Document Outline

• PowerFlex 7000 Medium Voltage AC Drive Air-Cooled (“B” Frame)—ForGe Control
• Summary of Changes
• Table of Contents
• 1 - Important User Information
  • Who Should Use This Manual
  • What Is Not in this Manual
  • General Precautions
  • Commissioning Support
  • Additional Resources
• 2 - PowerFlex 7000 Overview
  • Topology
  • Rectifier Designs
    • Configurations
  • Cooling Technology
  • Motor Compatibility
  • Simplified Electrical Diagrams
    • 2400V
    • 3300/4160V
    • 6600V
  • Operator Interface
    • Basic Configurations
• 3 - Component Definition and Maintenance
  • Control Power Off Tests
    • Interlocking
  • Control / Cabling Cabinet Components
  • Voltage-Sensing Assembly
    • Replacing the Voltage-Sensing Circuit Board Assembly
  • Input Transient Protection
    • Transient Suppression Network (TSN)
    • Surge Arresters
  • Filter Capacitor Cabinet
    • Filter Capacitors
    • Replacing Filter Capacitors
    • Testing Filter Capacitors
  • Converter Cabinet Components
  • PowerCage™ Overview
  • Resistance Checks
  • SGCT and Snubber Circuit
    • SGCT Testing
    • SGCT Anode-to-Cathode (Sharing) Resistance
    • Snubber Resistance (SGCT Device)
    • Snubber Capacitance (SGCT Device)
    • Replacing the SGCT
    • Replacing Snubber and Sharing Resistor
    • Replacing Snubber Capacitor
    • Replacing Sharing Resistors
  • Silicon Controlled Rectifier PowerCages
    • SCR Testing
    • SCR Anode-to-Cathode Resistance
    • SCR Sharing Resistance Test
    • SCR Gate-to-Cathode Resistance
    • Snubber Resistance (SCR Device)
    • Snubber Capacitance (SCR Device)
    • Replacing SCR and SCR Self-Powered Gate Driver Boards (SPGDB)
  • Uniform Clamping Pressure
    • Checking Clamping Pressure
    • Clamping Pressure Adjustment
  • Temperature Sensing
    • Replacing the Thermal Sensor
  • Replacing Heat Sinks/ Heat Pipes
    • Replacing Heat Sinks
    • Replacing Heat Pipes
  • PowerCage Gasket
    • Replacing PowerCage Gaskets
    • Removing the PowerCage
  • Self-Powered SGCT Power Supply - SPS
    • Board Calibration
    • Test Points
    • Testing Equipment
  • Self-Powered Gate Driver Board – SPGDB
    • Board Calibration
    • Test Points
    • Terminal/Connections
  • Testing Procedure for SCR Self-Powered Gate Driver Board
    • Testing Equipment
    • Procedure
  • Fiber Optic Cabling
  • Air Pressure Sensor
    • Replacing the Air Pressure Sensor
  • DC Link and Fan Cabinet Components
    • DC Link Reactor
    • Removing and Replacing Fans
    • Fan Installation
  • Impeller Maintenance
    • Impeller Removal from Motor Shaft
    • Installing Impeller Assembly onto Motor Shaft
    • Replacing Air Filters
  • Control Power Components
    • Ride-Through
  • AC/DC Power Supply
    • Terminal / Connections Descriptions (Pioneer Power Supply)
    • Terminal / Connections Descriptions (Cosel Power Supply)
    • Output Calibration
    • Power Supply Replacement
  • UPS Option
    • Replacing the UPS
  • Low Voltage Control Section
  • DC/DC Power Supply
    • Terminal/Connections Descriptions
    • Replacing a DC/DC Power Supply
  • Drive Processor Module
    • Replacing the Drive Processor Module
  • Analog Control Board (ACB)
    • LEDs
    • Interface Module (IFM)
    • Analog Inputs and Outputs
  • Current Loop Transmitter
    • Isolated Process Receiver
    • Non-Isolated Process Outputs
    • Auxiliary +24V Power Supply
    • Replacing the ACB Analog Control Board
  • Encoder Feedback Board
    • Encoder Options
    • 20B-ENC-1 & 20B-ENC-1-MX3 Encoder Interface
    • 80190-759-01, 80190-759-02 Universal Encoder Interface
    • Quadrature Encoder Operation
    • Positional Encoder Operations
  • External Input/Output Boards
    • Replacing the External Input/Output Board
  • Optical Interface Boards (OIB)
    • Replacing the Optical Interface Board
    • Optical Interface Base Board Test Points
• A - Catalog Number Explanation
  • PowerFlex 7000 Drive Selection Explanation
    • Service Duty Rating, Continuous Current Rating and Altitude Rating Code
• B - Preventative Maintenance Schedule
  • Preventative Maintenance Checklist
  • Operational Maintenance
  • Annual Maintenance
    • Initial Information Gathering
    • Physical Checks (NO Medium Voltage and NO Control Power)
    • Control Power Checks (No Medium Voltage)
    • Final Power Checks before Restarting
    • Additional Tasks During Preventive Maintenance
    • Final Reporting
    • Time Estimations
    • Tool / Parts / Information Requirements
  • Overview
  • PowerFlex 7000 Preventative Maintenance Schedule
• C - Torque Requirements
  • Torque Requirements for Threaded Fasteners
• D - Meggering
  • Drive Meggering
    • Meggering the PowerFlex 7000
  • Meggering Procedures
    • Required Equipment
    • Procedure
• E - Line & Load Cable Sizes
  • Max. Line Cable Sizes
  • Max. Load Cable Sizes
• F - Environmental Considerations
  • Air Quality Requirements
  • Hazardous Materials
    • Capacitor Dielectric Fluid
    • Printed Circuit Boards
    • Lithium Batteries
    • Chromate Plating
    • In Case Of Fire
    • Disposal
• G - Encoder Use and Torque Capabilities
  • When to use an Encoder?
  • PowerFlex 7000 Drive Performance (Torque Capabilities)
  • Glossary of Terms
• H - Specifications
  • “B” Frame Drive Specifications
• I - History of Changes
  • 7000-UM202A-EN-P, March 2013
• Index
• Back Cover