Page 1 User Manual Original Instructions PowerFlex 7000 Medium Voltage AC Drive Air-Cooled (’A’ Frame)—ForGe Control Bulletin Number 7000A...
Page 2 If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be impaired. In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment.
Page 3 Line/Motor Terminations ....... . . 41 Installation Requirements for Power Cabling ....41 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 4 Fiber-optic Cabling..........95 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 5 Current Loop Transmitter ....... . 148 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 6 Batteries ..........181 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 7 ............203 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 8 Table of Contents Notes: Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 9 • Spare part lists compiled for each customer order. • Human Machine Interface (HMI) operation and configuration. Rockwell Automation provides the site- and installation-specific electrical and design information for each drive during the order process cycle. If they are not available on site with the drive, contact Rockwell Automation®.
Page 10 HMI Interface Board Software Updater and Firmware Download Procedure 7000-IN010 Handling, Inspection, and Storage of Medium Voltage Line Filter Capacitors Industrial Automation Wiring and Provides general guidelines for installing a Rockwell Automation industrial Grounding Guidelines, publication system. 1770-4.1 Product Certifications website, Provides declarations of conformity, certificates, and other certification rok.auto/certifications.
Page 11 The PowerFlex 7000 drive provides a selectable option for enhanced torque control capabilities and increased dynamic control performance. This high- performance torque control (HPTC) feature delivers 100% torque at zero speed and provides torque control through zero speed with smooth direction transition. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 12 A common mode choke (CMC) mitigates the common mode voltage that is seen at the motor terminals. Standard (non-inverter duty rated) motors and motor cables can be used. This technology is ideal for motor retrofit applications. An integral starter is offered as an option. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 13 (which replaces the integral line reactor) and addresses the common mode voltage (which replaces the CMC in the Direct-to-Drive rectifier configuration). However, the AFE rectifier, its operation, and advantages are the same as the Direct-to-Drive configuration. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 14 Figure 5 - Motor Wave Forms at Full Load, Full Speed Arms 300.00 200.00 100.00 Motor Current 0.00 -100.00 -200.00 -300.00 Vrms 10.00K 7.50K 5.00K Motor Voltage 2.50K 0.00K -2.50K -5.00K -7.50K -10.00K 110.00 100.00 120.00 130.00 140.00 150.00 TIME (ms) Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 15 Figure 8 - 2400 Volt – AFE Rectifier with Integral Isolation Transformer DC Link Machine Converter Line Converter Integral ISTX SGCTs SGCTs U (T1) 2U (X1) V (T2) 2V (X2) W (T3) 2W (X3) Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 16 2W (X3) Figure 11 - AFE Rectifier with Integral Isolation Transformer DC Link Line Converter Machine Converter Integral ISTX SGCTs SGCTs U (T1) 2U (X1) V (T2) 2V (X2) W (T3) 2W (X3) Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 17 2W (X3) Figure 14 - AFE Rectifier with Integral Isolation Transformer LINE CONVERTER DC LINK MACHINE CONVERTER INTEGRAL ISTX SGCTs SGCTs U (T1) 2U (X1) V (T2) 2V (X2) W (T3) 2W (X3) Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 18 PLe). More information on functional safety and SIL and PL ratings can be found in the following standards: • EN 61508 • EN 62061 • EN 61800-5-2 • EN 13849-1 See publication 7000-UM203 for more information that is related to the functional safety option. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 19 Figure 16 - Operator Interface Basic Configurations There are three basic configurations for the HMI: • Remote mounted • Locally mounted • No HMI supplied Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 20 HMI is not required. See Publication 7000-UM201 for detailed instruction for the HMI. See Publication 7000A-UM151 for detailed instruction for “A” Frame drives that use the PanelView 550 HMI. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 21 • Relative humidity of the air not to exceed 95% noncondensing. For the equipment to operate in conditions other than conditions specified consult the local sales office of Rockwell Automation. The equipment requires the following site conditions: • Indoor installation only, no dripping water, or other fluids.
Page 22 The heat created by the drive is directly proportional to the power of the motor being driven and the efficiency of equipment within the room. When thermal load data is required, contact the Rockwell Automation sales office. • The area in which the drive is located must be free of radio frequency interference such as encountered with some welding units.
Page 23 If the shock indicator is blue, contact Rockwell Automation® Product Support Group in Cambridge, Ontario, Canada. The drive can have internal damage if physical shock was experienced during shipment or installation.
