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7000-IN007_-EN-P - Rockwell Automation

1. 42 Rockwell Automation Publication 7000 7 June 2014 Drive Installation Chapter 3 3 Use M10 hardware to join the choke cabinet s sidesheet to main drive cabinet s sidesheet Figure 37 shows bracket 81003 929 in the right cabinet representation When installing these cabinets together abut these cabinets along their side walls and align the cabinet fronts with no gaps These alignments are crucial for correctly aligning the plumbing and bus connectors at the back of the cabinet Failure to do so can cause undue stress on plumbing joints and leaks Use brackets 81003 929 as shown to secure the cabinet alignment Figure 35 Aligning and joining heat pipe main and choke cabinets for 3300 4160V and 6600V Cabinets bolted together at four corners using M10 bolts Rockwell Automation Publication 7000 7 June 2014 43 Chapter3 Drive Installation Figure 36 Aligning and joining heat pipe main and Line Reactor for 6600V only Cabinets Bolted Together
2. 1 i d 7 i E i 19 5 26 Rockwell Automation Publication 7000 7 June 2014 Drive Installation Chapter 3 Figure 21 AC Line Reactor Cabinet 6600V heat pipe RPDTD model 5 o Resistors Line Reactor sasa Line Reactor Baffle 9 5 Rockwell Automation Publication 7000 7 June 2014 27 Chapter3 Drive Installation Figure 22 AC Line Reactor with connection cabinet heat pipe model Fans
3. Rockwell Automation Publication 7000 7 June 2014 Latch Key Interlock Handle Latch Terminal blocks Customer TBC Figure 47 Access to power terminals AFE heat sink model Low Voltage Compartment Open r 38 9 9 T 0 1 LJ 0 Low Voltage Door Rockwell Automation Publication 7000 7 June 2014 Drive Installation Power Terminals Chapter 3 53 Chapter 3 54 Drive Installation Figure 48 Access to power terminals AFE heat pipe model Low Voltage Compartment Open 7 Power Termi
4. ss 1 1 e i e i 25 g 19 s 5 Bes B i Oooo lt gt N lt gt k I Wm 290803 oo O 1 244 Line Reactor ain Section of Heat Pipe Drive Choke Cabinet Rockwell Automation Publication 7000 7 June 2014 41 Chapter3 Drive Installation 2 Remove the lifting supports in the choke cabinet used for shipping and retain for future use Figure 34 Heat pipe choke cabinet no fans Remove top mounted lifting angle turnbuckle supports internal support angles and sidesheet brace prior to installing
5. Differential Pressure Ground bus Sensor Isolated Gate Driver Power Supplies IGDPS Inverter Modules Rectifier IGDPS not required in drives with SPS boards installed Rectifier Modules 30 Rockwell Automation Publication 7000 7 June 2014 Drive Installation Chapter 3 Figure 25 Converter cabinet heat sink model 6600V version shown Differential Pressure Ground bus Sensor Isolated Gate Driver Power Supplies Inverter Modules IGDPS Rectifier Modules Rectifier IGDPS not required in drives with SPS boards installed Rockwell Automation Publica
6. BEN Hall effect sensor T Current Transformers Rockwell Automation Publication 7000 7 June 2014 25 Chapter3 Drive Installation Figure 20 AC Line Reactor for AFE rectifier with connection cabinet heat sink model x Line Terminals Line Capacitors Motor Terminals Ez Zero Sequence __ DU Current 1 wo Transformer 112 if supplied LEUTE CM if supplied 2 i L 1089 Line Reactor LAT LA L Motor Filter Capacitors
7. 56 Rockwell Automation Publication 7000 7 June 2014 Drive Installation Chapter 3 Figure 50 Detail Power Terminal Dimensions heat sink AFE Rectifier Mel c S EE i 1 Terminals U V W behind 2U 2V 2W 834 0 b 32 84 2U le Y 14172 i Os opu 55 80 ma 1480 6 58 19 BL HR i ei ib i 2W 2V 2 303 2 2 897 4 11 92 111 35 27 423 9 16 66 544 5 a 21 40 x d x s 65 0 D D E 1 ni ns Lu V 775 3 05 3 05 3399 590 0 13 36 23 19 919 Section X X 38 95 Confirm the torque applied all power connections is correct Refer to Torque Requirements for Threaded Fasteners on page 73 for more information The drive provides for grounding cable shields and stress cones near the power terminals Rockwell Automation Publication 7000 7 June 2014 57 Chapter3 Drive Installation Power and Control Wiring 58 Drive line ups i e drive and input starter shipped in
8. MOTOR CAPACITORS LINE CAPACITORS c 90 Capacitors Resistors Line Reactor Baffle Line Reactor 28 Rockwell Automation Publication 7000 7 June 2014 Differential Pressure Sensor Inverter Modules Rectifier Modules Figure 23 Converter cabinet heat sink model 2400V version shown Drive Installation Chapter 3 Ground bus Isolated Gate Driver Power Supplies IGDPS Rectifier IGDPS not required in drives with SPS boards installed Note There may be minor variations in the
9. For tray Recommended spacing between different wire groups in the same tray For conduit Recommended spacing for wire groups in separate conduit mm in Wire Wire Application Signal Example Recommended Wire Group Power 1 Power 2 Control 3 Control 4 Signal 5 Signal 6 Category Group Cable AC Power 23kV 30 Per IEC NEC gt 600VAC AClines Local Codes and 9 00 9 00 9 00 9 00 Application Requirements Between 76 2 3 00 conduit Between conduit Power 2 AC Power to 480V 30 Per IEC NEC In tray 228 6 228 6 152 4 152 4 600V AC Local Codes and 9 00 9 00 6 00 6 00 Application Requirements Between 76 2 3 00 conduit Between conduit 3 115V AC Relay logic Per IEC NEC In tray 228 6 152 4 228 6 152 4 1154 DC 0 Local Codes and 9 00 6 00 9 00 6 00 Logic Application Requirements 115V AC Power Power supplies Between 76 2 3 00 instruments conduit Between conduit Control 4 24V AC 0 Per IEC NEC In tray 228 6 1524 1524 228 6 or 24V DC Logic Local Codes and 9 00 6 00 6 00 9 00 Application Requirements Between 76 2 3 00 conduit Between Conduit 5 Analog Signals 5 24V DC supplies Belden 8760 DC Supplies Belden 8770 Belden 9460 Digital Power supplies Signal low speed TTL Logic Level 6 Digital Pulse Train Belden 8760 All signal wiring must be run in separate steel conduit high speed Input E
10. Rockwell Automation Publication 7000 IN007E EN P June 2014 DC Link Inductor or CMC Barrier removed 33 Chapter3 Drive Installation Figure 29 DC Link Fan cabinet with panel removed to show CMC heat pipe model o Fans Common Mode Choke 34 Rockwell Automation Publication 7000 7 June 2014 Drive Installation Chapter 3 Figure 30 DC Link Fan cabinet with fan control panel removed to show main cooling fan Fan Inlet Ring Rockwell Automation Publication 7000 7 June 2014 35 Chapter3 Drive Installation Component and Device Designations 36 PowerFlex 7000 electrical drawings use IEC based conventions while remaining compatible with North American ANSI American National Standards Institute standards Component identifying symbols on the drawings are international each PowerFlex 7000 elementary drawing ED set provides a full listing of these symbols Each ED set also lists the device designations used on the drawings and labeling with explanations Wiring identification uses a source destination wire number convention on point to point multi conductor wiring and elsewhere as warranted The wire numbering system of unique single numbers for multi drop and point to point wiring is common in general control and power wiring Wiring that connects between the sheets or that ends at one point and starts at anothe
11. 6600V Figure 12 6600V AFE Rectifier Configuration 1 Direct to Drive LINE CONVERTER COMMON MODE CHOKE MACHINE CONVERTER e 5 A 5 Wsccis x i i d x x x AYYY due eem 0 o 4 W T3 i e e Figure 13 6600V AFE Rectifier Configuration 2 Separate Isolation Transformer LINE CONVERTER DC LIN MACHINE CONVERTER REMOTE L M ISTX COC CL amp A SGCIs SGCTs 4 20 X1 U T1 10 F o vem ws LA Wo En e 14144 ee Figure 14 6600V Configuration 3 18 Pulse DC LINK ISTX LINE CONVERTER Lt M MACHINE CONVERTER scs L M 18 Rockwell Automation Publication 7000 7 June 2014 Operator Interface PowerFlex 7000 Overview Chapter 2 The HMI Interface Board is an HMI enabling device for the PowerFlex 7000 drive It allows the user to acquire all the necessary executable tools documentation and reports required to commission troubleshoot and maintain the drive Via the HMI Interface Board the user can choose the style and size of the desired Windows based operator terminal to interact with the drive e g Panel Vie
12. 39 Joining Shipping Splits 3300 4160V and 6600V Heat Pipe Model 40 Installing Exhaust Fans and Air 46 45 Installation of Redundant Fan Assembly 49 External DUCEIDE ay rene ee hc e ear wom ite 50 Power Cabling Access uS e hola oh a d aec ua 51 Power Connections 55 Power Cabling Installation Requirements 55 Power and Control Wiring i re ek decries 58 Control Cables coi cea s wit Pih belt eina dett 58 Encoder Installation Guidelines 58 Terminating Customer Cables 61 Grounding Practices ed ve dedu REESE ot dues Fe ated eue 62 Guidelines for Drive Signal and Safety Grounds 63 Specifications for Customers and Power Integrators 63 Electrical Supplies Grounded and Ungrounded Systems 63 Rockwell Automation Publication 7000 INO07E EN P June 2014 5 Table of Contents Pre Commissioning Responsibilities General Reference Meggering Line amp Load Cable Sizes Specifications around Bus ea piel 64 64 Chapter 4 Inspection and Verification 65 Pre Commissioning Responsibilities 66 Pre Commissioning Checklist 67 Additional Requ
13. 7 What Is Not in this Manual 7 Manual c M PCS UM EE UU be 8 General Precautions 8 Commissioning ts aee i did Feo PLE ELE Id 9 Chapter 2 C 11 Rectifier Desghs iie ews woe perita E ENS TREE EE E E 12 ConBehtauobs ovd vod cereo Tu V dtt tei er 12 Cooling Technology edam comps Rae arene de Res dde CERE RRENEEE 14 Motor Compatibility ui ote del fece desk mien bd 15 Simplified Electrical Diagrams ooa eie ees vehe elt 16 2400V y ots Um I duce UL E UE I 16 3300 4 160 V ie eR ere uo ut 17 18 Operator Interface ee ae eee 19 Basic Configurations E REUS RU CH oes 19 Chapter 3 Safety and YOU 21 Transporting and Siting the Drive 21 Cabinet Layout and Dimensional Drawings of Drive 21 Control Cabling Cabinet vermes d eet t tid 22 IEC Component and Device 36 Power Wiring Selection eet s warn a Cnt incite rica 36 Cable Insulation es ane cles 37 15 18 11 I 39 Shock Indication Labels
14. 46 140 71 9 w starter 4 00x4 00 102x102 1 4 0 5 kV or 1 107mm 5kV 18 8 478 8 kV phase or 8 kV phase PF7000A 4160 50 2 46 140 71 13 71 18 w o starter 4 00x4 00 102x102 1 4 0 5 kV or 1 107mm 5 kV 17 1 435 8 kV phase or 8 kV phase PF7000A 4160V 60Hz RPDTD 46 140 71 9 w starter 4 00x4 00 102x102 1 4 0 5 kV or 1 107mm 5 18 3 8 467 8 kV phase or 8 kV phase PF7000A 4160V 60Hz RPDTD 46 140 71 13 71 18 w o starter 4 00x4 00 102x102 1 4 0 5 kV or 1 107mm 5 17 1 435 8 kV phase or 8 kV phase PF7000A 6600V 5OHz RPDTD 40 93 71 10 w starter 4 00x4 00 102x102 1 4 0 8 kV or 1 107mm 5 18 8 478 15 kV phase or 8 kV phase 2 PF7000A 6600V 50Hz RPDTD 40 93 71 14 71 19 w o starter 4 00x4 00 102x102 1 350MCM 1 177mm 8kV 17 1 435 us 8kVor15kV phase 15 kV phase ir Cooled PF7000A 2400V 60Hz RPTX 46 160 71 7 4 00x8 00 102 204 1 350 1 177 5 kV 33 8 860 8kVor15kV phase or 8kV phase PF7000A 3300V 50Hz RPTX 46 160 71 7 4 00 8 00 102x204 1 1 350MCM 1 177mm 8kV 33 8 860 8kVor15kV phase or 15 kV phase PF7000A 4160 50Hz RPTX 46 160 717 4 00x8 00 102x204 1 350MCM 1 177mm 8kV 33 8 860 8kVor15kV phase or 15 kV phase PF7000A 4160 60Hz RPTX 46 160 717 4 00x8 00 102x204 1 350MCM 1 177mm 8 kV 33 8 860 8kVor15kV phase or 15 kV phase PF
15. June 2014 Chapter 4 Pre Commissioning Responsibilities Rockwell Automation manages the start up service for each installed drive at the customers site but there are a number of tasks you must complete before you schedule RA personnel for drive commissioning This chapter outlines the required pre commissioning responsibilities Review this information prior to commissioning the drive as a reference for drive line up commissioning Record the information in the data sheets provided these are useful during future maintenance and troubleshooting exercises Perform the pre commissioning tasks in the order listed in this chapter Failure to do so may result in equipment failure or personal injury IMPORTANT Rockwell Automation requests a minimum of four weeks notice to schedule each start up The standard Rockwell Automation work hours are between 9 00 AM to 5 00 PM EST 8 hr day Monday through Friday not including observed holidays Additional working hours are available on a time and material basis In spection and Verification Before the drive commissioning occurs Rockwell Automation recommends the following 1 9 A WD Arranging a pre installation meeting with Rockwell Automation personnel to review a the start up plan b the start up schedule c the drive s installation requirements Inspecting the drive s mechanical and electrical devices Performing a tug test on all in
16. I x x x 4 e Figure 8 2400V Configuration 3 18 Pulse ISTX LINE CONVERTER TINK M MACHINE CONVERTER 16 Rockwell Automation Publication 7000 7 June 2014 3300 4160V PowerFlex 7000 Overview Chapter 2 Figure 9 3300 4160V AFE Rectifier Configuration 1 Direct to Drive LINE CONVERTER COMMON MODE CHOKE MACHINE CONVERTER n 365 x i SGCTs 1 x x m L 22 He W T3 m 1 ii o T x x x x x Figure 10 3300 4160V AFE Rectifier Configuration 2 Separate Isolation Transformer LINE CONVERTER DC LINK MACHINE CONVERTER ISTX SGCTs x 4 20 X1 0 11 10 e e o im 2V X2 V T2 1 AW o 2W 3 T x s 4 Lj ISTX 240421 Figure 11 3300 4160V Configuration 3 18 Pulse DC LINK LINE CONVERTER L M MACHINE CONVERTER ERA ji SGCTs _ L M Rockwell Automation Publication 7000 7 June 2014 17 Chapter2 7000 Overview
17. 500 5 1 253mm 34 4 874 w close coupled starter 8kV phase or 8kV phase PF7000 3300V 5OHz RPDTD 46 430 70 43 70 44 70 45 70 47 9 79x10 97 249x279 2 500 5kV 2 253mm 5kV_ 28 5 725 8kV phase or 8kV phase PF7000 3300V 50Hz RPDTD E495 70 32 11 81 16 22 300x412 2 SOOMCM SkV 2 253mm 5 16 5 421 cae or 8kV phase or 8kV phase 6325 N720 PF7000 3300V 50Hz RPDTD 46 375 70 43C 70 44C 5 61x7 19 142x183 500 5kV 1 253mm 5kV 34 4 874 70 45C 70 47C 8kV phase or 8kV phase w close coupled starter PF7000 4160V 50Hz RPDTD 46 375 70 43 70 44 70 45 70 47 9 79x10 97 249x279 1 2 500MCM 5kV 2 253mm 5 28 5 725 8kV phase or 8kV phase PF7000 4160V 50Hz RPDTD 46 375 70 43C 70 44C 5 61x7 19 142x183 500 5kV 1 253mm 5kV_ 34 4 874 70 45C 70 47C 8kV phase or 8kV phase w close coupled starter PF7000 4160V 60HZ RPDTD 46 430 70 43 70 44 70 45 70 47 9 79x10 97 249x279 2 500 5kV 2 253mm 8 28 5 725 8kV phase or 15kV phase PF7000 4160V 60Hz RPDTD E495 70 32 11 81 16 22 300x412 2 SOOMCM SkV 2 253mm 5 16 5 421 ae or 8kV phase or 8kV phase 6325 720 WF PF7000 4160V 60Hz RPDTD 46 375 70 43C 70 44C 5 61x7 19 142x183 1 500 5 1 253 0 8kV_ 34 4 874 70 45C 70 47 8kV phase or 15kV phase d
18. June 2014 Torque Requirements for Threaded Fasteners General Reference Appendix A Unless otherwise specified use the following values of torque in maintaining the equipment Diameter Pitch Material Torque N m Torque Ib ft M2 5 0 45 Steel 0 43 0 32 M4 0 70 Steel 1 8 13 M5 0 80 Steel 34 25 M6 1 00 Steel 6 0 44 M8 1 25 Steel 14 11 M10 1 50 Steel 29 21 M12 1 75 Steel 50 37 M14 2 00 Steel 81 60 1 4 20 Steel S A E 5 12 9 0 3 8 16 Steel S AE 21 27 20 Rockwell Automation Publication 7000 7 June 2014 73 AppendixA General Reference Preventative Maintenance Rockwell Automation recognizes that following a defined maintenance schedule Schedule improves your drive s performance and operational lifespan By rigorously following this maintenance schedule you can expect the highest possible uptime Annual maintenance includes a visual inspection of all drive components visible from the front of the unit resistance checks on the power components power supply voltage level checks general cleaning and maintenance checking of all accessible power connections for tightness and other tasks These tasks are described in detail in publication 7000 UM202_ EN P Inspection This indicates that the component should be inspected for signs of excessive accumulation of dust dirt etc or external damage e g looking at Filter Capacitors for bulges in the case
