Line Cable Terminations Motor Cable Terminations Hall Effect Sensor Current Transformer Fan Control Power Transformer Control Power Transformer Fuses Figure 2.
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2-24 Drive Installation Cabling Cabinet #3 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.
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Drive Installation Converter Cabinet 2-25 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).
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2-26 Drive Installation Control / DC Link / Fan Cabinet 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.
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Drive Installation Low Voltage Control Tub (Located in Control / DC Link / Fan Cabinet) 2-27 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.
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2-28 Drive Installation Low Voltage Control Tub (Located in Control / DC Link / Fan Cabinet) (cont.) 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.
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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 electrical drawing (ED) set.
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2-30 Drive Installation Power Wiring Selection (cont.) 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.
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Drive Installation 2-31 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.
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2-32 Drive Installation 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.
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Drive Installation Power Connections 2-33 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.
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2-34 Drive Installation 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 [3.94] [23.52] 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.
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Drive Installation Cable Entry Location (Top) 2-35 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.
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2-36 Drive Installation 400.0 [15.75] 112.8 [4.44] 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.
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Drive Installation 1000.4 [39.39] 2-37 700.0 [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] 2314.6 [91.12] 1890.0 [74.41] 1782.0 [70.16] Figure 2.
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2-38 Drive Installation 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. After the sections are brought together, the power and control wiring is to be re-connected as per the schematic drawings provided.
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Drive Installation 2-39 • Protection from Radiated and Conducted Noise Reasonable care should be taken when connecting and routing power and signal wiring on a machine or system. Radiated noise from nearby relays, solenoids, transformers, non linear loads (such as motor drives) etc. can couple onto signal wires producing undesired pulses. In fact the encoder itself may induce noise into signal lines run adjacent to it.
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2-40 Drive Installation Power and Control Wiring (cont.) • Signal Distortion The primary cause of signal distortion is cable length, more specifically cable capacitance. Generally speaking the longer the cable length the more there is a chance of signal distortion at the receiving end. The receiving end responds to either a logical ‘0’ or a logical ‘1’. Anywhere in between is undefined and the transition through this region should be < 1.0us.
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Drive Installation 2-41 • Unused Inputs Not all inputs, in either the quadrature or absolute encoders, may be necessary. For example, the absolute encoder can accept a 12bit encoder but will work with a lower resolution. Likewise, quadrature encoders may not utilize the Z track. The following should be used for unused inputs: 1. 20B-ENC Board. Any unused input should be wired to the encoder power rail. This also includes the B and B’ inputs if using a pulse tachometer.
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2-42 Drive Installation Grounding Practices (cont.) Connected to the neutral point of the output capacitor ISOLATION TRANSFORMER U (T1) 2U OUTPUT GROUND NETWORK 2V 2W AC MOTOR V (T2) W (T3) GROUND BUS Figure 2.27 – Ground Connection Diagram with Isolation Transformer TRANSFORMER Connected to the neutral point of the output capacitor AC LINE REACTOR U (T1) 2U 2V GROUND FILTER 2W AC MOTOR V (T2) W (T3) GROUND BUS Figure 2.
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Drive Installation 2-43 Grounding Guidelines and Practices for Drive Signal and Safety Grounds When interface cables carrying signals where the frequency does not exceed 1 MHz are attached for communications with the drive, the following general guidelines should be followed: • It is good practice for the mesh of a screen to be grounded around its whole circumference, rather than forming a pigtail that is grounded at one point.
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2-44 Drive Installation Identification of Types of Electrical Supplies – Grounded and Ungrounded Systems When dealing with an ungrounded, three-phase electrical supply system, the cable insulation must be capable of handling not only the phase to phase voltage, but also the voltage to ground if one of the other phases develops a ground fault. In practice, the cable insulation of an ungrounded, three-phase system must be good for at least a continuous voltage of root three (1.732) times (1.
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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.
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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.
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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.
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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.
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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.
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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.
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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 ...".
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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 ...
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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".
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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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.
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Operator Interface 3-55 From this screen, additional screens are accessible to perform the diagnostic trending functions. The screen shows the current status of the trend, (Unprogrammed, Running, Triggered, Stopped). If a trigger has been defined, the trigger parameter, its trigger condition and the type of trigger will be displayed. If data has already been captured, a time stamp indicating the last time the given trigger has occurred. This captured data can be viewed by pressing the [F9] softkey.
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3-56 Operator Interface 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. From this screen you may also set the interval between samples (i.e.
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Operator Interface 3-57 The condition is set to one of the conditions listed below by pressing the [cursor up] or [cursor down] keys to scroll through the conditions. Pressing [enter] ends the editing and accepts the shown condition. Trigger Conditions: = N= > < + N+ & N& Equal to Not Equal to Greater than Less than Boolean OR Boolean NOR Boolean AND Boolean NAND The value (data) is set through the use of the numerical keypad. Use the data entry keys [0]-[9] to enter the new value.
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3-58 Operator Interface Defining Sample Rate and Positioning Pressing the [F4] key sets the rates at which the samples are taken. This data field is then modified in the same manner as the trigger data is entered. Rates can be set from 0 msec (collect as fast as possible) to 20.000 seconds. When samples are collected, part of the buffer will store values prior to the trigger point and the remainder of the buffer will store values after the trigger.
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Operator Interface 3-59 Once the data has started to be collected, the status will show 'triggered' as in Figure 3.84. When the buffer contains a complete capture, it will show “stopped” (if a single capture), as shown in Figure 3.85. The time and date at which the trigger occurred is displayed. The trend buffers may only be viewed when their status is ‘stopped’. If in continuous mode, the capture will stop when the buffers are viewed. To view the trend buffers, press the [F9] key. Figure 3.
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3-60 Operator Interface Flash Memory Transfers Flash memory is used to store data in a non-volatile environment that is it is not lost when power is removed. The operator interface contains flash memory in two forms. The first is built into the operator interface. This form of flash is used to store the operator interface’s firmware and parameters from the drive. This information can also be stored on a removable flash memory card.
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Operator Interface 3-61 Figure 3.87 – Transfer Main Menu From this screen, additional screens are used to perform the various functions involving the flash memory. The screen shows the current access level of the operator interface. Any operation that will alter the contents of the flash memory or of the drive requires the access level to be something other than 'Monitor'. At the 'Monitor' level you may view the contents of the flash card. To change the access level, press the [F8] key.
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3-62 Operator Interface The screen will then ask you to confirm the operation. Press the [F8] key to proceed, or the [F9] key to abort. Performing a format will overwrite all existing data on the flash card. Formatting can take up to several minutes depending on the card involved. The status will indicate when the formatting is complete or if an error occurred. Additional cards may be formatted from this screen by pressing the [F2] key.
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Operator Interface 3-63 Select a Filename When working with existing files on the flash card, it is necessary to pick a file from the directory in order to use in the operation being performed. When the DIRECTORY screen is entered, all files that are relevant to the operation are displayed. The [cursor up] and [cursor down] keys are then used to select the desired file. Pressing [Enter] will select the file and proceed with the operation.
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3-64 Operator Interface From the TRANSFER screen, press the [F3] key. The operator interface will enter the DIRECTORY screen from which an existing firmware filename can be selected or entered. Refer to the sections entitled “Select a filename” and “Enter a filename”. (If nothing happens then you have not gained the required access to modify the flash memory. Exit to the TRANSFER screen and refer to the section entitled Enter/Modify an Access Level to gain access).
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Operator Interface 3-65 When the transfer completes successfully, the new firmware will automatically begin operation. Refer to the section Operator Interface Power-up Sequence. 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).
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3-66 Operator Interface Figure 3.92 – Transfer Parameters Menu 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.
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Operator Interface 3-67 Upload to Memory Card The parameters are read from the drive and stored on a memory card by pressing the [F4] key. The operator interface will enter the DIRECTORY screen in which a parameter filename can be entered. Refer to the section entitled “Enter a filename”. When the filename has been obtained, the TRANSFER: PARAMETERS screen such as that in Figure 3.
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3-68 Operator Interface Parameter File Format The parameter file stored on the flash card is in a DOS file format. This parameter file can be created off-line on a PC using any ASCII text editor and then written to the memory card via a PCMCIA Card Drive. Information is this section is not needed to operate the operator interface. It is required knowledge if you wish to create a parameter file off-line and then download into a drive. The filename must have the extension of *.
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Operator Interface 3-69 Figure 3.95 – Language Directory 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.
