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7000L-UM302_-EN-P - Rockwell Automation

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3. n ll a x E d p C Wu Tar Tar Ta Latch e e P o0o00oolL 00000 ud Key Interlock g A le P IZ a y f Handle Wu N l Latch d Terminal blocks Customer TBC A LI rit Wh j oO A Figure 2 58 Swing out of Low Voltage Compartment 7000L UM302B EN P June 2013 7000 C Frame Marine Power Connections 7000 C Frame Marine Drive Installation 2 53 The installer must ensure that interlocking with the upstream power source has been installed and is functioning The installer is responsible for ensuring that power connections are made to the equipment in accordance with local electrical codes The drive is supplied with provision for cable lugs The power terminals are identified as follows Incoming Connections Drives with AFE Rectifiers 2U 2V 2W e Drives with 18 Pulse Rectifiers Secondary dO 2U 2V 2W Secondary d 20 3U 3V 3W Secondary d 20 4U 4V 4W e Motor Connections U V W The installer is responsible for ensuring that power connections are made with appropriate torque Refer to Appendix B Torque Requirements in back of manual The drive is supplied with provision for grounding of cable shields and stress cones near the power terminals 7000L UM302B EN P June 2013 2 54 Dr
4. 1 Ensure the MV source power to the drive is locked out 2 Drain the coolant from the drive system 3 Lock out the control power 4 Access the DC Link cabinet and remove the cooling connections to the DC Link 5 Disconnect the 4 power connections to the DC Link Remember to note the location for each of the cables on the DC Link 6 Remove the hardware that secures the DC Link to the ground channels 7 Remove the DC Link frame ground connection 8 Using a lift truck remove the DC Link from the cabinet 9 Install the replacement in the reverse order b Liquid Cooled LAM DC Link Reactor Cooling Pipes xi 7000 C Frame Marine Figure 4 44 DC Link Reactor 7000L UM302B EN P June 2013 4 58 Component Definition and Maintenance Control Power Components 7000L UM302B EN P June 2013 The installer needs to verify that the DC Link power connectors go to the proper locations You must also ensure that they are routed the same way so that electrical clearances are not compromised The nameplate data must be compared to the old DC Link to ensure that the ratings are appropriate for the drive system Any changes in the nameplate should be noted since the parameters within the drive will need to be changed There are two configurations in which control power will be distributed for the drive The diffe
5. Printer gt Operator Interface Relays Customer Supplied C Hold up m gt 5V LOGIC 120V 1 ph AC DC Converter MD HSV FOR 9 Line Filter p 56V DC 7 DC DC CONVERTER gt 24V HECS A 24V ISOLATORS gt 424 XIO DC Fail SENSE CABLE 380V 50Hz or 20V Isolated m ue Gate Driver p Power Supply 20V VFD Fan Figure 4 46 6 pulse AFE Remote Transformer Starter 7000L UM302B EN P June 2013 7000 C Frame Marine AC DC Power Supply 7000 C Frame Marine Component Definition and Maintenance 4 61 The load demands on the AC DC converters are the DC DC converter and up to six IGDPS modules The DC DC is a fixed load however the quantity of IGDPS modules will vary depending upon the drive configuration Description The AC DC power supply accepts single phase voltage and produces a regulated 56V DC output for the DC DC power supply and the HV IGDPS modules for the SGCTs The input and output voltages are monitored and fail signals are annunciated upon either voltage going below a pre set level Single phase 95 265V ac 47 63 Hz 0 98PF 1000W or 0 98PF 21500W DC FAIL DC DC gt Power Supply AC DC Power Supply 56V 1000W or 1500W HV IGDPS D Power Supply DC Fail Figure 4 47 AC DC Converter Power Supply Upon loss of
6. ACB Connectors Description ACB J1 Control I O amp Control Power Monitor ACB J2 Line current inputs CT2U CT2W ACB J3 Line current inputs CT3U CT3W ACB J4 Line current inputs CTAU CTAW ACB J5 Motor current inputs HECSU HECSW ACB J6 DClink current inputs HECSDC1 HECDC2 ACB J7 Ground fault amp CMC Neutral current inputs GFCT INN ACB J8 Isolated amp Non isolated analog inputs AIN1 AIN2 AIN3 and Non isolated outputs AOUT1AOUT2 AOUT3 AOUT4 ACB J9 Air pressure inputs APO AP1 input from TSP ACB J10 Meter outputs AOUT5 AOUT6 AOUT7 AOUT8 and Speed Pot input AINO ACB J11 Communication connections printer outputs ACB J12 Communication connections PanelView ACB J13 DC power supplies XIO 24V 15V 24V 5V ACB J14 DC power supply monitoring 5V1 5V2 DC BUS ACB J15 DC ABUS 56V output monitoring in UPS option ACB J16 DPI interface ACB J17 Communication connections scan ports ACB J18 DC fail signal monitoring ACB J19 DC fail signal monitoring ACB J20 DC fail signal monitoring ACB J21 DC fail signal monitoring ACB J22 Communication connection XIO link CAN interface ACB J23 Communication connection parallel drive ACB J24 UPS fail signal monitoring ACB J25 Line voltage synchronous transfer feedback voltage inputs VSA VSB VSC ACB J26 Motor amp line DC link and Neutral Point Voltage inputs ACB J27 AC Motor amp Line voltage feedback inputs ACB J28 Encod
7. Low Voltage Control Panel e Figure 4 1 Control and Cabling Cabinet showing LV Control Panel 7000 C Frame Marine 7000L UM302B EN P June 2013 4 2 Component Definition and Maintenance Motor Terminals ON Current Transformer Line Terminals A amp Current Transformer 7000L UM302B EN P June 2013 j foy m A j n i N INIT Hall Effect Sensor Voltage Sensing Surge Arresters Figure 4 2 Large Footprint AFE Control and Cabling Cabinet with LV Control Panel removed 7000 C Frame Marine Voltage Sensing Assembly 7000 C Frame Marine Component Definition and Maintenance 4 3 The voltage sensing assembly consists of the voltage sensing board and the mounting plate The voltage sensing board has six independent channels which convert voltages up to 10800V 7 2kV x 1 5 pu down to low voltage levels which can be used by the PowerFlex 7000 control logic i e Signal Conditioning Board SCB Two of these assemblies can be linked together where one assembly acts as
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9. Test Point Fein Description TP1 5V Positive 5V Power Supply TP2 DIAG 0 OIB A RX1 Diagnostic Feedback TP3 CMD 0 OIB A TX1 Firing Command Signal TP4 DIAG 1 OIB A RX2 Diagnostic Feedback TP5 CMD 1 OIB A TX2 Firing Command Signal TP6 DIAG 2 OIB A RX3 Diagnostic Feedback TP7 CMD 2 OIB A TX3 Firing Command Signal TP8 DIAG 3 OIB A RX4 Diagnostic Feedback TP9 CMD 3 OIB A TX4 Firing Command Signal TP10 DIAG 4 OIB A RX5 Diagnostic Feedback TP11 CMD 4 OIB A TX5 Firing Command Signal TP12 DIAG 5 OIB A RX6 Diagnostic Feedback TP13 CMD 5 OIB A TX6 Firing Command Signal TP14 TFB A OIB A Temperature Feedback Signal TP15 GND Ground Reference for TP1 TP14 TP16 DIAG 6 OIB B RX1 Diagnostic Feedback TP17 CMD 6 OIB B TX1 Firing Command Signal TP18 DIAG 7 OIB B RX2 Diagnostic Feedback TP19 CMD 7 OIB B TX2 Firing Command Signal TP20 DIAG 8 OIB B RX3 Diagnostic Feedback TP21 CMD 8 OIB B TX3 Firing Command Signal TP22 DIAG_9 OIB B RX4 Diagnostic Feedback TP23 CMD_9 OIB B TX4 Firing Command Signal TP24 DIAG_10 OIB B RX5 Diagnostic Feedback TP25 CMD 10 OIB B TX5 Firing Command Signal TP26 DIAG 11 OIB B RX6 Diagnostic Feedback TP27 CMD 11 OIB B TX6 Firing Command Signal TP28 TFB B OIB B Temperature Feedback Signal TP29 GND Ground Reference for TP16 TP28 TP30 DIAG 12 OIB C RX1 Diagnostic Feedback TP31 CMD 12 OIB C TX1 Firing Command Signal TP32 DIAG 13 OIB C RX2 Diagnostic Feedback TP33 CMD 13 O
10. Figure 2 54 Access to Load Terminals bottom covers and UPS removed Load cable terminals with barrier plate removed Figure 2 55 Access to Load Terminals bottom covers UPS and terminal barrier removed 7000L UM302B EN P June 2013 7000 C Frame Marine Drive Installation 2 47 Motor Terminals Voltage Sensing o e o 2 I oL w Load Cable Removable Conduit Cover Figure 2 57 Motor Cable termination point Removable gland plate 7000 C Frame Marine 7000L UM302B EN P June 2013 2 48 Drive Installation IEC Component and Device Designation Power Wiring Selection 7000L UM302B EN P June 2013 PowerFlex 7000 electrical drawings use conventions that are based on IEC International Electrotechnical Commission standards while remaining basically compatible with North American ANSI American National Standards Institute standards The symbols used to identify components on the drawings are international and a full listing of the symbols is given as part of each PowerFlex 7000 elementary drawing ED set The device designations used on the drawings and labeling are also listed with explanations on each drawing set Wiring identificati
11. Figure 4 74 Encoder Interface 20B ENC 1 and 20B ENC 1 MX3 7000 C Frame Marine Component Definition and Maintenance 4 103 Operation at 5V does not allow for long cable lengths The reason for this is that it requires the power to be regulated within 5 at the encoder Due to the resistance and capacitance of the cable it would be very hard to keep the power regulated at the encoder to 4 75V With longer runs of cable this could drop below the 4 75V and the encoder would not operate properly As a general rule using 18Avg cabling with an Rdc of 19 3ohm km the longest cable distance from the board to the encoder is limited to 12 m 42ft The 20B ENC 1 MX3 encoder option is functionally identical to the 20B ENC 1 encoder with the addition of conformal coating Fig xxx shows the recommended jumper positions for use with the PowerFlex 7000 Drive Input Connections All encoder interface Connections are made to J1 The connections are as follows J1 Pin 1 A J1 Pin 2 A J1 Pin 3 B J1 Pin 4 B J1 Pin 5 Z J1 Pin 6 Z J1 Pin 7 Encoder Power Return J1 Pin 8 Encoder Power 12V 3 Watts 80190 759 01 80190 759 02 Universal Encoder Interface The Universal Encoder Interface allows the drive to be connected to an absolute position encoder or a standard quadrature encoder and also provides the option for dual or redundant quadrature encoders The Universal Encoder Interface provides 12 single ended or 6
12. Lug pad oriented for top cable entry Figure 2 65 Typical Line Cable Terminal Assembly shown assembled for top cable entry 7000L UM302B EN P June 2013 2 62 Drive Installation Grounding Practices 7000L UM302B EN P June 2013 The purpose of grounding is to provide for the safety of personnel limit dangerous voltages on exposed parts with respect to ground facilitate proper overcurrent device operation under ground fault conditions and provide for electrical interference suppression Generally the means used for external grounding of equipment should be in accordance with the Canadian Electrical Code CEC C22 1 or the National Electrical Code NEC NFPA 70 and applicable local codes Refer to the grounding diagrams that follow for ground connections The drive s main ground bus must be connected to the system ground This ground bus is the common ground point for all grounds internal to the drive Connected to the neutral point i of the output capacitor ISOLATION TRANSFORMER Figure 2 66 Ground Connection Diagram with Isolation Transformer Connected to the neutral point AC LINE of the output capacitor REACTOR TRANSFORMER GROUND FILTER GROUND BUS Figure 2 67 Ground Connection Diagram with Line Reactor Each power feeder from the substation transformer to the drive must be provided with properly sized ground cables Utilizing the conduit or c
13. o Varistors Varistors o e o e 69e o G0 5 kV fuses Location for 5 kV fuses 7 2 kV fuses Location for 7 2 kV fuses Figure 4 6 Transient Suppression Network 7000L UM302B EN P June 2013 7000 C Frame Marine Metal Oxide Varistor Replacement Surge Arresters 7000 C Frame Marine Component Definition and Maintenance 4 9 Metal oxide varistors MOV are part of the Transient Suppression Network located within the connection cabinet 1 Ensure there is no power to the equipment To prevent electrical shock ensure the main power has been disconnected before working N on the transient suppression network Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Failure to do so may result in injury or death Observe the locations of the connecting links Detach the connecting links by removing the screws Using a screwdriver remove the screws at the base Replace the MOV polarity is not an issue Bv tA d t PS Continue by replacing the screws and connecting links Each MOV panel is grounded Ensure that one MOV see Figure 4 8 for location is connected to the grounding lead Description Heavy duty distribution class surge arresters are used for transient overvoltage protection in the drives with AFE rectifiers The arresters are certified as per ANSI IEEE Std C62 11 1993 The surge arresters are basically MOV
14. 100 00 0 00 300 00 Vrms 10 00K 7 50K 5 00K 2 50K 0 00K 2 50K 5 00K 7 50K 10 00K 100 00 110 00 120 130 00 140 00 n 0 00 TIME ms 0 0 150 00 Figure 1 4 Motor waveforms full load full speed 7000L UM302B EN P June 2013 1 8 Overview of Drive SGCT Features and Benefits An SGCT is a Symmetrical Gate Commutated Thyristor with an integrated gate drive Positioning the gate drive close to the SGCT as shown in Figure 1 5 creates a low inductance path that provides more efficient and uniform gating of the device As a result the device is better suited than a conventional GTO to handle the fluctuating levels of voltage and current while it is switching on and off during gating An SGCT has similar characteristics to an IGCT used on some VSI drives including low conduction and switching losses low failure rate and double sided cooling for low thermal stress However the SGCT achieves voltage blocking capability in both forward and reverse directions up to 6500 volts by a NPT Non Punch Through structure and nearly symmetrical pnp transistor in the wafer while the current is unidirectional Unlike many VSI topologies that use IGBTs the semiconductors used in the PowerFlex 7000L feature a non rupture non arc failure mode In the unlikely event of a device failure the fault would be contained within the device Implementing SGCTs in the Po
15. Figure 4 30 Cooling System Reconnecting the Coolant System to a PowerCage Module 1 Ensure all power is off and locked out including the pumping system 2 Ensure a blanket or plastic sheet is covering the devices below the PowerCage being serviced Face shield and full arm chemical resistant gloves should be worn at all times when performing this task 3 Attach both the inlet and outlet manifolds to their bracketry be sure to close all the pipe clamps 4 If necessary remove the device blocking the left outlet hose and reconnected it to the lower nipple on the chill block to the extreme left Make sure to tighten the hose clamp Repeat this step for all outlet hoses and than all inlet hoses 5 Replace all SGCT SCR devices and circuit boards as described in Replacing the Silicon Controlled Rectifier and SGCT Replacement 6 Check coolant levels to ensure there is still enough coolant in the system If coolant must be added see Adding Coolant in the Cooling Cabinet Components section 7000L UM302B EN P June 2013 4 40 Component Definition and Maintenance Chill Block Removal Instructions for removing Chill Block assembly and Replacement Ensure all Power has been disconnected To prevent electrical shock ensure the main power has been disconnected before working on N a module Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Failure
16. m N V ESE E je d Jp m ss o o o o o o o o o Output Isolation Switch iI Output Isolation Switch Handle Output Contactor Liquid cooled DC Link Reactor Figure 2 49 Capacitor and CMC Cabinet 7000 C Frame Marine Drive Installation 2 43 Customer Terminal Blocks Output Contactor Control Module d Customer VO Control Board XIO B Hel kee 9 1 Ee 1 ERST jn 1 Drive lt JB ll e Control ut QO S
17. Conductivity Sensor XS Temperature Gauge T1 Temperature Sensor TS1 Figure 4 59 Temperature and Conductivity Sensors Fluid Conductivity An in line conductivity sensor XS as shown in Figure 4 59 measures the fluid conductivity The sensor sends a signal to a meter mounted on the pump cabinet door Two conductivity switches are part of the meter They are set at conductivity of lu S cm for the annunciation warning and 2uS cm for the trip value Temperature Sensor This temperature sensor TS1 shown in Figure 4 59 triggers the drive to shut down when the fluid temperature entering the converter cabinet is too high This situation could occur if the air cooling of the heat exchanger is cut off due to fan failure plugging of the air paths or failure of the thermostatic valve 7000L UM302B EN P June 2013 4 76 Component Definition and Maintenance Pump Maintenance and The following are the temperature values for alarm and trip signal Replacement cont 1 When coolant temperature is greater than 48 C 120 F an alarm signal is initiated It can only be reset when temperature reaches 38 C 100 F 2 When coolant temperature is greater than 62 C 144 F a trip signal is initiated It can only be reset when the temperature reaches 48 C 120 F 3 When coolant temperature is less than 4 C 40 F a trip signal is initiated It can only be reset when the temperature reaches 10 C 50 F De lonizi
18. Code Selection Absolute encoders can be purchased with either Gray code or Binary output format Gray code is a form of binary code where only a single bit changes at a time for each sequential number or position The fact that only a single bit changes at a time make it easier for the Universal Encoder Interface to read valid positional data and not ambiguous data If we compare the Natural Binary code to Gray code for the transition from 255 to 2556 here is what we get Binary Code Gray Code 255 011111111 010000000 256 100000000 110000000 All nine bits changed in the Binary Code while only the MSB of the Gray code changed In the Universal Encoder Interface there are delays created by the frequency filter components and input hysteresis Differences in these delays could cause errors due to reading a bit as ON when it is actually transitioning to OFF or vice versa In the case of Gray code since only one bit ever changes the ambiguity error is never more than one count For this reason and to reduce inrush currents Rockwell Automation recommends using Gray code Positional Encoders Data Polarity Absolute encoders typically have a High True output If the encoder model does not have a High True or Non Inverted Inverted option you should assume it to be High True In the case of a 10bit High True encoder the zero position is represented by 0000000000 Whereas a Low True encoder the zero position is 1111111111 On the
19. Ground Bus Inverter Modules Coolant Piping Gate Drive Power Supplies Rectifier Modules Figure 2 48 Converter Cabinet 7000 C Frame Marine 7000L UM302B EN P June 2013 2 42 Drive Installation ACIDC lt lt Power Supplies Disconnect Switch Power Transformers Coolant Pipes 7000L UM302B EN P June 2013 Q mw H o and ages Ni ll d Li LL NNI SIV IN rl n 3 j 49 WARE hi e 1 2 f
20. Notes Speed Regulation is based on of motor synchronous speed Tachometer to be mounted on the AC machine Operational 15 V DC Power Supply mounted in drive to power the tachometer as a standard option with the tachometer feed back card Customer is responsible for providing and mounting of tachometer Sleeve bearing motors require the tachometer to have an axial movement tolerance Recommended tachometers are shaft mounting type Magneto resistive models are more adaptable to harsh environments When installing the tachometer body and electronics must be isolated from ground options available from the tachometer manufacturer to accomplish this There are usually limits on tachometer cable lengths Ensure the maximum length is suitable for the application Tachometer Selection Recommended Tach PPR Motor RPM Tach ppr 3600 600 3000 600 1800 1024 1500 1024 1200 2048 1000 2048 900 2048 720 2048 600 2048 7000 C Frame Marine Catalog Number Explanation Drive Selection A 5 PowerFlex 7000 Drive The PowerFlex 7000 drives have been tested on a dynamometer to Performance Torque verify performance under locked rotor accelerating and low speed Capabilities high torque conditions Table A 5 below shows the PowerFlex 7000 drive torque capabilities as a percent of motor rated torque independent of the drive s momentary overload conditions Table A 5 PowerFlex 7000 Drive Torque Capab
21. 5 F8 key on the Diagnostic Setup screen ACCESS Current Access Advanced Monitor Service Rockwell Enter Password Faces T Tos ose exrr_ Figure 3 32 Access Screen The Current Access level is shown To select a different access level use the up down cursor keys to select the desired the level Then enter the password value PIN for that level using the data entry keys The value can be any number between 0 and 65535 As the number is entered via the keys 0 9 the value will be shown by a placeholder i e in the editing field as shown in Figure 3 33 ACCESS Monitor Current Access vanced Monitor Service Rockwell Enter Password aes Tos ose er Figure 3 33 Pin Entry The value may be edited by using the backspace key When the value has been typed in press the enter key If the correct PIN was entered the access level of the operator interface will change as shown in Figure 3 34 If the incorrect value was entered the operator interface will remain at the current access level 7000L UM302B EN P June 2013 3 30 Operator Interface 7000L UM302B EN P June 2013 ACCESS Monitor Current Access vanced Basic Service Rockwell Enter Password ases T Ter ose r Figure 3 34 Access Level Changed When the desired operations have been completed the operator interface should be placed back to the Monitor level in order to protect against unautho
22. BIL rating based on altitudes 1000 m 3 300 ft Refer to factory for derating on altitudes gt 1000 m 7000L UM302B EN P June 2013 1 10 Overview of Drive Specifications cont 7000L UM302B EN P June 2013 Description Specifications Voltage 18 Pulse AFE D2D Number of Rectifier Devices Su y por pnas 4160 V 6 4 6600 V 6 6 Voltage 18 Pulse AFE D2D f 2400 V 4500 V 6500 V R PIV Rat Po n meani tage 3300 V 4500 V 6500 V 4160 V 4500 V 6500 V 6600 V 6500 V 6500 V Output Waveform to Motor Sinusoidal Current Voltage Medium Voltage Isolation Fiber Optic Modulation Techniques SHE Selective Harmonic Elimination Synchronous Trapezoidal PWM Asynchronous and Synchronous SVM Space Vector Modulation Control Method Digital Sensorless Direct Vector Full Vector Control with Tach Feedback Optional Tuning Method Auto Tuning via Setup Wizard Speed Regulator Bandwidth 5 25 Radians Second Torque Regulator Bandwidth 15 50 Radians Second Speed Regulation 0 1 without Tachometer Feedback 0 01 0 02 with Tachometer Feedback Acceleration Deceleration Range Independent Accel Decel 4 x 1200 sec Acceleration Deceleration Ramp Rates 4 x Independent Accel Decel S Ramp Rate Independent Accel Decel 2 x 1200 sec Critical Speed Avoidance 3 x Independent with Adjustable Bandwidth Stall Protection Delay Speed
23. Flash A type of memory technology which will indefinitely store information and is unaffected by power loss It is used for storage of firmware parameters and data files PCMCIA A standard for flash memory cards Personal Computer Memory Card International Association 7000 C Frame Marine Overview Keypad 7000 C Frame Marine Operator Interface 3 3 The operator interface used on the PowerFlex 7000 C Frame Medium Voltage Drive is that of the Panel View 550 terminal Figure 3 1 This terminal however does not behave as a PanelView as only the hardware for the operator interface has been utilized The PanelView software has been replaced with unique software to tailor it to the requirements of the Medium Voltage Drive and its faceplate has been modified Figure 3 1 Figure 3 1 PowerFlex 7000 C Frame Operator Interface Terminal The keypad of the operator interface consists of two rows of five function keys item 1 of Figure 3 1 located below the operator interface display area item 4 of Figure 3 1 In the lower right corner of the operator interface are four keys which will be referred to as the cursor keys item 2 of Figure 3 1 Above the cursor keys are data entry keys consisting of the numeric values 0 9 a decimal point a negative a backspace key and a data entry key item 3 of Figure 3 1 All keys are of a membrane type The key is executed upon release Function S
24. Yes No Operation Status TRANSFER PENDING FT Ge es ics one ves wo can Figure 3 91 Load New Firmware The screen will then ask you to confirm the operation Press the F8 key to proceed or the F9 key to abort Performing a DOWNLOAD FIRMWARE operation will overwrite the existing firmware that is currently running Pressing the F3 key may restart an aborted download or one that failed prior to starting the download To select or enter a different filename press the F7 key Due to the nature of this operation all other operator interface functions will cease during a download Once the download begins the operator interface s screen will be unable to show any status information For this reason the two LEDs on the back of the operator interface are used as such e Flashing Green indicates that all is healthy and the transfer is proceeding e Solid Red the transfer has failed Firmware must be loaded via the method described in a above This is achieved by cycling power to the operator interface or simultaneously pressing the cursor left cursor right and Enter key at the same time while the flash card is inserted If more than one firmware file exists on the card the first one will be loaded and this process will need to be repeated in order to select the firmware file you desire When the transfer completes successfully the new firmware will automatically begin operation Refer to the sectio
25. or The metal sheath or foil may be left insulated from ground and the other conductors and the mesh cable screen grounded at one end only as stated above 7000 C Frame Marine 7000L UM302B EN P June 2013 2 64 Drive Installation Grounding Practices cont 7000L UM302B EN P June 2013 Grounding Requirements and Grounding Specification for Customers and Power Integrators An external ground must be attached to the main ground bus The grounding means must comply with applicable local codes and standards As general guidelines for information only the ground path must be of sufficiently low impedance and capacity that 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 4 volts over ground potential the current flowing into a ground fault will be of sufficient magnitude to cause the protection to operate The main grounding conductor s should be run separately from power and signal wiring so that faults do not damage the grounding circuit or will not cause undue interference with or damage to protection or metering systems or cause undue disturbance on power lines Identification of Types of Electrical Supplies Grounded and Ungrounded Systems When dealing with an ungrounded three phase electrical supply system the cable insulation must be capable of handling not only the phase to phase voltage but also the volt
26. 7000 C Frame Marine Meggering C 3 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 600 V 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 Output Grounding Network Remove the ground connection on the OGN if installed This connection should be lifted at the OGN capacitor rather than the grounding bus as the grounding cable is only rated for 600 V Note Injecting a 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 will be plugged into connectors on the Voltage Sensing Board marked J1 J2 and J3 and terminate on the Signal Conditioning Boards Every ribbon cable connection made on the VSBs should be marked for identification from the factory Confirm the marking matches the connections and disconnect the ribbon cables and move them clear of the VSB If these ribbon cables are not removed from the VSB then high potential will be applied d
27. DISPLAY Logic I 0 Logic command Logic status 1 Logic status 2 Local inputs Local outputs SCANPOrt input SCANPOrt output L00000 Figure 3 69 Bit Encoded Parameter VIEW PARAMETER Local outputs Ready Running Rev Rot tn Fault Warning Start Fans Close Input Close Qutput Cc cccccccco Close Bypass Bt speed Torque Lmt Test Mode synching Start Field Enable Field Reset Faults Cc Oc ccc ues T_T Ten Figure 3 70 Bit Description for Local Outputs The DISPLAY screen typical of Figure 3 68 is displayed The screen shows the name of the group being displayed to the right of the screen name FEATURE SELECT One or more pages of the members in the group are displayed along with the value for this tag in the drive and its unit of measurement Values that are bit encoded will show a hex value for the parameter value Use the up down cursor keys to select the parameter which is bit encoded and then press the enter key Figures 3 69 and 3 70 The VIEW PARAMETER screen will then show that parameter as it is decoded per bit as shown in Figure 3 70 7000L UM302B EN P June 2013 3 50 Operator Interface 7000L UM302B EN P June 2013 The left side of the pair shows the name of the bit while the right side shows the current value of the bit within the parameter All of these values are updated from the drive on a continual basis From the DISPLAY screen it is possible to modify a parame
28. Marine 4 67 Component Definition and Maintenance Cooling System IUH Y3 NYHOXI 1v3H 13Ni8VO ONIT009 INYA NI Q31V901 HIONVHOXA LYSH ANON OL AINON uo 1XIH W30NVHOX3 1v3H HOOQ 35VLION MOT 3101860 NIT009 40 3QISNI NO 738V1 OL 43434 SNOLLISOd 3A VA SNLVESdO W31SAS ONIT009 3HL 40 NOILVH3dO WWHON HO 3H V CILVOIONI SV SMLVLS SATA 9 Hild MOT4 1NV1000 3HL NI SI LINN 9NISN3S 3HL NI 9NIN3dO 3HLIVHL S3HNSNI HOIHM H1d3Q V OL Q3TISNI SI 38OHd ALIALLONONOO S SONLLhOH 3dld HAWOLSNO NO ONIANId IO DIOVId 38 AVN S3did MOT NO SNIVHO ONY S3dld HOIH NO INA INYA IHL 4O LUYA SY GIONTONI 3v IN3A ONY NIVHO HINOLSNO 3HL Ag 3NddNS 38 O1 CIHINDIY LON 38V S3ATVA LNIA ONY NIVHO SNILVTOSI t isd Gs edv086 1339X3 LON TIM 3uinssaid NALSAS WRWIXVIN tpt 9 29 q330X3 LON TIM IUNLVHIANIL WALSAS WRAIXVIW HSHOIH GaLNNOW H3ONVHOX3 LV3H dl AHOLOV4 L InSNOO HIOAH3S 3H SAG 3HL NVHL H3MO1HO OL IVnO3 13A31 V LY GALNNON 38 OL SI H3ONVHOXS 1V3H IHL E LIS LV NOLIVTIVLSNI HO A3T10VHE N3TIV AQ Q3Iddns ANY a3ddiHs SI LNV1000 SAI 3HL WO AYMY 1334 0 WZL NVHL SHOW Q39V d SI HIONVHOXA LVH 4I SHON NILSAS Td OL 46 9 St LHOI3M A8 SHALXIW HILVM G3ZINOIBQ 100A19 01 09 40 Ieb SN Sp SIHLII 002 SIHINDIH WALSAS Z Wdo s n 019 UM zzz NVHL 3HOW ON OL MOT 3HL LOIHLSH OL GITIVISI SI HOLOIHLS3H MO 14 V LINDHIO H3ZINOISQ 3HL HOS 1 S310N NHALLYd 1108 310H gt 81091 8918 ISNV S3HONI 9 1 WWE 38v 3AIHQ
29. PF7000 Technical Data Parameters Troubleshooting Publication 7000 TD002_ EN P PF7000 MV Drives General Handling Procedures Publication 7000 IN002_EN P MV 400A Vacuum Contactor Series D User Manual Publication 1502 UM050_ EN P MV 400A Vacuum Contactor Series E User Manual Publication 1502 UM052_ EN P Drive Specific Electrical and Mechanical Prints Drive Specific Spare Parts List Materials Torque Sealer Yellow Part number RU6048 Electrical Joint Compound ALCOA EJC no 2 or approved equivalent for Power Devices Aeroshell no 7 Part number 40025 198 01 for Vacuum Contactors 7000L UM302B EN P June 2013 4 158 Component Definition and Maintenance 7000L UM302B EN P June 2013 7000 C Frame Marine Appendix A Catalog Number Explanation for PowerFlex 7000 MV Drives 7000 A105 D EHD R18TX 1 1DD 3LL 760A First Second Third Fourth Fifth Sixth Position Position Position Position Position Position Bulletin Service Duty Enclosure Nominal Line Voltage Rectifier Options Number Continuous Type Control Voltage Type Code Current Rating System Frequency Altitude Rating R6TX Refer to Code D NEMA Type 1 Reference R18TX TABLE A 1 w gaskets and vents TABLE A 3 RPTX Refer to IEC IP42 RPDTD TABLE A 2 e R6TX 6 pulse rectifier for connection to remote transformer R18TX 18 pulse rectifier for connection to remote transforme
30. Switch on the test power and measure the test voltage and current drawn by the capacitor Repeat the test for all three phases and note down the test voltage and current The capacitor will charge during this test so care must be taken to prevent a shock or injury N When moving the test connections from one phase to the next wait for at least five minutes until the capacitor is discharged Using a hot stick 7000L UM302B EN P June 2013 7000 C Frame Marine Component Definition and Maintenance 4 21 8 Now calculate the capacitance from the measured values of test voltage and current For a good capacitor the calculated capacitance value for each of the three readings should be within 10 of the capacitor nameplate micro Farad If it is outside this range then the capacitor must be replaced Example An example is given below to demonstrate how the capacitance value is calculated Suppose a capacitor under test is rated at 400kV AR 6600V 50Hz 29 2 uF Let us say you are using 200V 50Hz test power and have recorded the values of voltage and current for each test as given in the table below Phase Neutral L1 N L2 N L3 N Test Voltage 200V 200V 200V Measured Current 1 87A 1 866A 1 861A Let us calculate the capacitance using the first reading In this case V 200V I 1 87 for L1 N Xc V I 200 1 87 106 95 C fof Xc c 2x3 14x50x 106 95 C 29 7 uF Where f frequency of t
31. To aid in troubleshooting a time and date stamp is also provided indicating the last time the drive was started and stopped for any reason To acknowledge the alarm s press the F6 key This will cause the F6 key to cease flashing and return to normal video If a new alarm were to occur the F6 key would again flash in reverse video To reset the drive press the F7 key This operation will reset any latched faults in the drive This has no action upon either the Fault or Warning queues If some faults still exist they will return as new faults Faults and Warnings are stored into separate queues Both work similar thus only the fault queue will be discussed To access the fault queue press the F9 softkey from the ALARM SUMMARY screen A screen typical of Figure 3 75 will be shown The screen shows all faults in chronological order as they have occurred A timestamp gives the date and time that the fault occurred The most recent fault occurs at the top of the list Use the F8 and F9 keys to shift to other pages if required Entries are not removed from the queue until the queue is cleared with the F7 key If the queue becomes full the oldest entries are discarded to make room for newer faults FAULTS Figure 3 75 Fault Queue Help for Alarms When viewing the fault or warning queue help text may be associated with the alarm entry Use the up down cursor keys to highlight the alarm in question and press the
32. V Line Assigned The changes take affect immediately however are not saved until you press F10 and exit the screen Any time prior to this you may cancel all the changes made after coming to the screen by pressing the F7 key The status of the drive is viewed by pressing the F7 key from the Top Level Menu This screen shown in Figure 3 73 constantly displays the latest status of the drive STATUS Not Ready Not Running Forward Rotn No Faults No Warnings Fans Off Input Open Output Open acres Tres repre ro e Figure 3 73 Status Screen All drive faults and warnings are logged to their respective queues Collectively the faults and warnings are referred to as Alarms When a new alarm occurs the F6 key on any screen will begin to flash in reverse video Pressing the F6 key on any screen will bring you to the screen as shown in Figure 3 74 ALARM SUMMARY Status Not Ready Fault Marnina Drive Started 00 00 66 66 06 Drive Stopped 66 060 66 60 66 Figure 3 74 Alarm Summary Screen 7000L UM302B EN P June 2013 3 52 Operator Interface 7000L UM302B EN P June 2013 The screen shows the current status of the drive as well as the last active Fault that tripped the drive and any pending warning The screen only shows a fault and or warning if the drive is still in the fault and or warning state This is independent of the content of the queues Note Terminal FRN gt 4 005
33. 1 amp Analog Inputs 3 Isolated 4 20mA or 0 10 V Analog Resolution Analog input 12 Bit 4 20 mA Analog input 13 Bit 0 10V Analog Outputs 1 Isolated 4 20 mA 8 Non isolated 0 10 V Communication Interface DPI Scan Time Internal DPI 2 ms min 4 ms max RI O Lon Works DeviceNet Can Open Communications Protocols Ethernet RS485 HVAC Optional Profibus RS485 DF1 Modbus RS232 DF1 Interbus USB Enclosure NEMA 1 IP21 NEMA 12 IP42 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 Plates Bronze Chromate Fiber Optic Interface Rectifier Inverter Cabinet Warning Trip Door Filter Painted Diffuser with Matted Filter Media Door Filter Blockage Air Flow Restriction Trip Warning Iron and chlorine free ethylene glycol Coolant mixed with de ionized water Coolant Conductivity 1 2 micro Siemens CM Heat Exchangers Liquid to Air Liquid to Liquid Ambient Temperature 0 to 45 C 32 F to 113 F Storage and Transportation Temperature Range 40 C to 70 C 40 F to 185 F Relative Hum
34. 7000L UM302B EN P June 2013 3 68 Operator Interface Loading Language Modules 7000L UM302B EN P June 2013 a First Line arevision number followed by a semi colon Number is not important the date followed by a semi colon i e 01 01 1996 Date is not important the time followed by a semi colon i e 12 01 01 Time is not important b Remaining Lines each line contains one parameter The line consists of the linear parameter number followed by a semi colon and the parameter value followed by a semi colon i e 1 0 2 0 5 2 In order to use a language in the operator interface it must first be loaded into the operator interface from the flash card From the TRANSFER screen press the F5 key The operator interface will enter the DIRECTORY screen from which an existing language module filename can be selected or entered Figure 3 95 Refer to the sections entitled Select a filename and Enter a filename If nothing happens then you have not gained the required access to modify the flash memory Exit to the TRANSFER screen and refer to the section entitled Enter Modify an Access Level to gain access When the filename has been obtained the TRANSFER LANGUAGE screen such as that in Figure 3 96 will be displayed showing the filename indicating the operation you are about to perform and showing the current status of the operation DIRECTORY Filename actum 98 02 25 16 39 97 06
35. C Frame Marine Operator Interface 3 41 FAULTS OVERVIEW DISABLED Figure 3 52 AC ON Disabled FAULTS OVERVIEW ENABLED Cine an SW Watchdog HW Watchdog SW 07C HW B C oc 074 Line Phasing Figure 3 53 Fault Overview Enabled The state of the fault masks which you are currently viewing is defined to the right of the screen name i e FAULTS OVERVIEW DISABLED or FAULTS OVERVIEW ENABLED To change the state of fault masks currently displayed press the F7 Each press of the F7 key will toggle the screen to show the masks in the other state To change the state of a mask on the FAULTS OVERVIEW screen use the cursor up and cursor down keys to select the desired mask and press the enter key In the example of Figure 3 52 the AC O V is currently disabled and is selected When enter is pressed its mask is enabled thus removing the fault from this screen as shown in Figure 3 54 Pressing F7 toggles the screen to show the enabled faults which the AC O V is one of Figure 3 55 If nothing happens you do not have proper access to the drive Exit to the SETUP screen and refer to the section entitled Enter Modify an Access Level to gain access 7000 C Frame Marine 7000L UM302B EN P June 2013 3 42 Operator Interface 7000L UM302B EN P June 2013 FAULTS OVERVIEW DISABLED Figure 3 54 AC O V Removed From List FAULTS OVERVIEW ENABLED Cine ae SH Watchdog HH Watchdog Fi
36. Industrial schedule 80 CPVC piping for pump panel headers and manifolds no condensation possibility Control hardware for cycling of main redundant cooling pumps and heat exchanger fans 7000 C Frame Marine Overview of Drive 1 3 Topology 7000 C Frame Marine 2U X1 Plug and play Power Cage concept Central location for easy access to all main power components Common modular design for rectifier inverter Same concept as air cooled drive for front access easy component replacement and no special tools 5 10 minutes to replace main power devices No need to remove any cooling lines for device replacement Reduced manufacturing time for faster delivery and lower cost Keyed mechanical interlock Interlocked with main disconnect means to prevent unsafe access to medium voltage section The PowerFlex 7000L utilizes a Pulse Width Modulated PWM Current Source Inverter CSI for the machine side converter as shown in Figure 1 1 This topology offers a simple reliable cost effective power structure that is easy to apply 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 6500 volt PIV rated power semiconductor devices the number of inverter components is kept to a minimum For example only six invert
37. Load Loss Detection Adjustable level delay speed set points Control Mode Speed or Torque Current Limit Adjustable in Motoring and Regenerative Output Frequency Range 0 2 85 Hz Normal Duty Heavy Duty Service Duty Rating A 150 Overload for Overload Rating 10 Overoad Tor 1 minute every 10 minutes 1 minute every 10 minutes Variable Torque Load Constant or Variable Torque Load gt 98 18 Pulse Typical VFD Efficiency gt 97 5 AFE Contact Factory for Guaranteed Efficiency of Specific Drive Rating Input Power Factor AFE Rectifier 0 98 minimum 30 100 Load IEEE 519 Harmonic Guidelines IEEE 519 1992 Compliant VFD Noise Level 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 40 character 16 line formatted text Languages English German French Chinese Mandarin Spanish Portuguese Italian 7000 C Frame Marine Overview of Drive 1 11 Description Specifications Control Power 220 240 V or 110 120 V 1 phase 50 60 Hz 20 Amp External I O 16 Digital Inputs 16 Digital Outputs a 50 60 Hz AC or DC External Input Ratings 120 240 V 1 mA 50 60 Hz AC or DC External Output Ratings 30 260 V
38. OIBs O OPTICAL INTERFACE BASF PCR 80190 5985 MJ e a Alay Es Pa ci ICT e E ae Ll my En E a i ux LC Es DEN c IPM TPIS TFB_A GND E EA EP m B Es A Ed ale o ma te gi e BH B IE25 1027 us BEBE amp ES 41 1228 TP29 DESIGNED IN WADE IN n MI E IP32 TP33 44 Bi ES Ba n ES Bg pas TP36 W Bd c ee ES T 5 TP42 Tp43 e5 TFB_B GND Es ms en c O PRODUCTIOI RA CANAD FEB Sel mener ARE Figure 4 80 Optical Interface Base Board OIBB 7000L UM302B EN P June 2013 4 116 Component Definition and Maintenance Optical Interface Base Board OIBB cont 7000L UM302B EN P June 2013 Optical Interface Base Board Test Points In addition to the command and diagnostic test points there are three ground reference test points These reference points are electrically identical but are physically placed to facilitate easy connection of Oscilloscope or Chart recorder test leads Table 4 F Test Points on Optical Interface Base Board OIBB
39. Port 1 2 Green Count Port 2 Red 10 Count End of Code Reached Red 11 Count Download CRC Error Red 14 Count Download Overflow Error 7000L UM302B EN P June 2013 7000 C Frame Marine 7000 C Frame Marine Component Definition and Maintenance 4 91 Drive Processor Module Replacement Before replacing the Drive Processor Module it is important to record all of the programmed drive parameters and settings Specifically the parameters fault masks fault descriptions and PLC links are critical This information is stored in NVRAM on each and as a result you may lose your settings with a new board The best method to record parameters is to use the memory on the terminal Other options include a flashcard HyperTerminal the door mounted printer or DriveTools to record the parameters to a file The printer and HyperTerminal options allow you to print all of the drive setup information Otherwise recording information by hand is the only option left In the situation where a board has failed you probably will not be able to save parameters after the failure That is why it is important to save all parameters when you are finished commissioning or servicing the drive In this case you should contact the customer to see if they have a copy of the last parameters or contact Product Support to check if they have a copy Instructions to Replace the Drive Processor Module 1 Record all drive setup information using
40. Some data must be entered in HEX To accomplish this use the cursor up down keys to scroll through the values 0 F for the right most digit To accept the digit and enter to the right of the current digit press the right cursor key Press the Enter key to accept the value The value may be edited the same as a value entered from the numeric keypad The new value is not sent to the drive until you exit the screen with the F10 key Prior to this you can modify the new value by repeating the above procedure or you can cancel the change by pressing the F7 key The CANCEL operation returns the new value to that of the actual value 7000L UM302B EN P June 2013 3 36 Operator Interface 7000L UM302B EN P June 2013 Enumerated Value When the parameter is an enumerated value the MODIFY PARAMETER screen typical of Figure 3 44 will be displayed This screen shows the name of the parameter for which you are make the changes i e Operating Mode e the tag code for the parameter i e 4 e the actual value of the parameter contained in the drive MODIFY PARAMETER Operating Mode P 4 Actual Normal New Normal acres cancer Process T 7 Figure 3 44 Modify Enumerated Value MODIFY PARAMETER Operating Mode P 4 Actual Normal New Normal Gate Test pc Current Pen ircui acres cancer Process T 7 Figure 3 45 Option List Viewed on Single Page To be allowed to make c
41. Trend Data Alarm Queues Wariables Printer Status Auto Dff Now using Up or Down arrow keys on the Terminal keypad select the item you want to print ie upload the info into laptop and press Enter key The required information will be transferred to your laptop and stored in the file C temp Example txt Repeat this step to upload other data into your laptop Note The most desirable selections are e Drive Setup for complete setup which include Parameters Fault Masks and Revisions e Trend Data for analyzing the drive trending e Variables snapshot of real time data while the drive running Note that while the data is being transferred the Printer Status will show Transfer in Process Once the data transfer is complete the Printer Status changes to either Auto Off or Auto On 7000L UM302B EN P June 2013 7000 C Frame Marine Component Definition and Maintenance 4 144 The last step is to stop the communication between your laptop and the drive and close the file Example txt At your laptop click on Transfer menu and select Stop option under Capture Text as shown in the screenshot below PF7000 Print HyperTerminal iof x File Edit View Call BREW SE Help Dle Serre Receive File Send Text File Pause Resume Capture to Printer m 4 gt Stop capturing DA Now close the HyperTerminal program and disconnect the laptop from the driv
42. a This will begin the selection process of a tag as described in the section entitled Select a Parameter When selecting a tag for the output words only parameters will be allowed Both parameters and read only parameters are allowed for the selection of input words When you have completed the selection process the selected tag will be assigned to the link To remove an assignment to the highlighted link press the delete Backspace key The changes made do not take affect until you press F10 and exit the screen Any time prior to this you may cancel all of the changes made after coming to the screen by pressing the F7 key XIO The drive uses XIO adapters to hardwire to discrete inputs and outputs Each drive contains one or more of these modules Each module contains a unique address that is assigned automatically according to where it is attached on the link This address value can be seen on the LED display of the module The drive must be configured with these address values to link them to a parameter in the drive To setup the XIO configuration use the up down arrow keys on the SETUP screen to select the XIO option and press the enter key Note This feature is currently inactive and is reserved for future enhancements 7000L UM302B EN P June 2013 3 46 Operator Interface Message Prompting All the changes you made while you were configuring the drive are stored in volatile memory of the drive This means
43. key on the main screen to display Diagnostics screen as shown in the picture below 7000L UM302B EN P June 2013 7000 C Frame Marine Component Definition and Maintenance 4 129 7000 C Frame Marine 2 Press F8 D SETUP The display will change to Diagnostics Setup screen as shown in the picture below UNPROGRAMMED igger Not Available 3 With Trace 1 selected press Enter key as shown in the picture below 7000L UM302B EN P June 2013 4 130 Component Definition and Maintenance Setting up Diagnostic Trending cont 7000L UM302B EN P June 2013 4 The display will change to Select Group screen as shown in the 5 picture below Now there are three ways to find the desired a parameter i search by group select the group by pressing up or down arrow keys and then press Enter key ii search by Alphabetical order press F7 key to move to the letters screen from there you can search the parameter by highlighting the first letter of the parameter and then pressing the Enter key iii by entering the parameter linear number press F7 and then F5 for the Code In the following example we will select the parameter by using a Linear number i e we will enter the Code For this follow the steps outlined below Press F7 LIST The display will change to Select Letter screen as shown in the picture below 6 Press F5 CODE The display will change to Select
44. 12 13 17 RUSSIAN 97712709 09 06 Figure 3 95 Language Directory 7000 C Frame Marine System Programming 7000 C Frame Marine Operator Interface 3 69 TRANSFER LANGUAGE FILENAME FRENCH LNG DOWNLOAD LANGUAGE PROCEED Yes No Operation Status TRANSFER PENDING HELP CLEAR LANG GE sii Fs oe ves so T can Figure 3 96 Transfer Language Module The screen will then ask you to confirm the operation Press the F8 key to proceed or the F9 key to abort If an attempt to download a language module that already exists is made the transfer will fail In order to download a newer version of a language all languages in the operator interface must first be cleared this is a characteristic of flash memory by pressing the F2 key on the TRANSFER LANGUAGE screen The screen as in Figure 3 97 will then ask you to confirm the operation Press the F8 key to proceed or the F9 key to abort TRANSFER LANGUAGE CLEAR LANGUAGES PROCEED Yes No Operation Status CLEAR PENDING Ger Tas T eee ace om wes so ext Figure 3 97 Clear Languages Pressing the F5 key may restart an aborted download or one that failed To select or enter a different filename press the F7 key The firmware for the complete drive system may be updated via serial port 2 on the Customer Interface Board Pressing the F9 key from the transfer screen will place the drive system into downlo
45. 17 Edit the Text When editing is complete the screen will appear as in Figure 3 18 METERS METERi Speed Digital spdmeter LineUolt YU line Uoltage Digital vitmeter METER4 Power Digital pwrmeter uses cancer access exit Figure 3 18 Editing Completed The operator interface contains a default set of meters This default set is selected by pressing the F2 key any time the Meters screen is displayed This results in the default text and tags as shown in Figure 3 15 The changes made do not take affect until you press F10 and exit the screen Any time prior to this you may cancel all of the changes made after coming to the screen by pressing the F7 key The result of selecting the V Line tag for meter 2 in our example is shown in Figure 3 19 after the METERS screen was exited Rev 4 XX Status Not Ready Speed Lineuolt P Uoltagse 33 U Power 2166 hp 2182 6 Hrs 8 Figure 3 19 Top Level Meter Modified 180 150 7000 C Frame Marine 7000L UM302B EN P June 2013 3 20 Operator Interface 7000L UM302B EN P June 2013 Viewing Revision Levels For the purpose of maintenance or upgrading of software the revision levels of all the software contained in the terminal and the drive may be viewed To access this screen press the F9 key A screen typical of Figure 3 20 shows the type of drive a16 character user definable string to uniquely iden