19. size shown is not commercially available in many cases use the next smaller standard size Cable enters termination point horizontally in this case therefore orient space for the stress cones horizontally also Minimum cable bend radius recommendations vary by national codes cable type and cable size Consult local codes for guidelines and requirements General relationship of cable diameter to bend radius is typically between 7x 12x 9 if the cable diameter is 1 2 54 cm the minimum bend radius could range between 7 12 in 18 8 30 48 5 For minimum cable insulation requirements refer to the PowerFlex 7000 Medium Voltage AC Drive User Manual for your particular frame or C Frame Stated voltages are peak line to ground Note Some cable manufacturers rate cabling based on RMS line to line 6 Ground lug capabilities A Frame two mechanical range lugs for ground cable connections or C Frame up to ten mechanical range lugs for ground cable connections are available typically these frames supply four Mechanical range lugs can accommodate cable size 6 250 13 3 127 mm 18 Pulse VFDs R18TX have nine line side connections from the secondary isolation transformer windings entering the VFD Lug pads are available for each connection The lug pad and enclosure can generally accommodate two cables per connection 18 cables in total applies to all B and C EORR MORS Max
20. 2 500 5kV 2 253mm 5kV 16 9 430 0285 0325 or 8kV phase or 8kV phase N720 PF7000 4160V 60Hz RPDTD 46 375 70 43C 70 44 5 61x7 19 142x183 500MCM 5kV or 1 253mm 5kVor 16 2 411 70 45C 70 47 8kV phase OR 8kV phase OR 2 w close coupled starter 2 250MCM 5 127mm 5kV 8kV phase 8kV phase PF7000 6600V 50Hz RPDTD 46 285 70 46 70 47 9 79x10 97 249x279 1 500 8kV 1 253mm 5 28 5 725 70 48 70 49 phase 8kV phase PF7000 6600V 50Hz RPDTD 40 285 70 46 70 47C 70 49C w 5 61x7 19 142x183 500 5kV OR 1 253mm OR 2 16 2 411 close coupled starter 2 250 127mm 8kV or 5kV phase 15kV phase ALAS PF7000 6600V 50Hz RPDTD 8325 5575 70 34 70 35 12 79x19 68 325x500 1 2 500MCM 8kV 2 253mm 8kV 16 9 430 Air 6215 6250 or 15kV phase or 15kV phase Cooled N625 cont d PF7000 6600V 60Hz RPDTD 40 285 70 46 70 47 9 79x10 97 249x279 1 2 500MCM 8kV or 2 253mm 5kV 28 5 725 70 48 70 49 15kV phase 8kV phase PF7000 6600V 60Hz RPDTD 40 285 70 46C 70 47C 70 49C w 5 61x7 19 142x183 500 5kV OR 1 253mm OR 2 16 2 411 close coupled starter 2 250 8kV 127mm 8kV or 5kV phase 15kV phase PF7000 2400V 60Hz RPTX 46 430 70 1 70 2 70 25 70 26 9 79x10 97 249x279 2 500MCM 5kV or 2 253mm 5kV 28 5 725 8kV phase 8kV phase PF7000 3300V 50Hz RPTX 46 430 70 10 70 27 70 28 70 30 9 79x10 97 249
21. 20 mA or 0 10V 2500 Analog Resolution Analog input 12 Bit 4 20 Internal parameter 32 Bit resolution Serial Communication 16 Bit resolution 1Hz Digital Speed Reference Analog Outputs One Isolated Eight Non isolated 4 20 mA or 0 10V 600 0 Communication Interface Ethernet IP DPI Scan Time Internal DPI 2 ms min 4 ms max Rockwell Automation Publication 7000 7 June 2014 93 Appendix D 94 Specifications Table 16 General Design Specifications Continued Description Communications Protocols DeviceNet ControlNet Optional Ethernet I P Lon Works Dual port Ethernet I P Open Profibus RS485 HVAC Modbus RS485 DF1 Interbus RS232 DF1 USB Enclosure NEMA 1 standard IP21 IEC NEMA 12 optional 42 IEC Lifting Device Standard Removable Mounting Arrangement Mounting Sill Channels Structure Finish Epoxy Powder Paint Exterior Sandtex Light Grey RAL 7038 Black RAL 8022 Internal Control Sub Plates High Gloss White RAL 9003 Interlocking Key provision for customer input Disconnecting Device Corrosion Protection Unpainted Parts Zinc Plated Bronze Chromate Ambient Temperature 0 40 32 104 F 0 50 C 32 122 F optional Fiber Optic Interface Rectifier Inverter Cabinet Warning Trip Door Filter Painted Defuser with Matted F
22. Initials Date Check All mechanical interlocks and door Ram Interlocks are tested for proper functionality and are not defeated or damaged All Kirk key interlocks are installed and tested for proper functionality The grounding of the drive should be in accordance with CEC NEC or IEC regulations Rockwell Automation Publication 7000 7 June 2014 67 Chapter4 Pre Commissioning Responsibilities Initials Date Check If the drive has an isolation transformer the transformer enclosure and or frame must be bonded to system ground at a minimum of two locations If the drive has an isolation transformer the wye secondary neutral point must not be grounded If shipping splits exist in the line up the ground bus between cabinets has been installed Table 8 Control Wiring Initials Date Check Based on your local regulation an ARC Flash study has been completed All low voltage wiring entering the drive is labeled appropriate wiring diagrams are available and all customer interconnections are complete If an encoder is used the encoder must be isolated from the motor frame The encoder cables should be routed in grounded steel conduit for electrical noise suppression and the conduit must be grounded at junction box but left isolated from the encoder with an insulated bushing The encoder cable shield to the drive is connected to the ground bus at t
23. inspecting the heat sinks for debris clogging the air flow path etc M Maintenance This indicates a maintenance task that is outside the normal preventative maintenance tasks and can include the inductance testing of Line Reactors DC Links or the full testing of an isolation transformer Replacement This indicates that the component has reached its mean operational life and should be replaced to decrease the chance of component failure It is very likely that components will exceed the design life in the drive and that is dependent on many factors such as usage heating etc C Cleaning This indicates the cleaning of a part that can be reused and refers specifically to the door mounted air filters in the liquid cooled drives and some air cooled drives Rv Review This refers to a discussion with Rockwell Automation to determine whether any of the enhancements changes made to the Drive Hardware and Control would be valuable to the application RFB R Refurbishment Replacement The parts can be refurbished at lower cost OR the parts can be replaced with new ones Encoder Usage When is an Encoder Required An encoder is required under the following conditions 1 When speed regulation accuracy must be between 0 01 0 02 of nominal speed 2 When the zero speed breakaway torque needed is greater than 90 of continuous running torque 3 When continuous running speed is greater than or equal
24. 0 2 in of water pressure drop to the PowerFlex 7000 drive air flow system For heat pipe models ensure a minimum top clearance of 600 mm 24 in above fan exhaust openings The control room must provide slightly more make up air creating a pressurized room This slight pressurization prevents unfiltered air drawing into the room The drive is intended to operate in conditions with no special precautions to minimize the presence of sand or dust but not in close proximity to sand or dust sources IEC 7211 defines this as being less than 0 2 mg m of dust If outside air does not meet this condition filter the air to ASHRAE American Association of Heating Refrigeration and Air Conditioning Engineers Standard 52 2 MERV 11 Minimum Efficiency Reporting Value This filtration eliminates from 65 to 80 of the particulate in Range 2 1 0 3 0 um and 85 of the particulate in Range 3 3 0 10 0 Clean or change filters regularly to ensure proper flow The make up air must be between 2 40 C Relative humidity must be less than 95 non condensing Approximately 10 of drive losses will still be rejected into the control room address this issue as needed to maintain the temperature in the control room within specification Failure to maintain proper flow of cooling air into the control room can result in the drive stopping on low differential pressure across the heat sinks Power Ca bling Access The drive s cabinetry p
25. 2 253mm 5kV 28 5 725 15kV phase or 8kV phase PF7000 A160V 60HZ RPTX 46 430 70 2 70 26 70 27 70 28 9 79x10 97 249x279 2 500MCM 8kV 2 253mm 5 28 5 725 70 29 70 31 15kV phase or 8kV phase 86 Rockwell Automation Publication 7000 7 June 2014 Line amp Load Cable Sizes Appendix PRODUCT INPUT LINE SIDE Bulletin Description Drive Drive Structure Code Drive Enclosure Opening Max Size amp No Incoming Size amp No Vertical Space V Freq Rect rating A Inches mm Cables Incoming Cables Avail for NEMA 2 4 5 6 8 9 1 2 45 6 8 9 Stress Cones Inches mm PF7000 4160V 60Hz RPTX E495 E625 70 32 11 81516 22 300x412 1 2 500MCM 5kV 2 253mm 5kV 16 5 421 G285 G325 or 8kV phase or 8kV phase B Frame 0 Air PF7000 6600V 50Hz RPTX 40 285 70 11 70 28 9 79x10 97 249 279 2 500 2 127mm 5kVor 28 5 725 Cooled 70 30 70 31 15kV phase 8kV phase cont d PF7000 6600V 50Hz RPTX E325 E575 70 36 70 37 12 79x19 68 325x500 2 500MCM 8kV 2 253mm 8kV 16 5 421 G215 G250 or 15kV phase or 15kV phase N625 PF7000 2400V 60Hz RP18TX 7 46 430 70 8 9 79x21 06 249x535 1 2 500MCM 5kV or 8kV 2 253mm 5kVor 17 7 449 sec Winding 8
26. Static control precautions are required when installing testing servicing or repairing this assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures refer to Allen Bradley publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook ATTENTION This drive contains ESD Electrostatic Discharge sensitive parts damage or a reduction in product life Wiring or application errors such as undersizing the motor incorrect or inadequate AC supply or excessive ambient temperatures may result in malfunction of the system ATTENTION An incorrectly applied or installed drive can result in component 8 Rockwell Automation Publication 7000 7 June 2014 Important User Information Chapter 1 ATTENTION Only personnel familiar with the PowerFlex 7000 Adjustable N Speed Drive ASD and associated machinery should plan or implement the installation start up and subsequent maintenance of the system Failure to comply may result in personal injury and or equipment damage Commissioning Support After installation Rockwell Automation Medium Voltage Support is responsible for commissioning support and activities in the PowerFlex 7000 product line Phone 519 740 4790 Option 1 for technical and option 4 for commissioning questions MVSupport_technical ra rockwell com or MVSupport_services ra roc
27. Stress Number of Rectifier Devices per phase Voltage AFE 18 Pulse 2400V 2 6 3300V 4 6 4160V 4 6 6600V 6 6 Output Current THD 15 497 596 Output Waveform to Motor Sinusoidal Current Voltage Medium Voltage Isolation Fiber Optic Modulation techniques Selective Harmonic Elimination SHE Synchronous Trapezoidal PWM Asynchronous or Synchronous SVM Space Vector Modulation Control Method Digital Sensorless Direct Vector Full Vector Control with Encoder Feedback Optional Tuning Method Auto Tuning via Setup Wizard Speed Regulator Bandwidth 1 10 rad s with standard control 1 20 rad s with HPTC optional Torque Regulator Bandwidth 15 50 rad s with standard control 80 100 rad s with HPTC optional Torque Accuracy with HPTC optional 5 0 196 without Encoder Feedback Speed Regulation 0 01 0 02 with Encoder Feedback Acceleration Deceleration Range Independent Accel Decel 4 x 30 s Acceleration Deceleration Ramp 4x Independent Accel Decel Rates S Ramp Rate Independent Accel Decel 2 x 999 s Critical Speed Avoidance 3 x Independent with Adjustable bandwidth Stall Protection Adjustable time delay 92 Rockwell Automation Publication 7000 7 June 2014 Specifications Appendix D Table 16 General Design Specifications Continued Description Load Loss Detection Adjustable level delay speed set points Control
28. diagrams provided with the equipment to assist in determining the points to disconnect Voltage Sensing Boards VSB Output Grounding Network Voltage Sensing Boards a Remove all ground connections from all of the VSBs in the drive Do this at the screw terminals on the VSB rather than the ground bus There are two grounds on each board marked GND 1 and GND 2 Note It is important to disconnect the terminals on the boards rather than from the ground bus as the grounding cable is only rated for 600V Injecting a high voltage on the ground cable will degrade the cable insulation Do not disconnect the white medium voltage wires from the VSBs They must be included in the test The number of VSBs installed in each drive varies depending on the drive configuration 80 Rockwell Automation Publication 7000 7 June 2014 Meggering Appendix B Output Grounding Network b Remove the ground connection on the OGN if installed Lift this connection at the OGN capacitor rather than the grounding bus as the grounding cable is only rated for 600V Note Injectinga high voltage on the ground cable during a Megger test will degrade the cable insulation 3 Disconnect connections between power circuit and low voltage control Voltage Sensing Boards The connections between the low voltage control and the power circuit are made through ribbon cable connectors The cables are plugged into con
29. the connector cable pair if you cannot make a ground connection through the mounting bracket machine ground DO NOT ground the encoder case through both the machine and cable wiring Use low capacitance wires lt 40 pF ft with 100 shield coverage for long cable runs and connect the shield only at the drive end Figure 51 Detail power terminal dimensions Drive Encoder wi 1 p Nr oe oe x Wrong Shield Pr Connection For more protection against electrical noise specify an encoder with complementary outputs and connect with twisted pair cable With this type of cabling the induced currents will self cancel Asa final precaution ground the shield together with all other parts of the system that require grounding to a single point ground This reduces varying ground potentials caused by high current fluxes from motors remote control switches and magnetic fields Signal Distortion The primary causes of signal distortion are cable length and capacitance The longer the cable the greater chance of signal distortion at the receiving end The receiving end responds to either a logical 0 or a logical 1 Anywhere in between is undefined and the transition through this region should be lt 1 0 us If the leading edge of the waveform is distorted it causes the transition time through this region to increase At some point the receiver can become
30. the dimension drawings and move the sections together Join the enclosure s side sheets with thread forming screws using the available holes Complete ground bus power and control connections as directed in the electrical diagrams and this installation guide Rockwell Automation Publication 7000 7 June 2014 Drive Installation Chapter 3 1 Attach choke section to main section of the drive Figure 32 Main and choke sections of 3300 4160V heat pipe drive cabinetry io eo P gr 12 Jol T3 Main Section of Heat Pipe Drive Choke Cabinet Figure 33 Main and choke sections of 6600V heat pipe drive cabinetry