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3-70 Operator Interface System Programming The firmware for the complete drive system may be updated via serial port #2 on the Customer Interface Board. Pressing the [F9] key from the transfer screen will place the drive system into download mode. Advanced Screen Operations A number of advanced functions have been incorporated into the operator interface. These operations are not required to operate the drive.
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Operator Interface – Control: number of control codes that did not conform to the anticipated ACK or NACK. The operator interface will have assumed ACK, which if wrong will result in a time-out error. – Seqnce: number of responses from the drive that did not correspond to the last request sent. 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.
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3-72 Operator Interface Figure 3.100 – Mixed Format Displayed 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.
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Operator Interface 3-73 Figure 3.101 – Data Segment Memory Dump The initial screen, (Figure 3.101) shows the data segment by default. Each screen shows the segment (in hex) which is being viewed. In the left column is the starting address (in hex) for the row of data. Eight bytes of data are shown in Hex, followed by the equivalent 8 ASCII characters (if relevant). Additional data within the segment is viewed by pressing the [F8] and [F9] keys.
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3-74 Operator Interface Figure 3.103 – Data at New Address 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.
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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.
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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.
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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
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7000A-RM001A-EN-P – January 2011 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 -A
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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 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.
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3-80 Operator Interface 2. Position the card vertically so the key slot is facing the right side of the operator interface. KEY SLOT Figure 3.107 – Key Slot Orientation 3. Insert the card into the card slot and push until the card is firmly seated. WARNING 7000A-RM001A-EN-P – January 2011 Do not force the card into the slot. Forcing the card into the slot may damage the connector pins.
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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 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.
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4-2 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.
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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.
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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 ‘A’ 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.
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Commissioning 4-5 PowerFlex 7000 ‘A’ 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.
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4-6 Commissioning PowerFlex 7000 ‘A’ 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 in Chapter 2 of User Manual for Cable Insulation Requirements).
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Commissioning 4-7 PowerFlex 7000 ‘A’ Frame Pre-Commissioning Checklist NOTES OR COMMENTS: 7000 “A” Frame 7000A-RM001A-EN-P – January 2011
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4-8 Commissioning Commissioning Preparation The following section identifies all the tools and resources required to successfully commission a PowerFlex 7000 ‘A’ 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.
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Commissioning Technical Publications 4-9 Each drive is shipped with the following publications: • • • User Manual – provides general information required by the User Technical Data, PowerFlex 7000 Medium Voltage AC Drives, Firmware Version x.
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4-10 Commissioning IMPORTANT NOTE FOR COMMISSIONING ENGINEER The COMMISSIONING ENGINEER is advised to go through this commissioning package and follow the steps outlined herein to commission PF7000 drive(s). It is the responsibility of the commissioning engineer to complete all datasheets included in this package and collect any other relevant information that may not have been included in the package. Important guidelines for capturing waveforms are also included in the package for quick reference.
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Commissioning 4-11 Key Steps to Commissioning a PF7000 Drive As a guide for a commissioning engineer, the major steps involved in the commissioning of medium voltage PF7000 drives are outlined below in a sequential order. For detailed instructions, always refer to PowerFlex7000 User Manual. • • • • • • • • • • • • • • • • • Review the drawings and identify all sources of energy that apply to the drive system and get better understanding of the application to which the drive system is applied.
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4-12 Commissioning PowerFlex 7000 “A” and “B” Frame Commissioning Datasheets It is imperative for Medium Voltage Product Support division to have the following information filledout and returned to Rockwell Automation Canada, Cambridge office immediately upon completion of the drive system commissioning. It is the responsibility of the Field Service Engineer to fill-out the required information and submit the completed documents along with the Field Service Report.
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Commissioning 4-13 PowerFlex 7000 “A” and “B” Frame Drive Commissioning Check List A commissioning check list has been provided as a quick reference to assist in starting up the drive system. This checklist should not be used as a detailed instruction or in no way includes all necessary steps to commission every possible drive configuration.
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4-14 Commissioning PowerFlex 7000 “A” and “B” Frame Drive Commissioning Check List Service Data 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. Record source of control power, auxiliary cooling information, environmental conditions, drive password.
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Commissioning 4-15 PowerFlex 7000 “A” and “B” Frame Drive Commissioning Check List Medium Voltage Tests Pre-Power Tests Inspect cabinets for debris (tools, hardware, metal shavings, etc.). Re-install control fuses (to be done with control power off). Power Tests Verify that line voltage is at rated value. Perform a phasing check (18-pulse drives only). Verify input line harmonic by checking line voltage and current waveforms at ACB board (only for AFE rectifier drive). Save the waveforms.
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4-16 Commissioning Drive Application Review 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.
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Commissioning 4-17 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.
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4-18 Commissioning Safety Tests 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.
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Commissioning ATTENTION 4-19 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.
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4-20 Commissioning Installation Review 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.
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Commissioning 4-21 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).
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4-22 Commissioning Installation Review (cont.) 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.
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Commissioning Service Data 4-23 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 ‘A’ 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.
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4-24 Commissioning Customer Information COMPANY NAME: ADDRESS: CITY: POSTAL/ZIP CODE: PROV/STATE/COUNTRY: SERVICE CONTACT: TELEPHONE: FAX: E-MAIL: APPLICATION: SERIAL NO.: DRIVE TAG ID NO.: COMMISSIONING ENGINEER: COMMISSIONING DATE: Motor Nameplate Data MOTOR TYPE: MANUFACTURER: HP / KW: KVA: RPM: SYNCHRONOUS MODEL NO.
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Commissioning 4-25 Drive Nameplate Data CATALOG NO.: SCHEMATIC DIAGRAM: Control Cell MAX VOLTS: Hz: Power Cell UNIT SERIES: Hz: BIL (kV): MAX VOLTS: MVA: CURRENT (Amp): RECTIFIER TYPE: NEMA TYPE SERVICE FACTOR: Motor Filter Capacitors MANUFACTURER: MODEL NO.: VOLTS: Hz: Number of Capacitors: Each Cap KVAR: Line Filter Capacitors (AFE Rectifier Only) MANUFACTURER: MODEL NO.: VOLTS: Hz: Number of Capacitors: Each Cap KVAR: DC Link MANUFACTURER: CURRENT (Amp) SERIAL NO.
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4-26 Commissioning Miscellaneous Information Auxiliary Cooling Blower Motor (if any) HP/KW: VOLTS: PHASE: FLC: RPM: S.F.
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Commissioning 4-27 Drive Circuit Boards ACRONYM PRODUCTION ASSEMBLY PART NUMBER ACB 80190-560- DPM 80190-580- OIB L (A,B,C) 80190-099- --- OIBB 80190-600- --- OIB M (A,B,C) 80190-099- --- XIO 80190-299- --- VSB L 1 81000-199- --- VSB L 2 81000-199- --- VSB M 1 81000-199- Operator Interface TFB L TFB M HARDWARE REVISION 2711-KSASL11 80190-639or 80190-53980190-639or 80190-539- FIRMWARE REVISION --- --PV Firmware PV Software ----- SCR SPGDB 80190-219- --- IGDPS L (1
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4-28 Commissioning Control Power Off Tests 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.
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Commissioning Grease marks from deadbolt pins 4-29 Adjust deadbolt counterpart so that grease marks from pins hit here. Figure 4.1 – Deadbolt 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.
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4-30 Commissioning Control Power Off Tests (cont.) 4. Bolt the cabinet door closed so the pins on the dead bolt counterpart make contact with the deadbolt assembly. Doing so should leave two marks of torque sealant or grease on the assembly where the pins made contact (See Figure 4. 3 – Deadbolt assembly). 5. Slightly loosen the adjustment bolts on the counterpart and make the necessary movements on the counterpart to ensure that the pins align with the landing plates on the deadbolt assembly.
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Commissioning 4-31 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 can be found in the table below. A simple schematic in Figure 4.3 shows how the snubber components are connected across a SGCT. Table 4.
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4-32 Commissioning Resistance Checks (cont.) 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 of each SGCT in the inverter bridge, looking for similar resistance values across each device.
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Commissioning 4-33 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 5 – 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.
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4-34 Commissioning Resistance Checks (cont.) 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 4.7 – Snubber Capacitor Test Refer to Table 4.A to determine the appropriate snubber capacitance value for the current rating of the SGCT used.
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Commissioning Control Power Tests 4-35 Prior to energizing the drive, verify that the control power being fed into the input breakers is rated as designated on the electrical diagram.
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4-36 Commissioning Three-Phase Input / Single Phase Input This configuration has one source of control power: • Three-phase control power for fan operation which is also converted to single-phase control power to operate the Interface, power supplies, I/O and additional auxiliaries. Similar to the three-phase configuration, the input power for the fan and control must be verified at the primary of DS1.