46. 2013 4 50 Component Definition and Maintenance Self Powered Gate Driver Board SPGDB cont 7000L UM302B EN P June 2013 Terminal connections description TB1 1 TB1 2 TB2 1 TB2 2 TB3 1 TB3 2 TB3 3 TB4 2 TB4 1 OP1 OTI Connection to SCR snubber circuit used to extract energy from the snubber for SPGDB operation Connection to SCR sensing resistor which indicates conduction status of SCR being operated Positive 20V power supply connection to temperature sensor board Provides power to temperature sensor board Common connection of positive 20V power supply to temperature sensor board Positive 15V power supply connection for test power used when commissioning drive or testing SPGDB Provides artificial sense voltage signal to allow SPGDB to gate the SCR when in test mode When the appropriate test power cable is used P N 81001 262 51 this input is shorted to TB3 1 to obtain the sense voltage Common connection of positive 15V power supply used for test power Cathode connection to SCR being controlled Gate connection to SCR being controlled Blue fiber optic cable receptacle Firing pulse command from the processor Grey fiber optic cable receptacle Diagnostic status of the SCR 7000 C Frame Marine Testing procedure for SCR self powered gate driver board 7000 C Frame Marine Component Definition and Maintenance 4 51 Equip
47. 2013 To rectify the problem add small quantities of water Measure the freeze temperature of the coolant after each addition and continue adding until the desired freezing temperature is achieved Leakage Checks When repairing leaks or working on the stack assemblies it is highly recommended that several layers of industrial grade absorbent pads be placed on top of the middle and lower stacks to prevent any coolant spills from falling down on to the lower components specifically the printed circuit boards Most leaks will be visible in the first 30 minutes and once the system begins to fill and pressurize you should be constantly inspecting all fittings and connections for drips It is best to have help in checking the inverter and rectifier section and the DC Link cabinet An absorbent cloth is ideal for checking that the coolant is actually leaking and is not just remnants of the repair If a leak is a visible at the threaded joint of a stainless steel fitting and a CPVC plastic pipe the leak can often be repaired by tightening the joint Use the following values of torque when tightening stainless threaded fittings into CPVC Thread Size Torque N m Ib ft Typical Wrench Size 1 4 inch NPT 9 5 N m 7 0 lb ft 15 mm 9 16 inch 3 8 inch NPT 9 5 N m 7 0 lb ft Li I pulqa 1 2 inch NPT 27 N m 20 lb ft 29 mm 1 1 8 inch If a leak persists it will be necessary to drain the system disassemble the thread
48. 20B ENC Board Any unused input should be wired to the encoder power rail This also includes the B and B inputs if using a pulse tachometer Failure to do this will result in phase loss warnings and improper operation of the encoder feedback logic i e missing counts 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 is dependent on the position of the POL QRDNT jumper If the jumper is installed then wire all unused inputs to ENC PWR otherwise use ENC COM 7000 C Frame Marine Drive Installation 2 61 4 hole insulator Bolts 7000 C Frame Marine Information Regarding Termination of Customer Cables Customer termination assemblies can accommodate either top or bottom customer cable entry Lug pad shown with bottom cable entry orientation M10 bus connection hardware Customer supplied lugs 4 lugs per phase maximum Figure 2 64 Typical Line Cable Termination shown assembled for bottom cable entry For top line cable entry it is necessary to remove the lug pads and re orient them as shown in Figure 2 65 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 See Appendix B for Torque Values of electrical connections A
49. 4000 Actual 4100 New 4166 Max 4160 CC CI Tees T 527 Figure 3 42 Parameter Data Entry 7000 C Frame Marine 7000 C Frame Marine Operator Interface 3 35 MODIFY PARAMETER Rated motor volt P 22 Min 4000 Actual 4100 New 4000 Max 4160 rca cancer eocess T 8 Figure 3 43 Modify Numerical Value To be allowed to make changes to the parameter the operator interface must be set to an Access Level other than Monitor You will be able to view the screen however pressing the data entry keys will have no effect If you are not in the correct level press the F8 key in order to gain access to the parameter Refer to the section entitled Enter Modify an Access Level for further information on the operation to change the level Having gained access use the data entry keys 0 9 to enter the new value The key can be typed at any time to enter a negative value The key is used to enter a decimal point for fractional values The entered new value can be edited by pressing the backspace key This key will delete the right most character i e number decimal point or negative sign shown on the screen Press the enter key to accept the new value as shown in Figure 3 43 If the new value that you entered is outside the limits defined the new value will not change For example If you entered 900 when the minimum value was 4000 the new value will still show 4100
50. 43 DC Link and Control Power Cabinet The door of the Control Power Panel is interlocked so that it cannot be opened unless the 3 phase control power is disconnected When the door is opened the AC Control Power transformer and the AC DC power supplies are accessible This is the section where the customer 3 phase power is brought into the drive The DC Link is mounted on the floor beneath the control power section The larger door is interlocked with the rest of the system and cannot be opened unless the MV power is locked out The DC Link is part of the cooling circuit for the PowerFlex 7000L C Frame drive and has 2 inlets and 2 outlets for coolant flow Power Connections are made to the DC Link through flexible leads and they are labeled L L M and M There is a Hall Effect current sensor on the M connection to the DC Link 7000L UM302B EN P June 2013 7000 C Frame Marine Component Definition and Maintenance 4 57 DC Link Reactor The DC Link maintains a ripple free current between the rectifier and the inverter Thermal levels in the DC Link are achieved through cooling water The DC Link Reactor does not normally require service To replace the DC Link refer to figure 4 44 and complete the following steps
51. 45 C 113 F Relative humidity of the air not to exceed 9596 non condensing For the equipment to operate in conditions other than those specified consult the local Rockwell Automation Sales office The equipment requires the following site conditions A Indoor installation only no dripping water or other fluids B Clean air for cooling requirements C Level floor for anchoring the equipment Refer to dimension drawings for the location of the anchoring points D Theroom in which the equipment is located must allow for full opening of the doors of the equipment typically 1200 mm 48 inches Also allowances have to be made for clearance for fan removal or Dimension drawings can be obtained by contacting the local Rockwell Automation Sales office The equipment does not require rear access for servicing E Allowance must be made for the stream of cooling air which exits the drive at the top The flow of cooling air into and out the drive must be kept clear and uninhibited 7000L UM302B EN P June 2013 2 6 Drive Installation F The room in which the equipment is located must be large enough to accommodate the thermal losses of the equipment since air conditioning may be required the ambient temperature must not exceed that for which the equipment is rated The heat created by the drive is directly proportional to the power of the motor being driven and the efficiency of equipment within the room G The a
52. As window enter a filename for instance Data from the Drive example txt in the field next to File name and select the cont directory from the dropdown list next to Save in at the top of the window In this example the selected directory is C temp Now click on Save button My Recent Documents Desktop n My Documents wm GE My Computer c L 3 My Network File name laces Save as type Text Documents t t Encoding An empty notepad file has been created So now close the Notepad program Step 2 Setting up HyperTerminal Connection Run HyperTerminal program On the Connection Description window enter a name for instance Parameters for the New Connection under the Name field as shown below and then click OK Connection Description Ab New Connection Enter a name and choose an icon for the connection Name Parameters Icon 7000L UM302B EN P June 2013 7000 C Frame Marine Component Definition and Maintenance 4 137 Now the Connect to window will appear Select COM1 from the dropdown list next to Connect Using and then click OK as shown below BI FimwareDownload Enter details for the phone number that you want to dial Country region United States of America 1 Area code 5 Phone number Connect using 3COM MEGAHERTZ 3CXM356 Mc 3COM MEGAHERTZ 3CXM358 Mode COMS COMI TCP IP Winsock Now the COM
53. Code screen as shown in the picture below 7000 C Frame Marine Component Definition and Maintenance 4 131 7 Enter the parameter linear number in our example we have entered 569 and then press Enter key Once you press the Enter key the parameter description will appears on the screen as shown in the picture below 8 Press Enter key again The display will change to the Diagnostics Setup screen and the desired parameter gets assigned to Trace 1 Now press the down arrow key to move the cursor to Trace 2 and repeat steps 3 8 above to assign a parameter to Trace 2 DIAGNOSTICS UP tatus Flagi rustatus Flagi ost Sample 5 7000 C Frame Marine 7000L UM302B EN P June 2013 4 132 Component Definition and Maintenance Setting up Diagnostic 9 Repeat above steps until you have assigned the desired Trending cont parameters to all the traces from Tracel to Trace16 10 Now press F9 TRIGGER key The first letter in the second line on the screen will toggle between C and S The letter C stands for Continuous and S stands for Single shot Select S for single shot 11 Press F2 CONDITION key The cursor will move to the equal sign This defines the trigger condition Press up or down arrow keys to select sign as the trigger condition for our example 12 Press F3 DATA key The cursor moves to the data field In our example we will enter 8 and then press Enter
54. D2 Yellow On Ready The OIB has received sufficient power for all transmit ports D3 Green On Power The OIB has received a voltage signal greater than 2V Optical Interface Board Replacement To replace the Optical Interface Boards 1 Ensure that all medium voltage and control voltage power to the drive is isolated and locked out 2 Note and mark the location and orientation of all the fiber optic cables Use the electrical drawing for reference 3 Using your static strap disconnect all of the connections It may be necessary to remove the 60 core cable connectors on the Optical interface base and the ground connection for access to the standoffs 4 Remove the OIB board from the OIBB There are four standoffs that snap into place on the OIB and they need to be carefully handled when disconnecting the boards There is also the 28 pin connection between the boards and this connection should be handled carefully as you do not want to bend the pins 5 Install the new OIB on the OIBB Ensure the standoffs snap into place Reconnect all fiber optic connections and verify the locations Apply Low Voltage power and complete a Gating Test System Test and Medium Voltage tests to ensure the new board functions properly 7000L UM302B EN P June 2013 4 114 Component Definition and Maintenance Optical Interface Boards OIB cont Dye d CONTROLLOSIX TT50 A10 CHASSIS Ho WITH
55. E sen I wr oc sto 13s E FIRMWARE amp Lia inn eg LABEL ens m os ii E O 3 Hi a u Rp220 8 5 aM 3 2 x E D pE DI a a e s n x RP3I 2 CARTE He dg 3 gt Fi vp use Ne be we sig 120 Lil zu wes Dto C NEN t 3 wi mg ys riaRPs4 di nae SI eu ra 3 vt p T 5 d d I m ui s 13 SIS Teru wu ross CIB ui tud U U 0087 are DG NEG Et oma Dui DD e RP4GLII t 4 ORPI dr A i pa 1 Il ER B B IB oS ts 199 ae Ae eno Resa vie wif wae sU pe fitta tud d E EE fa val nia Risi eRP26 e a Od fra use ni tia mi ge ie E p jmoeoococe gt xy CUN 109 of ES et m fa UBS n e TER mR UT lee d j ER ER a 5 m cu Cio E En LIE ee usi Mv Sun nom Ame EI Bo hide tole coetui iii im LEE Ly wo T2 Y ia 1 un CF Figure 4 67 Drive Processor Module DPM 7000 C Frame Marine 7000L UM302B EN P June 2013 4 90 Component Definition and Maintenance Drive Processor Module The following is the list of test points on the DPM cont NOTE Diagnostic Test Points on the DPM have a voltage output range of 5 to 5V Table 4 B Test Points on Drive Processor Module Test points Name Description DPM TP1 12V 1 2V DC power supply DPM TP2 1 8V 1 8V DC power supply DPM TP3 2 5V 2 5V DC power supply DPM TP4 3 3V 3 3V DC power supply DPM TP5 5V 5V DC power supply DPM TP6 D
56. June 2013 2 20 Drive Installation Control Wiring Connections cont Control Wire Power Connections Thermostat and Fan Connections Figure 2 26 Figure 2 27 9 Once all the connections have been made and neatly routed in each section the excess control wires can be looped up in the top wireways 10 Swing out the control section in the pump control cabinet 11 Route the XIO link cable control power wires and the fiber optic cable down through the wire ways grommeted cutout 12 Route the XIO link cable the control power wires into the pump control cabinet through the upper side grommeted cutout 13 Route the fiber optic cable into the pump control cabinet through the lower side grommeted cutout Figure 2 28 120 volt and XIO cables through upper cutout 14 Connect the XIO link cable to the XIO board XIO link A connector Figure 2 29 7000L UM302B EN P June 2013 7000 C Frame Marine Drive Installation 2 21 15 Connect the control power wires to the control power terminal blocks Refer to Electrical Drawings for corresponding wire numbers and terminal blocks 16 Connect the fiber optic cable to the TFB board XIO link cable TFB Fiber optic connected to XIO link A connected Figure 2 29 Figure 2 30 Use supplied silicone see Fig 2 31 to seal between cabinets to prevent moisture or dirt from entering Join sidesheets with M6 Taptite thread forming screws in holes provided Silicone se
57. June 2013 4 26 Component Definition and Maintenance SGCT and Snubber Circuit Similar to all power conductors or thyristors the SGCT must have a snubber circuit The snubber circuit for the SGCT is comprised of a snubber resistor in series with a snubber capacitor Sharing Resistor Snubber Snubber Resistor Capacitor Figure 4 18 SGCT and Snubber Circuit In addition to the snubber circuit a sharing resistor is connected in parallel with the SGCT The function of the sharing resistor is to ensure the voltage is shared equally among the SGCTs when connected in series SGCTs are connected in series to increase the total reverse voltage blocking PIV capacity as seen by the electrical circuit A single SGCT has a PIV rating of 6 5 kV At 4 16 kV 2 SGCTs must be connected in series to provide a net PIV of 13 kV to achieve the necessary design margin Similarly three SGCTs must be connected in series at 6 6 kV The cooling requirements of the SGCT are achieved by placing the SGCT between two liquid cooled chill blocks one chill block on the anode and the other chill block on the cathode The force placed on the SGCTs differs with the size of the device A 63 mm device 1500A requires 20 kN The clamp assembly on the right hand side of the inverter module generates these forces 7000L UM302B EN P June 2013 7000 C Frame Marine Component Definition and Maintenance 4 27 Checking Clamping Pressure Periodically the clampi
58. Loosen only bottom and front true union connector of the two valves Valves V4 and V11 are for Pump 1 and Valves V5 and V12 are for Pump 2 7 Unbolt the pump from its foot plate 8 Take the pump out and replace it with another 9 MAKE SURE THAT CORRECT VOLTAGE IS TAPPED FROM THE NEW PUMP WINDING ENSURE THE THREE PHASE SUPPLY IS TERMINATED IN THE ORIGINAL SEQUENCE TO KEEP THE SAME PUMP ROTATION DIRECTION Piping Tubing and Connectors The piping is schedule 80 type made from chlorinated polyvinyl chloride CPVC which has good high and low temperature properties it is unaffected by de ionized water or ethylene glycol The main piping is either 1 5 inch 38 mm or 2 0 inch 50 mm diameter The flexible tubing for the coolant path from the manifolds to the various hose barbs throughout the drive is 3 8 inch 10 mm inside diameter silicon The manifolds just as the chill blocks use hose barbs to provide easy connectivity of the hoses 7000 C Frame Marine 7000 C Frame Marine Component Definition and Maintenance 4 71 Non Return Valves The non return valves NV1 amp NV2 shown in Figure 4 55 are ball type valves made from CPVC These can not be changed with the drive on line All coolant must be drained to replace these parts NV1 NV2 V11 V12 From P2 Figure 4 55 Pressure Indicator and Switch Locations Pressure Indicator The pressure indicator PI shown in Figure 4 55 indicates the
59. Marine 7000L UM302B EN P June 2013 4 100 Component Definition and Maintenance Current Loop Transmitter cont DSP FPGA Non Isolated Process Outputs The drive supplies four non isolated 10 0 10 V outputs for customer use These outputs can drive loads with impedances as low as 600 ohms These outputs are all referenced to the Drive AGND and therefore should be isolated if they are required to drive outside the PowerFlex C frame enclosure IFM Pins 27 31 35 39 AID gt Analog Output gt 25 29 33 37 7000L UM302B EN P June 2013 gt 28 32 36 40 Figure 4 73 Non Isolated Configurable Analog Outputs on ACB Auxiliary 24V Power Supply An Isolated 24V Power Supply is built into the DC DC converter Connector P3 This supply may be used for any customer supplied equipment requiring up to 24 watts at 24 volts This supply may also be used to power any custom drive options such as isolation modules for additional Process Control Outputs The health of this power supply is monitored in the drive PIN NO DESCRIPTION 1 ISOLATOR 24V 1A ISOL COMM com4 3 EARTH 7000 C Frame Marine 7000 C Frame Marine Component Definition and Maintenance 4 101 ACB Analog Control Board Replacement To replace the ACB Analog Control Boards 1 10 Ensure that all medium voltage and control voltage power to the drive is
60. Optic Interface Boards Tach Feedback 4 zd A Circuit Board ns ciun UE He ei DC DC Drive Processor Aaaa m Power Module DPM ee Supply da 8 a Figure 4 63 Low Voltage Compartment 7000 C Frame Marine 7000L UM302B EN P June 2013 4 84 Component Definition and Maintenance DC DC Power Supply 7000L UM302B EN P June 2013 Description The DC DC power supply is used as a source of regulated DC voltage for various logic control boards and circuits The input to this power supply is from a regulated 56Vdc source m gt 45V LOGIC T 56VDC L gt 15V LOGIC DC DC gt 4 24 HECS C hold u Power Supply p L gt 24V ISOLATOR gt 24V IXO Sense Cable Figure 4 64 DC DC Converter Power Supply The capacitor at the input terminals is for power dip ride through purposes Upon loss of the 56V input the capacitors C hold up will maintain the voltage level This component is not required in all configurations Due to the critical nature of the ACB DPM Logic power source the DC DC power supply has been designed to provide redundancy for the 5V rail There are two separate 5V outputs each capable of powering the logic boards In the event of one failing the other power supply will be automatically switched in to provide the output power 7000 C Frame Marine P1 DC Input P2 SENSE To ACB P3 ISOLATOR To Isolator Modules P4 P
61. POWER SUPPLY 1756 PAT5 Ie e oao e o o o E E o o r Pal 990 00900000 000000000000 000000000900 0800 ugo L Do mm uu UO umm uo 000090 690 0690 0090099000900659009500600 o o o Optical Interface Boards OIB Figure 4 79 OIB Replacement Mounting Plate Accessible 7000L UM302B EN P June 2013 7000 C Frame Marine Optical Interface Base Board OIBB 7000 C Frame Marine Component Definition and Maintenance 4 115 This board provides the mechanical and electrical interconnections between the OIBs and the DPM It connects to either J11 or J12 on the DPM via a 60 Conductor shielded ribbon cable The drain wire for this cable must be attached to the screw terminal J8 The remaining connectors on the board complete the electrical connection of the installed OIBs to the DPM Each OIB can support from one to three
62. SELECT LETTER screen Figure 3 25 by pressing the F5 key It allows you to select the tag given that you know the tag code associated with the desired tag Every parameter i e tag has a unique code associated to identify it to devices incapable of making decisions based on a name such as a PLC for example 7000 C Frame Marine Operator Interface 3 25 Use the data entry keys 0 9 to enter the desired code on the SELECT CODE screen Figure 3 27 The entered code may be edited using the backspace key Press the enter key SELECT CODE I Enter Tag Code Panes TEM Figure 3 27 Select via Code Step 1 The screen will display one of two formats If the code you entered was valid it will show the name of the tag associated with the code Figure 3 28 This allows you to verify that this was the tag that you intended to select with the code before proceeding If correct press the enter key If incorrect immediately repeat the process by typing in another code If the tag code was not valid a message indicating such is displayed as in Figure 3 29 SELECT CODE ated motor volti Enter Tag Code Panes Figure 3 28 Valid Tag Code SELECT CODE Enter Tag Code 14 Invalid Tag Id Code ous T Figure 3 29 Invalid Tag Code 7000 C Frame Marine 7000L UM302B EN P June 2013 3 26 Operator Interface Edit Text 7000L UM302B EN P June 2013 When the enter
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64. 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 Medium Voltage Products 135 Dundas Street Cambridge ON N1R 5X1 Canada Tel 1 519 740 4100 Fax 1 519 623 8930 www ab com mvb Publication 7000L UM302B EN P June 2013 Copyright O 2013 Rockwell Automation Inc All rights reserved Printed in Canada Supersedes Publication 7000L UM302A EN P January 2011
65. TP22 Vvws Line Voltage Synchronous Feedback VSBC TP23 V3uv Line Voltage Feedback 3UV TP24 V3vw Line Voltage Feedback 3VW TP25 V3wu Line Voltage Feedback 3WU TP26 I3u Line current CT3U TP27 I3w Line current CT3W TP28 Vzs3 Zero Sequence Generation Line side VZS3 TP29 Vn2 Line Filter CAP Neutral Voltage for Bridge 2 LFCN2 TP30 V3 pk AC over voltage detection for 3UVW TP31 Vdcr2 Line side DCLINK Voltage for Bridge 2 VLDC2 TP32 Idc2 DCLINK current HECSDC2 TP33 Vwus Line Voltage Synchronous Feedback VSCA TP34 V4uv Line Voltage Feedback 4UV TP35 V4vw Line Voltage Feedback 4VW TP36 V4wu Line Voltage Feedback 4WU TP37 Mu Line current CT4U TP38 l4w Line current CT4W TP39 Vzs4 Zero Sequence Generation Line side VZS4 spare one TP40 Vnn CMC Neutral Voltage VNN TP41 Inn CMC Neutral current INN TP42 Ignd Ground Fault current GFCT TP43 Vspr Spare channel for inputs TP44 Vmtrp Motor Over Voltage Detection set point TP45 At Encoder A input TP46 B Encoder B input TP47 Z Encoder Z input TP48 A Encoder A input TP49 B Encoder B input TP50 Z Encoder Z input 7000L UM302B EN P June 2013 4 96 Component Definition and Maintenance ACB Analog Control Board Table 4 E Test Points on Analog Control Board cont cont Test points Name Description TP51 CP1 Control Power monitoring for channel 1 TP52 CP2 Contr
66. Thermostatic Valve Replacement Drive must be shut down while replacing the thermostatic valve 1 Open valve 10 and drain all coolant before replacing the thermostatic valve 2 Note three flanges A B and C on thermostatic valve If you cannot see the marks A B and C on thermostatic valve you should mark three flanges This is very important to put the thermostatic valve in correct position The mark C flange will be in upper direction and mark B flange will be in the bottom direction 3 First unbolt flange A and B Unbolt flange C which is in upper direction at the end To Heat Exchanger Thermostatic Valve Housing TV1 B Figure 4 57 Thermostatic Valve Replacement 7000 C Frame Marine 7000L UM302B EN P June 2013 4 74 Component Definition and Maintenance Pump Maintenance and Replacement cont 7000L UM302B EN P June 2013 Repair Instructions Element Testing Place element in water at a temperature 8 C to 1 C 15 F to 2 F above its nominal setting and stir water vigorously with the element for five minutes The temperature stamped on the side of the element is not the nominal temperature it is the temperature at which the element is set to open The stamped temperature is usually 6 C to 8 C 10 F to 15 F higher than the nominal After stirring vigorously immediately place the element in the housing If the element is fully stroked the seating and over travel spring can be felt as it is pus
67. Too much joint compound may result in contamination of other surfaces leading to system damage Slide the SGCT into place until the mounting brackets contact the surface of the chill block Do not force SGCT when inserting into place Make sure it slides in with little resistance Use a Phillips screwdriver to tighten the captive screws to the cathode side of the chill block Readjust the clamping load as described in Checking Clamping Pressure Connect the control power cable and fiber optic cables ensure the bend radius is not exceeded 7000L UM302B EN P June 2013 4 32 Component Definition and Maintenance Silicon Controlled Rectifier and SCR Self Powered Gate Driver Board Replacement 7000L UM302B EN P June 2013 The method for replacing the Silicon Controlled Rectifier SCR is almost identical to that of the SGCT The one exception is that the SCR and circuit board can be replaced independently of one another 1 Ensure there is no power to the equipment ATTENTION To prevent electrical shock ensure the main power has been disconnected before working on the drive Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Failure to do so may result in injury or death 2 Note the position of the Fiber Optic Cables for reassembly 3 To Remove the SCR and SCR SPGD Board it is necessary to remove the Gate Driver Power Supply connector from snubber circuit th
68. U p Ex p Boards Hd di i EE dis ACB lg Tr Ed MM UE o NI 0 n o A D E E P TRITT o gt HUITHTEITHIT E b IAUDIO IOKODILDI TEO e b MELLE TOT YF PY CUMUNU o gt KOUTOU TOU 1 MORTE A MINIMI UODO COT _ Communication Marine UPS 7F4 5 7 HipHHHHEH o I YUN UNE E 1l Card i g Ly e j i qu 79 47 S e e n e o o Figure 2 50 Pump Cabinet showing swing out low voltage panel 7000 C Frame Marine 7000L UM302B EN P June 2013 2 44 Drive Installation Grounding Network De ionizer Cartridge Motor Filter Capacitors Heat Exchanger Motor Terminals Coolant Pumps Voltage Sensing Figure 2 51 Pump Cabinet swing out low voltage panel removed 7000L UM302B EN P June 2013 7000 C Frame Marine 2 45 Drive Installation 7000L UM302B EN P June 2013
69. Universal Encoder Interface the position data is inverted in hardware That is a 1 will turn on an Optocoupler producing a 0 Therefore a High True encoder would produce 1111111111 for the zero position With the POL_QRDNT jumper you can control the polarity of the input With the jumper installed factory default it is setup to accept High True encoders and an extra inversion is done in the Universal Encoder Interface If you are using a Low True encoder then this jumper needs to be removed so that the zero position is inverted by the optocouplers alone 7000 C Frame Marine External Input Output Boards Component Definition and Maintenance 4 109 The other role of the POL_QRDNT jumper is to correct the data in the event the encoder was mounted so that a CCW rotation produced decrementing counts If this is the case the POL_QRDNT jumper should be configured to the opposite of what it should normally be for the data polarity For example if the Universal Encoder Interface is configured to operate with High True encoders POL_QRDNT installed remove it to correct for encoder mounting The External Input Output XIO Boards are connected through a network cable CAN Link to the Analog Control Board ACB This cable may be connected to either XIO Link A J4 or XIO Link B J5 The XIO board handles all external Digital Input and Output signals and sends them to the ACB through the cable There are 16 Isolated Inputs and
70. Yes to terminate the HyperTerminal Program 3 Printing Control Data Restart HyperTerminal program At the Connection Description window as shown below click Cancel Connection Description yy New Connection Enter a name and choose an icon for the connection Name From the File menu click Open The Open window will appear Locate the HyperTerminal connection that you just created in step 2 above ForGe_CONNECTION in this example and then click Open 7000L UM302B EN P June 2013 7000 C Frame Marine 7000 C Frame Marine Component Definition and Maintenance 4 145 Look in O HyperTerminal yForGe_CONNECTION ht G rore Parameters ht My Recent yParameters ht Documents PF7000_FRW_DL ht Desktop My Documents My Computer a File name My Network Files of type Session files ht Press the ENTER key This should bring up the following options menu in the HyperTerminal window ForGe_CONNECTION HyperTerminal File Edit View Call Transfer Help D 5 08 E 2J1 1 Welcome to the PowerFlex 7000 Forge Upload Utility Select an ption 1 Upload Event History csv 2 Upload fllarm Queue csv 3 Upload Trend Data csv 4 Upload Control Data bin 5 Upload Parameters csv 6 Upload Variables csv 7 Upload RevLevels csv Connected 0 00 09 115200 8 N 1 From the above menu select the desired option by pressing the
71. and pressing enter Regardless of the method used for configuration the default factory parameters will be obtained from the Drive Identity Module DIM The use of the DIM allows each drive to be customized at the factory to the intended application using all known information at the time of building the drive Enter Modify an Access Level The drive is protected from unauthorized changes via passwords consisting of a number between 0 and 65535 These passwords are associated with Access Levels Each Access Level except for the first one Monitor has its own password number PIN These values can be unique or all can be set to the same value The default level Monitor does not have a PIN associated with it With this Access Level the drive configuration can be viewed but no changes are allowed to the parameters In addition to providing the protection the Access Levels also filter out the amount of information that can be viewed at each level On any level other than Monitor any information that can be viewed may also be modified 7000 C Frame Marine 7000 C Frame Marine Operator Interface 3 29 The screen shown in Figure 3 32 is accessible from within a number of screens where the Access Level affects the operation of subsequent operations such as 1 F10 key on the Top Level Menu 2 F8 key on the Modify Parameter screen 3 F8 key on the Setup Screen 4 F8 key on the Transfer Screen
72. any of the options above if possible 2 Ensure that all medium voltage and control voltage power to the drive is isolated and locked out 3 It is required to first remove the transparent sheet on top of the Drive Processor Module by removing the 4 screws 4 Use static strap before removing any connectors 5 Remove the connectors J4 J11 and J12 after proper identification and marking if necessary Use the electrical drawing as the reference 6 Remove the 4 screws on the corners of the board fastening the board to the standoffs on the Analog Control Board ACB 7 Gently remove the Drive Processor Module from the four 34 pin female connectors and one 16 pin female connector on the ACB 8 Remove the DIM module from the DPM and plug it on the new DPM before the replacement of DPM 9 Follow Steps 7 3 in reverse to re install the boards back into the low voltage control cabinet 10 Apply control power to the drive The DPMs are shipped with no firmware installed so the drive will automatically go into download mode Install firmware in the drive following the guidelines in Installing Firmware 7000L UM302B EN P June 2013 4 92 Component Definition and Maintenance Drive Processor Module 11 Program the drive Refer to Technical Data Medium Voltage cont AC Drive Parameters Publication 7000 TD002_ EN P The parameters should also be saved to NVRAM and then externally to the drive using the optio
73. backlight In order to preserve the life of the lamp that provides this the backlighting is automatically shut off after a duration of inactivity on the keypad The backlight is restored by pressing any key The pressed key will not have any other affect on the operator interface when pressed with the backlight off 7000 C Frame Marine Operator Interface 3 15 To change the duration of the delay press the F2 key The current backlight delay will be shown in reverse video Figure 3 11 The value can be adjusted from 0 to 60 minutes A value of zero 0 will disable the delay keeping the light on indefinitely Press the cursor up or cursor down keys to change the value by a resolution of 1 minute Press the cursor left and cursor right keys to change the value by a resolution of 10 minutes To abort the change press the backspace key and the setting will return to its original value To accept the change press the enter key The backlight delay has been saved The setting may also be aborted by pressing any of the assigned function keys other than F1 The function associated with that key will be executed UTILITY 11 69 46 86 69 65 TUE Mainmenu Meters Backlight a min Digital spdmeter 572 Contrast Digital ammeter 573 J JDigsital viltmeter 574 Digital pPurmeter 575 Figure 3 11 Utility Light Changing Contrast The contrast controls the horizontal angle to which the display may be viewed
74. click Open At the Open dialog box locate the HyperTerminal connection you just created in step 2 eg Parameters and then click Open Look in a HyperT erminal x ec EB FirmwareDownload ht PF Parameters ht test ht File name Parameters ht Re Open Files of type Session files ht z Cancel EZ From the Transfer menu select Capture Text as shown below Parameters HyperTerminal File Edit view Call Transfer Help Pll lel a sendFie Dia 913 E Receive File Capture Text Send Text File Capture to Printer Creates a file of all incoming text 4 The Capture Text dialog box will appear Click on Browse button and search the file Example txt that you created in Step 1 above Folder C temp Example txt File C temp Example tt x Start Cancel Now click Start button 7000 C Frame Marine 7000L UM302B EN P June 2013 4 140 Component Definition and Maintenance Printing Uploading HyperTerminal will now act as a dummy printer and is waiting Data from the Drive for the information to be transmitted from the drive to the laptop cont From the drive Terminal hit F3 PRINT at the main screen as shown below 4OT FOR RELEHSE Status Ready Speed Current Woltage Power 15 6 Hrs j 160 156 The Terminal screen will change and display Printer options as shown below rca cru Parameters Fault asks Reuisions
75. collected part of the buffer will store values prior to the trigger point and the remainder of the buffer will store values after the trigger Pressing the F5 key will allow you to set the percentage of the trend buffer allocated to values collected after the trigger has occurred This data field is modified in the same manner as the trigger data is entered 7000L UM302B EN P June 2013 3 58 Operator Interface 7000L UM302B EN P June 2013 Starting the Trace The changes do not take affect and the trend is not started until you press F10 and exit the screen Any time prior to this you may cancel all the changes made after coming to the screen by pressing the F7 key When you exit the screen the trend is started and the screen such as Figure 3 83 will show the trigger condition and the status Pressing the F7 key on the DIAGNOSTICS screen may also start the trend DIAGNOSTICS Trigger U line Single Status RUNNING Last Trigger Not Available Ter roe TT Figure 3 83 Diagnostic Armed DIAGNOSTICS Trigger U line Continuous Status TRIGGERED Last Trigger Not Available Tar roe T_T Figure 3 84 Diagnostic Triggered Once the data has started to be collected the status will show triggered as in Figure 3 84 When the buffer contains a complete capture it will show stopped if a single capture as shown in Figure 3 85 The time and date at which the trigger occurred i
76. comply with specifications regarding wire type conductor sizes branch circuit protection and disconnect devices Failure to do so may result in personal injury and or equipment damage Before leaving the factory all drives have been tested both mechanically and electrically Immediately upon receiving the drive remove the packing and check for possible shipping damage Report any damage immediately to the claims office of the common carrier After unpacking the material check the item s received against the bill of lading to assure that the nameplate description of each item agrees with the material ordered Inspect the PowerFlex 7000 drive for physical damage as stated in the Rockwell Automation Conditions of Sale All claims for breakage and damage whether concealed or obvious must be made to the carrier by the Customer as soon as possible after receipt of the shipment Rockwell Automation will be glad to give the Customer reasonable assistance in the securing of adjustment for such damage claims Remove all packing material wedges or braces from within the drive Operate the contactors and relays manually to assure that they operate freely If any part of the equipment will not be installed when it is unpacked it should be stored in a clean dry place The storage temperature must be between 40 C 40 F and 70 C 185 F with a maximum humidity of 95 non condensing to guard against damage to temperature sensitive co
77. corresponding number to upload print the data To upload Control Data select option 4 7000L UM302B EN P June 2013 4 146 Component Definition and Maintenance Pri nting Uploading ForGe_CONNECTION HyperTerminal Control Data cont File Edit View Call Transfer Help 2J1 1 Welcome to the PowerFlex 7000 Forge Upload Utility Select an Option Event History csv Alarm Queue csv Trend Data csv Control Data bin Parameters csv Variables csv RevLevels csv Start KModem Transfer Connected 0 01 20 VT52 115200 8 N 1 After selecting the desired option you need to start the transfer by selecting Receive File from the Transfer menu as shown below ForGe_CONNECTION HyperTerminal File Edit View Call REGE Help Die 3 is Send Fil Rec Capture Te 2J1 1 Welci send text Fite erFlex 7000 Forge Upload Utility Select an 1 Upload Ei Capture to Printer csv 2 Upload fllarm Queue csv 3 Upload Trend Data csv 4 Upload Control Data bin 5 Upload Parameters csv 6 Upload Variables csv 7 Upload RevLevels csv Start KModem Transfer Receives a file from the remote system The Receive File window will pop Click Browse button and select the directory where you want to save the data file Make sure the Receiving Protocol is set to Xmodem then click Receive 7000L UM302B EN P June 2013 7000 C Frame Marine 7000 C Frame Marin
78. eaaa a Et usa Sion feli i SS mea e ds Le m ETT g MEE rame rum EIES mm URBES em ESE P 7 i ROCKWELL O sns Fa 3 Sob BE s 58 eu AUTOMATION E o Js B B 8 4 x B em oen AB SERENO tm te 4 neo li ic fia se sa 88 i E 1 lg B88 pesca p Ss i HTITI QE e ri Bim a dmm ls Ogaa 8 sas ERE 1 5 aan i L E Io senes bu Jed id M i pese C GLEN a aaa O Eii z f e 35V 15V 15V 24V 24V 24 e EON N I J T amp le mum of game Das ong cg n mm T aE a M pnl f Ce d wt E Lud g di EI mm mu d 423 aj TER Mis EE s rd Bx aas es aes ay I vl pene x HE er im MET TET TET TET TEL TE ea aa ag sae daar ower Aus oe meee Ered ur X w Ci ques ese a By E E An ANS BA eae Ex ib s3 si O Sr BBEBEBHE aoaia J9 APO amp API J10 SPEED POT METER OUTPUTS 7000 C Frame Marine Figure 4 69 ACB Analog Control Board 7000L UM302B EN P June 2013 4 94 Component Definition and Maintenance ACB Analog Control Board The Analog Control Board ACB receives all of the Analog Signals cont from the drive s internal components This includes the current and voltage feedback signals The boards also have isolated Digital I O for e stops contactor control and status feedback All of the test points for the currents system voltages control voltages and flux are on these boards Table 4 D Connectors on Analog Control Board
79. ees 4 82 Leakage CHECKS eri out e i emitte eise 4 84 System Drain iere eee Ee edes 4 84 Low Voltage Control Section eee 4 85 DC DC Power Supply eene 4 86 DeSCriptton P 4 86 Terminal Connections Descriptions 4 87 Replacement Procedure for DC DC Power Supply 4 88 Printed Circuit Board Replacement esses 4 89 IO Connectors on Control Boards esses 4 90 Drive Processor Module sse 4 9 Drive Processor Module Replacement 4 92 Instructions to Replace the Drive Processor Module 4 92 ACB Analog Control Board eee 4 95 LEEDS E 4 98 Interface Module IPM esee 4 99 Analog Inputs and Outputs eee 4 99 Current Loop Transmitter eee 4 100 Isolated Process Receiver n 4 101 Non Isolated Process Outputs eer 4 102 Auxiliary 24V Power Supply eee 4 102 ACB Analog Control Board Replacement 4 103 Tachometer Feedback Board ses 4 104 Encoder Options enitn ere lote 4 104 Quadrature Encoder Operation ess 4 108 Positional Encoder Operations es 4 109 Positional Encoder Guidelines sss 4 110 External Input Output Boards eee 4 1
80. energized check that all output voltages are present View 1 De energize the drive isolate and lock out the control power and remove all wire connections from the unit View 1 Remove quantity of 4 M6 H H T R S that will allow the DC DC Power Supply Assembly to be removed from the Low Voltage Panel View 1 Remove quantity of 4 M4 P H M S and Nylon Shoulder Washers from the back of the Mounting Plate View 2 Replace old DC DC Power Supply with the new one NOTE Make sure the Black Insulation is between the DC DC Power Supply and the Mounting Plate Repeat Steps 4 3 2 1 in this order to replace unit View 2 Ensure the ground wire of P4 plug is connected to the ground by M10 bolt 7000 C Frame Marine Component Definition and Maintenance 4 87 Printed Circuit Board Replacement 7000 C Frame Marine M4 P H M S and nylon Souder NAE HE 4 p al A Mounting Plate lt P Black Insulation 7 a PA DC DC ian Part ID Label power supply VIEW 2 VIEW 1 Figure 4 65 Replacement of DC DC Power Supply The replacement of printed circuit boards should be handled in a careful manner There are some basic precautions that should be taken They include the following Remove all power to the drive Do not remove the replacement board from the anti static bag until necessary Use anti static wrist strap
81. gating and Machine Converter Feedback Protection diagnostic lo Side 1 Side diagnostic Feedback Protection HW eoe 2 Control I Control es HW Y Faults E I EZ Line E o p Converter E Zo v Protection E IE Machine m S 22 2 Converter Motor Faults y g ET 2 Protection Model 3 z Speed v g D p I Flux Command Ine Current Ide ref S Synch gt Control lt E l v i Ref Speed Feedback Skip Speed Current and Flux Speed Speed Rei phase shift usc c t Control Torque Control and Speed calculator CO urren Ramp i command i A Torque current command j Synch i Transfer I Figure 1 6 PowerFlex 7000L C Frame Function Block Diagram Direct Vector Control The method of control in the PowerFlex 7000 C Frame medium 7000L UM302B EN P June 2013 voltage AC drive is called sensorless direct vector control meaning that the stator current is divided into torque producing and flux producing components allowing the motor torque to be changed quickly without affecting motor flux This method of control is used without tachometer feedback for applications requiring continuous operation above 6 Hertz and less than 100 starting torque Full vector control can also be achieved with tachometer feedback for applications requiring continuous operation down to 0 2 Hertz with up to 150 starting torque Vector control offers superior performance over volts hertz type drives The speed bandwidt
82. grounded in the Low Voltage Control Section There are no direct screw terminal connections on any of the Low Voltage circuit boards All wire terminal connections are made with plugs that plug into the circuit boards This means that changing boards only requires the removal of the plugs minimizing the chance of mistakes when reconnecting all of the wiring 7000L UM302B EN P June 2013 4 88 Component Definition and Maintenance 10 Connectors on Control Boards MOICR amp LINE MOICRSLINE ACVOTAE DOLINKAND LINE VOLTAGE FEEDBACKINFUIS NEJUIPALFONT SYNC TRANSFER VOUAGEINIPUIS FEECEACKINPUIS COWS COWS GO CONECION GONECTION MNTANG PARALLAL XOBO FD ERVE DC FALSIGNAL di MCCC Bi B B o DA B IE E cs INTERFACE CONECTTOOBB sil L2 ETATIS _ ug i 35 I d qe DAVAO NT DAVIS ENXIER eg lengli pliner ET T VESTA A OC ABLE 45V NEME lt 4 B QUIPUTMINTCANG DAVAI CPMJI2 PES hes OMNE f dotem cui NM A NUPSOFTOY Bd 3 E J5 dl j XOP FL2AV 45V 24V y AIVA LIE 45V DIG DO PONRSUPPLIES CPVENOTER Eroe OHRVO 2 DCFO ERSLFPLY DAV ri J3 Ju MNTOANG ance q
83. information about the various operations which may be performed The screen identifies the drive product to which the operator interface is attached and its overall state of operation Four digital meters show four selected parameters located in the drive A Hobbs meter displays the number of hours that the drive has been running The status of the drive will show one of the following NOT READY drive is not ready to start READY drive will start when commanded FORWARD RN drive is running in the forward direction REVERSERN drive is running in the reverse direction WARNING drive has a warning FAULTED the drive is faulted DISCHARGING waiting for the input filter capacitor to discharge on an Active Front End drive before re start Rev 4 XX Status Not Ready Speed 900 rpm Current ig A Voltage Power 6 2085 80 Hrs 0x 100 156 Figure 3 6 Top Level Menu 7000L UM302B EN P June 2013 3 12 Operator Interface How To 7000L UM302B EN P June 2013 The following sections describe how to perform the various operations on the drive using the operator interface Throughout the discussion a number of screens will be used to achieve the desired operation In many cases the same screen will be used for more than one operation however with possibly different data from the drive Throughout the section you want to focus on how the operation is performed The operator interface will take care
84. key is pressed for a valid tag code i e Figure 3 28 the selected tag will be used to continue the operation for which the selection process was being used if that tag is appropriate for the operation For example if you are performing a parameter modification operation but have selected a read only parameter tag code you will be unable to exit the screen with this read only parameter The screen will display this information along with the tag s current value such as shown in Figure 3 30 Re enter a tag code for a parameter or press F10 to return to the previous screen without making a selection SELECT CODE iring index V Enter Tag Code 286 Tag is Read Only Panes Figure 3 30 Selected Tag Inappropriate Various operations require a text string to be entered Operations requiring this are setting external faults adding text to selected Top Level Menu meters identifying the drive with a text string entering a filename The operator interface s keypad does not contain any alpha keys to allow direct input of the characters This section will describe the operation for which characters may be entered DRIUE TEXT DRIVE TYPE PowerFlex 7000 DRIVE NAME N Pacrens cmc can Figure 3 31 Typical Text Edit Screen 7000 C Frame Marine 7000 C Frame Marine Operator Interface 3 27 The screen shown in Figure 3 31 is typical of all screens using the edit text operation A
85. of what screens are needed to perform the operation Obtain Help Help is obtained for any screen by pressing the F1 function key Figure 3 7 shows the help screen which is displayed for the Top Level Menu After the name of the screen i e HELP is the name of the screen for which help is being accessed In this case the name of the Top Level Menu is REV This particular help screen contains three pages To view page two press the F8 key Page 2 is displayed To return to page 1 press the F9 key You can return to the original screen from which you asked for help at any time by pressing the F10 key HELP Rev 1 of 3 This is the Top Level screen or Main Menu From this screen all other screens may be accessed To access a screen press the soft function key Which corresponds to the desired screen The active function keys and their purpose are shown on acres Tre repre Fe enr Figure 3 7 Typical Help Screen Related Topics All of the help screens will have additional topics relating to the help currently being displayed These topics are highlighted just above the Softkeys Additional topics are selected via the cursor left and cursor right keys Figure 3 7 shows the additional topic of SOFTKEYS selected To access this information press the enter key The help for the additional topic will be displayed as in Figure 3 8 As with the original help screen the related
86. or enter a different filename press the F7 key Download from Memory Card The parameters are read from a memory card and written to the drive by pressing the F2 key The operator interface will enter the DIRECTORY screen from which an existing parameter filename can be selected or entered Refer to the sections entitled Select a filename and Enter a filename When the filename has been obtained the TRANSFER PARAMETERS screen similar to that shown in Figure 3 94 except the operation will show FILE TO DRIVE will be displayed showing the filename indicating the operation you are about to perform and showing the current status of the operation The screen will then ask you to confirm the operation Press the F8 key to proceed or the F9 key to abort Pressing the F4 key may restart an aborted transfer or one that failed To select or enter a different filename press the F7 key Parameter File Format The parameter file stored on the flash card is in a DOS file format This parameter file can be created off line on a PC using any ASCII text editor and then written to the memory card via a PCMCIA Card Drive Information is this section is not needed to operate the operator interface It is required knowledge if you wish to create a parameter file off line and then download into a drive The filename must have the extension of PAR in order to be recognized as a parameter file The format of the file is as follows
87. point using the Glycol and Battery Tester 2 If the freezing point of the coolant is at 45 C 50 F 2 C correction is not required If correction is required then follow the remaining steps 4 Water freezes at 0 C 32 F and pure ethylene freezes at 13 C 8 6 F but mixtures of the two freeze at lower temperatures For example a 50 50 mixture by weight of ethylene glycol and water freezes at 36 C 33 F The addition of ethylene glycol to the mixture will lower the freezing point Adjust the freeze temperature of the coolant mixture to 45 C 50 F using this method 5 Add either substance in small quantities and measure the freezing temperature after each addition until desired freezing temperature is achieved IMPORTANT It is better to have more water than glycol in the mixture because water is a better thermal conductor than glycol There are two possible causes of water loss in the drive Evaporation Up to 99 5 of liquid lost to evaporation is water because of the chemical properties of the substances in the mixture Leaks Glycol and water are lost proportionally depending on the concentration of the substances in the mixture For example if the mixture is 60 glycol and 40 water then any leakage will contain the same proportions of the liquids 7000L UM302B EN P June 2013 4 82 Component Definition and Maintenance Pump Maintenance and Replacement cont 7000L UM302B EN P June
88. pressing either the up or down key will provide a list of options to pick from Using the cursor keys make a selection and press enter If more options exist than can be displayed on the screen a triangle symbol or inverted triangle to the right of the list will show that there are more selections available in the indicated direction Continue to use the up down cursor keys to move to these additional selections For parameters that are comprised of bit fields the left right keys are used to move to the desired bit field The up and down keys toggle the bit between its possible states All four cursor keys have an auto feature such that after holding the key for 2 seconds the key will automatically repeat at a rate of 5 presses per second Data Entry Keys As the name implies these keys are used to enter data Pressing the keys 0 to 9 will enter the corresponding value into the editing field Pressing the key will change the value to a negative number Pressing the will allow a fractional value to be entered 7000 C Frame Marine Operator Interface 3 5 What is a Screen Screen Name 7000 C Frame Marine While entering a value the value may be edited using the backspace key This key will remove the right most digit or decimal point or negative The help screen uses the backspace key to return to the previous level of help The enter key varies depending on the screen If you are in the pro
