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PowerFlex 7000 Medium Voltage AC Drive Air-Cooled

1. i V aam sl 4 op lt Sp DIN 2 Z 74 79 E q 5 Rae D SEE S Sot SS E BS KIA Se K C x N x X LR x 5 oO 5 oO 5 J fo 5 J F a ER SIR Zl IR E x S sf SS SES _ SS 1 E 18553 pe S SS er S I mEn kez R Za a c 5 SI q L 00 O re l MHI Y Y g 2 Module Housing n Temperature Feedback Board Clamp Head z Figure 23 3300 4160V Four Device Rectifier PowerCage with SPS Boards installed SPS Mounting Assembly with Clamp Base Matched Set Temperature Feedback Board Matched Set Clamp Head Two SGCTs Two SGCTs Q Heat sink SPS Mounting Board Assembly without Module Housing Temperature Feedback Board Rockwell Automation Publication 7000 IN012B EN P June 2014 41 Chapter4 Commissioning the Drive
2. U U UD U 2 Clamp Base Matched Set Two SGCTs Temperature Matched Set Two SGCTs Clamp Head Feedback Board 43 Rockwell Automation Publication 7000 INO12B EN P June 2014 Chapter 4 Commissioning the Drive Figure 27 Snubber Circuit Assembly for SGCT module Rsh Cs 1 Rsn 2 Rsn 1 Cs 2 Anode Cathode Figure 28 Snubber Circuit Assembly heat pipe model a g Cee u Ee W EST Li RERIT I Desens E
3. Anode Cathode Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 In addition to the snubber circuit a sharing resistor connects in parallel with the SGCT The sharing resistor ensures the voltage s equal distribution among SGCTs connected in series Connect SGCTs 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 6500V This single device provides sufficient design margin for electrical systems with 2400V medium voltage supply At 4160V connect two SGCTs in series to provide a net PIV of 13 000V to achieve the necessary design margin Similarly connect three SGCTs in series at 6 6 kV providing a net PIV of 19 500V to achieve the necessary design margin To meet the cooling requirements of the SGCT place the SGCT between two forced air cooled heat sinks one heat sink on the anode and the other heat sink on the cathode The force on the SGCTs differs with the size of the device The clamp assembly on the right hand side of the inverter module generates these forces The SGCTs require uniform pressure to prevent damage and to ensure low thermal resistance Achieve uniform pressure by loosening the heat sink mounting bolts tightening the clamp then tightening the heat sink
4. oo oo Rockwell Automation Publication 7000 INO12B EN P June 2014 81 Chapter4 Commissioning the Drive There are low resistances between phases through a transformer winding and a high resistance between transformer windings Therefore the expected resistance measurements are listed in the table below Terminal Measurement Points Expected Resistance 2U gt 2V gt 2W Approximately 0 Q 3U gt 3V gt 3W Approximately 0 Q 4U gt 4V gt 4W Approximately 0 Q U gt V gt W Approximately lt Q If the measurement results are not as described above the inter wiring between the isolation transformer and drive needs to be re inspected Application of Medium Voltage Before running the drive with medium voltage configure the diagnostic trending to capture information in case of fault during commissioning ATTENTION Reset the trending before leaving the drive in production The diagnostic trending operation of the drive allows you to capture the relationships of 16 parameters over a period of time Trending is a valuable tool for troubleshooting the drive Diagnostics The PowerFlex 7000 drive captures parameters on a real time basis for later analysis The Diagnostics screen Figure 64 consists of s