Page 24 The protective plate is a flat cover plate that is bolted to the top plate. 2. Remove the bolts and plate and set aside for reuse. 3. Loosely assemble the two L-shaped panel components that are shipped with the drive as per Figure Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 25 4. Locate the exhaust hood on top of the cabinet per Figure 20 reinstall the original cover plate that was set aside. Care must be taken that the notches on the bottom flange are oriented toward the sides of the drive. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 26 ATTENTION: Any screws that are accidentally dropped in the equipment must be retrieved as damage or injury can occur. Figure 20 - Fan Hood Installation Assembled Exhaust Hood M6 Screw (12) Verify that notch orientation to sides Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 27 1. Remove and discard the protective plate and associated hardware that covers the fan opening on the cabinet. 2. Remove the top cover of the fan housing and set the top cover aside. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 28 6. Affix the redundant fan assembly to the drive top plate with the M6 thread screws provided. 7. Connect the fan wire harness to fan. 8. Reinstall the top cover onto the fan housing and tighten all hardware. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 29 3. Affix the fan to the drive top plate with the M6 screws provided. 4. Connect the wire harness to fan. Figure 24 - Fan Installation for Integral Isolation Transformer Assembled Exhaust Hood M6 Screw (6) Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 30 Attach Neutral Resistor Assembly ground to top plate. See electrical drawings to verify cable rating and to connect neutral resistor Motor filter Line filter assembly. capacitors capacitors Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 31 6. Connect the ground connection of the housing for the neutral resistor assembly to the top plate of the drive. 7. Reinstall the top plate of the neutral resistor housing. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 32 • Size and location of the top openings for the control wiring entry (balloon C). • Minimum aisle clearance in front of equipment (balloon M). The FRONT VIEW shows: • Minimum clearance that is required at top of drive for fan maintenance (balloon K). Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 33 Drive Installation Chapter 2 Figure 27 - PowerFlex 7000 “A” Frame Dimensional Drawing IMPORTANT Contact Factory for Seismic Mounting Information. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 34 PowerFlex 7000 “A” frame drive. Figure 28 - Direct-to-Drive™ (AFE with DTD DC Link) Converter Cabinet Line Reactor/Starter Control Link/Fan Cabinet Cabling Cabinet Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 35 Drive Installation Chapter 2 Figure 29 - AFE Rectifier (Separate Isolation Transformer) Converter Cabinet Control Link/Fan Cabinet Cabling Cabinet Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 36 Chapter 2 Drive Installation Figure 30 - AFE Rectifier (Integral Isolation Transformer) Converter Cabinet Control Link/Fan Cabinet Isolation Transformer and Cabling Cabinet Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 37 However, NEC requires shielded cables for installations above 2 kV. Cable Insulation The cable insulation requirements for the PowerFlex 7000 “A” frame drive are given in the following tables. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 38 Application and signal examples along with the recommended type of cable for each group are provided. A matrix providing the recommended minimum spacing between different wire groups that are run in the same tray or separate conduit is also provided. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 39 Note 5: Voltage drop in motor leads can adversely affect motor start and run performance. Installation and application requirements can dictate that larger wire sizes than indicated in IEC / NEC guidelines are used. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 40 4. Replace all barriers/covers by reversing the sequence, before applying medium voltage. The installer is responsible for modifying the plate for power cable access, to suit their requirements. Appropriate connectors must be used to maintain the environmental rating of the enclosure. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 41 The installer is responsible for verifying that power connections are made with appropriate torque (see page 183). The drive is supplied with provision for grounding of cable shields and stress cones near the power terminals. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 42 [3.94] 2314.6 2314.6 2314.6 [91.12] [91.12] [91.12] 214.5 [8.44] 2033.2 2033.2 2033.2 328.8 [12.94] [80.05] [80.05] [80.05] 1324.8 1324.8 1324.8 [52.16] [52.16] [52.16] Bottom Cable Entry) Right-hand side sheet is removed for clarity. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 43 251.9 [9.92] 251.9 [9.92] [44.61] [44.61] 429.0 [16.89] 429.0 [16.89] 314.7 [12.39] 314.7 [12.39] 189.2 [7.45] 189.2 [7.45] 2314.6 2314.6 [91.12] [91.12] Line Cables L1,L2,L3 L1,L2,L3 Motor Cables U,V,W U,V,W Section B-B Section A-A Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 44 1000.3 [39.38] 1000.3 [39.38] 112.8 [4.44] 112.8 [4.44] 112.8 112.8 [4.44] [4.44] 2314.6 2314.6 [91.12] [91.12] 1409.4 1409.4 [55.49] [55.49] 1180.8 1180.8 [46.49] [46.49] 952.2 952.2 [37.49] [37.49] 412.9 [16.26] 412.9 [16.26] Section A-A Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 45 Drive Installation Chapter 2 Figure 34 - Dimension Views of AFE Rectifier with Integral Isolation Transformer Section A-A Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 46 See the grounding diagrams that follow for ground connections. The main ground bus of the drive must be connected to the system ground. This ground bus is the common ground point for all grounds internal to the drive. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 47 6 m (20 ft) of its location. Tied the motor frame to the drive ground bus by way of ground wires within the power cables and/or conduit. The conduit or cable armor must be bonded to ground at both ends. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 48 The main grounding conductor must be run separately from power and signal wiring so that faults: • Do not damage the grounding circuit. • Do not interfere with or damage, protection, or the metering systems. Or cause undue disturbance on power lines. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 49 The key interlocking prohibits the upstream power being applied, until the access doors of the medium voltage drive are closed and locked shut. It is the responsibility of the installer to verify that the key interlocking is installed properly to the upstream equipment. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 50 Chapter 2 Drive Installation Notes: Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 51 Power Component Definition and Maintenance Cabling Cabinet Components Figure 37 - Direct-to-Drive with UPS Option Low Voltage Compartment Line Cable Terminations Hall Effect Sensors Current Transformers Control Power Transformer Fuses Motor Cable Terminations AC Line Reactor Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 52 Line Cable Terminations (Behind Disconnect Switch) Fused Disconnect Switch Disconnect Switch Operating Handle Vacuum Contactor Assembly Control Power Transformer Motor Cable Terminations (Hall Effect Sensors Behind) Control Power Transformer Fuses AC Line Reactor Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 53 Figure 39 - AFE Rectifier with Isolation Transformer Low Voltage Wireway Current Transformer Hall Effect Sensor Line Cable Terminations Motor Cable Terminations Hall Effect Sensor Current Transformer Control Power Transformer Fuses Fan-control Power Transformer Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 54 Top Cable Entry and Exit Locations Ground Bus Hall Effect Sensors Line Cable Terminations Motor Cable Terminations Current Transformers (CT) Integral Isolation Transformer SECTION A-A Bottom Cable Entry and Exit Locations Side View Front View Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 55 6. Replace the Hall Effect sensor. The arrow must be oriented as shown in Figure 7. Slide the load cable back into place and secure the hardware. 8. Plug the connector back into the sensor. The plug is keyed to avoid incorrect connection. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 56 5. Remove the hardware and slide the cable out. 6. Remove the two screws that are located in the base of the CT and remove the CT. 7. Replace the CT. 8. Verify the proper orientation. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 57 10. Reconnect the ring lugs. 11. Slide the line cable back into place 12. Secure the hardware. Figure 42 - Replacement of Current Transformer Current Transformer (CT) Current Transformer Cabling Cabinet Line Reactor / Starter Cabinet Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 58 Converter Cabinet Figure 43 - Converter Cabinet Components (2400V Version) Components Isolated Gate Driver Power Supplies (IGDPS) Inverter Modules Rectifier Modules Rectifier IGDPS (not required in drives with SPS boards installed) Voltage Sensing Boards Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 59 Chapter 3 Figure 44 - Converter Cabinet Components (3300/4160V Version) Inverter Modules Isolated Gate Driver Power Supplies (IGDPS) Rectifier IGDPS Rectifier Modules (Not required in drives with SPS boards installed) Voltage Sensing Boards Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 60 Power Component Definition and Maintenance Figure 45 - Converter Cabinet Components (6600V Version) Isolated Gate Driver Power Supplies (IGDPS) Inverter Modules Rectifier Modules Rectifier IGDPS Not required in drives with SPS boards installed) Voltage Sensing Boards Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 61 Table 4 - Input Voltage Range Voltage Range (V) 800…1449 1450…2499 2500…4799 4800…7200 ATTENTION: Grounds must be reconnected on the voltage sensing boards. Failure to do so can result in injury, death, or damage to equipment. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 62 9. For personnel and equipment safety, verify that both grounding connections are reconnected to the sensing board. 10. Replace clear plastic cover and refasten in place. Figure 46 - Sensing Board with Mounting Hardware Placement Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 63 There are three Y-connected surge arresters that are attached to the incoming MV lines. The neutral point of the arresters is connected to the ground bus. Figure 47 - Surge Arresters Drive Input from Line Terminals Heavy-duty Distribution Class Surge Arrester Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 64 7. Replace the surge arrester with an equivalent one (make sure that the voltage rating is the same). 8. Connect the leads to the surge arrester. 9. Surge arrester hardware to be torqued to 28 N•m (21 lb•ft). Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 65 Field Test and Care A field test in not necessary. The arresters do not require special care. However at dusty sites, clean the arrester when the whole drive is cleaned. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 66 Do not handle these boards without being properly grounded. ATTENTION: Static charges can destroy some circuit boards. Use of damaged circuit boards can also damage related components. A grounding wriststrap is recommended for handling sensitive circuit boards. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 67 Sharing Resistors The sharing resistors provide equal voltage sharing when using matched devices in series. SGCT PowerCage modules for 2400V systems do not need matched devices and have no sharing resistor. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 68 Resistor Anode Cathode Test Heatsink Heatsink Figure 50 - Snubber Circuit for SGCT Module (with SPS Board) Cs-1 Rsn-2 SPS Board Rsn-1 J1-1 J1-2 Snubber Cs-2 Resistor Test Cathode Anode Heatsink Heatsink Heatsink Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 69 Figure 52 - 2400V Two Device PowerCage Module (with SPS Boards Installed) SPS Mounting Assembly with SGCT SGCT Temperature Feedback Board Clamp Head Pivot Plate Heat sink SPS Board Mounting Assembly without Temperature Feedback Board Module Housing Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 70 Figure 54 - 3300/4160V Four Device Rectifier PowerCage Module (with SPS Boards Installed) SPS Mounting Assembly with Pivot Plate Matched Set Matched Set Clamp Head Temperature Feedback Board Two SGCTs Two SGCTs Heat sink Module Housing SPS Mounting Board Assembly without Temperature Feedback Board Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 71 Figure 56 - 6600V Six Device PowerCage Module (with SPS Boards Installed) Matched Set Matched Set Three SGCTs Pivot Plate Clamp Head Three SGCTs Heatsink SPS Mounting Assembly without SPS Mounting Assembly with Module Temperature Feedback Board Temperature Feedback Board Housing Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 72 Pressure on the SGCTs must be uniform to avoid damage and to help maintain low thermal resistance. To achieve uniform pressure: 1. Loosen the heatsink mounting-bolts. 2. Tighten the clamp. 3. Tighten the heatsink mounting-bolts. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 73 TB1 of the SPGD board. Measure between the test point and the wire that is connected to pin 1 of the TB1 female connector. Replace the snubber terminal connection once the measurement is complete. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 74 PowerCage module under the heatsink is a snubber circuit test- point. For each device, there is one test point. To verify the resistance, measure the resistance between the test point and the heat sink. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 75 Turn the multimeter from the resistance to capacitance measurement mode. Verify the snubber capacitor by measuring from the test point to the heat sink next to the right for standard rectifiers, or from heat sink to heat sink. For SPS rectifiers: Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 76 Figure 62 - Snubber Capacitor Test (Shown with SPS Board Installed) Sharing Resistor Snubber Snubber SPS Board Capacitor Resistor Snubber Test Point Test Point SGCT Heatsink Heatsink Snubber Capacitor Wire Use connector terminal screw for testing the snubber capacitor. SGCT Cathode Wire Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 77 4. Two brackets secure the board to the heatsink. Loosen the captive screws until the circuit board is free. Adjust the position of the heatsinks, as required, to allow free movement of the SGCT. 5. Slide the circuit board straight out. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 78 If equipped, reinstall the SPS board and mounting-bracket, and reconnect the snubber connection to J1 of the SPS board. 12. Connect the power cable and fiber-optic cables (verify that the bend radius is not exceeded). Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 79 Figure 64 - Replacing the SGCT (If SPS Board Is Installed) Inside nut for SGCT Captive Screws loosening and applying load to assembly. DO NOT ADJUST outside nut. Clamp Head Block SPS board mounting- assembly captive screws. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 80 4. Remove the push nuts on the end of the retaining rod. Pinch the clip together and pull off. Pull out the retaining rod. See Figure 5. Remove two bolts and swing out the PowerCage plug-in stab assembly. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 81 8. Slide the retaining rod into place and push the clips back into place. 9. Connect the leads to the resistor bank. 10. Install the PowerCage module as outlined in PowerCage Module Removal on page Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 82 Torque M8 hardware to 7 N•m (60 lb•in). 13 mm Socket M8 Bolt 5/16 in. Lock Washer 5/16 in. Flat Washer Electrical Lead 17 mm Flange M8 Hardware Location 6. Bundle and secure the connecting wires using wire ties. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 83 5. Check the indicating washer of the clamp. Checking the Clamping Pressure Periodically, the clamping force in the PowerCage module must be inspected. Verify that there is no power to the equipment. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 84 IMPORTANT Never rotate the calibration nut that is located outside the indicating washer at the end of the threaded rod. The rotation of the outer nut affects the torque calibration, which is factory set. Only adjust the inside nut (see Figure 69). Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 85 11. Replacement of the heatsink with the new thermal sensor is in the reverse order of removal. 12. Follow procedure Maintain Uniform Clamping Pressure on page 83 verify that the heatsinks are clamped to a uniform pressure. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 86 Mounting Screw Thermal Sensor and Cable Assembly Figure 71 - Replacing the Thermal Sensor (if SPS Board is Installed) Temperature Feedback Mounting Pad Circuit Board Insulating Bushing Mounting Screw Thermal Sensor and Cable Assembly Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 87 PowerCage from the clamp head. If the pivot plate is removed from the PowerCage, it must be replaced in the original orientation. See Figure 51 through Figure 56 for pivot plate location. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 88 This gasket is placed between the surface of the PowerCage module and heatsink module. The gasket must be in place to keep the SGCTs cool. Figure 73 - PowerCage Gasket Location Power Connection Gasket Resistors Power Connection PowerCage Housing Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 89 Apply the porous surface of the gasket to the PowerCage module. The gasket bonds almost immediately. Apply some pressure to the gasket for 15...30 seconds. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 90 A suggested sequence for torquing PowerCage module bolts is shown in Figure Note: The PowerCage module is shown with switching components, heatsinks, and clamps removed for ease of lifting. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 91 Power Component Definition and Maintenance Chapter 3 Figure 74 - Typical Torque Sequence 7. Replace interior assembly in the reverse order of removal. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 92 300V DC bus common TP15 20V DC output TP14 20V DC output common The green Status Indicator (DS1) on the SPS board indicates that the 20V DC output is within operating specification range. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 93 Connection to 300V DC internal bus (Short J1-5 to J1-6 to allow input to operate from 90V AC) J1 – 6 Connection to TOPSwitch programming resistor (Short J1-5 to J1-6 to allow input to operate from 90V AC) Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 94 SPS boards and remove the SPS test harness from the power converter cabinet. Do NOT leave the SPS test harness in the power converter cabinet. Reconnect all SGCT snubber connections to the J1 connectors on the SPS boards. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 95 The color codes of the connectors are: • BLACK or GREY – is the transmitting end of the fiber-optic. • BLUE – is the receiving end of the fiber-optic. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 96 3. Check the integrity of the sealant that has been applied where the clear tubing passed through the sheet metal barrier. 4. Installation of the replacement airflow sensor is in the reverse order of its removal. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 97 Figure 78 - DC Link and Fan Cabinet, Low Voltage Control Tub Shown Components Low Voltage Control Tub Retaining Hardware AC/DC Power Supply (Dual Power Supply with Diode Shown) Analog Drive Control Board Medium Voltage Barrier (for access to Line/ Motor Capacitors Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 98 Chapter 3 Power Component Definition and Maintenance Figure 79 - DC Link and Fan Cabinet, Low Voltage Control Tub Removed Inlet Ring DC Link Inductor Grounding Network/ Filter Motor Filter Capacitor Line Filter Capacitor Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 99 5. Place the new capacitor and tighten the screws securely. 6. Replace the ring lugs and 6.4 mm (¼ in.) hardware (Figure 80). IMPORTANT The maximum torque for the capacitor terminal is 3.4 N•m (30 lb•in.). Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 100 4. Assemble the new component in the reverse order of disassembly. 5. Reattach the leads strictly adhering to these torque requirements. IMPORTANT The maximum torque for the capacitor terminal is 3.4 N•m (30 lb•in.). Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 101 The capacitors are equipped with internal “bleeding resistors” to discharge the capacitor and reduce its voltage below 50V in 5 minutes when left disconnected. A typical three-phase capacitor is shown in Figure Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 102 ATTENTION: Verify that the load is not turning due to the process. A freewheeling motor can generate voltage that is back-fed to the equipment being worked on. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 103 5. Remove the grounding network and top bracket that holds the capacitor in place. At the bottom of the capacitor, there is no hardware securing the capacitor. The capacitor fits into a slot in the assembly. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 104 3. Verify that there is no voltage present on the capacitor by using a hot stick or any other appropriate voltage-measuring device. 4. Verify that there is no oil leak or bulge in any of the capacitors. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 105 3. Note the location of all cables and mark them accordingly. 4. Disconnect power cables from the capacitor terminals on all four bushings and isolate them from the capacitor (see Replacing the Filter Capacitors on page 103). Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 106 Xc = V/I = 200/1.87 = 106.95 π C= 1/ (2 C= 1/(2 x 3.14 x 50 x 106.95 C=29.7μ Similarly, you can calculate the capacitance for the remaining two measurements for L2-N and L3-N. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 107 Failure to do so can result in injury or death. The DC link reactor does not normally require service. If it is replaced, Rockwell Automation must approve the replacement link. The link is cooled by air that is drawn through its coils.