89. rockwell com Follow the steps below to set the elapsed time in the drive Turn off control power to the drive control boards and the Terminal Remove the Terminal serial connector from Analog Control Board ACB Port J12 Connect your laptop to ACB Port J12 using a null modem cable Turn on control power and wait until the boards are powered up and the LEDs on the boards become steady green Run Sethobb exe program on your laptop When prompted to Specify a COMM port to use lt 1 2 3 4 gt enter the correct port number and then press the Enter key When prompted to Specify the time preset including the 1 10 Hr enter actual operating hours eg if the actual operating hours 146 5 Hrs then enter 1465 and then press the Enter key The Sethobb exe will be closed automatically Now remove your laptop and reconnect the Terminal to ACB Port J12 and turn on power to the Terminal After the Terminal is powered up you should be able to see the actual operating hours on the main screen The Operator Terminal is an interface used to interact with a PowerFlex7000 drive In order to communicate with the drive the Terminal needs a valid firmware If it lacks the software it does not have the necessary information to communicate with the Analog Control Board ACB There are two methods of downloading the firmware into the Terminal which are described below Using Flash Memory Card If using a F
90. screen to show the other set of words The layout of the PLC rack is dependent on the DIP switch settings on the RIO adapter refer to the appropriate manual for information on the following adapters and their use 1203 GD1 1203 GK1 1203 CN1 1203 GD2 1203 GK2 1203 GK5 1203 GU6 1203 SMI and 1203 SSS Tags are assigned to rack module locations in pairs These pairs are referred to as links and consist of two input and two output words There are a total of four links that can be assigned to the RIO adapter The screens show the current tags and their tag code which are associated with each of the links To change the tag attached to a link use the cursor up and cursor down keys to highlight the desired link and press the enter key If nothing happens then you have not gained the required access to make changes Exit to the SETUP screen and refer to the section entitled Enter Modify an Access Level to gain access 7000 C Frame Marine 7000 C Frame Marine Operator Interface 3 45 PLC SETUP INPUTS U line Alpha line Cntrl board temp U neutral motor Current meter Uoltage meter Speed meter Power meter Figure 3 60 PLC Input Links PLC SETUP OUTPUTS Stop Mode Total Decel Time Rated motor volt Rated motor hp Speed cmd max Tach Select Ext flt 1 class Input ContCfg icons once ose T T exit Figure 3 61 PLC Output Links Al A2 B1 B2 Ci C2 DI PISANI DINA r
91. shield together with all other parts of the system that require grounding to a single point ground This will reduce varying ground potentials caused by high current fluxes created by motors remote control switches and magnetic fields Signal Distortion The primary cause of signal distortion is cable length more specifically cable capacitance Generally speaking the longer the cable length the more there is a 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 0us If the leading edge of the waveform is distorted it causes the transition time through this region to increase At some point the receiver may become unstable and either gain or lose encoder counts To reduce the effects of signal distortion at the encoder receiving electronics the following guidelines should be considered 1 Use a low capacitance cable Purchase a cable that has a capacitance of lt 120pf m 40pf ft As an example Belden 1529A is an 18A wg 3pair cable having a capacitance of 114pf m 35pf 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 single wire c
92. that adjusts the 56 Volt DC output for the power supply Isolate the output of the power supplies multiple supplies in series will affect your measurements With the control power on and the output of the AC DC Converter isolated from the drive control adjust the potentiometer until the output equals 56 volts DC Perform this test on each power supply When all adjustments are complete reconnect the power supply to the circuit and re measure the output Readjust if necessary If it is not possible to maintain 56 V DC the power supply may be faulty Replacement Procedure 1 Ensure control power has been isolated and locked out Disconnect the terminals at the unit 2 3 Remove the two M6 bolts per Figure 4 50 4 Extract the power supply complete with bracket from the drive 5 Remove the bracket from the failed power supply four M4 screws and nylon shoulder washers 6 Attach bracket to replacement power supply Note Make sure the Black Insulation is between the AC DC power supply and the mounting plate 7 Repeat Steps 5 4 3 2 and 1 in this order to replace the unit see Figure 4 50 8 Reapply control power and verify voltage levels L9 I en ACIDC Exi Power Supply Power Supplies i I Optional Power Transformer Fuse Blocks Hold up Capacitors la Figure 4 50 Replacement of AC DC Power Supply on Low Voltage Panel 7000L UM302B EN P June 2013 7000 C Fram
93. that when power to the drive is lost so will be the changes To permanently store the changes the contents of the memory must be stored to NVRAM memory When you exit a group of screens on which you have changed the drive data you will be prompted as in Figure 3 62 to save the data If you wish to save the data press F8 Yes and the NVRAM screen refer to Store Retrieve Configuration will be entered Figure 3 63 If you wish the data to reside as temporary data in RAM only press F9 No Pressing F10 Exit will return you to the screen from which you previously exited Note that the data can still be saved at a later time by accessing the NVRAM screen directly from the Top Level Menu Refer to Store Retrieve Configuration MESSRGE You have changed the setup data in the drive s working RAM If you Wish the changes to be Permananent they must be SAVED in the drive NURAM Do you Wish to save to NURAM Yes No fs Ts I9 exit Figure 3 62 Message Prompt Screen Operation Operation Status Dus qu Ta e Figure 3 63 NVRAM Screen 7000L UM302B EN P June 2013 7000 C Frame Marine Operator Interface 3 47 Store Retrieve Configuration NVRAM To access the memory functions press F5 on the Top Level Menu Within this screen it is possible to perform three operations on the memory of the drive To perform these operations you must have the proper access to the drive Refer to the s
94. that will cause the trigger The possible options are Equal to Boolean OR N Not Equal to N Boolean NOR gt Greater than amp Boolean AND lt Less than N amp Boolean NAND Data Defines the trigger value with respect to the read only parameter in Trace 1 Setting up the Trend The Access level must be Basic or higher level before programming the drive s trending feature To change Access level to Basic press F10 Access key on the main screen The display will change to Access screen Select Basic by pressing down arrow key and then press Enter key The Access level will change to Basic Press F10 EXIT key again to exit to the main screen Note The parameter assigned to Tracel is used for trigger purpose The Condition and Data defined in steps 11 and 12 must be satisfied for the trend to trigger In most cases the parameter 569 DrvStatus Flagl is assigned to Tracel for trigger purpose A value of 18 Hex for Data Step 12 below is used to capture the trend when the drive detects either an Alarm or a Fault condition If you are interested in the fault condition only then set Data as 8 Hex If you are interested in Alarm condition only then set Data as 10 Hex You can reset the Alarm or Fault in the drive but don t Re Arm the trend until you print upload the trend data into your laptop Print the Alarm Queue as well so that you know which alarm or fault condition was detected by the drive Press F9 DIAGS
95. the master assembly and the second assembly acts as the slave assembly In this manner up to twelve independent voltage channels can be measured When two assemblies are linked together the master assembly is used to send the twelve voltage signals to the SCB board For drives that require the synchronous transfer option one additional module is used This assembly uses a separate connector to output the transfer voltages directly to the SCB board Below is a table of the input voltage ranges for each of the input terminals on the voltage sensing board There are four separate inputs taps for each of the six independent channels This assembly has been designed to operate at a nominal input voltage of up to 7200V with a continuous 40 overvoltage The output voltages are scaled to provide close to 10V peak for a 140 input voltage at the high end of each of the voltage ranges Each of the channels has only four taps thus they must be used to provide a range of input voltages and software will be used to provide a given amount of gain so that 140 will correspond to the maximum numerical value of the analogue to digital converter Table 4 A Nominal Input Voltage Ranges Tap Voltage Range D 800 1449V C 1450 2499V B 2500 4799V A 4800 7200V ATTENTION Grounds must be reconnected on the voltage sensing boards Failure to do so may result AN in injury death or damage to equipment 7000L UM302B EN P June
96. the top hose of the outlet manifold of the chillblock to be serviced Slide the hose clamp toward the chillblock 7 Have a hose plug assembly and a M10 bolt ready Per Figure 4 27 pull the hose from the upper manifold hose barb and collect the fluid in a container Figure 4 28 Converter PowerCage Module Service per Step 7 7000 C Frame Marine 7000L UM302B EN P June 2013 4 38 Detachment of Coolant System from PowerCage Modules cont 7000L UM302B EN P June 2013 Component Definition and Maintenance Per Figure 4 29 insert the hose plug on the hose barb of the upper manifold Insert a M10 bolt in the end of the chillblock hose Note that there may still be limited fluid leakage during this procedure Figure 4 29 Converter PowerCage Module Service per Step 8 Shows flow plugs installed Repeat this procedure for the lower manifold connection point The chillblock can be extracted from the PowerCage per Instructions for removing Chillblock assembly 7000 C Frame Marine Matched Set 2 SGCTs Component Definition and Maintenance 4 39 Matched Set 2 SGCTs 7000 C Frame Marine Outlet Manifold O il Clamp Head o o i o o E Inlet Manifold Clamp Base Module Housing
97. to create an empty txt file examplel txt and upload or print the data from drive into laptop Required Laptop with Windows HyperTerminal program A null modem cable with a 9 pin female connector for the laptop serial port and a 9 pin male connector for the ACB Printer Port J11 A serial cable with pins 2 3 swapped at one end will also work Here is a typical pin out of a complete null modem cable Essentially only 3 pins 2 3 and 5 are all that is required 9 Pin Female 9 Pin Male Connector Connector Pin Pin DCD e RED RTS 7 a CTS 8 2 TXD BRN TXD3 3 RXD BLK RXD2 4 DTR GRN DERG 5 COM BLU COMS 6 DSR 7 WH _ DIR4 7 RTS YEL DCDi 8 CTS i NC SHLD g amp Ol Case 7000L UM302B EN P June 2013 7000 C Frame Marine Component Definition and Maintenance 4 135 Method Step 1 Creating an empty notepad txt file Run NotePad Program Start Program Accessories gt Notepad 1 E j jj EU EL a 5 55 d Notepad f tr Programs A blank Notepad window will appear as shown below Untitled Notepad From the File menu select Save As as shown below l Untitled Notepad MF 7000 C Frame Marine 7000L UM302B EN P June 2013 4 136 Component Definition and Maintenance Printing Uploading On the Save
98. to you During this activity a special window is used within the current screen to inform you of this activity The time required for the activity will vary 7000 C Frame Marine Operator Interface 3 7 7000 C Frame Marine Accessing Writing to Drive When first powered up the operator interface knows very little about the information in the drive As each screen is activated the operator interface requests information from the drive which it will store within the operator interface for future reference When the operator interface requests information from the drive a window is used to display a message Accessing Drive During this time the operator interface will not respond to any user input until the task at hand is completed You will notice that subsequent activation of the same screen for the same data will be much quicker since the operator interface already has most or all of its required information You can selectively choose to download the complete database to the operator interface on command thus eliminating the initial access delays If uninterrupted the operator interface will automatically download the database on power up or during periods of inactivity Refer to the section on Advanced Screen Operations Database Download Some screens require that information be written to the drive During this task a window is used to display the message Writing to Drive During this time th
99. to display the ACCESS screen as represented by the symbol P Obtain the access from this screen and press F10 to exit This will return you to the MODIFY PARAMETER screen When you are finished with this screen press F10 exit and you will be returned to the SELECT screen via symbols M and T Pressing F10 again will return you to the DISPLAY screen via the symbol D Successive presses of the F10 key will return you to the DISPLAY GROUP and finally to either the MAINMENU or the MESSAGE screens If you have changed any data in the drive the F10 Exit key will bring up the MESSAGE screen The message will remind you that the changes made in the drive are only temporary unless saved to NVRAM If you desire the data to be temporary press F9 No and you will continue onto the MAINMENU If you press F8 Yes the NVRAM screen is entered from which you can save the data Exiting the NVRAM screen returns you to the MAINMENU Pressing the F10 Exit key on the MESSAGE screen will return you to the DISPLAY GROUP screen 7000 C Frame Marine 3 77 Operator Interface Z Jo abed aos nuejy EUIUUAL 0004 Xa 4J4amod Q Q SS929y 9J 40 24 PIS yuej e oduil 0j JepJo ui uejDeip au uo uwous jou ale ABUL Kay uue v o4 pue djaH 4 9U 0 sseooe e eu su9aJos v 9 ON pJ9 Nr c3 Nd lt PJ9 z3 SJO JOLWEIE d Jjueleq 74 1xe eAug X01 84 daH djey 1 S 9 9 UOISIABM daH 1
100. to do so may result in injury or death 2 Remove SCR SCGT s and circuit board s outlined in SGCT Replacement Procedure and Replacing the Silicon Controlled Rectifier The SGCT and SCR can be destroyed or damaged by static charges Personnel must be N properly grounded before removing circuit boards from the PowerCage Use of damaged circuit boards may also damage related components A grounding wrist strap is recommended for handling 3 Detach coolant hoses from upper and lower manifolds This procedure is more clearly explained in Detachment of Coolant System from PowerCage Modules 4 Using a 14 mm socket with an extension of at least 40 cm remove the M8 bolt on the bottom flange of the chill block which connects the chill block assembly to the PowerCage 5 If present remove the M10 bolt at the top of the chill block using a 17 mm socket with an extension of at least 40 cm 6 Slowly and carefully pull the assembly out of the PowerCage The chill block assembly is heavy and it is recommended that two people pull the assembly out to avoid damage 7000L UM302B EN P June 2013 7000 C Frame Marine Connection Stabs 7000 C Frame Marine M8 Bolt to be removed Component Definition and Maintenance 4 41 Support Bracket Figure 4 31 Chill Block Removal and Replacement Instructions for inserting Chill Block assembly 1 2 Ensure all power is disconnected Sl
101. to physical shock during the shipping and installation process Even if the indicators show that no shock was attained full inspection and verification in accordance with the Commissioning process outlined in Chapter 4 is still essential Red Plastic Housing ES 51mm 2 0 Z QZ o 1 21mm i T 0 8 Figure 2 34 Shock Indicator 7000 C Frame Marine Drive Installation 2 25 Installation of Exhaust Air Hood Even though this is a liquid cooled drive some sections still require air circulation On the top of the cabinets with cooling fans sheet metal exhaust hoods are to be installed The components to make up the exhaust hood have been packaged and shipped with the drive and are to be found on a separate skid marked with the same identifying tags on the skid The first step is to 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 keep the hardware for reuse Secondly locate the fan hoods on the separate skid and lift these over the respective holes located on the top of the drive cabinet Locate the exhaust hood on top of the cabinet per Figure 2 35 and reuse the existing hardware set aside earlier Care must be taken that the notches on the bottom flange are oriented toward the sides of the drive Affix assembly to the drive top plate Tighten all hardware Any screws that are accidentally droppe
102. twisted shielded cable with the shield connected at the signal source end only The shield at the other end is to be wrapped with electrical tape and isolated Connections are to be made as shown on the drawings provided 7000L UM302B EN P June 2013 2 58 Drive Installation Power and Control Wiring cont 7000L UM302B EN P June 2013 Encoder Installation Guidelines The most frequent problems encountered when transmitting an encoder s signal s to the drive are signal distortion and electrical noise Either of these problems can result in a gain or loss of encoder data counts quadrature encoders or corrupt positional data absolute encoders Many of these problems can be avoided by applying good installation and wiring practices This section is a general guideline and recommended practices for field installed equipment It applies to either encoder board and both quadrature and absolute encoders Protection from Radiated and Conducted Noise Reasonable care should be taken 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 In fact the encoder itself may induce noise into signal lines run adjacent to it To avoid radiated and or conducted noise power and signal lines should be run separately with a minimum distance between them of at leas
103. 000 C Frame Marine Power and Control Wiring 7000 C Frame Marine Drive Installation 2 57 Drive line ups i e Drive and Input Starter which are delivered in two or more sections for ease of handling will require that the power and control wiring be re connected After the sections are brought together the power and control wiring is to be reconnected as per the schematic drawings provided Control Cables Control cable entry exit should be located near the terminal block TBC the customer s connections are to be routed along the empty side of the TBC terminals These terminals are sized to accept a maximum AWG 14 wire gauge The low voltage signals includes 4 20mA are to be connected using twisted shielded cable with a minimum AWG 18 wire gauge Based on using a WA terminal block for customer connections comparable wire sizes would be 0 5 4 mm as equivalent to 422 410 AWG Of special concern is the tachometer signal Two tachometer inputs are provided to accommodate a quadrature tachometer senses motor direction The tachometer power supply is isolated and provides 15 Volts and a ground reference Many tachometer outputs have an open collector output in which case a pull up resistor must be added to ensure that proper signals are fed to the system logic Refer to Appendix A When is a Tachometer Required to see if one needs to be supplied IMPORTANT Low voltage signals are to be connected using
104. 02B EN P June 2013 Testing Snubber Resistors Access to the snubber resistor is not required to test the resistance Located within the PowerCage under the chill block is a snubber resistor test point For each device there is one test point To verify the resistance follow the procedures outlined in Chapter 4 Measure resistance between chillblock and test point Figure 4 33 Testing the Snubber Resistor The anode cathode resistance check will measure the parallel combination of the sharing resistor and SGCT anode cathode resistance The sharing resistor has a resistance much lower than a good SGCT thus the measurement will be slightly less than the resistance of the sharing resistor A measurement between 60 kQ and 75 kQ indicates the SGCT is in good condition and that wiring to the SGCT is correct If the SGCT fails it may be shorted The anode to cathode resistance check will be 0 Q for a complete short but SGCT can fail when partially shorted Sharing resistors provide equal sharing of the voltage when matched devices are used in series Sharing resistors in SCR PowerCages provide a diagnostic function 7000 C Frame Marine Component Definition and Maintenance 4 45 Testing Sharing Resistors SGCT PowerCages To determine the sharing resistor value simply measure the resistance between the anode and cathode chill blocks A value between 60 KO and 75 kQ indicates a good sh
105. 11 External Input Output Board Replacement 4 113 Optical Interface Boards OIB i 4 114 Optical Interface Board Replacement 4 115 Optical Interface Base Board OIBB 4 117 Optical Interface Base Board Test Points 4 118 Downloading Firmware eene 4 119 7000 C Frame Marine Chapter 4 Component Definition and Maintenance cont Appendix A Catalog Number Explanation for PowerFlex 7000 MV Drives 7000 C Frame Marine Table of Contents Introduction eee He Ee eee SERRE ege 4 119 Overview d eese tecti tee Shaina pide ep ete 4 119 Preparation for Downloading Firmware 4 120 PF7000 in Download Mode ee 4 122 Reloading the Parameters eee 4 125 Setting Elapsed Time eee 4 126 Download the Terminal Firmware esses 4 126 Setting up Diagnostic Trending esee 4 129 Diagnostic Setup ete t Eee etnia 4 129 Setting up the Trend seen 4 130 Printing Uploading Data from the Drive 4 136 OV rVIeW iini nera anandia 4 136 Required tolo 4 136 Method feist etre e Ete licen dia 4 137 Printing Uploading Control Data 4 143 OV rVIEW iie n Reps eas 4 143 Required Tod erone aare tbe et citet 4 143 Method reae teet etit ett
106. 1250 hp 933 kW B Frame for higher power air cooled configurations C Frame for all liquid cooled configurations If you have multiple drive types or power ranges ensure you have the correct manual For detailed information on Troubleshooting Parameters and Functional Description for MV variable frequency drives please refer to Technical Data publication 7000 TD002 EN P For detailed information on receiving and handling for Medium Voltage variable frequency drive and related equipment please refer to General Handling Procedures publication 7000 IN002 EN P Reference Manuals for A B and C Frame drives are also available These manuals provide additional technical information about the drive components Contact your local Rockwell Automation Sales office to order copies of these publications Please note This manual deals specifically with the PowerFlex 7000 C Frame drive Information on auxiliary cabinetry or special components we are contracted to supply with the drive will be contained within the Service Manual you will receive with your order 7000L UM302B EN P June 2013 P 2 Preface Manual Conventions Symbols are used throughout this manual to indicate specific types of information Warnings tell readers where people may be hurt if procedures are not followed properly Cautions tell readers where machinery may be damaged or economic loss can occur if A procedures are not followed pro
107. 16 Isolated Outputs on the card and they are used for Runtime I O including Start Stop Run Fault Warning Jog and External Reset signals The boards also handle the standard drive fault signals Transformer Line Reactor Overtemperature DC Link Overtemperature etc and several spare configurable fault inputs There is an option in software to assign each XIO a specific function General IO External IO or Liquid Cooling XIO1 DIGITAL 1 0 7000 C Frame Marine INPUTS Figure 4 77 XIO Board 7000L UM302B EN P Ju
108. 2 7 When the drive has been placed at its installation area the lag bolts that fasten the shipping skid to the drive must be removed The drive is moved off the shipping skid and the shipping skid can be discarded Position the drive in its desired location Verify that the drive is on a level surface and that the position of the drive will be vertical when the anchor bolts are installed The location of the anchor points is provided with the dimension drawing of the drive Install and tighten the anchor bolts M12 or 2 hardware required Engineered bolt systems are required for seismic requirements Consult factory Remove the top lifting angles retain the hardware An additional set of mounting brackets has been supplied by Rockwell Automation for securing the drive to the roof for roll and pitch concerns The hardware removed for the lifting angles are to be used to secure these brackets to the drive An additional mounting drawing specific for the order should be used to understand how to brace the drive to the vessel structure using these brackets If this drawing cannot be located please contact Rockwell Automation Sales office The Drive may have been shipped in two or more shipping sections which are to be connected at installation It is essential that the surfaces are level Arrange the sections per the information provided in the dimension drawings and move the sections together Ground bus power and control connec
109. 2 Drive Installation Hall Effect Sensor Voltage Sensing Hall Effect Sensor Motor Terminals Surge Arresters Line Terminals Current Transformer Figure 2 39 General Control and Cabling Cabinet with Control Panel removed 7000L UM302B EN P June 2013 7000 C Frame Marine Drive Installation 2 33 Customer Wiring Terminals Analog Control ad an oo oo joo oo joo oo Di Board z 3 3 Tach Feedback Circuit Board Drive Processor Module DPM ha ia ho foo faa oo on foe oa 60 Joa fou fou fou ba fno foo foo foo Eu foo foo foo foo foo fon foo foo fa bd EA NEA LTE E TTE I T ET Fiber Optic Interface Boards DC DC Power Supply Figure 2 40 Low Voltage Tub Compartment 7000 C Frame Marine 7000L UM302B EN P June 2013 2 34 Drive Installation Ground Bus Inverter Modules Coolant Piping Gate Drive Power Supplies Rectifier Modules Figure 2 41 Converter Cabinet 7000L UM302B EN P June 2013 7000 C Frame Marine Drive Installation 2 35 Dynamic Braking Resistor 0 m Cooling Fans Dynamic Braking Chopper Modules Coolant Piping Figure 2 42 Dynamic Braking Cabinet 7000 C Frame Marine 7000L UM302B EN P June 2013 2 36 Drive Installat
110. 2 mm and 5 8 bolt and nut hardware Strap wrench for tightening CPVC unions Screwdriver assortment Cable ties Wire cutters 7000 C Frame Marine Drive Installation 2 9 Install CPVC Piping Splices Open doors of capacitor cabinet Cabinet 5 next to DC Link Choke cabinet Cabinet 6 Refer to Figure 2 4 Remove capacitor from position 3 if installed not all configurations have a capacitor in this location It is not necessary to remove capacitor from position 2 Capacitors weigh up to 100 kg 220 lbs Use two people to remove the unit from the A structure CPVC Pipe Splices Capacitor Capacitor Capacitor Position 1 Position 2 Position 3 Figure 2 4 Capacitor Cabinet Remove CPVC pipe splices shipped in the capacitor cabinet Install and tighten the 4 CPVC unions with strap wrench 14 to 1 2 turn past hand tight Ensure O ring is seated inside male end of union Refer to Figures 2 5 2 6 2 7 and 2 8 Do not use CPVC primer or cement 7000 C Frame Marine 7000L UM302B EN P June 2013 2 10 Drive Installation Connect the Sections cont IL IE t FD at TE EH i ms d f 1 LII mi Pipe Splice 2 S i 1 N i It Jun j ai Fa L N j dal o IA VIPD VU Gs VY CONE me ii ES xm F hl BI Pipe Splice 1 Capacitor DC Link Cabinet Choke Cabinet Figure 2 5 CPVC Pipe Splices Capacitor
111. 2 not shown for clarity Figure 2 6 Typical Strap Wrench not supplied used to tighten unions on CPVC pipe splices 7000L UM302B EN P June 2013 7000 C Frame Marine Drive Installation 2 11 Pipe Splice 1 Pipe Splice 2 Figure 2 7 Capacitor Cabinet after pipe Figure 2 8 DC Link Choke Cabinet after splices installed pipe splices installed Note Install according to flow direction labels as shown Connect Power M L M L Power Bus 7000 C Frame Marine Locate the four 4 Power Bus pieces of the splice kit in DC Link Choke cabinet and remove shipping wrapping See Figure 2 9 Connect Power Bus M L M L on the red insulators in the DC Link Choke cabinet and mating bus pieces in the capacitor cabinet Hardware required is pre attached to bus connections cabling and insulators in the cabinet where the power bus splice kit will attach Remove and attach as shown in Figures 2 9 to 2 13 Torque M10 carriage bolts connecting bus to bus in the capacitor cabinet to 29 Nm 21 ft Ibs Torque M12 hardware supplied for cable to bus stab connections to 50 Nm 37 ft Ibs After cable connections have been made ensure cable connections to choke stabs are torqued to 50 Nm 37 ft lbs Ensure a minimum of 3 75mm clearance exists between Medium Voltage Bus field connections including hardware and all cabinet sidesheets 7000L UM302B EN P June 2013 2 12 Drive Installation Connect the Se
112. 2 pulse offerings in terms of lowering line side harmonics Isolation transformers are available in indoor dry type cast coil and outdoor oil filled designs for maximum flexibility in dealing with floor space installation costs and control room air conditioner loading Refer to Specification 80001 005 Rectifier Duty Transformers for more details on transformer requirements and features Sample line current and voltage are also shown in Figure 1 2 The THD of line current is approximately 5 6 while the THD of line voltage line to line is approximately 2 0 THD of line voltage is a function of system impedance The 18 pulse rectifier consists of one master bridge and two slave bridges and will always have a total of 18 SCR switching devices Figure 1 2 18 pulse Rectifier and its input waveforms a Line current b Line to line voltage at PCC 7000L UM302B EN P June 2013 7000 C Frame Marine Overview of Drive 1 5 Active Front End AFE Rectifier An active front end AFE rectifier suitable for the PowerFlex 7000L topology is also commonly called a PWM rectifier This is particularly attractive since it does not require an isolation transformer to meet IEEE 519 1992 Most available technologies in today s MV market require a multi winding transformer to mitigate the unwanted harmonics by phase shifting the transformer secondary windings Depending on the topology the transformer can ha
113. 2013 4 4 Component Definition and Maintenance Voltage Sensing Circuit The number of sensing boards is dependent upon the drive rectifier Board Assembly configuration Replacemen Spiaeement 1 Ensure there is no power to the equipment To prevent electrical shock ensure the main power has been disconnected before working N on the sensing board Verify that all circuits are voltage free using a hot stick or appropriate high voltage measuring device Failure to do so may result in injury or death N Mark the position of the ribbon cables and wires 3 Remove the screws and lift the ring lugs from the terminals to remove the wires 4 Release the locking mechanism located on each side of the ribbon cable connector and pull the ribbon cable straight out to prevent bending the pins 5 Remove the four nuts and washers that secure the assembly to the studs welded to the frame 6 Remove the old VSB and replace with the new VSB on the studs using the existing hardware to secure the assembly Do not overtorque the connections or you may break the studs 7 Replace ring lugs on terminals Plug in ribbon cables making sure that cables are positioned properly and fitting is secure locking mechanism is engaged 8 For personnel and equipment safety ensure both grounding connections are re connected to the sensing board Figure 4 3 Sensing Board with Mounting Hardware Placement 7000L UM302B EN
114. 2013 Hazardous Materials Environmental protection is a top priority for Rockwell Automation The facility that manufactured this medium voltage drive operates an environmental management system that is certified to the requirements of ISO 14001 As part of this system this product was reviewed in detail throughout the development process to ensure that environmentally inert materials were used wherever feasible A final review has found this product to be substantially free of hazardous material Please be assured that Rockwell Automation is actively seeking alternatives to potentially hazardous materials for which no feasible alternatives exist today in the industry In the interim the following precautionary information is provided for your protection and for the protection of the environment Please contact the factory for any environmental information on any material in the drive or with any general questions regarding environmental impact e Capacitor Dielectric Fluid The fluids used in the filter capacitors and the snubber capacitors are generally considered very safe and are fully sealed within the capacitor housings Shipping and handling of this fluid is typically not restricted by environmental regulations In the unlikely event that capacitor fluid leaks out avoid ingestion or contact with skin or eyes as slight irritation could result Rubber gloves are recommended for handling To clean up soak into an absorbent material an
115. 2B EN P June 2013 2 66 Drive Installation 7000L UM302B EN P June 2013 7000 C Frame Marine Chapter Objectives Terminology 7000 C Frame Marine Chapter 3 Operator Interface This chapter describes how you use the operator interface to modify and obtain information contained within the drive In this chapter you will learn how to e Modify information associated with the initial drive setup e View drive parameters drive status e View and Reset Alarm Conditions e Request printouts of the information in the drive e Perform diagnostic trending e Modify the operation of the operator interface The chapter deals only with the operation of the operator interface Specific references to a particular parameter are only for illustrative purposes Refer to PowerFlex 7000 Medium Voltage AC Drive Technical Data Publication 7000 TD002_ EN P for information about the actual tags within the drive and their use Parameter A memory location within the drive to which data may be written to or read Setting a parameter i e writing to it will modify how the drive behaves Prior to using the drive a number of parameters must be set Additional parameters may be changed while the drive is in use in order to adjust its operation i e the speed could be changed via a parameter Read only Parameter A memory location which can only be read A read only parameter contains real time data and is used to re
116. 3 Detachment of Coolant System from PowerCage Modules 4 36 Reconnecting the Coolant System to PowerCage Module 4 38 Chill Block Removal and Replacement 4 41 Instructions for Inserting Chill Block Assembly 4 42 PowerCage Removal and Replacement 4 43 Snubber Resistors 22 eee eR e Let egeo 4 44 Testing Snubber Resistors ie 4 45 Sharing Resistors irreale eem iens 4 45 Testing Sharing Resistors ie 4 46 SGCT PowerCages 0 1 0 csssseeesceesecceseceseceeseetsceses 4 46 SCR Pow erCages ien entes 4 47 Snubber and Sharing Resistor Replacement 4 47 Self Powered Gate Driver Board SPGDB 4 49 D SGEHptlon 6 etn e er rie tentes 4 49 Board Calibration e 4 49 Test Points Description esee 4 50 Terminal Connections Description i 4 51 Testing Procedure for SCR Self Powered Gate Driver Board 4 52 Equipment Needed ie 4 52 Procedure sinfonia sala tetas 4 52 Fiber Optic Cabling iano eee entem eret 4 56 DC Link and Control Power Section eese 4 57 DG ink Reactor irent 4 58 Control Power Components ie 4 59 Ride Through 5 4 2 uie etepued 4 59 AC DC Power Supply i 2 000 periret edens 4 62 Description nd nes eee ete ttem ees 4 62 Location eee 4 63 T
117. 3 87 TRANSFER Current Access Basic Fans ore noces svsren exrt_ Figure 3 87 Transfer Main Menu From this screen additional screens are used to perform the various functions involving the flash memory The screen shows the current access level of the operator interface Any operation that will alter the contents of the flash memory or of the drive requires the access level to be something other than Monitor At the Monitor level you may view the contents of the flash card To change the access level press the F8 key Refer to the section Enter Modify an Access Level 7000 C Frame Marine Operator Interface 3 61 Format Flash Card Flash card files have a characteristic unlike normal DOS files They can not be modified once written New files can be added to the card however they cannot be selectively removed When a new flash card is to be used or all the files removed from an existing card the card must first be formatted Formatting erases all data on the card and creates a DOS file structure To format a card press the F2 key on the TRANSFER screen The screen will appear as in Figure 3 88 indicating the operation you are about to perform and showing the current status of the operation If nothing happens then you have not gained the required access to modify the flash memory Exit to the TRANSFER screen and refer to the section entitled Enter Modify an Access Level to gain access T
118. 4 120 Component Definition and Maintenance Preparation for Downloading Firmware cont 7000L UM302B EN P June 2013 PF7000 in Download Mode To place the drive in download mode you should be in the UTILITY TRANSFER screen You will not be able to do this if the drive is running Ensure the drive is stopped and the E Stop is pressed This is just a precaution as all versions of firmware 7 xxx and later will not allow you to attempt a download while running Current Access Advanced This time press F9 for SYSTEM and a screen will appear telling you that you are in download mode There are two status LEDs D9 and D11 on the DPM which provides indication of the programming process The following illustrates the states of the LED Solid Green when both LEDs are solid green the Application firmware is running Flashing Green when either D9 or both LEDs are flashing the board is in download mode If the DPM bootcode gt 1 006 then only D9 will be flashing and D11 will stay solid If the bootcode lt 1 005 then both LEDs will be flashing After putting the drive in download mode the following is the display on the drive terminal SYSTEM IS IN DOWNLOAD MODE Connect your PC to DPM data port And download new firmware Press any Key to Continue 7000 C Frame Marine 7000 C Frame Marine Component Definition and Maintenance 4 121 If you press any Key after this me
119. 4 ankle 94 IN 93 63 djeH INVHAN 63 ed SJo4 iojoeul q 10 24 welBold 4 welbad 4 9 JoJSUeJ Sniejs 7 3 nueyuleW 1r 199 8S jeuu03 c 3 euuoJ Euu03 c4 Q SS929y 94 ii apo yoajes i 18987 399S dnog joejeg dnog 4 86 Bue1 4 ww pO Ann AWan Z4 Jejuud juuq 3 Figure 3 104 Menu Hierarchy 7000L UM302B EN P June 2013 7000 C Frame Marine Operator Interface 3 78 740 ed nuejy BUI 0004 Xa 4J4amog Q SSe29y 9 J fue arcidui oj Jepio ui WesHeIp y uo uwous jou ale ABUL pezi M dnos Kay uue v 94 pue djeH 4 eu oj sseooe BABY SU3 JIS y SjoN 9660 9 4 Jejeuieled AjIpow o QU o SJOJOWEIE d dmes OIX OO E dnjeg Bojeuy OIX Bojeuy suoneouunuuo2 9 OL dnjag synej 9 Td 9660 74 JazAjeuy 090 014 MSINBAO SUNEH azhjeuy 2 4 MN AQ 14 eseqejeq ulejqo v 013 SYSE 1ne 4 ssoooy g j 2 J JPWLd MaIA dnog Aejdsiq Aeidsiq y 4 Mail feq dnjas erq S 1 dnjag jeuse xy dmes q 84 MalA 6 4 dieH yne4 xa Jeujoyx3 oDueu piomssed sonsouDeiq sBuiueM SjneJ ebenbue a ebueu 64 sbeiq 64 BuiueM 9 4 SjneJ 6 J eB Bue1 64 ssa00y 84 so29V 0 4 aessa swuelYy 9 4 dmas 84 O 9 ON 64 SeA 84 pis uey SOJ nuejuleW Figure 3 105 Menu Hierarchy 7000 C Frame Marine 7000L UM302
120. Analog Processor Board ACB and connect it to the serial port on your laptop You may need a gender changer 2 Turn on your laptop and run dosfwdl exe program On your laptop you should see the screen similar to one shown below Em the nane of the firmware file to download CE xit gt 3 Type in the firmware filename e g FRN_4006 FMW as shown in the screen below and then hit Enter key bj me of the firmware file to download CE xit gt FRN_4006 FMY 7000L UM302B EN P June 2013 4 126 Component Definition and Maintenance Downloading the Terminal Firmware cont 7000L UM302B EN P June 2013 4 Now you will be prompted to enter Port address of your laptop Choose a correct port address and then hit Enter key CAManzoor Software PF7000 1 P _FRN4 006 dosfwdl exe Enter the nawe of the firmware file to download CE xit gt FRN_ 4886 FMU Port to use for file download 1 2 3 4 CE xit 5 When you see the screen similar to one shown below then at that moment turn on control power to the Terminal Manzoor Software PF7000 1 P _FRN4 006 dosfwdl exe Enter the nane of the firmware file to download E xit gt FRN_4606 FMW Port to use for file download 1 2 3 4 Exit Download on Port 1 Hit any key to abort download request Sending Request 6 As soon as control power is applied to the Terminal the firmware download will start automatically and the following message will ap
121. B EN P June 2013 Operator Interface 3 79 PCMCIA Memory Card Description Installation Data The memory card slides into the card slot located on the backside of the PowerFlex 7000 B Frame operator interface These instructions show how to insert the card in the Operator interface The memory card should be kept free from moisture extreme temperatures and direct A sunlight Failure to observe this caution could result in damage to the card Do not subject memory card to flexing or extreme shock Failure to observe this caution could result in damage to the card Installing the Memory Card 1 Locate the vertical card slot on the back of the operator interface See Figure 3 106 e Du 2711 K5A9 E AUENA ATTENT d Lis CARD SLOT COMMUNICATION CABLE Figure 3 106 Rear View of Operator Interface 7000 C Frame Marine 7000L UM302B EN P June 2013 3 80 Operator Interface 2 Position the card vertically so the key slot is facing the right side of the operator interface KEY SLOT Figure 3 107 Key Slot Orientation 3 Insert the card into the card slot and push until the card is firmly seated Do not force the card into the slot Forcing the card into the slot may damage the connector AN pins 7000L UM302B EN P June 2013 7000 C Frame Marine Chapter 4 Component Definition and Maintenance Control Cabling Cabinet Components p
122. DC output V outputs lt 49 VDC this output goes from low to high 7000L UM302B EN P June 2013 4 62 Component Definition and Maintenance AC DC Power Supply cont AC DC Power Supplies Pioneer Location The AC DC power supply is located in the low voltage panel in the far right hand section of the drive A typical low voltage compartment is shown in Figure 4 48 Figure 4 48 Location of AC DC Pioneer Power Supply on Low Voltage Panel 7000L UM302B EN P June 2013 7000 C Frame Marine Component Definition and Maintenance 4 63 Terminal Connections Descriptions The terminal connections are shown in Figure 4 50 pea MSA Control signals DC outputs s TR 3 TOP FRONT VIEW 853 VIEW sis Li Single phase input Figure 4 49 Terminal locations on AC DC Pioneer power supply P1 AC input PIN 1 2 3 P2 DC output PIN 1 2 3 4 P3 FAIL output PIN 3 15 14 7000 C Frame Marine LABEL EARTH LINE NEUTRAL LABEL 56V 56V COMM 56V 56V COMM LABEL DC POWER FAIL OUTPUT POWER GOOD CURRENT SHARING DC POWER FAIL COMMON 7000L UM302B EN P June 2013 4 64 Component Definition and Maintenance AC DC Power Supply Ensure the output of the supply is 56V DC cont There is a potentiometer on the top of the power supply
123. Enumerated Value eese 3 36 Bit Encoded Value iii 3 37 Analog POMS verserna teens 3 38 Fault Masks rite ed 3 39 User Definable External Text 3 42 A E tredici b eee ee eti tesetet 3 43 KIO 5 e etfi eter leder e Ee Een os 3 45 Message Prompting eee 3 45 Store Retrieve Configuration NVRAM 3 46 InitialiZe ssaa een DE 3 46 Nr EU 3 47 In 3 47 Display Parameters eene 3 48 Custom GOrOoup ge eta i nie nant 3 50 View Drive Status ied ee e ette m eres 3 51 View and Reset Alarms e 3 51 Help for Alarms 2 eiecti eta 3 52 Request Printouts ie 3 53 Perform Diagnostic Trending esses 3 54 Assigning a Trace e 3 55 Setting the Trigger ii 3 56 Defining Sample Rate and Positioning 3 57 Starting the Trace paeen aenn eiin ikate 3 58 Flash Memory Transfers eee 3 59 Format Flash Card eee 3 61 Maew a Dir ctoty iaia 3 62 selecta Filename eerte tees 3 62 Enter a Filename eere 3 63 Loading Programs Firmware 3 63 Parameter Transfers eee 3 65 7000L UM302B EN P June 2013 iv Table of Contents Chapter3 Operator Interface cont Chapter 4 Component Definition and Maintenance 7000L UM302B EN P June 2013 Upload to Opera
124. FF and Flashes alternately LED 1 Red with LED 3 while gating 7000L UM302B EN P June 2013 4 30 Component Definition and Maintenance Symmetrical Gate 1 Ensure there is no power to the equipment Commutated Thyristor Replacement cont To prevent electrical shock ensure the main power has been disconnected before working on N the drive Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Failure to do so may result in injury or death 2 Note the position of the fiber optic cables for assembly 3 Toremove the SGCT it is necessary to remove the gate driver power cable and fiber optic cables Exceeding the minimum bend radius 50 mm 2 in of the fiber optic cables may result in damage The fiber optic cables can be damaged if struck or bent sharply The minimum bend radius is 50 N mm 2 inches The connector has a locking feature that requires pinching the tab and gently pulling straight out The component on the printed circuit board should be held to prevent damage 4 Remove the load on the clamp head assembly as described on page 5 26 5 Two screws secure the board to the chill block Loosen the captive screws with a long Phillips screwdriver until the circuit board is free It may be necessary to adjust the position of the chill blocks to allow free movement of the SGCT 6 SGCTs can now be extracted by pulling the Gate Driver board forward between the u
125. FM 20 4 di ra gt d n Current Boost Optical gt 18 Interface ES 19 gt 21 Figure 4 71 Process Loop Transmitter Block Diagram This type of transmitter is known as a 4 wire transmitter and will sink current from a receiver The receiver is connected by two wires only from pins 20 connection and either pins 18 19 21 connection The recommended connection is shown above The type of shielded cable used is application specific and is determined by the length of the run the characteristic impedance and the frequency content of the signal 7000 C Frame Marine Component Definition and Maintenance 4 99 Isolated Process Receiver These inputs are individually configurable to accept either a 10 0 10V input signal or a 4 20 mA signal When configured for voltage input each channel has an input impedance of 75 Kohms When used as a current loop input the transmitter must have a minimum loop compliance of 2 volts to satisfy the 100 ohm input impedance Regardless of input configuration each input is individually isolated to 100V DC or 70V RMS AC A block diagram of the receiver is shown below 2 6 10 lt n AD DSP FPGA Buffer NH XI Ut 159 7 Isolation Amplifier 3711 4812 V f I P pins m 2 VP pins S WPpns Figure 4 72 Process Loop Receiver Block Diagram 7000 C Frame
126. GND Digital ground DPM TP8 ITP1 Digital to Analog output Assignable diagnostic test point DPM TP9 ITP2 Digital to Analog output Assignable diagnostic test point DPM TP10 ITP3 Digital to Analog output Assignable diagnostic test point DPM TP7 ITP4 Digital to Analog output Assignable diagnostic test point DPM TP11 RTP4 Digital to Analog output Assignable diagnostic test point DPM TP12 RTP3 Digital to Analog output Assignable diagnostic test point DPM TP13 RTP2 Digital to Analog output Assignable diagnostic test point DPM TP14 RTP1 Digital to Analog output Assignable diagnostic test point This table defines the states of LED D9 and D11 on the DPM board D9 is used for the Inverter side processor and D11 is for the Rectifier side processor The other two LEDs D6 and D7 are the watchdogs for the Inverter and Rectifier code respectively Table 4 C Description of D9 and D11 Function Color Rate or Count Pulse Meaning Green 10 Count PreExecution OK Red 25 Hz No Bootcode Green 25 Hz No Application Green 5 Hz Downloading via Serial Port Green 2Hz Serial Port Active ie Terminal Green 1Hz Waiting Loading Application Green Solid Operation Running or Successful Red Solid Operation Failed Red 2 Count POST RAM Failed Red 3 Count POST NVRAM Failed Red 4 Count POST DPRAM Failed Red 8 Count FPGA Loading Failed POST USART Failed Red 9 Count 1 Green Count
127. I Properties window will appear Set the port settings as shown below and then click OK Port Settings Bits per second MEX Data bits e Parity None Stop bits fi Flow control Xon Xoff e Restore Defaults Cca Apply Now close the HyperTerminal program Following message box will appear 7000 C Frame Marine 7000L UM302B EN P June 2013 4 138 Component Definition and Maintenance Printing Uploading Data from the Drive cont HyperTerminal xi You are currently connected 4re you sure you want to disconnect now Click Yes At this point you will be prompted to save the session HyperTerminal x 2 Do you want to save session Parameters E No Cancel Click Yes to terminate the HyperTerminal program Step 3 Uploading the Data from the drive 7000L UM302B EN P June 2013 Now that you have created an empty notepad file and setup HyperTerminal connection you are ready to upload the data from the drive Connect a null modem cable between your computer s serial port and the serial port J11 on the Analog Control Board ACB Restart HyperTerminal program On the Connection Description window click Cancel Connection Description 2 x hb New Connection Enter a name and choose an icon for the connection Name 7000 C Frame Marine Component Definition and Maintenance 4 139 From the File menu
128. IB C TX2 Firing Command Signal TP34 DIAG 14 OIB C RX3 Diagnostic Feedback TP35 CMD 14 OIB C TX3 Firing Command Signal TP36 DIAG_15 OIB C RX4 Diagnostic Feedback TP37 CMD_15 OIB C TX4 Firing Command Signal TP38 DIAG_16 OIB C RX5 Diagnostic Feedback TP39 CMD 16 OIB C TX5 Firing Command Signal TP40 DIAG 17 OIB C RX6 Diagnostic Feedback TP41 CMD 17 OIB C TX6 Firing Command Signal TP42 TFB C OIB C Temperature Feedback Signal There is no provision in the drive for the use of this signal it is only provided for Rockwell internal testing TP43 GND Ground Reference for TP30 TP42 7000 C Frame Marine Downloading Firmware 7000 C Frame Marine Component Definition and Maintenance 4 117 Introduction With the introduction of the PowerFlex 7000 Medium Voltage Drive all drive control functions are loaded on the Drive Processor Module DPM with firmware via a serial connection on the Drive Processor Module data port J4 The firmware is packaged into a single executable file with the extension exe This document describes how to download new or updated firmware to the drive using the DPM data port All firmware downloaded via this means is stored in non volatile Flash memory The latest firmware and the associated release notes are available on the Medium Voltage intranet site or can be obtained from Medium Voltage Product Support Overview When the system is powered up the drive executes the Application C
129. Mae 1 14 Direct Vector Control sienien ninure e i as 1 14 Control Hardware eee aaa 1 15 Operator Interface calura ia ete ere 1 16 Chapter 2 Drive Installation Safety and Codes cositas pate bates 2 1 Unpacking and Inspection eee 2 1 Transportation and Handling eee 2 2 Overhead Eating rtr eet dee 2 3 Rod or Pipe Rollers eee 2 4 Fork Lift Tr cks aaa 2 4 SLOTASE E 2 5 Siting OF the DIVE 2 endete re cen iet tee cbe 2 5 Site Considerations esses 2 5 Installation 2 2 nana lean aac 2 7 Joining Shipping Splits eee 2 7 Removal of Lifting Angles eee 2 23 Shock Indication Labels eee 2 24 Installation of Exhaust Air Hood sees 2 25 Internally Mounted Fans eere 2 26 Externally Mounted Fans and Fan Hood 2 27 Cabinet Layout and Dimensional Drawings of Drive 2 28 Typical PowerFlex 7000L Drive Structure Layout 2 29 Control Cabling Cabinet eee 2 31 Major Components esee rennen rennen 2 31 IEC Component and Device Designations 2 49 7000 C Frame Marine 7000L UM302B EN P June 2013 ii Table of Contents Chapter 2 Drive Installation Power Wiring Selection sca erae eoi ta RR aude 2 49 cont Cable Insulation zs heo es Decor Dando ib
