Rockwell Automation Allen-Bradley PanelView 550 Manuals

Manuals and User Guides for Rockwell Automation Allen-Bradley PanelView 550. We have 1 Rockwell Automation Allen-Bradley PanelView 550 manual available for free PDF download: User Manual

Rockwell Automation Allen-Bradley PanelView 550 User Manual

Rockwell Automation Allen-Bradley PanelView 550 User Manual (434 pages)

Medium Voltage AC Drive Liquid-Cooled, C Frame ForGe Control

Brand: Rockwell Automation | Category: DC Drives | Size: 44.56 MB

Table of Contents

Table of Contents
3
Preface

13
- Summary of Changes
  13
- What Is Not in this Manual
  13
- Who Should Use this Manual
  13
- Additional Resources
  14
- Commissioning Support
  14
- General Precautions
  14
Chapter 1 Introduction

15
- Liquid Cooling
  15
  - Benefits of Liquid Cooling Include
    15
  - Benefits of the 7000L "C" Frame Liquid-Cooled Drive
    16
Overview of Drive

15
- Topology
  17
- Rectifier Designs
  18
- Motor Compatibility
  21
- SGCT Features and Benefits
  22
- Specifications
  23
  - Simplified Electrical Drawings
    27
  - Control Overview
    29
- Control Hardware
  30
- Direct Vector Control
  30
- Operator Interface
  31
Chapter 2 Safety and Codes

33
Drive Installation

33
- Transportation and Handling
  33
  - Overhead Lifting
    34
  - Rod or Pipe Rollers
    35
  - Fork Lift Trucks
    36
  - Storage
    36
- Unpacking and Inspection
  33
- Siting of the Drive
  36
  - Site Considerations
    36
- Installation
  37
- Joining Shipping Splits
  38
- Connect the Sections
  39
- Control Wiring Connections
  47
  - Removal of DC Link Choke Turnbuckle Supports
    54
- Removal of Lifting Angles
  54
- Control/Cabling Cabinet
  59
- Major Components
  59
- IEC Component and Device Designation
  68
- Power Wiring Selection
  68
  - General Notes
    68
  - Cable Insulation
    69
- Power Cabling Access
  71
  - Access the Customer Power Cable Terminations
    71
- Power Connections
  74
  - Incoming Connections
    74
- Liquid Connections
  75
  - Liquid-To-Air Heat Exchangers
    75
- Pipe Materials and Layout
  76
- External Piping to the Drive
  77
  - External Piping Cleaning
    77
- Controlled Siphon into Open-Top Reservoir
  78
- Liquid-To-Liquid Heat Exchangers
  80
- Power and Control Wiring
  83
- Grounding Practices
  87
- Interlocking
  89
Chapter 3 Chapter Objectives