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Commissioning 4-37 Failure of LED to illuminate indicates a problem with the power-up self-test. Refer to Publication 7000-TD002_-EN-P for information on troubleshooting. Control Power Transformer (CPT) A control power transformer is supplied only in certain drive configurations. If there is no control transformer supplied in the drive being commissioned, please disregard the following information on setting the control voltage output level.
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4-38 Commissioning Control Power Tests (cont.) AC/DC Converter (PS1) Every PowerFlex 7000 ‘A’ or ‘B’ Frame drive will be supplied with at least one AC/DC power supply. As the number of devices increases or to provide a redundant power supply, the number of AC/DC power supplies installed may be more than one. The electrical schematics provided by Rockwell Automation will identify how many AC/DC power supplies have been installed in the drive being commissioned.
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Commissioning 4-39 DC/DC Converter (PS2) The DC/DC converter has no provision for output power adjustments. A green LED on front case of the power supply indicates that the power supply is functioning properly. Using a Digital Multimeter, measure each of the outputs of the DC/DC converter to ensure that they meet the values specified on the electrical schematics. Compare these measured values to those displayed on the Operator Terminal under the Metering group.
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4-40 Commissioning Control Power Tests (cont.) 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, Chapter 3 of the Technical Data manual, publication 7000-TD002_-EN-P. M4 (P.H.M.S.) and nylon shoulder washer Mounting Plate Black Insulation DC/DC power supply Part ID Label VIEW “2” M6 (H.H.T.R.S.) VIEW “1” Figure 4.
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Commissioning 4-41 SGCT Power Supplies (IGDPS) Note: Refer to Figure 4.12 for location of IGDPS. Inverter Modules Isolated Gate Drive Power Supplies (IGDPS) Transient Suppression Network Transient Suppression Network Fuses Rectifier Modules Voltage Sensing Boards Figure 4.
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4-42 Commissioning Inverter Modules Isolated Gate Drive Power Supplies (IGDPS) Rectifier Modules Voltage Sensing Boards Figure 4.
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Commissioning 4-43 Inverter Modules Isolated Gate Driver Power Supplies (IGDPS) Rectifier Modules Voltage Sensing Boards Figure 4.
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4-44 Commissioning The circuitry for the IGDPS is encapsulated in epoxy. As a result the module cannot be field repaired and there are no test points or adjustments available on this board. If one of the six isolated 20 V output fails, the entire board must be replaced. IGDPS Board LEDs There is one green LED on each of the 6 output channels of IGDPS. If the IGDPS is healthy, then all six LEDs will be illuminated. If any of the LEDs in not ON then the IGDPS might be defective and must be replaced.
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Commissioning Gating Tests 4-45 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.
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4-46 Commissioning 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 7000A-RM001A-EN-P – January 2011 Ensure that the drive is no longer running in test mode prior to applying medium voltage to the drive line-up.
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Commissioning 4-47 SGCT Firing Test Unlike the SCR Self-powered gate Driver Board, the SGCT has an integrated firing circuit mounted on the device. The power for this circuit is derived from the SGCT Power Supplies (IGDPS), and preliminary observations are possible by monitoring the healthy lights on the firing circuit without putting the drive into gating test mode. There are 4 LEDs on the firing card.
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4-48 Commissioning There is also a Gating Test that fires the individual devices one at a time, in what is described as a Z-pattern. Basically, for each section, the Top Left device will turn on for 2 seconds, then turn off. The next device to the right will turn on for 2 seconds, and the pattern will continue. When you reach the end of the first stack of devices, the right device in the middle stack down will fire and the pattern continues right to left until the end of the middle stack is reached.
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Commissioning 4-49 The PV550 display screens are given as an example. The actual screen data may differ. Ensure you have Advanced access. Now, from the main screen, press SETUP [F8] to get to Parameters, and then Enter. You should be on Feature Select, the first group. Press Enter, Operating Mode is highlighted on the first line. Press Enter and use the down arrow to get to System Test. Press Enter, and then EXIT and you will be in System Test mode.
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4-50 Commissioning System Test (cont.) 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.
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Commissioning 4-51 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.
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4-52 Commissioning System Test (cont.) Example: • SpdCmd Anlg Inp (4-20mA) Reference command Input Scaling The customer 4-20 mA speed input is coming to the Current Loop Receiver on the ACB, and they want the maximum input to represent 60 Hz. 1. Reference Command Remote Maximum (Ref Cmd R Max) should be set for 60 Hz. 2. The Reference Select parameter should be set to ‘Remote 4-20 mA’. 3. Have the source supply 20 mA to the drive.
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Commissioning 4-53 Use the down arrow to highlight the output you wish to assign. When you press Enter, you will be brought to the entire list of parameters in the Select Group screen. Use the arrow and enter keys to find the parameter you wish to assign, and press Enter. This will take you back to the Analog screen and you will see the new parameter name beside your selected output. Press EXIT [F10], go up to Parameters. Press Enter, and then scroll down the list until you reach Analog Outputs.
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4-54 Commissioning System Test (cont.) Highlight the appropriate Analog Scale parameter and press Enter. You can enter your new value, and then press Enter, and EXIT (F10). Ensure you save to NVRAM when you are finished. The analog outputs from the ACB to IFM 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.
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Commissioning 4-55 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.
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4-56 Commissioning Input Phasing Check There are 3 voltage test points on the ACB Board that will allow you to look at each voltage level individually. These test points are labeled as follows: Table 4.
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Commissioning DC Current Test 4-57 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 Rectifier and Idc feedback while increasing the DC current through the drive rectifier. The following instructions detail how to run DC current test: The PV550 display screens are given as an example. The actual screen data may differ. Ensure that you have Service access.
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4-58 Commissioning Press the start button and the drive should start running, pumping 0.1 pu (10%) of rated current through the DC link. Alpha Rectifier 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. The Idc waveform can be observed from T21 (Idc1) on the ACB board.
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Commissioning Tuning Procedure 4-59 The PowerFlex 7000 ‘A’ Frame medium voltage drive must be tuned to the motor and load to which it is connected. There are three drive functions that require tuning. These are listed below in the order in which they are usually performed: 1. Rectifier 2. Mtr Impedance 3. FluxSpeedReg The first two functions can be tuned with the motor stationary, but third function requires the motor to rotate.
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4-60 Commissioning Tuning Procedure (cont.) • T DC Link The tuning of the current regulator is controlled by three parameters – two in the Current Control group, and one in the Drive Hardware group: 1. Current regulator bandwidth CurReg Bandwidth 2. DC Link time constant T DC Link 3.
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Commissioning 4-61 L Input High - indicates that the measured L Input is greater than 0.5 pu. The L Input must be tuned using the manual method described below. T DC Link Low - indicates that the measured dc link time constant is less than 0.020 second. The step response of the current regulator should be checked using the manual method described below. T DC Link High - indicates that the measured dc link time constant is greater than 0.150 second.
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4-62 Commissioning Tuning Procedure (cont.) 7. Record the value of the rectifier input voltage by looking at parameter Rec Input Voltage (P696). Let this value be Vin1. 8. The value of input impedance for AFE drives is calculated as follows: Lin = Vin 0 − Vin1 ⇒ for PWM drives I dc + Cin (Vin 0 − Vin1 ) Cin is the value of input filter capacitor given by Line Filter Cap (P133) 9. The value of input impedance for SCR drives is calculated as follows: Lin = 3(Vin0 − Vin1 ) ⇒ for SCR drives I dc 10.
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Commissioning 4-63 3. Set parameter Idc Test Command in Current Control to 0.225 pu for AFE rectifier drives and 0.400pu for SCR drives. 4. Set parameter CurReg Bandwidth in Current Control to 100 rad/sec. A lower than the normal bandwidth makes the step response easier to measure. 5. Set parameter T DC Link in Current Control to 0.020 sec, which is at the low end of the normal range of values and should produce an under-damped response. 6.
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4-64 Commissioning Tuning Procedure (cont.) Idc Reference Idc Feedback 63% 0% Figure 4.18 – Current Regulator Tuned Correctly 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 given by Idc Test Command. 13. Stop the drive.
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Commissioning 4-65 Motor Impedance Auto-tuning 1. Ensure that the motor is stationary. If the motor is turning, the results of the test may be invalid. It is not necessary to lock the rotor. 2. Set parameter Autotune Select in Auto-tuning to Motor Impedance. 3. Start the drive. In the first half of the test the output frequency is zero and the dc current is ramped to 0.6pu for a few seconds. This step will calculate R Stator. After this the current is ramped down to zero. 4.