130. N LN LN ZN A 7000L UM302B EN P June 2013 power has been disconnected before working on the converter cabinet Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Failure to do so may result in injury or death The PowerCage can house either SCRs or Silicon Gate Commutated Thyristors SGCT The SGCT circuit board is sensitive to static charges It is important that these boards should not be handled without proper grounding Some circuit boards can be destroyed by static charges Use of damaged circuit boards may also damage related components A grounding wrist strap is recommended for handling sensitive circuit boards 7000 C Frame Marine Component Definition and Maintenance 4 25 Matched Set 2 SGCTs Matched Set 2 SGCTs Outlet Manifold E J y g Clamp Head o o 1 d o o E Inlet Manifold 9 Clamp Base Module Housing al Figure 4 16 4 Device PowerCage Matched Set 3 SGCTs Matched Set 3 SGCTs Outlet Manifold NS l IT i Clamp Head o o o o q B o PI I Inlet Manifold o o 2 a e d ES e Clamp Base Module Housing Figure 4 17 6 Device PowerCage 7000 C Frame Marine 7000L UM302B EN P
131. P June 2013 the Gate Driver circuitry The drive control decides which device to fire and sends an electrical signal to the OIB boards The OIB board converts that electrical signal to an optical signal which is transmitted via fiber optics to the gate driver cards Typically the Transmit ports are Grey and the Receive ports are Blue The gate driver accepts that signal and turns the device on and off accordingly The diagnostic fiber optic signals work the same way but the source is the gate driver boards and the destination is the drive control boards Each OIB contains one extra fiber optic receiver RX7 which is used for temperature measurement X8 X3 XI OPTICAL INTERFACE PCB O RX5 won Bin 82 da aS a 3 ROCKWELL AB oui 3 J 2 RX7 ci ss E Pui 22 READY h uh D d P2 5 te L3 u i POWER DESIGNED IN MADE IN CANADA USA Manc PRODUCTION ASSEMBLY P N I D R4 TX6 RX6 no Rm O X9 i X Figure 4 78 Optical Interface Board The OIB boards are mounted directly on the Optical Interface Base Board OIBB using two parallel 14 pin connectors for the electrical connection and plastic clips to provide the mechanical strength There is one OIBB for the inverter and one OIBB for the rectifier device The OIBBs are interfaced to the DPM using two ribbon cables to connect to J11 and J12 Each OIB board can handle the Firing and Diagnostic duplex fiber optic connect
132. P June 2013 7000 C Frame Marine Input Transient Protection Transient Suppression Network TSN 7000 C Frame Marine Component Definition and Maintenance 4 5 Overview Input transient protection is provided in two forms Transient Suppression Network TSN or Surge Arresters The TSN is optimized for 6P and 18P rectifier designs Surge Arresters are optimized for AFE and D2D rectifier designs Description The Transient Suppression Network Module consists of an assembly of suppressors that are connected to each of the three phase input lines and the structure s ground bus There are three assemblies for an 18 pulse drive A transient voltage spike in excess of the semiconductor rating will destroy or shorten the lifespan of the device The Transient Suppression Network Module provides suppression of transient overvoltages appearing on the input of the drive and is a standard feature of the drive The two basic blocks of the TSN module are the MOV suppressor and the MOV fuse MOV Suppressor The transient suppressors used in the module are heavy duty metal oxide varistors or MOVs Varistors are voltage dependent nonlinear resistors They have symmetrical voltage current characteristics similar to back to back connected Zener Diodes The varistor has very high resistance below its voltage rating and appears as an open circuit The leakage current through the device would be very small in this region W
133. PowerFlex 7000 Medium Voltage AC Drive Allen Bradley Liquid Cooled C Frame Fourth Generation ForGe Control Bulletin 7000L Marine User Manual Rockwell Afon Bradey Rochel Sao 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 b
134. Publications 1502 UM050 EN P Series D and 1502 UM052 EN P Series E for a detailed description of all 400A contactor maintenance Final Reporting A complete detailed report on all steps in the Preventive Maintenance procedures should be recorded to identify changes Acompleted copy of this checklist should be included A detailed description of ALL ADJUSTMENTS AND MEASUREMENTS that were taken during the process should be included in an addendum Interlock Adjustments Loose Connections Voltage Readings Megger Results Parameters etc THIS INFORMATION SHOULD BE COMMUNICATED TO MV PRODUCT SUPPORT SO THAT FUTURE SUPPORT ACTIVITIES WILL HAVE THE LATEST SITE INFORMATION AV AILABLE This can be faxed to 519 740 4756 7000L UM302B EN P June 2013 4 156 Component Definition and Maintenance Annual Maintenance cont 7000L UM302B EN P June 2013 Time Estimations gt Operational Maintenance 0 5 hours per filter gt Annual Maintenance Initial Information Gathering 0 5 hours Physical Checks Torque Checks 2 0 hours Inspection 2 0 hours Cleaning 2 5 hours Meggering 1 5 hours Control Power Checks Contactor Adjustments 2 0 hours Voltage Level Checks 1 0 hours Firing Check 0 5 hours System Test 2 0 hours Medium Voltage Checks Final Inspection 0 5 hours Phasing Check 1 5 hours Autotuning 2 0 hours Operation to Ma
135. RANSFER FORMAT FORMAT FLASH CARD PROCEED Yes No Operation Status FORMAT PENDING ar rower T_T fares es ex Figure 3 88 Format the Flash Card The screen will then ask you to confirm the operation Press the F8 key to proceed or the F9 key to abort Performing a format will overwrite all existing data on the flash card Formatting can take up to several minutes depending on the card involved The status will indicate when the formatting is complete or if an error occurred Additional cards may be formatted from this screen by pressing the F2 key 7000 C Frame Marine 7000L UM302B EN P June 2013 3 62 Operator Interface View a Directory The directory of a flashcard is shown by pressing the F7 key on the TRANSFER screen The directory shows the filename and extension along with a date and time stamp of when the file was created A screen typical of Figure 3 89 will be shown DIRECTORY Filename 99 07 30 98 62 25 ISH LNG 97 06 12 PAR 99710720 IAN LNG 97712709 ER PAR 88782717 Dur eo peer 69 16 13 11 69 13 GJ aj DMN Figure 3 89 Typical Directory Any screen or operation that requires a filename to be entered or picked from the directory uses this DIRECTORY screen It is always obtainable from the F7 key on any applicable screen When the directory is entered from the TRANSFER screen all files will be shown When entered from one of the
136. RMS MODIFY NEXT PG PREU PG EXIT Figure 3 5 Communications Error Language Changing When the language used by the drive changes either via the operator interface or an external device the operator interface must do considerable work The database strings are all invalidated the character set for the server is changed and all strings used by the operator interface are linked to the new language During this possibly lengthy process the Language Changing message is displayed General Operation The operations that can be performed on a screen vary depending on the actual screen being displayed The majority of the operations are activated by the function keys located along the bottom of the screen Although the meaning of these keys do change from one screen to the next there are some functions which are available on most screens and always have the same assignment 7000 C Frame Marine Operator Interface Power up Sequence 7000 C Frame Marine Operator Interface 3 9 The operations for these latter keys will not be explained within the description of individual screen operations They are explained here and apply equally to all screens F1 Help This operation is active on every screen even if the Softkey is not displayed Help is context sensitive and will display help that relates to the screen that you are currently viewing F6 Alarms The F6 Softkey will always get you to the Alar
137. Redundancy Installed Removed Removed Dual Quadrature Encoder Option with Redundancy Installed Removed Installed Pise s uad GUSELDQUAD mustpe Removed Installed Installed Gray Code Absolute Encoder Low True Removed Installed Removed Natural Binary Absolute Encoder Low True Removed Removed Installed Gray Code Absolute Encoder High True Removed Removed Removed Natural Binary Absolute Encoder High True Figure 4 75 Universal Encoder Board 7000L UM302B EN P June 2013 7000 C Frame Marine Component Definition and Maintenance 4 105 Connections to the Universal Encoder Interface are made via a 1492 IFM20F interface module The connections to the IFM are as follows Table 4 G Encoder Functions IFM Pin Quadrature Encoder Function Absolute Encoder Function 1 A1 E0 2 A1 E1 3 B1 E2 4 B1 E3 5 ENC_COM ENC_COM 6 Z1 E4 7 Z1 E5 8 A2 Redundant or Dual ENC E6 9 A2 Redundant or Dual ENC E7 10 ENC_COM ENC_COM 11 B2 Redundant or Dual ENC E8 12 B2 Redundant or Dual ENC E9 13 Z2 Redundant or Dual ENC E10 14 Z2 Redundant or Dual ENC E11 15 ENC_COM ENC_COM 16 ENC_COM ENC_COM 17 ENC_COM ENC_COM 18 ENC PWR 12V ENC PWR 12V 19 ENC PWR 12V ENC PWR 12V 20 ENC PWR 12V ENC PWR 12V Figure 4 76 20 pin Interface Module IFM 7000 C Frame Marine 7000L UM302B EN P June 2013 4 106 Component Definition and Maint
138. To change the contrast press the F3 key The current value of the contrast will be shown in reverse video Figure 3 12 Press the cursor up or cursor down keys to change the value of the contrast The screen will change instantly to show the effect of the change To abort the change press the backspace key and the setting will return to its original value To accept the change press the enter key The contrast setting has been saved The setting may also be aborted by pressing any of the assigned function keys other than F1 The function associated with that key will be executed 7000 C Frame Marine 7000L UM302B EN P June 2013 3 16 Operator Interface 7000L UM302B EN P June 2013 UTILITY 11 12 07 66 69 65 TUE Mainmenu Meters Backlight 16 min Disital spdmeter 572 Contrast I igital ammeter 573 gital vitmeter 574 D Di Digital purmeter 575 Figure 3 12 Utility Contrast Setting Time The clock setting controls the time stamp that the drive uses on the information contained on the alarm summary screen To change the time press the F5 key The hour s position of the clock will be in reverse video Figure 3 13 Press the cursor up or cursor down keys to change the value by a resolution of 1 unit Press the cursor left and cursor right keys to change the value by a resolution of 10 units To change the minutes press the F5 key again and repeat the procedure Likewise to change th
139. V5 and V12 Note that the non return valve NV1 or NV2 will stop coolant from flowing back to the pump being serviced Follow the pump seal replacement instructions from the pump manufacturer Refer to pump nameplate for manufacturer s model information Typical pump seal replacement information is provided at www goulds com pdf SST C SST F 20IOM pdf Figure 4 54 Drain Fill Pump 7000L UM302B EN P June 2013 4 70 Component Definition and Maintenance Pump Maintenance and Replacement cont 7000L UM302B EN P June 2013 Pump Replacement While the drive is running one of the pumps must be in operation Two pumps run alternatively The switching from one pump to another pump depends upon the Control Program setup If the drive is running and you need to replace one pump it is important to select the pump in operation by changing the pump selector switch position from auto to the pump number which is in operation Perform the following steps to replace the pump ON LINE 1 Select the running pump by changing the pump selector switch 2 Open the overload relay of the pump to be replaced by pressing the RED button of the overload relay 3 Check voltages at terminal T1 T2 and T3 of the pump contactor PC make sure that there is no voltage 4 Disconnect wire T1 T2 and T3 at pump 5 Close Valve V4 and V11 if pump 1 is to be replaced OR V5 and V 12 if pump 2 is to be replaced 6
140. WR To ACB 7000 C Frame Marine Component Definition and Maintenance 4 85 Terminal Connections Descriptions PIN NO 1 3 PIN NO LB6 3o0oo0 o0oubLRutc 13 14 PIN NO 1 3 PIN NO LBZO ovoo oumrutrt LABEL 56V 56V COMM EARTH LABEL 56V 56V RTN SVA DGND com1 5VB DGND com1 IDO ID1 LABEL ISOLATOR 24V 1A ISOL COMM com4 EARTH LABEL 24V_XIO 24V 2A XIO_COMM com3 HECSPWR 424V 1A LCOMM com2 HECSPWR 24V 1A 15V_PWR 15V 1A ACOMM coml 15V_PWR 15V 1A 5V_PWR 5V 5A DGND com1 EARTH DESCRIPTION ONLY 56V input 56V common earth ground DESCRIPTION ONLY 56V input supply 56V input supply return Not Connected Not Connected Isolated 24V Supply Isolated 24V Supply return Not Connected Not Connected Primary 5V supply before OR ing diode 5V 15V Common Secondary 5V supply before OR ing diode 5V 15V Common Power Supply ID Pin 0 Power Supply ID Pin 1 DESCRIPTION ONLY 24V 1A com4 0V com4 EARTH DESCRIPTION ONLY 24V 2A com3 OV com3 24V 1A com2 OV com2 24V 1A com2 15V 1A coml OV coml 15V 1A coml 5V 10A coml OV coml earth ground 7000L UM302B EN P June 2013 4 86 Component Definition and Maintenance DC DC Power Supply cont 7000L UM302B EN P June 2013 Replacement Procedure for DC DC Power Supply Refer to Figure 4 65 1 With the drive
141. Yes and transfer the parameters Once the parameters are transferred press the F10 EXIT key to get back to the main screen It is important to go through the parameters and ensure the settings are proper for the drive New parameters may need to be changed for the specific drive application and this should be understood from reviewing the release notes beforehand You should also correct any information such as the drive name the operating hours or the external fault text if present You should then press F5 NVRAM and save the parameters to NVRAM Then cycle control power one more time and the drive should come up with no faults or warnings and the drive will be ready to run At this point you may also want to save the parameters to the Operator Interface terminal the Flash Card via software or as a hardcopy This will provide a record of the new settings 7000 C Frame Marine 7000L UM302B EN P June 2013 4 124 Component Definition and Maintenance Setting Elapsed Time Downloading the Terminal Firmware 7000L UM302B EN P June 2013 When you replace the existing DPM board in the drive with a new board the operating hours counter will start from zero Therefore if you want to keep the actual operating hours in the drive you can restore them by running a utility program Sethobb exe which is usually supplied with the firmware package You can also request a copy of the program by e mail at MVSupport_Technical ra
142. abinet Layout and Generic Dimensional Drawings have not been included in this user s i i i manual Please reference the order specific project drawings for Dimensional Drawings api C p project d gs for of Drive detailed dimensions of conduit openings and mounting penetrations 7000L UM302B EN P June 2013 7000 C Frame Marine Drive Installation 2 29 Figure 2 37 Typical Footprint PowerFlex 7000 C Frame Marine Drive Structure Layout 7000 C Frame Marine 7000L UM302B EN P June 2013 2 30 Drive Installation Figure 2 38 Typical Footprint PowerFlex 7000 C Frame Marine Drive Structure Layout 7000L UM302B EN P June 2013 7000 C Frame Marine Drive Installation 2 31 Control Cabling Cabinet Shows the medium voltage area located in the control cabling cabinet behind the low voltage compartment and with barriers removed Note The control cabling cabinet comes in two different configurations e Large Footprint AFE rectifier Figure 2 37 e Small Footprint AFE rectifier Figure 2 38 Major Components The following diagrams are presented to show what the typical layout of each cabinet will be for the PowerFlex 7000 C Frame Marine Drive 7000 C Frame Marine 7000L UM302B EN P June 2013 2 3
143. able armor as a ground on its own is not adequate 7000 C Frame Marine Drive Installation 2 63 Note that if a drive isolation transformer is used the WYE secondary neutral point should not be grounded Each AC motor frame must be bonded to grounded building steel within 6 m 20 feet of its location and tied to the drive s ground bus via ground wires within the power cables and or conduit The conduit or cable armor should be bonded to ground at both ends Grounding Guidelines and Practices for Drive Signal and Safety Grounds When interface cables carrying signals where the frequency does not exceed MHz are attached for communications with the drive the following general guidelines should be followed e Itis good practice for the mesh of a screen to be grounded around its whole circumference rather than forming a pigtail that is grounded at one point Coaxial cables with a single conductor surrounded by a mesh screen should have the screen grounded at both ends Where a multi layer screened cable is used that is a cable with both a mesh screen and a metal sheath or some form of foil there are two alternative methods The mesh screen may be grounded 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 which is physically closest to the main equipment ground bus
144. abling can be used In either case always check with the encoder manufacturer for the recommended cable 7000 C Frame Marine 7000L UM302B EN P June 2013 2 60 Drive Installation Power and Control Wiring 3 Keep cable distances as short as is practically possible Rockwell Automation s recommendation for cable distances are cont a For the 20B ENC encoders the distance should be kept to a maximum of 65m 200ft Longer cable distances could cause excessive surge currents The operating frequency of the encoder has no bearing on this recommended distance due to AC Termination used However if the frequency can be kept so that the cable s characteristic impedance is around 348ohms this will improve the surge currents and may increase the maximum distance to 100m 330 ft For the Universal Encoder Interface the distance can be extended out to 200 m 650 ft 100 Khz This distance can be increased to 500m at frequencies below 55Khz It is not recommended to exceed this distance since the voltage drop across the cable could cause a lower than expected power at the encoder Unused Inputs Not all inputs in either the quadrature or absolute encoders may be necessary For example the absolute encoder can accept a 12bit encoder but will work with a lower resolution Likewise quadrature encoders may not utilize the Z track The following should be used for unused inputs 1 7000L UM302B EN P June 2013
145. ad Torque as Percent Required Drive Tachometer Application Torque of Full Load Drive Torque Service Required for Extra Profile Accelerating Peak Running Duty Rating Starting Torque Agitators Liquid CT 100 100 100 Heavy Yes Slurry CT 150 100 100 Heavy Yes Blowers Centrifugal Damper Closed VT 30 50 40 Normal No Damper Open d Sai 110 100 Normal No Chipper Wood Starting Empty 4 20 Contact Factory No Compressors Axial vane Loaded VT 40 100 100 Normal Conveyors 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 Extruders Rubber or Plastic Contact Factory Yes Fans Centrifugal ambient Damper closed VT 25 60 50 Normal Damper open VT 25 110 100 Normal Fans Centrifugal hot gases Damper closed VT 25 60 100 Normal No Damper open E a E EUR Contact rest No Fans Propeller axial flow M0 Noma No Kilns Rotary loaded ame HR Rh eH Yes Mixers Chemical CT 175 T5 100 Contact Factory Yes Liquid CT 100 100 Heavy Yes Slurry CT 150 125 Heavy Yes Solids CT 175 125 Contact Factory Yes Pulper No Pumps Centrifugal Discharge open No Oil field Flywheel Contact Factory Yes Propeller Normal No Fan Pump Normal No Reciprocating Positive Displacement Contact Factory Yes Screw type started dry Normal No Screw type primed discharge open Heavy Yes Slurry handling discharge open Heavy Yes Turbine Cent
146. ad mode 7000L UM302B EN P June 2013 3 70 Operator Interface Advanced Screen Operations 7000L UM302B EN P June 2013 A number of advanced functions have been incorporated into the operator interface These operations are not required to operate the drive They are meant as service tools for trained technicians and have been included here only for completeness All operations are accessed via a two key sequence Communications Statistics The screen depicted in Figure 3 98 shows statistics involving the serial communications between the operator interface and the drive as well as the contents of the transmit and receive buffers It is called from any screen except the PRINTER screen by pressing the F10 key and the cursor down key at the same time COMMUNICATIONS 10f 1 ERRORS Parity Framing Qverun 6 Timeouts Chksum 8 E Control Seqnce m scs usc eser T en Figure 3 98 Communications Statistics amp Buffer The ERRORS show the number of occurrences of a particular error since the last time the counters were reset Parity number of parity errors in characters received Framing number of framing errors in the characters received Overrun number of characters received that were not read prior to accepting the next character Resends number of times the operator interface had to resend data due to a NACK being sent by the drive Timeouts number of
147. ad the current conditions within the drive such as running speed Tag A generic reference to either a parameter or a read only parameter PanelView 550 The PanelView 550 is a product marketed by Rockwell Automation consisting of a hardware terminal and a software package integrated into a single product The Medium Voltage Drive only uses the hardware portion of the product and has replaced the software package 7000L UM302B EN P June 2013 3 2 Operator Interface 7000L UM302B EN P June 2013 PowerFlex Operator interface References to the operator interface refer to the product consisting of the Panel View 550 interface hardware and the unique software contained within it which allows it to function with the Medium Voltage Drive Editing Field An area of a screen that is displayed in reverse video When the field is in this state data may be entered into it via the keypad XIO the eXternal Inputs and Output adapters used by the drive to interface hardwired signals to the drive Operation A task which is to be performed In order to complete the task a number of screens may be involved i e selecting a parameter is an operation that requires at minimum two screens This operation itself is an operation of modifying a parameter NVRAM Non Volatile Random Access Memory This is memory that is not affected by loss of power It is used for long term storage of data such as parameters and alarm queues
148. age System Frequency Voltage ETEQUORE Modification Number Nominal Control Hz y Externally Supplied Line 3 phase Control Power AHD 2400 ABD 80 ACD CPD 3300 50 CND CKD EPD 4160 208 EHD 60 EBD 230 JPD 6600 50 JND 400 JKD 7000L UM302B EN P June 2013 7000 C Frame Marine Catalog Number Explanation Drive Selection A 3 PowerFlex 7000 Drive The PowerFlex 7000 medium voltage AC drive selection tables are Selection Explanation based on two types of drive service duty ratings Normal Duty 110 overload for one 1 Minute once every 10 minutes used for Variable Torque VT applications only Drives with this rating are designed for 10046 continuous operation with 11046 overload for one 1 minute once every 10 minutes Heavy Duty 150 for one 1 Minute once every 10 minutes used for Constant Torque CT or Variable Torque VT applications Drives with this rating are designed for 10046 continuous operation with 15046 overload for one 1 minute once every 10 minutes Service Duty Rating Continuous Current Rating amp Altitude Rating Code There are five different codes that define service duty and altitude in the drive catalog number per Table A 2 For example Catalog number 7000 A105DEHD R18TX has a continuous current rating of 105 amps with a normal duty service rating up to 1000 meters altitude Catalog number 7000 B105DEHD R18TX has a con
149. age or personal injury could result The following methods of handling are recommended 7000L UM302B EN P June 2013 7000 C Frame Marine Drive Installation 2 3 Overhead Lifting 1 Attach rigging to the lifting angles on the top of the cabinetry Ensure that the load rating of the lifting device and rigging is sufficient to safely AN raise the drive Refer to shipping weights on the packing slip enclosed with the shipment 2 Do not pass ropes or cables through the support holes in the lifting angles Use slings with safety hooks or shackles 3 Select or adjust the rigging lengths to compensate for an unequal weight distribution of load and maintain the drive in an upright position 4 To reduce the tension on the rigging and the compressive load on the lifting device do not allow the angle between the lifting cables chains and vertical to exceed 45 degrees ATTENTION Drives may contain heavy equipment that could be adversely affected by tilting Max Figure 2 1 Overhead Lifting 7000 C Frame Marine 7000L UM302B EN P June 2013 2 4 Drive Installation 7000L UM302B EN P June 2013 Rod or Pipe Rollers This method is only suitable when there are no inclines and the drive is being moved on one floor level 1 Boards 50 8 mm x 152 4 mm 2 in x 6 in or equivalent and at least 300 mm 12 inches longer than the drive must be placed under the shipping skid Carefully ease the s
150. age 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 good 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 2 1 9 times the rated line to line voltage 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 the enclosure door is opened and the low voltage compartment hinged out in the case of the incomer cabinet It is the responsibility of the installer to ensure that the drive is grounded properly typically at the point on the ground bus in the incomer cabinet close to the incoming power terminations 7000 C Frame Marine Drive Installation 2 65 Interlocking Access to the medium voltage areas of the drive is restricted by the use of key interlocking for safety At installation the key interlocking is set up so that access to the medium voltage compartments of the equipment can only be made when the upstream power is locked in the off position Additionally the key interlocking prohibits the upstream power being applied until the medium voltage drive s access doors have been closed and locked shut It is the responsibility of the installer to ensure that the key interlocking is installed properly to the upstream equipment 7000 C Frame Marine 7000L UM30
151. ages Press the cursor up or cursor down keys to select the desired group i e reverse video the group name Press the enter key The SELECT screen Figure 3 24 is displayed showing the members of the selected group The name of the selected group currently being displayed is shown after the screen name i e Motor Ratings Again using the cursor up or cursor down keys and if required the F8 and F9 keys to change the page select the desired tag Press the enter key and the selected tag will be used to continue the operation for which the selection process was being used 7000 C Frame Marine Operator Interface 3 23 SELECT GROUP Feature Select ontro asks Motor Model Speed Control Speed Command Fault Config Tach Option Figure 3 23 Selecting a Group SELECT Motor Ratings mnn mnn amps Rated motor kw Rated motor hp Rated motor rpm Rated motor freq Service Factor Fes T Te repre rc enr Figure 3 24 Selecting a Member of a Group From the SELECT GROUP screen Figure 3 23 the tag can also be selected via its name by pressing the F7 key Via Name When you know the name of the tag that you wish to select but do not know what group it belongs to or are unsure of the full name this method of selection may be appropriate Selecting via a name is initiated from the SELECT GROUP screen Figure 3 23 by pressing the F7 key This displays the SELECT LETTER screen shown in Fi
152. alant Figure 2 31 Capacitor Cabinet 7000 C Frame Marine 7000L UM302B EN P June 2013 2 22 Drive Installation Removal of DC Link Choke Tumbuckle Supports if used on design supplied Remove turnbuckles which attach choke to top lifting angle pair as follows Remove cotter pins see Fig 2 32 from bottom turnbuckle jaw then top Carefully remove turnbuckles Retain for future use Remove cotter pins Figure 2 32 Choke Cabinet Re install any capacitors that were removed Proceed with Removal of Lifting Angles 7000L UM302B EN P June 2013 7000 C Frame Marine Drive Installation 2 23 Removal of Lifting Angles Lifting angles should be removed only when the Drive is in its final 7000 C Frame Marine location The lifting angles are retained with 5 8 11 hardware The 5 8 bolts need to be re installed in their holes in the top of the Drive to prevent the ingress of foreign matter into the enclosures See Figure 2 33 N XY e SQ SR 7 N Fi NN 7 Ne 7 NI ra N SN Figure 2 33 Insert bolts Refer to the technical drawings and installation manual for your Drive mounting instructions N Failure to correctly anchor the cabinet may result in damage to the equipment or injury to personnel Contact the area Rockwell Automation sales office if you do not have these documents An additional set of mounting brackets has been supplied by Rockwell Automation for sec
153. are However at very dusty sites it is suggested to clean the arrester when the whole drive is cleaned PowerFlex 7000 18 pulse and some AFE drives will come with a grounding network installed The number of capacitors will vary depending on the system voltage 1 Ensure there is no power to the equipment To prevent electrical shock ensure the main power has been disconnected before working on the N capacitor Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Failure to do so may result in injury or death n Note the position of the leads 3 Remove the 6 4 mm 4 inch hardware and disconnect the leads connected to the terminals 4 Four brackets are used to secure the capacitor Loosen the four screws at the base of the brackets and lift the capacitor out 5 Place the new capacitor and tighten the screws securely an Replace the ring lugs and 6 4 mm inch hardware See Figure 4 9 The maximum torque for the capacitor terminal is 3 4 Nm 30 Ib in 7000 C Frame Marine Component Definition and Maintenance 4 13 Important Torque on capacitor terminals 3 4 Nm 30 Ib in Loosen screws to release capacitor Reactor Transformer Capacitors Resistor Bank Figure 4 9 Location of Ground Filter in C Frame Drive 7000 C Frame Marine 7000L UM302B EN P June 2013 4 14 Component Definition and Maintenance Output Ground
154. aring resistor Sharing Resistor Snubber Capacitor ADS Test Point Snubber Resistors Anode Chill block Cathode Chill block SGCT Anode Chill Block Cathode Chill Block SGCT Figure 4 34 SGCT Power Cage 7000 C Frame Marine 7000L UM302B EN P June 2013 4 46 Component Definition and Maintenance Sharing Resistors cont Disconnect Points MM XJ O Cs 1 ZN Snubber and Sharing Resistor Replacement 7000L UM302B EN P June 2013 Rsn 1 SCR PowerCages To obtain the sharing resistor value disconnect the 2 pole plug of the self powered gate driver board labeled SHARING and SNUBBER on the circuit board The red wire of the plug is the sharing resistor Measure the resistance between the red wire of the plug and the chill block to the left the anode chill block A value of approximately 80 kQ indicates a healthy sharing resistor To Gate Driver Board Anode Cathode Chillblock Chilblock Figure 4 35 SCR PowerCage Snubber Circuit Connections In the liquid cooled drive the sharing and snubber resistors can be replaced independently The sharing resistor is located in the same spot on every chill block assembly and the number of snubber resistors can vary with the drive rating The snubber and sharing resistors are
155. ates network activity Normal Decimal point OFF No activity on the network Normal at Power on during firmware download and with unprogrammed drive 7000L UM302B EN P June 2013 7000 C Frame Marine 7000 C Frame Marine Component Definition and Maintenance 4 111 External Input Output Board Replacement To replace the External Input Output Boards 1 Ensure that all medium voltage and control voltage power to the drive is isolated and locked out Note and Mark the location and orientation of all the plugs cables and connectors into the XIO board Use the electrical drawing as a reference Using your static strap disconnect all of the connections Remove the XIO board assembly from the low voltage control cabinet The XIO board mounts on a DIN rail so a special 3 piece assembly is used to secure the board The assembly does not come with the new board so the old board needs to be removed from the assembly and the new board installed in its place Install the new XIO board assembly in the low voltage control cabinet Reconnect all connections and verify the locations Apply Low Voltage power and complete a System Test and Medium Voltage tests to ensure the new board functions properly 7000L UM302B EN P June 2013 4 112 Component Definition and Maintenance Optical Interface Boards OIB The Optical Interface Boards are the interface between the DPM and 7000L UM302B EN
156. be adjusted by turning the device itself TO REPLACE THE SCR FOLLOW STEPS 8 11 and 16 18 TO REPLACE THE SCR SPGD BOARD FOLLOW STEPS 12 15 and 16 18 8 Remove the tie wrap holding the G C wire in place and remove the device from the assembly se Install the new device in the same position and using the same orientation as the original SCR and firmly secure the G C wires with a tie wrap 10 Connect the Gate Cathode phoenix connector to the Gate Driver Board 11 Apply a thin layer of Electrical Joint Compound Alcoa EJC No 2 or approved equivalent to the contact faces of the new SCRs to be installed The recommended procedure is to apply the compound to the pole faces using a small brush and then gently wiping the pole face with an industrial wipe so that a thin film remains Examine the pole face before proceeding to ensure that no brush bristles remain IMPORTANT Too much joint compound may result in contamination of other surfaces leading to system damage 7000 C Frame Marine 7000L UM302B EN P June 2013 4 34 Component Definition and Maintenance Silicon Controlled Rectifier and SCR Self Powered Gate Driver Board Replacement cont Clamp Head Adjusting Nut used for loosening and applying load to assembly DO NOT ADJUST calibration nut Disc Springs Figure 4 23 SCR Removal 12 13 14 15 16 17 18 7000L UM302B EN P June 2013 While grounded use a long P
157. be used based on the criteria considered by the distribution system designer applicable marine standard s requirements and local standards However NEC requires shielded cable for installations above 2 kV 7000 C Frame Marine Cable Insulation Drive Installation 2 49 The cable insulation requirements for the PowerFlex 7000 drive are given in the tables below ATTENTION Voltage ratings shown in the following tables are peak line to ground Some cable manufacturers rate voltage line to line RMS Ensure the cable meets the rating specified in the following tables Cable Insulation Requirements for 18P and 6P AFE Drives with Isolation Transformer Cable Insulation Rating kV System Voltage V RMS Maximum Peak Line to Ground Line Side Machine Side 2400 24 1 222 3000 gt 5 12 gt 2 75 3300 gt 5 63 gt 3 0 4160 gt 7 1 gt 3 8 6000 gt 10 8 gt 5 5 6300 2114 258 6600 211 8 26 0 Cable Insulation Requirements for Direct to Drive Technology Cable Insulation Rating kV System Voltage V RMS Maximum Peak Line to Ground Line Side Machine Side 2400 222 222 3000 gt 2 15 gt 2 75 3300 gt 3 0 gt 3 0 4160 gt 3 8 gt 3 8 6000 gt 5 5 gt 5 5 6300 gt 5 8 gt 5 8 6600 gt 6 0 gt 6 0 7000 C Frame Marine 7000L UM302B EN P June 2013 2 50 Drive Installation The following table identifies genera
158. ber optic cable Board Calibration No field calibration is required for this board 7000 C Frame Marine 7000 C Frame Marine Component Definition and Maintenance 4 49 Test points description TP1 SCR gate output attach oscilloscope between TP1 and TP2 to see gating pulses TP2 SCR cathode output TP3 Common reference point for all other test point measurements except for TP1 which uses TP2 as its reference point TP4 The positive 20 V rail used for the SPGDB operation TP5 The positive 5 V rail used for the SPGDB operation TP6 The sense voltage taken from the sense resistor across the SCR being controlled TP7 Trigger signal which remains active for a fixed period of time after the SCR being controlled has turned on and the voltage across it has collapsed TP8 Internal gating signal that indirectly turns on the SCR that is being controlled TP9 Gating signal received from the commanding drive control board through the appropriate fiber optic cable The yellow LED LED 1 on the SGPDB indicates that the SCR being controlled has a gating current flowing which is used to turn the SCR on Test power connection Fiber optic transmitter and receiver Thermal sensing connection TP9 TP8 TP7 TP6 TP5 TP4 TP3 Gate and cathode p thyristor connection TP2 Figure 4 37 Self Powered Gate Driver Board LED Snubber connection 7000L UM302B EN P June
159. ce Chromate plated parts must be disposed of according to local regulations and must not be disposed of with general landfill refuse In Case Of Fire This drive is highly protected against arcing faults and therefore it is very unlikely the drive would be the cause of a fire In addition the materials in the drive are self extinguishing i e they will not burn without a sustained external flame If however the drive is subjected to a sustained fire from some other source some of the polymer materials in the drive will produce toxic gases As with any fire individuals involved in extinguishing the fire or anyone in close proximity should wear a self contained breathing apparatus to protect against any inhalation of toxic gases Disposal When disposing of the drive it should be disassembled and separated into groups of recyclable material as much as possible i e steel copper plastic wire etc These materials should then be sent to local recycling facilities In addition all disposal precautions mentioned above must also be taken for those particular materials 7000 C Frame Marine 7000L UM302B EN P June 2013 4 150 Component Definition and Maintenance Preventive Maintenance Check List Operational Maintenance 7000L UM302B EN P June 2013 The preventive maintenance activities on the PF7000 Liquid Cooled Drive C Frame can be broken down into two categories Operational Maintenance can be complet
160. cedure or you can cancel the change by pressing the F7 key The CANCEL operation returns the new value to that of the actual value Bit Encoded Value When the parameter is a bit encoded value the MODIFY PARAMETER screen typical of Figure 3 48 will be displayed This screen shows the name of the parameter for which you are make the changes i e Logic Mask e the tag code for the parameter i e 241 e the name of the bit currently selected Adapter 0 e the actual value of the parameter bits contained in the drive 7000 C Frame Marine 7000L UM302B EN P June 2013 3 38 Operator Interface 7000L UM302B EN P June 2013 MODIFY PARAMETER Logic mask Actual New Adapter acres cancer sees ex Figure 3 48 Modify Bit Encoded Value To be allowed to make changes to the parameter the operator interface must be set to an Access Level other than Monitor You will be able to view the screen however pressing the data entry keys will have no effect If you are not in the correct level press the F8 key in order to gain access to the parameter Refer to the section entitled Enter Modify an Access Level for further information on the operation to change the level Having gained access press the left right cursor keys to move to the various bits within the parameter As each bit is selected the name of the bit is displayed Use the up down arrow keys to toggle the state of the bit The new value i
161. cess of a selection operation the enter key will accept the selection and proceed to a different screen based on the selection in order to complete the operation If you are in the process of entering data the enter key will accept the edited data The operator interface uses menu driven screens to perform various operations on the drive You can think of a screen as a window or template overlaying data from the drive The operator interface combines a screen with the drive data to formulate what you see on the display area of the operator interface Individual screens display a particular type of data and allow selected operations to be performed on this data A number of different screens may be used while performing a single operation Components Although the data displayed on any particular screen will vary the general makeup of a screen is the same for all Figure 3 2 shows a typical screen and its components Page Number SELECT GROUP Feature Select Motor Ratings Quners Control Masks Motor Model Peed Comman Selected Item Fault Config Heartbeat Figure 3 2 Screen Components 7000L UM302B EN P June 2013 3 6 Operator Interface 7000L UM302B EN P June 2013 The upper left hand corner contains the name of the screen i e SELECT GROUP Knowing the name of the screen will assist you in the orientation of the menu system On some screens to the right of the screen name will be the name of the selecte
162. checkbox against Bootcode and click OK After downloading the bootcode proceed with the drive firmware download as explained earlier After downloading new firmware the DPM resets automatically 7000L UM302B EN P June 2013 7000 C Frame Marine Component Definition and Maintenance 4 123 Reloading the Parameters For major revision level upgrades the majority of the parameters that were stored in the Operator Interface or other external means can still be used but there may be things such as new parameters changed scaling on an existing parameter or added functionality to existing parameters that may have to be addressed IT IS IMPORTANT TO REFER TO THE RELEASE NOTES BEFORE UPGRADING FIRMWARE To reload the parameters from the Operator Interface once again obtain ADVANCED level access Then follow the same steps to get to the UTILITIES TRANSFER PARAMETERS screen Then choose F3 MEM gt DRV This will prompt you for confirmation and you can press F8 for YES The parameters will then be transferred There are differences between parameters for different revision levels so you may get some errors and a Transfer Incomplete message You can also transfer from the Card to the Drive using F2 CRD gt DRV and the difference is that you will first get a screen asking you to choose from all the available parameter listings on the card Select the one you want using the arrow keys and press Enter Then you can press F8 for
163. ck or appropriate voltage measuring device Failure to do so may result in injury or death Physical Checks NO Medium Voltage and NO Control Power Power Connection Inspection Inspect PF7000 drive input output bypass contactor sections and all associated drive components for loose power cable connections and ground cable connections torque them to the required torque specifications Inspect the bus bars and check for any signs of overheating discoloration and tighten the bus connections to the required torque specifications Clean all cables and bus bars that exhibit dust build up Use torque sealer on all connections gt Carry out the integrity checks on the signal ground and safety grounds 7000L UM302B EN P June 2013 7000 C Frame Marine Component Definition and Maintenance 4 153 7000 C Frame Marine gt Check for any visual physical evidence of damage and or degradation of components in the low voltage compartments This includes Relays Contactors Timers Terminal connectors Circuit breakers Ribbon cables Control Wires etc Causes could be corrosion excessive temperature or contamination Clean all contaminated components using a vacuum cleaner DO NOT use a blower and wipe clean components where appropriate gt Check for any visual physical evidence of damage and or degradation of components in the medium voltage compartments inverter rectifier cabling DC Link co
164. ctions cont MV Bus 4 pieces Ground Bus Link 1 piece Inside DC Link Choke Cabinet aa Figure 2 9 DC Link Choke Cabinet Power Bus 4 pieces Ground bus 1 shipped disassembled L Figure 2 10 DC Link Choke Cabinet before field power bus connections 7000L UM302B EN P June 2013 7000 C Frame Marine Drive Installation 2 13 a co Figure 2 11 DC Link Choke Cabinet after field connections of power bus M zi v m ud a a C L d M EI AREA z h 0 G SITL i Figure 2 12 Capacitor Cabinet after field connections of power bus 7000 C Frame Marine 7000L UM302B EN P June 2013 2 14 Drive Installation Connect the Sections cont M10 Carriage Bolt M10 Washer M10 Lockwasher M10 Nut Figure 2 13 Capacitor Cabinet Connect left side of Medium Voltage bus pieces with M10 hardware Connect cables from DC Link Choke to MV Bus pieces using supplied M12 hardware Figure 2 14 DC Link Choke Cabinet after connection of cables from DC Link Choke to red insulators 7000L UM302B EN P June 2013 7000 C Frame Marine Drive Installation 2 15 Connection points are labeled on bus and DC Link Choke Connect cables from labeled stabs M L L L on DC Link Choke to corresponding labeled stabs M L M L on bus Typical cable connection from DC link choke to bus Figur
165. cuits are voltage free using a hot stick or appropriate voltage measuring device Failure to do so may result in injury or death 2 Before removing the PowerCage all the components located within the PowerCage need to be removed to avoid any damage to the components Consult the required sections to remove clamping pressure SGCT and SCR boards detachment of cooling system and chill block removal The SGCT and SCR can be destroyed or damaged by static charges Personnel must be properly grounded before removing circuit boards from the PowerCage Use of damaged circuit boards may also damage related components A grounding wrist strap is recommended for handling 3 With all the components removed detach the manifold assembly by removing the bolts on the outer flange Carefully lift the PowerCage down placing the front face down Do not overtorque these bolts when replacing the PowerCage The PowerCage is heavy and it is preferred that two people should extract the PowerCage from the drive to prevent injury or damage 4 When replacing the PowerCage it is important to place the bolts on the outer flange loosely Torque bolts alternately on one flange and then the opposite flange to ensure even tightening of the module A suggested sequence for torquing PowerCage bolts is shown in Figure 4 32 When replacing the PowerCage always be sure all the PowerCage components are removed 5 After the PowerCage is securely fasten
166. d 2 50 Wire Group Numbers eee 2 51 Power Cabling Access ie 2 52 To Access the Customer Power Cable Terminations 2 52 Power Connections ie 2 54 Incoming Connections eee 2 54 Liquid Connections tet Eee e cete tiet stud 2 55 Liquid to Liquid Heat Exchangers 2 55 Power Control Wiring eese 2 58 Control Cables 1 mL eg dete te ues 2 58 Encoder Installation Guidelines 2 59 Protection from Radiated and Conducted Noise 2 59 Signal Distortion i 2 60 Unused Inputs einer 2 61 Information Regarding Termination of Customer Cables 2 62 Grounding Practices ie 2 63 Grounding Guidelines and Practices for Drive Signal and Safety Grounds e 2 64 Grounding Requirements and Grounding Specifications for Customers and Power Integrators 2 64 Identification of Types of Electrical Supplies Grounded and Ungrounded Systems 2 65 Ground BUS me Een ec ee ee aeee 2 65 Interlockimnp uiid eerte hed eet eee ern 2 66 Chapter 3 Operator Interface Chapter Objectives sre efr deiti toii pter Ate a 3 1 Terminology tiet e eter ure ete leen 3 1 Dna EE 3 3 Keypad me pee RE eerte 3 3 Function Softkeys Keys see 3 3 Cursor Selection Keys sse 3 4 Data Entry Keys needed 3 4 W
167. d Cond Per IEC NEC PLC I O Local Codes and 228 6 1524 1524 228 6 Application UE 9 00 6 00 6 00 9 00 Requirements Between 76 2 3 00 Conduit Eus DON Analog Signals 5 24V DC Belden 9760 DC SINE plan Belden 8770 Belden 9460 EF Ho lw Low Speed TTL Logic Level Pulse Train Input Belden 8760 Tachometer Belden 9460 PLC den 9463 The minimum spacing between conduits containing different Communications wire groups is 76 2 mm 3 inches All signal wiring must be run in separate steel conduit A wire tray is not suitable Digital High Speed Note 1 Steel conduit or cable tray may be used for all PowerFlex 7000 Drive power or control wiring and steel conduit is required for all PowerFlex 7000 Drive signal wiring All input and output power wiring control wiring or conduit should be brought through the drive conduit entry holes of the enclosure Use appropriate connectors to maintain the environmental rating of the enclosure The steel conduit is REQUIRED for all control and signal circuits when the drive is installed in European Union countries The connection of the conduit to the enclosure shall be on full 360 degree and the ground bond at the junction shall be less than 0 1 ohms In EU countries this is a usual practice to install the control and signal wiring Note 2 Spacing between wire groups is the recommended minimum for parallel runs of 61 m 200 feet or less Note 3 The customer
168. d discard into an emergency container or if significant leakage occurs pump fluid directly into the container Do not dispose into any drain or into the environment in general or into general landfill refuse Dispose of according to local regulations If disposing of an entire capacitor the same disposal precautions should be taken e Printed Circuit Boards Printed circuit boards may contain lead in components and materials Circuit boards must be disposed of according to local regulations and must not be disposed of with general landfill refuse 7000 C Frame Marine Component Definition and Maintenance 4 149 e Lithium Batteries This drive contains four small lithium batteries Three are mounted to printed circuit boards and one is located in the PanelView user interface Each battery contains less than 0 05g of lithium which is fully sealed within the batteries Shipping and handling of these batteries is typically not restricted by environmental regulations however lithium is considered a hazardous substance Lithium batteries must be disposed of according to local regulations and must not be disposed of with general landfill refuse Chromate Plating Some sheet steel and fasteners are plated with zinc and sealed with a chromate based dip gold colored finish Shipping and handling of the chromate plating parts is typically not restricted by environmental regulations however chromate is considered a hazardous substan
169. d in the equipment must be retrieved as damage A or injury may occur 7000 C Frame Marine 7000L UM302B EN P June 2013 2 26 Drive Installation Internally mounted fans Capacitor cabinets have internally mounted fans which are installed and wired by Rockwell Automation refer to Figure 2 35 The customer only needs to install the fan hood Fan Hood to be installed on site Internally mounted fans Figure 2 35 Fan Hood Installation Internally Mounted Fans 7000L UM302B EN P June 2013 7000 C Frame Marine Drive Installation 2 27 Externally mounted fans and fan hood The converter has cooling fans that are externally mounted refer to Figure 2 36 It is necessary to re install and connect the fans and install the fan hood Shipped with the drive is a plate with the fans mounted and wired to terminal blocks On site the fan assembly is to be mounted on the top plate of the converter cabinet as shown in Figure 2 36 Wiring for fan power is to be routed through the hole near the terminal blocks The plate is fastened to the cabinet with M6 hardware Connect wires to the terminal blocks per the electrical diagram Position the fan hood over the fan assembly and fasten with M6 hardware Fan Hood External fans Terminal blocks Figure 2 36 Fan Hood Installation Externally Mounted Fans and Fan Hood 7000 C Frame Marine 7000L UM302B EN P June 2013 2 28 Drive Installation C
