Page 1 PowerFlex 7000 Medium Voltage AC Drive Liquid-Cooled (’C’ Frame)—ForGe Control Bulletin Number 7000L User Manual Original Instructions...
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: Table Of Contents
Tools Required (not supplied)....... . . 34 Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 4 MOV Fuse ..........83 Transient Suppression Network Fuse Replacement ....84 Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 5 Coolant Pumps ..........128 Pump Maintenance and Replacement......129 Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 6 Non-Isolated Process Outputs ....... 168 Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 7 Locking and Interlocking Devices ......195 Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 8 ............221 Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 9: Preface
This manual is intended for use by personnel familiar with medium voltage Manual and solid-state variable speed drive equipment. The manual contains material that enables regular operation and maintenance of the drive system. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 10: What Is Not In This Manual
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®. If you have multiple drive types or power ranges, ensure you have the correct documentation for each specific PowerFlex 7000 product: •...
Page 11: General Precautions
• The medium voltage doors must be properly secured using the handle mechanism (if provided), the key interlock (if provided), and the door bolts. Failure to do so voids the arc resistant structural integrity. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 12: Abbreviations
Selective Harmonic Elimination Safety Integrity Level SPGDB Self-powered Gate Driver Board Self-powered SGCT Power Supply Safe Torque Off Transient Suppression Network Uninterruptible Power Supply Variable Frequency Drive Voltage Sensing Board Voltage Source Inverter External Input/Output Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 13: Additional Resources
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system. Product Certifications website, rok.auto/certifications. Provides declarations of conformity, certificates, and other certification details. You can view or download publications at rok.auto/literature.
Page 14 Notes: Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 15: Overview Of Drive
Introduction The PowerFlex® 7000 drive represents the third generation of medium voltage drives at Rockwell Automation®. The PowerFlex 7000 medium voltage AC drive is part of the PowerFlex family of AC drive products. The Allen-Bradley® PowerFlex family of drives incorporates leading-edge technology, embedded communications, and significant commonality across multiple platforms, networks, operator interface programming and hardware.
Page 16 - No need to remove any cooling lines for device replacement - Reduced manufacturing time for faster delivery and lower cost • Keyed mechanical interlock - Interlocked with main disconnect means to prevent unsafe access to medium voltage section Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 17: Topology
IEEE 519-2014 guideline for harmonics. The 18-pulse rectifier consists of one master bridge and two slave bridges and will always have a total of 18 silicon controlled rectifier (SCR) switching devices. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 18: Active Front End (Afe Rectifier)
AFE drive meet the harmonic requirements in the IEEE 519-2014 guideline for harmonics. Figure 3 - Active Rectifier (PWM) and Input Current/Voltage Waveforms Line Current Line-to-line voltage at PCC Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 19: Direct-To-Drive Technology
30…50% of a drive system size and 50…70% of the system’s weight. This means that there is no interwiring between drive and transformer (for external transformer configurations). This makes the PowerFlex 7000L drive the simplest to install. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 20: Motor Compatibility
Unlike many VSI topologies that use IGBTs, the semiconductors used in the PowerFlex 7000L feature a non-rupture, non-arc failure mode. In the unlikely event of a device failure, the fault would be contained within the device. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 21 4. Reduction of component count, hence improving reliability, cost, and size of the drive. 5. Fail safe failure mode (non-rupture). Figure 5 - SGCT with Integrated Gate Drive and Unit Cell Structure Cathode Gate Anode Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 22: Simplified Electrical Drawings
DC Link Machine Converter Line Converter SGCTs SGCTs SGCTs SGCTs 2U (X1) 2U (X1) U (T1) U (T1) 2V (X2) 2V (X2) V (T2) V (T2) 2W (X3) 2W (X3) W (T3) W (T3) Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 23: Control Overview
Chapter 1 Overview of Drive Control Overview Figure 10 - PowerFlex 7000L “C” Frame Function Block Diagram Flux Range Inv Flux CurCmd InvTorque CurCmd Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 24: Direct Vector Control
Figure 11 - Control Hardware Layout OIBB OIBB • ACB - Analog Conditioning Board • DPM - Drive Processor Module • OIBB - Optical Interface Base Board • XIO - External Input/Output • OIB - Optical Interface Board Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 25: Functional Safety
(Cat 3, PL e). 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 7000L-UM303F-EN-P - April 2022...
Page 26: Operator Interface
IMPORTANT This configuration applies to both the eHIM and PanelView Plus 6 terminal. The HIM is mounted on the LV door of the VFD. There is also a service access port (RJ-45 connector) on the LV door. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 27 Ethernet cable, when required. This is ideal for unmanned sites, where a dedicated HIM is not required. See publication 7000-UM201 for detailed instruction for the HIM. See publication 7000-UM151 for detailed instruction for ‘B’ frame drives using the PanelView 550 HIM. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 28 Chapter 1 Overview of Drive Notes: Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 29: Drive Installation
IMPORTANT All claims for breakage and damage whether concealed or obvious must be made to the carrier by the Customer as soon as possible after receipt of the shipment. Rockwell Automation is glad to give the Customer reasonable assistance in the securing of adjustment for such damage claims.