Page 108 Installation of the replacement DC link is performed in the reverse order of its removal. The installer must verify that the flexible DC link leads are connected to the appropriate terminal and routed so that electrical clearances are maintained. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 109 4. Using a crane, hoist, or similar lifting provision, affix tie straps around opposite vertical brackets of the fan assembly and carefully lift the fan assembly out of the cabinet. ATTENTION: Do not support the assembly on the impeller or damage can result. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 110 Handle the fan assembly with extreme caution. If handled improperly, the fan becomes unbalanced. Fan installation is performed in the reverse order of its removal. Rotate the impeller by hand to make sure that there is no contact with the inlet ring. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 111 2. Remove the bolts that retain the cross channel and withdraw the fan and channel from housing. 3. Disassemble and replace the fan. 4. Reassemble in the reverse order of removal. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 112 It is positioned such that the impeller sits outside but does not touch the ring. Replacement The ring sits inside the impeller 10 mm (0.40 in.). This procedure requires coming in contact with the internal electrical connectors and devices. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 113 Move the ring and retighten bolts to help mitigate interference. 4. Replace all panels and barriers that are opened or removed during inlet ring replacement. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 114 Use only replacement filters that are provided, or approved for use by Rockwell Automation Replacement of the filters is performed in the reverse order of its removal. Check that there are no openings that would allow foreign matter into the drive. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 115 Power Component Definition and Maintenance Chapter 3 Figure 87 - Filter Replacement Retaining Hardware Filter Figure 88 - Airflow Through PowerCage Module Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 116 Chapter 3 Power Component Definition and Maintenance Figure 89 - Airflow Pattern for Drive Cooling Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 117 110…240V is supplied directly to the LV panel through the CPT. Figure 90 - FPT Wiring Configurations FPT is Required: Main Customer- 380…480V supplied 2.4…6.6 kV Redundant LV Panel 110…240V FPT is Not Required: Main Customer- supplied 380…480V Redundant LV Panel 110…240V Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 118 Chapter 3 Power Component Definition and Maintenance Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 119 5 cycles after control power is interrupted. If control power is not restored during the 5 cycles, a controlled shutdown occurs. Figure 91 illustrates the control power distribution for AFE drives with integral starter/line reactor. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 120 600 W/ 1000W/ 1500 W Filter 24V-Isolators 24V-XIO Sense Cable DC Fail 380V 50 Hz Line 460V 60 Hz Reactor 3 PH 20V Isolated Gate Driver Power Supply Inverter only for SPS Drives Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 121 600 W/ 1000W/1500 W 1 PH +24V-ISOLATORS +24-XIO DC Fail Sense Cable 380V 50 Hz Tx Fan 20V Isolated Gate Driver 460V 60 HZ Line Power Supply 3 PH Reactor Inverter only for SPS Drives Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 122 600 W/ 1000W/ 1500 W 1 PH + 24V-ISOLATORS +24-XIO Sense Cable Tx Fan 20V Isolated 380V, 50 Hz Gate Driver Power Supply 460V, 60 HZ 3 PH Inverter only for SPS Drives Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 123 Supply DC FAIL: Upon loss of DC output (V outputs ≤ 49V DC) this output goes from low to high. (1) Cosel power supply output 57V DC, Pioneer power supply output is56V DC. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 124 The AC/DC power supply is located in the low voltage panel at the top right- hand section of the drive, see Figure Figure 95 - Location of AC/DC Cosel (single) Power Supply on Low Voltage Panel AC/DC Power Supply (Cosel) Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 125 Control Component Definition and Maintenance Chapter 4 Figure 96 - Location of AC/DC Cosel (Dual) Power Supply on Low Voltage Panel AC/DC Power Supply (Cosel) Diode Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 126 Single Phase Input DC Outputs Control Signals Figure 98 - Terminal Locations on 600 W AC/DC Power Supply (Cosel) Terminal/Connections Descriptions (600W Cosel Power Supply) Single Phase Input Control Signals Adjustment Pot DC Outputs Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 127 56…57V DC. (1) 56V DC for Cosel model numbers -XRWAC and earlier. 57V DC for Cosel model numbers -XRWAD and newer. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 128 AC/DC power supply and the mounting plate of the bracket. 7. Repeat steps 6...1 in this order to replace the unit. 8. Reapply control power and verify voltage levels. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 129 4. Remove the diode cover from the diode. 5. Remove the M6 Hex screws from diode. 6. Remove the diode from the panel. 7. Remove the four M6 bolts from the bracket holding the power supply. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 130 11. Clean the diode contact area and apply thermal grease to the area. 12. Repeat Steps 10...1 in this order to replace the unit. 13. Reapply control power and verify voltage levels. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 131 7. Clean the diode contact area and apply thermal grease to the area. 8. Reinstall the unit following the steps 6…1 in reverse. M6 Head Screw M6 Hex Screw (Phillips Head) Diode Safety Cover Diode Low Voltage Bracket Swing-out Tub M6 Bolts Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 132 The following diagram shows the current configuration of the internal UPS option. Figure 99 - 300 W AC/DC Power Supply 300 W AC/DC Power Supply Hold-up Capacitor The Holding Bracket Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 133 If the date has passed and the batteries were never recharged, do not use the UPS. Contact Rockwell Automation. (1) 56V DC for Cosel model numbers -XRWAC and earlier. 57V DC for Cosel model numbers -XRWAD and newer.