31. unstable and either gain or lose encoder counts Rockwell Automation Publication 7000 7 June 2014 59 Chapter3 Drive Installation To reduce the effects of signal distortion at the encoder receiving electronics consider the following guidelines 1 Use alow capacitance cable lt 120 pF m 40 pF ft For example Belden 1529 A is an 18Awg 3pair cable having a capacitance of 114 pF m 35 pE ft 2 Use twisted pair cabling with a shield that covers 100 of the cable This is especially true in the case of quadrature encoders It is still a better choice for absolute encoders although the data in these encoders will not exhibit the same frequency spectrum as quadrature encoders and you can use single wire cabling In either case always check with the encoder manufacturer for the recommended cable 3 Keep cable distances as short as possible Rockwell Automation recommends the following cable lengths a For the 20B ENC encoders maximum cable length is 65 m 200 ft Longer cable distances could cause excessive surge currents The operating frequency of the encoder has no bearing on this recommended distance due to the AC Termination However keeping the frequency such that the cable s characteristic impedance is 348 Q improves the surge currents and may increase the maximum distance to 100 m 330 ft b For the Universal Encoder Interface maximum length is 200 m 650 ft 100 KHz or to 500 m 1600 f
32. w close coupled starter PF7000 6600V 50HZ RPDTD 46 285 70 46 70 47 70 48 70 49 9 79x10 97 249x279 2 500MCM 8kV 2 253mm 8 28 5 725 15kV phase or 15kV phase PF7000 6600V 50Hz RPDTD E325 70 34 70 35 12 79x19 68 325 500 2 500MCM 2 253mm 8kV 16 5 421 5575 15kV phase 15kV phase 6215 6250 25 PF7000 6600V 50Hz RPDTD 40 285 70 46C 70 47 70 49C 5 61x7 19 142x183 500MCM 8kV or 1 253mm 8 34 4 874 w close coupled starter 15kV phase or 15kV phase PF7000 6600V 6OHz RPDTD 40 285 70 46 70 47 70 48 70 49 9 79x10 97 249x279 2 500MCM 8kVor 2 253mm 5kV 28 5 725 15kV phase or 8kV phase PF7000 6600V 60Hz RPDTD 40 285 70 46C 70 47 70 49C 5 61x7 19 142x183 500MCM 8kV 1 253mm 5kV 34 4 874 w close coupled starter 15kV phase or 8kV phase PF7000 2400V 6OHz RPTX 46 430 70 1 70 2 70 25 70 26 9 79x10 97 249x279 1 2 500 5kV 2 253mm 5 28 5 725 8kV phase or 8kV phase PF7000 3300V SOHz RPTX 46 430 70 10 70 27 70 28 70 30 9 79x10 97 249x279 2 500MCM 8kV 2 253mm 5kV 28 5 725 15kV phase or 8kV phase PF7000 3300V 50Hz RPTX E495 70 32 11 81 16 22 300x412 2 500 5kV 2 253mm 5 16 5 421 E625 or 8kV phase or 8kV phase G285 6325 N720 PF7000 4160V 50Hz RPTX 46 430 70 10 70 27 70 29 70 30 9 79x10 97 249x279 2 500MCM 8kVor
33. 0 1024 2048 1500 1024 2048 1200 2048 2048 1000 2048 2048 900 2048 4096 720 4096 4096 600 4096 4096 450 4096 8192 360 8192 8192 300 8192 8192 Rockwell Automation Publication 7000 7 June 2014 75 AppendixA General Reference PowerFlex 7000 Drive Performance Torque Capabilities 76 Table 12 Encoder Selection Continued Standard Control Mode 3600 600 3000 600 1800 m 1024 1500 1024 1200 m 2048 1000 m 2048 900 2048 720 2048 600 2048 The PowerFlex 7000 drives have been tested on a dynamometer to verify performance under locked rotor accelerating and low speed high torque conditions Table 13 shows the PowerFlex 7000 drive torque capabilities as a percent of motor rated torque independent of the drive s momentary overload conditions Table 13 PowerFlex 7000 Drive Torque Capabilities Parameter 7000 Torque Capability 7000 Torque Capability 7000 Torque Capability with without Encoder of with Encoder of Encoder and High Performance Motor Rated Torque Motor Rated Torque Torque Control HPTC Breakaway Torque 90 150 150 90 0 8 Hz 140 0 8 Hz Accelerating Torque 150 0 75 Hz 125 9 75 Hz 140 9 75 Hz 100 1 2 Hz Steady State Torque 125 9 75 Hz 150 0 60 Hz D 140 3 60 Hz Max Torque Limit 150 150 1 Drive will require over sizing t
34. 00 Heavy Yes BLOWERS centrifugal Damper dosed VT 30 50 40 Normal No Damper opened VT 40 110 100 Normal No CHIPPER W00D 50 40 200 Contact factory No starting empty COMPRESSORS Axial vane loaded 40 100 100 Normal No Reciprocating starting 100 100 100 Contact factory Yes unloaded CONVEYORS Armored face CT 175 150 200 Contact factory Yes Belt type loaded CT 150 130 100 Heavy Yes Drag type CT 175 150 100 Contact factory Yes Screw type loaded CT 200 100 100 Contact factory Yes DRAG LINE T 100 200 200 Contact factory Yes Rockwell Automation Publication 7000 7 June 2014 77 Appendix A General Reference Table 15 Typical Application Load Torque Profiles Continued Application Load Torque Load Torque as Percent of Full Load Drive Torque Required Drive Encoder Required for Profile 1 i Service Duty Rating Extra Starting Break away Accelerating Peak Running Torque EXTRUDERS CT 150 150 100 Contact factory Yes rubber or plastic FANS centrifugal ambient Damper closed VT 25 60 50 Normal No Damper open VT 25 110 100 Normal No FANS centrifugal hot gases Damper closed VT 25 60 100 Normal No Damper open VT 25 200 175 Contact factory No FANS VT 40 110 100 Normal No propeller axial flow GRINDING MILL CT 175 180 100 Contact factory Yes Ball Sag Mill HOISTS
35. 7000A 6600 50Hz RPTX 40 105 718 4 00x8 00 102x204 1 1 350 1 177mm 33 8 860 15 kV phase 15 kV phase PF7000A 2400V 60Hz RPTXI 46 160 713 4 00x4 00 102x102 1 350MCM 1 177mm 5kV 20 0 508 8kVor15kV phase or8kV phase PF7000A 3300V 50Hz RPTXI 46 160 713 4 00x4 00 102x102 1 350MCM 1 177mm 5kV 20 0 508 8kVor15kV phase or8kV phase PF7000A 4160V 50Hz RPTXI 46 140 713 4 00 4 00 102x102 1 350MCM 1 177mm 5 kV 20 0 508 3 8kVor15kV phase or8kV phase PF7000A 4160V 60Hz RPTXI 46 160 713 4 00x4 00 102x102 1 350MCM 1 177mm 5kV 20 0 508 8kVor15kV phase or8kV phase PF7000A 6600V 50Hz RPTXI 40 105 71 6 71 15 4 00 4 00 102 102 1 4 0 8 kV or 1 177mm 8kV 20 0 508 15 kV phase or 15 kV phase Rockwell Automation Publication 7000 INOO7E EN P June 2014 85 AppendixC line amp Load Cable Sizes PRODUCT INPUT LINE SIDE Bulletin Description Drive Drive Structure Code Drive Enclosure Opening Max Size amp No Incoming amp Vertical Space V Freq Rect rating A Inches mm Cables Incoming Cables Avail for NEMA 2 4 5 6 8 9 1 2 45 6 8 9 Stress Cones Inches mm o Y F PF7000 2400V 60Hz RPDTD 46 430 70 40 70 41 70 44 70 45 9 79x10 97 249x279 2 500MCM 5kV 2 253mm 5kV 28 5 725 8kV phase or 8kV phase PF7000 2400V 60Hz RPDTD 46 375 70 40C 70 41C 70 44C 5 61x7 19 142x183
36. 79x21 06 249x535 1 2 500MCM 2 177mm 17 7 449 70 55 L L 70 58 1 1 15 kV s Winding 15 kV s Winding PF7000L 6600V 60Hz R18TX 375 657 70 50 L A 70 53 L A 9 79x21 06 249x535 1 2 500MCM 2 177mm 17 7 449 70 55 1 1 70 58 1 1 15 kV s Winding 15 kV s Winding Notes This data is normative only do not base final design criteria solely on this data Follow national and local installation codes industry best practices and cable manufacturer recommendations 1 Some A Frames most B Frames and all C Frames have a single enclosure opening provision for both line and load cables designated by 1 Most A Frames and some B Frames have separate opening provisions for line and load cables All cabling capacities shown in this table are worst case conditions when both line and load cabling enters and exits in the same direction 2 Cable sizes are based on overall dimensions of compact stranded three conductor shielded cable common for industrial cable tray installations Maximum sizing stated accounts for minimum rated cable insulation requirements and the next higher rated cable i e 8 kV is not commercially available in many areas of the world therefore Rockwell Automation provides an 8 kV minimum rating as well as a 15 kV rating when applicable Enclosure openings will accommodate the thicker insulation on the higher rated cable IEC ratings show the equivalent to the NEMA sizes The exact cable mm
37. A 6600 50Hz RPTX 40 105 718 4 00x8 00 102x204 1 1 350MCM 177mm 33 8 860 15 kV phase 15 kV phase PF7000A 2400V 60Hz RPTXI 46 160 713 4 00 4 00 102x102 1 350MCM 177mm 5 kV 20 6 524 8 kV 15 kV phase 8kV phase PF7000A 3300V 50Hz RPTXI 46 160 713 4 00 4 00 102x102 1 350MCM 177mm 5 kV or 20 6 524 3 8 15 kV phase 8 kV phase PF7000A 4160V 50Hz RPTXI 46 140 713 4 00 4 00 102x102 1 350MCM 177mm 5 kV or 20 6 524 3 8 15 kV phase 8 kV phase PF7000A 4160V 60Hz RPTXI 46 160 713 4 00 4 00 102x102 1 350MCM 177mm 5 kV or 20 6 524 3 8kV 15 kV phase 8 kV phase PF7000A 6600V 50Hz RPTXI 40 105 71 6 71 15 4 00x4 00 102x102 1 4 0 8 kV or 177mm 8 kV or 20 6 524 3 15 kV phase 15 kV phase PF7000 2400V 60Hz RPDTD 46 430 70 40 70 41 9 79x10 97 249x279 1 2 500 5KV or 2 253mm75kV 28 5 725 70 44 70 45 8kV phase 8kV phase PF7000 2400V 60Hz RPDTD 46 375 70 40C 70 41C 70 44C w 6 52 9 88 168x251 500MCM 5kV or 1 253mm 5kVor 16 2 411 close coupled starter 8kV phase OR 8kV phase OR 2 B Frame 2 250 5kV 127mm 5 or Air 8kV phase 8kV phase Cooled 3300V 50Hz RPDTD 46 430 70 43 70 44 9 79x10 97 249x279 1 2 500 5kVor 2 253mm 5kV 28 5 725 70 45 70 47 8kV phase 8kV phase PF7000 3300V 50Hz RPDTD E495 E625 70 32 11 81x16 22 300x412 2 500 SkV 2 253mm 5kV 16 9 430 0285 0325 8kV pha
38. Based on our experiences in drive systems the highest probability for the source of the fault exists in either the input or output zones The drive itself rarely has been a source of a ground fault when it is properly installed This is not to say there will never be any ground fault problems associated with the drive but the chances are the fault is outside of the drive Also the procedure for meggering the drive is more complex than meggering outside the drive With these two factors it is recommended to first megger the input and output zones when encountering a ground fault If the location of the ground fault can not be located outside the drive the drive will need to be meggered This procedure must be performed with due care as the hazards to drive exist if the safety precautions in the procedure are not followed This is due to the fact the megger procedure applies high voltage to ground all the control boards in the drive have been grounded and if not isolated they will have high potential applied to them causing immediate damage Meggering the PowerFlex 7000 is potentially hazardous and may cause severe burns injury or death Where ATTENTION Use caution when performing Megger test High voltage testing appropriate connect the test equipment to ground Ensure you check the insulation levels before energizing power equipment Megger tests provide a resistance measurement from the phase to phase and phase to ground by apply
39. CT 100 200 200 Contact factory Yes KILNS rotary loaded 250 125 125 Contact factory Yes MIXERS Chemical CT 175 75 100 Contact factory Yes Liquid T 100 100 100 Heavy Yes Slurry CT 150 125 100 Heavy Yes Solids CT 175 125 175 Contact factory Yes PULPER VT 40 100 150 Contact factory No PUMPS Centrifugal discharge open VT 40 100 100 Normal No Oil field Flywheel T 150 200 200 Contact Factory Yes Propeller VT 40 100 100 Normal No Fan Pump VT 40 100 100 Norma No Reciprocating Positive CT 175 30 175 Contact factory Yes Displacement Screw type started dry VT 75 30 100 Normal No Screw type primed discharge CT 150 100 1000 Heavy Yes open Slurry handling discharge CT 150 100 100 Heavy Yes open Turbine Centrifugal deep 50 100 100 Normal No well Vane type positive CT 150 150 175 Contact factory Yes displacement SEPARATORS AIR VT 40 100 100 Normal No fan type 1 PowerFlex 7000 Frame suitable only for normal service duty rating 78 Rockwell Automation Publication 7000 7 June 2014 Drive Meggering Appendix B Meggering When a ground fault occurs there are three zones in which the problem may appear input to the drive the drive output to the motor The ground fault condition indicates a phase conductor has found a path to ground Depending on the resistance of the path to ground a current with magnitude ranging from leakage to fault level exists
40. D There is also a service access port RJ 45 connector on the LV door No HMI supplied A service access port RJ 45 connector is located on the LV door of the VFD Customers use their own laptop as the HMI All programs required to use the laptop as the are stored in the VFD Their laptop is connected to the VFD via a hardwired Ethernet cable when required This is ideal for unmanned sites where a dedicated is not required See Publication 7000 UM201_ for detailed instruction for the HMI Interface Board Rockwell Automation Publication 7000 7 June 2014 Safety and Codes Transporting and Siting the Drive Cabinet Layout and Dimensional Drawings of Drive Chapter 3 Drive Installation This section details the processes for connecting cabinets and installing physical components such as fan hoods as well as installing cabling grounding and interlocking the unit s Refer to the Transportation amp Handling Guide for PowerFlex 7000 Medium Voltage Drives for details regarding siting and leveling drive cabinetry before continuing with the remaining installation tasks Z000 IN008_ EN P Where appropriate separate diagrams and instructions are available for both the heat sink and the heat pipe B Frame models Assume any B Frame diagram not specifically identified as a heat pipe model represents a heat sink model electrical equipment Installation must comply with specifications r
41. Effect Sensors Grounding Network For use with Isolation Transformer or Ground Filter Sensing Boards For use with Line reactor Line Terminals Motor Terminals Motor Filter Capacitors Current Transformers Surge Arresters 22 Rockwell Automation Publication 7000 7 June 2014 Drive Installation Chapter 3 Figure 17 Cabling cabinet for AFE rectifier heat pipe model 0 0 P 0 0 Grounding Network For use 2 with Isolation Transformer ee 1 nee 2 9 Ground Filter For use with Line Reactor Surge Arresters NO L Motor Terminals 3 TL PA _ 21 Hall Effect Current Sensors B aud s Voltage Sensing Boards in hee I E 48 n 5 H Line Terminals E n Current Transformers Zero Sequence Current transformer 8 4 see
42. Installation Instructions Allen Bradley PowerFlex 7000 Medium Voltage AC Drive Air Cooled B Frame ForGe Control Publication 7000 INO07E EN P Allen Bradley Rockwell Software Automation Important User Information Read this document and the documents listed in the additional resources section about installation configuration and operation of this equipment before you install configure operate or maintain this product Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes laws and standards Activities including installation adjustments putting into service use assembly disassembly and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice If this equipment is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwe
43. M6 thread forming screws d Quantity 20 Locate the exhaust hood on top of the cabinet as show in Figure 43 and re install the original cover plate previously set aside Align the notches on the bottom flange toward the sides of the drive Affix the assembly to the drive top plate and tighten all hardware Rockwell Automation Publication 7000 7 June 2014 47 Chapter 3 48 Drive Installation For drives with an acoustic hood shown in Figure 41 locate the exhaust hood refer to Figure 43 ATTENTION Ensure you retrieve any screws that accidentally fall into the equipment to avoid potential damage or injury Figure 42 Fan hood installation Assembled Exhaust Hood 6 Screw Quantity 12 Ensure notch orientation to sides Rockwell Automation Publication 7000 7 June 2014 Drive Installation Chapter 3 Figure 43 Acoustic fan hood installation Assembled Acoustic Exhaust Hood Top Plate for Converter and Common Mode Choke DC Link Cabinet Remove Existing Screw and reinsert with Hood Quantity 11 Installation of Redundant Fan Assembly Redundant Fan components are shipped already assembled Figure 44 Figure 44 Redundant Fan Assembly Redundant Fan Assembly Rockwell Automation Publication 7000 7 June 2014 49 Chapter3 Drive Installation 1 Remove and discard the protective