Page 30: Transportation And Handling
4. To reduce the tension on the rigging and the compressive load on the lifting device, do not allow the angle between the lifting cables/chains and vertical to exceed 45°. ATTENTION: Drives can contain heavy equipment that could be adversely affected by tilting. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 31: Rod Or Pipe Rollers
3. The drive can be rolled to its designated location. Steady the load to prevent tipping. Figure 15 - Rod or Pipe Rollers 50.8 x 152.4 mm (2 x 6 in.) Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 32: Fork Lift Trucks
The heat created by the drive is directly proportional to the power of the motor being driven and the efficiency of equipment within the room. If thermal load data is required, contact the Rockwell Automation Sales office. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 33: Installation
For Direct-to-Drive liquid-cooled 6600V Drives (430A, 495A, and 575A rated current) the Drive will be shipped in two sections as shown in Figure Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 34: Connect The Sections
It is not necessary to remove capacitor from position #2. ATTENTION: Capacitors weigh up to 100 kg (220 lb). Use two people to remove the unit from the structure. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 35 CPVC unions with strap wrench (1/4 to 1/2 turn past hand tight). Ensure O-ring is seated inside male end of union. Refer to Figure Figure 19, and Figure 20. Do not use CPVC primer or cement. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 36 Drive Installation Figure 18 - CPVC Pipe Splices (Capacitor #2 not shown for clarity) Pipe Splice #2 Pipe Splice #1 Capacitor Cabinet DC Link Choke Cabinet Figure 19 - Typical Strap Wrench (not supplied) Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 37: Connect Power: M+, L+, M-, L- Power Bus
After cable connections have been made, the cable connections to choke stabs must be torqued to 50 N•m (37 ft•lb). • Keep a minimum of 75 mm (3 in.) clearance between the medium voltage bus field connection (including hardware) and all cabinet sidesheets. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 38 Figure 21 - DC Link Choke Cabinet Power Bus (four pieces); Ground Bus Shipped Disassembled MV Bus (4 pieces) Ground Bus Link (1 piece) Inside DC Link Choke Cabinet Figure 22 - DC Link Choke Cabinet before Field Power Bus Connections Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 39 Chapter 2 Drive Installation Figure 23 - DC Link Choke Cabinet after Field Connections of Power Bus Figure 24 - Capacitor Cabinet after Field Connections of Power Bus Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 40 Connection points are labeled on bus and DC Link Choke. Connect cables from labeled stabs M+, L+, L-, L+ on DC Link Choke to corresponding labeled stabs M+, L+, M-, L+ on bus. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 41 Use the supplied hardware. Figure 28 - Ground Bus Link Figure 29 - Install Ground Bus Link Ground Bus Link Figure 30 (route under wire duct) Wire Duct Figure 30 Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 42: Control Wiring Connections
Control Wiring Connections See the EDs and wiring diagrams that are supplied with the drive. Contact Rockwell Automation representative for assistance. Rockwell Automation field service representatives must perform the final wiring connections. 1. Remove the wireway covers on top of the line and motor filter capacitor sections and the DC Link section.
Page 43 Figure 33 - Belden Shielded Cables 5. Route three fan control wires and two cabinet over-temperature control wires through the grommeted cutout in the center of the DC choke section (Figure 34). Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 44 7. Connect the numbered wires to the corresponding numbered terminal blocks (Figure 36 Figure 39). Figure 35 - Route Control Wires through Grommeted Cutout 8. See the electrical drawing and make the above control wiring connections. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 45 Chapter 2 Drive Installation Figure 36 - 56V DC Connections 56V DC Connections Red - Positive Black - Negative Figure 37 - AC DC fails Belden Cable Connection ACDC fails Belden cable connections Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 46 12. Route the XIO link cable, the control power wires into the pump control cabinet through the upper side grommeted cutout. 13. Route the fiber-optic cable into the pump control cabinet through the lower side grommeted cutout. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 47 (Figure 15. Connect the control power wires to the control power terminal blocks. See the Electrical Drawings for corresponding wire numbers and terminal blocks. 16. Connect the fiber-optic cable to the TFB board. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 48 TFB Fiber Optic connected • Use supplied silicone (see Figure 43) to seal between cabinets to prevent moisture or dirt from entering. Join sidesheets with M6 Taptite thread forming screws in holes provided. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 49: Removal Of Dc Link Choke Turnbuckle Supports
44) from bottom turnbuckle jaw then top. Carefully remove turnbuckles. Retain for future use. Figure 44 - Choke Cabinet Remove Cotter Pins • Re-install any capacitors that were removed. • Proceed with Removal of Lifting Angles. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 50: Removal Of Lifting Angles
Drive mounting instructions. Failure to correctly anchor the cabinet may result in damage to the equipment or injury to personnel. Contact the area Rockwell Automation sales office if you do not have these documents. Shock Indication Labels Shock indication labels are devices that permanently record the physical shock to which equipment is subjected.
Page 51: Installation Of Exhaust Air Hood
Affix assembly to the drive top plate, and tighten all hardware. ATTENTION: Any screws that are accidentally dropped in the equipment must be retrieved as damage or injury may occur. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 52: Internally-Mounted Fans
The plate is fastened to the cabinet with M6 hardware. Connect wires to the terminal blocks per the electrical diagram. Position the fan hood over the fan assembly and fasten with M6 hardware. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 53 Chapter 2 Drive Installation Figure 48 - Fan Hood Installation (Externally-mounted Fans and Fan Hood) Fan Hood External Fans Terminal Blocks Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 54: Typical Powerflex 7000L Drive Structure Layout
Shows the medium voltage area located in the control/cabling cabinet behind the low voltage compartment and with barriers removed. The control/cabling cabinet comes in two different configurations: • AFE rectifier (Figure • 18-pulse rectifier (Figure Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 55: Major Components
The following diagrams show the typical layout of each cabinet for PowerFlex 7000 “C” frame drives. Figure 50 - Low Voltage Tub Compartment ANALOG CONTROL BOARD Analog Control Board Drive Processor Tach Feedback DC/DC Power Supply Fiber Optic Interface Boards Module (DPM) Circuit Board Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 56 Chapter 2 Drive Installation Figure 51 - Converter Cabinet (4160V AFE shown) Ground Bus Inverter Modules Coolant Piping Isolated Gate Drive Power Supplies (IGDPS) Rectifier Modules Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 57 Chapter 2 Drive Installation Figure 52 - Converter Cabinet (6600V AFE shown) Ground Bus Inverter Modules Isolated Gate Driver Power Supplies (IGDPS) Rectifier Modules Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 58 Chapter 2 Drive Installation Figure 53 - Capacitor Cabinet Cooling Fan Grounding Network Motor Line Capacitors Line Capacitors Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 59 Chapter 2 Drive Installation Figure 54 - Pump Cabinet (showing swing-out low voltage panel) Pumping Panel Deionizer Cartridge Swingout Low Voltage Panel Coolant Pumps Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 60: Iec Component And Device Designation
The power terminals are now visible. • The installer is responsible for modifying the power cable access plates to suit the requirements. • Use appropriate connectors to maintain the environmental rating of the enclosure. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 61 Chapter 2 Drive Installation Figure 55 - Swing-out of Low Voltage Compartment Latch Key Interlock Handle Terminal Blocks - Customer (TBC) Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 62 Chapter 2 Drive Installation Figure 56 - Access to Power Terminals Low Voltage Compartment (Open) Low Voltage Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 63: Power Connections
The installer is responsible for verifying that power connections are made with appropriate torque. See Torque Requirements on page 211. The drive is supplied with provision for grounding of cable shields and stress cones near the power terminals. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 64: Liquid Connections
Outlet Coolant Connection Warm Fluid to Heat Exchanger Inlet Coolant Connection Fluid Return from Heat Exchanger Piping to Heat Exchanger through side of cabinet Piping to Heat Exchanger Routing through bottom of cabinet Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 65: Pipe Materials And Layout
Pipe Materials and Layout All material that contacts fluid between the heat exchanger and drive must be either Schedule 80 CPVC or stainless steel. Rockwell Automation recommends using stainless steels AISI 304L or 316L to connect the drives to heat exchangers.
