Document Outline

• PowerFlex 7000 Medium Voltage AC Drive Air-Cooled (“A” Frame)—ForGe Control
• Summary of Changes
• Table of Contents
  • Who Should Use This Manual 11
  • What Is Not in this Manual 11
  • General Precautions 11
  • Additional Resources 12
  • Introduction 13
  • Topology 13
  • Rectifier Designs 14
    • Configurations 14
  • Motor Compatibility 16
  • Simplified Electrical Drawings 17
    • 2400V 17
    • 3300/4160V 18
    • 6600V 19
  • Operator Interface 20
    • Basic Configurations 20
  • Safety and Codes 23
  • Drive Storage 23
  • Siting of the Drive 23
    • Site Considerations 23
    • Generator Note: 24
  • Installation 25
    • Shock Indication Labels 25
    • Installation of Exhaust Air Hood 26
    • Installation of Redundant Fan Assembly 29
    • Installation of Integral Transformer Cooling Fan 30
    • Neutral Resistor Assembly 31
    • Installation of Neutral Resistor Assembly (Direct-to-Drive) 32
  • Cabinet Layout and Dimensional Drawings of Drive 33
  • Drive Layout 35
  • IEC Component and Device Designations 38
  • Power Wiring Selection 38
    • General Notes 38
    • Cable Insulation 38
  • Power Cabling Access 41
    • Access the Customer Power Cable Terminations 41
  • Power Connections 42
    • Line/Motor Terminations 42
    • Power Cabling Installation Requirements 42
  • Power and Control Wiring 47
    • Control Cables 47
  • Grounding Practices 47
    • Grounding Guidelines and Practices for Drive Signal and Safety Grounds 49
    • Grounding Requirements and Grounding Specification for Customers and Power Integrators 49
    • Identification of Types of Electrical Supplies - Grounded and Ungrounded Systems 50
    • Ground Bus 50
  • Interlocking 50
  • Cabling Cabinet Components 51
  • Hall Effect Sensor Replacements 55
  • Current Transformer Replacement 56
  • Converter Cabinet Components 57
  • Converter Cabinet 60
  • Voltage-Sensing Assembly 60
  • Voltage-Sensing Circuit Board Assembly Replacement 61
  • Surge Arresters 62
    • Description 62
    • Operation 63
    • Surge Arrester Replacement 63
    • Field Test and Care 64
  • PowerCage™ Overview 65
  • Resistance Checks 66
    • SGCT and Snubber Circuit 67
    • SGCT Anode-to-Cathode Sharing Resistance 72
    • Snubber Resistance 73
    • Snubber Capacitance 74
    • Replacing the SGCT 75
    • Replacing Snubber and Sharing Resistor 78
    • Replacing Snubber Capacitor 80
    • Replacing Sharing Resistors 82
  • Uniform Clamping Pressure 82
    • Clamping Pressure Adjustment 83
  • Temperature Sensing 84
    • Replacing the Thermal Sensor 84
  • Heatsink Replacement 86
  • PowerCage Gasket 87
    • Replacement of PowerCage Gaskets 87
    • Removal of old Gasket Material 87
  • PowerCage Removal 88
  • Self-Powered SGCT Power Supply - SPS 90
    • Board Calibration 90
    • Test Points 90
    • Testing Equipment 92
  • Fiber Optic Cabling 93
  • Air Pressure Sensor 94
    • Air Pressure Sensor Replacement 94
  • D.C. Link / Fan / Control Components 95
    • Output Grounding Network Replacement 96
    • Ground Filter Component Replacement 97
    • Filter Capacitors 98
    • Replacing Filter Capacitors 99
    • Testing Filter Capacitors 100
  • DC Link Reactor Replacement 102
  • Fan Replacement 104
    • DC Link Section 104
    • Safety Notes 104
    • Fan Installation 105
    • Top of Integral Isolation Transformer Section 106
    • Top of Integral Line Reactor and Input Starter Section 107
    • Impeller Removal from Motor Shaft 107
    • Installation of Impeller Assembly onto Motor Shaft 109
  • Impeller Maintenance 110
    • Isolation Transformer Cooling Fan 110
  • Inlet Ring Removal and Replacement 110
    • DC Link / Fan Section 111
    • Top of Integral Isolation Transformer Section 111
  • Replacement of Air Filters 111
  • Control Power Components 114
    • Ride-Through 114
  • AC/DC Power Supply 117
    • Description 117
    • Location 117
    • Terminal / Connections Descriptions (Pioneer Power Supply) 120
    • Terminal / Connections Descriptions (Cosel Power Supply) 121
    • Output Calibration 122
    • Power Supply Replacement 122
  • UPS Option 124
    • Replacing the UPS 125
  • Low Voltage Control Section 127
  • DC/DC Power Supply 129
    • Description 129
    • Terminal/Connections Descriptions 130
    • Replacement Procedure for DC/DC Power Supply 131
  • Printed Circuit Board Replacement 132
  • Drive Processor Module 133
    • Drive Processor Module Replacement 135
  • Analog Control Board 137
    • Interface Module (IFM) 141
    • Analog Inputs and Outputs 141
    • Current Loop Transmitter 142
    • Isolated Process Receiver 143