170. d item from the previous screen as shown in Figure 3 3 Some screens have more than one page associated with them The current page number and the number of pages which make up the data currently being displayed on the screen is shown in the upper right hand corner i e showing page 1 of 2 pages Along the bottom of the screen are one or two rows of Softkeys which represent the assignment to the actual function keys In Figure 3 2 Softkeys F6 F10 are shown Pressing F8 will display the next page of data In the very lower right hand corner is a small dot This dot indicates the healthy state of the operator interface terminal Under normal conditions this dot will flash at a rate of 5 Hz During communication errors the dot will flash at a rate of 1 Hz SELECT Speed Control ota ece ime Load Inertia High Ramp Type SPUTA Spd err deadband Spdreg bandwidth 1 8 Total inertia 1 66 Speed fdbk mode Stator Freq acres Tre vepres ro 07 Figure 3 3 Screen Name amp Item The remainder of the screen shows the data from the drive The presentation of the data is dependent on the screen Screens that allow an item to be selected show the current selection in reverse video An example of this is shown in Figure 3 2 in which the Speed Control group is selected Information Windows Numerous screens require communications with the drive in order to function At times the duration of this activity will be noticeable
171. d that all screens have this ability via the F1 and F6 keys respectively 7000L UM302B EN P June 2013 3 76 Operator Interface 7000L UM302B EN P June 2013 Example As an example of using the chart we will modify a parameter while displaying it starting from the Top Level Menu referred to in the chart as the MAINMENU screen This example assumes you have read the previous sections of this manual The example will concentrate more on the flow of screens and how it relates to the chart rather then the actual operations being performed by each screen The symbols refer to those of the chart Descriptions of movement i e lateral refer to flow depicted on the chart Displaying the MAINMENU press the F4 key The DISPLAY GROUP screen is now shown Cursor to a parameter group and press the enter key This laterally moves us to the DISPLAY screen Since you selected a parameter group pressing the F7 key takes us into a selection operation symbol D in which the SELECT screen is displayed This allows us to use the cursor keys to select the desired parameter Pressing the enter key laterally moves us to the symbol T which ends the selection process For this example the symbol T laterally moves to the symbol M that defines a new process in which the selected parameter can be modified The MODIFY PARAMETER screen is now displayed To change the parameter you must have the proper access to it If required press the F8 key
172. d whenever they become dirty or the DI Cartridge is changed The loose particles on the outside Mesh Filter can be removed by opening the tap on the bottom of the clear plastic container The loose particle and the liquid should be collected in a small container and then discarded The filter can then be removed and cleaned or changed When the Mesh Filters are cleaned changed they should be thoroughly checked for damage before they are re installed 7000 C Frame Marine 7000 C Frame Marine Component Definition and Maintenance 4 151 Maintenance of the Water pumps The two water pumps should be greased and checked for leaks whenever preventive maintenance is scheduled or every 3 months which ever comes first Check Coolant Levels in the reservoir The level of coolant should be measured or marked on the side reservoir Masking tape placed vertically on the side of the reservoir can be marked with a pen or pencils for future level references The coolant level will go down due to evaporation Significant change in coolant levels could be sign of leak in the drive or heat exchanger and should be checked thoroughly Percentage of Glycol in coolant should also be checked periodically Since Water will evaporate faster than Glycol the percentage could change as the liquid evaporates The heat transfer quality changes as the percentages changes A correct Glycol content should be maintained to balance the heat transfer qual
173. database do not have to be obtained Without obtaining the entire database the operator interface will access portions of the drive database as required This slows down the first access to the operation that requires the data Subsequent operations requiring the same data are not affected Aborting the download will not affect portions of the database already obtained Once the database has been obtained the operator interface will start up in one of two modes depending on to what degree the drive has previously been configured a b On an unconfigured drive the operator interface will enter the Setup Wizard mode Until the user has gone through the entire Setup Wizard this will be the default mode to power up in The Setup Wizard can be cancelled at any time by pressing the appropriate softkey Once the drive has been configured through the Setup Wizard the Top Level Menu will be displayed from this point forward The Setup Wizard can be re entered via the Setup Menu 7000 C Frame Marine Top Level Menu 7000 C Frame Marine Operator Interface 3 11 This screen Figure 3 6 represents the main menu from which all other screens and the operations which they perform are activated To activate an operation simply press the function key corresponding to the Softkey shown on the screen A screen for that operation will be displayed Refer to the section entitled How To for
174. differential optically isolated inputs as well as a 12V 3Watt galvanically isolated encoder power source When using absolute encoders the 12 single ended inputs are used For quadrature encoders the 6 differential inputs are used Either type of encoder with frequencies up to 200 Khz can be interfaced to the Universal Encoder Interface 7000 C Frame Marine 7000L UM302B EN P June 2013 4 104 Component Definition and Maintenance Tachometer Feedback Board The 80190 759 02 Universal Encoder Interface is functionally cont identical to the 80190 759 01 with the addition of conformal coating The Universal Encoder interface is configured via jumpers installed on the 12 position header J4 The header has three positions labeled Park and used to store the jumpers when indicated as Removed in the table below Each function is selected by moving its corresponding jumper from the park location to the selected function location if labeled Installed The following table describes the functions available Removing the Universal Encoder Interface while control power is applied may result in N damage to the board Only remove the board when the control power is Off Table 4 F Encoder Configurations ENC TYPE POL QRDNT CD DQUAD CONFIGURATION Installed Installed Installed Single Quadrature Encoder Option Factory Default Installed Installed Removed Dual Quadrature Encoder Option without
175. discharge pressure of the pumps Refer to Piping diagram supplied for the expected pressure value Diagram is pasted in the pump cabinet Pressure Switch The pressure switch PS shown in Figure 4 55 detects the drop in pressure if a pump fails or if there is a major pipe break When low pressure is detected the backup pump will start but if the pressure does not reach operating levels within a set period of time the drive will shut down The pressure trip setting is set at the factory and varies with the construction of the drive 7000L UM302B EN P June 2013 4 72 Component Definition and Maintenance Pump Maintenance and Replacement cont 7000L UM302B EN P June 2013 Thermostatic Valve The thermostatic valve TV1 shown in Figure 4 56 is similar to an automobile thermostat When the fluid is cool the valve bypasses the flow away from the heat exchanger to re circulate within the drive As the fluid increases in temperature the valve gradually opens letting a trickle of fluid flow through the heat exchanger The thermostatic element is set to begin opening at 29 C 85 F and is fully open at 38 C 100 F All flow then travels to the heat exchanger The thermostatic valve keeps the semiconductor devices from getting too cold and it keeps the chill block near room temperature to prevent condensation Figure 4 56 Thermostatic Valve 7000 C Frame Marine Component Definition and Maintenance 4 73
176. e Component Definition and Maintenance 4 147 L Receive File Place received file in the following folder C Documents and Settings mderewol Desktop Use receiving protocol modem v Receive Close Cancel Now the Receive Filename dialog will appear Here you need to enter the file name but make sure you also enter a correct extension as given in the options menu For Control Data use bin extension For all other data use csv extension Click OK E Receive Filename modem never sends a filename so you must specify a filename for storing the received file Folder C Documents and Settingsmderewol Deskto Filename Testcsd Now the following dialog box will appear where you can see the file transfer progress Xmodem file receive for ForGe CONNECTION Storing as C Documents and Settings mderewol Desktop Test csv Packet 50 Error checking CRC Retries o_o Total retries os File x Lastemor Throughput Elapsed 00 00 02 When the data transfer is complete the above dialog box will close automatically This way use can select any option you want to print upload Once you have printed all the data files you can then shutdown the HyperTerminal program and unplug the null modem cable from the DPM board 7000L UM302B EN P June 2013 4 148 Component Definition and Maintenance Environmental Considerations 7000L UM302B EN P June
177. e Printing Uploading Overview Control Data In PF7000 drives with ForGe control a specific memory location has been set aside to capture and store critical data in the event of a fault condition This data is referred to as Control Data There are total 8 buffers where the data is stored sequentially on first in first out basis which ensures the data of 8 most recent faults is always available The data can be retrieved for analysis The method of retrieving Control Data is explained below Required Laptop with Windows HyperTerminal program A null modem cable with a 9 pin female connector for the laptop serial port and a 9 pin male connector for Drive Processor Module DPM data port J4 A serial cable with pins 2 3 swapped at one end will also work 7000 C Frame Marine 7000L UM302B EN P June 2013 4 142 Component Definition and Maintenance Printing Uploading Here is a typical pin out of a complete null modem cable Control Data cont Essentially only 3 pins 2 3 and 5 are all that is required 9 Pin Female 9 Pin Male Connector Connector Pin Pin 1 DCD RED RTS 7 sg CTS 8 2 TXD BRN TXD 3 4 DTR GRN DSR 6 5 COM BLU COM 5 7 COM YE DOO 1 8 CTS NC SHLD es Case Method 1 Connect your laptop to the drive using a 9 pin null modem cable to DPM data port J4 2 Set up HyperTerminal connection Run HyperTerminal program At the Connection Descripti
178. e Marine UPS Option 7000 C Frame Marine Hold up Capacitor Component Definition and Maintenance 4 65 The PowerFlex 7000 C Frame drive has the option for internal and external UPS power to keep the control power active within the drive in the event of a control power loss The following diagram shows the current configuration of the internal UPS option 300W AC DC Power Supply Holding Bracket Figure 4 51 300W AC DC Power Supply The UPS is installed in the incoming cabling section below the LV control section The UPS will keep control power to all the critical 120V AC loads and an extra AC DC Power Supply that feeds the DC DC Power Supply for powering all the drive control components The main drive cooling fan and the AC DC Power Supply that feeds the IGDPS boards are not powered from this UPS The UPS is configured for the AS400 communication protocol and has several status signals that are fed back to the Customer Interface Board to allow the control to respond to various conditions including low batteries loss of input power UPS on bypass etc 7000L UM302B EN P June 2013 4 66 Component Definition and Maintenance UPS Option cont If the customer has an external UPS the firmware will essentially not expect any of the signals mentioned in the above section and will not display any information relating to the UPS status The firmware will operate in the same manner
179. e 2 15 DC Link Choke Cabinet Typical Cable Connection e Connect Ground Bus Link from top left of DC Link Choke cabinet to ground bus in adjacent capacitor cabinet by sliding underneath wire duct Use supplied hardware O O O O O O O O Figure 2 16 Ground Bus Link 7000 C Frame Marine 7000L UM302B EN P June 2013 2 16 Drive Installation Connect the Sections cont Ground Bus Link See Figure 2 18 route under wire duct Wire Duct See Figure 218 d Figure 2 17 Install Ground Bus Link M6 Hardware 4 places tighten to 6 Nm 4 4 ft Ibs at each end of bus link Figure 2 18 Ground Bus Connection Points Install Ground Bus Link using Supplied Hardware 7000L UM302B EN P June 2013 7000 C Frame Marine Drive Installation 2 17 Control Wiring Refer to Electrical Drawings and wiring diagrams supplied with Connections Drive Contact Rockwell Automation representative for assistance Final wiring connections to be performed by Rockwell Automation field service representative 1 Remove the wireway covers located on top of the line and motor filter capacitor sections and the DC Link section 2 If drive has strip heater wiring it will be coiled up in the top wireway Route these wires down through the grommeted cutout for connection on the terminal blocks located in the upper left side of the capacitor section Figure 2 19 Strip heater terminal block 3 Route the control wiring which ha
180. e M4 mounting screws 7 When all damaged snubber resistors have been replaced re assemble the bus bars with the original hardware 8 Re connect any leads that were removed 9 Install the chill block assembly as described in Chill Block Removal and Replacement Readjust the clamping load as described in Checking Clamping Pressure 10 Verify the snubber and sharing resistances 7000 C Frame Marine 7000L UM302B EN P June 2013 4 48 Component Definition and Maintenance Self Powered Gate Driver Board SPGDB 7000L UM302B EN P June 2013 Description This board is used in drives where SCRs are used as the rectifying device on the input of the drive The SCRs require a gating pulse in order to turn on and this is achieved by using the SPGDB The SPGDB receives its command from the drive processor via a light signal which is transmitted through a fiber optic cable The power source for the SPGDB is from the snubber network of the SCR a patent pending design of Rockwell Automation This unique design gives the SPGDB the ability to conserve the amount of energy that it supplies to the SCR This reduces the amount of energy required by the drive to operate thus making the drive more efficient Also this board will determine the health of the SCR It has the hardware necessary to diagnose the condition of the SCR This status is relayed to the processor via a fail safe light signal transmitted through a fi
181. e etes 4 144 Environmental Considerations eee 4 150 Hazardous Materials eee 4 150 Disposal isa sin Rr eiie fe 4 151 Preventive Maintenance Check List esses 4 152 Operational Maintenance eene 4 152 Annual Maintenance i 4 154 Initial Information Gathering esses 4 154 Physical Checks NO MV and NO Control Power 4 154 Control Power Checks No Medium Voltage 4 156 Final Power Checks before Restarting 4 156 Additional Tasks During Preventive Maintenance 4 157 Emal Reportg invia ioni eet 4 157 Time Estimations esee 4 158 Tool Parts Information Requirements 4 159 Catalog Number Explanation esee A 1 Service Duty Rating Continuous Current Rating and Altitude Rating Code eere A 2 Nominal Line Voltage Control Voltage System Frequency A 2 PowerFlex 7000 Drive Selection Explanation A 3 When is a Tachometer Required esses A 4 PowerFlex 7000 Drive Performance Torque Capabilities A 5 Glossary Of Terms ee eles A 5 Typical Application Load Torque Profiles A 6 7000L UM302B EN P June 2013 vii viii Table of Contents Appendix B Torque Requirements Torque Requirements for Threaded Fasteners Appendix C Meggering Appendix D Pre
182. e fiber optic cable and the SCR gate cathode connection Exceeding the minimum bend radius 50 mm 2 in of the fiber optic cables may result in damage The fiber optic cables can be damaged if struck or bent sharply The minimum bend radius is 50 mm 2 inches The connector has a locking feature that requires pinching the tab and gently pulling straight out The component on the printed circuit board should be held to prevent damage Remove the load on the clamp head assembly as described on page 5 26 5 Loosen the 2 captive screws with a long Phillips screwdriver until the circuit board is free It may be necessary to adjust the position of the chill blocks to allow free movement of the SCR 6 Slide the SCR and SCR SPGD Board straight out 7 While grounded unplug the Gate Cathode phoenix connector from the SCR SPGD Board 7000 C Frame Marine Component Definition and Maintenance 4 33 The SCR and SCR SPGD Board can be destroyed or damaged by static charges Personnel must be properly grounded before removing the replacement SCR and SCR SPGD Board from the protective anti static bag that it is supplied in Use of damaged circuit boards may also damage related IMPORTANT components A grounding wrist strap is recommended for handling sensitive circuit boards Never adjust the orientation of the SCR by pulling the Gate and Cathode Leads These connections are sensitive and the device orientation should only
183. e level is specified for these input devices MOV Fuse In series with each of the Phase MOVs is a medium voltage fuse As seen in Figure 4 5 these fuses may be located on the assembly or remote from the assembly on the Line Terminal Module Check the part number on your module and the information in this documentation to determine which assembly you should have in your case The fuses provide overload protection for the conductors feeding the suppression network and overcurrent protection if a short circuit occurs on the downstream side of the fuse These conductors will normally have a much smaller current carrying capacity than the drive input conductors and thus will not be protected by the drive input fuses The fuses also serve to isolate a failed MOV Varistors initially fail in a short circuited condition The high follow through current will open the fuse and remove the MOV from the circuit 7000 C Frame Marine Component Definition and Maintenance 4 7 7000 C Frame Marine The fuses used are E rated current limiting fuses with a high interrupting rating Because they are current limiting they will limit both the magintude and duration of fault currents They are small dimension ferrule type fuses with a fiberglass body and mount in standard fuse clips IMPORTANT The fuses sent with the Transient Suppression Network have been selected based on their characteristics including internal resistance This i
184. e operator interface will not respond to any user input until the task at hand is completed Communication Error While the operator interface is reading or writing to the drive it is possible for communications to be disrupted for a number of reasons If this were to occur a special window is used to inform you of this During this time the operator interface will not respond to any user input until the task at hand is completed The window for the Communication Error can take on two forms If a window has already been displayed showing Accessing Drive or Writing to Drive then the communication error message will be added to the window already in use Some screens constantly read from the drive in order to show real time data An example of this is the Top Level Menu When a communication error occurs on a screen showing real time data a window is opened showing a box around the Communication Error Two examples of this are shown in Figures 3 4 and 3 5 In both cases once communications has been re established the information window will be removed and the operator interface will return to normal operation 7000L UM302B EN P June 2013 3 8 Operator Interface 7000L UM302B EN P June 2013 Rev 4 XX Status Not Ready Speed 900 rpm Current Power 2086 0 Hrs ax 1600 156 Figure 3 4 Communications Error DISPLAY Feedback U line una Alpha line Alpha machine a cmon aa ALA
185. e seconds press the F5 key again Each press of the F5 key will highlight the next position of the clock The highlighted position may be modified via the cursor keys To abort the change press the backspace key and the clock will return to its original time To accept the change press the enter key The new clock setting has been recorded The setting may also be aborted by pressing any of the assigned function keys other than F1 and F5 The function associated with that key will be executed UTILITY nnd 769 85 TUE Mainmenu Meters Backlight 16 min Digital spdmeter 572 Contrast 5 igital ammeter 573 D Digital vltmeter 5 4 Digital purmeter 575 Figure 3 13 Utility Time 7000 C Frame Marine 7000 C Frame Marine Operator Interface 3 17 Setting Date The calendar setting controls the date stamp that the drive uses on the information contained on the alarm summary screen To change the date press the F4 key The year position of the calendar will be in reverse video Figure 3 14 Press the cursor up or cursor down keys to change the value by a resolution of 1 unit Press the cursor left and cursor right keys to change the value by a resolution of 10 units To change the month press the F4 key again and repeat the procedure Likewise to change the day press the F4 key again Each press of the F4 key will highlight the next position of the calendar The highlighted position
186. e terminal connections Please refer to these labels 9 Reinstall the sheet metal that was removed and complete one final check to ensure connections are secure and correct 7000 C Frame Marine 7000L UM302B EN P June 2013 4 20 Component Definition and Maintenance Filter Capacitor Cabinet Testing Filter Capacitors cont 1 Ensure there is no power to the equipment before testing the capacitor ATTENTION To prevent electrical shock ensure the main power has been disconnected before working on N the capacitor Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Failure to do so may result in injury or death Verify the load is not running due to process A freewheeling motor can generate voltage that A will be back fed to the equipment being worked on 2 Follow appropriate safety steps to isolate the equipment from medium voltage d Verify that there is no voltage present on the capacitor by using a hot stick or any other appropriate voltage measuring device 4 Perform visual inspection to ensure there is no oil leak or bulge in any of the capacitors 5 Note the location of all the cables and mark them accordingly 6 Disconnect power cables from the capacitor terminals on all four bushings and isolate them from the capacitor 7 Connect a low voltage single phase test power for instance 110V or 220V across a phase and the neutral of the capacitor
187. e the source of the diagnostic trigger Information that has to be programmed in the diagnostic setup is listed below Trace Rate Post Trigger 7000 C Frame Marine The Read Only Parameter which is assigned to a particular list The item linked to Trace 1 is used as the trigger value There are 16 traces in total although not all have to be active The time delay between sample periods Any value between 0 and 20 000 msec can be set Use numeric keypad to enter the value and press the enter key to accept The percentage of the list which will occur after the after the trigger point Any value between 0 and 100 may be used Defines whether you want a continuous or a single shot trigger Pressing this key will place an S or a C in front of the trigger parameter You will almost always want a Single Shot S trigger S Single shot gt gt the trigger occurs only once and stops The trigger must be manually re armed The Re Arm function clears the memory buffer which contains the data stored from the previous trend It is necessary to reset the trending feature in order for a second trigger to occur unless you have continuous trigger enabled 7000L UM302B EN P June 2013 4 128 Component Definition and Maintenance Setting up Diagnostic C Continuous capture gt gt auto re arm is enabled to Trending cont collect new trends until stopped by viewing contents of captured data Cond Defines the condition
188. ection entitled Enter Modify an Access Level Initialize The drive contains a default set of parameters and setup information This can form a basis for configuring the drive To initialize the drive with the default set of data press the F3 key The screen will appear as in Figure 3 64 indicating the operation you are about to perform The screen then will ask you to confirm the operation Press the F8 key to proceed or the F9 key to abort Performing an initialization will overwrite the data currently in the drive Previous changes that were saved to NVRAM will not be affected Operation INITIALIZE PROCEED Yes No Operation Status INITIALIZE PENDING Tae T uni com sme Fes ves 9 Te Figure 3 64 Initialize Operation Save The changes that you have made to the drive data must be saved if you do not want to lose the data when the drive is powered off To save the changes press the F5 key Figure 3 65 Operation SAVE TO NURAM PROCEED Yes No Operation Status SRUE PENDING Cur T Le pee Fes ves wo T0 Figure 3 65 Save Operation 7000 C Frame Marine 7000L UM302B EN P June 2013 3 48 Operator Interface Display Parameters 7000L UM302B EN P June 2013 To confirm the operation press the F8 key to proceed or the F9 key to abort Saving the data will overwrite the previously stored data in the NVRAM Load The changes that you stored in NVRAM are automat
189. ed cable insulation is required between the transformer and the drive so it can withstand the common mode voltage stress Rather than use an Isolation Transformer the Direct to Drive Active Front End uses the semiconductor switching pattern to reduce line current harmonics to levels that comply to the world s most accepted harmonic standards The Active Front End is the best method of harmonic cancellation because it does not suffer from complexity and high component count like multi pulse drive topologies do Direct to Drive technology produces virtually no common mode voltage so it is suitable for new or existing motors and imposes no stress on the drive input The advantage of Direct to Drive technology over an Isolation Transformer is that no extra insulation is required in the motor in the motor cables or in the line cables In addition to mitigating Common Mode Voltage Direct to Drive technology mitigates dv dt or Reflected Wave Voltage Stress on motors The simplicity of its design results in a lower initial capital investment lower operating cost lower installation cost and lower maintenance cost relative to drives that require isolation transformers 7000 C Frame Marine Motor Compatibility 7000 C Frame Marine Motor current Motor voltage 100 00 200 00 300 00 200 00 Overview of Drive 1 7 The PowerFlex 7000L with Direct to Drive technology is typically s
190. ed joint clean the threads and reassemble with a generous amount of Teflon paste applied to the threads No matter how well you drain the system with the pumps be aware that there will be liquid in the tubes manifolds and chill blocks This requires special care in removing connections as there will definitely be liquid leaking out Use absorbent pads or containers to catch the liquid System Drain Turn off the pumping system and disconnect the switch on the cabinet door Attach the transfer pump to Drain Fill line Ensure that the flow arrow on pump is in the correct direction Open valve V6 and V7 to Pump coolant out 7000 C Frame Marine Component Definition and Maintenance 4 83 Low Voltage Control Section The low voltage control section panel houses all of the control circuit boards relays Operator Interface Terminal DC DC power supply and most other low voltage control components Refer to Figure 4 63 for a generic representation of a low voltage tub arrangement p EN Zale Analog Control Board O Fiber
191. ed to the backplane refer to the appropriate sections to replace all other components 7000L UM302B EN P June 2013 7000 C Frame Marine Component Definition and Maintenance 4 43 Figure 4 32 Typical Torque Sequence Snubber Resistors A test point is provided inside the PowerCage to measure the resistance of the snubber resistor and capacitance of the snubber capacitor The test point is the electrical connection between the snubber resistor and snubber capacitor The procedure is to place one probe of the multi meter on the test point and the other probe on the appropriate chill block to determine the value of the resistor or capacitor Snubber resistors are connected in series with the snubber capacitors Together they form a simple RC snubber that is connected across each semiconductor SCR or SGCT The purpose of the snubber circuit is to reduce the dv dt stress on the semiconductors and to reduce the switching losses The snubber resistors are connected as sets of thick film resistors The number of resistors depends on the type of the semiconductor and the configuration and frame size of the drive 7000 C Frame Marine 7000L UM302B EN P June 2013 4 44 Component Definition and Maintenance Sharing Resistors 7000L UM3
192. ed while the drive is running These checks should be done periodically depending on operating conditions the time between maintenance should not exceed three months Annual Maintenance should be completed during scheduled downtime Refer to the Tools Parts Information Requirements at the end of this section for a list of documentation and materials needed to properly complete the preventive maintenance documents The PowerFlex 7000 C frame drive uses a mixture of de ionized water and Glycol to cool down the devices One of the desired qualities of this mixture is the low conductivity a second is the low freezing point The latter is required in climates where the temperature can drop below 0 C The maintenance on the system can be done with the drive running by closing valve V8 and V9 They must be re opened when the changes are done The cooling system maintenance includes the following tasks Changing the DI Cartridge The DI cartridge keeps the conductivity low by removing positive ions from the DI water glycol solution It needs to be changed whenever the conductivity warning appears This occurs when the conductivity increase above 1US The DI cartridge cannot be cleaned it must be replaced Changing or Cleaning the Mesh Filters The DI Cartridge require clean DI water Glycol solution to prevent damage There are two Mesh filters one before and one after the DI Cartridge These should be changed or cleane
193. een This chart does not introduce you to the use of the operator interface however is useful as a reference to the preceding material How do you read it Each of the boxes represents a screen and contains the screen name From a particular screen a downward arrow shows what other screens can be displayed and which function key is required to move to that screen Pressing exit F10 on the screen will move you in the opposite direction returning you to the screen from which you came A lateral arrow shows to which screen you can move by pressing the enter key while making a selection Again pressing exit F10 on the screen will move you in the opposite lateral direction returning you to the screen from which you came Some of the operations have screens in common These are shown only once on the diagram Their use is indicated by symbols inserted into a circle For example The ACCESS screen is displayed from the MAINMENU by pressing the F10 key In this location marked by an the operation of the screens ACCESS and PASSWORD CHANGE are shown in their entirety These operations are also available from the MODIFY PARAMETER screen and SETUP screens by pressing the F8 key At these locations the operation of screens is represented by the symbol P which represents the same flow as previously defined For sake of clarity the soft function key calls to the HELP operation and the ALARMS screen have not been shown It is implie
194. enance Tachometer Feedback Board Quadrature Encoder Operation cont The Universal Encoder Interface will accept either single or dual quadrature encoders Configuration of the board to accept the encoders is done through jumpers on J4 Boards shipped from the factory come defaulted to single quadrature encoder configuration For dual encoder configurations the primary encoder is wired to pins to 7 on the 1492 IFM20 module See table below To select the dual encoder option remove the CD QUAD jumper and place it in PARK This will configure the board to accept two individual quadrature encoders In this mode the drive can switch between encoders for applications such as Synchronous Transfer between two motors with each having their own encoder For redundant encoder option remove both the CD QUAD and POL QRDNT jumpers and place them in PARK With this configuration the drive will switch over to the redundant encoder when it detects a problem with the primary encoder Consult factory for availability of dual Quadrature Encoder options ATTENTION When the drive switches over to the redundant encoder it cannot switch back A without recycling control power 7000L UM302B EN P June 2013 7000 C Frame Marine 7000 C Frame Marine Component Definition and Maintenance 4 107 Positional Encoder Operations Besides quadrature encoders the Universal Encoder Interface will also accept positional abso
195. enter key An ALARM HELP screen typical of that shown in Figure 3 76 will be shown for that alarm Not all alarms will have this additional help text For those alarms the screen shown in Figure 3 77 is displayed 7000 C Frame Marine Operator Interface 3 53 Request Printouts 7000 C Frame Marine ALARM HELP Line Self Test The Line Converter board has failed its powerup test Check the DC Power at the drive control board for the presence Of 5 15 amp 15 volts Replace the DCB if the fault persists acres Tres ra prev ve er Figure 3 76 Alarm Help ALARM HELP Rect Hdwr Qvrcnt No Help Available ee Tre sspe Po exit Figure 3 77 No Alarm Help When the drive contains the optional printer you can obtain hard copies of the data that you are able to view on the terminal The printouts are requested from the PRINTER screen Press F3 while displaying the Top Level Menu The screen typical of Figure 3 78 is displayed It shows the current status of the printer A B part 80025 290 01 and the type of reports that are available Refer to the Syntest SP401 Thermal Printer User Manual for information regarding the use of the printer hardware and a description of the various reports available Using the cursor up and cursor down keys select the desired report and press the enter key The report will be sent to the printer The printer can automatically print out the a
196. er Terminals Figure 4 12 Motor Terminal Assemblies Note Arrows on Hall Effect sensors indicate direction of current flow Customer terminals shown for bottom cable entry Customer must remove and re orient terminals if top entry is required 7000L UM302B EN P June 2013 7000 C Frame Marine Current Transformer Replacement 7000 C Frame Marine Customer Line Terminals Component Definition and Maintenance 4 17 Ensure there is no power to the equipment To prevent electrical shock ensure the main power has been disconnected before working on the N current transformer Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Failure to do so may result in injury or death Note the location of all wires and the orientation of the CT For quick reference when checking the orientation of the CT look for the white dot IMPORTANT The CT and wires must be in the proper orientation Note the position before disassembly Disconnect the wires The bus bar must be disassembled to allow removal of the CT Remove the M10 hardware to allow the bus bar to slide out Remove the four screws located in the base of the CT and remove Replace the CT ensuring the proper orientation Fasten the CT securely with the four screws in the base Reconnect the ring lugs Replace the bus bar and tighten into place Figure 4 13 Line Terminals Note Customer termi
197. er interface ACB J30 DPM connection A D SUB system ACB J31 DPM connection DACs serial data ACB J32 DPM power supply 5V ACB J33 DPM connection Faults amp other I O ACB J34 DPM connection Encoder 7000L UM302B EN P June 2013 7000 C Frame Marine Component Definition and Maintenance 4 95 7000 C Frame Marine Table 4 E Test Points on Analog Control Board Test points Name Description TP1 Vuv Motor Voltage Feedback UV TP2 Vw Motor Voltage Feedback VW TP3 Vwu Motor Voltage Feedback WU TP4 lu Motor Current HECSU TP5 lw Motor Current HECSW TP6 Vzs Zero Sequence Generation Motor side VZS TP7 Vn Motor Side Filter CAP Neutral Voltage MFCN TP8 V pk Motor Over Voltage Detection for UVW TP9 Vdci1 Motor Side DCLINK Voltage for Bridge 1 VMDC1 TP10 Vdci2 Motor Side DCLINK Voltage for Bridge 2 VMDC2 TP11 Vuvs Line Voltage Synchronous Feedback VSAB TP12 V2uv Line Voltage Feedback 2UV TP13 V2vw Line Voltage Feedback 2VW TP14 V2wu Line Voltage Feedback 2WU TP15 I2u Line current CT2U TP16 12w Line current CT2W TP17 Vzs2 Zero Sequence Generation Line side VZS2 TP18 Vn1 Line Filter CAP Neutral Voltage for Bridge 1 LFCN1 TP19 V2 pk AC over voltage detection for 2UVW TP20 Vdcr1 Line side DCLINK Voltage for Bridge 1 VLDC1 TP21 Idc1 DCLINK current HECSDC1
198. er switching devices are required at 2400V 12 at 3300 4160V and 18 at 6600V The PowerFlex 7000L has the additional benefit of inherent regenerative braking for applications where the load is overhauling the motor i e downhill conveyors etc or where high inertia loads i e fans etc need to be slowed down quickly Symmetrical Gate Commutated Thyristors SGCTs are used for machine converter switches Silicon controlled rectifiers SCRs for 18 pulse or SGCTs for AFE rectifiers are used for the line converter switches An AFE configuration is shown in Figure 1 1 LINE CONVERTER DC LINK MACHINE C ONVERTER L M 9 hi CWS T T A seots y r sccs x X X X U T1 2V 2 2W X3 V T2 CD W T3 a y ys x J z 2 2 e ET e Figure 1 1 AFE Rectifier 4160 Volt 7000L UM302B EN P June 2013 1 4 Overview of Drive Rectifier Designs There are two offered designs for the rectifier of the PowerFlex 7000L drive 18 Pulse Rectifier An 18 pulse phase controlled rectifier is shown in Figure 1 2 In an 18 pulse configuration the IEEE 519 1992 requirements are met in the majority of cases without the need for passive filters however a multi winding isolation transformer is required to mitigate the low order harmonics by phase shifting principles The 18 pulse solution is superior to 6 or 1
199. eration Firmware is the program that is run in the operator interface to provide all the functionality described in this manual Firmware is loaded from the flash card in one of two ways a Ifa operator interface has a memory card inserted when it is powered up or rebooted and that card has a valid firmware file with the extension of FMW the operator interface will automatically load the first FMW file it encounters on the card b The user can select from one or more FMW files on the card and load the selected firmware into the operator interface This is the method that will be described here From the TRANSFER screen press the F3 key The operator interface will enter the DIRECTORY screen from which an existing firmware filename can be selected or entered Refer to the sections entitled Select a filename and Enter a filename If nothing happens then you have not gained the required access to modify the flash memory Exit to the TRANSFER screen and refer to the section entitled Enter Modify an Access Level to gain access 7000L UM302B EN P June 2013 3 64 Operator Interface 7000L UM302B EN P June 2013 When the filename has been obtained the TRANSFER PROGRAM screen such as that in Figure 3 91 will be displayed showing the filename indicating the operation you are about to perform and showing the current status of the operation TRANSFER PROGRAM FILENAME REV3_14 FMW DOWNLOAD FIRMWARE PROCEED
200. erminal Connections Description i 4 64 Replacement Procedure eene 4 65 UPS Option tape ee ee HER Ee e 4 66 UPS Replacement Procedure n 4 67 Colina Systemi zi ni iaia ein 4 68 Cooling Circuit iii 4 69 Chill BIOGES net t titi hae 4 69 Coolant Pumps ie eui Ln terit eria ens 4 69 Pump Maintenance and Replacement 4 70 Pump Seal Replacement eee 4 70 Pump Replacement esee 4 71 Piping Tubing and Connectors esses 4 71 Non Return Valves e 4 72 7000L UM302B EN P June 2013 v vi Table of Contents Chapter 4 Component Definition and Maintenance cont 7000L UM302B EN P June 2013 Presstire Indicator conteret gens 4 72 Pressure Switch iaia 4 72 Thermostatic Valve ciali lla zio 4 73 Thermostatic Valve Replacement 4 74 Repair Instructions Element Testing 4 75 Element Replacing ci iii 4 75 Heat Exchatnget seietan tete nia 4 76 Temperature Gauge e 4 77 Fluid Conductivity recite Ieri Ee ette 4 77 Temperature Sensor iii 4 77 De ionizing Cartridge and Mesh Filter 4 78 Replacing the Mesh Filters eene 4 79 Reservoir Circuit c eon Pepe eee 4 79 Fluid Lop up eere etes tette tea 4 80 DUAIMETS EE 4 81 Coolant ien eed ge es eed
201. es IGDPS are mounted on the cabinet s right side sheet Cooling pipes are throughout the cabinet and are connected to each chill block Unlike the air cooled drive thermal sensors are not installed on the chill block The thermal sensor is located in the pump cabinet PowerCage A PowerCage is a Rockwell Automation patented converter module consisting of the following elements e Epoxy resin housing e Power semi conductors with gate driver circuit boards Chill blocks Clamp e Snubber resistors e Snubber capacitors e Sharing resistors e Piping for coolant to flow to each chill block All drives have six PowerCages three rectifiers and three inverter modules The liquid cooled drive has two types of rectifiers the 18 pulse SCR and the PWM rectifier All inverter modules use SGCTs as semi conductors The size of the PowerCage will vary depending on the system voltage and the components will also vary depending on the system current All PWMR modules use SGCTs as semi conductors The power semi conductor usage in the converter section is as follows eee ester ww Rete 3300 4160V PWM rectifier 12 12 0 3300 4160V 18P 12 0 18 6600V 18P 18 0 18 6600V PWM rectifier 18 18 0 7000 C Frame Marine 7000L UM302B EN P June 2013 4 24 Component Definition and Maintenance Power Cage cont ATTENTION To prevent electrical shock ensure the main ATTENTION A A ATTENTIO
202. face s firmware and parameters from the drive This information can also be stored on a removable flash memory card This second form of flash allows the data from one drive to be physically transferred to another drive for loading All files on the flash card use a DOS format thus can be read or written by any PC that contains a PCMCIA drive Flash memory cards which are supported are those that contain the following memory chips from INTEL 7000L UM302B EN P June 2013 3 60 Operator Interface 7000L UM302B EN P June 2013 28F010 28F020 28F0088A 28F0168A These chips are used in the following memory cards available from Rockwell Automation 2711 NM11 2711 NM24 2711 NM12 2711 NM28 2711 NM14 2711 NM216 This section describes how you will transfer information between these two forms of flash memory and the drive You will learn how to Format a flash card e Look at the directory of files on a flash card containing the DOS file format e Select a program firmware from the flashcard and load it into the operator interface e Save the parameters from the drive on the flash card or in the operator interface Download parameters to the drive from a flash card or that previously saved in the operator interface e Load a language module from the flash card You will access the Transfer operations from the Utility screen by pressing the F7 key This results in the display of the screen shown in Figure
203. face to obtain the majority of the information it requires on your command instead of as needed The operation is initiated from any screen by pressing the F10 key and the cursor up key at the same time Obtaining the entire drive database is a lengthy process As the operator interface is receiving the database it will display what portion of the database it is currently obtaining and the percent done If the operator interface is successful in obtaining the complete database it will display a message indicating such and wait for a key press from you If unsuccessful it will immediately return to the screen from which this call was made The download may be aborted at any time by pressing any key on the operator interface The portion of the database already obtained will be valid A subsequent request to download the database will continue from where the previous download had terminated This screen will always return to the screen from which the download was requested 7000 C Frame Marine Operator Interface Menu Hierarchy Chart 7000 C Frame Marine Operator Interface 3 75 The screens of the operator interface are used to form a menu driven system to access the various operations in the drive The hierarchy of this menu system is shown in Figures 3 104 and 3 105 What does it show The chart shows the relationship between screens and a particular operation It also shows the path to reach a particular scr
204. for that screen Use NEXT PG to View additional pages zm xA ARROWS Fes T Tres ra erev ro er Figure 3 9 Help on Help 7000 C Frame Marine 7000L UM302B EN P June 2013 3 14 Operator Interface Modify Operator Interface Operation Utility 7000L UM302B EN P June 2013 The utility operation of screens change the characteristics of the operator interface Within this operation you will e Set the clock and calendar e Change the delay for the display backlight shutoff e Change the contrast of the display e Define the meters that will be displayed on the Top Level Menu e View the revision levels of all software in the drive line up e Transfer data between the operator interface flash memory flash memory card and the drive e Load a new language module You will access the Utility operation from the Top Level Menu by pressing the F2 key This results in the display of the screen shown in Figure 3 10 In all operations on this screen the value currently being acted upon is shown in reverse video Only when the value is in this state may it be modified UTILITY M 2508 69 85 TUE Backlight 168 min Contrast 5 Mainmenu Meters Digital spdmeter 572 igital ammeter 573 1 ziD 3 Digital vltmeter 574 4 Digital purmeter 575 Figure 3 10 Utility Operation Screen Changing Backlight Delay The display of the operator interface is only readable with the aid of a
205. g on whether you successfully changed the PIN incorrectly entered the existing PIN or incorrectly verified the new PIN PASSWORD CHANGE Basic Enter Password eek Enter New Password Verify New Password Status Invalid Password ues T_T Ten Figure 3 37 Invalid PIN PASSWORD CHANGE Basic Enter Password Enter New Password Verify New Password Status Invalid Verify acres I I Ten Figure 3 38 Invalid PIN Verification If you were not successful in changing the password simply start over again by typing in the current password value 7000 C Frame Marine 7000L UM302B EN P June 2013 3 32 Operator Interface Drive Setup 7000L UM302B EN P June 2013 This section describes how to Select an alternate language enter data to a drive parameter e assign a tag to an analog port e enable and disable a fault via a mask assign text to be associated with optional external fault inputs e re enter Setup Wizard configure the XIO link define the tags to be accessible by a PLC You will access the SETUP screen from the Top Level Menu by pressing the F8 key This will result in the typical screen shown in Figure 3 39 The Current Access level is shown If it states Monitor then you are restricted to only viewing the basic drive setup You cannot make any changes You must be in at least the Basic access level in order to modify any of the drive parameters and you may onl
206. ggering 7000L UM302B EN P June 2013 ATTENTION There exists the possibility of serious or fatal injury to personnel if safety guidelines are not AN followed The following procedure details how the Megger test on the PowerFlex 70004 is to be performed Failure to comply with this procedure may result in poor Megger reading and damage to drive control boards Equipment Required Torque Wrench and 7 16 inch socket Phillips Screwdriver 2500 5000 Volt Megger Procedure 1 Isolate and Lock Out the Drive System from High Voltage 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 indictor that power sources have been disconnected also the control power in the drive is de energized 2 Isolate the Power Circuit from System Ground Float the drive It is necessary to remove the grounds on the following components within the drive Refer to the electrical diagrams provided with the equipment to assist in determining the points which need to be disconnected Voltage Sensing Boards VSB Output Grounding Network OGN Voltage Sensing Boards Remove all ground connections from all of the VSBs in the drive This has to be done 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
207. gure 3 25 Using the cursor keys select i e reverse video the letter with which the desired tag starts with The cursor up and cursor down keys move vertically within a column the cursor left and cursor right key move laterally within the rows When the appropriate letter has been selected press the enter key 7000 C Frame Marine 7000L UM302B EN P June 2013 3 24 Operator Interface 7000L UM302B EN P June 2013 All tags which begin with that letter and are appropriate for the operation on which the selection is being performed will be displayed as in Figure 3 26 Using the cursor up or cursor down keys and if required the F8 and F9 keys to change the page select the desired tag Press the enter key and the selected tag will be used to continue the operation for which the selection process was being used From either of these two screens SELECT LETTER or SELECT LIST you can return directly to the default selection method via groups by pressing the F7 key SELECT LETTER Cu T TTT Fus oo exit Figure 3 25 Selecting via a Letter Step 1 SELECT LIST his y UE Decel time 1 Decel time Decel time Decel time 4 Deflt spd select Direction mask Figure 3 26 Selecting Name via List Step 2 From the SELECT LETTER screen Figure 3 25 the tag may also be selected via a code by pressing the F5 key Via Code This method of selecting a tag is initiated from the
208. gure 3 55 AC O V Now Enabled The changes to the fault masks do not take effect until the screen is exited via the F10 key i e exiting the FAULTS OVERVIEW will change the masks in the drive as will exiting the FAULTS SETUP screen In our example exiting the FAULTS OVERVIEW screen and returning to the FAULTS SETUP screen now shows the AC O V mask as being ON Figure 3 56 FRULTS Line ae SW Watchdog HH Watchdog Figure 3 56 AC O V Mask is ON 7000 C Frame Marine Operator Interface 3 43 User Definable External Text The drive contains a number of external fault inputs You can custom define the text associated with these inputs which will be used on the alarm screen and the fault mask screens To define the text use the up down arrow keys on the SETUP screen to select the External Text option and press the enter key A screen typical of Figure 3 57 will be seen EXTERNAL SETUP Coolant OT PumP i Fail Pump 2 Fail Gee T_T eee Figure 3 57 External Setup Text To modify the text attached to a particular fault input use the cursor up and cursor down keys to select the desired input To modify the text press the cursor right key If nothing happens then you have not gained the required access to make changes Exit to the SETUP screen and refer to the section entitled Enter Modify an Access Level to gain access The first character position of the string will be in reverse v