Page 66: External Piping To The Drive
120.6 (4.7) External Piping to the Drive External Piping Cleaning Rockwell Automation liquid-cooled drive piping and heat exchangers are flushed and cleaned at the factory and piping is capped to prevent contamination. Leave the drive pipe caps installed until final assembly.
Page 67: Controlled Siphon Into Open-Top Reservoir
Chapter 2 Drive Installation Controlled Siphon into Rockwell Automation recommends this method of pipe routing for pipes and Open-top Reservoir heat exchangers higher than the reservoir coolant level. The reservoir is located in the VFD pump cabinet. This method controls the siphoning of coolant into the open top reservoir when the coolant pumps are off for maintenance.
Page 68: Liquid-To-Liquid Heat Exchangers
• Pipes through top plate of cabinet • Pipes through bottom plate of cabinet • Pipes through right side of cabinet Removable plates are provided in each of these locations. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 69 Figure 63 - Connection to Liquid-to-Liquid Heat Exchanger (Back Plates Removed) Access for connections through top of cabinet Access for connections to heat exchanger through right side of cabinet Liquid-to-Liquid Heat Exchanger Access for connections to heat exchanger through bottom of cabinet Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 70 > 0 <32 50.8 > 0 <32 (1) For 50/60 Hz values not shown here, please contact the factory. (2) L/m = Liters per minute (3) US Gpm = Gallons per minute (U.S.) Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 71: Power And Control Wiring
Encoder wires and shields must maintain continuity throughout, from the encoder to the drive. Avoid the use of a terminal block in a junction box, as it has the potential of creating radiated noise and ground loops. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 72 In either case, always check with the encoder manufacturer for the recommended cable. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 73: Information Regarding Termination Of Customer Cables
Figure 66 - Typical Line Cable Termination (Shown for Bottom Cable Entry – 18-pulse) 4-hole Insulator Lug pad shown with bottom cable entry orientation Bolts M10 bus connection hardware Customer supplied lugs 4 lugs per phase maximum Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 74: Grounding Practices
Figure 68 - Ground Connection Diagram with Isolation Transformer Isolation Transformer Connected AC Motor U (T1) to neutral point of the output V (T2) Output capacitor Ground W (T3) Network Ground Bus Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 75: Grounding Guidelines And Practices For Drive Signal And Safety
- The metal sheath or foil can be left insulated from ground and the other conductors and the mesh cable screen grounded at one end only as stated above. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 76: Grounding Requirements And Grounding Specification For Customers And Power Integrators
Additionally, the key interlocking prohibits the upstream power being applied until the access doors are locked. It is the responsibility of the installer to ensure that the key interlocking is installed properly to the upstream equipment. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 77: Power Component Definition And Maintenance
Chapter Power Component Definition and Maintenance Control / Cabling Cabinet Figure 70 - Control and Cabling Cabinet showing LV Control Panel (AFE Rectifier shown) Components Low Voltage Control Panel Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 78 Power Component Definition and Maintenance Figure 71 - AFE Control and Cabling Cabinet (with LV Control Panel removed) Hall Effect Sensor Voltage Sensing Motor Terminals Hall-effect Sensor Surge Arresters Line Terminals Current Transformer Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 79 Power Component Definition and Maintenance Figure 72 - 18-pulse Control and Cabling Cabinet (with LV Control Panel removed) Motor Terminals Hall Effect Sensor Voltage Sensing Transient Suppression Networks Hall Effect Sensor Line Terminals Current Transformers Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 80: Voltage Sensing Assembly
6. Remove the old VSB and replace with the new VSB on the studs, using the existing hardware to secure the assembly. Do not overtorque the connections or you may break the studs. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 81: Input Transient Protection
The two basic blocks of the TSN module are the MOV suppressor and the MOV fuse. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 82: Mov Suppressor
This impedance will be mainly that provided by the Isolation Transformer or the AC Line Reactor on the input of the drive. That is why an impedance level is specified for these input devices. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 83: Mov Fuse
Figure 75 - Simplified Wiring Diagram Drive Input Power from Line Terminals Transient Suppression Network Medium Voltage Input Fuses Phase MOV Suppressor Ground MOV Suppressor Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 84: Transient Suppression Network Fuse Replacement
(See Figure 76 for location.) Figure 76 - Transient Suppression Network Connecting links Ground location Varistors Varistors 5 kV fuse example 5 kV fuse location 7.2 kV fuse example 7.2 kV fuse location Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 85: Metal Oxide Varistor Replacement
Maximum Continuous Operating Voltage (MCOV) rating. There are three Y-connected surge arresters attached to the incoming MV lines. The neutral point of the arresters is connected to the ground bus. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 86: Operation
When the incoming energy exceeds the handling capability of the arrester and causes arrester failure, the housing is designed to split open to vent without causing damage to any adjacent components. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 87: Surge Arrester Replacement
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. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 88: Field Test And Care
6. Replace the ring lugs and 6.4 mm (1/4 in.) hardware (see Figure 79). IMPORTANT The maximum torque for the capacitor terminal is 3.4 N•m (30 lb•in). Figure 79 - Capacitor in Grounding Network Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 89 Figure 81 - Torque Values for Ground Filter Assembly Torque to 3.4 N•m (30 lb•in) maximum Torque to 1.2 N•m (11 lb•in) maximum Loosen screws to release capacitors Remove screws for replacing resistor bank Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 90: Ground Filter Replacement
Note the position before disassembly. 3. The round bus bar must be removed. Remove the M10 hardware and slide the bar out. 4. Remove the screws from the three terminals to allow removal of the ring lugs. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 91: Current Transformer Replacement
5. Remove the four screws located in the base of the CT and remove. 6. Replace the CT, ensuring the proper orientation. Fasten the CT securely with the four screws in the base. 7. Reconnect the ring lugs. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 92: Filter Capacitor Cabinet
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 Figure 85 - Motor Filter Capacitor Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 93: Filter Capacitor Replacement
8. There are instruction labels on each capacitor which detail how to tighten the terminal connections. Refer to these labels. 9. Reinstall the sheet metal that was removed, and complete one final check to verify connections are secure and correct. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 94: Testing Filter Capacitors
Power Component Definition and Maintenance Testing Filter Capacitors There are two ways to test line filter capacitors. Rockwell Automation recommends the first method as it reduces the chance of retorque issues because the capacitors are not disconnected. If the readings are unsatisfactory, the second method is more accurate, but involves disconnecting and testing them individually.