    • Non-Isolated Process Outputs 144
    • Auxiliary +24V Power Supply 144
    • Analog Control Board Replacement 145
  • Encoder Feedback Board 145
    • Encoder Options 145
    • Quadrature Encoder Operation 150
    • Positional Encoder Operations 150
    • Positional Encoder Guidelines 151
  • External Input/Output Boards 152
    • External Input/Output Board Replacement 153
  • Optical Interface Boards 154
    • Optical Interface Board Replacement 156
  • Start-up Commissioning Services 159
    • Drive Commissioning 159
  • PowerFlex 7000 Drive Selection Explanation 163
    • Service Duty Rating, Continuous Current Rating and Altitude Rating Code 163
  • Preventative Maintenance Checklist 165
  • Operational Maintenance 165
  • Annual Maintenance 165
    • Initial Information Gathering 166
    • Physical Checks (NO Medium Voltage and NO Control Power) 166
    • Control Power Checks (No Medium Voltage) 167
    • Final Power Checks before Restarting 168
    • Additional Tasks During Preventive Maintenance 168
    • Final Reporting 169
    • Time Estimations 170
    • Tool / Parts / Information Requirements 170
  • PowerFlex 7000 Maintenance Schedule 172
    • I – Inspection 172
    • M – Maintenance 172
    • R – Replacement 172
    • C – Cleaning 172
    • Rv – Review 172
    • RFB/R – Refurbishment/Replacement 172
  • PowerFlex 7000 Preventative Maintenance Service Schedule 173
  • General Notes 175
    • Maintenance of Medium Voltage Motor Control Equipment 175
    • Periodic Inspection 175
    • Contamination 175
    • High Voltage Testing 176
    • Maintenance after a Fault Condition 176
  • Part-specific Notes 176
    • Cooling Fans 176
    • Operating Mechanisms 177
    • Contacts 177
    • Vacuum Contactors 177
    • Power Cable and Control Wire Terminals 177
    • Coils 178
    • Batteries 178
    • Pilot Lights 178
    • Solid-State Devices 178
    • Locking and Interlocking Devices 178
  • Torque Requirements for Threaded Fasteners 179
  • Drive Meggering 181
  • Meggering the PowerFlex 7000A 181
    • Equipment Required 182
    • Isolate and Lock Out the Drive System from High Voltage 182
    • Isolate the Power Circuit from System Ground (Float the drive) 182
    • Disconnect Connections between Power Circuit and Low Voltage Control 183
    • Meggering the Drive 184
    • Reconnecting Connections between Power Circuit and Low Voltage Control 185
    • Reconnect the Power Circuit to the System Ground 185
  • Max. Line Cable Sizes 187
  • Max. Load Cable Sizes 190
  • Air Quality Requirements 193
  • Hazardous Materials 194
    • Capacitor Dielectric Fluid 194
    • Printed Circuit Boards 194
    • Lithium Batteries 194
    • Chromate Plating 195
    • In Case Of Fire 195
    • Disposal 195
  • Drive Specifications 197
  • 7000A-UM200B-EN-P, May 2013 201
  • 7000A-UM200A-EN-P, March 2013 201
• Preface
  • Who Should Use This Manual
  • What Is Not in this Manual
  • General Precautions
  • Additional Resources
• 1 - Overview of Drive
  • Introduction
  • Topology
  • Rectifier Designs
    • Configurations
  • Motor Compatibility
  • Simplified Electrical Drawings
    • 2400V
    • 3300/4160V
    • 6600V
  • Operator Interface
    • Basic Configurations
• 2 - Drive Installation
  • Safety and Codes
  • Drive Storage
  • Siting of the Drive
    • Site Considerations
    • Generator Note:
  • Installation
    • Shock Indication Labels
    • Installation of Exhaust Air Hood
    • Installation of Redundant Fan Assembly
    • Installation of Integral Transformer Cooling Fan
    • Neutral Resistor Assembly
    • Installation of Neutral Resistor Assembly (Direct-to-Drive)
  • Cabinet Layout and Dimensional Drawings of Drive
  • Drive Layout
  • IEC Component and Device Designations
  • Power Wiring Selection
    • General Notes
    • Cable Insulation
  • Power Cabling Access
    • Access the Customer Power Cable Terminations
  • Power Connections
    • Line/Motor Terminations
    • Power Cabling Installation Requirements
  • Power and Control Wiring
    • Control Cables
  • Grounding Practices
    • Grounding Guidelines and Practices for Drive Signal and Safety Grounds
    • Grounding Requirements and Grounding Specification for Customers and Power Integrators
    • Identification of Types of Electrical Supplies - Grounded and Ungrounded Systems
    • Ground Bus
  • Interlocking
• 3 - Component Definition and Maintenance
  • Cabling Cabinet Components
  • Hall Effect Sensor Replacements
  • Current Transformer Replacement
  • Converter Cabinet Components
  • Converter Cabinet
  • Voltage-Sensing Assembly