209. gure 4 20 Clamp Head Adjusting Nut used for loosening and applying load to assembly DO NOT ADJUST calibration nut Disc Springs Figure 4 20 Detail of the clamping assembly 7000L UM302B EN P June 2013 7000 C Frame Marine Symmetrical Gate Commutated Thyristor Replacement Component Definition and Maintenance 4 29 The Symmetrical Gate Commutated Thyristor SGCT or device with attached circuit board is located within the PowerCage assembly SGCTs must be replaced in matched sets 4160V systems use sets of 2 e 6600V systems use sets of 3 SGCTs can be removed and replaced without interrupting the cooling fluid path To remove SGCTs the following procedure is to be employed Adjusting Nut SGCT Retaining Screws DO NOT ADJUST calibration nut Indicating Washer 7000 C Frame Marine Figure 4 21 Replacing the SGCT The SGCT and associated control board are a single component There will never be a time when the device or the circuit board will be changed individually There are 4 LEDs on the SGCT and the following table describes their functions LED 4 Greeti e Green indicates that the Power Supply to the Card is LED 3 Green a Green indicates that the Gate Cathode resistance is LED ON indicates the gate is ON and Flashes alternately LEDA Aol with LED 4 while gating LED ON indicates the gate is O
210. h range is 5 25 radians per second while the torque bandwidth range is 15 50 radians per second 7000 C Frame Marine Control Hardware ACB Analog Conditioning Board DPM Drive Processor Module OIBB Optical Interface Base Board XIO External Input Output OIB Optical Interface Board 7000 C Frame Marine Overview of Drive 1 15 The control hardware includes a processor board DPM with an interface to six fiber optic boards depending on the voltage and number of switching devices via OIBB an analog conditioning board ACB and an external IO board XIO The control hardware is used for rectifier and inverter induction or synchronous drive control and the two rectifier types 18 pulse or Active Front End The DPM features two floating point DSPs Digital Signal Processor and a FPGA Field Programmable Gate Array for advanced functions such as gating and diagnostics fault handling and drive synchronization control OIBB OIBB ACB OIB OIB iq_ OIB OIB DPM lt oB oB XIO Figure 1 7 Control Hardware Layout for PowerFlex 7000 C Frame 7000L UM302B EN P June 2013 1 16 Overview of Drive Operator Interface 7000L UM302B EN P June 2013 Figure 1 8 PowerFlex 7000L Operator interface terminal The operator interface terminal features a 16 line 40 character pixel based LCD display tha
211. hanges to the parameter the operator interface must be set to an Access Level other than Monitor You will be able to view the screen however pressing the data entry keys will have no effect If you are not in the correct level press the F8 key in order to gain access to the parameter Refer to the section entitled Enter Modify an Access Level for further information on the operation to change the level Having gained access press the up or down cursor keys to obtain a list of possible options to select from Use the up down arrow keys to move the highlighting to the desired option Figure 3 45 If more options exist then what can be displayed on a single screen a triangle or inverted triangle symbol will indicate in which direction the list can be expanded Figure 3 46 7000 C Frame Marine Operator Interface 3 37 Use the up down cursor keys to scroll onto these additional options Press the enter key to accept the new value as shown in Figure 3 47 MODIFY PARAMETER xIO General IO P 592 Rctual unassigned New acne cancer eocess T exit Figure 3 46 Option List Viewed on Multiple Pages MODIFY PARAMETER Operating Mode P 4 Actual Normal New System Test acres cancer eocess T ear Figure 3 47 Modification Completed The new value is not sent to the drive until you exit the screen with the F10 key Prior to this you can modify the new value by repeating the above pro
212. hatis a Screen in ede ederent 3 5 COMPONENTS stia 3 5 Information Windows eee 3 6 Accessing Writing to Drive nn 3 7 Communication Error ie 3 7 Language Changing ii 3 8 General Operation ii 3 8 Operator Interface Power up Sequence 3 9 Top Level Menu ila bia D Ee tete cin 3 11 How to Obtain Help teen eerte 3 12 Related Topics iiiter ctas 3 12 Help On Help eer etd 3 13 Modify Operator Interface Operation Utility 3 14 7000L UM302B EN P June 2013 7000 C Frame Marine Chapter 3 7000 C Frame Marine Table of Contents Operator Interface Changing Backlight Delay 3 14 cont Changing Contrast esee 3 15 Setting Time scien itn oe eed ete 3 16 setting D te 4 2 ede eerte eie de 3 17 Selecting Meters scarola terrere 3 17 Viewing Revision Levels iii 3 20 Transfer Data in Memory eere 3 21 Picking an Access Level eese 3 21 selecta Pararmietet unie ien eee eget 3 22 Via Groups iine eeu ena 3 22 Via Name uie e es 3 23 Via Code oues UR Ru idee ed edd 3 24 Edit Lexts nce 3 26 Configure the Drive ie 3 28 Enter Modify an Access Level 3 28 Drive Setup ueteri 3 32 Language Selection eese 3 33 Modify Parameters ie 3 34 Numerical Value eee 3 34
213. he applied voltage Similarly you can calculate the capacitance for the remaining two measurements for L2 N and L3 N 7000 C Frame Marine 7000L UM302B EN P June 2013 4 22 Component Definition and Maintenance Converter Cabinet Components T A z ef a Ground Bus tur Inverter Modules NN i ui solated Gate Driver Power Supplies Coolant Piping Rectifier Modules 15 z J LA ej i f Poll D 1 Figure 4 15 Converter Cabinet Components standard 4160V AFE design shown 7000L UM302B EN P June 2013 7000 C Frame Marine Component Definition and Maintenance 4 23 Converter Cabinet The converter cabinet contains three rectifier modules and three inverter modules Figure 4 15 shows a 4160 volt converter with a Pulse Width Modulation Rectifier PWMR Isolated Gate Driver Power Suppli
214. he reservoir Use the 200 litre 55 gallon barrel to mix coolant and or to premix the de ionized water and glycol Check the freeze protection concentration with a glycol tester and add fluid accordingly Add coolant by pouring it into the top of the reservoir IMPORTANT Pour the coolant slowly into the reservoir to avoid disturbing the coolant level switches and causing a trip fault Filter Filter _ V8 L 9 De ionizing Cartridge Figure 4 61 Reservoir Circuit 7000L UM302B EN P June 2013 7000 C Frame Marine Component Definition and Maintenance 4 79 Strainers Cleaning the Strainer 1 Open valve V1 shown in Figure 4 62 to ensure flow to the pumps 2 Close valve V2 and V3 Loosen strainer by hand Clean it properly in water and dry it before putting it back 3 Open V2 and V3 slowly to avoid a rush of air into the pumps The air will gradually be purged from the system by flowing through the reservoir 4 Close valve V1 Strainer STR1 V3 To Pump P1 To Pump P2 Figure 4 62 Cleaning the Strainer 7000 C Frame Marine 7000L UM302B EN P June 2013 4 80 Component Definition and Maintenance Pump Maintenance and Replacement cont 7000L UM302B EN P June 2013 Coolant The cooling fluid is a mixture of de ionized water and ethylene glycol De io
215. he screen is exited via the F10 key Note The characters entered may only be valid for the currently selected language Any characters used which are unique for a given language i e other than the four sets defined above can only be meaningfully displayed in the selected language because other languages do not contain the appropriate display characters 7000L UM302B EN P June 2013 3 28 Operator Interface Configure the Drive 7000L UM302B EN P June 2013 In order to tailor the drive to your motor and application a number of elements must be defined in the drive The section describes how you will set or configure these elements of the drive via this operator interface You will learn how to e Change a parameter setting e Assign a parameter to an Analog Port e Selectively enable or disable i e Mask certain faults e Define your own faults attached to external inputs e Configure the XIO e Define the information sent to your optional PLC connection e Save and Restore your settings in the drive e Select an alternate language if previously loaded in operator interface There are two methods to configure the drive This section defines the more complete method to configure the drive for any application The drive may also be configured for the majority of applications by using the Setup Wizard The Setup Wizard can be entered from the SETUP screen by selecting the Setup Wizard from the list of options
216. hed down To determine if the element will close at a specific temperature place the element in a bath of water approximately 3 C 5 F below the start to open temperature This is the number stamped on the element Due to the effect of hysteresis the element will close 3 C 5 F below the start to open temperature Element Replacing Refer to Figure 4 58 1 Remove four cap screws lock washers and separate upper housing and lower housing 2 Remove element assembly and seal 3 Remove housing gasket Clean housing sections and remove any scale or foreign material from seal faces 4 Lubricate the new element seal and slide it in place over top of the element assembly into position shown in section view 5 Place new housing gasket in recess of upper housing 6 Insert element into upper housing to position shown in section view 7 Place lower housing over exposed section of element against face of upper housing 8 Secure housings with cap screws and lock washers Seal Type Upper housing Sleeve O Ring or Lip Seal cena li with O Ring Gasket Lock washer Cap screw N Element assembly with Lip Seal Lower housing Figure 4 58 Element Assembly Cross Section 7000 C Frame Marine 7000 C Frame Marine Component Definition and Maintenance 4 75 Temperature Gauge Temperature is indicated by the temperature gauge T1 as shown in Figure 4 59
217. hen a voltage transient occurs in which the voltage exceeds the knee in the curve the varistor resistance changes from its high state by several orders of magnitude to a very low level The voltage will be essentially clamped for a change in current of several orders of magnitude This can be seen in Figure 4 5 7000L UM302B EN P June 2013 4 6 Component Definition and Maintenance Transient Suppression Network TSN cont 7000L UM302B EN P June 2013 log scale VOLTAGE VOLTS High Short Resistance A Circuit Region k Voltage Clamping Region Region k 8 7 6 5 4 3 UON 0 2 3 d 5 10 10 10 10 10 10 10 10 10 10 10 10 10 10 CURRENT AMPERES log scale Figure 4 4 Typical MOV V I Characteristic Curve When the MOV is clipping the voltage transient the energy of the transient is being absorbed by the MOV The varistor has a limited energy absorbing capability and generally there is not enough time for the heat generated to be conducted out of the device The MOV is sized based on the steady state voltage rating the energy in the transient and the repetition rate of the transients A critical element in the MOV selection and protection offered is the impedance in the line supplying the transient This impedance will be mainly that provided by the Isolation Transformer or the AC Line Reactor on the input of the drive That is why an impedanc
218. hillips screwdriver to remove the 2 screws that hold the SCR SPGD Board to the metal bracket on the red glastic assembly Retain the hardware Pull the 4 plastic clips that secure the SCR SPGD Board to the glastic assembly Retain the hardware Install the new SCR SPGD Board in the assembly with the 4 plastic clips and use the screws to secure the board to the metal bracket Connect the Gate Cathode phoenix connector to the Gate Driver Board Slide the SCR and SCRGD Board back into place until the mounting bracket makes contact with the chill block Use the Phillips screwdriver to tighten the assembly to the chill block Readjust the clamping load as described in Checking Clamping Pressure Connect the control power cable and the fiber optic cables ensuring that the bend radius is not exceeded 7000 C Frame Marine Component Definition and Maintenance 4 35 Figure 4 24 SCR and SPGDB assembly Detachment of Coolant In the event that service is required to snubber components it will be System from necessary to extract a chillblock assembly from a converter PowerCage PowerCage Modules module in order to access the snubber and sharing resistors To avoid draining coolant from the entire converter it is possible to isolate the fluid path of one converter module from the remainder of the drive using the following technique Ensure that power has been disconnected 2 Ensure all pumps have been turned off Al
219. hipping platform over the roller pipes until the drive weight is borne on the roller pipes The drive can be rolled to its designated location Steady the load to prevent tipping 50 8 mm x 152 4 mm Figure 2 2 Rod or Pipe Rollers Fork Lift Trucks A single fork lift truck may be used on drives not exceeding 3 m 120 inches in length if the lift truck has sufficient lifting capacity Larger drives can be moved with two forklift trucks operating in tandem 1 Insert forks into openings of shipping skids from the rear of the drive Carefully balance the drive on the forks because the drives are usually heavier at one side Use safety straps when handling to steady the drive while moving 7000 C Frame Marine Siting of the Drive 7000 C Frame Marine Drive Installation 2 5 Storage If it is necessary to store the drive be certain to store in a clean dry dust free area Storage temperature should be maintained between 40 C 40 F and 70 C 185 F If storage temperature fluctuates or if humidity exceeds 85 space heaters should be used to prevent condensation The drive should be stored in a heated building having adequate air circulation The drive must never be stored outdoors Site Considerations The standard environment in which the equipment is designed to operate is Elevation above sea level less than 1000 meters 3250 feet Ambient air temperature between 0 C 32 F and
220. ically used each time the drive is powered up If you make changes to the data in the drive without saving and then wish to use the previously stored data press the F4 key Figure 3 66 Operation DOWNLOAD NURAM PROCEED Yes No Operation Status DOWNLOAD PENDING De TL Figure 3 66 Load Operation To confirm the operation press the F8 key to proceed or the F9 key to abort Loading the data will overwrite the data currently being used by the drive The parameters of the drive can be displayed continually showing the value contained in the drive From the Top Level Menu press the F4 key The DISPLAY GROUP screen of Figure 3 67 is displayed The screen shows one or more pages of groups that can be displayed The number of groups displayed depends on the current access level Using the cursor up and cursor down keys select the group you wish to display and press the enter key Figure 3 68 DISPLAY GROUP eature Selec Motor Ratings Owner s Control Masks Logic I 0 Motor Model Speed Control Figure 3 67 Display Screen 7000 C Frame Marine 7000 C Frame Marine DISPLAY Feature Select Auto restart dly Coast Speed Deflt Spd select Input ContCfa IO configuration Operating Mode Output ContCfa Passcode Operator Interface 3 49 1of 2 666 sec 40 6 Hz Local Not Running Configi Gate Test Not Running 488053 Figure 3 68 Feature Select Group Chosen
221. ideo as shown in Figure 3 58 Refer to the section entitled Edit Text When editing is complete the screen will appear as in Figure 3 59 EXTERNAL SETUP 1 Coolant OT 2 Pump i Fail 3 Pump 2 Fail 4 E 5 E Gee e pe Figure 3 58 Modify Text 7000 C Frame Marine 7000L UM302B EN P June 2013 3 44 Operator Interface 7000L UM302B EN P June 2013 EXTERNAL SETUP NPUT 1 Coolant OT NPUT 2 Pump i Fail NPUT Pump 2 Fail 3 MU UP to 12 chr INPUT 6 Figure 3 59 Modification Completed The changes made do not take affect until you press F10 and exit the screen Any time prior to this you may cancel all of the changes made after coming to the screen by pressing the F7 key PLC The drive can be optionally connected to a PLC via a RIO Remote Input Output adapter The drive appears to the PLC as a rack of information The tags that are associated with each of the words within a rack can be defined To setup the PLC link use the up down arrow keys on the SETUP screen to select the PLC option and press the enter key This will display a screen as shown in Figure 3 60 or 3 61 The PLC setup consists of eight words of input and eight words of output These are shown on separate screens The type of PLC word being viewed is defined to the right of the screen name i e PLC SETUP INPUTS or PLC SETUP OUTPUTS To switch to the other screen press the F8 key Each press of the F8 key will toggle the
222. idity 95 Non Condensing Altitude Standard 0 to 3300 ft 0 to 1000 m Altitude Optional 0 to 16400 ft 1001 to 5000 m Seismic UBC Rating 1 2 3 4 Standards NEMA IEC CSA UL ANSI IEEE 7000 C Frame Marine 7000L UM302B EN P June 2013 1 12 Overview of Drive Simplified Electrical Drawings DC LINK ISTX LINE CONVERTER L M MACHINE CONVERTER 3300 4160 Volt 18 Pulse DC LINK LINE CONVERTER MACHINE CONVERTER L M O SGCTs SGCTs QU X1 U 11 pool m D X2 wol wp O o uw V zEO 3300 4160 Volt Active Front End 7000L UM302B EN P June 2013 7000 C Frame Marine Overview of Drive 1 13 DC LINK ISTX LINE CONVERTER L M MACHINE CONVERTER 6000 6600 Volt 18 Pulse DC LINK LINE CONVERTER L M MACHINE CONVERTER 6000 6600 Volt Active Front End 7000 C Frame Marine 7000L UM302B EN P June 2013 1 14 Overview of Drive Control Overview Line Converter Machine Converter DC Link Inductor V k iy C00 Y Motor fil Cap S X Mi dL A 1 A i i I i i I v v Line Line Line gating I 1 Machine j Machine Converter y Converter and le Line I Machine
223. ify that the signal between TP1 and TP2 is as shown in Figures 4 39 and 4 40 Remove the jumper between TB3 1 and TB3 2 Apply a constant fiber optic signal to the OP1 input Apply a 60 Hz 33 duty cycle signal at a 0 to 2V level between the TB1 2 input and COM Verify the signals in Figures 4 41 and 4 42 Note that in Figure 4 42 there should be a 220 uS 20 uS time between the rising edge of the U4 pin7 pulse and the falling edge of the TP7 signal 7000L UM302B EN P June 2013 4 52 Component Definition and Maintenance He it ior topped 0 Boves m eje ig pore Spo del Figure 4 39 SCR gating pulse 7000L UM302B EN P June 2013 7000 C Frame Marine Component Definition and Maintenance 4 53 Setup stopped Eile Control n Ls Measure Analyze Utilities Help fea Eile Control Acquisit 1 00 MSa Setup on is stopped Arosa aja Fn e o ea AJ Figure 4 40 Expanded SCR gating pulse Measure Analyze Utilities Help 1 er V div 2 Ola Ajova ova md U4 pin TRIGGER ENABLE i TP TRIGGER ejesig 7000 C Frame Marine HY J2 00 sav ala M fos lt o gt i ED it Figure 4 41 V Sense Trigger to SCR gating pulse 7000L UM302B EN P June 2013 4 54 Component Definition and Maintenance File Control Setup Measure Analyze Utilities Help 5 23 PM SoHE S Let Dear marian Pietre doctus uote ac ae ee ER Besito
224. ilities 7000 Torque Capability 7000 Torque Capability Parameter Without Tachometer With Tachometer of Motor Rated Torque of Motor Rated Torque Breakaway Torque 150 ga 90 0 8 Hertz 140 0 8 Hertz dius 125 9 75 Hertz 140 9 75 Hertz 100 1 2 Hert Steady State Torque 125 9 75 Hertz 14 D t 60 denn 5 3 Maximum Torque Limit 150 150 Drive will require over sizing to achieve greater than 100 continuous torque Glossary of Terms 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 Ib ft WE total system inertia 1b ft that the motor must accelerate including motor gear box and load t time seconds 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 7000 C Frame Marine 7000L UM302B EN P June 2013 A 6 Catalog Number Explanation Drive Selection Table A 6 Typical Application Load Torque Profiles Load Lo
225. ine Component Definition and Maintenance 4 19 Filter Capacitor Replacement 1 Ensure there is no power to the equipment To prevent electrical shock ensure the main power has been disconnected before working on N the capacitor Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Failure to do so may result in injury or death 2 Note the location of all the cables and mark them accordingly 3 Remove the 4 power connections to the terminals and the single ground connector from the drive to the capacitor frame This is located at the back top right corner of the capacitor 4 Remove the front bracket that holds the capacitor in place At the rear of the capacitor there is no hardware securing the capacitor it fits into a slot in the assembly 5 Remove the capacitor from the drive THESE CAPACITORS CAN WEIGH AS MUCH AS 100 kg 220 Ibs SO YOU WILL REQUIRE AT LEAST TWO PEOPLE TO REMOVE A CAPACITOR 6 Install the new capacitor sliding it back until it fits into the slot Fasten the front bracket 7 Reconnect all the power cables and the ground connection These use M14 hardware but should only be tightened to 30 Nm 22 ft Ibs due to capacitor mechanical constraints You may want to fasten these connections before fully sliding the capacitor into place depending on the available space 8 There are instruction labels on each capacitor detailing how to tighten th
226. ing Network Capacitor Replacement cont Important Torque on capacitor terminals 3 4 Nm 30 Ib in maximum Important Torque on resistor bank assembly Loosen screws to 1 2 Nm 11 0 Ib in maximum release capacitors Remove screws for replacing resistor bank Figure 4 10 Torque Values for Ground Filter Assembly Ground Filter The number of capacitors will vary depending on the system voltage Replacement 1 Ensure there is no power to the equipment To prevent electrical shock ensure the main power has been disconnected before working on the N capacitor Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Failure to do so may result in injury or death dI Note the position of the leads bai Disconnect the leads connected to the capacitor resistor bank 4 Loosen and remove mounting screws as indicated in Figure 4 11 and remove the component SA Assemble the new component in the reverse order of disassembly 6 Reattach the leads strictly adhering to the torque requirements outlined in Figure 4 8 7000L UM302B EN P June 2013 7000 C Frame Marine Component Definition and Maintenance 4 15 The maximum torque for the capacitor terminal is 3 4 Nm 30 Ib in Important Torque on Resistor Bank Assembly 1 2 Nm 11 0 Ib in maximum Important Torque on capacitor terminals 3 4 Nm 30 Ib in maximum Remove screws for replacing re
227. ion ii p j Motor Filter i Lf Capacitors Yu Il da Line Filter Lecce ope Capacitors la k Figure 2 43 Capacitor Cabinet 7000L UM302B EN P June 2013 7000 C Frame Marine Drive Installation 2 37 AC DC Power Supplies Disconnect Switch Power Transformers Liquid Cooled DC Link Reactor Cooling Pipes Figure 2 44 DC Link Inductor Cabinet 7000 C Frame Marine 7000L UM302B EN P June 2013 2 38 Drive Installation Pumping Panel ag NE yy i f 5 009 MII lo000 000d 000d o oc Il gl f pause faced ood A Ms l d p od LPS TE LAT Swingout F iue Low Voltage uf L I I I I T I n Panel sl eo E 7000L UM302B EN P June 2013 TE a o _ s ABS lcoonjle eec ooon oo
228. irectly to the low voltage control through the SCBs and cause immediate damage to those boards Note The VSB ribbon cable insulation is not rated for the potential applied during a Megger test It is important to disconnect the ribbon cables at the VSB rather than the SCB to avoid exposing the ribbon cables to high potential 7000 C Frame Marine 7000L UM302B EN P June 2013 C 4 7000L UM302B EN P June 2013 Meggering 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 will not only protect them from damage but remove 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 Megger test Meggering the Drive Note Verify the drive and any connected equipment is clear of personnel and tools prior to commencing the Megger test Barricade off any open or exposed conductors Conduct a walk around inspection before commencing the test All three phases on the line and
229. is occurs the operator interface will switch to the new language if the required language module is loaded LANGUAGE FIERE Deutsch Gee T_T Te Figure 3 41 Language Selection 7000 C Frame Marine 7000L UM302B EN P June 2013 3 34 Operator Interface 7000L UM302B EN P June 2013 Modify Parameters To change a parameter Use the up down arrow keys on the SETUP screen to select the Parameters option and press the enter key This will begin the selection process of a parameter as described in the section entitled Select a Parameter The selection process to change a parameter can also be initiated while displaying the members of a parameter group on the DISPLAY screen Figure 3 68 by pressing the F7 key When you have successfully selected a parameter one of three possible screens will be displayed depending on the type of parameter Numerical Value When the parameter is a numerical value the MODIFY PARAMETER screen typical of Figure 3 42 will be displayed This screen shows the name of the parameter for which you are making the changes i e Rated motor volt the tag code for the parameter i e 22 the minimum and maximum allowable limits to which the parameter must be set i e 4000 to 4160 theunits in which the parameter data is being displayed the actual value of the parameter contained in the drive MODIFY PARAMETER Rated motor volt P 22 Min
230. 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 these connections must be removed before grounding the shield at the customer end of the cable Shields for cables from one enclosure to another must be grounded only at the source end cabinet If splicing of shielded cables is required the shield must remain continuous and insulated from ground Note 4 AC and DC circuits must be run in separate conduits or trays Note 5 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 Table 2 A Wire Group Numbers 7000L UM302B EN P June 2013 7000 C Frame Marine Drive Installation 2 51 The wire sizes must be selected 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 that used if a main voltage source connection to the motor was used The distance between the drive and motor may affect the size of the conductors used Consult the wiring diagrams and appropriate CEC or IEC NEC regulations to determine correct powe
231. isolated and locked out It is required to remove the transparent sheet on top of the Drive Processor Module and the Drive Processor Module also before removing the ACB Remove the transparent sheet on top of the DPM by removing the 4 screws Use static strap before removing any connectors Remove the connectors J4 J11 and J12 on DPM after proper identification and marking if necessary Use the electrical drawing as the reference Remove the 4 screws holding it on the standoffs above the ACB Gently remove the DPM mounted on the four 34 pin connectors Remove the screws holding encoder interface board and gently remove the board mounted on the 8 pin connector Remove the connectors J1 J2 J3 J4 J5 J6 J7 J8 J9 J10 J12 J13 J14 J16 J22 J24 J25 J26 J27 on ACB after proper identification and marking if necessary Use the electrical drawing as the reference Remove the ACB board by removing the 4 screws and 6 standoffs screwed to support the DPM amp encoder interface board Follow Steps 8 2 in reverse to reinstall the boards back into the low voltage control cabinet Apply Low Voltage power and complete a System Test and Medium Voltage tests to ensure the new board functions properly 7000L UM302B EN P June 2013 4 102 Component Definition and Maintenance Tachometer Feedback Board 7000L UM302B EN P June 2013 Encoder Options There are two positional encoder interface boards that may be used with
232. ity and freezing point of the liquid Maintenance of the heat exchanger The liquid to air exchangers have fans chiller fins and tubing They should be checked for debris and cleaned periodically Make sure all inspection opening cover plates are re installed after inspection 7000L UM302B EN P June 2013 4 152 Component Definition and Maintenance Annual Maintenance As the name implies these maintenance tasks should be performed on an annual basis These are recommended tasks and depending on the installation conditions and operating conditions you may find that the interval can be lengthened For example we do not expect that torqued power connections will require tightening every year Due to the critical nature of the applications run on MV drives the key word is preventive Investing approximately 8 0 hours per year on these tasks is time well spent in adding insurance against unexpected downtime Initial Information Gathering Some of the important information to be recorded includes Print Drive Setup Print Fault Warning Queues Save Parameters to NVRAM Save Parameters to Operator Interface Circuit Board Part Numbers Serial Numbers Revision Letters This only needs to recorded if parts have been modified changed since the last PM activities To prevent electrical shock ensure the main power has been disconnected before working on the drive Verify that all circuits are voltage free using a hot sti
233. ive Installation Liquid Connections Liquid to Liquid Heat Exchangers There are three options for routing piping between the liquid to liquid heat exchanger to the supply and return coolant Pipes through top plate of cabinet Pipes through bottom plate of cabinet Pipes through right side of cabinet Removable plates are provided in each of these locations Access for connections through top of cabinet Access for connections to heat exchanger through E right side of cabinet b Liquid to Liquid Heat Exchanger Access for connections y to heat exchanger through HB bottom of cabinet Figure 2 59 Connection to Liquid to Liquid Heat Exchanger rear of pumping cabinet shown with back plates removed 7000L UM302B EN P June 2013 7000 C Frame Marine Drive Installation 2 55 OLOZALE 60 Figure 2 61 Customer connection points to internal Heat Exchanger for external coolant loop 7000 C Frame Marine 7000L UM302B EN P June 2013 2 56 Drive Installation 1 25 or 2 0 NPTF Drive Coolant Inlet Female Pipe Threads Drive Coolant Outlet Process Water Outlet Process Water Inlet Figure 2 62 Pipe Flange Detail Please refer to project Specific drawings for detailed requirements for the coolant flow and pressures required 7000L UM302B EN P June 2013 7
234. key 13 Press F4 RATE key The cursor moves to the rate field Here 7000L UM302B EN P June 2013 we will enter 0 which is the fastest sample rate 1 msec sample and then press Enter key 7000 C Frame Marine Component Definition and Maintenance 4 133 14 Press F5 POST key and enter 10 this is the percentage of post trigger samples and then press the Enter key 15 Now press F10 EXIT key to exit to Diagnostic screen On the Diagnostics screen verify that the Status is Running which means the Diagnostic Trend is ready and will capture the data whenever the trigger condition is satisfied If the Status shows Stopped then press F7 Re Arm key This will change the Status to Running RUNNING rigger Not Available 16 Now press F10 EXIT to exit to the main screen 7000 C Frame Marine 7000L UM302B EN P June 2013 4 134 Component Definition and Maintenance Printing Uploading Overview Data from the Drive The data from the drive such as drive setup parameters variables trend data fault masks alarm queues etc can be uploaded and saved into laptop using HyperTerminal program When using the HyperTerminal program to upload the data you will be prompted to select a file to store this data Therefore you need to open an empty Notepad file and then save that file on your pc before uploading the data from the drive The following example illustrates the method
235. l cement mining and metals forest products power generation and water waste water The PowerFlex 7000L is a global product that adheres to the most common standards from NEC IEC NEMA UL and CSA It is available with the world s most common supply voltages at medium voltage from 2400 6600 volts 5 The design focus is on high reliability ease of use and lower total cost of ownership gt For2400V and 3300V designs contact factory The PowerFlex 7000L C Frame liquid cooled drive utilizes a closed loop system to cool the converter main power components and the integral DC link inductor The Main Benefits of Liquid Cooling Include Smaller drive dimension compared to air cooled drives of similar rating Higher power rating capability Quiet operation in control room Low loss rejection to the control room reduces air conditioner loading Majority of losses rejected outside the control room via a liquid to air or liquid to liquid type heat exchanger 7000L UM302B EN P June 2013 1 2 Overview of Drive 7000L UM302B EN P June 2013 The Main Benefits of the 7000L C Frame Liquid cooled Drive Include Completely integrated MV drive package reduces customer installation costs and start up time Higher power rating capability up to 9000 hp 6715 kW 18 Pulse and AFE rectifiers for low harmonic solutions that meet TEEE 519 1992 Harmonic Guidelines Motor friendly current and voltage output
236. l wire categories that will be encountered when installing the PowerFlex 7000 Drive Each category has an associated wire group number that is used in the following sections to identify the wire to be used Application and signal examples along with the recommended type of cable for each group are provided A matrix providing the recommended minimum spacing between different wire groups run in the same tray or separate conduit is also provided For Tray Recommended spacing between different wire groups in the same tray For Conduit Recommended spacing for wire groups in separate conduit mm inches Wire Application Signal Recommended cux E Category pp Example Cable Per IEC NEC AC Power 2 3 kV 3D Local Codes and 228 6 228 6 228 6 228 6 gt 600V AC AC Lines Application ia 9 00 9 00 9 00 9 00 Requirements Between 76 2 3 00 Conduit es um Per IEC NEC AC Power Local Codes and 228 6 228 6 1524 1524 TO 600V AC Application Tia 9 00 9 00 6 00 6 00 RE Between 76 2 3 00 Conduit a DUE 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 115V AC Erud IEC NEC on 115V DC Relay Logic Local Codes and 228 6 152 4 228 6 152 4 PLC I O Application a 9 00 6 00 9 00 6 00 Requirements E ee 15V AC Power Supplies Between 76 2 3 00 E ee Instruments Conduit Wia
237. larms as they occur This feature is selected as one of the report formats In the Figure 3 78 the AUTO ON indicates that this feature is currently enabled To disable the feature use the cursor down key to select the text and press the enter key The text will change to AUTO OFF if a printer is attached The automatic alarm printout feature is now disabled Pressing the enter key again while selected will enable the feature 7000L UM302B EN P June 2013 3 54 Operator Interface Perform Diagnostic Trending 7000L UM302B EN P June 2013 PRINTER ae xi Parameters Fault Masks Status Trends FaultAlarm Variables Printer Status Ready fares IL Ten Figure 3 78 Typical Printer Screen The diagnostic trending operation of screens allows you to capture the relationships of a number of parameters over a period of time Within this operation you will e Define the Parameters to which the Trend Apply e Define the Trigger Condition to Begin the Trend e Define the Sampling Rate and position of the Trigger e View the results of the Trend You will access the Diagnostic Trend operation from the Top Level Menu by pressing the F9 key This results in the display of the screen shown in Figure 3 79 DIRGNOSTICS Trisser Status UNPROGRAMMED Last Trigger Not Available Figure 3 79 Diagnostic Screen From this screen additional screens are accessible to perform the diagnostic trendi
238. lash Memory Card 2711 NM4 or 2711 NM8 or 2711 NM 16 copy the appropriate file to the Flash Card in the root directory Ensure that there are no other files on the card containing the FMW extension 7000 C Frame Marine 7000 C Frame Marine Component Definition and Maintenance 4 125 Power off the Terminal and insert the memory card Apply power to the terminal The terminal on power up will sense new firmware and download it from the card You will see a series of codes on the screen 2 20 21 and then the drive application firmware will start The process may take several minutes When the download is finished remove the card from the Terminal If you leave the card in the terminal it will reload the firmware each time the terminal is powered up DOSFWDL This is a DOS program which copies the FMW file out the serial port of the laptop to the serial port of the terminal The program is usually included in the firmware package The method is described below In this example we are using firmware file FRN 4006 FMW Note If you are using a newer firmware just make sure the filename is max 8 character long You can rename the file but keep the filename extension as FMW Also when you are prompted to enter the filename make sure you enter the correct filename as illustrated in the following example Method 1 Make sure the Terminal is powered off Disconnect Terminal s serial cable connector from
239. ll screens have the F3 F4 and F5 keys in common if applicable Once in the editing field all operations are performed on the character in reverse video Pressing the cursor left and cursor right keys will move to the next character position in the string Pressing the cursor up and cursor down keys will cycle through the characters contained in a set each time the key is pressed Note that when the first member of a set is displayed pressing cursor down will wrap around to the last member of the set There are four sets of characters available Press the F3 key to cycle among the sets The sets consist of a the upper case letters A Z b the lower case letters a z c the numbers 0 9 and the characters and d the characters space 1 19 90 amp ez Note these character set may vary depending on the language selected A special set consisting of A Z 0 9 and the underscore character are used for filenames and cannot be selected via the F3 key or modified by the F5 key When a letter is in the editing field pressing the F5 key may change its case To delete the entire string i e fill it with spaces press the F4 key To abort the changes to the string being edited press the backspace key This will restore the string to its contents when the screen was first entered The editing operation is completed by pressing the enter key Changes are not permanently made until t
240. low the system to cool down before servicing any components in the coolant system 3 Remove all SCR SGCT devices and their circuit boards as outlined in Replacing the Silicon Controlled Rectifier and SGCT Replacement 4 Drape a waterproof plastic sheet over all the devices under the PowerCage being serviced Personnel must wear suitable protective personal gear to avoid direct contact with the coolant ethylene glycol water mixture 5 Two flow restrictor clamps per Figure 4 25 are provided with the spare parts kit of each drive 7000 C Frame Marine 7000L UM302B EN P June 2013 4 36 Component Definition and Maintenance Detachment of Coolant System from PowerCage Modules cont Figure 4 25 Flow Restrictor Clamp Also required are two 2 pieces of 3 8 hose included in spare parts kit and four 4 M10 bolts with a length from 10 to 30 mm for use as plugs in the 3 8 hose not included See Figure 4 25 M10 bolts must be clean D Figure 4 26 Flow Stopper for Servicing 2 required 6 Insert the 2 clamps per Figure 4 26 on the inch 19 mm silicon hoses to isolate flow between the vertical manifolds and the horizontal manifolds of the converter modules 7000L UM302B EN P June 2013 7000 C Frame Marine Component Definition and Maintenance 4 37 Figure 4 27 Converter PowerCage Module Service per Step 6 Loosen the hose clamp of
241. lute encoders Parallel positional data is converted to a serial stream and transmitted to the DPM when requested by the drive The board will also generate pseudo quadrature differential signals including a zero position mark derived from the binary data to the DPM There are three different positional encoder configurations available For all of these configurations remove the ENC TYPE jumper The other jumpers configure the board for the type of positional data Gray Code or Natural Binary set by CD DQUAD and High or Low True data set by POL QRDNT 1 Gray code Low True In this configuration the board will invert the incoming gray code data and then convert it to binary for transmission to the DPM 2 Natural Binary Low True No conversion is done on the incoming data but it is inverted 3 Gray code High True In this configuration the incoming gray code data is simply converted to binary No inversion is done on the input data 4 Natural Binary High True The positional data is simply converted to the serial stream No inversion or conversion is done on the data Consult factory for availability of Positional Encoders 7000L UM302B EN P June 2013 4 108 Component Definition and Maintenance Tachometer Feedback Board cont 7000L UM302B EN P June 2013 Positional Encoder Guidelines When selecting a positional encoder there are certain guidelines that should be followed for optimal performance 1
242. lves V8 and V9 if provided and unscrew the housing see Figure 4 61 2 Drain some of the coolant by loosening the drain at the base of the filter Some spillage may occur so a pail should be placed underneath 3 The filter may be cleaned or replaced however the de ionizing cartridge must be discarded and replaced with a new one Do not recycle the resin cartridge It has been contaminated with ethylene glycol 4 Open valves V8 and V9 if provided after cleaning The high conductivity warning will stop once the conductivity decreases to its normal level Reservoir Circuit The reservoir is a cross linked polyethylene fifteen gallon container Level switch LS see Figure 4 60 is a warning switch that annunciates when the fluid drops down below the first level switch Level switch LSDL see Figure 4 60 triggers the drive and cooling pumps to shut down when the fluid drops below critical level 7000 C Frame Marine 7000L UM302B EN P June 2013 4 78 Component Definition and Maintenance Pump Maintenance and Fluid Top up Replacement cont Keep the coolant at the proper level in the reservoir There are two float switches within the reservoir one indicates a low coolant level LS alarm and requires a top up of the fluid and the other indicates a very low coolant level LSDL trip and triggers a shut down of the drive De ionized water and chloride free ethylene glycol or a mixture of the two may be added to t
243. m Summary Screen A new alarm will cause this key to flash in reverse video F8 Next Page When a screen is capable of displaying data that requires more than one page this Softkey will be active The Softkey will increment the page number being viewed F9 Previous Page When a screen is capable of displaying data that requires more then one page this Softkey will be active The Softkey will decrement the page number being viewed F10 Exit When you are viewing any screen other than the Top Level Menu this Softkey will return you to the previous screen When the operator interface is powered up or reset it will go through two noticeable operations a Linking to Drive During this phase the operator interface is establishing communications with the drive communications board The screen will also show information about the software product contained in the PowerFlex operator interface such as software part number and revision level date and time stamp of program creation 7000L UM302B EN P June 2013 3 10 Operator Interface 7000L UM302B EN P June 2013 b Obtaining Drive Database During this phase the database of information about the drive is obtained from the drive Obtaining the database at this point in time is optional and may be aborted by pressing any key on the operator interface Obtaining the entire database does however speed up subsequent operations since relevant portions of the
244. machine sides of the drive are connected together 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 Note Be sure the Megger is discharged prior to disconnecting it from the equipment Connect the Megger to the drive following the specific instructions for that model If the Megger has a lower voltage setting normally 500V or 1000V apply that voltage for 5 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 5kV from any drive input or output terminal to ground Perform a Megger test at 5 kV for 1 minute and record the result 7000 C Frame Marine Meggering C 5 The test should produce a reading greater than the minimum values listed below If the test results produced a value lower than these values start segmenting the drive system down 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 The DC Link reactor may have to be completely isolated from the drive at which point all four of its power cables must disconnected It is imperative to ensure the electrical components to be meggered are electrically isolated from grou
245. maller and lighter than drive technologies that use Isolation Transformers Isolation Transformers represent 30 to 50 of a drive system size and 50 to 70 of the system s weight This means that there is no interwiring between drive and transformer for external transformer configurations This makes the PowerFlex 7000L the simplest to install The PowerFlex 7000L 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 VFD is typically 3 C 5 5 F higher compared to across the line operation Dv dt in the voltage waveform is less than 10 volts microsecond The peak voltage that the motor insulation will see is the rated motor RMS voltage divided by 0 707 Reflected wave and dv dt issues often associated with VSI voltage source inverter drives are a non issue with the PowerFlex 7000L Typical motor waveforms are shown in Figure 1 5 These motor friendly waveforms are achieved by utilizing a selective harmonic elimination SHE pattern in the inverter to eliminate major order harmonics in conjunction with a small output capacitor integral to the drive to eliminate harmonics at higher speeds Standard motors are compatible without derating even on retrofit applications Motor cable distance is virtually unlimited This technology has been tested controlling motors up to 15 km 9 3 miles away from the drive
246. may be modified via the cursor keys To abort the change press the backspace key and the calendar will return to its original date To accept the change press the enter key The new calendar setting has been recorded The setting may also be aborted by pressing any of the assigned function keys other than F1 and F4 The function associated with that key will be executed You can not set the day of the week The operator interface will determine the day of the week based on the date that you set in the calendar UTILITY 11 29 69 2709705 TUE Mainmenu Meters Backlight 168 min Contrast 5 J Digital spdmeter 572 Digital ammeter 573 Digital Vltmeter 574 Digital purmeter 575 Figure 3 14 Utility Date Selecting Meters The utility screen Figure 3 10 shows the four tags assigned to the four meters on the Top Level Menu These can be changed by pressing the F8 key This displays a new screen Figure 3 15 from which the selection and text associated with the meter is changed 7000L UM302B EN P June 2013 3 18 Operator Interface 7000L UM302B EN P June 2013 METERS Digital spdmeter 572 Disital ammeter 5 Digital vitmeter Digital pwrmeter ases cancer Process eur Figure 3 15 Utility Meter To change the tag attach to a meter use the cursor up and cursor down keys to highlight the desired meter and press the enter key If nothing happens
247. ment needed Digital oscilloscope Function generator w duty cycle control DC power supply 15V 300 mA required Digital multimeter Temperature sensor board 80190 639 02 Procedure 1 ets SO oo 10 11 12 13 14 15 16 17 18 19 20 21 22 Connect a clamped ABB 5STP03D6500 SCR to the gate cathode leads of the SPGDB board TB4 1 TB4 2 Attach a temperature sensor board to the TB2 1 TB2 2 terminals Apply 15V test power to terminals TB3 1 and TB3 3 TB3 1 is at 15V while TB3 3 is the 15V return Leave TB3 2 open Measure TP4 to TP3 which should be 14 4V 100mV Measure TP5 to TP3 which should be 5 0V 250mV Measure TB2 1 to TB2 2 which should be 14 4V 100mV Measure the voltage at U4 pin2 to COM which should be 1 0V 100mV Measure the voltage at U4 pin3 to COM which should be OV Measure the voltage at U4 pin7 to COM which should be 3 6V 100mV Verify that the OT1 LED is off Measure TP7 to TP3 which should be OV Measure TP9 to TP3 which should be 5 0V 250mV Measure TP8 to TP3 which should be OV Measure TP1 to TP2 which should be OV Connect a jumper between TB3 1 and TB3 2 and verify that the voltage at TP6 is 2 2V 100mV Apply a 60Hz 33 duty cycle signal to the OP1 fiber optic input Verify that the diagnostics transmitter LED OT1 is on Verify that the signals at TP9 and TP8 are as shown in Fig 4 38 Ver
248. mponents in the controller 7000L UM302B EN P June 2013 2 2 Drive Installation Transportation and Handling The PowerFlex 7000 drive is shipped on a wooden skid which is bolted to the underside of the cabinetry The drive should remain bolted to the shipping skid until it is delivered to its final installation area Lifting angles are supplied bolted to the top of the cabinetry The drive must be kept in an upright position during any handling Refer to General Handling Procedures publication 7000 IN002_ EN P for a more detailed description The drive must be transported on a pallet or via use of the lifting beam supplied as part of all 2300 mm 91 inch high cabinets Ensure that the load rating of the lifting device is sufficient to safely raise the N controller sections Refer to the packing slip enclosed with shipment for shipping weights Round rollers can be used to assist in moving the drive to the installation site Once at the final site the pipe rolling technique can be used to place the cabinet in the desired position Care must be exercised when using either a forklift or the pipe rolling technique for positioning purposes to ensure that the equipment is not scratched dented or damaged in any manner Always exercise care to stabilize the drive during handling to guard against tipping and injury to personnel Never attempt to lift or move the drive by any means other than the methods listed as structural dam
249. n _ 5V1 V2 amp DOBLB AME a DAV ADSLB DAM DACSSERAL Pam OOWSOONECIIOS SET DATA PANIERGUIPUIS Jia gt Na COWSCONECTIOS TERMINAL PANE VE co Bi CONTRO METER STAIB amp QUIPUB amp ONR 4 Ji J0 gt SPEEDROT PONR INPUT MNTCANG ACB ARPFEEBLFE BO NU Lie ee a Neo Me B P B A B 5 J N 4 MOR oK GRANDFALLTE ISQATED amp NOMSOATED LINEGLFFENTINPUIS Q FEENT QRANT CVCNEUIRIL ANALGGINPUTSAND INFUIS NUS QRENTINPUIS NONISQATEDQUIPUIS Figure 4 66 IO Connectors on Control Boards 7000L UM302B EN P June 2013 7000 C Frame Marine Drive Processor Module Component Definition and Maintenance 4 89 This module contains the control processors It is responsible for all the drive control processing and stores all of the parameters used for the drive control Ea TI a TIL O rag De O O fra RTPI RTP2 A RIP4 Ph ITP2 ITP3 ITP4 DGND SV 433V 42 5V 418V 12V J ul M m J10 a Ey cm e eg CE e e 7 T EE Mus ey RPM mie Ben DATNE iu ay AB p e l 5a direh Bh Es e Ch decem us s x Vey E us p lee 5 eus DA neso l E ri 8 D TEM uM pem end Tl ru ria w un DE PR 3 LI cw em ta LI lo ol eus Phi ware 2231 5 M r ree 0085 ur ee tr US Reel f magg ti El DPM mi ROCKWELL f U nae AUTOMATION 1 03 03 i pna RT D ja URS EN d H s 5 80190 578 51 870 gta eum Us cung aps E is
250. n Operator Interface Power up Sequence 7000 C Frame Marine Operator Interface 3 65 Parameter Transfers 7000 C Frame Marine WARNING Any time the operator interface is powered up with a flash card inserted which contains a valid firmware FMW file the operator interface will attempt to load new firmware note item a above For this reason it is not advisable to leave a memory card containing a firmware file in the operator interface after the firmware has been downloaded The parameters used by the drive are stored within the drive itself The operator interface is used to review and modify these parameters When a Drive Control Board is changed it is necessary to re enter the parameters into the new board The operator interface can simplify this process by reading all the parameters from the old Drive Control Board and storing them either in the operator interface or on a flash card When the new board has been installed the previously stored parameters are then downloaded to the new board The flash card provides an added benefit when more than one drive is using the same set of parameters Parameters can be entered on the first drive then uploaded and stored on the flash card The flash card may then be taken to the remaining drives and the parameters downloaded to those drives Note This feature does not replace the saving of parameters to the Drive NVRAM refer to section Store Retrieve Configurati