Page 95: Converter Cabinet
Cooling pipes are throughout the cabinet and are connected to each chill block. Unlike the air-cooled drive, thermal sensors are not installed on the chill block. The thermal sensor is located in the pump cabinet. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 96: Converter Cabinet Components
Chapter 3 Power Component Definition and Maintenance Converter Cabinet Components Figure 86 - Converter Cabinet Components (4160V AFE shown) Ground Bus Inverter Modules Coolant Piping Isolated Gate Driver Power Supplies (IGDPS) Rectifier Modules Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 97 Chapter 3 Power Component Definition and Maintenance Figure 87 - Converter Cabinet Components (6600V AFE shown) Ground Bus Inverter Modules Isolated Gate Driver Power Supplies (IGDPS) Rectifier Modules Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 98: Powercage
It is important that these boards must not be handled without proper grounding. ATTENTION: Static charges can destroy some circuit boards. Use of damaged circuit boards can also damage related components. A grounding wrist strap is recommended for handling sensitive circuit boards. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 99 Matched Set 2 SGCTs Outlet Manifold Clamp Base Module Housing Inlet Manifold Figure 89 - Six Device PowerCage Outlet Manifold Matched Set 3 SGCTs Matched Set 3 SGCTs Module Housing Clamp Base Inlet Manifold Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 100: Sgct And Snubber Circuit
The force placed on the SGCTs differs with the size of the device. A 63 mm device (1500A) requires 20 kN. The clamp assembly on the right hand side of the inverter module generates these forces. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 101: Checking Clamping Pressure
If proper force (as designated on the clamp head block) is applied to the clamping assembly, the indicating washer should just be able to rotate with fingertip touch. The disc should not rotate freely. Some force will need to be applied with your fingertips. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 102 Only adjust the adjusting nut (Figure 92). Figure 92 - Detail of the Clamping Assembly Clamp Head Adjusting Nut use for loosening and applying load to assembly DO NOT ADJUST calibration nut Disc Springs Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 103: Symmetrical Gate Commutated Thyristor Replacement
3. To remove the SGCT, it is necessary to remove the gate driver power cable and fiber optic cables. Exceeding the minimum bend radius (50 mm [2 in.]) of the fiber optic cables may result in damage. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 104 7. While grounded, remove the SGCT from the anti-static bag. 8. Assemble the brace angle from the old SGCT to the new SGCT. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 105: Silicon Controlled Rectifier And Scr Self-Powered Gate Driver
SCR and SCR SPGD Board from the protective anti-static bag that it is supplied in. Use of damaged circuit boards may also damage related components. A grounding wrist strap is recommended for handling sensitive circuit boards. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 106 14. Install the new SCR SPGD Board in the assembly with the 4 plastic clips and use the screws to secure the board to the metal bracket. 15. Connect the Gate-Cathode phoenix connector to the Gate Driver Board. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 107: Detachment Of Coolant System From Powercage Modules
(ethylene glycol – water mixture). 5. Two flow restrictor clamps per Figure 97 are provided with the spare parts kit of each drive. Figure 97 - Flow Restrictor Clamp Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 108 Slide the hose clamp toward the chill block. IMPORTANT Depending on the drive configuration, there could be one or two hose clamps connecting the hose to the outlet manifold. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 109 Figure 101 - Converter PowerCage Module (Service – per Step 8) Repeat this procedure for the lower manifold connection point. The chill block can be extracted from the PowerCage per Chill Block Replacement on page 110. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 110: Reconnecting The Coolant System To A Powercage Module
40 cm. 6. Slowly and carefully pull the assembly out of the PowerCage. ATTENTION: The chill block assembly is heavy and it is recommended that two people pull the assembly out to avoid damage. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 111: Insert The Chill Block Assembly
Commutated Thyristor Replacement on page 103 Silicon Controlled Rectifier and SCR Self-Powered Gate Driver Board Replacement on page 105. 6. Readjust the clamping load as described in Checking Clamping Pressure on page 101. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 112: Powercage Replacement
Carefully lift the PowerCage down, placing the front face down. Do not overtorque these bolts when replacing the PowerCage. IMPORTANT The PowerCage is heavy. Rockwell Automation recommends that two people extract the PowerCage from the drive to prevent injury or damage.
Page 113: Snubber Resistors
PowerCage under the chill block is a snubber resistor test point. For each device, there is one test point. Figure 104 - Testing the Snubber Resistor Measure resistance between Chill Block and test point Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 114: Sharing Resistors
A value between 60…75 kΩ indicates a good sharing resistor. Figure 105 - SGCT PowerCage Snubber Capacitor Sharing Resistor Snubber Resistors Test Point Cathode Anode Chill Chill Block Block SGCT Anode Chill Block SGCT Cathode Chill Block Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 115: Snubber And Sharing Resistor Replacement
The number of snubber resistors varies with the size of drive and application. Shown below is a three-snubber resistor configuration. There can be up to five snubber resistors on each chill block. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 116: Snubber Capacitor Replacement
PowerCage module. 3. Apply a drop of Loctite 425 to the thread of the 25 mm flange side of the replacement capacitor. 4. Hand-tighten the replacement capacitor onto the threaded stud. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 117: Self-Powered Gate Driver Board - Spgdb
The power source for the SPGDB is from the snubber network of the SCR, a patent pending design of Rockwell Automation. This unique design gives the SPGDB the ability to conserve the amount of energy that it supplies to the SCR. This reduces the amount of energy required by the drive to operate, thus making the drive more efficient.