91
Operator Interface

91
- Terminology
  91
- Overview
  92
- Keypad
  93
  - Function (Softkeys) Keys
    93
  - Cursor (Selection) Keys
    93
  - Data Entry Keys
    94
- What Is a Screen
  94
  - Components
    94
  - Information Windows
    96
  - Accessing/Writing to Drive
    96
  - Communication Error
    96
  - Languange Changing
    97
  - General Operation
    98
- Operator Interface Power-Up Sequence
  99
- Top Level Menu
  99
- How to
  100
  - Obtain Help
    100
  - Related Topics
    101
  - Help on Help
    102
- Modify Operator Interface Operation (Utility)
  102
  - Changing Backlight Delay
    103
  - Changing Contrast
    104
  - Setting Time
    104
  - Setting Date
    105
  - Selecting Meters
    106
  - Viewing Revision Levels
    108
  - Transfer Data in Memory
    109
  - Picking an Access Level
    110
- Select a Parameter
  110
  - Via Groups
    110
  - Via Name
    111
  - Via Code
    113
- Edit Text
  114
- Configure the Drive
  116
  - Enter/Modify an Access Level
    116
- Drive Setup
  120
  - Language Selection
    121
  - Modify Parameters
    122
  - Numerical Value
    122
  - Enumerated Value
    124
  - Bit Encoded Value
    125
  - Analog Ports
    126
  - Fault Masks
    128
  - User Definable External Text
    131
  - Plc
    132
  - Xio
    133
  - Message Prompting
    134
  - Store/Retrieve Configuration (NVRAM)
    135
  - Initialize
    135
  - Save
    135
  - Load
    136
- Display Parameters
  137
  - Custom Group
    138
- View Drive Status
  139
- View and Reset Alarms
  140
  - Help for Alarms
    141
- Perform Diagnostic Trending
  142
  - Assigning a Trace
    144
  - Setting the Trigger
    144
  - Defining Sample Rate and Positioning
    146
  - Starting the Trace
    146
- Request Printouts
  142
- Flash Memory Transfers
  148
  - Format Flash Card
    149
  - View a Directory
    150
  - Select a Filename
    151
  - Enter a Filename
    151
- Loading Programs (Firmware)
  152
- Parameter Transfers
  153
  - Upload to Operator Interface
    154
  - Download from Operator Interface
    154
  - Upload to Memory Card
    155
  - Download from Memory Card
    155
  - Parameter File Format
    156
- Loading Language Modules
  156
- Advanced Screen Operations
  158
  - Communications Statistics
    158
  - Protocol Analyzer
    159
  - Print Screen
    160
  - Memory Dump
    160
  - Database Download
    162
- System Programming
  158
- Operator Interface Menu Hierarchy Chart
  162
  - What Does It Show
    162
  - How Do You Read It
    163
  - Example
    163
- PCMCIA Memory Card Installation Data
  167
  - Description
    167
  - Installing the Memory Card
    167
Chapter 4 Start-Up Commissioning Services

169
- Drive Commissioning
  169
- Commissioning the Drive
  170
Commissioning

169
- Powerflex 7000 'C' Frame Pre-Commissioning Checklist
  171
  - Receiving and Unpacking
    171
  - Installation / Mounting
    172
  - Safety
    172
  - Control Wiring
    172
  - Power Wiring
    173
  - Drive Line-Up Status
    173
  - Cooling System Status
    173
- Pre-Commissioning Responsibilities
  171
- Commissioning Preparation
  175
  - Recommended Tools and Equipment
    175
- Additional Manuals