44. Mode Speed or Torque Current Limit Adjustable in Motoring and Regenerative Output Frequency Range 0 2 75 Hz Standard 75 Hz 85Hz Optional need specific Motor Filter Capacitor MFC Service Duty Rating Normal Duty Heavy Duty 110 Overload for 1 min every 10 150 Overload for 1 min every 10 min min Variable Torque Load Constant Torque Load Typical VFD Efficiency gt 97 5 AFE gt 98 18 Pulse Contact Factory for Guaranteed Efficiency of Specific Drive Rating Input Power Factor AFE Rectifier 0 95 minimum 10 100 Load IEEE 519 Harmonic Guidelines IEEE 519 1992 Compliant VFD Noise Level lt 85 dB A per OSHA Standard 3074 Regenerative Braking Capability Inherent No Additional Hardware or Software Required Flying Start Capability Yes Able to Start into and Control a Spinning Load in Forward or Reverse Direction Operator Interface 10 Color Touchscreen 2711 110 4 9 VAC Built in PDF viewer Redesigned PanelView Plus 6 Logic Module with 512 Mb of memory Languages English French Spanish Portuguese German Chinese Italian Russian and Polish Control Power 220 240V or 110 120V Single phase 50 60 Hz 20 A External 1 0 16 Digital Inputs 16 Digital Outputs External Input Ratings 50 60 Hz AC or DC 120 240V 1mA External Output Ratings 50 60 Hz AC or DC 30 260 Analog Inputs Three Isolated 4
45. Source Inverter CSI for the machine side converter as shown in Figure 6 This topology applies to a wide voltage and power range The power semiconductor switches used are easy to series for any medium voltage level Semiconductor fuses are not required for the power structure due to the current limiting DC link inductor With 6500V PIV rated power semiconductor devices the number of inverter components is minimal For example only six inverter switching devices are required at 2400V 12 at 3300 4160V and 18 at 6600V The PowerFlex 7000 also provides inherent regenerative braking for applications where the load is overhauling the motor e g downhill conveyors etc or where high inertia loads e g fans etc are quickly slowed down The drive uses Symmetrical Gate Commutated Thyristors SGCTs for machine converter switches and Silicon controlled Rectifiers SCRs for 18 Pulse rectifier configurations or SGC Ts for Active Front end AFE rectifier configurations for the line converter switches The PowerFlex 7000 provides a selectable option for enhanced torque control capabilities and increased dynamic control performance This High Performance Torque Control HPTC feature delivers 100 torque at zero speed and provides torque control through zero speed with smooth direction transition Rockwell Automation Publication 7000 7 June 2014 11 Chapter2 PowerFlex 7000 Overview Rectifier Designs Configurat
46. at Four Corners using M10 Bolts x NOTE There is no required order of operations for installing fans and hoods and joining cabinets Joining cabinets first allows roof top access to the upper bolts but these are also accessible from the front if you choose to install the fans first Figure 37 Connecting the cabinets with M10 hardware split drives only 81003 929 M10 Hardware M10 Hardware for Back Bracket 44 Rockwell Automation Publication 7000 7 June 2014 Drive Installation Chapter 3 4 Install top mounted fans Figure 38 3300 4160V heat pipe drive with fans attached C3 CJ a 1 5 H B oj o o e 9 E B H H a L e Je H B 8 8 H 5 H B k e gt JO 5 5 Connect the cables from the choke to M L L bus connections at the top left corner of the choke cabinet Ins
47. ay have to clean dirty drive prior to commencing the Megger test 5 Reconnect connections between power circuit and low voltage control Reconnect the ribbon cables J1 J2 and J3 in all the VSBs Do not cross the cable connections Mixing the feedback cables may result in serious damage to the drive 6 Reconnect the power circuit to the system ground Voltage Sensing Boards a Securely reconnect the two ground conductors on the VSBs The two ground connections on the VSB provide a reference point for the VSB and enable the low voltage signal to be fed to the SCBs If you do not connect the ground conductor the monitored low voltage signal could then rise up to medium voltage potential which is a serious hazard to avoid at all times Always ensure the ground conductors on the VSB are securely connected before applying medium voltage to the drive Failure to connect both ground connections on the voltage sensing board will result in high potential in the low voltage cabinet within the drive that will damage the drive control and possible cause injury or death to personnel Output Grounding Network b Reconnect the ground connection on the OGN capacitor The bolt connection should torque down to 3 4 Nem 30 lbein Exceeding the torque rating of this connection may result in damage to the capacitor Failure to reconnect the OGN ground may result in impressing the neutral voltage offset on the motor cables an
48. cabinet layout for different voltage classes This installation manual does not show SPS boards installed Rockwell Automation Publication 7000 7 June 2014 29 Chapter3 Drive Installation Figure 24 Converter cabinet heat sink model 3300 4160V version shown
49. ce to meet IEEE 519 1992 requirements and other global harmonic standards while still providing a simple robust power structure that maximizes uptime by minimizing the number of discrete components and the number of interconnections required A Common Mode Choke CMC mitigates the common mode voltage seen at the motor terminals so standard non inverter duty rated motors and motor cables can be used making this technology ideal for retrofitting existing motor applications Rockwell Automation Publication 7000 7 June 2014 PowerFlex 7000 Overview Chapter 2 Figure 2 3300 4160V AFE Rectifier Direct to Drive LINE CONVERTER COMMON MODE CHOKE MACHINE CONVERTER 1 Me t x ASGCs Man 16 14 L M AFE Rectifier with Separate Isolation Transformer For applications when the line voltage is higher than the motor voltage a transformer is required for voltage matching In this case providing an AFE rectifier with a separate isolation transformer is ideal The isolation transformer provides the input impedance replaces the requirement for an integral line reactor and addresses the common mode voltage replaces the requirement for a CMC that is supplied in the Direct to Drive rectifier configuration However the AFE rectifier i
50. d stator which may result in equipment damage For drives that did not originally have the OGN connected or even installed this is not a concern Transient Suppression Network c Re install the fuses on the TSN Rockwell Automation Publication 7000 7 June 2014 83 AppendixB Meggering Notes 84 Rockwell Automation Publication 7000 7 June 2014 Line amp Load Cable Sizes Appendix Max Line Cable Sizes PRODUCT INPUT LINE SIDE Bulletin Description Drive Drive Structure Code Drive Enclosure Opening Max Size amp No Incoming Max Size amp No Vertical Space V Freq Rect rating A Inches mm Cables Incoming Cables Avail for NEMA 2 4 5 6 8 9 1 2 45 6 8 9 Inches mm PF7000A 2400V 60Hz RPDTD 46 140 71 9 w starter 4 00x4 00 102x102 1 34 0 5 kV or 1 107mm 5 18 8 478 8 kV phase or 8 kV phase PF7000A 2400V 60Hz RPDTD 46 140 71 13 71 18 w o starter 4 00x4 00 102x102 1 4 0 5 kV or 1 107mm 5 kV 17 1 435 8 kV phase or 8 kV phase PF7000A 3300V S0Hz RPDTD 46 140 71 9 w starter 4 00x4 00 102x102 1 34 0 5 kV or 1 107mm 5kV 18 8 478 8 kV phase or 8 kV phase PF7000A 3300V 5OHz RPDTD 46 140 71 13 71 18 w o starter 4 00x4 00 102x102 1 44 0 5 kV or 1 107mm 5 17 1 435 8 kV phase or 8 kV phase PF7000A 41601 50 2
51. egarding wire type conductor sizes branch circuit protection and disconnect devices Failure to do so may result in personal injury and or equipment damage ATTENTION The CEC NEC or local codes outline provisions for safely installing Follow all guidelines for siting the components before continuing with these installation procedures There may be some variation in the process depending on the type and number of drive components in your particular installation Follow the correct procedures recommended for your particular components and contact your Rockwell Automation sales or service representative if you have any questions during any part of the installation process Generic dimensional drawings for the B Frame drives will be available in a forthcoming PowerFlex 7000 Reference Manual revision Drawings specific to your unit and your installation are available as a package with your unit For additional copies or if you have questions contact your Rockwell Automation sales representative Rockwell Automation Publication 7000 7 June 2014 21 Chapter3 Drive Installation Control Cabling Cabinet The following diagrams illustrate the medium voltage area located in the control cabling cabinet behind the low voltage compartment and with barriers removed Note Heat pipes are only available within AFE rectifier B Frame models Figure 16 Cabling cabinet for AFE rectifier heat sink model Hall
52. el 45 kV 0 1000 m Power Bus Design Copper Tin plated Ground Bus Copper Tin plated 6 x 51 mm 4 x 2 in Customer Control Wire Way Separate and Isolated Input Power Circuit Protection Vacuum Contactor with Fused Isolating Switch or Circuit Breaker Output Voltage 0 2400V 0 3300V 0 4160V 0 6000V 0 6300V 0 6600V Inverter Design PWM Inverter Switch SGCT Inverter Switch Failure Mode Non rupture Non arc Inverter Switch Failure Rate FIT 100 per 1 Billion Hours Operation Inverter Switch Cooling Double Sided Low Thermal Stress Inverter Switching Frequency 420 440 Hz Rockwell Automation Publication 7000 7 June 2014 91 AppendixD Specifications Table 16 General Design Specifications Continued Description Number of Inverter SGCTs Voltage SGCTs per phase 2400V 2 3300V 4 4160V 4 6600V 6 Inverter PIV Rating Voltage PIV each device Total PIV Peak Inverse Voltage 24001 65001 65001 33004 65004 13 000V 4160V 6500V 13 000V 6600V 6500V 19 500V Rectifier Designs Direct to Drive transformerless AFE rectifier AFE with separate isolation transformer 18 Pulse with separate isolation transformer Rectifier Switch SCR 18 Pulse SGCT AFE Rectifier Rectifier Switch Failure Mode Non rupture Non arc Rectifier Switch Failure Rate FIT 50 SGCT 100 SCR per 1 Billion Hours Operation Rectifier Switch Cooling Double Sided Low Thermal
53. ents will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature Medium Voltage Products 135 Dundas Street Cambridge ON N1R 5X1 Canada Tel 1 519 740 4100 Fax 1 519 623 8930 Online www ab com mvb Allen Bradley Rockwell Software Rockwell Automation and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 7000 7 June 2014 Supersedes Publication 7000 IN007D EN P June 2013 Copyright O 2014 Rockwell Automation Inc All rights reserved Printed in Canada
54. for Stress Cones NEMA 26 ip 245 68 Inches mm PF7000 2400V 60Hz RPA8TX 7 46 430 70 8 9 79 21 06 249x535 1 2 500MCM 5kV 2 253mm 5kV 16 4 415 8kV phase 8kV phase PF7000 3300V 50Hz RP18TX7 46 430 70 9 9 79x21 06 249x535 1 2 500MCM 5kV 2 253mm 5kV or 16 4 415 8kV phase 8kV phase PF7000L 4160V 50Hz RPDTD 375 575 70 71 L A 70 72 1 1 70 76 41 2223 62 285x600 1 4 500MCM 4 253mm 5 kV 16 4 415 LA 70 77 L L 70 89 L A 5kVor8kV phase g kV phase 70 94 LL PF7000L 4160V 60Hz RPDTD 375 625 70 71 L A 70 72 1 1 122323 62 285x600 1 4 500MCM 4 253mm 5 kV 16 4 415 70 76 LA 70 77 L L 5kVor8kV phase g kV phase PF7000L 6600V 50Hz RPDTD 325 575 70 80 L A 70 85 1 1 70 86 11 22 23 62 285x600 1 4 500 4 253mm 8 16 4 415 L L 70 87 L L 70 88 L L 8 or 15 kV phase 15 kV phase ee 70 91 L A 70 92 L A 70 93 Frame LA Liquid Cooled PF7000L 6600V 60Hz RPDTD 325 575 70 80 L A 70 85 1 1 70 86 11 22 23 62 285x600 1 4 500 4 253mm 8 16 4 415 L L 70 87 L L 70 88 L L 8 or 15 kV phase 15 kV phase 70 91 L A 70 92 L A 70 93 L A 70 93 L A PF7000L 4160V 50Hz R18TX 375 657 70 50 L A 70 55 1 1 9 79x21 06 249x535 1 2 500 2 253mm25 kV 16 4 415 5kVor8V phase 8 kV phase PF7000L 4160V 60Hz R18TX 375 657 70 50 L A 70 55 1 1 9 79x21 06 249
55. fy the drive is on a level surface and that the position of the drive will be vertical when you install the anchor bolts The drive s dimension drawing will show the location of the provided anchor points Install and tighten the anchor bolts M12 hardware required Engineered bolt systems are mandatory for seismic requirements Consult the factory for further information if necessary Remove the top lifting angles and retain the hardware Install the hardware from the lifting angles in the tapped holes at the top of drive this prevents leakage of cooling air as well as keeping dust out of the equipment Shock Indication Labels Shock indication labels are devices that permanently record the physical shock occurring to the equipment At the time of final preparation for shipment the factory applies a shock indication label that records shock levels in excess of 10G on the inside door of the converter cabinet During the shipping and installation process drives may inadvertently experience excess shock and vibration which may impair its functionality When you have situated the drive in its installation area open the converter door and inspect the shock indication labels If sufficient shock levels occur the chevron shaped window will appear black in one of the two windows Record the shock values There is a greater possibility of the drive having sustained internal damage as the result of physical shock during the shippi
56. garding customer responsibilities prior to commissioning This manual is intended for use by personnel familiar with medium voltage and solid state variable speed drive equipment The manual contains material that enables qualified engineering personnel to install the drive system This manual provides information specific to installing and configuring the PowerFlex 7000 B Frame drive The following topics are covered in other manuals in the next paragraph Physically transporting or siting the drive cabinetry Commissioning specific processes and configuration as managed by a Rockwell Automation commissioning engineer Details concerning the operator interface or configuring drive parameters Dimensional and electrical drawings generated for each customer s order Spare parts lists compiled for each customer s order Troubleshooting potential usage problems Refer to the following documents for additional product detail or instruction relating to PowerFlex 7000 Frame drives Drive specific Technical Specifications Transportation and Handling Procedures receiving and handling instructions for Medium Voltage variable frequency drive and related equipment Installation Guide detailed installation and pre commissioning procedures and information Commissioning Guide required procedures and checklists for Rockwell Automation field service engineers Drive specific User Manual instructions for dail