  • Voltage-Sensing Circuit Board Assembly Replacement
  • Surge Arresters
    • Description
    • Operation
    • Surge Arrester Replacement
    • Field Test and Care
  • PowerCage™ Overview
  • Resistance Checks
    • SGCT and Snubber Circuit
    • SGCT Anode-to-Cathode Sharing Resistance
    • Snubber Resistance
    • Snubber Capacitance
    • Replacing the SGCT
    • Replacing Snubber and Sharing Resistor
    • Replacing Snubber Capacitor
    • Replacing Sharing Resistors
  • Uniform Clamping Pressure
    • Clamping Pressure Adjustment
  • Temperature Sensing
    • Replacing the Thermal Sensor
  • Heatsink Replacement
  • PowerCage Gasket
    • Replacement of PowerCage Gaskets
    • Removal of old Gasket Material
  • PowerCage Removal
  • Self-Powered SGCT Power Supply - SPS
    • Board Calibration
    • Test Points
    • Testing Equipment
  • Fiber Optic Cabling
  • Air Pressure Sensor
    • Air Pressure Sensor Replacement
  • D.C. Link / Fan / Control Components
    • Output Grounding Network Replacement
    • Ground Filter Component Replacement
    • Filter Capacitors
    • Replacing Filter Capacitors
    • Testing Filter Capacitors
  • DC Link Reactor Replacement
  • Fan Replacement
    • DC Link Section
    • Safety Notes
    • Fan Installation
    • Top of Integral Isolation Transformer Section
    • Top of Integral Line Reactor and Input Starter Section
    • Impeller Removal from Motor Shaft
    • Installation of Impeller Assembly onto Motor Shaft
  • Impeller Maintenance
    • Isolation Transformer Cooling Fan
  • Inlet Ring Removal and Replacement
    • DC Link / Fan Section
    • Top of Integral Isolation Transformer Section
  • Replacement of Air Filters
  • Control Power Components
    • Ride-Through
  • AC/DC Power Supply
    • Description
    • Location
    • 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
    • Description
    • Terminal/Connections Descriptions
    • Replacement Procedure for DC/DC Power Supply
  • Printed Circuit Board Replacement
  • Drive Processor Module
    • Drive Processor Module Replacement
  • Analog Control Board
    • Interface Module (IFM)
    • Analog Inputs and Outputs
    • Current Loop Transmitter
    • Isolated Process Receiver
    • Non-Isolated Process Outputs
    • Auxiliary +24V Power Supply
    • Analog Control Board Replacement
  • Encoder Feedback Board
    • Encoder Options
    • Quadrature Encoder Operation
    • Positional Encoder Operations
    • Positional Encoder Guidelines
  • External Input/Output Boards
    • External Input/Output Board Replacement
  • Optical Interface Boards
    • Optical Interface Board Replacement
• A - Commissioning
  • Start-up Commissioning Services
    • Drive Commissioning
• B - Catalog Number Explanation
  • PowerFlex 7000 Drive Selection Explanation
    • Service Duty Rating, Continuous Current Rating and Altitude Rating Code
• C - 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
  • PowerFlex 7000 Maintenance Schedule
    • I – Inspection
    • M – Maintenance
    • R – Replacement
    • C – Cleaning
    • Rv – Review
    • RFB/R – Refurbishment/Replacement
  • PowerFlex 7000 Preventative Maintenance Service Schedule
  • General Notes
    • Maintenance of Medium Voltage Motor Control Equipment
    • Periodic Inspection
    • Contamination
    • High Voltage Testing
    • Maintenance after a Fault Condition
  • Part-specific Notes
    • Cooling Fans
    • Operating Mechanisms
    • Contacts
    • Vacuum Contactors
    • Power Cable and Control Wire Terminals
    • Coils
    • Batteries
    • Pilot Lights
    • Solid-State Devices
    • Locking and Interlocking Devices
• D - Torque Requirements
  • Torque Requirements for Threaded Fasteners
• E - Meggering
  • Drive Meggering
  • Meggering the PowerFlex 7000A
    • Equipment Required
    • Isolate and Lock Out the Drive System from High Voltage
    • Isolate the Power Circuit from System Ground (Float the drive)
    • Disconnect Connections between Power Circuit and Low Voltage Control
    • Meggering the Drive
    • Reconnecting Connections between Power Circuit and Low Voltage Control
    • Reconnect the Power Circuit to the System Ground
• F - Line & Load Cable Sizes
  • Max. Line Cable Sizes
  • Max. Load Cable Sizes
• G - Environmental Considerations
  • Air Quality Requirements
  • Hazardous Materials
    • Capacitor Dielectric Fluid
    • Printed Circuit Boards
    • Lithium Batteries
    • Chromate Plating
    • In Case Of Fire
    • Disposal
• H - Specifications
  • Drive Specifications
• I - History of Changes
  • 7000A-UM200B-EN-P, May 2013
  • 7000A-UM200A-EN-P, March 2013
• Index
• Back Cover