251. nals shown for bottom cable entry Terminals can be removed and re installed with orientation for top cable entry 7000L UM302B EN P June 2013 4 18 Component Definition and Maintenance Filter Capacitor Cabinet 7000L UM302B EN P June 2013 Filter Capacitors Filter capacitors are used on the motor side for all drives The AFE Rectifier option also includes filter capacitors on the line side Refer to Figure 4 1 Cabling Cabinet for 18 pulse Rectifier and Figure 4 2 Cabling Cabinet for AFE Rectifier The filter capacitors are three phase four bushing units and oil filled The three phase capacitors are comprised of internal single phase units that are connected in a Y configuration The neutral point of the Y is connected to the fourth bushing which is accessible and can be used for neutral point voltage measurement or other protection diagnostics purposes Depending on the drive configuration the fourth bushing may or may not be connected to circuitry The metal cases of the capacitors are grounded through a stud on the capacitor housing The capacitors are equipped with internal bleeding resistors to discharge the capacitor and reduce its voltage below 50V in 5 minutes when left disconnected A typical three phase capacitor is shown below Figure 4 14 Motor Filter Capacitor Allow 5 10 minutes for motor capacitors to safely discharge voltage prior to opening A cabinet doors 7000 C Frame Mar
252. nd 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 M Ohms Air Cooled Drive 1k M Ohm Drive with input output Caps Disconnected 5k M Ohm Isolation Transformer 5k M Ohm Motor 5k M Ohm Note The motor filter capacitors and line filter capacitors Gf 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 Note Humidity and dirty standoff insulators may also cause leakage to ground because of tracking You may have to clean a dirty drive prior to commencing the Megger test 5 Reconnecting 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 7000 C Frame Marine 7000L UM302B EN P June 2013 C 6 7000L UM302B EN P June 2013 Meggering Reconnect the Power Circuit to the System Ground Voltage Sensing Boards Securely reconnect the two gr
253. nd apply medium voltage If there were any input or output cables removed verify the input phasing and bump the motor for rotation If there were any changes to the motor input transformer or associated cabling you will have to retune the drive to the new configuration using autotuning Save all parameter changes if any to NVRAM Run the application up to full speed full load or to customer satisfaction Capture the drive variables while running in the highest access level if possible 7000 C Frame Marine 7000 C Frame Marine Component Definition and Maintenance 4 155 Additional Tasks During Preventive Maintenance gt Investigation of customer s concerns relating to drive performance Relate any problems found during above procedures to customer issues Informal instruction on drive operation and maintenance for plant maintenance personnel Reminder of safety practices and interlocks on MV equipment and on specific operating concerns Reminder of the need to properly identify operating conditions Recommendation for critical spare parts which should be stocked in plant to reduce production downtime Gather information on all spare parts on site and compare that with factory recommended critical spares to evaluate whether levels are sufficient Contact MV Spare Parts group for more information Vacuum Bottle Integrity Testing using a Vacuum Checker or AC Hipot Refer to
254. ne 2013 4 110 Component Definition and Maintenance External Input Output Boards cont The standard drive comes with one XIO board additional boards up to 5 can be daisy chained together from XIO Link B J5 on the first board to XIO Link A J4 on the second board for a total of 6 XIO cards However at this time the drive only supports the use of addresses 1 to 3 depending on the drive s features and application U6 on the XIO board displays the board s address which is automatically calculated from the XIO board s position in the network XIO Link A and B ports are interchangeable but it may make wiring easier to follow if Link A is used for upstream that is closest to the ACB and Link B is used for downstream or farthest from the ACB LED D1 and display U6 indicate the status of the board The following table illustrates the possible states for D1 LED Status Description Solid Red Board Failure Alternate Flashing of Red and No Communication Available to ACB board Green Normal at Power on during firmware download and with unprogrammed drive Table 4 F Status of U6 Display Display Description Explanation No valid address found More than 6 XIO cards on network XIO cable failure XIO card failure ACB failure 0 Card in Master mode Rockwell Use Only Remove connection to J3 and recycle power 1 6 Valid address Normal Decimal point ON Indic
255. ng Cartridge and Mesh Filter The circuit shown in Figure 4 60 filters and de ionizes the stream at a rate of about 0 3 L second 5 U S gallons per minute This stream can be isolated for cleaning and maintenance by closing the incoming and outgoing valves The filter is a 500 micron fine mesh type which can be cleaned many times by rinsing in clean water The de ionizing cartridge is a mixed bed cartridge type which can be disassembled easily for de ionizing cartridge replacement Reservoir Level Switch LS Mesh Filters Level Shut Down Low LSDL De ionization Cartridge DEI Figure 4 60 De ionizing Filter DEI1 Rear View 7000L UM302B EN P June 2013 7000 C Frame Marine Component Definition and Maintenance 4 77 Replacing the Mesh Filters When the conductivity of the coolant approaches the alarm level of 1 0 microSiemen a conductivity alarm and or fault occurs To correct the problem first clean the fine mesh filters see Figure 4 60 and put the purification system back online The filters should be checked periodically and replaced when worn out If the conductivity does not decrease after cleaning the filters the de ionization cartridge should be replaced Note that if the filters are clogged coolant conductivity will increase even if the de ionization cartridge is still functioning properly The filters and the de ionization cartridge can be changed while the drive is running 1 Close va
256. ng force in the PowerCage should be inspected Ensure there is no power to the equipment To prevent electrical shock ensure the main power has been disconnected before working on N the drive Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Failure to do so may result in injury or death Indicating Washer Calibration Nut DO NOT ADJUST m Clamp Bar N Adjusting Nut Pressure Pad Figure 4 19 Clamp Head Illustration If proper force as designated on the clamp head block is applied to the clamping assembly the indicating washer should just be able to rotate with fingertip touch The disc should not rotate freely Some force will need to be applied with your fingertips Clamping Pressure Adjustment 1 Ensure that all power to the drive is off 2 Do not loosen the adjustment nut completely 3 Tighten with a 21 mm 13 16 inch open ended wrench on the adjusting nut upward motion until the indicating washer can be turned by fingers with some resistance IT SHOULD NOT SPIN FREELY 7000 C Frame Marine 7000L UM302B EN P June 2013 4 28 Component Definition and Maintenance Checking Clamping Pressure cont Never rotate the calibration nut located outside the indicating washer at the end of the threaded rod The rotation of the calibration nut will affect the torque calibration which is factory set Only adjust the adjusting nut See Fi
257. ng functions The screen shows the current status of the trend Unprogrammed Running Triggered Stopped Ifa trigger has been defined the trigger parameter its trigger condition and the type of trigger will be displayed If data has already been captured a time stamp indicating the last time the given trigger has occurred This captured data can be viewed by pressing the F9 softkey 7000 C Frame Marine Operator Interface 3 55 When a trigger has been defined and is currently Stopped it can be re started by pressing the F7 key If the status is Running the user can force the trigger to occur by pressing the F2 key Note that in doing so that the trigger condition did not actually occur but all data buffers can be viewed as if the condition had occurred To define a trend press the F8 key to display the setup screen shown in Figure 3 80 DIAGNOSTICS SETUP Trigger PESCE Hd Trace 3 Trace 4 Rate mSec B Post Sample x a Figure 3 80 Diagnostic Setup DIAGNOSTICS SETUP S Trigger U line MEE U line race Trace 3 Trace 4 Rate mSec 6 Post Sample x A Figure 3 81 Assign a Trace From this screen the tags to be monitored are assigned to a trace The tag which you assign to the first trace Trace 1 is used as the trigger parameter By default when assigning a tag to Trace 1 the trigger value i e data will be set to the tag s minimum value and the trigger condi
258. nized water has been purified of most ionized solids and has very low conductivity The ethylene glycol is an iron and chloride free type and also has low conductivity Water is an active solvent and gathers contaminants from everything it contacts In nature ionized solids such as Sodium Na Calcium Ca and chloride CI are stripped from rocks and soil by water Also found in water are organic molecules from decaying debris bacteria and microbes that normally grow in water and dissolved ionized gases such as chlorine C15 and carbon dioxide CO Conductivity is primarily the result of ionized solids and gases in water The other materials in water contribute very little to electric current flow When a voltage is impressed on water current flows by using the ionic molecules as stepping stones for the current Most bacteria and organic materials offer few stepping stones for current so if the ionized solids and gases are removed the water becomes relatively non conductive Dissolved ionized solids and gases can be removed by using ion exchange resins Such resins attract ions in the water replacing them with H and OH ions which ultimately join to form water Ion exchange resins are synthetic polymers with several ion exchange sites attached to the surface The ion exchange resins gradually lose their effectiveness and need to be replaced or recharged NOTE Do not recycle the de ionizing cartridge because it has been contamina
259. njury or death Wear proper Personal Protective Equipment PPE Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment PPE gt gt gt 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 Who Should Use This Manual What Is Not in this Manual 7000 C Frame Preface Overview This User Manual is intended for use by personnel familiar with medium voltage and variable speed solid state drive equipment The manual contains material that will allow the user to operate the drive system This manual is designed to provide only information specific to the PowerFlex 7000 C Frame drive Therefore customer specific topics are not presented These customer specific topics include e Dimensional and Electrical Drawings generated for each customer specific order This manual does provide generic drawings for illustrative purposes only e Spare Parts Lists compiled for each customer specific order This manual does provide a generic list of possible components and a description of their characteristics and functionality The above information is provided to the customer during the order process cycle Three User Manuals address this product line A Frame for lower power air cooled configurations up to approximately
260. ns described earlier in this section CONTROLLOS IY ITSG AIO CHASSIS WITH POWER SUPPLY VT88 P T8 jit o00l0000loococlocooojlooooooooo000o090002000 0090 lQ900300 0000 009000000920 0650 08990320 0829 9899 Analog Control Board ACB e ANALOG CONTROL BOARD Figure 4 68 ACB and DPM Replacement 7000L UM302B EN P June 2013 7000 C Frame Marine Component Definition and Maintenance 4 93 ACB Analog Control Board The Analog Control Board ACB is the hub for all control level signals external to the drive Analog I O External Fault signals through the XIO board DPI communication modules Remote I O terminal interface printers modem and other external communication devices are routed through this board
261. ntactor load break harmonic filter etc This includes main cooling fan power devices heatsinks circuit boards insulators cables capacitors resistors current transformers potential transformers fuses wiring etc Causes could be corrosion excessive temperature or contamination Verify that torque on heatsink bolts electrical connections to bullet assemblies is within specifications 13 5 N m Clean all contaminated components using a vacuum cleaner DO NOT use a blower and wipe clean components where appropriate NOTE An important component to check for contamination is the heatsink The fine grooves in the aluminum heatsinks can capture dust and debris gt Carry out the physical inspection and verification for the proper operation of the contactor isolator interlocks and door interlocks Carry out the physical inspection and verification for the proper operation of the key interlocks Physical verification of the additional cooling fans mounted in the AC Line Reactor cabinet Harmonic Filter cabinet for mounting and connections Carry out the cleaning of the fans and ensure that the ventilation passages are not blocked and the impellers are freely rotating without any obstruction Carry out the insulation meggering of the drive motor isolation transformer line reactor and the associated cabling Refer to User Manual Appendix D Meggering for meggering procedure Check clamp head indicator washer
262. ntrol Wireway Separate and Isolated Input Power Circuit Protection Vacuum Contactor with Fused Isolating Switch or Circuit Breaker Input Impedance Device Isolation Transformer or AC Line Reactor 0 2300 V 0 3300 V Output Voltage 0 4160 V 0 6600 V Inverter Design PWM Inverter Switch Symmetrical Gate Commutated Thyristor 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 420 540 Hz Voltage SGCTs per phase 2400 V 2 Number of Inverter SGCTs 3300 V 4 4160 V 4 6600 V 6 Voltage PIV SGCT PIV Rating 2 Red Peak Inverse Voltage 4160 V 6500 V 6600 V 6500 V Rectifier Designs ARE E 19 Pulse Rectifier Switch FERIS d SGCT AFE Direct to Drive Rectifier Switch Failure Mode Non rupture Non arc Rectifier Switch Failure Rate FIT 50 SCR 100 SGCT per 1 Billion Hours Operation Rectifier Switch Cooling Double Sided Low Thermal Stress oococoQ Optional For 2400V and 3300V configurations contact factory Voltage Sag tolerance is reduced to 25 when control power is supplied from medium voltage via CPT MOVs are used for 18 Pulse Surge Arrestors are used for AFE D2D configurations Short circuit fault rating based on input protection device contactor or circuit breaker
263. o U FIX o o O o o o o Q Figure 2 45 Pump Cabinet showing swing out low voltage panel De ionizer Pu Cartridge Coolant Reservoir behind L V Panel Heat Exchanger Coolant Pumps 7000 C Frame Marine Drive Installation 2 39 Ground Bus Surge Suppression Network Line Capacitors Hall Effect Sensor Voltage Sensing Line Terminals Figure 2 46 Line Reactor and Incoming Cabling Cabinet 7000 C Frame Marine 7000L UM302B EN P June 2013 2 40 Drive Installation QI Hall Effect Sensors Line Terminals Ground Fault Current Transformer Figure 2 47 General Incoming Cabling Location Line Reactor section 7000L UM302B EN P June 2013 7000 C Frame Marine Drive Installation 2 41
264. o to Call for Commissioning Rockwell Automation Medium Voltage Support group is responsible for Commissioning Support and activities for this product line They may be contacted at 519 740 4100 request Medium Voltage Support Project Manager The support they offer 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 7000 C Frame 7000L UM302B EN P June 2013 P 4 Preface 7000L UM302B EN P June 2013 7000 C Frame Table of Contents Preface Overview Who Should Use This Manual jouait ee batte te P 1 What is Not in this Manual eese P 1 Manual Conventions rensas nseni P 2 General Precautions iii P 3 Who to Call for Commissioning i P 3 Chapter 1 Overview of Drive Ttt Odd eH soleiris 1 1 Iaquid Cooling tete ter ceret eene Li 1 1 Topology sisi ie ee ee 1 3 Rectifier Designs I8 Pulse Rectifier iie e eret 1 4 Active Front End AFE Rectifier 1 5 Direct to Drive Technology eene 1 6 Motor Compatibility esee 1 7 SGCT Features and Benefits e 1 9 Specifications RE 1 9 Simplified Electrical Drawings 3300 4160 volt selciato fici 1 12 6000 6600 volt 5 2 1 2 1 ia 1 13 Control Overview o e WT ada
265. ode contained in the on board flash memory If it does not have valid firmware then the entire system will drop into a download mode In the download mode the system is waiting to receive a firmware download via the serial data port J4 on the DPM The system may also be placed into download mode from the Drive Terminal This can only be accomplished if you have obtained a minimum of ADVANCED level access Once that has been obtained from the main screen selecting UTILITY TRANSFER SYSTEM will place the drive into download mode 7000L UM302B EN P June 2013 4 118 Component Definition and Maintenance Preparation for Downloading Firmware 7000L UM302B EN P June 2013 Ensure the parameters are saved to NVRAM and saved to the Operator Interface Terminal and saved to any other external source such as the Flash Card DriveTools or printed to a hardcopy Hit F10 Access and highlight Advanced Press Enter or enter the password value if password required and you should have Advanced level access ACCESS Monitor Current Access Basic Advanced eruice Rockwell Enter Password acres oso os 67 Hit F10 to Exit and then F5 for NVRAM Press F5 for SAVE and F8 for YES The parameters should now be saved to NVRAM Press F10 again to EXIT Operation SAVE TO NURAM Operation Status COMPLETED De T De pe T9 Pacers Toe T ext To save to the Operator Interface Terminal and Flash Card P
266. of the numerical keypad Use the data entry keys 0 9 to enter the new value The key can be typed at any time to enter a negative value The key is used to enter a decimal point for fractional values The entered new value can be edited by pressing the backspace key This key will delete the right most character i e number decimal point or negative sign shown on the screen Press the enter key to accept the new value as shown in Figure 3 82 If the new value that you entered is outside the limits defined the new value will be pegged at the closest limit For example If you entered 900 when the minimum value was 1000 the new value will show 1000 Some data must be entered in HEX To accomplish this use the cursor up down keys to scroll through the values 0 F for the right most digit To accept the digit and enter to the right of the current digit press the right cursor key Press the Enter key to accept the value The value may be edited the same as a value entered from the numeric keypad DIAGNOSTICS SETUP S Trigger U line U line race Trace 3 Trace 4 Rate mSec 5 Post Sample Xx 16 Figure 3 82 Trigger Condition Defining Sample Rate and Positioning Pressing the F4 key sets the rates at which the samples are taken This data field is then modified in the same manner as the trigger data is entered Rates can be set from 0 msec collect as fast as possible to 20 000 seconds When samples are
267. oftkeys Keys Along the bottom of the display area is one or two rows of Softkeys These Softkeys represent the physical function keys The function of the actual keys will vary between displays The bottom row of keys i e F6 F10 is always shown The upper row is shown only if they are required for keys F2 F5 Thus a single row of Softkeys always refers to the keys F6 F10 7000L UM302B EN P June 2013 3 4 Operator Interface 7000L UM302B EN P June 2013 Even though the upper row of Softkeys i e F1 F5 may not be shown on some displays the F1 HELP key is always active F2 F5 are only active if shown Cursor Selection Keys The cursor keys are normally used to select an item on the display When an item on the display is selected that item will be displayed in reverse video To change the selection press the key in the desired direction On selection screens having more than one page the page will automatically change when the cursor is moved beyond the displayed list Some displays such as the Utility screen use these keys to modify the data value Pressing the cursor up and cursor down keys will change the value by a fine amount i e 1 unit Using the cursor left and cursor right keys will change the value by a course amount i e 10 units For entries requiring a HEX value the keys cursor up down are used to scroll to the desired HEX value For parameters which contain an Enumeration string
268. ol Power monitoring for channel 2 TP53 CP3 Control Power monitoring for channel 3 TP54 CP4 Control Power monitoring for channel 4 TP55 Vitrp AC Over Voltage Detection set point for 2UVW amp 3UVW TP56 AGND Analog ground TP57 AGND Analog ground TP58 AGND Analog ground TP59 AGND Analog ground TP60 5V 5V DC power supply TP61 15V 15V DC power supply TP62 15V 15V DC power supply TP63 24V 24V DC power supply TP64 24V 24V DC power supply TP65 24VCOM 24V common TP66 DGND Digital ground TP67 AGND Analog ground TP68 AP1 Analog Control Inputs Air pressure input AP1 TP69 APO Analog Control Inputs Air pressure input APO TP70 AIN1 Analog Control Input AIN1 TP71 AIN2 Analog Control Input AIN2 TP72 AINO Analog Control Input AINO TP73 AIN3 Analog Control Input AIN3 TP74 IPIS Input Isolating Switch TP75 IPCS Input Contactor Status TP76 IP Input Contactor Command TP77 OPIS Output Isolating Switch TP78 OPCS Output Contactor Status TP79 OP Output Contactor Command TP80 BPIS Bypass Isolating Switch TP81 BPCS Bypass Contactor Status TP82 BP Bypass Contactor Command TP83 DGND Digital Ground Return LEDs There are two power LEDs on the ACB labeled D7 and D9 e D9 is the 15V DC voltage OK signal e D7 is the 5V DC voltage present signal 7000L UM302B EN P June 2013 7000 C Frame Marine Component Definition and Maintenance 4 97 Interface Module IFM The Interface Module is used to make all customer useable connections to
269. on window enter any name for new connection under the Name field as shown below and then click OK Connection Description a5 New Connection Enter a name and choose an icon for the connection Name FoGe_CONNECTION Icon The Connect to window will appear as shown below Select COM1 from the dropdown list next to Connect using and then click OK 7000L UM302B EN P June 2013 7000 C Frame Marine 7000 C Frame Marine Component Definition and Maintenance 4 143 Connect To e g hfg Enter details for the phone number that you want to dial Country region 50505 Area code 51 E Phone number Connect using COMI COMI TCP IP Winsock Now the COMI Properties window will appear Set the port settings as shown below and then click OK COM1 Properties Port Settings Bits per second 11 5200 v Data bits Parity Stop bits Flow control xon xott E Now close HyperTerminal program At this point following message box will appear HyperTerminal You are currently connected Are you sure you want to disconnect now 7000L UM302B EN P June 2013 4 144 Component Definition and Maintenance Printing Uploading Click Yes and you will be prompted to save the connection Control Data cont HyperTerminal A Do you want to save the connection named gfhfg Click
270. on After downloading parameters they must still be saved within the drive in order to make them permanent To transfer parameters press the F4 key from the TRANSFER screen The screen shown in Figure 3 92 will be displayed If nothing happens then you have not gained the required access to modify the flash memory Exit to the TRANSFER screen and refer to the section entitled Enter Modify an Access Level to gain access Within this screen it is possible to perform four different parameter transfers TRANSFER PARAMETERS Figure 3 92 Transfer Parameters Menu 7000L UM302B EN P June 2013 3 66 Operator Interface 7000L UM302B EN P June 2013 Upload to Operator Interface The parameters are read from the drive and stored in the operator interface by pressing the F5 key The screen will appear as in Figure 3 93 indicating the operation you are about to perform The screen will then ask you to confirm the operation Press the F8 key to proceed or the F9 key to abort Performing a DRIVE TO MEMORY transfer will overwrite any previous parameters stored within the operator interface TRANSFER PARAMETERS DRIUE TO MEMORY PROCEED Yes No Operation Status TRANSFER PENDING Pacem om ves wo ex Figure 3 93 Transfer Stored Parameters Download from Operator Interface The parameters stored in the operator interface are downloaded to the drive by pressing the F3 key A screen similar to
271. on uses a source destination wire number convention on point to point multi conductor wiring and in situations where the system is warranted The wire numbering system of unique single numbers for multi drop and point to point wiring continues to be used for general control and power wiring Wiring that connects between the sheets or that ends at one point and starts at another 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 The reference system is explained on a sheet in each drawing set The unique wire numbering system serves as confirmation that the correct wire is being traced 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 The following tables identify general wire selections that will be encountered when installing the PowerFlex 7000 drive line up General Notes Adherence to the following recommended field power cabling insulation levels for medium voltage drives will help to ensure trouble free start up and operation The cable insulation level must be increased over that which would be supplied for an across the line application with the same rated line to line voltage Either shielded or unshielded cable may
272. only seen bus transients within their capability However caution should be taken if there is a harmonic filter on the MV bus to which PF7000 is connected The filter should satisfy relevant international or local standards such as IEEE Std 1531 Clause 6 4 to avoid high inrush currents The surge arrester is certified as per ANSI IEEE Std C62 11 1993 Certification tests include high current short duration tests low current long duration tests and fault current withstand tests The fault current withstand tests consist of different combinations of kA and number of cycles including a 20kA 10 cycle test under which the arresters are non fragmenting and without expelling any internal components When the incoming energy exceeds the handling capability of the arrester and causes arrester failure the housing is designed to split open to vent without causing damage to any adjacent components 7000L UM302B EN P June 2013 7000 C Frame Marine 7000 C Frame Marine Component Definition and Maintenance 4 11 Surge Arrester Replacement 1 Surge Arresters Ensure there is no power to the equipment Isolate the drive by lock out tag out To prevent electrical shock ensure the main power has been disconnected before working on the surge N arrester Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Failure to do so may result in injury or death Wait for a minim
273. operations screens only the files that are relevant to the operation being performed will be shown Only the root directory of the card is used as sub directories are not supported in the operator interface Select a Filename When working with existing files on the flash card it is necessary to pick a file from the directory in order to use in the operation being performed When the DIRECTORY screen is entered all files that are relevant to the operation are displayed The cursor up and cursor down keys are then used to select the desired file Pressing Enter will select the file and proceed with the operation Press the F10 key to abort the selection operation and return to the previous screen without continuing with the operation 7000L UM302B EN P June 2013 7000 C Frame Marine Loading Programs Firmware 7000 C Frame Marine Operator Interface 3 63 Enter a Filename When a new file is being created the DIRECTORY screen is used to enter the new filename Upon entering the screen all existing files relevant to the operation are shown as shown in Figure 3 90 DIRECTORY Filename Figure 3 90 Typical File Selection An existing filename can be used as a basis for the new filename by first selecting that filename Press the F2 key The filename can now be edited Refer to the section entitled Edit Text for further details When complete pressing the Enter key will proceed with the op
274. or for 6 devices whether they are SCRs or SGCTs Physically on the OIBBs there is provision for 18 devices for the inverter and the rectifier The top OIB board on the OIBB is for the A devices the middle OIB board on the OIBB is for the B devices and the bottom OIB board on the OIBB is for the C devices Test points for the OIB gating diagnostic and temperature feedback signals are on the OIBB 7000 C Frame Marine 7000 C Frame Marine Component Definition and Maintenance 4 113 Each OIB board also has input RX7 for a signal from a Temperature Feedback Board The quantity and location of thermistor connections is dependant on the drive configuration Typically there is one temperature sensor from the Line Converter and one temperature sensor from the Machine Converter each going into the respective OIB board in the A position However some drive configurations only require one thermistor feedback connection The temperature feedback connection on OIBC is not implemented on the OIBB and is never used For more information see the drawings supplied with your drive The alarm and trip setpoints for each of these signals are programmable in software There are 3 LEDs on the OIB board and the following table illustrates the status and description for the LED states LED Status Description D1 Red On Run The OIB has received an Enable signal and is enabled to send and receive gating commands
275. ork Fuse Replacement 4 19 Metal Oxide Varistor Replacement eese 4 10 Surge ATIeSLets i1 egere dne eee e lee etat 4 10 IDEeseripionk etr oett oreet pp eI tra 4 10 Operation encre tee er tete eerte era 4 11 Surge Arrester Replacement n 4 12 Field Test and Care eee 4 13 Output Grounding Network Capacitor Replacement 4 13 Ground Filter Replacement eene 4 15 Hall Effect Sensor Replacement eese 4 17 Current Transformer CT Replacement 4 18 Filter Capacitor Cabinet e 4 19 Filter Capacitors eee dena 4 19 Filter Capacitor Replacement see 4 20 Testing Filter Capacitors ii 4 21 Converter Cabinet Components ie 4 23 Converter Cabinet 4 24 7000 C Frame Marine Chapter 4 Component Definition and Maintenance cont 7000 C Frame Marine Table of Contents PowerCagelM il ten etie tete Het e redi 4 24 SGCT and Snubber Circuit eese 4 27 Uniform Clamping Pressure eere 4 27 Checking Clamping Pressure eee 4 28 Clamping Pressure Adjustment eese 4 28 Temperature Sensing c iii 4 29 Symmetrical Gate Commutated Thyristor Replacement 4 30 Silicon Controlled Rectifier and SCR Self Powered Gate Driver Board Replacement usse 4 3
276. ound 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 the ground conductor was not connected the monitored low voltage signal could then rise up to medium voltage potential which is a serious hazard that must be avoided at all times You must always ensure the ground conductors on the VSB are securely connected before applying medium voltage to the drive ATTENTION Failure to connect both ground connections on the voltage sensing board will result in high i potential in the Low Voltage cabinet within the drive which will result in damage to the drive control and possible injury or death to personnel Output Grounding Network Reconnect the ground connection on the OGN capacitor The bolt connection should be torque down to 3 4 Nm 30 Ib in Exceeding the torque rating of this connection may result in damage to the capacitor Failure to reconnect the OGN ground may result in the neutral voltage offset being impressed on N the motor cables and 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 Re install the fuses on the TSN 7000 C Frame Marine www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second
277. owly push the Chill block assembly into the PowerCage Ensure that the stabs are aligned with their connectors at the back of the PowerCage This is difficult to see When the stabs are properly aligned and in place the chill block assembly will be seated squarely and the support bracket should be resting on the PowerCage base when positioned correctly Note If the stabs are not seated properly in the brackets damage can occur Measure the snubber resistance and sharing resistance to ensure that contact has been made If rear access to the drive is available remove backplates and visually verify When sure that the chill block stabs are properly positioned replace the M8 and M10 bolts and tighten Magnetized sockets are recommended with 40 cm extensions Re connect the coolant system to the chill blocks Reconnecting the coolant system before re installing the SCR SGCTs ensures no coolant is spilled on the devices or circuit boards Replace SCR SGCT and circuit boards explained in SGCT Replacement Procedure and Replacing the Silicon Controlled Rectifier Readjust the clamping load as described in Checking Clamping Pressure 7000L UM302B EN P June 2013 4 42 Component Definition and Maintenance PowerCage Removal 1 Ensure there is no power to the equipment and Replacement ATTENTION To prevent electrical shock ensure the main power has been disconnected before working on the drive board Verify that all cir
278. part of the chill block assembly Servicing of resistors requires that the chill block be removed from the PowerCage See Chill block Removal and Replacement 1 Remove the chill block outlined in Chill Block Removal and Replacement 2 Note all connections for correct replacement 7000 C Frame Marine Component Definition and Maintenance 4 47 3 Remove the screws holding the bus bars to the resistor terminals The position of the sharing resistor is common on all drive sizes The number of snubber resistors varies with the size of drive and application Shown below is a three snubber resistor configuration There can be up to 5 snubber resistors on each chill block Sharing Resistor Screws and bus bar to be removed Snubber Resistors Figure 4 36 Snubber and Sharing Resistor Replacement 4 After removing the bus bars unscrew the two screws holding each resistor in place Measure each resistor on the assembly to verify which resistors are damaged 5 Apply a thin layer of Electrical Joint Compound Alcoa EJC No 2 or approved equivalent to the contact faces of the new resistors to be installed The recommended procedure is to apply the compound to the pole faces using a small brush and then gently wiping the pole face with an industrial wipe so that a thin film remains Examine the pole face before proceeding to ensure that no brush bristles remain 6 Install the new resistor s on the chill plate and replace th
279. pear on your laptop screen C Manzoor Software PF7000x1 PY_FRN4 006 dosfwdlexe FRN_4006 FM download acknowledged by terminal Terminal verifying file and preparing for transfer 7 The screens shots copied below show the progress status of firmware file transfer Manzoor Software PF7000 1 P _FRN4 006 dosfwdl exe FRN_4006 FMW download acknowledged by terminal File transfer started 34 FRN_4906 FMW download acknowledged by terminal File transfer started 100 Download successfully completed Hit any key to continue 7000 C Frame Marine Component Definition and Maintenance 4 127 8 Once the firmware download is complete the message Download successfully completed will appear on your laptop screen At this point press any key to close the DOSFWDL program 9 Now remove the serial cable from your laptop and connect it to ACB board port J12 The Terminal will now start communicating with the drive Setting up Diagnostic The diagnostic trending is a valuable tool for troubleshooting faults Trending in the drive It is a method of capturing the variation in the values of different variables over a period of time prior to and after a fault or warning condition In the PF7000 drive with ForGe control the maximum number of parameters that can be assigned for trending is 16 The length of the trend buffer is 100 samples Diagnostic Setup The diagnostic setup is used to defin
280. perly Both of the above could indicate A possible trouble spot Tell what causes the trouble spot Give the result of an improper action Tell the reader how to avoid trouble This symbol alerts the user to a potential electrical shock hazard that exists on a AN component or printed circuit board 7000L UM302B EN P June 2013 7000 C Frame General Precautions ATTENTION gt ATTENTION ATTENTION gt Preface P 3 This drive contains ESD Electrostatic Discharge sensitive parts and assemblies 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 reference Allen Bradley publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook An incorrectly applied or installed drive can result in component 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 Only personnel familiar with the PowerFlex 7000 Adjustable 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 Wh
281. pper and lower manifolds Use a Phillips screwdriver to remove the brace angle of the SGCT Retain the brace angle and its hardware The SGCT can be destroyed or damaged by static charges Personnel must be properly grounded N before removing the replacement SGCT from the protective anti static bag that it is supplied in Use of damaged circuit boards may also damage related components A grounding wrist strap is recommended for handling sensitive circuit boards 7000L UM302B EN P June 2013 7000 C Frame Marine 7000 C Frame Marine Component Definition and Maintenance 4 31 SGCT Brace Figure 4 22 Replacing the SGCT Brace Angle IMPORTANT SGCTs come in matched sets in systems with 10 11 12 more than one device per leg When replacing the device it is necessary to replace all devices in the matched set even if only one has failed While grounded remove the SGCT from the anti static bag it is supplied in Assemble the brace angle from the old SGCT to the new SGCT Apply a thin layer of Electrical Joint Compound Alcoa EJC No 2 or approved equivalent to the contact faces of the new SGCTs to be installed The recommended procedure is to apply the compound to the pole faces using a small brush and then gently wipe the pole face with an industrial wipe so that a thin film remains Examine the pole face before proceeding to ensure that no brush bristles remain IMPORTANT
282. quired the trigger type the trigger condition and the trigger value These are selected for modification by pressing the F9 F2 and F3 keys respectively If nothing happens then you have not gained the required access to make changes Press the F8 key and refer to the section entitled Enter Modify an Access Level to gain access There are two types of triggers possible A Single trigger occurs once and stops The trigger must then be manually re armed This is the default type of trigger A Continuous trigger will re arm itself and continue to collect new trends until viewing the contents of the captured data stops it The current type of trigger is shown by either a C or S in front of the Trigger label refer to Figure 3 81 To switch between the two types press the F9 key The trigger condition and trigger value are set with the F2 and F3 keys respectively When the respective field is in reverse video that field may be modified The condition is set to one of the conditions listed below by pressing the cursor up or cursor down keys to scroll through the conditions Pressing enter ends the editing and accepts the shown condition Trigger Conditions Equal to N Not Equal to gt Greater than lt Less than Boolean OR N Boolean NOR amp Boolean AND N amp Boolean NAND 7000 C Frame Marine 7000 C Frame Marine Operator Interface 3 57 The value data is set through the use
283. r RPTX AFE rectifier for connection to remote transformer RPDTD Direct to Drive Technology Table A 1 Catalog Number Descriptions Catalog Number Description 7000A PowerFlex 7000 A Frame Variable Frequency AC Drive Air cooled 7000 PowerFlex 7000 B Frame Variable Frequency AC Drive Air cooled 7000L PowerFlex 7000 C Frame Variable Frequency AC Drive Liquid cooled 7000 C Frame Marine 7000L UM302B EN P June 2013 A 2 Catalog Number Explanation Drive Selection Table A 2 Service Duty Rating Continuous Current Rating and Altitude Rating Code Continuous Current Capability Service Duty Rating and Altitude Rating Code Code Rating A Normal Duty 40 40 Amp 0 1000 m Altitude 40 C Ambient 46 46 Amp 53 53 Amp B Normal Duty 61 61 Amp 1001 5000 m Altitude 70 70 Amp 2000 m Altitude 37 5 C Ambient 81 81 Amp 3000 m Altitude 35 0 C Ambient 93 93 Amp 4000 m Altitude 32 5 C Ambient 105 105 Amp 5000 m Altitude 30 0 C Ambient 120 120 Amp 140 140 Am C Heavy Duty l 160 160 Am 0 1000 m Altitude 185 185 Amp ena m 1001 5000 m Altitude P 2000 m Altitude 37 5 C Ambient 285 Ze Amp 3000 m Altitude 35 0 C Ambient 325 325 Amp 4000 m Altitude 32 5 C Ambient 375 375 Amp 5000 m Altitude 30 0 C Ambient 430 430 Amp Z Custom Configuration Contact Factory Table A 3 Nominal Line Voltage Control Volt
284. r wiring If assistance is needed contact your local Rockwell Automation Sales Office Power Cabling Access The drive is built with provision for either the top or bottom power cable entry Cable access plates are provided on the top and bottom plates of the connection cabinet identified by the customer specific dimension drawing To Access the Customer Power Cable Terminations e 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 e Note that there is a key interlock to prevent swinging the low voltage control compartment open unless the medium voltage source is locked out e 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 compartment e Slowly pull the handle so that the low voltage compartment swings out The power terminals are now visible The installer is responsible for modifying the power cable access plates to suit the requirements Note that appropriate connectors must be used to maintain the environmental rating of the enclosure 7000 C Frame Marine 7000L UM302B EN P June 2013 2 52 Drive Installation
285. rea in which the drive is located should be free of radio frequency interference such as encountered with some welding units This may cause erroneous fault conditions and shut down the drive H The equipment must be kept clean Dust in the equipment decreases system reliability and inhibits cooling D Power cable lengths to the motor are virtually unlimited due to the near sinusoidal voltage and current waveforms Unlike voltage source drives there are no capacitive coupling dv dt or peak voltage issues that can damage the motor insulation system The CSI PWM topology utilized in the PowerFlex 7000 medium voltage AC drive has been tested with motors located up to 15 km 9 3 miles from the drive J Only personnel familiar with the function of the drive should have access to the equipment K The drive is designed for front access and should be installed with adequate and safe clearance to allow for total door opening The back of the unit may be placed against a wall although some customers prefer back access also If back access is desired set drive 300 mm 12 inches out from wall An incorrectly applied or installed drive can result in component damage or a reduction in N product life Ambient conditions not within the specified ranges may result in malfunction of the drive 7000L UM302B EN P June 2013 7000 C Frame Marine Installation Joining Shipping Splits 7000 C Frame Marine Drive Installation
286. rent methods are dependent on what drive option the customer has chosen 1 Line Reactor Drive refer to Figure 4 45 2 Remote Transformer and Starter refer to Figure 4 46 Ride Through Standard controls with 5 cycle ride through The drive main control boards will remain energized for a total of 5 cycles after control power is interrupted If control power is not restored during the 5 cycles a controlled shutdown will occur 7000 C Frame Marine Component Definition and Maintenance 4 59 Figure 4 45 illustrates the control power distribution for 6 pulse and PWM drives with integral starter line reactor Printer C Hold up P Operator Interface Relays gt 5V LOGIC Customer Supplier 120V 1 ph Li AC DC Converter e MEE 56V DC od 1000W 1500W O DC Fail CD 380V 50Hz or Line 460V 60Hz Reactor 3 ph Fan VFD O 7000 C Frame Marine 15V LOGIC DC DC CONVERTER 24V HECS 424V ISOLATORS 24 XIO SENSE CABLE 20V Isolated Gate Driver Power Supply 20V Figure 4 45 AFE Line Reactor Drives 7000L UM302B EN P June 2013 4 60 Component Definition and Maintenance Figure 4 46 illustrates the control power distribution for 6 pulse and AFE drives with remote transformer starter or integrated line reactor with remote starter
287. ress F2 UTILITY F7 TRANSFER and F4 PARAMETERS You should now be on the following screen uses om xs w en In order to save parameters to the Operator Interface Terminal press F5 DRV gt MEM To save to the Flash Card you must first insert the card in the terminal Remove the back cover and insert the card in the slot on the terminal It can only go in one way Then press F4 DRV gt CRD 7000 C Frame Marine 7000 C Frame Marine Component Definition and Maintenance 4 119 Saving to the card means that you will have to choose a file name Use the Up and Down arrows to select the character and then use the Right arrow to go to the next character Press the Enter key when finished FILENAME 2882 PRR DRIUE TO FILE PROCEED Yes No Operation Status TRRNSFER PENDING Panes om ves w exit Press F8 for YES and the parameters will be transferred to the card Press F10 to EXIT Here is a typical pin out of a complete null modem cable Essentially only 3 pins 2 3 and 5 are all that is required 9 Pin Female Connector Pin 9 Pin Female Connector Pin 1 DCD RED E 2 TXD BRN m 3 RXD BLK 4 DTR GRN 5 COM BLU 6 DER WHT 7 RTS YEL 8 CTS si NC SHLD m 9 Pin Male Connector Pin 9 Pin Male Connector Pin RTS 7 CTS 8 TXD 3 RXD 2 DSR6 COMO DTR 4 DCD 1 Case 7000L UM302B EN P June 2013
288. rifugal deep well Normal No Vane type positive displacement Contact Factory Yes Separators air fan type too wo Noma No 7000L UM302B EN P June 2013 7000 C Frame Marine Appendix B Torque Requirements for Threaded Fasteners Unless otherwise specified the following values of torque are to be used in maintaining the equipment DIAMETER PITCH MATERIAL Torque N m Torque Ib ft 7000 C Frame Marine 7000L UM302B EN P June 2013 B 2 Torque Requirements 7000L UM302B EN P June 2013 7000 C Frame Marine Drive Meggering Meggering the PowerFlex 7000 7000 C Frame Marine Appendix C 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 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
289. rior to this you may cancel all of the changes made after coming to the screen by pressing the F7 key 7000 C Frame Marine 7000L UM302B EN P June 2013 3 40 Operator Interface 7000L UM302B EN P June 2013 Fault Masks A number of the faults within the drive may be selectively enabled or disabled by you To view or modify the current fault mask settings use the up down arrow keys on the SETUP screen to select the Fault Masks option and press the enter key A typical screen as shown in Figure 3 50 shows all of the user maskable faults Associated with each fault is the state of the mask If OFF it means the fault is disabled and will not occur The normal state is ON or enabled To change the state of the mask use the cursor up or cursor down keys to select the desired fault and press the enter key Each press of the enter key will toggle the state of the mask as shown in Figure 3 51 If nothing happens you do not have proper access to the drive Exit to the SETUP screen and refer to the section entitled Enter Modify an Access Level to gain access ine sum SW Watchdog HH Watchdog Line Stest Line Chksum Figure 3 51 Fault Mask OFF Figures 3 50 and 3 51 show all fault masks regardless of their current state The fault masks can be viewed according to their state by pressing the F7 key on the FAULTS SETUP screen This will display the FAULTS OVERVIEW screen typical of Figures 3 52 and 3 53 7000
290. rized modifications From this screen press the F8 key The level will change back to Monitor as shown in Figure 3 32 The default value for the password PIN of the Basic and Advanced levels is zero 0 or simply pressing the enter key This value can be changed from the ACCESS screen First use the up down cursor keys to select the level for which you wish to modify the PIN Press the F9 key The typical PASSWORD CHANGE screen shown in Figure 3 35 is displayed showing the Access Level for which the new PIN will be applied to PASSWORD CHANGE Basic Enter Password acres r Figure 3 35 PIN Change Enter the current PIN value via the data keys 0 9 and press the enter key As in the ACCESS screen the entered value is shown via placeholders and may be edited with the backspace key If you entered the correct PIN the screen now asks you for the new PIN Type in the new PIN value using the data entry keys 0 9 followed by the enter key The screen now asks you to verify the new PIN Type in the new PIN again followed by the enter key as shown in Figure 3 36 7000 C Frame Marine Operator Interface 3 31 PASSWORD CHANGE Basic Enter Password Enter New Password seek Verify New Password seek Status Password Changed ues I I Ten Figure 3 36 PIN Change Completed At the end of the operation you will see a status as shown in either Figures 3 36 3 37 or 3 38 dependin
291. s displayed The trend buffers may only be viewed when their status is stopped If in continuous mode the capture will stop when the buffers are viewed To view the trend buffers press the F9 key 7000 C Frame Marine Flash Memory Transfers 7000 C Frame Marine Operator Interface 3 59 DIAGNOSTICS Trigger U line Single Status Stopped Last Trigger 14 15 35 66 16 66 Gee roe TT Figure 3 85 Diagnostic Stopped DIRGNOSTICS UIEM Y Of 13 Trace 1 Trace 2 Trace 3 Trace 4 CH Hz Cpu Cpu PUUN UW VIVA wu 4 9 9 1 5 1 3 2 3 3 9 3 2 4 9 4 COCACACACACACA 4 1887 rus Tres repe 7s Figure 3 86 View the Trend Buffer s A screen such as Figure 3 86 will be shown Upon initial entry the screen will be positioned to the trigger point shown by the T gt To view data either side of the trigger point press the F8 and F9 keys Changes made to the diagnostic list setup are not permanent unless they are saved to the NVRAM in the drive Upon exiting the DIAGNOSTICS screen Figure 3 79 you will be prompted to save the changes to NVRAM Refer to the section Message Prompting for further details Flash memory is used to store data in a non volatile environment that is it is not lost when power is removed The operator interface contains flash memory in two forms The first is built into the operator interface This form of flash is used to store the operator inter
292. s with or without an air gap in series packed in sealed housing They provide overvoltage protection similar to what the TSN module does They differ from the TSN in that fusing is not required for the operation of surge arresters There are 3 types of surge arresters depending on the voltage class of the drive as shown in the table below Drive voltage 2 4 kV 3 3 kV 4 16kV 4 8 kV 6 0 6 9 kV Arrester rating RMS 3 kV 6 kV 9 kV Arrester MCOV RMS 2 55 5 10 7 65 The most severe temporary overvoltage occurs when one phase is grounded in an ungrounded system The full line to line voltage is applied to the arrester in this case The arresters are designed to operate under this condition continuously without any problems as shown by their Maximum Continuous Operating Voltage MCOV rating 7000L UM302B EN P June 2013 4 10 Component Definition and Maintenance Surge Arresters cont There are three Y connected surge arresters attached to the incoming MV lines The neutral point of the arresters is connected to the ground bus Drive input power from line terminals U V W Heavy duty distribution class surge arrester Operation The operation of arresters without a gap is the same as that of MOVs in the TSN Depending on design the arrester may also be gapped Both gapped and un gapped arresters provide adequate overvoltage protection The arresters are able to withstand or ride through most comm