57. h both a mesh screen and a metal sheath or some form of foil there are two alternative methods Ground the mesh screen at both ends to the metal sheath The metal sheath or foil known as the drain should unless otherwise specified be grounded at one end only again as specified above at the receiver end or the end that is physically closest to the main equipment ground bus or Leave the metal sheath or foil insulated from ground and ground the other conductors and the mesh cable screen at one end only as stated above Specifications for Customers and Power Integrators Attach an external ground to the main ground bus in compliance with applicable local codes and standards As general guidelines che ground path must be of sufficiently low impedance and capacity that e the rise in potential of the drive ground point when subjected to a current of twice the rating of the supply should be no higher than 4V over ground potential and the current flowing into a ground fault will be of sufficient magnitude to cause the protection to operate Run the main grounding conductor s separately from power and signal wiring so that faults do not damage the grounding circuit or will not interfere with or damage protection or metering systems or cause undue disturbance on power lines Electrical Supplies Grounded and Ungrounded Systems When dealing with an ungrounded three phase electrical supply system the cable
58. he drive end only All AC and DC circuits are run in separate conduits All wire sizes used are selected by observing all applicable safety and NEC IEC regulations Remote 1 0 Interface is properly configured active All 3 phase control wiring is within specified levels and has been verified for proper rotation UVW Table 9 Power Wiring Initials Date Check All single phase control wiring is within specified levels and has grounded neutrals The power cable connections to the drive motor and isolation transformer adhere to CEC NEC IEC or appropriate local standards The cable terminations if stress cones are used adhere to the appropriate standards Appropriate cable insulation levels are adhered to as per Rockwell Automation specifications refer to Cable Insulation on page 37 All shields for shielded cables must be grounded at the source end only If shielded cables are spliced the shield must remain continuous and insulated from ground All wire sizes used are selected by observing all applicable safety and NEC IEC regulations 68 Rockwell Automation Publication 7000 7 June 2014 Initials Date Check Pre Commissioning Responsibilities Chapter 4 All power connections are torqued as per Rockwell Automation specifications Refer to Torque Requirements for Threaded Fasteners on page 73 All customer p
59. ilter Media Door Filter Blockage Air Flow Restriction Trip Warning Storage and Transportation 40 709 40 185 F Temperature Range Relative Humidity Max 95 non condensing Altitude Standard 0 1000 m 0 3300 ft Altitude Optional 1001 5000 m 0 16 400 ft Seismic UBC Rating 1 2 3 4 Standards NEMA IEC CSA UL ANSI IEEE 5 Optional 1 Voltage Sag tolerance is reduced to 25 when control power is supplied from medium voltage via CPT 2 MOVs are used for 18 Pulse Surge arrestors are used for AFE Direct to Drive configurations 3 Short circuit fault rating based on input protection device contactor or circuit breaker 4 rating based on altitudes lt 1000 m 3300 ft Refer to factory for derating on altitudes gt 1000 m 6 Under certain conditions power system analysis will be required Rockwell Automation Publication 7000 7 June 2014 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http www rockwellautomation com support you can find technical manuals technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools You can also visit our Knowledgebase at http www rockwellautomation com knowledgebase for FAQs technical information support chat a
60. imum cable size for B Frame two per phase and Frame four per phase is 500 253 mm limited by lug pad assembly size and clearance requirements hs cabling methods can vary widely maximum cable sizes shown do not account for the size of the conduit hub Verify size of conduit hub s against the Drive enclosure openings shown AO Rockwell Automation Publication 7000 IN007E EN P June 2014 87 AppendixC line amp Load Cable Sizes Max Load Cable Sizes PRODUCT OUTPUT MOTOR SIDE Bulletin Description Drive Drive Structure Code Drive Enclosure Opening Max Size amp No Size amp Vertical Space Avail V Freq Rect rating A Inches mm Incoming Cables Incoming Cables for Stress Cones 2 5 68 9 245 689 Inches mm PF7000A 2400V 60Hz RPDTD 46 140 71 9 w starter 4 00 4 00 102x102 1 4 0 5 kV or 107mm 5 kV 18 4 467 8 kV phase 8 kV phase PF7000A 2400V 60Hz RPDTD 46 140 71 13 71 18 w o starter 4 00x4 00 102x102 1 4 0 5 kV or 107mm 5 kV 16 7 424 8 kV phase 8 kV phase PF7000A 3300V 50Hz RPDTD 46 140 71 9 w starter 4 00 4 00 102x102 1 4 0 5 kV or 107mm 5 kV 18 4 467 8 kV phase 8kV phase PF7000A 3300V 50Hz RPDTD 46 140 71 13 71 18 w o starter 4 00x4 00 102x102 1 4 0 5 kV or 107
61. ing a high voltage to the power circuitry Perform this test to detect ground faults without damaging any drive equipment This test involves floating the drive and all connected equipment to a high potential while measuring the leakage current to ground Floating the drive means to temporarily remove any existing paths to ground necessary for normal operation of the drive ATTENTION There are risks of serious or fatal injury to personnel if you do not follow safety guidelines Rockwell Automation Publication 7000 7 June 2014 79 AppendixB Meggering Following this procedure to perform Megger tests on the PowerFlex 7000B Failure to comply with this procedure may result in poor Megger reading and damage to drive control boards Meggering Procedures Required Equipment Torque Wrench and 7 16 in socket Phillips Screwdriver 2500 5000 Megger Procedure 1 Isolate and lock out the drive system from any high voltage source Disconnect any incoming power sources medium voltage sources should be isolated and locked out and all control power sources should be turned off at their respective circuit breaker s Verify with a potential indicator that power sources have been disconnected and that the control power in the drive is de energized 2 Isolate the power circuit from system ground float the drive Remove the grounds on the following components within the drive refer to the electrical
62. insulation rating must handle both the phase to phase voltage and the voltage to ground if one of the other phases develops a ground fault In practice the cable insulation of an ungrounded three phase system must be rated for at least a continuous voltage of root three 1 732 times 1 1 times the rated voltage of the supply 1 732 x 1 1 1 9 times the rated line to line voltage Rockwell Automation Publication 7000 7 June 2014 63 Chapter3 Drive Installation Interlocking 64 Ground Bus The drive ground bus runs along the top of the drive at the front The ground bus is accessible at the top of each of the drive enclosures when you open the enclosure door and the low voltage compartment hinged out in the case of the incomer cabinet Ensure you ground the drive properly typically at the point on the ground bus in the incomer cabinet close to the incoming power terminations Access to the medium voltage areas of the drive is restricted by the use of key interlocking for safety At installation configure the key interlocking to enable access to the medium voltage compartments only when the upstream power is locked in the OFF position Additionally the key interlocking prohibits applying the upstream power until you close and lock shut the medium voltage drive s access doors The key interlocking must be properly installed to the upstream equipment Rockwell Automation Publication 7000 7
63. ions The PowerFlex 7000 offers three rectifier configurations for B Frame drives Direct to Drive Active Front End AFE rectifier with integral line reactor and Common Mode Choke AFE rectifier with separate isolation transformer 18 Pulse with separate isolation transformer Direct to Drive Direct to Drive technology does not require an isolation transformer or multiple rectifier bridges as in Voltage Source Inverter VSI topologies offered by others The approach is completely different Instead of multiple uncontrolled rectifiers a single AFE rectifier bridge is supplied The rectifier semiconductors used are Symmetrical Gate Commutated Thyristors SGCTs Unlike the diodes used in VSI rectifier bridges SGCTs are turn ed on and off by a gating signal A Pulse Width Modulation PWM gating algorithm controls the firing of the rectifier devices very similar to the control philosophy of the inverter The gating algorithm uses a specific 42 pulse switching pattern Figure 1 called Selective Harmonic Elimination SHE to mitigate the Sth 7th and 11th harmonic orders Figure 1 Typical PWM switching pattern line voltage waveform Vine 10 00K Time ms A small integral line reactor and capacitor addresses the high harmonic orders 13th and above and provides virtually sinusoidal voltage and current waveforms back to the distribution system This delivers excellent line side harmonic and power factor performan
64. ired Resources 71 Technical Publications and Manuals 71 Appendix Torque Requirements for Threaded Fasteners 73 Preventative Maintenance 74 Encoder Usage PPM 74 When is an Encoder Required 74 PowerFlex 7000 Drive Performance Torque Capabilities 76 Glossary tope pred de 77 Appendix B Dive Meggering us osa sa aos ati CERE a INS e 79 Meggering the PowerPlex 7000 79 Meggering Procedtites existe ze acne Shae tee es pele 80 Reg uired a etaient 80 Procedure A batons i 80 Appendix C Max Line Cable 51268 85 Load Cable Sizes c fiend ees preted Rv Pel 88 Appendix D Specifications us te 91 Rockwell Automation Publication 7000 1 007 June 2014 Who Should Use This Manual What Is Not in this Manual Rockwell Automation Publication 7000 7 June 2014 Chapter 1 Important User Information This document provides procedural information for installing the PowerFlex 7000 medium voltage B Frame drives heat sink and heat pipe models This document also includes specific information re
65. ive Figure 54 Ground connection diagram with isolation transformer Connected to the neutral point ISOLATION Y ofthe output capacitor TRANSFORMER Figure 55 Ground connection diagram with line reactor Connected to the neutral point AC LINE of the output capacitor REACTOR TRANSFORMER GROUND FILTER GROUND BUS Provide each power feeder from the substation transformer to the drive with properly sized ground cables Using conduit or cable armor as a ground on its own is insufficient Note that if you use a drive isolation transformer do not ground the WYE secondary neutral point Bond each AC motor frame to grounded building steel within 6 m 20 ft of its location and tie it to the drive s ground bus via ground wires within the power cables and or conduit The conduit or cable armor should bond to ground at both ends Rockwell Automation Publication 7000 7 June 2014 Drive Installation Chapter 3 Guidelines for Drive Signal and Safety Grounds When using interface cables carrying signals where the frequency does not exceed 1 MHz for communications with the drive follow these general guidelines Ground screen mesh around the entire circumference rather than forming a pigtail grounded only at one point For coaxial cables with a single conductor surrounded by mesh screen ground the screen at both ends When using a multi layer screened cable that is a cable wit
66. kV sec Winding PF7000 3300V s0Hz RP18TX 7 46 430 70 9 9 79x21 06 249x535 2 500 8kV or 2 253mm 8kV 17 7 449 15kV sec Winding 15kV sec Winding PF7000L 4160V 50Hz RPDTD 375 575 70 71 L A 70 72 1 1 70 76 2223 62 285x600 1 4 500MCM 4 253mm 18 0 457 LA 70 77 L L 70 89 L A 5 or 8 kV phase 5 kV or 8kV phase 70 94 L L PF7000L 4160V 60Hz RPDTD 375 625 70 71 L A 70 72 1 1 70 76 2223 62 285x600 1 4 500MCM 4 253mm 18 0 457 LA 70 77 L L 5 kV or 8 kV phase 5 kV 8 kV phase PF7000L 6600V 50Hz RPDTD 325 575 70 80 L A 70 85 1 1 70 86 11 22 23 62 285x600 1 4 500 4 253mm 18 0 457 L L 70 87 L L 70 88 L L 8 15 kV phase 5kVor8kV phase 70 91 L A 70 92 L A 70 93 Frame Liquid PF7000L 6600V 60Hz RPDTD 325 575 70 80 L A 70 85 1 1 70 86 11 22 23 62 285x600 1 4 500 4 253mm 18 0 457 Cooled L L 70 87 L L 70 88 L L 8kV or 15 kV phase 5 kV or 8 kV phase 70 91 L A 70 92 L A 70 93 L A 70 93 L A PF7000L 4160V 50Hz R18TX 375 657 70 50 L A 70 55 L L 9 79 21 06 249x535 1 2 500 2 253mm2 17 7 449 8 15 kV s Winding 5 kV org kV s Winding PF7000L 4160V 60Hz R18TX 375 657 70 50 L A 70 55 LL 9 79x21 06 249x535 1 2 500 2 253mm 17 7 449 8 15 kV s Winding 5 kV or 8 kV s Winding PF7000L 6600V 50Hz R18TX 375 657 70 50 L A 70 53 L A 9
67. kwell com Rockwell Automation support includes but is not limited to quoting and managing product on site start ups quoting and managing field modification projects quoting and managing customer in house and on site product training Rockwell Automation Publication 7000 7 June 2014 9 Chapter1 Important User Information Notes 10 Rockwell Automation Publication 7000 7 June 2014 Topology Chapter 2 PowerFlex 7000 Overview The PowerFlex 7000 is a general purpose stand alone medium voltage drive that controls speed torque direction starting and stopping of standard asynchronous or synchronous AC motors It works on numerous standard and specialty applications such as fans pumps compressors mixers conveyors kilns fan pumps and test stands in industries such as petrochemical cement mining and metals forest products power generation and water waste water The PowerFlex 7000 meets most common standards from the National Electrical Code NEC International Electrotechnical Commission IEC National Electrical Manufacturers Association NEMA Underwriters Laboratories UL and Canadian Standards Association CSA It is available with the world s most common supply voltages at medium voltage from 2400 6600V The design focus is on high reliability ease of use and lower total cost of ownership The PowerFlex 7000 uses a Pulse Width Modulated PWM Current
68. ll use and troubleshoot the drive line up This section describes how to determine what technical publications are required and how to obtain them in the event that the service binder is not available when pre commissioning or when you require additional information The PowerFlex 7000 Frame Commissioning Manual Publication 7000 13012 EN P This is a Rockwell Automation internal document for commissioning engineers conducting commissioning procedures Customers can request copies of the manual from their local Rockwell Automation Office The PowerFlex 7000 Technical Data publication Use this document for parameter details and programming during commissioning or troubleshooting Refer to 7000 TD002 EN P for the latest firmware revision The PowerFlex 7000 Frame User Manual Publication 7000 UM202 Use this document for general information regarding the usage and programming of the operator interface after installation before or after commissioning Additional Manuals The electrical schematics that ship with the drive should list any additional manual necessary for configuring the drive line up The schematic titled General Notes identifies all required Rockwell Automation publications by publication number Rockwell Automation Publication 7000 7 June 2014 71 Chapter4 Pre Commissioning Responsibilities Notes 72 Rockwell Automation Publication 7000 7
69. ll Automation Inc with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequence P P IMPORTANT Identifies information that is critical for successful application and understanding of the product Labels may also be on or inside the equipment to provide specific precautions SHOCK HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present BURN HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures ARC FLASH HAZARD Labels may be on or inside the equipment for example a motor control center to alert people to potential Arc Flash Arc Flash will cause severe injury o