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4-66 Commissioning Tuning Procedure (cont.) L Leakage High - indicates that the measured leakage inductance is greater than 0.35 pu. Possible causes are: 1. The inductance of long motor cables is increasing the apparent leakage inductance of the motor. In this case, the measured leakage inductance is probably correct. 2. The motor is very small (leakage inductance generally increases with decreasing motor size).
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Commissioning 4-67 The other aspect of flux control is the variation of motor flux with speed. This is determined by two parameters: 1. Base Speed in Flux Control 2. FlxCmd RatedLoad in Flux Control 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.
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4-68 Commissioning Tuning Procedure (cont.) 4. After completing the flux regulator tuning, the drive waits for a few seconds and adds a sinusoidal perturbation specified by parameter Autotune Trq Stp to the torque command, causing the speed to vary. After the initial transient has decayed (this usually takes a few seconds), the variation in torque and speed are measured and used to calculate the Total Inertia. The torque perturbation is then removed and the drive performs a normal stop.
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Commissioning 4-69 Tuning abort - indicates that the deviation in motor speed was greater than 10 Hz. The measured inertia value is invalid. Parameter Autotune Trq Stp must be set to a lower value and the test repeated. Inertia high - indicates that the measured total inertia is greater than 20 seconds. This warning is intended to draw attention to an unusually high inertia value.
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4-70 Commissioning Tuning Procedure (cont.) Speed Regulator Manual Tuning [Induction Motor] If it is not possible to tune the speed regulator using the auto-tune function, then the step response of the speed regulator can be tuned manually using the following procedure. To obtain accurate results, the load torque must be steady. 1. Set parameter SpdReg Bandwidth in Speed Control to 1.0 rad/sec. Speed Control Parameter Screen 2. Set parameter Total Inertia in Speed Control to an initial value of 1.
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Commissioning 4-71 Speed Error 63% 10 ms 0% Figure 4.19 –Correctly Tuned Speed Regulator 8. Set parameter SpdReg Bandwidth to the normal operating value. Confirm that the response time is equal to the inverse of the speed regulator bandwidth and that there is minimal overshoot. For example, if the speed regulator bandwidth is set to 2 rad/sec, the speed should rise to 63% of its final value in 0.5 second. 9. Set parameter Speed Ref Step to zero and stop the drive.
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4-72 Commissioning Tuning Procedure (cont.) 4. FluxSpeed Regulator [SYNCHRONOUS MOTORS] IMPORTANT Before the FluxSpeed 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.
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Commissioning 4-73 FluxSpeed Reg Auto-tuning [Synchronous Motor] The tuning of the FluxSpeed regulator for a synchronous machine is determined by following parameters: 1. 2. 3. 4. 5. 6.
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4-74 Commissioning Tuning Procedure (cont.) • Speed Regulator Refer details given for Induction motor section. Note: If a position encoder is fitted to the motor, the FluxSpeed regulator auto-tuning is performed with the encoder feedback turned off because it is assumed that the encoder has not been aligned with the rotor axis yet. Since less starting torque is produced with the encoder feedback off, this test should be performed with reduced load.
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Commissioning 4-75 Parameter FlxCmd RatedLoad in Flux Control is set to a value calculated to produce rated voltage at rated speed and load. The value of parameters Autotune T rotor and Autotune Lmd are calculated from the step response data. If the flux regulator auto-tuning is successful, then parameter Lm Rated in Motor Model is set equal to Autotune L Magn, parameter T Rotor in Motor Model is set equal to Autotune T Rotor, and parameter Lmd in Motor Model is set equal to Autotune Lmd.
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4-76 Commissioning Running the Load Motor Starting Torque When starting without a tachometer or encoder, the drive operates in an open loop mode below approx. 3 Hz at which point the drive switches to closed loop speed control. The starting currents are set by three parameters; Torque Commands 0 sensorless (P86), 1 (P87), Torque Command 0 sensorless sets the breakaway torque and Torque Command 1 sensorless is the torque at the transition point from open to closed loop.
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50%/___ 75%/___ 100%/___ ___%/___ ___%/___ ___%/___ ___%/___ ___%/___ ___%/___ ___%/___ ___%/___ 2 3 4 5 6 7 8 9 10 11 12 7000 “A” Frame 25%/___ %SPEED / RPM 1 TEST # AMPS MOTOR/DRIVE OPERATING POINT VOLTS (Vline) Speed Ref (Hz) Speed Fdbk (Hz) Flux Ref (pu) Torque Ref (pu) I DC Ref (pu) I DC Fdbk (pu) DRIVE VARIABLES Alpha Machine (degrees) Inverter Heatsink Temp (°C) Rectifier Heatsink Temp (°°C) 4-77 7000A-RM001A-EN-P – January 2011 Alpha Line (degrees) Commission
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4-78 Commissioning Capturing Data 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.
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Commissioning 4-79 Table 4.D – Oscilloscope Setting Oscilloscope Time Base Ch. 1 Ch. 2 10ms/div. Ch. 3 Waveform TestPoint Waveform Label 2U Line Voltage V2uv V2uv 2V Line Voltage V2vw V2vw 2W Line Voltage V2wu V2wu Sheet Name Input Phasing Note: Use the same settings on the oscilloscope when capturing waveforms for the two Slave bridges.
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4-80 Commissioning Sample waveforms captured on ACB test points showing 20 deg Phase Shift between Master and two Slave Bridges [Ch1-Master: V2uv (red), Ch2-Slave 1: V3uv (blue), Ch3-Slave 2: V4uv (green)] Harmonic Analysis Measure the harmonic (resonance) levels at the input to the drive. (required for AFE drives only) NOTE: If you notice considerable distortion in the waveforms then you MUST send those waveforms to MV Support via e-mail at mvsupport_technical@ra.rockwell.
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Commissioning 4-81 Summary: • • • • • Drive input contactor should be closed. If the drive input contactor configuration is set to NOT RUNNING, you will have to temporarily change it to ALL FAULTS. Ensure that the drive is not running when capturing these waveforms. Capture line voltage at ACB test point “V2uv” and line current at ACB test point “I2u”. Label the waveforms as “V2uv”, and “I2u”. Save the worksheet as “Harmonics (Drive Not Running)”. Table 4.
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4-82 Commissioning DC Current Test Perform DC Test. Refer to the commissioning section of the PoweFlex7000 user manual for a more detailed procedure. Summary: • • • • • Make sure the Diagnostic Trend has been setup and is armed. Run the DC Test with Idc Command Test (P119) set to 0.1pu. Increase Idc Command Test from 0.1 0.3pu (for AFE drives) or from 0.1 0.7pu (for 18-pulse drives) in steps of 0.1pu.
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Commissioning 4-83 Sample waveforms of DC Test recorded on 18-Pulse Drive Idc Cmd Test = 0.5pu [Ch1: Vdcr1, Ch2: Idc1 at ACB test points] Load Test After autotuning of the drive, run the motor on load and capture the following waveforms at 50% load and at 100% load. If the system is not ready for 100% load test, then capture the waveforms at the max load you are allowed to run the drive at. Also, print variables at 50% and 100% load points.
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4-84 Commissioning Sample Waveforms: Sample waveforms recorded on a AFE Drive running under full load condition (Ch1: Line Voltage, Ch2 - Line Current, Ch3 - Motor Voltage, Ch4 - Motor Current) Sample waveforms recorded on 18-Pulse Drive running at 75% load (Ch1: Line Voltage, Ch2 - Line Current, Ch3 - Motor Voltage, Ch4 - Motor Current) 7000A-RM001A-EN-P – January 2011 7000 “A” Frame
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Commissioning Synchronous Transfer 4-85 When commissioning a drive employing synchronous transfer, the following waveforms should be captured and submitted with the commissioning package. Refer to the “Synchronous Transfer Commissioning Guidelines” for a detailed commissioning procedure. While measuring the bypass (BP) contactor closing time: • Capture 120V bypass close command from the BP Contactor Close output (J1-12) at the ACB (refer to electrical drawing for specific wire/terminal number).
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4-86 Commissioning While simulating a synchronous transfer to determine the best lead angle: • Make sure the Diagnostic Trend has been setup and is armed. • Capture motor voltage at ACB test point “Vuv” & bypass voltage at ACB test point “Vuvs”. • Capture and trigger on falling edge of the DC Link current waveform at ACB test point “Idc1”. • Label the waveforms as “Vuv”, “Vuvs” and “Idc1”. • Save the worksheet as “Drift @ 15 Degree Lead Angle”, for example. Table 4.