5. lt m wauw z Control Signals Pan Outputs Single Phase Input Qlolalololo 4 TT FRONT VIEW So I 05 Z IEW E o g O o D D D D Figure 46 Terminal locations on AC DC Power Supply Cosel x vw ey ae en X m A d 1 8 o 7 L Single Phase TW Input eg 2226 DC S l y Outputs FRONT VIEW Control Signals wa O y 2 62 Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 DC DC Converter PS2 The DC DC converter has no provision for output power adjustments A green LED on front case of the power supply indicates that the power supply is functioning properly Using a Digital Multimeter measure each of the outputs of the DC DC converter to ensure that they meet the values specified on the electrical schematics Compare these measured values to those displayed on the Operator Terminal under the Metering group Record all plug values on the relevant Commissioning Guide data sheet If any values are out of the expected range a bad DC DC converter is suspect For additional information on how to troubleshoot the DC DC converter refer to the troubleshooting section Chapter 3 of the Technical Data manual publication 7000
6. LINE CONVERTER COMMON MODE CHOKE MACHINE CONVERTER L Mt X sccts X FS l SGCTs Ss LR hi b e L hd s 8 l e L kd L et T ka hd Ue FR z x E x x x x x c e aNs Figure 10 2400V AFE Rectifier with Separate Isolation Transformer REMOTE LINE CONVERTER Do ENE MACHINE CONVERTER ISTX e 6 RAAT D X SGCTs h x i SGCTs 7 ES x E 1U gt 29 X1 U ka Sr R vow 202 l l 2 iwo 20 8 l Wa A D i x z xX x xy UU x x __ x x x e 2000 e Figure 11 3300 4160V 18 Pulse Rectifier with Separate Isolation Transformer REMOTE DC LINK ISTX 4U Z1 LINE CONVERTER MACHINE CONVERTER E T Rockwell Automation Publication 7000 IN012B EN P June 2014 17 Chapter2 PowerFlex 7000 Overview 6600V Figure 12 6600V Direct to Drive transformerless AFE rectifier LINE CONVERTER COMMON MODE CHOKE MACHINE CONVERTER e gt gt 4 L SGCTs x SGCTs pou FF x y X IR z FS FS x x OM e o gl 6 S P L 1 gt L Go d 45 L Figure 13 2400V AFE Rectifier with Separate Isolation Transformer REMOTE LINE CONVERTER DC LINK MACHINE CONVERTER ISTX Sees e X sccTs X ES P Wsccis y x ES x b4 x x x ES x x E z 2U X1 U T1 1U a d 6 KJ o
7. Sharing Resistor Snubber Snubber Resistor Capacitor Test Point Measure capacitance SECT between heat sink and test point or from heat sink to heat sink Heatsink Heatsink Snubber test point Rockwell Automation Publication 7000 IN012B EN P June 2014 49 Chapter4 Commissioning the Drive Snubber Test Point 50 Figure 35 Snubber Capacitor Test shown with SPS Board installed Use Connector Terminal Screw for Testing Snubber Capacitor SGCT Cathode Wire Refer to Table 1 on page 46 to determine the appropriate snubber capacitance value for the current rating of the SGCT used The capacitance measured is actually affected by the snubber capacitor and other capacitance in the circuit including capacitance from the gate driver circuit You are actually looking for a consistent reading for all devices If the capacitor is out of tolerance refer to publication 7000 UM202_ EN P for Sharing Resistor Snubber Snubber Resistor Capacitor SPS Board J1 Test Point SGCT gt Heatsink Snubber Capacitor Wire detailed instructions on how to replace the snubber capacitor Rockwell Automation Publication 7000 IN012B EN P June 2014 Silicon Controlled Rectifier PowerCages Commissioning the Drive Chapter 4 Figure 36 shows the snubber circuit Figure 37 shows the physi
8. Disconnect SCR Phoenix connector from board Test points for Gate to Cathode The resistance value from gate to cathode should be between 10 20 Q A value close to 0 Q indicates that there is an internal short in the SCR An extremely high value indicates that the gate connection in the device has broken If a Gate to Cathode test reveals a damaged SCR refer to publication 7000 UM202_ EN P for the SCR replacement procedure Rockwell Automation Publication 7000 IN012B EN P June 2014 Snubber Resistance SCR Device Commissioning the Drive Chapter 4 Access to the snubber resistor is not required to test the resistance The snubber circuit test point is located within the PowerCage under the heat sinks For each device there is one test point To verify the resistance measure the resistance between the test point and the heat sink above Figure 42 Snubber resistance test Sharing Resistor Heatsink p Snubber Snubber Resistor Capacitor Fa Test Point Heatsink Resistance value between test point and heat sink to its left is snubber resistance ob To Gate Driver Board Refer to Table 2 on page 52 to determine the appropriate snubber resistance value for the current rating of the SCR used If the resistor is found to be out of tolerance refer to publication 7000 UM202_ EN P for the snubber resistor assembly