70. m can result in a gain or loss of encoder data counts quadrature encoders or corrupt positional data absolute encoders This section provides general guidelines and recommended practices for field installed equipment and applies to either encoder board and both quadrature and absolute encoders Protection from Radiated and Conducted Noise Take care when connecting and routing power and signal wiring on a machine or system Radiated noise from nearby relays solenoids transformers non linear loads such as motor drives etc can couple onto signal wires producing undesired pulses The encoder itself may also induce noise into adjacent signal lines Rockwell Automation Publication 7000 7 June 2014 Drive Installation Chapter 3 To avoid radiated and or conducted noise run power and signal lines separately with a minimum distance between them of at least 75 mm 3 in If they must overlap somewhere in the system run the power lines at 90 to the signal lines Signal lines should also use twisted pair shielded cable and run in separate conduit grounded to the building ground Encoder wires and shields should maintain continuity from the encoder to the drive Avoid using a terminal block in a junction box This has the potential of creating radiated noise and ground loops Ground the encoder case to the building ground to insure proper and reliable operation Most encoders provide for a case ground connection through
71. mm 5 16 7 424 8 kV phase 8 kV phase PF7000A 4160V 50Hz RPDTD 46 140 71 9 w starter 4 00 4 00 102x102 1 4 0 5 kV or 107mm 5 kV 18 4 467 8 kV phase 8 kV phase PF7000A 4160V 50Hz RPDTD 46 140 71 13 71 18 w o starter 4 00x4 00 102x102 1 4 0 5 kV or 107mm 5 kV 16 7 424 8 kV phase 8 kV phase PF7000A 4160V 60Hz RPDTD 46 140 71 9 w starter 4 00 4 00 102x102 1 4 0 5 kV or 107mm 5 kV 18 4 467 8 kV phase 8 kV phase PF7000A 4160V 60Hz RPDTD 46 140 71 13 71 18 w o starter 4 00x4 00 102x102 1 4 0 5 kV or 107mm 5 kV or 16 7 424 8 kV phase 8 kV phase PF7000A 6600V 50Hz RPDTD 40 93 71 10 w starter 4 00x4 00 102x102 1 4 0 8 kV or 107mm 8 or 18 4 467 15 kV phase 15 kV phase m PF7000A 6600V 50Hz RPDTD 40 93 71 14 71 19 w o starter 4 00x4 00 102x102 1 350MCM 177mm 8kV or 20 6 524 8kV 15 kV phase 15 kV phase Cooled PF7000A 2400V 60Hz RPTX 46 160 717 4 00x8 00 102x204 1 1 350MCM 177mm 5 kV or 33 8 860 8kV or 15 kV phase 8 kV phase PF7000A 3300V 50Hz RPTX 46 160 717 4 008 00 102x204 1 1 350 177mm 8 kV 33 8 860 8kV or 15 kV phase 15 kV phase PF7000A 4160 50Hz RPTX 46 160 717 4 00 8 00 102x204 1 350 177mm 8 kV or 33 8 860 8 15 kV phase 15 kV phase PF7000A 4160 60Hz RPTX 46 160 717 4 00 8 00 102x204 1 350MCM 177mm 8 kV 33 8 860 8kV or 15 kV phase 15 kV phase PF7000
72. nals Low Voltage Door Rockwell Automation Publication 7000 7 June 2014 Drive Installation Chapter 3 Power Connection Ensure that interlocking with the upstream power source is installed and functioning correctly Verify that all equipment power connections meet with local electrical codes The drive provides for cable lugs The following table details the power terminals Table 4 Incoming Connections Drives with AFE Rectifiers 2U 2V Secondary d0 2U 2V 2W Secondary d 20 30 Secondary d 20 4U 4V 4W Motor Connections U V W Power Cabling Installation Requirements The following drawings illustrate a front view of the 900 mm input cabinet for AFE drives typical line cable termination assemblies 18 Pulse Rockwell Automation Publication 7000 7 June 2014 55 Chapter3 Drive Installation Figure 49 Front View of 900 mm Control Cabling Cabinet AFE heat pipe model V 10 1V 1W
73. ncoder Belden 9460 A wire tray is not suitable PLC Belden 9463 Communications The minimum spacing between conduits containing different wire groups is 76 2 mm 38 1 Belden 8760 18 AWG twisted pair shielded Belden 8770 18 AWG 3 conductor shielded Belden 9460 18 AWG twisted pair shielded Belden 9463 24 AWG twisted pair shielded 2 You may use steel conduit or cable tray for all PowerFlex 7000 Drive power or control wiring and steel conduit is mandatory for all PowerFlex 7000 Drive signal wiring Bring all input and output power wiring control wiring or conduit through the drive conduit entry holes of the enclosure Use appropriate connectors to maintain the environmental rating of the enclosure The steel conduit is MANDATORY for all control and signal circuits when installing the drive in European Union countries The connection of the conduit to the enclosure shall be on full 360 and the ground bond at the junction Shall be less than 0 1 In EU countries this is a usual practice to install the control and signal wiring 3 Spacing between wire groups is the recommended minimum for parallel runs of 61 m 200 ft or less 4 The customer is responsible for the grounding of shields On drives shipped after November 28 02 the shields are removed from the drive boards On drives shipped prior to November 28 02 all shields are connected at the drive end and you must remove these connections before g
74. nd forums software updates and to sign up for product notification updates For an additional level of technical phone support for installation configuration and troubleshooting we offer TechConnect support programs For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com support Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwellautomation com rockwellautomation support overview page or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comm
75. nectors on the voltage sensing board marked J1 J2 J3 and terminate on the signal conditioning boards Every ribbon cable connection made on the VSBs should be marked for identification from the factory a Confirm the marking matches the connections and disconnect the ribbon cables and move them clear of the VSB If you do not remove these ribbon cables from the VSB then high potential applies directly to the low voltage control through the SCBs causing immediate damage to those boards Note The VSB ribbon cable insulation is not rated for the potential applied during a Megger test You must disconnect the ribbon cables at the VSB rather than the SCB to avoid exposing the ribbon cables to high potential Potential Transformer Fuses A Megger test may exceed the rating of potential transformer fusing Removing the primary fuses from all potential and control power transformers in the system not only protects them from damage but removes a path from the power circuit back to the drive control Transient Suppression Network A path to ground exists through the TSN network as it has a ground connection to dissipate high energy surges in normal operation If this ground connection is not isolated the Megger test will indicate a high leakage current reading through this path falsely indicating a problem in the drive To isolate this ground path all fuses on the TSN must be removed before proceeding with the Megge
76. ng and installation process Rockwell Automation Publication 7000 7 June 2014 39 Chapter3 Drive Installation Joining Shipping Splits 3300 4160V and 6600V Heat Pipe Model 40 Even if the shock indicators are clear perform a full equipment inspection and verification Refer to Pre Commissioning Responsibilities on page 65 for details on the inspection and verification process Figure 31 Shock Indicator Red Plastic Housing i 22 51 mm QQ Window Area appears black lt 2 0 if subjected to shock o 21 0 8 IMPORTANT Refer to publication 7000 008 EN P for details regarding moving and siting the drive before continuing with these installation procedures The 3300 4160 and 6600V heat pipe drives are the B Frame models that ship in multiple sections two for 3300 4160V and three for 6600V All other Frame models ship as a single unit For the 3300 4160V heat pipe model the choke section ships separately from main section of the drive Figure 32 For the 6600V heat pipe model the choke cabinet and the line reactor section ship separately from the main section of the drive Figure 33 the drive Use metal shims if necessary to level the cabinets before joining ATTENTION Install the drive a level surface 1 mm over the length of them attempting to level after joining may result in twisting the cabinets Arrange the sections as directed in
77. o achieve greater than 100 continuous torque Rockwell Automation Publication 7000 7 June 2014 15096 Glossary of Terms General Reference Appendix A Breakaway Torque Torque required to start a machine from standstill Accelerating Torque Torque required to accelerate a load to a given speed in a certain period of time The following formula may be used to calculate the average torque to accelerate a known inertia WK T WK x change in RPM 308t where T acceleration torque in Nem Ibeft W force kgf 1b gyration radius m ft Wk total system inertia kg fx m Ibeft that the motor must accelerate including motor gear box and load e t time s to accelerate total system load Steady State Torque Continuous operating torque required to control the load without instability Torque Limit An electronic method of limiting the maximum torque available from the motor The software in a drive typically sets the torque limit to 150 of motor rated torque Table 14 Typical Application Load Torque Profiles Table 15 Typical Application Load Torque Profiles qm Application Load Torque Load Torque as Percent of Full Load Drive Torque Required Drive Encoder Required for Break away Accelerating Peak Running mae AGITATORS Liquid CT 100 100 100 Heavy Yes Slurry T 150 100 1
78. ottom cable entry 18 Pulse 4 hole insulator Lug pad shown with bottom cable entry orientation Bolts M10 bus connection hardware Customer supplied lugs 4 lugs per phase maximum For top line cable entry remove the lug pads and re orient them as shown in Figure 53 To remove the lug pads disconnect the M10 bus connection hardware 17 mm hex tooling required Remove the two bolts that secure the lug pad to the 4 hole insulator Refer to Torque Requirements for Threaded Fasteners on page 73 for more information regarding these electrical connections Figure 53 Typical Line Cable Terminal Assembly modified for top cable entry 18 Pulse Lug pad oriented for top cable entry Rockwell Automation Publication 7000 7 June 2014 61 Chapter3 Drive Installation Grounding Practices 62 Grounding increases personnel safety limits dangerous voltages on exposed parts with respect to ground facilitates proper over current device operation under ground fault conditions and provides electrical interference suppression Generally all external equipment grounding should meet the Canadian Electrical Code CEC C22 1 or the NEC NFPA 70 and applicable local codes Refer to the following diagrams for ground connections Do not connect the drives main ground bus to the system ground This ground bus is the common ground point for all grounds internal to the dr
79. ower cabling has been meggered or hi pot tested before connecting to drive system Table 10 Drive Line up Status Initials Date Check Power wiring phase rotation has been verified per the specific electrical diagrams supplied by Rockwell Automation The medium voltage and low voltage power is available for startup activities The motor is uncoupled from the driven load The load is available for full load testing Rockwell Automation Publication 7000 7 June 2014 69 Chapter4 Pre Commissioning Responsibilities Notes 70 Rockwell Automation Publication 7000 7 June 2014 Additional Required Resources Technical Publications and Manuals Pre Commissioning Responsibilities Chapter 4 Prior to scheduling your drive commission ensure you have the following Self powered gate driver board test power cable wire harness Part no 80018 298 51 supplied with SCR rectifier drives only Rockwell Automation electrical and mechanical diagrams for each drive PLC program if supplied with a PLC Commissioning data sheets All required manuals see below for list If any of the above information is not available prior to the time of commissioning please contact the factory Each drive ships with a service binder containing all technical publications required to insta
80. pads are available for each connection The lug pad and enclosure can generally accommodate two cables per connection 18 cables in total applies to all p and C configurations 8 Maximum cable size for B Frame two per phase and C Frame four per phase is 500 MCM 253 mm limited by lug pad assembly size and clearance requirements 9 As cabling methods vary widely maximum cable sizes shown do not account for the size of the conduit hub Verify size of conduit hub s against the Drive enclosure openings shown 90 Rockwell Automation Publication 7000 7 June 2014 Appendix D Specifications generic manual specifications and those included with your specific design or ATTENTION In the event of discrepancies between information published in electrical drawings take the DD or EE ratings as correct values Specifications Table 16 General Design Specifications Description Motor Type Induction or Synchronous Input Voltage Rating 2400V 3300V 4160V 6600V Input Voltage Tolerance 10 of Nominal Voltage Sag 30 Control Power Loss Ride through 5 Cycles Std gt 5 Cycles Optional UPS Input Protection Surge Arrestors AFE Direct to Drive Metal Oxide Varistor MOV 18 Pulse Input Frequency 50 60 Hz 0 2 Power Bus Input Short circuit 25 kA RMS SYM 5 Cycle Current Withstand 2400 6600V Basic Impulse Lev
81. plate and associated hardware covering the fan opening on the cabinet 2 Remove the top cover of the fan housing and set aside 3 Remove the shipping cover plate on the bottom of the redundant fan assembly and discard Position the assembly over the opening verifying the locating hole on the housing base aligns with the front right side of the cabinet 5 Align the mounting holes and wire harness connections Figure 45 Redundant Fan Assembly Orientation icc Remove cover to install housing M6 Screw x12 6 Affix the redundant fan assembly to the drive top plate with the M6 thread forming screws provided 7 Connect the fan wire harness to fan 8 Reinstall the top cover onto the fan housing and tighten all hardware External Ducting The PowerFlex 7000 design conducts exhaust air outside of the control room requiring special consideration for conditions present in the atmosphere outside the control room ATTENTION If the drive configuration includes multiple exhaust outlets duct each outlet separately to prevent back feeding hot exhaust into the drive 50 Rockwell Automation Publication 7000 7 June 2014 Drive Installation Chapter 3 The following requirements are mandatory for systems that will externally duct the exhaust air and draw cleansed outside air External ducting including an external filtering system must not add more than 50 Pa