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Commissioning 4-87 While performing a live synchronous transfer: • • • • Capture motor voltage at ACB test point “Vuv” & bypass voltage at ACB test point “Vuvs”. Capture and trigger on falling edge of the DC Link current waveform at ACB test point “Idc1”. Label the waveforms as “Vuv”, “Vuvs” and “Idc1”. Save the worksheet as “Synch on Motor 01”, for example. Table 4.J – Oscilloscope Setting Waveform Test-Point Waveform Label Ch. 1 DC Link Current Idc1 Idc1 Ch.
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4-88 Commissioning 7000A-RM001A-EN-P – January 2011 7000 “A” Frame
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Chapter 5 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 5.
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5-2 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 5.
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Component Definition and Maintenance 5-3 Low Voltage Wireway Current Transformer Line Cable Terminations Hall Effect Sensor Motor Cable Terminations Hall Effect Sensor Current Transformer Fan Control Power Transformer Control Power Transformer Fuses Figure 5.
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5-4 Component Definition and Maintenance Fan Housing Top Cable Entry and Exit locations Ground Bus Hall Effect Sensors Line Cable Terminations Motor Cable Terminations Current Transformers (CT) (Back) (Front) Integral Isolation Transformer Side View Bottom Cable Entry and Exit locations Front View Figure 5.
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Component Definition and Maintenance Hall Effect Sensor Replacement 5-5 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 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 sensor.
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5-6 Component Definition and Maintenance Current Transformer Replacement 1. Ensure there is no power to the equipment. 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. ATTENTION 2. Note the location of all wires and the orientation of the CT.
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Component Definition and Maintenance 5-7 Converter Cabinet Components Inverter Modules Isolated Gate Drive Power Supplies (IGDPS) Rectifier Modules Voltage Sensing Boards Figure 5.7 – Converter Cabinet Components (3300/4160 V version) Note: For 2400V version, refer to page 4-41. For 6600V version, refer to page 4-43.
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5-8 Component Definition and Maintenance Converter Cabinet The converter cabinet contains three rectifier modules and three inverter modules. Figure 5.7 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.
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Component Definition and Maintenance Voltage-Sensing Circuit Board Assembly Replacement 5-9 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. Remove clear plastic cover. 3. Mark the position of the ribbon cables and wires. 4.
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5-10 Component Definition and Maintenance Surge Arresters Description Heavy duty distribution class surge arresters are used for transient overvoltage protection in the drives with AFE rectifiers. The arresters are certified as per ANSI/IEEE Std C62.11-1993. The surge arresters are basically MOVs, with or without an air gap in series, packed in sealed housing. They provide overvoltage protection similar to what the TSN module does.
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Component Definition and Maintenance 5-11 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. However, caution should be taken if there is a harmonic filter on the MV bus to which PF7000 is connected.
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5-12 Component Definition and Maintenance Surge Arresters (cont.) Surge Arresters Figure 5.10 – Surge Arresters Note: When the surge arrester is disconnected from MV, it is possible that a small amount of static charge is retained by the arrester. As a precautionary measure, install a temporary ground on the line-end of the arrester and discharge the stored energy. Remove temporary ground before the arrester is reinstalled.
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Component Definition and Maintenance PowerCage™ 5-13 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.
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5-14 Component Definition and Maintenance PowerCage™ (cont.) 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.
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Component Definition and Maintenance Matched set 2 SGCTs Clamp Base Matched set 2 SGCTs Temperature Feedback Board Module housing 5-15 Heatsink Clamp head Figure 5.12 – 4-Device PowerCage Matched set 3 SGCTs Matched set 3 SGCTs Clamp Base Heatsink Clamp head Module housing Temperature Feedback board Figure 5.
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5-16 Component Definition and Maintenance SGCT and Snubber Circuit 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 5.14 – SGCT and snubber circuit In addition to the snubber circuit, a sharing resistor is connected in parallel with the SGCT.
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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 5-17 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.
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5-18 Component Definition and Maintenance Checking Clamping Pressure 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.
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Component Definition and Maintenance IMPORTANT 5-19 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 5.15 and 5.16.) Clamp head block DO NOT ADJUST outside nut. SGCT captive screws Disc springs Inside nut used for loosening and applying load to assembly Figure 5.
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5-20 Component Definition and Maintenance Temperature Sensing (cont.) 4. Remove the device (SGCT) that is secured to the heatsink with the thermal sensor. (Refer to Figure 5.11, 5.12, 5.13, 5.16 or 5.17). 5. Disconnect the fiber optic cable to the temperature feedback board. 6. Remove two M8 screws holding the heatsink in place. 7. Remove the heatsink with the temperature feedback board from the PowerCage. 8. Disconnect the plug that connects the thermal sensor to the circuit board. 9.
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Component Definition and Maintenance Symmetrical Gate Commutated Thyristor Replacement 5-21 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.
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5-22 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.
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Component Definition and Maintenance 5-23 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.
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5-24 Component Definition and Maintenance Heatsink Replacement The PowerFlex drive uses an aluminum or copper heatsink, depending on the drive rating. Figure 5.19 – Heatsink 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.
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Component Definition and Maintenance 5-25 6. Install the new heatsink and hand-tighten the bolts. 7. Replace the SGCT per the instructions on pages 5-21 to 5-23. 8. Follow procedure “Uniform Clamping Pressure” to ensure the heatsinks are clamped to a uniform pressure. 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.
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5-26 Component Definition and Maintenance PowerCage Gasket (cont.) Replacement of PowerCage Gaskets The gaskets do not normally require replacement, but in the event that they become damaged, they may require replacement. Removal of old Gasket Material Pull all the material possible off by hand. Scrape off as much material as possible with a sharp knife. Do not score the PowerCage with the knife. All the material will not come off! Remove as much as possible to leave an even surface to bond to.
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Component Definition and Maintenance PowerCage Removal 5-27 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 voltage-measuring device. Failure to do so may result in injury or death. 2.
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5-28 Component Definition and Maintenance Note: The PowerCage is shown with switching components, heatsinks and clamps removed for ease of lifting. Figure 5.21 – Typical Torque sequence 7. Replace interior assembly in the reverse order of removal.
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Component Definition and Maintenance Snubber Resistors 5-29 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.
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5-30 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.
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Component Definition and Maintenance 5-31 Retaining rod Detach the leads of the resistor assembly. Pinch and remove clips at ends of retaining rod. Extract retaining rod. Figure 5.
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5-32 Component Definition and Maintenance Snubber and Sharing Resistor Replacement (cont.) Push Nut Retaining Rod Resistor Bank Figure 5.25 – Removing resistor bank from PowerCage 5. Remove the resistor bank from the Power Cage. 6. Place the new resistor bank assembly back into the PowerCage. 7. Slide the retaining rod into place and push the clips back into place. 8. Connect the leads to the resistor bank 9. Install the PowerCage as outlined in “PowerCage Removal”.
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Component Definition and Maintenance 5-33 SGCT PowerCages The snubber circuit is shown in Figure 5.26. Figure 5.30 shows the physical locators of the same circuit. Measure the resistance across two adjacent heatsinks. A value between 60 kΩ and 75 kΩ indicates a good sharing resistor. Cs-1 Rsn-2 Rsh Cs-2 Rsn-1 Anode Cathode Snubber Resistor Test Point Figure 5.26 – Snubber Circuit for SGCT module Rsn-2 Rsh Cs-1 Anode Rsn-1 Cs-2 Cathode Figure 5.
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5-34 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.
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Component Definition and Maintenance Fiber Optic Cabling 5-35 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.
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5-36 Component Definition and Maintenance Air Pressure Sensor An air pressure sensor is located in both the converter cabinet and the integral rectifier transformer cabinet (if applicable). In both cases, it is located in the upper left-hand quadrant of the cabinet. Flexible tube for low pressure port High pressure port Mounting screw Wire terminals Figure 5.
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Component Definition and Maintenance 5-37 D.C. Link / Fan / Control Components Low voltage Control Tub Retaining Hardware Fan AC/DC Power Supply Inlet Ring ANALOG CONTROL BOARD M+ L+ Analog Control Board L- M- Grounding Network/ Filter Motor Filter Capacitor Medium Voltage Barrier (for access to Line/Motor Capacitors) Figure 5.30 – DC Link and Fan cabinet with low voltage control tub shown DC Link Inductor Line Filter Capacitor Figure 5.