9. Sharing Resistor Snubber Snubber Capacitor To Gate Driver Board Resistor Test Point Heatsink P7 Heatsink SCR Resistance Measurement Measured Resistance Inverter Rectifier SCR only SCR Anode Cathode Resistance heat sink to heat sink k Q Lowest Highest Lowest Highest SCR Gate Cathode Resistance across SCR Phoenix Connector Q Snubber Resistance Test point Heat sink above Q Lowest Highest Lowest Highest Snubber Capacitance Test Point heat sink on Right pF Lowest Highest Lowest Highest Sharing Resistance Red wire from snubber Phoenix connector heat sink on left k Q Lowest Highest Lowest Highest Rockwell Automation Publication 7000 INO12B EN P June 2014 53 Chapter 4 54 Commissioning the Drive SCR Anode to Cathode Resistance Performing an Anode to Cathode resistance test verifies the integrity of the SCR Unlike the SGCT the SCR uses the snubber circuit to power the self powered gate driver boards The resistance measurement taken across each SCR should be constant an inconsistent value may indicate a damaged sharing resistor self powered gate driver board or SCR Using an ohmmeter measure the anode to cathode resistance across each SCR in the rectifier bridge while looking for similar resistance values across each device Easy access from the anode to cathode is available by going from heat sink to heat sink Figure 39 Figure 39 Anode to
10. e Speed regulation is based on a percentage of motor synchronous speed s Encoder to be mounted on the AC machine e Operational 15V DC Power Supply mounted in drive to power the encoder as a standard option with the encoder feed back card Customer is responsible for providing and mounting of encoder Sleeve bearing motors require the encoder to have an axial movement tolerance Recommended tachometers are shaft mounting type Magneto resistive models are more adaptable to harsh environments When installing the encoder body and electronics must be isolated from ground options available from the encoder manufacturer to accomplish this e There are usually limits on encoder cable lengths Ensure the maximum length is suitable for the application Rockwell Automation Publication 7000 IN012B EN P June 2014 General Reference Appendix A Table 12 Encoder Selection High Performance Motor RPM Minimum Tach PPR Recommended Tach PPR Vs ka Control HPTC sau ipi in 3000 1024 1024 1800 1024 2048 1500 1024 2048 1200 2048 2048 1000 2048 2048 900 2048 4096 720 4096 4096 600 4096 4096 450 4096 8192 360 8192 8192 300 8192 8192 Standard Control Mode 3600 600 3000 600 1800 1024 1500 1024 1200 2048 1000 2048 900 2048 720 2048 600 2048 Rockwell Automation Publication 7000 IN012B EN P June 2014 125 AppendixA Gen
11. B Frame drives e Drive specific Technical Data additional troubleshooting parameters and specification information for MV variable frequency drives 7000 TD002_ EN P e Transportation and Handling Procedures receiving and handling instructions for Medium Voltage variable frequency drive and related equipment 7000 IN008_ EN P e Installation Guide detailed installation and pre commissioning procedures and information Z000 IN007_ EN P e Operator Interface Guide HMI Offering with Enhanced Functionality s For drives equipped with the PanelView 550 HMI see 7000 UM151_ EN P Rockwell Automation Publication 7000 INO12B EN P June 2014 9 Chapter1 Important User Information General Precautions Commissioning Support Rockwell Automation provides the site and installation specific electrical and design information for each drive during the order process cycle If they re not available on site with the drive contact Rockwell Automation If you have multiple drive types or power ranges ensure you have the correct documentation for each specific PowerFlex 7000 product s A Frame for lower power air cooled configurations up to approximately 1250 hp 933 kW s B Frame for higher power air cooled configurations heat sink or heat pipe models s C Frame for all liquid cooled configurations and assemblies Static control precautions are required when installing testing servi