82. r death Wear proper Personal Protective Equipment PPE Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment PPE Allen Bradley Rockwell Software Rockwell Automation and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies New and Updated Information This manual contains new and updated information Summary of Changes This table contains the changes made to this revision Topic Page Replace Tachometer with Encoder Throughout Added HPTC information to Topology section 1 Updated When is an Encoder Required section and table 74 Replaced Encoder Selection table 55 Added information to Drive Torque Capabilities table 16 Updated Typical Application Load Torque Profiles u Updated Speed Regulator Bandwidth 92 Updated Torque Regulator Bandwidth 92 Inserted Torque Accuracy with HPTC 92 Added Polish to list of available Languages 93 Added Dual port Ethernet IP to Communications Protocols 94 Rockwell Automation Publication 7000 1 007 June 2014 Summary of Changes Notes 4 Rockwell Automation Publication 7000 7 June 2014 Important User Information PowerFlex 7000 Overview Drive Installation Table of Contents Chapter 1 Who Should Use This Manual
83. r phase shifted secondary windings The inverter is the same configuration for all available rectifier options Figure 4 3300 4160V 18 Pulse rectifier DC LINK LINE CONVERTER MACHINE CONVERTER x SGCTs x E These VFDs are supplied with heat sinks for low and mid power configurations and heat pipes for high power configurations While both configurations draw heat away from the semiconductors heat pipes are bigger more efficient and require larger fans and airflow Information and graphics in this manual show both configurations Rockwell Automation Publication 7000 7 June 2014 PowerFlex 7000 Overview Chapter 2 Motor Compatibility CURRENT VOLTAGE The PowerFlex 7000 achieves near sinusoidal current and voltage waveforms to the motor resulting in no significant additional heating or insulation stress Temperature rise in the motor connected to the is typically 3 C 5 5 F higher compared to across the line operation Voltage waveform has dv dt of less than 10 V us The peak voltage across the motor insulation is the rated motor RMS voltage divided by 0 707 Reflected wave and dv dt issues often associated with voltage source inverter VSI drives are a non issue with the PowerFlex 7000 Figure 5 shows typical motor waveforms The drive uses a selective harmonic elimination SHE pattern in the inverter to elimina
84. r point on a drawing has an arrow and drawing reference to indicate the ongoing connection The drawing reference indicates the sheet and the X Y coordinates of the continuation point Each drawing set contains a sheet explaining this reference system The unique wire numbering system serves as confirmation that you are tracing the correct wire from sheet to sheet or across a drawing Wires in multi conductor cables are typically identified by color rather than by number The abbreviations used to identify the colors on the drawings are fully identified on a sheet in the drawing set Power Wiring Selection The following tables show general wire selections common to the PowerFlex 7000 drive installations General notes Adherence to the following recommended field power cabling insulation levels for medium voltage drives ensures easier start up and operation Increase the cable insulation level over the default supplied for an across the line application with the same rated line to line voltage Use either shielded or unshielded cable based on the requirements of the distribution system designer and local standards However NEC requires shielded cable for installations above 2 kV Rockwell Automation Publication 7000 7 June 2014 Drive Installation Chapter 3 Cable Insulation These tables provide cable insulation requirements for the PowerFlex 7000 B Frame drive ground Some cable manufacturers
85. r test Surge Arrestors Drives supplied after 2009 will have surge arrestors instead of a TSN Surge arrestors can remain in the circuit during the meggering procedure Rockwell Automation Publication 7000 7 June 2014 81 Appendix B Meggering 4 Megger the drive Note Verify the drive and any connected equipment is clear of personnel and tools prior to commencing the Megger test Barricade any open or exposed conductors Conduct a walk around inspection before commencing the test All three phases on the line and machine sides of the drive connect through the DC Link and snubber network Therefore a test from any one of the input or output terminals to ground will provide all the sufficient testing required for the drive equipment ATTENTION Discharge the Megger prior to disconnecting it from the a Connect the Megger to the drive following the specific instructions for that model b If the Megger has a lower voltage setting normally 500 1000V apply that voltage for five seconds as a precursor for the higher voltage rating This may limit the damage if you forgot to remove any grounds If the reading is very high apply 5 kV from any drive input or output terminal to ground c Perform a Megger test at 5 kV for one minute and record the result The test should produce a reading greater than the minimum values listed below If the test results produced a value lower than these values
86. rate voltage line to line RMS Ensure the ATTENTION Voltage ratings shown in the following tables are peak line to cable meets the rating specified in the following tables Table 1 Cable insulation requirements for AFE and 18 Pulse drives with isolation transformer System Voltage V RMS Cable Insulation Rating kV maximum peak line to ground Line Side Machine Side 2400 24 1 222 3000 25 12 22 75 3300 25 63 23 0 4160 271 23 8 6000 210 8 255 6300 2114 258 6600 211 8 26 0 Table 2 Cable insulation requirements for Direct to Drive technology System Voltage V RMS Cable Insulation Rating kV maximum peak line to ground Line Side Machine Side 2400 222 222 3000 22 75 22 75 3300 23 0 23 0 4160 23 8 23 8 6000 255 255 6300 25 8 25 8 6600 26 0 26 0 Table 3 identifies general wire categories common to the PowerFlex 7000 B Frame drive Each category has an associated wire group number used in the following sections to identify the appropriate wire to use The table also provides application and signal examples along with the recommended type of cable for each group and a matrix providing the recommended minimum spacing between different wire groups run in the same tray or separate conduit Rockwell Automation Publication 7000 7 June 2014 37 Chapter 3 Drive Installation Table 3 Wire group numbers
87. rounding the shield at the customer end of the cable You must ground shields for cables from one enclosure to another only at the source end cabinet If you must splice shielded cables the shield must remain continuous and insulated from ground 5 ACand DC circuits must run through separate conduits or trays 6 Voltage drop in motor leads may adversely affect motor starting and running performance Installation and application requirements may dictate that larger wire sizes than indicated in IEC NEC guidelines are used Select the wire sizes individually observing all applicable safety and CEC or IEC NEC regulations The minimum permissible wire size does not necessarily result in the best operating economy The minimum recommended size for the wires between the drive and the motor is the same as if using a main voltage source connection to the motor The distance between the drive and motor may affect the size of the conductors used Rockwell Automation Publication 7000 7 June 2014 Installation Drive Installation Chapter 3 Consult the wiring diagrams and appropriate CEC or IEC NEC regulations to determine correct power wiring If you need assistance contact your local Rockwell Automation Sales Office When you have placed the drive at the installation site remove the lag bolts that fasten the shipping skid Move the drive off the shipping skid and discard the skid Position the drive in its desired location Veri
88. rovides for either the top or bottom power cable entry Cable access plates are available on the top and bottom plates of the connection cabinet check your customer specific dimension drawings for details To access the customer power cable terminations 1 3 Open the door of the low voltage control compartment The low voltage control compartment is hinged on its left side The power terminals are behind the low voltage control compartment The key interlock prevents the low voltage control compartment from swinging open unless the medium voltage source is locked out Turn each of the three latches on the right side of the low voltage compartment one quarter turn using an 8 mm hexagonal key wrench There is a pull handle provided on the right side of the low voltage comp artment Slowly pull the handle so the low voltage compartment swings out The power terminals are now visible The power cable access plates may require modification to suit the requirements Use the appropriate connectors to maintain the environmental rating of the enclosure Rockwell Automation Publication 7000 7 June 2014 51 52 Chapter3 Drive Installation Figure 46 Swing out of low voltage compartment heat sink and heat pipe models
89. rs 2 7 used with Line Reactor 9 Rockwell Automation Publication 7000 7 June 2014 23 Chapter3 Drive Installation Figure 18 Cabling Cabinet for AFE Rectifier 6600V heat pipe RPDTD Motor Terminals Surge Arrestors Grounding Filter for use with Line Reactor Zero Sequence is Effect Current Current Transformer Current Transformer Voltage Sensing Boards Line Terminals 24 Rockwell Automation Publication 7000 7 June 2014 Drive Installation Chapter 3 Figure 19 Cabling Cabinet for 18 Pulse rectifier motor filter capacitors not shown Motor Terminals Transient Suppression Network A E E ja Hall effect Sensor IN a p EXIT 1 h r e IMS Voltage Sensing 2 Boards A 7 Line Terminals
90. se 8kV phase N720 88 Rockwell Automation Publication 7000 7 June 2014 Line amp Load Cable Sizes Appendix C PRODUCT OUTPUT MOTOR SIDE Bulletin Description Drive Drive Structure Code Drive Enclosure Opening Max Size amp No Max Size amp Vertical Space Avail V Freq Rect rating A Inches mm Incoming Cables Incoming Cables for Stress Cones NEMA 245699 ic245689 Inches mm PF7000 3300V 50Hz RPDTD 46 375 70 43C 70 44 5 61x7 19 142x183 500MCM 5kV or 1 253mm 5kVor 16 2 411 70 45C 70 47C 8kV phase OR 8kV phase OR 2 w close coupled starter 2 250MCM 5kV 127mm 5kV or 8kV phase 8kV phase PF7000 4160V 50Hz RPDTD 46 375 70 43 70 44 9 79x10 97 249x279 1 2 500 5kV or 2 253mm75kV 28 5 725 70 45 70 47 8kV phase 8kV phase PF7000 4160V 50Hz RPDTD 46 375 70 43C 70 44 5 61x7 19 142x183 500MCM 5 or 1 253mm 5kVor 16 2 411 70 45 70 47C 8kV phase OR 8kV phase OR 2 w close coupled starter 2 250MCM 5 127mm 5kV or 8kV phase 8kV phase PF7000 4160V 60Hz RPDTD 46 430 70 43 70 44 9 79x10 97 249x279 1 2 500MCM 5kVor 2 253mm 8kV 28 5 725 70 45 70 47 8kV phase 15kV phase PF7000 4160 60Hz RPDTD 495 625 70 32 11 81x16 22 300x412
91. segment the drive system into smaller components and repeat the test on each segment to identify the source of the ground fault This implies isolating the line side of the drive from the machine side by removing the appropriate cables on the DC Link reactor You may need to completely isolate the DC Link reactor from the drive at which point you must disconnect all four power cables Ensure all electrical components to be meggered are electrically isolated from ground Items that may produce lower than expected readings are surge capacitors at the motor terminals motor filter capacitors at the output of the drive The meggering procedure must follow a systematic segmentation of electrical components to isolate and locate a ground fault Type of Drive Minimum Megger Value Liquid cooled Drive 200 Air cooled Drive 1k MO Drive with input output Caps Disconnected 5k Isolation Transformer 5k MO 82 Rockwell Automation Publication 7000 IN007E EN P June 2014 Meggering Appendix B The motor filter capacitors and line filter capacitors if applicable may result in the Megger test result being lower than expected These capacitors have internal discharge resistors designed to discharge the capacitors to ground If you are uncertain of the Megger test results disconnect the output capacitors IMPORTANT Humidity and dirty standoff insulators can cause leakage to ground because of tracking You m
92. t at frequencies below 55 Khz Rockwell Automation does not recommend exceeding this distance because the voltage drop across the cable can cause decreased power at the encoder Unused Inputs You may not require all inputs in either the quadrature or absolute encoders For example the absolute encoder accepts a 12 bit encoder but also works with a lower resolution Likewise quadrature encoders may not use the Z track Follow these guidelines for unused inputs 1 20B ENC Board Wire any unused input to the encoder power rail This also includes the B and inputs if using pulse encoder Failure to do this will result in phase loss warnings and improper operation of the encoder feedback logic i e missing counts 2 Universal Encode Interface When used as a quadrature encoder interface the same rule applies as for the 20B ENC Board When operating as an absolute encoder interface the wiring of unused inputs depends on the position of the POL_QRDNT jumper If the jumper is installed wire all unused inputs to ENC PWR otherwise use ENC COM 60 Rockwell Automation Publication 7000 7 June 2014 Drive Installation Chapter 3 Terminating Customer Cables Customer termination assemblies can accommodate either top or bottom customer cable entry For clarity Figure 52 and Figure 53 show only one phase of three there are a total of nine lug pads Figure 52 Typical Line Cable Termination shown assembled for b
93. talling Exhaust Fans and Air Hoods Install a sheet metal exhaust hood on the top of the cabinet with the cooling fan The exhaust hood components ship with the drive packed in the control cabling cabinet For drives with an acoustic hood the components are shipped assembled as shown in Figure 41 Remove the protective plate covering the fan opening on the drive It is a flat cover plate bolted to the top plate Remove the bolts and plate and retain for re use Rockwell Automation Publication 7000 7 June 2014 45 Chapter3 Drive Installation Assembling Exhaust Fans The cabinet top fan assembly is similar to the model shown in Figure 39 Figure 39 Fan assembly heat pipe model shown Fan Assembly Back of fan housing slides under retaining bracket M6 Taptite Qty 4 Slide the edge of the fan housing s bottom edge under the retention bracket and anchor the M6 hardware in the locations shown Assembling Fan Hoods Assemble the two L shaped panel components shipped with the drive as shown in Figure 41 46 Rockwell Automation Publication 7000 7 June 2014 Drive Installation Chapter 3 Figure 40 Fan hood assembly o 9 9 d 2 ne Flat plate _ x Quantity 1 gem lt gt D lt Es Exhaust hood panels Quantity 2 1 414
94. te major order harmonics plus a small output capacitor integral to the drive to eliminate harmonics at higher speeds Standard motors are compatible without de rating even on retrofit applications Motor cable distance is virtually unlimited Rockwell Automation has tested this technology for controlling motors up to 15 km 9 3 mi away from the drive Figure 5 Motor waveforms full load full speed 300 00 200 00 100 00 0 00 100 00 200 00 300 00 Vms 10 00K 7 50K 5 00K 2 50K 0 00K 2 50K 5 00K 7 50K 10 00K 1 110 00 120 00 130 00 140 00 j 100 00 TIME ms 150 00 Rockwell Automation Publication 7000 7 June 2014 15 Chapter2 PowerFlex 7000 Overview Simplified Electrical 2400V Diagrams Figure 6 2400V AFE Rectifier Configuration 1 Direct to Drive LINE CONVERTER COMMON MODE CHOKE MACHINE CONVERTER A soc IF Xsccts x LR ses Yd ag OMM e d x x Figure 7 2400V AFE Rectifier Configuration 2 Separate Isolation Transformer LINE CONVERTER DC LINK MACHINE CONVERTER 7 AAA f A SGCTS x 86018 x 2U X1 1U e p va NOS 1 2W X3 1 W T3