Page 134 See the manual that comes with the UPS for instructions. 8. When the configuration has been confirmed, install the mounting bracket. (1) Reprinted from 700-3000 VA User’s Guide by permission of Eaton Corporation. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 135 DC/DC +/- 24V-HECS Power Supply 56…57V DC +/- 24V-ISOLATORS C hold-up +24-XIO Sense Cable (1) 56V DC for Cosel model numbers -XRWAC and earlier. 57V DC for Cosel model numbers -XRWAD and newer. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 136 (To Isolator Modules) ISOLATOR (+24V, 1 A) +24V, 1A/com4 ISOL_COMM (com4) 0V/com4 EARTH EARTH (1) 56V DC for Cosel model numbers -XRWAC and earlier. 57V DC for Cosel model numbers -XRWAD and newer. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 137 5. Replace old DC/DC Power Supply with the new one. Verify that the black insulation is between the DC/DC power supply and the mounting plate. Repeat steps 4...1 in this order to replace unit (View 2, Figure 103). Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 138 All wire/terminal connections are made with plugs that plug into the circuit boards. Changing boards only requires the removal of the plugs, which minimizes the chance of mistakes when reconnecting the wiring. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 139 Figure 104 - Drive Processor Module (DPM) Test Points Secondary Primary Inverter Gating Battery Signals Rectifier Gating Signals Interface Module DPM Data Port Primary Secondary Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 140 POST – USART failed: 1 Green Count = Port 1 2 Green Count = Port 2 10 count End of code reached 11 count Download – CRC error 14 count Download – Overflow error Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 141 9. Apply control power to the drive. The DPMs are shipped with no firmware installed, so the drive automatically goes into download mode. Install firmware in the drive following the guidelines in publication 7000-UM201A. 10. Program the drive. See publication 7000-TD002. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 142 Chapter 4 Control Component Definition and Maintenance Figure 105 - ACB and DPM Replacement Analog Control Board Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 143 DC Fail Signal Monitoring DPI™ Meter Inputs & Comms Connections DC Power Supply DC -ABUS +56V XIO-PWR(+24V,+/-15V, +/-24V, Speed Pot Input Terminal (PanelView) Monitoring Monitoring (in UPS option) +5V DIG, DC Power Supplies) Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 144 AC Motor and Line-voltage feedback inputs ACB-J28 Encoder interface ACB-J30 DPM connection, A/D SUB system ACB-J31 DPM connection, DACs serial data ACB-J32 DPM power supply, +5V ACB-J33 DPM connection, Faults & other I/O ACB-J34 DPM connection, Encoder Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 145 ACB-TP37 Line current, CT4U ACB-TP38 Line current, CT4W ACB-TP39 Vzs4 Zero sequence generation line-side, VZS4 (spare one) ACB-TP40 CMC neutral voltage, VNN ACB-TP41 CMC neutral current, INN ACB-TP42 Ignd Ground fault current, GFCT Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 146 ACB-TP77 OPIS Output isolating switch ACB-TP78 OPCS Output contactor status ACB-TP79 Output contactor command ACB-TP80 BPIS Bypass isolating switch ACB-TP81 BPCS Bypass contactor status ACB-TP82 Bypass contactor command ACB-TP83 DGND Digital ground return Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 147 The isolated process output is configured as 4...20 mA. The three isolated process inputs are individually configurable for either a range of -10/0/+10V or 4...20 mA (Refer to Programming Manual). The following information shows the connections for each input and output. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 148 The recommended connection is shown in Figure 108. The type of shielded cable that is used is application-specific. The type is determined by the length of the run, the characteristic impedance, and the frequency content of the signal. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 149 Pin numbers that are shown are for connection to the first of three isolated process receivers. Figure 110 - Process Loop Receiver Connections User-supplied power (Sinking) 4-Wire Transmitter Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 150 Different scaling resistors are mounted on the terminal block for line side and machine side There are two status indicators on the ACB labeled D7 and D9. D9 is the ±15V DC voltage-OK signal, and D7 is the +5V DC voltage-OK signal. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 151 Acceptable outputs are analog line driver or push pull. 2. The drive does not operate properly with single ended quadrature encoders. Rockwell Automation recommends using differential inputs only for these types of encoders. Single ended outputs are only acceptable for Positional Encoders.
Page 152 The board also provides a galvanized, isolated 12V/3 W supply to power the attached encoder. The 20B-ENC-1 Encoder interface can be configured for 5V operation, however Rockwell Automation recommends operation at 12V. Figure 112 - Encoder Interface (20B-ENC-1 and 20B-ENC-1-MX3)
Page 153 ‘park’ location to the selected function location. The following table describes the functions available. ATTENTION: Removing the Universal Encoder Interface while control power is applied can result in damage to the board. Only remove the board when the control power is off. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 154 Removed Natural-binary absolute encoder low-true Removed Removed Installed Gray-code absolute encoder high-true Removed Removed Removed Natural-binary absolute encoder high-true Installed Installed Installed Single-quadrature encoder option (factory default) Figure 113 - Universal Encoder Board Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 155 Z2- (redundant or dual ENC) ENC_COM ENC_COM ENC_COM ENC_COM ENC_COM ENC_COM ENC PWR (+12V) ENC PWR (+12V) ENC PWR (+12V) ENC PWR (+12V) ENC PWR (+12V) ENC PWR (+12V) Figure 114 - 20-pin Interface Module (IFM) Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 156 DPM. 2. Natural Binary, Low True. No conversion is done on the incoming data but the data is inverted. (1) Consult factory for availability of Positional Encoders. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 157 OFF or vice versa. In the case of gray code, since only 1 bit ever changes, the ambiguity error is never multiple counts. For this reason and to reduce inrush currents, Rockwell Automation recommends using gray code positional encoders.