  176
- Powerflex 7000 "C" Frame Manual
  176
- Powerflex 7000 Parameters
  176
- Resources Required to Complete Drive Commissioning
  176
- Technical Publications
  176
- Important Note for Commissioning Engineer
  177
- Key Steps to Commissioning a Powerflex 7000 Drive
  178
- Powerflex 7000 "C" Frame Commissioning Datasheets
  179
- Powerflex 7000 "C" Frame Drive Commissioning Checklist
  180
- Drive Application Review
  183
  - Rockwell Automation Drive Line-Up Drawings
    183
  - Electrical System One-Line Diagram
    184
  - Verify One-Line Diagram on Site
    184
  - Inspect Process
    184
- Safety Tests
  185
  - Lockout Tagout
    185
  - Step down Transformer Fusing
    186
  - Fuse and O/L Protection
    186
- Installation Review
  186
  - Inspect for Shipping Damage
    186
  - Inspect Cabinets for Debris
    187
  - Protective Barriers
    187
  - Component Grounding
    187
  - Information on Splice Kits
    188
  - Power Cabling
    188
  - Control Wiring
    188
- Liquid-Cooling Connections
  189
- Service Data
  190
  - Why this Information Is Needed
    190
- Customer Information
  191
- Control Power off Tests
  195
  - Interlocking
    195
- Resistance Checks
  196
  - SGCT Testing
    197
  - SGCT Anode-To-Cathode Resistance
    198
  - Snubber Resistance (SGCT Device)
    199
  - Snubber Capacitance (SGCT Device)
    200
  - SCR Testing
    200
  - SCR Anode-To-Cathode Resistance
    201
  - SCR Sharing Resistance Test
    202
  - SCR Gate-To-Cathode Resistance
    203
  - Snubber Resistance (SCR Device)
    204
  - Snubber Capacitance (SCR Device)
    205
- Control Power Tests
  206
  - Three-Phase Input
    207
  - Three-Phase Input / Single Phase Input
    207
  - Power Supply Tests
    208
  - Circuit Board Healthy Lights
    208
  - Control Power Transformer (CPT)
    208
  - AC/DC Converter (PS1)
    209
  - DC/DC Converter (PS2)
    210
  - SGCT Power Supplies (IGDPS)
    211
  - IGDPS Board Leds
    214
- Commissioning the Cooling System
  214
  - Heat Exchanger Checks
    215
  - Pumping Cabinet Control Power Checks
    216
  - System Fill
    217
  - System Fill and Air Venting
    218
  - Normal Operation
    220
- Gating Tests
  220
  - Gating Test Mode
    220
  - SCR Firing Test
    222
  - SGCT Firing Test
    224
- System Test
  225
  - System Test Mode
    225
  - Start/Stop Control Circuit
    226
  - Status Indicators
    227
  - Analog I/O
    227
  - Configurable Alarms
    231
- 18 Pulse Phasing Test
  231
  - Line Terminal Resistance Measurements
    232
  - Application of Medium Voltage
    233
  - Input Phasing Check
    233
- DC Current Test
  235
- Tuning Procedure
  238
  - Rectifier
    238
  - Motor Impedance
    243
  - Fluxspeed Regulator [INDUCTION MOTORS]
    244
  - Fluxspeed Regulator [SYNCHRONOUS MOTORS]
    249
- Running the Load
  253
  - Motor Starting Torque
    253
  - Reaching Specific Load Points
    253
- Capturing Data
  255
- Drive Input Voltage Phasing Checks
  255
  - Summary
    255
- (Required for AFE Drives Only)
  257
  - Summary
    257
- Harmonic Analysis
  257
- DC Current Test
  258
  - Summary
    258
- Load Test
  259
- Synchronous Transfer
  261
Chapter 5