95. ternal connections within the drive and verify wiring Verifying critical mechanical connections for proper torque requirements Verifying and adjusting mechanical interlocks for permanent location Confirmingall inter sectional wiring connections Re verifying control wiring from any external control devices such as PLCs etc Confirming cooling system is operational Rockwell Automation Publication 7000 7 June 2014 65 Chapter4 Pre Commissioning Responsibilities Pre Commissioning Responsibilities 66 9 Verifying proper phasing from isolation transformer to drive 10 Confirming drive cabling to motor isolation transformer and line feed 11 Confirming test reports indicating megger hipot test is complete on line and motor cables 12 Control power checks to verify all system inputs such as starts stops faults and other remote inputs 13 Applying medium voltage to the drive and perform operational checks 14 Bump motor and tune drive to the system attributes If the load is unable to handle any movement in the reverse direction uncouple the load prior to bumping the motor for directional testing 15 Running the drive motor system throughout the operational range to verify proper performance Note Customer personnel must be on site to participate in the system start up procedures hazardous Severe injury or death can result from electrical shock burn or unintended actua
96. ting when applicable Enclosure openings will accommodate the thicker insulation on the higher rated cable ratings show the equivalent to the NEMA sizes The exact cable size shown is not commercially available many cases use the next smaller standard size 3 Cable enters termination point horizontally in this case therefore orient space for the stress cones horizontally also 4 Minimum cable bend radius recommendations vary by national codes cable type and cable size Consult local codes for guidelines and requirements General relationship of cable diameter to bend radius is typically between 7x 12x e g if the cable diameter is 1 2 54 cm the minimum bend radius could range between 7 12 in 18 8 30 48 5 For minimum cable insulation requirements refer to the PowerFlex 7000 Medium Voltage AC Drive User Manual for your particular frame or C Frame Stated voltages peak line to ground Note Some cable manufacturers rate cabling based on RMS line to line 6 Ground lug capabilities A Frame two mechanical range lugs for ground cable connections or C Frame up to ten mechanical range lugs for ground cable connections are available typically these frames supply four Mechanical range lugs can accommodate cable size 6 250MCM 13 3 127 mn 7 18 Pulse VFDs R18TX have nine line side connections from the secondary isolation transformer windings entering the VFD Lug
97. tion 7000 7 June 2014 31 Chapter3 Drive Installation Figure 26 Converter Cabinet 3300 4160V heat pipe model Inverter modules Ground bus Isolated Gate Driver Power Supplies IGDPS Isolated Gate Driver Power Supplies IGDPS Rectifier modules Figure 27 Converter Cabinet 6600V heat pipe model Inverter modules Isolated Gate Isolated Gate Driver Power Driver Power NE gt 24 k 72 up Supplies L p 4 A 2 IGDPS a e IGDPS Rectifier modules 32 Rockwell Automation Publication 7000 7 June 2014 Drive Installation Chapter 3 Figure 28 DC Link Fan cabinet with fan control panel heat sink model Converters Single phase control power transformer Ground Bus Fan Power Disconnect e 5 Cac E e e
98. tion of control equipment Hazardous voltages can exist in the cabinet even with the circuit breaker in the OFF position Rockwell Automation recommends disconnecting or locking out control equipment from power sources and confirm discharge of stored energy in capacitors If it is necessary to work in the vicinity of energized equipment follow the safety related work practices of NFPA 70E Electrical Safety Requirements for Employee Work Places ATTENTION Servicing energized industrial control equipment can be Notwithstanding the safety references here follow all local codes and safety practices when working on this product susceptible to damage or destruction by static charges Personnel working near ATTENTION The CMOS devices used the control circuit boards are static sensitive devices must be appropriately grounded To avoid complications during commissioning ensure that the drive line up is ready for commissioning This chapter includes a seven point Pre Commissioning Checklist Review the checklist to ensure you complete all points in the order presented prior to beginning the drive commissioning Completing the checklist helps ensure that the start up proceeds in an efficient manner Rockwell Automation Publication 7000 7 June 2014 Pre Commissioning Responsibilities Chapter 4 Pre Commissioning Checklist Once all points of the checklist are complete initial each check box and provide the date Pho
99. to 0 1 Hz but less than 6 Hz 4 For minimizing restart times using the flying start capability in forward or reverse direction 5 At any time when high performance torque or speed control mode HPTC is enabled 74 Rockwell Automation Publication 7000 7 June 2014 General Reference Appendix A Table 11 PowerFlex Speed Regulation Encoder Frequency Output lt 6 Hz 6 15 Hz gt 15 Hz Without Encoder Not applicable 0 1 0 1 With Encoder 0 02 0 01 0 01 With Encoder and HPTC 0 01 0 01 0 01 mode enabled Notes Speed regulation is based on a percentage of motor synchronous speed Encoder to be mounted on the AC machine Operational 15V DC Power Supply mounted in drive to power the encoder as a standard option with the encoder feed back card Customer is responsible for providing and mounting of encoder Sleeve bearing motors require the encoder to have an axial movement tolerance Recommended encoders are shaft mounting type Magneto resistive models are more adaptable to harsh environments When installing the encoder body and electronics must be isolated from ground options available from the encoder manufacturer to accomplish this There are usually limits on encoder cable lengths Ensure the maximum length is suitable for the application Table 12 Encoder Selection Mode Torque Control HPTC i m 3000 1024 1024 180
100. tocopy the checklist and fax the copy to Medium Voltage Support along with the planned start up date Upon receiving this checklist the Medium Voltage Support will contact the site to finalize arrangements for a start up engineer to travel to the site at your convenience Please print the following information Medium Voltage Support Name Date Rockwell Automation Company Fax 1 866 465 0103 or Phone Pages Fax 1 519 740 4756 Fax Drive Serial Number CSM Service Engineer Requested YES NO Scheduled Commissioning Date Table 5 Receiving and Unpacking Initials Date Check The drives have been checked for shipping damage upon receiving After unpacking the item s received are verified against the bill of materials Any claims for breakage or damage whether concealed or obvious are made to the carrier by the customer as soon as possible after receipt of shipment All packing material wedges or braces are removed from the drive Table 6 Installation and Mounting Initials Date Check The drive is securely fastened in an upright position ona level surface Seismic zones require special fastenings Consult factory Lifting Angles have been removed Bolts have been inserted into original location on top of drive leakage of cooling air All contactors and relays have been operated manually to verify free movement Table 7 Safety
101. ts operation and advantages are the same as the Direct to Drive configuration Figure 3 3300 4160 AFE Rectifier with separate isolation transformer LINE CONVERTER DC LIN MACHINE CONVERTER REMOTE ISTX AAKT SGCTs 86018 x i x x 1U 2 4 eoe A wod 2109 i 3 091 x x x x x x Rockwell Automation Publication 7000 IN007E EN P June 2014 Chapter2 7000 Overview Cooling Technology 14 18 Pulse Rectifier with Separate Isolation Transformer For high power constant torque applications and or when the line voltage is higher than the motor voltage a transformer is required for voltage matching The 18 Pulse rectifier uses SCRs instead of the SGCTs used for an AFE rectifier When used for high power and constant torque applications the 18 Pulse rectifier has lower losses than the AFE rectifier making it ideal for the highest power requirements The 18 Pulse isolation transformer provides the required input impedance and addresses common mode voltage just like the separate isolation transformer used with the AFE rectifier However instead of a PWM switching pattern and a single rectifier bridge the 18 Pulse configuration mitigates line side harmonics through harmonic current cancellation in the isolation transforme
102. two or more sections for ease of handling require reconnection for power and control wiring After joining the sections reconnect the power and control wiring as shown in the schematic drawings provided with the drive Control Cables Locate control cable entry exit near the terminal block Route connections along the empty side of the TBC terminals These terminals accept a maximum AWG 14 wire gauge Connect the low voltage signals includes 4 20 mA using twisted shielded cable with a minimum AWG 18 wire gauge Based on using a W4 terminal block for customer connections comparable wire sizes would 0 5 4 mm as equivalent to 722 810 AWG Two encoder inputs accommodate a quadrature encoder senses motor direction The encoder power supply is isolated and provides 15V and a ground reference Many encoder outputs have an open collector output which requires an additional pull up resistor to feed proper signals to the system logic Refer to Torque Requirements for Threaded Fasteners on page 73 to see if one is required IMPORTANT Connectlow voltage signals using twisted shielded cable connecting the shield at the signal source end only Wrap the shield at the other end with electrical tape and isolate it Make connections as shown on the drawings provided Encoder Installation Guidelines Common problems an encoder signal transmission to the drive include signal distortion and electrical noise Either proble
103. w CE terminal laptop or desktop computer The HMI Interface Board removes past issues with compatibility between the drive and configuration tools as all the necessary tools are acquired from the drive The HMI Interface Board is well suited for applications that require remote placement of the operator terminal and remote maintenance Figure 15 Operator Interface APE 1000 Terminal Home Display Alarms Setup Diagnostics Utility X x Basic Configurations There are three basic configurations for the HMI Interface Board Remote mounted HMI The not mounted in the traditional location on the low voltage door of the Variable Frequency Drive VFD A remote mounting plate complete with E Stop push button and is supplied loose for the customer to mount wherever desired The HMI connects to the VFD via a hardwired Ethernet cable There is no functional distance limitation Rockwell Automation Publication 7000 7 June 2014 19 Chapter 2 20 PowerFlex 7000 Overview This is ideal for non PLC users wanting to control and monitor remotely e g at the driven machine control room etc Also ideal for customers having policies in place to control access to medium voltage equipment and the associated requirements of PPE when using the operator interface at the VFD etc Locally mounted HMI Similar to the existing PanelView 550 the HMI is mounted on the LV door of the VF
104. x279 1 2 500MCM 8kV or 2 253mm 5kVor 28 5 725 15kV phase 8kV phase PF7000 3300V 50Hz RPTX 495 625 70 32 11 81x16 22 300x412 1 2 500 SkV 2 253mm 5kV 16 9 430 0285 0325 8kV phase 8kV phase 20 PF7000 4160V 50Hz RPTX 46 430 70 10 70 27 70 29 70 30 9 79x10 97 249x279 1 2 500MCM 8kV or 2 253mm 5kVor 28 5 725 15kV phase 8kV phase PF7000 4160V 60Hz RPTX 46 430 70 2 70 26 70 27 9 79x10 97 249x279 1 2 500 5kVor 2 253mm 5kVor 28 5 725 70 28 70 29 70 31 8kV phase 8kV phase PF7000 4160V 60Hz RPTX 495 625 70 32 11 81x16 22 300x412 1 2 500 SkV 2 253 5kV 16 9 430 0285 0325 8kV phase 8kV phase 20 PF7000 6600V 50Hz RPTX 40 285 70 11 70 28 9 79 10 97 249x279 1 2 500 8kV 2 253mm 8kVor 28 5 725 70 30 70 31 or 15kV phase 15kV phase PF7000 6600V 50Hz RPTX E325 E575 70 36 70 37 12 79x19 68 325x500 1 2 500 8kV 2 253mm 8kV 16 9 430 0215 G250 or 15kV phase or 15kV phase 25 Rockwell Automation Publication 7000 INOO7E EN P June 2014 89 AppendixC line amp Load Cable Sizes PRODUCT OUTPUT MOTOR SIDE Bulletin Description Drive Drive Structure Code Drive Enclosure Opening Max Size amp No Max Size amp No Vertical Space Avail V Freq Rect rating A Inches mm Incoming Cab Cables Incoming Cables
105. x535 1 2 500MCM 2 253mm 5 kV 16 4 415 5KV or 8V phase 8 kV phase PF7000L 6600V 50Hz R18TX 375 657 70 50 L A 70 53 L A 9 79x21 06 249x535 1 2 500MCM 2 253mm 8 kV 16 4 415 70 55 L L 70 58 1 1 8 or 15 kV phase 15 kV phase PF7000L 6600V 60Hz R18TX 375 657 70 50 L A 70 53 L A 9 79x21 06 249x535 1 2 500 2 253mm 8 kV 16 4 415 70 55 L L 70 58 L L 8 or 15 kV phase 15 kV phase Notes This data is informative only do not base final design criteria solely on this data Follow national and local installation codes industry best practices and cable manufacturer recommendations 1 Some A Frames most Frames and all Frames have a single enclosure opening provision for both line and load cables designated by 1 Most A Frames and some B Frames have separate opening provisions for line and load cables All cabling capacities shown in this table are worst case conditions when both line and load cabling enters and exits in the same direction 2 Cable sizes are based on overall dimensions of compact stranded three conductor shielded cable common for industrial cable tray installations Maximum sizing stated accounts for minimum rated cable insulation requirements and the next higher rated cable i e 8 kV is not commercially available in many areas of the world therefore Rockwell Automation provides an 8 kV minimum rating as well as 15 kV ra
106. y and recurring drive usage or maintenance tasks Drive specific Technical Data additional troubleshooting parameters and specification information for MV variable frequency drives Chapter1 Important User Information Rockwell Automation provides the site and installation specific electrical and design information for each drive during the order process cycle If they are not available on site with the drive contact Rockwell Automation If you have multiple drive types or power ranges ensure you have the correct documentation for each specific PowerFlex 7000 product Frame for lower power air cooled configurations up to approximately 1250 hp 933 kW Frame for higher power air cooled configurations heat sink or heat pipe models Frame for all liquid cooled configurations Manual Conventions This manual uses a variety of symbols to indicate specific types of information WARNING Warnings indicate where people may be hurt if users do not follow procedures properly ATTENTION Cautions indicate where machinery damage or economic loss may occur if users do not follow procedures properly Both of the above symbols could indicate A possible trouble spot Tell what causes the trouble spot e Give the result of an improper action SHOCK HAZARD This symbol indicates a potential electrical shock hazard on a component or printed circuit board General Precautions and assemblies

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