Page 158 DC link overtemperature) and several spare fault inputs that are configurable. There is an option in software to assign each XIO a specific function (General I/O, External I/O, or liquid cooling). Figure 115 - XIO Board OUTPUTS Status Indicators INPUTS Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 159 The XIO board mounts on a DIN rail. A 3-piece assembly is used to secure the board. Remove the old board and install the new board in its place. 5. Install the new XIO board assembly in the low-voltage control cabinet. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 160 Each OIB board can handle the Firing and Diagnostic duplex fiber-optic connector for six devices. Physically, on the OIBBs, there is provision for 18 devices for the inverter and the rectifier. This capacity is enough to handle the Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 161 The top OIB board on the OIBB is for the ‘A’ devices. The middle OIB board is for the ‘B’ devices. The bottom OIB board is for the ‘C’ devices. Figure 117 - Optical Interface Base Board (OIBB) Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 162 7. Carefully handle the five standoffs that snap into place on the OIBB, when removing the boards. 8. Install the new OIBB. Verify that the standoffs snap into place. 9. Reinstall the ground nut that holds the OIBB in place. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 163 10. Reconnect all connections and verify the locations. ATTENTION: Reconnect the fiber-optic cables in their proper location. Failure to do so can result in injury or damage to equipment. Figure 118 - OIB Replacement (Mounting Plate Accessible) Optical Interface Boards Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 164 Chapter 4 Control Component Definition and Maintenance Notes: Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 165 Normal Duty, 0...1000 m Altitude. Maximum 50 °C (140 °F) Ambient Heavy Duty, 0...1000 m Altitude. Maximum 50 °C (122 °F) Ambient Normal Duty, 0...1000 m Altitude. Maximum 20 °C (68 °F) Ambient Custom Configuration (Contact Factory) Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 166 (1) A Control Power Transformer-modification must be selected (6, 6B, and so on) to size the transformer. (2) Control Circuit Power is supplied from separate/external source. (3) Three-phase Control Circuit Power is supplied from separate/external source. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 167 “normal duty” service rating up to 5000 m altitude. The ambient temperature rating is reduced at higher altitudes. If 40 °C (104 °F) ambient is required at 1001...5000 m altitude, a rating code of Z is required. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 168 Appendix A Catalog Number Explanation Notes: Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 169 Due to the critical nature of the applications that are run on MV drives, the key word is preventive. By spending approximately 8.0 hr/yr on these tasks, unexpected downtime can be reduced. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 170 NOT use a blower). Wipe clean components where appropriate. 4. Check for any visual or physical evidence of damage or degradation of components in the medium voltage compartments. For example inverter/rectifier, cabling, DC Link, contactor, load break, and harmonic filter. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 171 4. Verify the proper voltage levels at the CPT (if installed), AC/DC Power Supplies, DC/DC converter, isolated gate power-supply boards. page 197 for appropriate procedures/voltage levels for the previously referenced checks. 5. Verify the gate pulse patterns by using the Gate Test Operating Mode. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 172 Contact MV Spare Parts group for more information. 4. Vacuum Bottle Integrity Testing by using a Vacuum Checker or AC high potential. See Publication 1502-UM050 for a detailed description of all contactor maintenance. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 173 – Vacuum Bottle Integrity Check 3.0 hours • Final Report 3.0 hours (1) Time cannot be required depending on the nature of the maintenance and the condition of the drive system. These times are only estimations. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 174 Materials • Torque Sealer (Yellow) Part number --- RU6048. • Electrical Joint Compound ALCOA EJC No. 2 or approved equivalent (For Power Devices). • Aeroshell no. 7 Part number 40025-198-01 (for Vacuum Contactors). Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 175 Rv – Review A discussion with Rockwell Automation to determine whether any of the enhancements/changes made to the Drive Hardware and Control would be valuable to the application. RFB/R – Refurbishment/Replacement The parts can be refurbished at lower cost or the parts can be replaced with new ones.
Page 176 Appendix B Preventative Maintenance Schedule Rockwell Automation PowerFlex 7000 Drive Preventative Maintenance Schedule Period Interval (Years) (1) (2) Air-Cooling Door Mounted Air Filters System Main Cooling Fan Motor RFB/R I Redundant Cooling Fan Motor (if supplied) RFB/R I Small Aux. Cooling Fans “Caravel”...
Page 177 Preventative Maintenance Schedule Appendix B Rockwell Automation PowerFlex 7000 Drive Preventative Maintenance Schedule Period Interval (Years) (1) (2) Air-Cooling Door Mounted Air Filters System Main Cooling Fan Motor RFB/R Redundant Cooling Fan Motor (if supplied) RFB/R Small Aux. Cooling Fans “Caravel”...