Page 118: Board Calibration
The yellow LED (LED 1) on the SPGDB indicates that the SCR being controlled has a gating current flowing which is used to turn the SCR on. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 119: Terminal/Connections Description
262-51, this input is shorted to TB3-1 to obtain the sense voltage. TB3-3 – Common connection of positive 15V power supply used for test power TB4-2 – Cathode connection to SCR being controlled TB4-1 – Gate connection to SCR being controlled Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 120: Testing Procedure For Scr Self-Powered Gate Driver Board
Figure 113 Figure 114. Note that Figure 114 there should be a 220 μS, ±20 μS time between the rising edge of the U4-pin7 pulse and the falling edge of the TP7 signal. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 121 Chapter 3 Power Component Definition and Maintenance Figure 110 - Gating Pulses Figure 111 - SCR Gating Pulse Figure 112 - Expanded SCR Gating Pulse Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 122 Chapter 3 Power Component Definition and Maintenance Figure 113 - V Sense Trigger to SCR gating pulse Figure 114 - Expansion of V Sense Trigger to SCR gating pulse Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 123: Fiber Optic Cabling
BLACK or GREY – is the transmitting end of the fiber optic. • BLUE – is the receiving end of the fiber optic. Figure 115 - Common Mode Choke and Control Power Cabinet Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 124 Chapter 3 Power Component Definition and Maintenance Power Transformer AC/DC Power Supplies Disconnect Switch Liquid-cooled Common Mode Choke Reactor Cooling Pipes Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 125: Dc Link Reactor
6. Remove the hardware that secures the DC Link to the ground channels. 7. Remove the DC Link frame ground connection. 8. Using a lift truck, remove the DC Link from the cabinet. 9. Install the replacement in the reverse order. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 126 The nameplate data must be compared to the old DC Link to ensure that the ratings are appropriate for the drive system. Any changes in the nameplate should be noted since the parameters within the drive will need to be changed. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 127: Cooling System
Chapter 3 Power Component Definition and Maintenance Cooling System Figure 117 - Generic Cooling System Overview Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 128: Cooling Circuit
The pumps must not run dry, as this damages the seals. The pumps must not be excessively noisy (pumping air pockets) when filling the system. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 129: Pump Maintenance And Replacement
24…30 months, regardless of whether it is leaking or not. See the pump nameplate for manufacturer's model information. Typical pump seal replacement information is provided on the manufacturer website. Figure 118 - Pump Cabinet Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 130: Pump Replacement With Drive Running
4. Isolate power to the pump motor to verify that there is no voltage at pump motor leads. 5. Check voltages at terminal T1, T2, and T3 at pump to verify that there is no voltage. 6. Disconnect wires T1, T2, and T3 at pump. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 131: Piping, Tubing, And Connectors
The non-return valves (NV1 & NV2) shown in Figure 120 are ball-type valves made from CPVC. These valves cannot be changed with the drive on-line. All coolant must be drained to replace these parts. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 132: Pressure Indicator
38 °C (100 °F). All flow then travels to the heat exchanger. The thermostatic valve keeps the semiconductor devices from getting too cold, and it keeps the near room temperature to help prevent condensation. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 133: Thermostatic Valve Replacement
3 °C (5 °F) below the start to open temperature. This is the number stamped on the element. Due to the effect of hysteresis, the element closes 3 °C (5 °F) below the start to open temperature. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 134: Element Replacing
If the heat exchanger is at a higher elevation, then air release valves should be installed at the highest point. The largest heat exchanger is 287 cm (113 in.) tall. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 135 On a liquid-to-liquid heat exchanger, process water will be required to transfer heat from the drive coolant. The water temperature, pressure and flow rate are as specified by the factory on the piping schematic drawing mounted inside the pump cabinet. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 136: Pumping Cabinet Control Power Checks
1 μS/cm for the annunciation warning and 2 μS/cm for the trip value. Change the deionization cartridge when the conductivity rises to the warning level. Figure 125 - Temperature and Conductivity Sensors Conductivity Sensor x5 Temperature Sensor TS1 Strainer STR1 V6 Fill/Drain Valve Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 137: Temperature Sensor
V8. The filter is a 500-micron fine-mesh type, which can be cleaned many times by rinsing in clean water. The de-ionizing cartridge is a mixed-bed cartridge type, which can be disassembled easily for de-ionizing cartridge replacement. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 138 Chapter 3 Power Component Definition and Maintenance Figure 126 - Deionizer Reservoir Circuit Vent Button Deionizer Cartridge Filter FIL1 Flow Restrictors Reservoir Filter FIL2 Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 139: Addressing High Coolant Conductivity
4. Add one 4 L jug of concentrated ethylene glycol with corrosion inhibitor (Rockwell Automation PN 80026-739-01) to the reservoir. If the coolant level is high in the reservoir, drain some coolant from the reservoir before adding the ethylene glycol. Use the small transfer pump with tubing that is mounted on the right side of the pump cabinet to add or remove the coolant.