265
Component Definition and Maintenance

265
- Control / Cabling Cabinet Components
  265
- Voltage-Sensing Assembly
  268
- Voltage-Sensing Circuit Board Assembly Replacement
  268
- Input Transient Protection
  269
  - Overview
    269
- Transient Suppression Network (TSN)
  270
  - Description
    270
  - MOV Suppressor
    270
  - MOV Fuse
    271
- Transient Suppression Network Fuse Replacement
  272
- Metal-Oxide Varistor Replacement
  273
- Surge Arresters
  274
  - Description
    274
  - Operation
    275
  - Surge Arrester Replacement
    276
  - Field Test and Care
    277
- Output Grounding Network Capacitor Replacement
  277
- Ground Filter Replacement
  279
- Hall Effect Sensor Replacement
  280
- Current Transformer Replacement
  281
- Filter Capacitor Cabinet
  282
  - Filter Capacitors
    282
  - Filter Capacitor Replacement
    284
  - Testing Filter Capacitors
    285
  - Converter Cabinet Components
    287
- Converter Cabinet
  289
- Powercage
  289
- SGCT and Snubber Circuit
  291
- Checking Clamping Pressure
  292
  - Clamping Pressure Adjustment
    292
- Symmetrical Gate Commutated Thyristor Replacement
  293
- Board Replacement
  296
- Detachment of Coolant System from Powercage Modules
  299
  - Reconnecting the Coolant System to a Powercage Module
    303
- Silicon Controlled Rectifier and SCR Self-Powered Gate Driver
  299
- Chill Block Removal and Replacement
  303
  - Instructions for Removing Chill Block Assembly
    303
  - Instructions for Inserting Chill Block Assembly
    304
- Powercage Removal and Replacement
  305
- Snubber Resistors
  306
  - Testing Snubber Resistors
    307
- Sharing Resistors
  307
  - Testing Sharing Resistors
    308
- Snubber and Sharing Resistor Replacement
  309
- Snubber Capacitor Replacement
  311
- Self-Powered Gate Driver Board - SPGDB
  312
  - Description
    312
  - Board Calibration
    312
  - Test Points Description
    312
  - Terminal/Connections Description
    313
- Testing Procedure for SCR Self-Powered Gate Driver Board
  314
  - Equipment Needed
    314
  - Procedure
    314
- Fiber Optic Cabling
  318
  - DC Link Reactor
    320
- Control Power Components
  322
  - Ride-Through
    322
- AC/DC Power Supply
  323
  - Description
    323
  - Location
    324
  - Terminal / Connections Descriptions
    325
  - Replacement Procedure
    326
- UPS Option
  327
  - UPS Replacement Procedure
    328
- Cooling System
  329
  - Cooling Circuit
    330
  - Chill Blocks
    330
  - Coolant Pumps
    330
- Pump Maintenance and Replacement
  331
  - Pump Seal Replacement
    331
  - Pump Replacement with Drive Running
    332
  - Piping, Tubing and Connectors
    334
  - Non-Return Valves
    334
  - Pressure Indicator
    335
  - Pressure Switch
    335
  - Thermostatic Valve
    335
  - Thermostatic Valve Replacement
    335
  - Repair Instructions - Element Testing
    336
  - Element Replacing
    336
  - Heat Exchanger
    337
  - Fluid Conductivity
    338
  - Temperature Sensor
    338
  - De-Ionizing Cartridge and Mesh Filter
    339
  - Replacing the Mesh Filters
    340
  - Reservoir Circuit
    341
  - Fluid Top-Up
    341
  - Strainers
    341
  - Coolant
    342
  - Maintaining Coolant Ratio
    343
  - Leakage Checks
    344
  - System Drain
    345
- Low Voltage Control Section
  345
- DC/DC Power Supplydescription
  346
  - Description
    346
  - Terminal/Connections Descriptions
    347
  - Replacement Procedure for DC/DC Power Supply
    348
- Printed Circuit Board Replacement
  349
  - IO Connectors on Control Boards
    349
- Drive Processor Module
  350
  - Drive Processor Module Replacement
    352
  - Instructions to Replace the Drive Processor Module
    352
- ACB Analog Control Board
  354
  - Leds
    358
  - Interface Module (IFM)
    358
  - Analog Inputs and Outputs
    358
- Current Loop Transmitter
  359
  - Isolated Process Receiver
    359
  - Non-Isolated Process Outputs
    360
  - Auxiliary +24V Power Supply
    361
  - ACB Analog Control Board Replacement
    361
- Tachometer Feedback Board
  362
  - Encoder Options
    362
  - Quadrature Encoder Operation
    365
  - Positional Encoder Operations
    366
  - Positional Encoder Guidelines
    367
- External Input/Output Boards
  368
  - External Input/Output Board Replacement
    369
- Optical Interface Boards (OIB)
  370
  - Optical Interface Board Replacement
    371
- Optical Interface Base Board (OIBB)
  373
  - Optical Interface Base Board Test Points
    374
- Downloading Firmware
  375
  - Introduction
    375
  - Overview
    375
  - Powerflex 7000 in Download Mode
    378
- Reloading the Parameters
  381
- Setting Elapsed Time
  382
- Downloading the Terminal Firmware
  383
  - Using Flash Memory Card
    383
  - Dosfwdl
    383
  - Method
    384
- Setting up Diagnostic Trending
  384
  - Diagnostic Setup
    385
  - Setting up the Trend
    385
- Printing (Uploading) Data from the Drive
  391
  - Overview
    391
  - Creating an Empty Notepad (.Txt) File
    392
  - Setting up Hyperterminal Connection
    394
  - Uploading the Data from the Drive
    396
- Printing (Uploading) Control Data
  399
  - Set up Hyperterminal Connection
    400
  - Printing Control Data
    401
- Environmental Considerations
  403
  - Hazardous Materials
    403
  - Disposal
    405
- Operational Maintenance
  405
- Preventive Maintenance Check List
  405
- Annual Maintenance
  406
  - Initial Information Gathering
    406
  - Physical Checks
    407
  - Power)
    407
  - Control Power Checks (no Medium Voltage)
    408
  - Final Power Checks before Restarting
    408
  - Additional Tasks During Preventive Maintenance
    409
  - Final Reporting
    409
  - Time Estimations
    410
  - Tool / Parts / Information Requirements
    410
Appendix A Rating Code

415
Powerflex 7000 Drive Selection Explanation

415
- When Is an Encoder Required
  416
- Powerflex 7000 Drive Performance (Torque Capabilities)
  417
- Glossary of Terms
  418
- Torque Requirements
  421
Appendix B Drive Meggering

423
- Meggering the Powerflex 7000
  423
  - Equipment Required
    424
  - Procedure
    424
Appendix D

429
- Powerflex 7000 Maintenance Schedule
  429

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