Page 178 • National Electrical Manufacturers Association (NEMA) Standard • No. ICS 1.1 (Safety Guidelines for the Application, Installation, and Maintenance of Solid-Sate Control) for MV Drives. • ICS 1.3 (Preventive Maintenance of Industrial Control and Systems Equipment) for MV Controllers. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 179 For additional information, see NEMA ICS 1.3, PREVENTIVE MAINTENANCE OF INDUSTRIAL CONTROL AND SYSTEMS EQUIPMENT. Published by the National Electrical Manufacturers Association, Also NFPA70B, ELECTRICAL EQUIPMENT MAINTENANCE, published by the National Fire Protection Association. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 180 Replace all vacuum bottles in the contactor simultaneously to avoid misalignment and uneven contact wear. If the vacuum battles do not require replacement, check and adjust over-travel to the value listed in the product user manual. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 181 Solid-state Devices ATTENTION: Use of unrecommended test equipment for solid-state controls can result in damage to the control or test equipment or unintended actuation of the controlled equipment. See paragraph titled HIGH VOLTAGE TESTING. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 182 Check these devices for proper working-condition and capability of performing their intended functions. Make any necessary replacements only with Allen-Bradley® renewal parts or kits. Adjust or repair only in accordance with Allen-Bradley instructions found in the product user manuals. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 183 Torque (N•m) Torque (lb•ft) M2.5 0.45 Steel 0.43 0.32 0.70 Steel 0.80 Steel 1.00 Steel 1.25 Steel 1.50 Steel 1.75 Steel 2.00 Steel ¼ in. Steel S.A.E. 5 3/8 in. Steel S.A.E. 2 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 184 Appendix C Torque Requirements Notes: Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 185 ATTENTION: There are risks of serious or fatal injury to personnel if you do not follow safety guidelines. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 186 Disconnect Output Grounding Network 4. Remove the ground connection on the OGN (if installed). Lift this connection at the OGN capacitor rather than the grounding bus, as the grounding cable is only rated for 600V. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 187 8. Remove all fuses on the TSN before proceeding with the insulation resistance test. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 188 DC Link reactor. b. Isolate the DC Link reactor from the drive by disconnecting the four power cables. c. Verify that all electrical components being insulation resistance tested are electrically isolated from ground. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 189 Make sure that the ground conductors on the VSB are securely connected before applying medium voltage to the drive. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 190 For drives that did not originally have the OGN connected (or installed), there is no need for concern. Enable Transient Suppression Network 16. Reinstall the fuses on the TSN. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 191 (5) Cable sizes are based on overall dimensions of compact-stranded three-conductor shielded cable (common for industrial-cable tray installations). Maximum sizes stated accounts for minimum rated cable insulation requirements. The next higher-rated cable (8 kV is not commercially available in many areas of the world. Rockwell Automation provides an 8 kV (minimum rating) and a 15 kV rating, when applicable.
Page 192 (5) Cable sizes are based on overall dimensions of compact-stranded three-conductor shielded cable (common for industrial cable tray installations). Maximum sizing stated accounts for minimum rated cable insulation requirements and the next higher-rated cable. 8 kV is not commercially available in many areas of the world. Rockwell Automation provides an 8 kV (minimum rating) and a 15 kV rating, when applicable.
Page 193 (1) IEC 60721-3-3 “Classification of Environmental Conditions - Part 3: Classification of Groups of Environmental Parameters and their Severities - Section 3: Stationary Use at Weather Protected Locations”. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 194 Appendix F 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 make sure that environmentally inert materials were used wherever feasible.
Page 195 When disposing of the drive, it must be disassembled and separated into groups of recyclable material as much as possible (that is steel, copper, plastic, wire). Send these materials to local facilities for recycling. Follow all previously mentioned disposal precautions. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 196 Appendix F Environmental Considerations Notes: Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 197 Services The Rockwell Automation standard work hours are between 9:00 a.m. to 5:00 PM EST (8 hr/day) Monday through Friday, not including observed holidays. Additional work hours are available on a time and material basis.
Page 198 15. Verify proper performance, run the drive motor system throughout the operational ranges. Customer personnel are required on-site to participate in the start-up of the system. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 199 Inverter Design Inverter Switch SGCT Inverter Switch Failure-Mode Non-rupture, Non-arc Inverter Switch Failure-Rate (FIT) 100 per 1 Billion Hours Operation Inverter Switch Cooling Double Sided, Low Thermal Stress Inverter Switching Frequency 420…440 Hz Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 200 Independent Accel/Decel – 4 x 30 s Acceleration/Deceleration Ramp 4 x Independent Accel/Decel Rates S Ramp Rate Independent Accel/Decel – 2 x 999 s Critical Speed Avoidance 3 x Independent with Adjustable bandwidth Stall Protection Adjustable time delay Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 201 Serial Communication 16-Bit resolution (.1 Hz) (Digital Speed Reference) Analog Outputs One Isolated, Eight Non-isolated, 4…20 mA or 0…10V (600 Ω) Communication Interface EtherNet IP™/DPI™ Scan Time Internal DPI – 2 ms…4 ms. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 202 (4) BIL rating that is based on altitudes < 1000 m (3300 ft). See factory for derating on altitudes >1000 m (3281 feet). (5) Optional. (6) Under certain conditions, power system analysis is required. Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 203 148 color code 95 current transformer length 95 replacement 56 filter capacitors 101 replacement 103 testing 104 D.C. link 97 reactor replacement 107 removal 108 gasket 88 replacement 89 general precautions 9 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 204 75 motor terminations 41 snubber circuit 68 snubber resistance 74 neutral resistor direct-to-drive 31 self-powered SGCT power supply. See SPS hood assembly 30 board non-isolated process outputs 150 service duty rating 167 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 205 145 thermal sensors 85 replacement 85 topology 11 torque requirements 183 torque sequence 91 transformer cooling fan 29 uninterruptible power supply. See UPS UPS 132 connect battery 134 location 132 replace 133 Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 206 Index Notes: Rockwell Automation Publication 7000A-UM200G-EN-P - February 2020...
Page 208 How Are We Doing? form at http://literature.rockwellautomation.com/idc/groups/literature/documents/du/ra-du002_-en-e.pdf. Rockwell Automation maintains current product environmental information on its website at http://www.rockwellautomation.com/rockwellautomation/about-us/sustainability-ethics/product-environmental-compliance.page. Allen-Bradley, Direct-to-Drive, DPI, PanelView, PowerCage, PowerFlex, Rockwell Automation, and Rockwell Software are trademarks of Rockwell Automation, Inc. ControlNet, DeviceNet, and EtherNet/IP are trademarks of ODVA, Inc.

Rockwell Automation Allen-Bradley PowerFlex 7000 User Manual

Quick Links

Related Manuals for Rockwell Automation Allen-Bradley PowerFlex 7000

Summary of Contents for Rockwell Automation Allen-Bradley PowerFlex 7000