Page 140: Reservoir Circuit
3. Open V2 and V3 slowly to avoid a rush of air into the pumps. The air will gradually be purged from the system by flowing through the reservoir. 4. Close valve V1. Figure 128 - Cleaning the Strainer Strainer STR1 To Pump P1 Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 141: Coolant
1. Measure and record the reservoir coolant freeze point using the glycol and battery tester. 2. If the freezing point of the coolant is at -45 °C (-50 °F) ±2 °C, correction is not required. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 142: Leakage Checks
29 mm (1-1/8 in.) If a leak persists, it will be necessary to drain the system, disassemble the threaded joint, clean the threads and reassemble with a generous amount of Teflon paste applied to the threads. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 143: System Drain
The drive takes approximately 170 L (45 U.S. gal) to fill the system. The drum SHOULD NEVER BE DISCARDED. In the event that you need to drain the system, you will want this to store the coolant for reuse. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 144 Power Component Definition and Maintenance Figure 129 - Cooling Cabinet Overview showing Valve Locations – 1 V9 (if provided) STR1 (if provided) V2 (hidden) (if provided) STR2 V7 drain/fill (if provided) V6 drain/fill Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 145: System Fill And Air Venting
2. Open valves VI, V2, V3, V4, V5, V6, V7, V10, V11, V12, V13, V14. Some drives may not have all valves. 3. Open V8 30° rotation to prevent water hammer during air purging. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 146: Normal Operation
14. Run Pump 1 for several minutes. 15. Place pump selector switch to Auto. Normal Operation 1. Open valves V1, V2, V3, V4, V5, V8, V11, V12, V13, and V14. Close valves V6, V7, and V10. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 147: Control Component Definition And Maintenance
5 cycles after control power is interrupted. If control power is not restored during the 5 cycles, a controlled shutdown will occur. Figure 133 illustrates the control power distribution for PWM drives with integral starter/line reactor. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 148 380V 50 Hx Line 460V 60 Hz Reactor 3-ph 20V Isolated Gate Driver Power Supply Figure 134 illustrates the control power distribution for AFE drives with remote transformer/starter or integrated line reactor with remote starter. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 149: Ac/Dc Power Supply
0.98PF@1000 W or 1000 W/1500 W HV IGDPS 0.98PF@1500 W Power Supply DC Fail DC FAIL: Upon loss of DC output (V outputs ≤ 49 V DC) this output goes from low to high. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 150: Terminal / Connections Descriptions
When all adjustments are complete, reconnect the power supply to the circuit and remeasure the output. Readjust if necessary. If it is not possible to maintain 56V DC, the power supply can be faulty. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 151: Replacement Procedure
137). 8. Reapply control power and verify voltage levels. Figure 137 - Replacement of AC/DC Power Supply on Low Voltage Panel Power Supplies (Optional) AC/DC Power Supply Fuse Blocks Power Transformer Hold-up Capacitors Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 152: Ups Option
ACB board for fault conditions. There is also a hold-up capacitor on the output of the 300W AC/DC Power Supply to maintain the 56V DC in the event of a failure of the power supply. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 153: Replace The Ups
ATTENTION: Before installing the new UPS, check the battery recharge date on the shipping carton label. If the date has passed and the batteries were never recharged, do not use the UPS. Contact Rockwell Automation. 5. Before installing the new UPS, the internal battery must be connected.
Page 154: Low Voltage Control Section
XIO Boards DCB/CIB Mounting Plate Drive Control Board Signal Conditioning (Machine) Boards Fiber Optic Interface Boards 24V DC Isolated Supply Drive Control Board (Line) DC/DC Converter Analog Isolators 1203 Communication Module Customer Interface Board Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 155: Dc/Dc Power Supply Description
+5V, ±15V Common Power Supply ID Pin 0 Power Supply ID Pin 1 PIN No. Label Description Only ISOLATOR (+24V, 1A) +24V, 1A/com4 P3 – ISOLATOR (To Isolator Modules) ISOL_COMM (com4) 0V/com4 EARTH EARTH Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 156: Replacement Procedure For Dc/Dc Power Supply
Plate. Repeat Steps 4, 3, 2, 1 in this order to replace unit. (View 2) 6. Ensure the ground wire of P4 plug is connected to the ground by M10 bolt. Figure 142 - Replacement of DC/DC Power Supply Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 157 Chapter 4 Control Component Definition and Maintenance M4 Hardware and Nylon Shoulder Washer Mounting Plate Black Insulation M6 Hex Head DC/DC Power Cap Screw Part ID Label Supply DC Power Good Indicator Light Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 158: Drive Processor Module
Figure 143 - Drive Processor Module (DPM) Test Points Secondary Primary Inverter Gating Battery Signals Rectifier Gating Signals Interface Module DPM DataPort Primary Secondary Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 159 POST – USART Failed: 9 Count 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 7000L-UM303F-EN-P - April 2022...
Page 160: Drive Processor Module Replacement
Install firmware in the drive following the guidelines the Installation Manual. 11. Program the drive. See publication 7000-TD002. Save the parameters to NVRAM and externally, using the options described earlier in this section. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 161 Chapter 4 Control Component Definition and Maintenance Figure 144 - ACB and DPM Replacement Analog Control Board (ACB) ANALOG CONTROL BOARD Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 162: Analog Control Board
Inputs DC Fail Signal Monitoring Meter Inputs & Comms Connections DC Power Supply DC -ABUS +56V Monitoring XIO-PWR(+24V,+/-15V, +/-24V, +5V Speed Pot Input Terminal (Panelview) Monitoring (in UPS option) DIG, DC Power Supplies) Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 163 AC Motor & 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 7000L-UM303F-EN-P - April 2022...
Page 164 Motor Over Voltage Detection set point TP45 Encoder A+ input TP46 Encoder B+ input TP47 Encoder Z+ input TP48 Encoder A-input TP49 Encoder B- input TP50 Encoder Z- input TP51 Control Power monitoring for channel 1 Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 165: Light-Emitting Diodes
Digital Ground Return Light-emitting Diodes There are two power light-emitting diodes on the ACB labeled D7 and D9: • D9 is the ±15V DC voltage-OK signal • D7 is the +5V DC voltage present signal. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 166: Interface Module (Ifm)
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. The following information will show the connections for each. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 167: Current Loop Transmitter
2V to satisfy the 100 Ω input impedance. Regardless of input configuration, each input is individually isolated to ± 100V DC or 70V rms AC. A block diagram of the receiver is shown in Figure 148. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 168: Non-Isolated Process Outputs
PowerFlex “C” frame enclosure. Figure 149 - Non-Isolated Configurable Analog Outputs on ACB IFM Pin # FPGA 27, 31, 35, 39 Analog Output 25, 29, 33, 37 28, 32, 36, 40 Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 169: Auxiliary +24V Power Supply
Acceptable outputs are Analog Line Driver or Push Pull. 2. The drive will not operate properly if using 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 170 The board also provides a galvanically isolated 12V/3 W supply to power the attached encoder. You can configure the 20B-ENC-1 Encoder interface for 5V operation, however Rockwell Automation recommends operation at 12V. Figure 150 - Encoder Interface (20B-ENC-1 and 20B-ENC-1-MX3)
Page 171 Gray Code Absolute Encoder Low True Removed Installed 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 Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 172 Z2+ (Redundant or Dual ENC) 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) Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 173: Quadrature Encoder Operation
DPM. The board also generates “pseudo” quadrature differential signals, including a zero position mark, derived from the binary data to the DPM. IMPORTANT Consult the factory for availability of Positional Encoder options. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 174: Positional Encoder Guidelines
OFF or vice versa. In the case of Gray code, since only one bit ever changes, the ambiguity error is never more than one count. For this reason, and to reduce inrush currents, Rockwell Automation recommends using Gray code Positional Encoders.