12. a dialog shown in Figure 67 will be displayed to help compose the hexadecimal value Check the applicable options and click OK Figure 67 Binary Trigger Parameter fiE P 569 DrvStatus Flag1 x T Running T Reverse Rotn T Faulted T Warings T Fans On T Input Closed T OutputClosed A e Enum Parameter A dialog Figure 68 provides a list of possible values Select the desired value and click OK Figure 68 Enum Trigger Parameter P 4 Operating Mode x DB Gate Test The Post Sample value can be set from 0 99 To adjust the value 1 Select the Post Sample field and click the Soft Keypad Icon 2 Enter the desired value in the Soft Keypad dialog Alternatively a keyboard can be used to type directly into the field 3 Click OK to accept Rockwell Automation Publication 7000 INO12B EN P June 2014 85 Chapter 4 86 Commissioning the Drive The Rate of which the data is captured can be set from 0 20 000 mSec A value of 0 captures the data as quickly as possible and is determined by loading of the drive processor To adjust the value 1 Select the Rate field and press the Soft Keypad Icon 2 Enter the desired value in the Soft Keypad dialog Alternatively a keyboard can be used to type directly into the field 3 Click OK to accept The setup and trigger conditions are sent to the drive when the Accept button is pressed or another screen is selected This also arms the diagnostics trigger
13. ee LED 1 Red Se T Rockwell Automation Publication 7000 INO12B EN P June 2014 73 Chapter4 Commissioning the Drive System Test 74 While the drive is idle without gating LEDs 4 Green 3 Green and 1 RED should be on while LED 2 Yellow is off If other combinations of LEDs are illuminated refer to publication 7000 UM202_ EN P for instructions on troubleshooting the SGCT firing cards When you put the drive into gating test mode the inverter automatically enters the test pattern gating mode Monitor the SGCT LEDs and ensure that LEDs 4 Green and 3 Green remain on while LEDs 1 Red and 2 Yellow toggle on and off alternately at the converter s operating frequency There is also a gating test that fires the individual devices one at a time in what is described as a Z pattern For each section the top left device turns on for 2 seconds then turns off The next device to the right turns on for 2 seconds and the pattern continues At the end of the first stack of devices the right device in the middle stack down fires and the pattern continues right to left until reaching the end of the middle stack Then the left device in the bottom stack fires and the pattern continues to the last device then returns to the top This tests for correct fiber optic cables connected to the corresponding
14. following information to MV Tech Support for review via e mail at mvsupport_service ra rockwell e Drive setup after completing the auto tuning e Drive variables captured in running condition at load or no load or uncoupled or with load e Une voltage and line current waveforms for harmonics on AFE drives when drive is energized e Black Box Data before leaving the site followed by instructions on relevant Tech Note 26 Rockwell Automation Publication 7000 IN012B EN P June 2014 Key Steps to Commission a PowerFlex 7000 Drive Chapter 4 Commissioning the Drive As a guide for a commissioning engineer the major steps involved in the commissioning of medium voltage PowerFlex 7000 drives are outlined below in a sequential order For detailed instructions always refer to the relevant PowerFlex 7000 user manual Review the drawings and identify all sources of energy that apply to the drive system and get better understanding of the application to which the drive system is applied Follow safety procedures and apply Lockout Tagout procedures before working on the equipment Complete all power off checks and note down motor and drive nameplate data Apply control power and perform power on checks Perform gating test Program the drive after verifying the information on EDs and DDs against the equipment nameplate data Ensure the drive hardware and parameters are correct such as HECS CT ratio and burden resistors insta