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5-38 Component Definition and Maintenance D.C. Link / Fan / Control Components (cont.) Mounted on top of the cabinet is an air exhaust hood. The exhaust hood must be installed to prevent foreign objects from entering the drive. Output Grounding Network Replacement PowerFlex 7000 drives may have either a grounding network or a ground filter in place of the grounding network. The number of capacitors will vary depending on the system voltage. 1. Ensure there is no power to the equipment.
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Component Definition and Maintenance 5-39 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 voltagemeasuring device. Failure to do so may result in injury or death. 2. Note the position of the leads. 3.
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5-40 Component Definition and Maintenance D.C. Link / Fan / Control Components (cont.) Filter Capacitors Filter capacitors are used on the motor side for all drives. The AFE rectifier also includes filter capacitors on the line side. Refer to Figure 5.31 (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.
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Component Definition and Maintenance 5-41 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 voltage-measuring device. Failure to do so may result in injury or death. ATTENTION Verify the load is not turning due to the process.
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5-42 Component Definition and Maintenance D.C. Link / Fan / Control Components (cont.) Testing Filter Capacitors Two methods of testing/checking the capacitors are explained below. The first method is simple, easy, and takes least amount of time to check the capacitors. In this method, you would need a digital multimeter (DMM) to measure the capacitance in micro-Farad (µF) across each phase-toneutral of the capacitors.
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Component Definition and Maintenance 5-43 5. Using a DMM measure the capacitance across each phase-to-neutral of capacitors without removing any connections. If the difference between the highest and the lowest readings is below 15% then all capacitors are in good condition. 6. If the difference between the highest and the lowest readings is off by 15% or more, then you might have a bad capacitor. 7. Before disconnecting the capacitors, note the location of all the cables and mark them accordingly. 8.
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5-44 Component Definition and Maintenance D.C. Link / Fan / Control Components (cont.) 5. Note the location of all the cables and mark them accordingly. 6. Disconnect power cables from the capacitor terminals on all four bushings and isolate them from the capacitor. (Refer to “Filter Capacitor Replacement” guidelines in the Classic User Manual Component Definition and Maintenance chapter (Chapter 6) for using proper torque when reconnecting the capacitors) 7.
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Component Definition and Maintenance 5-45 Let us calculate the capacitance using the first reading. In this case: V = 200V, I = 1.87 for L1-N Xc = V/I = 200/1.87 = 106.95 C= 1 2π f Xc C=1 2 × 3.14 × 50 × 106.95 C = 29.7 μF Where, f = frequency of the applied voltage. Similarly, you can calculate the capacitance for the remaining two measurements for L2-N and L3-N.
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5-46 Component Definition and Maintenance DC Link Reactor Replacement The DC Link maintains a ripple-free current between the rectifier and the inverter. 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. The DC link reactor does not normally require service.
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Component Definition and Maintenance 5-47 The DC link is heavy and has provision for lifting with forks of a lift truck. Step 3: Unfasten DC link leads and remove terminal assembly. Disconnect ground wire and LV wires for thermal switch. Fan Barrier Step 4: Remove DC link hardware and lift link out of front drive. Step 2: Remove grounding filter/ network assembly. Step 1: Remove hardware and DC link and fan barrier. Figure 5.
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5-48 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 5.37. To prevent electrical shock, ensure the main power has been disconnected before working on the current transformer.
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Component Definition and Maintenance 5-49 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 5.38 – Isolation Transformer Fan Removal 1.
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5-50 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 5.39 – 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.
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Component Definition and Maintenance Impeller Maintenance (DC Link / Fan Section) 5-51 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.
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5-52 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.
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Component Definition and Maintenance 5-53 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.
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5-54 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).
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Component Definition and Maintenance 5-55 DC Link / Fan Section NOTE: If rear panel access is possible, remove rear middle panel of the DC link / fan portion of the cabinet and remove the inlet ring from the back. Procedure If rear panel access is not possible, follow this procedure: 1. Remove bolts and swingout low voltage panel (see Fig. 5.30). 2. Remove bolts from the inlet ring being careful not to allow the ring to fall. 3.
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5-56 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.
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Component Definition and Maintenance 5-57 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 5.
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5-58 Component Definition and Maintenance Replacement of Air Filters (cont.) Figure 5.42 – Air Flow Pattern for Drive Cooling Figure 5.
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Component Definition and Maintenance Control Power Components 5-59 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 5.44) 2. AFE Rectifier with Separate Isolation Transformer – Config. #2 (refer to Figure 5.45) 3. AFE Rectifier with Integral Isolation Transformer – Config. #3 (refer to Figure 5.
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5-60 Component Definition and Maintenance Control Power Components (cont.) Figure 5.45 illustrates the control power distribution for AFE drives with remote transformer/starter (A) or integrated line reactor with remote starter (B).
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Component Definition and Maintenance 5-61 Figure 5.46 illustrates the control power distribution for AFE drives with integral transformer and remote starter. Printer Operator Interface Relays Customer Supplier 120V 1-ph +5V-LOGIC C Hold-up AC/DC Converter 56V DC 1000W/1500W Line Filter +/-15V-LOGIC DC/DC CONVERTER +/-24V-HECS +24V-ISOLATORS +24-XIO DC Fail SENSE CABLE Tx Fan 380V 50Hz or 460V 60Hz 3-ph VFD 20V Isolated Gate Driver Power Supply 20V Fan Figure 5.
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5-62 Component Definition and Maintenance AC/DC Power Supply 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.
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Component Definition and Maintenance 5-63 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 5.48. AC/DC Power Supply (Pioneer) Figure 5.
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5-64 Component Definition and Maintenance AC/DC Power Supply (cont.) AC/DC Power Supply (Cosel) Figure 5.
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Component Definition and Maintenance 5-65 Terminal / Connections Descriptions (Pioneer Power Supply) The terminal connections are shown below in Figure 5.50. DC outputs Earth Line Neutral Control signals TOP VIEW FRONT VIEW Single phase input Figure 5.
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5-66 Component Definition and Maintenance AC/DC Power Supply (cont.) Terminal / Connections Descriptions (Cosel Power Supply) The terminal connections are shown below in Figure 5.51. Single phase input FRONT VIEW Control signals DC outputs Figure 5.
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Component Definition and Maintenance 5-67 Output Calibration 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. Isolate the output of the power supplies; multiple supplies in series will affect your measurements. With the control power on and the output of the AC/DC Converter isolated from the drive control, adjust the potentiometer until the output equals 56 volts DC.
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5-68 Component Definition and Maintenance M6 Bolts M6 Bolts Bracket Black Insulation Low Voltage Swing-out Tub Figure 5.52 – Replacement of Pioneer AC/DC Power Supply on Low Voltage Panel Black Insulation Bracket M6 Bolts Black Insulation Bracket Low Voltage Swing-out Tub Figure 5.
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Component Definition and Maintenance Low Voltage Control Section 5-69 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 5.54 for a generic representation of a low voltage tub arrangement.
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5-70 Component Definition and Maintenance Low Voltage Control Section (cont.) AC to DC Cosel Power Supply Analog Control Board Drive Processor Module Optical Interface Boards ANALOG CONTROL BOARD DC to DC Power Supply Hinged Panel (Closed) Hinged Panel (Open) Figure 5.
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Component Definition and Maintenance DC/DC Power Supply 5-71 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 +/-15V - LOGIC DC/DC Power Supply +/- 24V - HECS +24V - ISOLATOR +24 - XIO Sense Cable Figure 5.56 – DC/DC converter power supply The capacitor at the input terminals is for power dip ride-through purposes.
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5-72 Component Definition and Maintenance DC/DC Power Supply (cont.) P3 – ISOLATOR (To Isolator Modules) Terminal/connections descriptions (cont.) PIN NO. 1 2 3 P4 – PWR (To ACB) LABEL ISOLATOR (+24V,1A) ISOL_COMM (com4) EARTH PIN NO.
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Component Definition and Maintenance 5-73 M4 (P.H.M.S.) and nylon shoulder washer Mounting plate Black insulation Part ID label DC/DC Power Supply VIEW “2” M6 (H.H.T.R.S.) VIEW “1” Figure 5.57 – Replacement of DC/DC power supply Printed Circuit Board Replacement The replacement of printed circuit boards should be handled in a careful manner. There are some basic precautions that should be taken. They include the following: Remove all power to the drive.
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5-74 Component Definition and Maintenance 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 .
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Component Definition and Maintenance Drive Processor Module 5-75 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 5.