Page 175: External Input/Output Boards
LED Status Description Solid Green Normal Operation Solid Red Board Failure No Communication Available to ACB board (Normal at Alternate Flashing of Red and Green Power on, during firmware download and with unprogrammed drive) Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 176: External Input/Output Board Replacement
5. Install the new XIO board assembly in the low voltage control cabinet. 6. Reconnect all connections and verify the locations. 7. Apply low voltage power and complete both system and medium voltage tests to ensure the new board functions properly. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 177: Optical Interface Boards (Oib)
OIBC is not implemented on the OIBB and is never used. For more information, see the drawings supplied with your drive. The alarm and trip set points for each of these signals are programmable in software. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 178: Optical Interface Board Replacement
5. Install the new OIB on the OIBB. Ensure the standoffs snap into place. 6. Reconnect all fiber optic connections and verify the locations. 7. Apply low voltage power and complete gating, system, and medium voltage tests to confirm board performance. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 179 Chapter 4 Control Component Definition and Maintenance Figure 155 - OIB Replacement (Mounting Plate Accessible) Optical Interface Boards (OIB) Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 180: Optical Interface Base Board (Oibb)
J8. The remaining connectors on the board complete the electrical connection of the installed OIBs to the DPM. Each OIB can support from one to three OIBs. Figure 156 - Optical Interface Base Board (OIBB) Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 181: Replace The Optical Interface Base Board
OIB B, TX1 Firing Command Signal TP18 DIAG_7 OIB B, RX2 Diagnostic Feedback TP19 CMD_7 OIB B, TX2 Firing Command Signal TP20 DIAG_8 OIB B, RX3 Diagnostic Feedback TP21 CMD_8 OIB B, TX3 Firing Command Signal Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 182 OIB C Temperature Feedback Signal – There is no provision in the drive for TP42 TFB_C the use of this signal, it is only provided for Rockwell internal testing. TP43 Ground Reference for TP30 – TP42 Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 183: Preventative Maintenance Schedule
The coolant level will go down due to evaporation. Significant change in coolant levels could be sign of leak in the drive or heat exchanger and should be checked thoroughly. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 184: Annual Maintenance
• Clean all contaminated components using a vacuum cleaner (DO NOT use a blower), and wipe clean components where appropriate. (a) This only needs to recorded if parts have been modified/changed since the last PM activities. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 185: Control Power Checks (No Medium Voltage)
4. Verify the proper gate pulse patterns using Gate Test Operating Mode. 5. If there have been any changes to the system during the outage, place the drive in System Test Operating Mode and verify all functional changes. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 186: Final Power Checks Before Restarting
2. This information should be communicated to MV Product Support so future support activities have the latest site information available. • This can be faxed to (519) 740-4756 or e-mailed to MVSupport_Technical@ra.rockwell.com. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 187: Time Estimations
Speed Wrench • Feeler Gauge • Vacuum Bottle Checker or AC-Hipot • Minimum of 7.5 kV Hotstick / Potential Indicator • Minimum of 10 kV Safety Gloves • Vacuum Cleaner with Anti-static Hose Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 188 Drive-Specific Spare Parts List Materials • Torque Sealer (Yellow) Part number — RU6048 • Electrical Joint Compound EJC no. 2 or approved equivalent (for Power Devices) • Aeroshell no. 7 Part number 40025-198-01 (for Vacuum Contactors) Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 189: Powerflex 7000L Maintenance Schedule
C – Cleaning and refers specifically to the door-mounted air filters in the liquid-cooled drives and some air-cooled drives. This refers to a discussion with Rockwell Automation to determine whether any of the enhancements/changes Rv – Review made to the Drive Hardware and Control would be valuable to the application.
Page 190 (5) When inverter snubber capacitors are replaced, the MV connections for the inverter need to be inspected. (6) A 10-year inverter snubber capacitor replacement interval applies to all drive configurations. (7) Replace UPS batteries annually for 50°C rated VFDs. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 191 (5) When inverter snubber capacitors are replaced, the MV connections for the inverter need to be inspected. (6) A 10-year inverter snubber capacitor replacement interval applies to all drive configurations. (7) Replace UPS batteries annually for 50°C rated VFDs. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 192: General Notes
Do not clean with compressed air. The compressed air can displace dirt, dust, or debris into other parts or equipment, or damage delicate parts. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 193: High-Voltage Testing
Do not lubricate these devices, because oil or grease on the pole faces (the mating surfaces) of the operating magnet can cause the device to stick in the ‘ON’ mode. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 194: Contacts
Pilot Lights Replace any burned out lamps or damaged lenses. Do not use solvents or cleaning- agents on the lenses. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 195: Solid-State Devices
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 7000L-UM303F-EN-P - April 2022...
