Document Outline

• PowerFlex 7000 Medium Voltage AC Drive Liquid-Cooled ("C" Frame) - ForGe Control
• Important User Information
• Summary of Changes
• Table of Contents
• 1 - Overview of Drive
  • Introduction
  • Liquid Cooling
    • Benefits of Liquid Cooling Include:
    • Benefits of the 7000L “C” Frame Liquid-cooled Drive:
  • Topology
  • Rectifier Designs
    • 18 Pulse Rectifier
    • Active Front End (AFE Rectifier)
  • “Direct-to-Drive” Technology
  • Motor Compatibility
  • SGCT Features and Benefits
  • Specifications
    • Simplified Electrical Drawings
    • Control Overview
  • Direct Vector Control
  • Control Hardware
  • Operator Interface
• 2 - Drive Installation
  • Safety and Codes
  • Unpacking and Inspection
  • Transportation and Handling
    • Overhead Lifting
    • Rod or Pipe Rollers
    • Fork Lift Trucks
    • Storage
  • Siting of the Drive
    • Site Considerations
  • Installation
  • Joining Shipping Splits
  • Connect the Sections
    • Tools Required (not supplied)
    • Install CPVC Piping Splices
    • Connect Power: M+, L+, M-, L- Power Bus
  • Control Wiring Connections
    • Removal of DC Link Choke Turnbuckle Supports
  • Removal of Lifting Angles
    • Shock Indication Labels
    • Installation of Exhaust Air Hood
    • Internally mounted fans
    • Externally mounted fans and fan hood
    • Typical PowerFlex 7000L Drive Structure Layout
  • Control/Cabling Cabinet
  • Major Components
  • IEC Component and Device Designation
  • Power Wiring Selection
    • General Notes
    • Cable Insulation
  • Power Cabling Access
    • Access the Customer Power Cable Terminations:
  • Power Connections
    • Incoming Connections
  • Liquid Connections
    • Liquid-to-Air Heat Exchangers
  • Pipe Materials and Layout
  • External Piping to the Drive
    • External Piping Cleaning
  • Controlled Siphon into Open- top Reservoir
  • Liquid-to-Liquid Heat Exchangers
  • Power and Control Wiring
    • Control Cables
    • Encoder Installation Guidelines
    • Information Regarding Termination of Customer 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 - Operator Interface
  • Chapter Objectives
  • Terminology
  • Overview
  • Keypad
    • Function (Softkeys) Keys
    • Cursor (Selection) Keys
    • Data Entry Keys
  • What is a Screen?
    • Components
    • Information Windows
    • Accessing/Writing to Drive
    • Communication Error
    • Languange Changing
    • General Operation
  • Operator Interface Power-up Sequence
  • Top Level Menu
  • How To
    • Obtain Help
    • Related Topics
    • Help on Help
  • Modify Operator Interface Operation (Utility)
    • Changing Backlight Delay
    • Changing Contrast
    • Setting Time
    • Setting Date
    • Selecting Meters
    • Viewing Revision Levels
    • Transfer Data in Memory
    • Picking an Access Level
  • Select a Parameter
    • Via Groups
    • Via Name
    • Via Code
  • Edit Text
  • Configure the Drive
    • Enter/Modify an Access Level
  • Drive Setup
    • Language Selection
    • Modify Parameters
    • Numerical Value
    • Enumerated Value
    • Bit Encoded Value
    • Analog Ports
    • Fault Masks
    • User Definable External Text
    • PLC
    • XIO
    • Message Prompting
    • Store/Retrieve Configuration (NVRAM)
    • Initialize
    • Save
    • Load
  • Display Parameters
    • Custom Group
  • View Drive Status
  • View and Reset Alarms
    • Help for Alarms
  • Request Printouts
  • Perform Diagnostic Trending
    • Assigning a Trace
    • Setting the Trigger
    • Defining Sample Rate and Positioning
    • Starting the Trace
  • Flash Memory Transfers
    • Format Flash Card
    • View a Directory
    • Select a Filename
    • Enter a Filename
  • Loading Programs (Firmware)
  • Parameter Transfers
    • Upload to Operator Interface
    • Download from Operator Interface
    • Upload to Memory Card
    • Download from Memory Card
    • Parameter File Format
  • Loading Language Modules
  • System Programming
  • Advanced Screen Operations
    • Communications Statistics
    • Protocol Analyzer
    • Print Screen
    • Memory Dump
    • Database Download
  • Operator Interface Menu Hierarchy Chart
    • What Does It Show?
    • How Do You Read It?