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5-76 Component Definition and Maintenance Drive Processor Module (cont.) The following is the list of test points on the DPM: Table 5.B – Test Points on Drive Processor Module Test points DPM-TP1 DPM-TP2 DPM-TP3 DPM-TP4 DPM-TP5 DPM-TP6 DPM-TP8 DPM-TP9 DPM-TP10 DPM-TP7 DPM-TP11 DPM-TP12 DPM-TP13 DPM-TP14 Name +1.2V +1.8V +2.5V +3.3V +5V DGND ITP1 ITP2 ITP3 ITP4 RTP4 RTP3 RTP2 RTP1 Description +1.2V DC power supply +1.8V DC power supply +2.5V DC power supply +3.
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Component Definition and Maintenance 5-77 Drive Processor Module Replacement Before replacing the Drive Processor Module, 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.
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5-78 Component Definition and Maintenance Drive Processor Module (cont.) 11. Program the drive. Refer to Technical Data “Medium Voltage AC Drive Parameters” – Publication 7000-TD002_-EN-P. The parameters should also be saved to NVRAM and then externally to the drive using the options described earlier in this section. Analog Control Board Figure 5.
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Component Definition and Maintenance ACB Analog Control Board 5-79 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 5.
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5-80 Component Definition and Maintenance ACB Analog Control Board (cont.) The Analog Control Board (ACB) receives all of the Analog Signals from the drive’s internal components. This includes the current and voltage feedback signals. The boards also have isolated Digital I/O for fan status, e-stops, and contactor control and status feedback. All of the test points for the currents, system voltages, control voltages, and flux are on these boards. Table 5.
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Component Definition and Maintenance 5-81 Table 5.
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5-82 Component Definition and Maintenance ACB Analog Control Board (cont.) 7000A-RM001A-EN-P – January 2011 Table 5.E – Test Points on Analog Control Board (cont.
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Component Definition and Maintenance 5-83 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 5.62 – Interface Module Analog Inputs and Outputs The PowerFlex 7000 offers one isolated process current loop transmitter and three isolated process current loop receivers, embedded into the control.
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5-84 Component Definition and Maintenance ACB Analog Control Board (cont.) Current Loop Transmitter The current loop transmitter will transmit 4-20mA output to an external receiver. The loop compliance on the transmitter is 12.5V. Loop compliance is the maximum voltage at which a transmitter can generate to achieve the maximum current and is usually a function of the power supply voltage. Therefore, the PowerFlex 7000 transmitter can drive a receiver with an input resistance up to 625 ohms.
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Component Definition and Maintenance 5-85 Isolated Process Receiver These inputs are individually configurable to accept either a -10/0/+10V input signal or a 4-20 mA signal. When configured for voltage input, each channel has an input impedance of 75 Kohms. When used as a current loop input, the transmitter must have a minimum loop compliance of 2 volts to satisfy the 100 ohm input impedance. Regardless of input configuration, each input is individually isolated to ± 100V DC or 70V RMS AC.
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5-86 Component Definition and Maintenance ACB Analog Control Board (cont.) DSP Non Isolated Process Outputs The drive supplies four non isolated -10/0/+10 V outputs for customer use. These outputs can drive loads with impedances as low as 600 ohms. These outputs are all referenced to the Drive AGND and therefore should be isolated if they are required to drive outside the PowerFlex ‘A’ frame enclosure. Buffer FPGA A2D IFM Pin# 27,31,35,39 Analog Output 25,29,33,37 28,32,36,40 Figure 5.
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Component Definition and Maintenance 5-87 ACB Analog Control Board Replacement To replace the ACB Analog Control Boards, 1. Ensure that all medium voltage and control voltage power to the drive is isolated and locked out. 2. It is required to remove the transparent sheet on top of the Drive Processor Module and the Drive Processor Module also before removing the ACB. Remove the transparent sheet on top of the DPM by removing the 4 screws 3. Use static strap before removing any connectors. 4.
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5-88 Component Definition and Maintenance Tachometer Feedback Board Encoder Options There are two positional encoder interface boards that may be used with the PowerFlex 7000 Forge Control. The encoder interface boards do not have any user accessible test points; however, buffered and isolated versions of each of the signals A+, A-, B+, B-, Z+ and Z- are available on the ACB at test points TP45-TP50. Regardless of which type of encoder board, the following conditions should be adhered to: 1.
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Component Definition and Maintenance 5-89 Operation at +5V does not allow for long cable lengths. The reason for this is that it requires the power to be regulated within 5% at the encoder. Due to the resistance and capacitance of the cable it would be very hard to keep the power regulated at the encoder to 4.75V. With longer runs of cable this could drop below the 4.75V and the encoder would not operate properly. As a general rule, using 18Avg cabling with an Rdc of 19.
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5-90 Component Definition and Maintenance Tachometer Feedback Board (cont.) 80190-759-01, 80190-759-02 Universal Encoder Interface The Universal Encoder Interface allows the drive to be connected to an absolute position encoder or a standard quadrature encoder and also provides the option for dual or redundant quadrature encoders. The Universal Encoder Interface provides 12 single ended or 6 differential, optically isolated inputs as well as a 12V/3Watt galvanically isolated encoder power source.
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Component Definition and Maintenance 5-91 Figure 5.68 – Universal Encoder Board Connections to the Universal Encoder Interface are made via a 1492IFM20F interface module. The connections to the IFM are as follows: Table 5.
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5-92 Component Definition and Maintenance Tachometer Feedback Board (cont.) Figure 5.69 – 20-pin Interface Module (IFM) Quadrature Encoder Operation The Universal Encoder Interface will accept either single or dual quadrature encoders. Configuration of the board to accept the encoders is done through jumpers on J4. Boards shipped from the factory come defaulted to single quadrature encoder configuration.
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Component Definition and Maintenance ATTENTION 5-93 When the drive switches over to the redundant encoder, it cannot switch back without recycling control power. Positional Encoder Operations Besides quadrature encoders, the Universal Encoder Interface will also accept positional (absolute) encoders. Parallel positional data is converted to a serial stream and transmitted to the DPM when requested by the drive.
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5-94 Component Definition and Maintenance Binary Code Gray Code 255 011111111 010000000 256 100000000 110000000 All nine bits changed in the Binary Code while only the MSB of the Gray code changed. In the Universal Encoder Interface there are delays created by the frequency filter components and input hysteresis. Differences in these delays could cause errors due to reading a bit as ON when it is actually transitioning to OFF or vice versa.
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Component Definition and Maintenance External Input/Output Boards 5-95 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.
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5-96 Component Definition and Maintenance LED D1 and display U6 indicate the status of the board. The following table illustrates the possible states for D1. LED Status Description Solid Green Normal Operation Solid Red Board Failure Alternate Flashing of Red and Green No Communication Available to ACB board (Normal during boot-up or unprogrammed) Table 5.
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Component Definition and Maintenance Optical Interface Boards 5-97 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.
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5-98 Component Definition and Maintenance Optical Interface Boards (cont.) Figure 5.
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Component Definition and Maintenance 5-99 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.
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5-100 Component Definition and Maintenance Figure 5.
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Component Definition and Maintenance Downloading Firmware 5-101 Introduction With the introduction of the PowerFlex 7000 Medium Voltage Drive, all drive control functions are loaded on the Drive Processor Module (DPM) with firmware via a serial connection on the Drive Processor Module data port J4. The firmware is packaged into a single executable file (with the extension .exe). This document describes how to download new or updated firmware to the drive using the DPM data port.
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5-102 Component Definition and Maintenance Preparation for Downloading Firmware Ensure the parameters are saved to NVRAM, and saved to the Operator Interface Terminal, and saved to any other external source such as the Flash Card, DriveTools, or printed to a hardcopy. Hit F10 (Access), and highlight Advanced. Press Enter, or enter the password value (if password required) and you should have Advanced level access. Hit F10 to Exit, and then F5 for NVRAM. Press F5 for SAVE, and F8 for YES.
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Component Definition and Maintenance 5-103 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. Remove the back cover and insert the card in the slot on the terminal. It can only go in one way. Then press F4 (DRV>CRD).
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5-104 Component Definition and Maintenance Preparation for Downloading Firmware (cont.) PF7000 in Download Mode To place the drive in download mode, you should be in the UTILITY – TRANSFER screen. You will not be able to do this if the drive is running. Ensure the drive is stopped, and the E-Stop is pressed. This is just a precaution, as all versions of firmware 7.xxx and later will not allow you to attempt a download while running.
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Component Definition and Maintenance 5-105 If you press any Key after this message the PanelView will show: COMMUNICATION ERROR Connect your PC to the DPM data port J4. Locate the PowerFlex 7000 Medium Voltage Drive firmware an executable file Double click on the file to download the firmware. The executable program will open the following screen: The DPM are preloaded with Bootcode and select the Firmware by clicking in the checkbox against Firmware and click OK.