Page 196 Appendix A Preventative Maintenance Schedule Notes: Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 197: Overview
(limit the current to 200 mA). The voltage range is adapted to nominal voltage of energized part. 2. Feed the power supply with 25% of the nominal voltage of the energized item for 15 minutes. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 198: Control Equipment And Boards
Energize control equipment up once per year to achieve power supply capacitor integrity. • Power up the ACB board once a year • Replace the lithium battery in the DPM every 3 years Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 199: Sgct/Scr/Sps
Signal Conditioners These components have a 3 year lifetime storage period. Ethylene Glycol If stored in a factory-sealed drum, ethylene glycol has a 5 year lifetime storage period. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 200: Spare Parts Maintenance Schedule
(1) Recommended energizing item up for 1…2 hours every year of storage. If the item was stored for a longer time without energizing (longer than 3 years), then the reconditioning procedure must be applied. (2) With an average storage temperature of 25 °C (77 °F) the energizing procedure should be performed at least every five years, and at higher temperatures every three years. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 201: Spare Parts Connection Matrix
Assembly of AC power source, PowerFlex 7000 PS1 and IGDPS power supply. b. Assembly of variable DC power source with current limiting function, SPS board, and wire harness provided with the drive. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 202: Power Supply Connection Guidelines
2. Connect the Pioneer/Cosel power supply 56V DC output terminals to the DC input terminals of IGDPS. 3. Use 14 AWG (2.1 mm wire) to connect the devices. Figure 158 - IGDPS DC Input Terminals Old Style Drawing New Style Drawing Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 203: Intellivac Control Module
1. Connect the AC source to the AC input terminals of Absopulse AC/DC converter. 2. Use 12 AWG (3.3 mm ) wire to connect the devices. Figure 160 - Absopulse AC/DC Converter AC Input Terminals New Style Drawing Old Style Drawing Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 204: Absopulse Dc/Dc Converter
DC input terminals of DC/DC converter. 3. Use 12 AWG (3.3 mm ) wire to connect the devices. Figure 161 - Absopulse DC/DC Converter DC Input Terminals Old Style Drawing New Style Drawing Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 205: 1606 Power Supply
200mA) to the +5V and DGND pin to the +5V pin of ACB DC input connector J13. 2. Use 18 AWG (0.8 mm ) wire to connect the devices. Figure 163 - Analog Control Board AC Input Terminals Old Style Drawing New Style Drawing Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 206: Power Components Connection Guidelines
)wire to connect the DC source with IGDPS. 4. Use #16 AWG (1.3 mm ) to connect the IGDPS with SGCT. Figure 164 - IGDPS DC Input Terminals Old Style Drawing New Style Drawing Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 207: Sgct - Sps Board
1. Connect the AC source 120V or 240V to the test plug of SPS board. 2. Use SPS wire harness provided with the drive to connect the SPS with AC source. Figure 166 - SPS Board AC Input Terminals Old Style Drawing New Style Drawing Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 208: Scr - Spgdb
(20V DC/100mA) to the test plug. 2. Use 14 AWG (2.1 mm ) wire to connect the devices. Figure 167 - SCR - SPGDB Input Terminals SPGDB2U4A SPGD_ AC_IN TST_PWR 2U4A-LA4 New Style Drawing Old Style Drawing Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 209: Connection Wires Size
0.0508 1.29 1.310 0.0453 1.15 1.040 0.0403 1.02 0.820 0.0359 0.91 0.650 0.0320 0.81 0.520 0.0285 0.72 0.410 0.0254 0.65 0.330 0.0226 0.57 0.260 0.0201 0.51 0.200 0.0179 0.45 0.160 0.0159 0.40 0.130 Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 210 Appendix B PowerFlex 7000 Drive Spare Part Storage Requirements and Recommendations Notes: Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 211: Torque Requirements
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 1/4 in. Steel S.A.E. 5 5/16 in. Steel S.A.E. 2 3/8 in. Steel S.A.E. 2 Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 212 Appendix C Torque Requirements Notes: Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 213: Powerflex 7000L Insulation Resistance Test
ATTENTION: There exists the possibility of serious or fatal injury to personnel if safety guidelines are not followed. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 214: Equipment Required
OGN capacitor rather than the grounding bus as the grounding cable is only rated for 600V. Injecting a high voltage on the ground cable during an insulation resistance test will degrade the cable insulation. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 215 This implies isolating the line side of the drive from the machine side by removing the appropriate cables on the DC Link reactor. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 216 For drives that did not originally have the OGN connected (or even installed), this is not a concern. Transient Suppression Network Re-install the fuses on the TSN. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 217: Hazardous Materials
Appendix 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.
Page 218: Chromate Plating
(for example, steel, copper, plastic, wire). These materials should then be sent to local recycling facilities. In addition, all disposal precautions mentioned above must also be taken for those particular materials. Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 219 Translated versions are not always available for each revision. 7000L-UM303E-EN-P, March 2020 Change Added warning for motor filter capacitors and indicative fault codes Changed input frequency to ±5% Changed inspect to replace for power devices in year 12 Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 220 Appendix F History of Changes Notes: Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 221: Index
34 distance 16 current loop transmitter 167 motor cable distance 20 current source inverter 17 termination 16 current transformer cabling cabinet 54 location 92 calibration nut 101 replace 91 capacitive coupling 33 Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 222 68 piping 65 high performance torque control 17 control wire connection 46 horsepower 15 externally-mounted 52 hose hood 52 coolant 111 internally-mounted 52 HTX1 135 fiber optic cables length 123 overview 123 Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 223 74 location 99 line terminal 92 output grounding network liquid connections 64 capacitor replace 88 liquid-to-air insulation resistance test 214 heat exchanger 64 overhead lifting 30 liquid-to-liquid cooling requirements 70 heat exchanger 68 Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 224 140 conditioning board 80 pumping cabinet distortion 72 control power checks 136 silicon-controlled rectifiers 17 PVC 67 sinusoidal current 20 PWMR 95 siting 32 snubber capacitor 100 circuit 100 quadrature encoder 171 resistor Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 225 132 diagram 133 replace 133 time estimations 187 top-up fluid 140 torque requirements 211 filter capacitor 93 transient suppression network 81 insulation resistance test 215 location 79 replace 84 TS1 135 Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 226 Index Notes: Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 227 PowerFlex 7000 Medium Voltage AC Drive Liquid-Cooled (’C’ Frame)—ForGe Control User Manual Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022...
Page 228 Rockwell Automation maintains current product environmental compliance information on its website at rok.auto/pec. Allen-Bradley, Direct-to-Drive, DPI, expanding human possibility, IntelliVAC, PanelView, PowerCage, PowerFlex, and Rockwell Automation are trademarks of Rockwell Automation, Inc. ControlNet, DeviceNet, and EtherNet/IP are trademarks of ODVA, Inc.

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