    • Example
  • PCMCIA Memory Card Installation Data
    • Description
    • Installing the Memory Card
• 4 - Commissioning
  • Start-up Commissioning Services
    • Drive Commissioning
    • Commissioning the Drive
  • Pre-Commissioning Responsibilities
  • PowerFlex 7000 ‘C’ Frame Pre-Commissioning Checklist
    • Receiving and Unpacking
    • Installation / Mounting
    • Safety
    • Control Wiring
    • Power Wiring
    • Drive Line-up Status
    • Cooling System Status
  • Commissioning Preparation
    • Recommended Tools and Equipment
  • Technical Publications
  • PowerFlex 7000 “C” Frame Manual
  • PowerFlex 7000 Parameters
  • Additional Manuals
  • Resources Required to Complete Drive Commissioning
  • Important Note for Commissioning Engineer
  • Key Steps to Commissioning a PowerFlex 7000 Drive
  • PowerFlex 7000 “C” Frame Commissioning Datasheets
  • PowerFlex 7000 “C” Frame Drive Commissioning Checklist
  • Drive Application Review
    • Rockwell Automation Drive Line-up Drawings
    • Electrical System One-line Diagram
    • Verify One-line Diagram on Site
    • Inspect Process
  • Safety Tests
    • Lockout Tagout
    • Step Down Transformer Fusing
    • Fuse and O/L Protection
  • Installation Review
    • Inspect for Shipping Damage
    • Inspect Cabinets for Debris
    • Protective Barriers
    • Component Grounding
    • Information on Splice Kits
    • Power Cabling
    • Control Wiring
  • Liquid-Cooling Connections
  • Service Data
    • Why this Information is Needed
  • Customer Information
  • Control Power Off Tests
    • Interlocking
  • Resistance Checks
    • SGCT Testing
    • SGCT Anode-to-Cathode Resistance
    • Snubber Resistance (SGCT Device)
    • Snubber Capacitance (SGCT Device)
    • SCR Testing
    • SCR Anode-to-Cathode Resistance
    • SCR Sharing Resistance Test
    • SCR Gate-to-cathode Resistance
    • Snubber Resistance (SCR Device)
    • Snubber Capacitance (SCR Device)
  • Control Power Tests
    • Three-Phase Input
    • Three-Phase Input / Single Phase Input
    • Power Supply Tests
    • Circuit Board Healthy Lights
    • Control Power Transformer (CPT)
    • AC/DC Converter (PS1)
    • DC/DC Converter (PS2)
    • SGCT Power Supplies (IGDPS)
    • IGDPS Board LEDs
  • Commissioning the Cooling System
    • Heat Exchanger Checks
    • Pumping Cabinet Control Power Checks
    • System Fill
    • System Fill and Air Venting
    • Normal Operation
  • Gating Tests
    • Gating Test Mode
    • SCR Firing Test
    • SGCT Firing Test
  • System Test
    • System Test Mode
    • Start/Stop Control Circuit
    • Status Indicators
    • Analog I/O
    • Configurable Alarms
  • 18 Pulse Phasing Test
    • Line Terminal Resistance Measurements
    • Application of Medium Voltage
    • Input Phasing Check
  • DC Current Test
  • Tuning Procedure
    • 1. Rectifier
    • 2. Motor Impedance
    • 3. FluxSpeed Regulator [INDUCTION MOTORS]
    • 4. FluxSpeed Regulator [SYNCHRONOUS MOTORS]
  • Running the Load
    • Motor Starting Torque
    • Reaching Specific Load Points
  • Capturing Data
  • Drive Input Voltage Phasing Checks
    • Summary:
  • Harmonic Analysis (required for AFE drives only)
    • Summary:
  • DC Current Test
    • Summary:
  • Load Test
  • Synchronous Transfer
• 5 - Component Definition and Maintenance
  • Control / Cabling Cabinet Components
  • Voltage-Sensing Assembly
  • Voltage-Sensing Circuit Board Assembly Replacement
  • Input Transient Protection
    • Overview
  • Transient Suppression Network (TSN)
    • Description
    • MOV Suppressor
    • MOV Fuse
  • Transient Suppression Network Fuse Replacement
  • Metal-Oxide Varistor Replacement
  • Surge Arresters
    • Description
    • Operation
    • Surge Arrester Replacement
    • Field Test and Care
  • Output Grounding Network Capacitor Replacement
  • Ground Filter Replacement
  • Hall Effect Sensor Replacement
  • Current Transformer Replacement
  • Filter Capacitor Cabinet
    • Filter Capacitors
    • Filter Capacitor Replacement
    • Testing Filter Capacitors
    • Converter Cabinet Components
  • Converter Cabinet
  • PowerCage™
  • SGCT and Snubber Circuit
  • Checking Clamping Pressure
