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Rockwell Automation PowerFlex 7000 Tech Note
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Rockwell Automation PowerFlex 7000 Tech Note

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Medium Voltage Support – Technical Services Update
Title:
Product Service Advisory PSA 2012-01-001 Tech Note
(Supersedes PSA 2011-05-001 and PSA 2010-02-001 Tech Notes)
Issued By:
Carlos Siri
Reviewed By:
Manish Pande
Fred Jason
Only personnel who have been trained and understand the PowerFlex 7000 MV Variable
Frequency Drive (VFD) and the Bulletin 1500 product line can work on this equipment.
Appropriate PPE and applicable safety procedures must be followed at all times.
Please refer to the attached sheets.
Please submit any questions you have about this document to:
Rockwell Automation Canada Inc.
135 Dundas Street
Cambridge, Ont.
N1R 5X1
Attn: Medium Voltage Support
Phone:
1.519.740.4790 (Option 1 for MV Technical Support)
Fax:
1.519.740.4756
Email:
mvsupport_technical@ra.rockwell.com
NOTE: The original Customer Letter and subsequent updates mailed/posted refer to Firmware Versions
5.006 through 6.001. In firmware version 6.002 or higher, the Line Filter Capacitor protection method is
upgraded to provide better detection and annunciation, more robust lockout and password reset
functionality, as well as higher immunity to nuisance trips. Please download and install Firmware Version
6.002 or higher per Product Safety Advisory (PSA) 2012-01-001 located on
http://www.rockwellautomation.com/knowledgebase, as ID number 221486.
Page 1 of 17
• Classic Control Users
Date:
March 2, 2012
Date:
March 5, 2012
Tech Note for PSA 2012-01-001
Product Update Number:
PF7000_GEN-95
Products Affected
Active Front End (AFE) Rectifier
PowerFlex 7000 VFD
(7000A, 7000B, 7000L)
•
Classic Control
PF7000_GEN-95

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Summary of Contents for Rockwell Automation PowerFlex 7000

  • Page 1 Fred Jason Classic Control Only personnel who have been trained and understand the PowerFlex 7000 MV Variable Frequency Drive (VFD) and the Bulletin 1500 product line can work on this equipment. Appropriate PPE and applicable safety procedures must be followed at all times.
  • Page 2 “Line Cap Failure” fault lockout and password reset process INTRODUCTION: IMPORTANT: This document is valid for PowerFlex 7000 drive with Firmware revision 6.002 or higher, for the Classic Control platform. For Forge Control platform users refer to the specific Forge Control Tech Note (PF7000_4...
  • Page 3 Introduction With the introduction of the PowerFlex 7000 Medium Voltage VFD, all VFD control functions are loaded on the Drive Control Boards (DCBs) with firmware via a serial connection on the Customer Interface Board (CIB) via the serial port (J8) on the CIB.
  • Page 4 Preparation for Downloading Firmware Required  Boot Code Verify that the boot code rev. level is 2.001 or higher. (The boot code chips are located on DCBs and CIB). If the boot code rev. level is lower than 2.001, then all three chips must be replaced with boot code 2.005. ...
  • Page 5 Here is a typical pin out of a complete null-modem cable. Although the above cable will work, only a cable with pin connectors 2, 3 and 5 is all that is required. Saving Original Settings Ensure the parameters are saved to NVRAM, and saved to the Operator Interface Terminal, and saved to any other external source such as the Flash Card, DriveTools, or printed to a hardcopy.

  • Page 6: Download Mode

    To save to the Operator Interface Terminal and Flash Card, Press [F2] (UTILITY), [F7] (TRANSFER), and [F4] (PARAMETERS). You should now be on the following screen: To save parameters to the Operator Interface Terminal, press [F5] (DRV>MEM). To save to the Flash Card, you must first insert the card in the terminal.

  • Page 7: Communication Error

    When the system is in download mode, the status of LEDs on CIB labeled OBP1 (D1), and on two DCBs labeled D1, provide indication of the Firmware download process. These LEDs are bicolor and may flash at different rates to indicate the current condition.
  • Page 8 From ‘Connect to’ window, select COM1 from the dropdown list as shown below, and then click OK. At the ‘COM1 Properties’ window, set port settings as shown below and then click OK. Now, close HyperTerminal program. A message box will pop as shown below. Click Yes. Page 8 of 17 Tech Note for PSA 2012-01-001 PF7000_GEN-95...
  • Page 9 You will be prompted to save the connection that you just created. Click Yes. This will close the HyperTerminal program. The first step is complete. Now, you are ready to download the Firmware into the drive. For this you need to follow the steps as outlined below.
  • Page 10 If the drive is in download mode, the character C will appear every 3 seconds inside the HyperTerminal window. At the HyperTerminal window, click on Transfer menu and select ‘Send file…’. The ‘Send File’ window will appear as shown below: At the Send File window, click Browse button and locate the Firmware file saved in your laptop.
  • Page 11 After the download is complete, the “Download Successful” message will appear inside the HyperTerminal window. At this point the system is still in download mode. Now, close the HyperTerminal program and disconnect your laptop from the drive and cycle the control power to drive control boards. After the boards are powered up, you need to transfer the parameters from the Terminal memory back to drive.
  • Page 12 Once you ensure the settings are proper for the VFD, you should then press [F5] (NVRAM) from Main Menu Screen, and save the parameters to NVRAM. Then cycle control power one more time, and the drive should come up with no faults or warnings, and the drive will be ready to run.
  • Page 13 Answer #2: Testing Line Filter Capacitors The test involves disconnecting all LFCs from the circuit, and testing each LFC individually by applying 120V across each phase-to-neutral and measuring the current in each phase. This method is most accurate and can be used to confirm the integrity of the LFC.
  • Page 14 6. Now, calculate the capacitance from the measured values of test voltage and current. For a good LFC, the calculated capacitance value for each of the three readings should be within +15% of the LFC nameplate micro-Farad. If it is outside this range then the LFC must be replaced.
  • Page 15 2. From the Faults screen, scroll down (by pressing the down arrow key) and highlight “Line Cap Failure”, then press the [ENTER] key to gain access to Alarm Help text screen for the “Line Cap Failure” fault, as shown in Figure 4 (refer to Figures 3 and 4).
  • Page 16 Figure 7 – Press [F7]–List key Figure 8 – Press [F5]-Code key Figure 9 – Enter parameter number then press the [Enter] key Alternatively, from the Main Menu, press [F4] (DISPLAY) and then [F7] (CUSTOM). You can then place parameters 299 and 780 in the ‘Display Custom’...
  • Page 17 B) PanelView CE (VersaView) Terminal In order to access the required parameters 299 and 780 you will need to place these two parameters in the ‘Display Custom’ screen and access the parameters from this location. From the MainMenu, press ‘Display’ and then ‘Custom’ and enter the parameter numbers 691 and 921 into the ‘Display Custom’...