293. s been coiled up and left hanging in the upper area of the motor filter capacitor section back up through the two grommeted cutouts back into the wireway There is a fiber optic cable in this bundle and care must be taken not to damage it The fiber optic cable control power wires and the XIO link cable will be required in the pump control cabinet Figure 2 20 Control Wiring 7000 C Frame Marine 7000L UM302B EN P June 2013 2 18 Drive Installation Control Wiring 4 Route the 8 gauge black and red twisted pairs of wire and the Belden Connections cont shielded cables down through the grommeted cutout into the AC DC power supply section Figure 2 21 5 Route the 3 fan control wires 2 cabinet over temperature control wires down through the grommeted cutout into the center of the DC choke section Figure 2 22 Figure 2 22 Fan Thermostat Control Wires 7000L UM302B EN P June 2013 7000 C Frame Marine Drive Installation 2 19 6 Route the control wires down through the grommeted cutout into the control power disconnect section Figure 2 23 7 Connect the numbered wires to the corresponding numbered terminal blocks Figures 2 24 to 2 27 Figure 2 23 8 Refer to the electrical drawing and make the above control wiring connections 56V DC Connections AC DC fails Belden Red Positive cable connections Black Negative Figure 2 24 Figure 2 25 7000 C Frame Marine 7000L UM302B EN P
294. s for proper clamp pressure and adjust as necessary Refer to User Manual Chapter 5 Component Definition and Maintenance for details on proper clamp pressure 7000L UM302B EN P June 2013 4 154 Component Definition and Maintenance Annual Maintenance cont 7000L UM302B EN P June 2013 Control Power Checks No Medium Voltage gt Apply 3 Phase Control power to the PF7000 drive and test power to all of the vacuum contactors input output and bypass in the system verifying all contactors can close and seal in Refer to Publication 1502 UM050_ EN P for a detailed description of all contactor maintenance Verify all single phase cooling fans for operation This includes the cooling fans in the AC DC Power supplies and the DC DC converter Verify the proper voltage levels at the CPT if installed AC DC Power Supplies DC DC converter isolated gate power supply boards Refer to Chapter 4 Commissioning for appropriate procedures voltage levels for the above checks Verify the proper gate pulse patterns using Gate Test Operating Mode If there have been any changes to the system during the outage place the drive in System Test Operating Mode and verify all functional changes Final Power Checks before Restarting gt gt Ensure all cabinets are cleared of tools and all component connections are back in place and in the running state Put all equipment in the normal operating mode a
295. s necessary for optimum MOV performance and protection Do not substitute other fuses without contacting the factory first Note Voltage sensing occurs after the MOV fuse and as a result open fuses will be detected in drive control as a Master or Slave Undervoltage or Unbalance Drive Input Power from Line Terminals ie x U V Ww Transient Suppression Network Medium Voltage Input Fuses Phase MOV Suppressor Ground MOV Suppressor Figure 4 5 Simplified Wiring Diagram 7000L UM302B EN P June 2013 4 8 Component Definition and Maintenance Transient Suppression Two sizes of fuses 5 kV 7 2 kV are available within the Transient Network Fuse Suppression Network TSN located inside the connection cabinet The Replacement 18 pulse drive contains three TSNs 1 Ensure there is no power to the equipment To prevent electrical shock ensure the main power has been disconnected before working N on the drive Verify that all circuits are voltage free using a hot stick or appropriate voltage measuring device Failure to do so may result in injury or death 2 Fuses are held in a place with a fuse clip To remove the fuse pull firmly 3 To replace the fuse hold it in position and push firmly until the fuse is seated within the fuse clip Install fuses so that the rating is visible Make sure to replace the fuse with another of the same rating See Figure 4 7 for location Location of ground Connecting links
296. s not sent to the drive until you exit the screen with the F10 key Prior to this you can modify the new value by repeating the above procedure or you can cancel the change by pressing the F7 key The CANCEL operation returns the new value to that of the actual value Analog Ports The drive contains a number of external analog ports to which you can assign any parameter To setup an analog port use the up down arrow keys on the SETUP screen to select the Analog option and press the enter key This will display a series of screens as shown in Figure 3 49 The screen shows the current tags and their tag code which are associated with each of the analog ports To change the tag attached to a port use the cursor up and cursor down keys to highlight the desired port and press the enter key If nothing happens then you have not gained the required access to make changes Exit to the SETUP screen and refer to the section entitled Enter Modify an Access Level to gain access 7000 C Frame Marine Operator Interface 3 39 Figure 3 49 Analog Setup This will begin the selection process of a tag as described in the section entitled Select a Parameter When you have completed the selection process the selected tag will be assigned to the port To remove an assignment to the highlighted port press the delete Backspace key The changes made do not take affect until you press F10 and exit the screen Any time p
297. s rs pes seed Pa ened rie Lorin arora pce oce AEA 220uS ECONOMIZED GATING EXTENSION i TP7 TRIGGER SCR GATE CATHODE P t o e alal H E0 0 us v ofa it 100 000000 us lt o gt i cw Jt Figure 4 42 Expansion of V Sense Trigger to SCR gating pulse 7000L UM302B EN P June 2013 7000 C Frame Marine Component Definition and Maintenance 4 55 Fiber Optic Cabling The equipment is provided with fiber optic cabling as a means of interfacing the low voltage control to the medium voltage circuits The user of the equipment should never need to change the routing of the fiber optic cables Each end of a fiber optic cable is provided with a connector that plugs and latches into its respective location on a circuit board To disconnect a fiber optic cable depress the ridged plastic tab at the end connector and pull To install a fiber optic cable insert the fiber optic port of the circuit board so that the plastic tab latches into place If the user finds it necessary to replace fiber optic cables great care must be taken to prevent the cables from becoming strained or crimped as a resulting loss in light transmission will result in loss in performance The minimum bend radius permitted for the fiber optic cables is 50 mm 2 0 inches When installing the fiber optic cable the colour of the connector at the end of the cable must match the colour of the connector socket on the circuit board Lengths of fiber optic cables
298. sistor bank Loosen screws to release capacitors Figure 4 11 Ground Filter Capacitor Resistor 7000 C Frame Marine 7000L UM302B EN P June 2013 4 16 Component Definition and Maintenance Hall Effect Sensor 1 Ensure there is no power to the equipment Replacement To prevent electrical shock ensure the main power has been disconnected before working on T the Hall Effect sensor Verify that all circuits are voltage free using a hot stick or appropriate mmm voltage measuring device Failure to do so may result in injury or death 2 Note the location of all wires and the orientation of the Hall Effect sensor For quick reference look for the white arrow when checking the orientation of the Hall Effect sensor look for the white arrow The Hall Effect sensor and wires must be in the proper orientation Note the position before disassembly 3 The round bus bar must be removed Remove the M10 hardware and slide the bar out 4 Remove the screws from the three terminals to allow removal of the ring lugs 5 Remove the four screws on the base of the Hall Effect sensor 6 Replace the Hall Effect sensor Note the arrow must be oriented as shown in the illustration below 7 Slide the bus bar back into place and secure with the M10 hardware 8 Fasten the ring lugs on the wires back into place in the correct position Do not overtighten or you will break the threaded stud Hall Effect Sensors Custom
299. ssage the Panel View will show COMMUNICATION ERROR Connect your PC to the DPM data port J4 Locate the PowerFlex 7000 Medium Voltage Forge Drive firmware an executable file BI PF 7KFirmware7001_G exe Double click on the file to download the firmware The executable program will open the following screen Modules Available for Download Bootcode FRN1 005 v Firmware FRN7 001 Cancel p ancel The DPM are preloaded with Bootcode and select the Firmware by clicking in the checkbox against Firmware and click OK This will start the process of the downloading of firmware attempting connection to the drive The following screen will be displayed J FORGE Download Utility 1 008 Port com v ABORT Download Brive Firmware FRN7 001 Module Status Attempting Connection to Drive Power 7000L UM302B EN P June 2013 4 122 Component Definition and Maintenance Preparation for The progress of the download is continously displayed on the screen Downloading Firmware as shown cont Download Drive Firmware FRN7 001 Module Status Downloading Firmware Power The completion of the download is displayed on the screen as shown EJ FORGE Download Utility 1 008 Port comi Y START Download Drive Firmware FRN7 001 Module Status Download Completed Successfully 7000 If the DPM does not have bootcode or needs an upgrade then first select the Bootcode by clicking in the
300. st level intended for normal operation is the Advanced level From this level the drive can be configured in its entirety Two additional levels are used for trained service personal and are only used when physical hardware changes are made to the drive Individual PIN numbers protects all levels except the first Use the up down cursor keys to select the desired access level Then enter the PIN value for the given access level and press enter If the correct PIN was entered the access level will change Refer to Enter Modify an Access Level for complete information on the use of Access Levels Various operations require that a parameter be selected AII selection operations are done via one of three methods described in this section All parameters are organized into groups Selecting via groups is the default method The screens associated with the selection process are called automatically as part of the operation from other screens Via Groups This is the default screen Figure 3 23 used in the selection of a parameter It shows all the groups that are accessible for the operation currently being performed For example if you are selecting a parameter any groups that are showing read only parameters only will not be shown The current access level will also affect the number of groups that are currently viewable and can be selected from If more than one page of groups exist press the F8 and F9 keys to view the other p
301. t 75 mm 3 inches If they have to overlap somewhere in the system then the power lines should be run at 90 to the signal lines Signal lines should also use twisted pair shielded cable and run in separate conduit that should be grounded to the building ground Encoder wires and shields should maintain continuity throughout from the encoder to the drive Avoid the use of a terminal block in a junction box This has the potential of creating radiated noise and ground loops The encoder case must be grounded to the building ground to insure proper and reliable operation Most encoders have provision for a case ground connection through the connector cable pair if a ground connection cannot be made through the mounting bracket machine ground DO NOT ground the encoder case through both the machine and cable wiring Use low capacitance wires lt 40pf ft with 100 shield coverage for long cable runs and connect the shield only at the drive end Encoder x H ES ies H I t t I i t1 lea aa i vA uA Wrong Shield LIT Connection de Figure 2 63 Detail Power Terminal Dimensions 7000 C Frame Marine Drive Installation 2 59 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 As a final precaution ground the
302. t makes text and graphics easy to read Bar chart meters are configurable for common process variables including speed voltage and load Everything is user friendly about the PowerFlex 7000L operator interface terminal including the greeting on the opening screen The terminal is designed for the greatest ease of use for start up monitoring and troubleshooting The setup wizard helps the user to set the required parameter menus by asking questions or prompting selections for desired operation Warnings and comments appear complete with help text to keep the user on the right track The setup wizard combined with the auto tuning feature allows the drive to be tuned to the motor and load as quickly and accurately as possible resulting in fast start ups smooth operation and less down time Up to five test modes are available including low voltage gate check and running at full current without motor connected Enhanced diagnostic functions are available on the operator interface terminal including separate fault and warning queues in non volatile RAM NVRAM extended fault text strings and on line help and trend buffers for 16 variables 7000 C Frame Marine Safety and Codes Unpacking and Inspection 7000 C Frame Marine Chapter 2 Drive Installation The Canadian Electrical Code CEC National Electrical Code NEC or local codes outline A provisions for safely installing electrical equipment Installation MUST
303. te a horizontal stack The sharing and snubber resistors on mounted on a plate with cooling tubes embedded within As cool liquid flows through the cooling tubes the entire plate is cooled which in turn cools the resistors Chill Blocks The chill blocks are constructed of highly conductive copper machined parts that are silver soldered together The parts are machined to a fine surface finish The copper chill block provides good heat transfer from the electrical device to the chillblock The coolant system is connected to each chill block with flexible 10 mm 3 8 in hose which fits onto stainless steel hose barbs which are part of the chill block assembly Chill Block Coolant Hose Figure 4 53 Chill Block Assembly Coolant Pumps Two pumps P1 and P2 are used to move coolant through the system Figure 4 54 One of the pumps is used as a backup The control logic alternates the primary and secondary pump once every eight 8 hours Ensure that the pumps never run dry as this will damage the pump seals Ensure the pumps don t cavitate pumping air pockets when filling the system 7000 C Frame Marine Pump Maintenance and Replacement 7000 C Frame Marine Component Definition and Maintenance 4 69 Pump Seal Replacement Waid Lil mae Do not run the pumps without coolant Ensure coolant is present in the system Damage to the A pump seals may result Isolate the pump by closing valve V4 and V11 or
304. ted by ethylene glycol and would contaminate the recycling facility It is imperative that iron and chloride free ethylene glycol is used This is pure ethylene glycol without corrosion inhibitors and other additives which increase the conductivity of the coolant In addition de ionized water may be added to the system for top up Distilled water can only be used when no de ionized water is available and when it is necessary to run the drive on line Using distilled water will significantly reduce the life of the ion exchange resin and also reduce the life of mesh filters 7000 C Frame Marine 7000 C Frame Marine Component Definition and Maintenance 4 81 Maintaining Coolant Ratio Mixing pure ethylene glycol and de ionized water produces the coolant used as the cooling medium in the liquid cooled PowerFlex 7000L Medium Voltage C Frame drive During operation the concentration of pure ethylene glycol and de ionized water may change due to fluid leakage or evaporation therefore the freezing point of the coolant may not be correct The following instruction detail the steps required to record and correct the freezing point of the coolant mixture Required items Glycol and battery tester Part No 80025 862 01 De ionized water 19 litre 5 gallon container Part 80025 784 60 Pure ethylene glycol 19 litre 5 gallon container Part 80025 784 61 1 Measure and record the reservoir coolant freeze
305. ted from any screen by pressing the F10 key and the cursor right key at the same time The screen will clear and a message will indicate that the screen is being printed as well as the percentage completed When complete the original screen will return Memory Dump The memory dump allows any directly accessible memory i e memory which is directly addressable and does not require access through a port to be monitored It is called from any screen except the PRINTER screen by pressing the F10 key and the cursor left key at the same time MEMORY SEGMENT 0046 AALAND DOBNU NDOO cc MOTENO NOTOWOO O NOANA NOT Coco C Cor QWs Dre MOD A 1 E E 4 i gets Figure 3 101 Data Segment Memory Dump The initial screen Figure 3 101 shows the data segment by default Each screen shows the segment in hex which is being viewed In the left column is the starting address in hex for the row of data Eight bytes of data are shown in Hex followed by the equivalent 8 ASCII characters if relevant Additional data within the segment is viewed by pressing the F8 and F9 keys 7000 C Frame Marine Operator Interface 3 73 To change the segment and or offset being viewed press the F7 key A display similar to Figure 3 102 will be shown Each successive press of the F7 key toggles between highlighting the segment and offset value The highlighted value is the field that is currentl
306. ter If the group you are currently viewing contains parameters press the F7 key The operator interface then allows you to select the parameter you wish to modify Refer to the section entitled Modify Parameters for further details If you have modified any parameters in the drive you will be prompted to make the changes permanent This prompt will occur upon exiting the DISPLAY GROUP screen Refer to Message Prompting for further details Custom Group From the DISPLAY GROUP screen Figure 3 67 you can select a group which you have custom defined by pressing the F7 key This custom group contains selected tags from one or more other groups arranged by you onto a single screen for more convenient viewing Figure 3 71 To assign a tag to the display use the cursor up and cursor down keys to highlight the desired item position and press the enter key This will begin the selection process of a tag as described in the section entitled Select a Parameter When you have completed the selection process the selected tag will be assigned to the item as in Figure 3 72 To remove a tag from the highlighted item press the delete Backspace key DISPLAY CUSTOM m Gase T L5 Figure 3 71 Display Custom Screen 7000 C Frame Marine View Drive Status View and Reset Alarms 7000 C Frame Marine Operator Interface 3 51 DISPLAY CUSTOM YU line Fes Toce T T L5 Figure 3 72
307. terface and the drive board This data can be displayed in either one of two formats the data shown in hexadecimal Figure 3 99 the data shown as a mixture Figure 3 100 of a control characters b printable ASCII characters c hexadecimal data PROTOCOL ANALYZER 1 of 13 RK 81 16 84 TR 18 66 16 82 a7 FS a8 RK 18 a6 Ta G1 66 66 GE ae Gi 16 64 BS 18 62 66 FS G1 4E GF 74 28 52 ED 65 61 64 79 26 26 20 SF 84 18 Figure 3 99 Hexadecimal Displayed PROTOCOL ANALYZER 1 Of 13 RK 61 DL ET TR DL AK DL ST F8 00 RK DL AK Ta 81 66 aa AK AK 81 DL ET RX DL ST 00 FS 61 N o t R TR RK y SF ET DL TR Figure 3 100 Mixed Format Displayed 7000 C Frame Marine 7000L UM302B EN P June 2013 3 72 Operator Interface 7000L UM302B EN P June 2013 Pressing the F7 key changes the format of the displayed data When data is shown as a mixture a particular value is displayed based on the priority defined above control characters is highest The RX row displays data received by the operator interface The TX row displays the data transmitted by the operator interface Print Screen The print screen operation allows a screen dump of the operator interface s display This requires the use of a second RS232 port communicating at 9600 Baud to an external computer Special software is required in the computer to receive the data and to interpret the data The operation is initia
308. that shown in Figure 3 93 will be shown except the operation will show MEMORY TO DRIVE To confirm the operation press the F8 key to proceed or the F9 key to abort Performing a MEMORY TO DRIVE transfer will overwrite the active parameters in the drive It will not affect the parameters stored within the drive s NVRAM After parameters have been downloaded you will be prompted to make the new parameters downloaded to the drive permanent Refer to section Message Prompting for further details Upload to Memory Card The parameters are read from the drive and stored on a memory card by pressing the F4 key The operator interface will enter the DIRECTORY screen in which a parameter filename can be entered Refer to the section entitled Enter a filename When the filename has been obtained the TRANSFER PARAMETERS screen such as that in Figure 3 94 will be displayed showing the filename indicating the operation you are about to perform and showing the current status of the operation 7000 C Frame Marine 7000 C Frame Marine Operator Interface 3 67 TRANSFER PARAMETERS FILENAME PUMP PAR DRIVE TO FILE PROCEED Yes No Operation Status TRANSFER PENDING Figure 3 94 Transfer File Parameters The screen will then ask you to confirm the operation Press the F8 key to proceed or the F9 key to abort Pressing the F4 key may restart an aborted transfer or one that failed To select
309. 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 ATTENTION Use caution when performing a Megger test appropriate the cause of the test equipment should be connected to ground High voltage testing is potentially hazardous and AN may cause severe burns injury or death Where It is recommended that the insulation levels be checked before energizing power equipment Performing a Megger test will provide a resistance measurement from the phase to phase and phase to ground by applying a high voltage to the power circuitry This test is performed to detect ground faults without damaging any equipment This test is performed by floating the drive and all connected equipment to a high potential while measuring the leakage current to ground Floating the drive implies temporary removal of any existing paths to ground necessary for normal operation of the drive 7000L UM302B EN P June 2013 C 2 Me
310. the ACB The pin numbers listed on the following pages refer to IFM pin numbers a Connection to ACB J8 Figure 4 70 Interface Module IFM Analog Inputs and Outputs The PowerFlex 7000 C Frame offers one isolated process current loop transmitter and three isolated process current loop receivers embedded into the control These are accessible on the ACB The isolated Process Output is configured as 4 20 mA The three isolated process inputs are individually configurable for either a range of 10 0 10V or 4 20 mA Refer to Programming Manual The following information will show the connections for each 7000 C Frame Marine 7000L UM302B EN P June 2013 4 98 Component Definition and Maintenance Current Loop Transmitter DSP 7000L UM302B EN P June 2013 The current loop transmitter will transmit a 4 20mA output to an external receiver The loop compliance on the transmitter is 12 5V Loop compliance is the maximum voltage at which a transmitter can generate to achieve the maximum current and is usually a function of the power supply voltage Therefore the PowerFlex 7000 C Frame transmitter can drive a receiver with an input resistance up to 625 ohms The figure below shows a block diagram of the transmitter 415V 415V Isolated DC DC Converter 5V D A FPGA gt A I
311. the PowerFlex 7000 Forge Control The encoder interface boards do not have any user accessible test points however buffered and isolated versions of each of the signals A A B B Z and Z are available on the ACB at test points TP45 TP50 Regardless of which type of encoder board the following conditions should be adhered to 1 Do not attach encoders with open collector outputs to the drive Acceptable outputs are Analog Line Driver or Push Pull 2 The drive will not operate properly if using single ended Quadrature encoders Rockwell Automation recommends using differential inputs only for these types of encoders Single ended outputs are only acceptable for Positional Encoders 20B ENC 1 amp 20B ENC 1 MX3 Encoder Interface This encoder interface allows the drive to be connected to a standard Quadrature Encoder The 20B ENC encoder interface provides 3 optically isolated differential encoder inputs for A and B phases as well as a Z track These inputs cannot be configured for use with a single ended Encoder Differential encoders only are supported The board also provides a galvanically isolated 12V 3Watt supply to power the attached encoder The 20B ENC 1 Encoder interface may be configured for 5V operation however Rockwell recommends operation at 12V Note Must be configured for 12V operation
312. then you have not gained the required access to make changes Press the F8 key in order to gain access and refer to the section entitled Enter Modify an Access Level This will begin the selection process of a tag as described in the section entitled Select a Parameter When you have completed the selection process the selected tag will be assigned to the meter i e V Line The name of the meter will have been changed to a default string as shown in Figure 3 16 for meter 2 METERS METER1 Speed Digital spdmeter Meter2 U line Voltage Digital vitmeter METER4 Power Digital pwrmeter 575 ases cancer Process eur Figure 3 16 Utility Meter V Line The text consists of 8 characters This text is displayed on the Top Level Menu along with the value and units of the tag Select the meter that you wish to modify via the cursor up and cursor down keys To modify the text press the cursor right key If nothing happens then you have not gained the required access to make changes Press the F8 key in order to gain access and refer to the section entitled Enter Modify an Access Level The first character position of the string will be in reverse video as shown in Figure 3 17 Refer to the section entitled Edit Text 7000 C Frame Marine Operator Interface 3 19 METERS Digital spdmeter M line g Digital vltmeter Digital purmeter Fuss cancer sess S cam Figure 3
313. tify a drive revision level of the terminal software and its part number revision level of the bootcode contained in the terminal revision level of various boards contained in the drive These are identified by name REVISION LEVELS DRIVE TYPE PowerFlex 7000 DRIVE NAME Powerflex 7000 SOFTWARE P N REV MUD Terminal 8189 xxx 801 PUSSO BootCode Complete Drive RCP Firmware ICP Firmware CIP Firmware rl eE Figure 3 20 Utility Rev Level To modify the user definable text string press the F8 key If nothing happens then you have not gained the required access to make changes Exit to the Top Level Menu screen and refer to the section entitled Enter Modify an Access Level A screen typical of Figure 3 21 will be displayed To modify the text refer to the section entitled Edit Text noting the following exception When the text has been entered as in Figure 3 22 the enter key has no effect Simply press the exit key F10 to accept the edited string Prior to exiting the screen the string can be returned to its state upon entry to the screen by pressing the F7 key 7000 C Frame Marine 7000 C Frame Marine Operator Interface 3 21 DRIVE TEXT DRIVE TYPE Powerflex 7000 DRIVE NAME gowerFlex 7000 Gee T_T pe Faso _ an Figure 3 21 Edit the Drive Name DRIVE TEXT DRIVE TYPE Powerflex 7000 DRIVE NAME Pump 18 Gee T_T pe Faso an Figure 3 22 Edi
314. times the operator interface did not receive data from the drive within a specified time period Chksum number of times the operator interface detected a checksum error in the data it received from the drive Discard number of characters discarded by the operator interface as they were not what was anticipated Control number of control codes that did not conform to the anticipated ACK or NACK The operator interface will have assumed ACK which if wrong will result in a time out error Segqnce number of responses from the drive that did not correspond to the last request sent 7000 C Frame Marine Operator Interface 3 71 To reset the above counters press the F8 key The BUFFERS show the current contents in hexadecimal of the Transmit TX and Receive RX buffers contained in the operator interface These buffers are circular in nature The Psh push and Pop values indicate the location in the buffer where the next character will be loaded or unloaded respectively If the values are equal then the buffer is empty To aid in viewing the buffer locations the cursor keys can be used to highlight the buffer contents The current location of the cursor is shown in reverse video in the mid right screen Protocol Analyzer The protocol analyzer is accessed from the COMMUNICATIONS screen by pressing the F7 key The screen shows the data and the relationship of the data exchanged between the operator in
315. ting Completed Transfer Data in Memory The operator interface contains long term storage in two forms Flash memory contained in the operator interface is used to store the firmware and optionally language modules and parameters used in the drive This information can also be stored on a removable flash card that can be taken to another drive In order to transfer information from the two forms of memory press the F7 key This displays a new screen Figure 3 87 from which all flash memory operations are performed Refer to the section entitled Flash Memory Transfers for instructions on these features Picking an Access Level Access Levels are used in the drive to protect parameters from unauthorized changes and to filter out the amount of information viewed Each access level takes on the parameters and permissions of the lower access levels The default access level is Monitor In this level only a small subset of the parameter database is viewable No changes are allowed to any configuration information 7000L UM302B EN P June 2013 3 22 Operator Interface Select a Parameter 7000L UM302B EN P June 2013 The next level is Basic This level and all levels above it allow changes to be made to any parameter that can be viewed The number of parameters viewable increases from the previous level This level will be sufficient for configuring and maintaining the drive for the majority of applications The la
316. tinuous rating of 105 amps with a normal duty service rating up to 5000 meters altitude Please note that the ambient temperature rating of the drive is reduced at higher altitudes If 40 C ambient is required at 1001 5000 meters altitude then a rating code of Z is required Catalog number 7000 C105DEHD R18TX has a continuous current rating of 105 amps with a heavy duty service rating up to 1000 meters altitude Note The factory should be contacted for assistance sizing air cooled drives that require greater than 150 overload Refer to Table A 5 for typical application load torque profiles to determine which drive overload rating is best suited for your application 7000 C Frame Marine 7000L UM302B EN P June 2013 A 4 Catalog Number Explanation Drive Selection When is a Tachometer Required 7000L UM302B EN P June 2013 A tachometer 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 to 0 1 Hz but less than 6 Hz 4 For minimizing restart times using the flying start capability in forward or reverse direction Power Flex Speed Regulation ut tachometer 6 15Hertz Above 15 Hertz Without Tachometer Not applicable With Tachometer 0 02 96 0 01
317. tion will be equal to A tag must be assigned to Trace 1 before the trigger value or condition can be set From this screen you may also set the interval between samples i e Rate and the location of the trigger point within the view buffer By default the trigger will occur in the middle of the buffer however you may change this by indicating the percentage of samples which will follow i e Post the trigger point 7000 C Frame Marine 7000L UM302B EN P June 2013 3 56 Operator Interface 7000L UM302B EN P June 2013 Assigning a Trace To assign a tag to a trace use the cursor up and cursor down keys Highlight the desired trace and press the enter key Since there are more traces then can be seen on a single screen use the up down arrow keys to extend the list to the additional traces on the screen If nothing happens then you have not gained the required access to make changes Press the F8 key and refer to the section entitled Enter Modify an Access Level to gain access This will begin the selection process of a tag as described in the section entitled Select a Parameter When you have completed the selection process the selected tag will be assigned to the trace as in Figure 3 81 To remove a tag from the highlighted trace press the delete Backspace key Setting the Trigger Once you have assigned a tag to Trace 1 you may proceed to set the trigger value Three items of information are re
318. tions are to be made per the electrical diagrams provided Side sheets of the enclosures are to be joined with thread forming screws using the available holes Liquid cooled Drives may require joining of the coolant pipes Some enclosure ratings may require the addition of silicone sealant where cabinets join together to prevent the possible ingress of dripping water For some Direct to Drive liquid cooled Drives 6600V 430A 495A 575A rated the Drive will be shipped in two sections as shown in Figure 2 3 7000L UM302B EN P June 2013 2 8 Drive Installation Joining Shipping Splits cont m i Lifting Angles n SPL DC LINK CAP CHOKE PUMP CAB dn CAB CAB 5 6 7 Connect the Sections 7000L UM302B EN P June 2013 Wood Skid 1st SECTION 2nd SECTION Figure 2 3 Typical Split Drive The 1st section consists of 5 cabinets The 2nd section consists of 2 cabinets Final placement requires that the 1st and 2nd sections are joined at final installation site Heavy Magnetic DC Link Chokes up to 4600 kg 10 000 Ibs are shipped inside DC Link Choke cabinet Professional Millwright Rigging contractors are required for safe final placement of Drive sections Field connect the following CPVC pipe splices 2 pieces Power Bus Splice Kit 4 pieces Ground Bus Splice 1 piece Control Wiring Tools Required not supplied Adjustable or socket wrenches for 6 10 1
319. to variable torque loads 8 Figure 1 3 Active rectifier PWM and its input current voltage waveforms 8 Line current b Line to line voltage at PCC b 7000 C Frame Marine 7000L UM302B EN P June 2013 1 6 Overview of Drive Direct to Drive Technology 7000L UM302B EN P June 2013 The PowerFlex 7000L with Direct to Drive technology allows you to connect supply power directly to the drive without an Isolation Transformer connect a new or existing motor directly to the drive without extra motor filtering Most Medium Voltage Drive Manufacturers use multi winding isolation transformers to mitigate unwanted harmonics by phase shifting the transformer secondary windings Depending on the topology the transformer can have up to 15 sets of secondary windings The disadvantages to this method are the high degree of drive and transformer complexity a very high component count and many interconnecting cables and connection points This leads to much higher maintenance requirements and lower reliability Manufacturers also use isolation transformers to protect motors from Common Mode Voltage stress When transformers are used they allow the motor neutral point to be connected to ground but with this method the common mode voltage that would otherwise be impressed on the motor is impressed on the transformer The disadvantage to this method is that increased transformer insulation and increas
320. topic help may also have related topics 7000 C Frame Marine Operator Interface 3 13 Press the backspace key to return to the previous level of help i e the previous related topic To exit help completely press F10 to return to the screen from which help was called HELP Rev lof 7 Fi HELP Calls the help text for the current screen F2 UTILITY Selecting this screen allows various operations of the terminal to be Viewed and or modified such as setting the clock Fs T Tres ra prev Po ext Figure 3 8 Help on Related Topic Softkey Help on Help The previous sections described how you can access help for a particular screen by pressing the F1 key while on that screen This also applies while in any of the help screens Pressing F1 while in a help screen will give you a help screen describing how to use the help system An example of a screen giving help on the help system is shown in Figure 3 9 As with the help screens previously described the screens will contain related topics To return to a previous screen of help information press the backspace key To return to the screen from which help was originally accessed press the F10 key HELP HELP 10f 2 Help is context sensitive The current screen determines the help text which is displayed To receive help on any screen goto that screen and press the Fi HELP key One 1 or more pages of text will be displayed
321. tor Interface 3 66 Download from Operator Interface 3 66 Upload to Memory Card 3 66 Download from Memory Card 3 67 Parameter File Format 3 67 Loading Language Modules 3 68 System Programming seen 3 69 Advanced Screen Operations ees 3 70 Communications Statistics eee 3 70 Protocol Analyzer iii 3 71 Print Screen ax ewe ets 3 72 Memory Dump eene enne 3 72 Database Download eee 3 74 Operator Interface Menu Hierarchy Chart What does it show e 3 75 How do you read it e 3 75 Example 2 pH ee etel 3 76 PowerFlex 7000 Terminal Menu Tree 3 77 PCMCIA Memory Card Installation Data Description dcn e ERO ce 3 79 Installing the Memory Card esses 3 79 Control Cabling Cabinet Components sese 4 1 Voltage Sensing Assembly sse 4 4 Voltage Sensing Circuit Board Assembly Replacement 4 5 Input Transient Protection esee 4 6 Transient Suppression Network TSN eese 4 6 Description 2 3 con natant aah tice 4 6 MOV Suppressor salivare aussi 4 6 MOV BUSE ie cete ete eene rage Se Fe rs 4 7 Simplified Wiring Diagram esee 4 9 Transient Suppression Netw
322. um of 10 minutes to allow the stored energy in the drive to be discharged Observe the location of the connecting leads Using proper method to ensure the leads are at ground potential Use temporary ground when necessary Detach the connecting leads Loosen the bolt that attaches the surge arrester to the ground bus Remove the arrester Remove temporary ground when applicable Replace the surge arrester with an equivalent one make sure that the voltage rating is the same Connect the leads to the surge arrester Surge arrester hardware to be torqued to 28 Nm 21ft Ibs n Figure 4 7 Surge Arresters 7000L UM302B EN P June 2013 4 12 Component Definition and Maintenance Output Grounding Network Capacitor Replacement 7000L UM302B EN P June 2013 Note When the surge arrester is disconnected from MV it is possible that a small amount of static charge is retained by the arrester As a precautionary measure install a temporary ground on the line end of the arrester and discharge the stored energy Remove temporary ground before the arrester is reinstalled To avoid electrical shock when removing the arrester from service consider it to be fully energized until both the line and ground leads are disconnected Field Test and Care No field testing is necessary The arresters do not require special c
323. uring the drive to the roof for roll and pitch concerns The hardware removed for the lifting angles are to be used to secure these brackets to the drive An additional mounting drawing specific for the order should be used to understand how to brace the drive to the vessel structure using these brackets If this drawing cannot be located please contact Rockwell Automation Sales office 7000L UM302B EN P June 2013 2 24 Drive Installation Window Area appears Blue lt if subjected to shock 7000L UM302B EN P June 2013 Shock Indication Labels Shock indication labels are devices that permanently record the physical shock to which equipment is subjected At the time of final preparation for shipment from the factory a shock indication label is installed on the inside door of the converter cabinet During the shipping and installation process drives may inadvertently be subjected to excess shock and vibration which may impair its functionality When the drive has been placed in its installation area the converter door is to be opened and the shock indication labels inspected The drive is shipped with a label that records shock levels in excess of 10G If these shock levels have been attained the chevron shaped window will appear blue in one of the two windows If these shock levels have been attained record the values There is a greater possibility of the drive having sustained internal damage if it has been subjected
324. used in the product include Duplex Simplex 5 0 meter 5 0 meter 5 5 meter 6 0 meter 6 0 meter 10 0 meter 6 5 meter 7 0 meter There is one duplex fiber optic for each thyristor which manages gating and diagnostic functions The healthy status of the thyristor is determined by the circuitry on the respective driver boards This information is then sent to the main processor via a fail safe light signal in the fiber optic The firing command for the thyristor is initiated by the main processor and transmitted to the appropriate gate driver board via the gating fiber optic The color codes of the connectors are BLACK or GREY is the transmitting end of the fiber optic BLUE is the receiving end of the fiber optic 7000 C Frame Marine 7000L UM302B EN P June 2013 4 56 Component Definition and Maintenance DC Link and Control Power Section i Power Transformer AC DC Power Supplies Fuse Blocks al TI i Can Liquid Cooled i AA DC Link Reactor Cooling Pipes is I of Figure 4
325. ve up to 15 sets of secondary windings Elimination of the isolation transformer reduces capital and installation costs saves on valuable floor space and increases overall system efficiency The AFE rectifier requires a switching pattern that complies with similar rules as the inverter The pattern used for the example shown in Figure 1 3 is a 42 pulse selective harmonic elimination SHE pattern which eliminates the 5 7th and 11 harmonics The integral input capacitors are designed to reduce the current harmonics of the higher order The filter transfer function technique is used to place the filter break frequency in a region where no harmonics are present This prevents the excitation of system harmonic frequencies Other factors that are considered when designing the filter are the input power factor and the requirement on Total Harmonic Distortion THD of input current and voltage waveforms The AFE rectifier is ideal when a distribution transformer is required to step down the distribution voltage to match the VFD and motor voltage The rectifier input current the rectifier terminal voltage and the line current and voltage waveforms are shown in Figure 1 3 The line current THD is approximately 4 5 while line to line voltage THD is approximately 1 596 THD of line voltage is a function of system impedance Input power factor with the AFE rectifier is equal to or greater than 0 98 for the typical speed and load range when applied
326. ventative Maintenance Schedule 7000L UM302B EN P June 2013 icon ROSTA B 1 Drive Mes serine ius iaia a de ee ate ees C 1 Meggering the PowerFlex 7000 eee C 1 Equipment Required eere C2 PLOCE QUIS dm reete tht etr ot ee ES C 2 Powerflex 7000 Maintenance Schedule D 1 7000 C Frame Marine Introduction Liquid Cooling 7000 C Frame Marine Chapter 1 Overview of Drive The PowerFlex 7000 represents the third generation of medium voltage drives at Rockwell Automation The PowerFlex 7000 medium voltage AC drive is part of the PowerFlex family of AC drive products The Allen Bradley PowerFlex family of Drives incorporates leading edge technology embedded communications and significant commonality across multiple platforms networks operator interface programming and hardware Designed for end users solution providers and OEMs PowerFlex 7000 liquid cooled drives meet applications ranging from 3 000 to 9 000 horsepower 2240 6715 kW The PowerFlex 7000L 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 is intended for use on a host of standard and specialty applications such as fans pumps compressors mixers conveyors kilns fan pumps and test stands Primary industries for these applications include petrochemica
327. waveforms for use with standard new and existing motors Inverter duty motors not required Motor temperature derating not required No additional dv dt or peak voltage stress to motor insulation system Tested up to 15 kilometers 9 3 miles cable distance between drive and motor Spacious cable termination cabinet for ease of use by installation contractor Cable termination stabs accommodate 3 cables in 3 cables out Direct to Drive or AFE rectifier 9cables in 3 cables out 18 pulse Top or bottom entry and exit of line and load cables 90 of drive losses are rejected outside the control room Integral liquid cooled DC link inductor reduces overall dimension and eliminates external interwiring Integral pumping panel includes Line supply c w disconnect and fusing Closed loop coolant system Iron and chloride free liquid ethyl glycol deionized water mixture Low conductivity coolant 1 2 micro Siemens cm Isolated from medium voltage Fully serviceable low voltage compartment isolated from medium voltage power Monitors coolant temperature flow level conductivity and pressure Redundant pumping system optional Automatic pump change over on pump failure 1 2 turn valves with quick disconnect couplers for pump replacement when drive is operating Full drip tray to contain any spilled coolant Drain and fill pump for convenient filling
328. werFlex 7000L B Frame results in significant advantages including 1 Simplification of the snubber design and a reduction in the size of the snubber capacitor by a factor of 10 2 Operation at a higher switching frequency 420 540 Hz hence reducing the size of passive components DC link inductor and motor filter cap by 5096 3 Improving performance of the drive 4 Reduction of component count hence improving reliability cost and size of the drive 5 Fail safe failure mode non rupture Anode Figure 1 5 SGCT with integrated gate drive left and unit cell structure right 7000L UM302B EN P June 2013 7000 C Frame Marine Overview of Drive 1 9 Specifications 7000 C Frame Marine Description Specifications ARCEM NEMA 3000 9000 hp Power Rating Liquid Cooled IEC 2240 6715 kW Motor Type Induction or Synchronous Input Voltage Rating 2 2400V 3300V 4160V 6600V Input Voltage Tolerance 10 of Nominal Voltage Sag 30 Control Power Loss Ride Through 5 Cycles Std Input Protection Metal Oxide Varistor MOV 18P Surge Arrestors AFE D2D Input Frequency 50 60 Hz 5 Input Short circuit Current Withstand 5 Cycle 3300 V 6000 V 25 MVA RMS SYM Basic Impulse Level 50 kV 0 1000 m Power Bus Design Copper Tin plated Ground Bus Copper Tin plated 6 x 51 mm A x 2 in Customer Co
329. with respect to the operation of the drive with an internal or external UPS The output of the UPS feeds a 300W AC DC Power Supply This is 20 of the standard AC DC Power Supply used in the drive because the load represented by the DC DC Power Supply is much smaller than the load of the IGDPS boards and we are able to reduce the size accordingly We still use the standard AC DC Power Supply to feed the IGDPS boards The 300W AC DC Power Supply has its AC input monitored by the UPS and the DC output is monitored by the ACB board for fault conditions There is also a hold up capacitor on the output of the 300W AC DC Power Supply to maintain the 56VDC in the event of a failure of the power supply UPS Replacement Procedure 1 Ensure Control Power has been isolated and locked out 2 Remove the hardware that fastens the holding bracket to the cabinet assembly and remove the holding bracket 3 Disconnect the input and output wiring connected to and from the UPS Disconnect the 15 pin status plug from the UPS Remove the UPS and install the new UPS Reconnect all the connections removed in the previous steps SS Oy pns cue Before reconnecting the mounting bracket apply control power to the unit and ensure the UPS is programmed for AS400 communication protocol Refer to the manual that comes with the UPS for instructions 8 Once this has been confirmed install the mounting bracket 7000L UM302B EN P June 2013 7000 C Frame
330. ximum Load Site Dependent Additional Tasks Investigation Depends on Nature of the Problem Informal Training Refresher 2 0 hours Spare Parts Analysis 1 0 hours Vacuum Bottle Integrity Check 3 0 hours Final Report 3 0 hours Note indicates that the time may not be required depending on the nature of the maintenance and the condition of the drive system These times are only estimations 7000 C Frame Marine 7000 C Frame Marine Component Definition and Maintenance 4 157 Tool Parts Information Requirements The following is a list of the tools recommended for proper maintenance of the PF7000 drives Not all of the tools may be required for a specific drive preventive procedure but if we were to complete all of the tasks listed above the following tools would be required Tools 100 MHz Oscilloscope with minimum 2 Channels and memory 5kV DC Megger Digital Multimeter Torque Wrench Laptop Computer with Relevant Software and Cables Assorted Hand Tools Screwdrivers Open Ended Metric Wrenches Metric Sockets etc 5 16 Allen Keys Speed Wrench Feeler Gauge Vacuum Bottle Checker or AC Hipot Minimum of 7 5 kV Hotstick Potential Indicator Minimum of 10 kV Safety Gloves Vacuum Cleaner with Anti static Hose Anti static Cleaning Cloth No 30 Torx Driver Documentation PF7000 User Manual Publication 7000 UM151_ EN P
331. y Rockwell 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 PP 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 i
332. y being edited MEMORY SEGMENT 6646 New Address a 3 3 6 3 4 a C Com cCONcCOCO 2 6 3 7 3 4 F BGG 7 a a 8 5 D 8 0 ADDRESS NEXT PG PREU PG EXIT Figure 3 102 Edit the Segment Offset The segment offset address is edited via the numeric keypad and the arrow keys All values of 0 9 can be entered directly via the numeric keypad To enter a value of A F the cursor up and cursor down keys must be used to cycle through the possible values Note that the value 0 9 can also be entered via this method Once a digit has been entered via the arrow keys it must be accepted by means of the cursor right key The value may be edited via the cursor left key which acts as a backspace to remove the last digit entered The value is accepted by pressing either the enter or F7 key The edited segment offset can be aborted by pressing the delete key To accept the segment offset value entered press the enter key The screen will show the data at the entered address as shown in Figure 3 103 MEMORY SEGMENT AGGG aa a cnmavccemcc ANUOOALH O CODIDCOCOCD c CO Cc Jc PALO CODO Cap p Cocococo p Coo a 1 6 1 a 8 B 6 i Ut Figure 3 103 Data at New Address 7000 C Frame Marine 7000L UM302B EN P June 2013 3 74 Operator Interface 7000L UM302B EN P June 2013 Database Download The database download operation allows the operator inter
333. y modify the parameters for which you can view at the given access level At power up the operator interface access level is Monitor If this is the current mode and you wish to change any of the setup data press the F8 key now in order to change the access level before proceeding into any of the other setup operations available from this screen Figure 3 40 Refer to the section Enter Modify an Access Level Current Access Monitor AIO Fault Masks External Text Setup Wizard Parnes access ua se err Figure 3 39 Setup Screen 7000 C Frame Marine Operator Interface 3 33 Current Access Basic AIO Fault Masks External Text Setup Wizard aes access Teese enr Figure 3 40 Basic Access Level Language Selection The drive is capable of supporting multiple languages The operator interface supports these languages via language modules which must initially be loaded via the flash card refer to the section Flash Memory Transfers To select an alternate language press the F9 key on the SETUP screen The screen will show all language modules currently loaded as in Figure 3 41 Associated with each language is a module revision level Use the cursor up and cursor down keys to select the desired language and press the enter key The operator interface will switch to the new language selected It is possible for other devices attached to the drive to request a language change If th

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