    • Clamping Pressure Adjustment
  • Symmetrical Gate Commutated Thyristor Replacement
  • Silicon Controlled Rectifier and SCR Self-Powered Gate Driver Board Replacement
  • Detachment of Coolant System from PowerCage Modules
    • Reconnecting the Coolant System to a PowerCage Module
  • Chill Block Removal and Replacement
    • Instructions for removing Chill Block assembly
    • Instructions for inserting Chill Block assembly
  • PowerCage Removal and Replacement
  • Snubber Resistors
    • Testing Snubber Resistors
  • Sharing Resistors
    • Testing Sharing Resistors
  • Snubber and Sharing Resistor Replacement
  • Self-Powered Gate Driver Board – SPGDB
    • Description
    • Board Calibration
    • Test points description
    • Terminal/connections description
  • Testing procedure for SCR self-powered gate driver board
    • Equipment needed:
    • Procedure:
  • Fiber Optic Cabling
    • DC Link Reactor
  • Control Power Components
    • Ride-Through
  • AC/DC Power Supply
    • Description
    • Location
    • Terminal / Connections Descriptions
    • Replacement Procedure
  • UPS Option
    • UPS Replacement Procedure
  • Cooling System
    • Cooling Circuit
    • Chill Blocks
    • Coolant Pumps
  • Pump Maintenance and Replacement
    • Pump Seal Replacement
    • Pump Replacement with Drive Running
    • Piping, Tubing and Connectors
    • Non-Return Valves
    • Pressure Indicator
    • Pressure Switch
    • Thermostatic Valve
    • Thermostatic Valve Replacement
    • Repair Instructions - Element Testing
    • Element Replacing
    • Heat Exchanger
    • Fluid Conductivity
    • Temperature Sensor
    • De-Ionizing Cartridge and Mesh Filter
    • Replacing the Mesh Filters
    • Reservoir Circuit
    • Fluid Top-up
    • Strainers
    • Coolant
    • Maintaining Coolant Ratio
    • Leakage Checks
    • System Drain
  • Low Voltage Control Section
  • DC/DC Power SupplyDescription
    • Description
    • Terminal/Connections Descriptions
    • Replacement Procedure for DC/DC Power Supply
  • Printed Circuit Board Replacement
    • IO Connectors on Control Boards
  • Drive Processor Module
    • Drive Processor Module Replacement
    • Instructions to Replace the Drive Processor Module
  • ACB Analog Control Board
    • LEDs
    • Interface Module (IFM)
    • Analog Inputs and Outputs
  • Current Loop Transmitter
    • Isolated Process Receiver
    • Non-Isolated Process Outputs
    • Auxiliary +24V Power Supply
    • ACB Analog Control Board Replacement
  • Tachometer 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 (OIB)
    • Optical Interface Board Replacement
  • Optical Interface Base Board (OIBB)
    • Optical Interface Base Board Test Points
  • Downloading Firmware
    • Introduction
    • Overview
    • PowerFlex 7000 in Download Mode
  • Reloading the Parameters
  • Setting Elapsed Time
  • Downloading the Terminal Firmware
    • Using Flash Memory Card
    • DOSFWDL
    • Method
  • Setting up Diagnostic Trending
    • Diagnostic Setup
    • Setting up the Trend
  • Printing (Uploading) Data from the Drive
    • Overview
    • Creating an empty notepad (.txt) file
    • Setting up HyperTerminal Connection
    • Uploading the Data from the drive
  • Printing (Uploading) Control Data
    • Set up HyperTerminal connection
    • Printing Control Data
  • Environmental Considerations
    • Hazardous Materials
    • Disposal
  • Preventive Maintenance Check List
  • 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
• A - Catalog Number Explanation
  • PowerFlex 7000 Drive Selection Explanation
    • Service Duty Rating, Continuous Current Rating & Altitude Rating Code
  • When is an Encoder Required?
  • PowerFlex 7000 Drive Performance (Torque Capabilities)
  • Glossary of Terms
• B - Torque Requirements for Threaded Fasteners
  • Torque Requirements
• C - Meggering
  • Drive Meggering
  • Meggering the PowerFlex 7000
    • Equipment Required
    • Procedure
• D - Preventative Maintenance Schedule
  • PowerFlex 7000 Maintenance Schedule
    • I – Inspection
    • M – Maintenance
    • R – Replacement
    • C – Cleaning
    • Rv – Review
    • RFB/R – Refurbishment/Replacement
• Back Cover