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5-106 Component Definition and Maintenance Preparation for Downloading Firmware (cont.) The progress of the download is continously displayed on the screen as shown. The completion of the download is displayed on the screen as shown. If the DPM does not have bootcode or needs an upgrade, then first select the Bootcode by clicking in the checkbox against Bootcode and click OK. After downloading the bootcode proceed with the drive firmware download as explained earlier.
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Component Definition and Maintenance Reloading the Parameters 5-107 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.
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5-108 Component Definition and Maintenance Setting Elapsed Time Downloading the Terminal Firmware When you replace the existing DPM board in the drive with a new board, the operating hours counter will start from zero. Therefore, if you want to keep the actual operating hours in the drive, you can restore them by running a utility program (Sethobb.exe), which is usually supplied with the firmware package. You can also request a copy of the program by e-mail at MVSupport_Technical@ra.rockwell.com.
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Component Definition and Maintenance 5-109 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.
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5-110 Component Definition and Maintenance Downloading the Terminal Firmware (cont.) 4. Now, you will be prompted to enter Port address of your laptop. Choose a correct port address and then hit Enter key. 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.
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Component Definition and Maintenance 5-111 8. Once the firmware download is complete, the message “Download successfully completed!” will appear on your laptop screen. At this point, press any key to close the DOSFWDL program. 9. Now, remove the serial cable from your laptop and connect it to ACB board port J12. The Terminal will now start communicating with the drive. Setting up Diagnostic Trending The diagnostic trending is a valuable tool for troubleshooting faults in the drive.
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5-112 Component Definition and Maintenance Setting up Diagnostic Trending (cont.) C = Continuous capture >> auto re-arm is enabled to collect new trends until stopped by viewing contents of captured data. Cond Defines the condition that will cause the trigger. The possible options are: = Equal to N= Not Equal to > Greater than < Less than Data + N+ & N& Boolean OR Boolean NOR Boolean AND Boolean NAND Defines the trigger value with respect to the read-only parameter in Trace 1.
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Component Definition and Maintenance 5-113 2. Press F8 [D_SETUP]. The display will change to ‘Diagnostics Setup’ screen as shown in the picture below. 3. With Trace-1 selected, press Enter key as shown in the picture below.
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5-114 Component Definition and Maintenance Setting up Diagnostic Trending (cont.) 4. The display will change to ‘Select Group’ screen as shown in the picture below.
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Component Definition and Maintenance 5-115 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.
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5-116 Component Definition and Maintenance Setting up Diagnostic Trending (cont.) 9. Repeat above steps until you have assigned the desired parameters to all the traces from Trace1 to Trace16. 10. Now press F9 [TRIGGER] key. The first letter in the second line on the screen will toggle between C and S. The letter C stands for Continuous and S stands for Single shot. Select S for single shot. 11. Press F2 [CONDITION] key. The cursor will move to the “=” equal sign. This defines the trigger condition.
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Component Definition and Maintenance 5-117 14. Press F5 [POST] key and enter 10 (this is the percentage of posttrigger 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.
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5-118 Component Definition and Maintenance Printing (Uploading) Data from the Drive 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.
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Component Definition and Maintenance 5-119 Method Step-1: Creating an empty notepad (.txt) file 7000 “A” Frame - 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.
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5-120 Component Definition and Maintenance Printing (Uploading) Data from the Drive (cont.) - 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.
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Component Definition and Maintenance 7000 “A” Frame 5-121 - 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. - Now, close the HyperTerminal program. Following message box will appear.
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5-122 Component Definition and Maintenance Printing (Uploading) Data from the Drive (cont.) - 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.
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Component Definition and Maintenance - - 7000 “A” Frame 5-123 From the File menu, click Open….At the Open dialog box, locate the HyperTerminal connection you just created in step-2, (e.g. 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.
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5-124 Component Definition and Maintenance Printing (Uploading) Data from the Drive (cont.) - 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 (v) arrow keys on the Terminal keypad select the item you want to print (i.e.
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Component Definition and Maintenance - 5-125 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. Now close the HyperTerminal program and disconnect the laptop from the drive.
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5-126 Component Definition and Maintenance Printing (Uploading) Control Data (cont.) Here is a typical pin out of a complete null-modem cable. Essentially, only 3 pins (2, 3 and 5) are all that is required. Method 1. Connect your laptop to the drive using a 9-pin null-modem cable to DPM data port (J4). 2. Set up HyperTerminal connection - Run HyperTerminal program - At the ‘Connection Description’ window, enter any name for new connection under the Name field as shown below and then click OK.
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Component Definition and Maintenance 7000 “A” Frame 5-127 - Now, the ‘COM1 Properties’ window will appear. Set the port settings as shown below and then click OK. - Now close HyperTerminal program. At this point following message box will appear.
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5-128 Component Definition and Maintenance Printing (Uploading) Control Data (cont.) - Click Yes, and you will be prompted to save the connection. - Click Yes to terminate the HyperTerminal Program. 3. Printing Control Data - Restart HyperTerminal program. - At the ‘Connection Description’ window as shown below, click Cancel. - 7000A-RM001A-EN-P – January 2011 From the File menu, click Open… The Open window will appear.
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Component Definition and Maintenance 7000 “A” Frame 5-129 - Press the ENTER key. This should bring up the following options menu in the HyperTerminal window. - From the above menu select the desired option by pressing the corresponding number to upload (print) the data. To upload Control Data, select option 4.
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5-130 Component Definition and Maintenance Printing (Uploading) Control Data (cont.) 7000A-RM001A-EN-P – January 2011 - After selecting the desired option, you need to start the transfer by selecting Receive File … from the Transfer menu as shown below. - The Receive File window will pop. Click Browse button and select the directory where you want to save the data file. Make sure the Receiving Protocol is set to Xmodem, then click Receive.
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Component Definition and Maintenance 7000 “A” Frame 5-131 - Now, the Receive Filename dialog will appear. Here you need to enter the file name, but make sure you also enter a correct extension as given in the options menu. For Control Data use .bin extension. For all other data use .csv extension. Click OK. - Now, the following dialog box will appear where you can see the file transfer progress. - When the data transfer is complete, the above dialog box will close automatically.
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5-132 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.
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Component Definition and Maintenance • 5-133 Lithium Batteries This drive contains one small 3V lithium battery on the DPM board. The battery part # 346567-Q01 or BR2335 contains approximately 0.09 g of lithium metal. These batteries meet shipping regulations at the time of publication, however there are specific marking and packaging requirements. Properly packaged single, spare or expired batteries may be shipped consigned as UN3090 PI 968 Part 1.
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5-134 Component Definition and Maintenance 7000A-RM001A-EN-P – January 2011 7000 “A” Frame
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Appendix A 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
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A-2 Catalog Number Explanation – Drive Selection Table A-1 – Supply Voltage, Control Voltage, Frequency and Control Power Transformer Selection Voltage Frequency Nominal Line 2400 3300 4160 6600 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.
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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 (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.
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A-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.
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Catalog Number Explanation – Drive Selection PowerFlex 7000 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-4 below shows the PowerFlex 7000 drive torque capabilities as a percent of motor rated torque, independent of the drive’s momentary overload conditions.
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A-6 Catalog Number Explanation – Drive Selection Table A-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
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Appendix B 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.
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B-2 Torque Requirements 7000A-RM001A-EN-P – January 2011 7000 “A” Frame
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Appendix C 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.
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C-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.
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Meggering C-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).
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C-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.
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Meggering C-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.
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C-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.
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Appendix D 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.
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D-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.
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Preventative Maintenance Schedule D-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.
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D-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.
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Preventative Maintenance Schedule D-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.
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D-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.
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Preventative Maintenance Schedule D-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.
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D-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.
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D-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.
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D-10 Preventative Maintenance Schedule Rockwell Automation PowerFlex 7000 Preventative Maintenance Service Schedule (cont.
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Preventative Maintenance Schedule General Notes D-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.
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D-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.).
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Preventative Maintenance Schedule Part-specific Notes D-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.
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D-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).
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Preventative Maintenance Schedule D-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.
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D-16 Preventative Maintenance Schedule 7000A-RM001A-EN-P – January 2011 7000 “A” Frame
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Appendix E 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
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E-2 Specifications Specifications (cont.
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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
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E-4 Specifications 7000A-RM001A-EN-P – January 2011 7000 “A” Frame
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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-RM001A-EN-P – January 2011 Copyright © 2011 Rockwell Automation, Inc. All rights reserved. Printed in Canada.