15. indicates that the measured value of magnetizing inductance is greater then 15 0 pu This warning is intended to draw attention to an unusually high value of magnetizing inductance The most likely cause is incorrect scaling of the analog field current reference s T Rotor Low indicates that the calculated value of rotor time constant is less than 0 2 seconds e T Rotor High indicates that the calculated value of rotor time constant is greater than 5 0 seconds Rockwell Automation Publication 7000 INO12B EN P June 2014 109 Chapter4 Commissioning the Drive Running the Load 110 e Regulator Limit indicates that the torque command was greater than Trq Lmt Motoring or Trq Lmt Braking The measured inertia value is invalid Parameter Autotune Trq Stp or parameter Autotune Spd Cmd must be set to a lower value and the test repeated e Tuning Abort indicates that the deviation in motor speed was greater than 10 Hz The measured inertia value is invalid Parameter Autotune Trq Stp must be set to a lower value and the test repeated e Inertia high indicates that the measured total inertia is greater than 20 seconds This warning is intended to draw attention to an unusually high inertia value For a very high inertia load such as a large fan this may be a valid result and parameter Total Inertia should be manually set equal to Autotune Inertia However a high inertia measurement could also be produced by a value of Autotune Trq
16. 0 S Gea ee ee 10 Set the CurReg Bandwidth parameter to the normal value of 200 rad s Confirm that the rise time of the current feedback is now approximately 5 ms and that the overshoot is not excessive 11 Set the Idc Ref Step parameter to zero The dc link current will return to a steady level given by Idc Test Command 12 Stop the drive Set the Operating Mode to Normal and Idc Test Command to 0 000 pu Motor Impedance The motor impedance tuning function calculates stator resistance R Stator P 129 and total leakage inductance L Total Leakage P 130 in the Motor Model Group Use these parameters to reconstruct the rotor flux If you adjust these parameters incorrectly the resulting distortion in the flux feedback may cause speed feedback or motor synchronization errors 98 Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 You must tune these parameters during commissioning they are affected by motor parameters and cable length Perform the tuning process with the motor stationary using the following procedure ATTENTION During tuning the motor may rotate in the wrong direction To avoid possible equipment damage disconnect the motor from the load and test for direction before proceeding if the equipment is sensitive to reverse direction rotation 1 Ensure that the motor is stationary Motor turning ma
17. 20 mA Internal parameter 32 Bit resolution Serial Communication 16 Bit resolution 1Hz Digital Speed Reference Analog Outputs One Isolated Eight Non isolated 4 20mAor0 10V 600 0 Communication Interface Ethernet IP DPI Scan Time Internal DPI 2 ms min 4 ms max Rockwell Automation Publication 7000 INO12B EN P June 2014 131 Appendix B 132 Specifications Table 15 General Design Specifications Continued Description Communications Protocols DeviceNet ControlNet Optional Ethernet I P Lon Works Dual port Ethernet I P Can Open Profibus RS485 HVAC Modbus RS485 DF1 Interbus RS232 DF1 USB Enclosure NEMA 1 standard IP21 IEC NEMA 12 optional IP42 IEC Lifting Device Standard Removable Mounting Arrangement Mounting Sill Channels Structure Finish Epoxy Powder Paint Exterior Sandtex Light Grey RAL 7038 Black RAL 8022 Internal Control Sub Plates High Gloss White RAL 9003 Interlocking Key provision for customer input Disconnecting Device Corrosion Protection Unpainted Parts Zinc Plated Bronze Chromate Ambient Temperature 0 40 C 32 104 F 0 50 C 32 122 F optional Fiber Optic Interface Rectifier Inverter Cabinet Warning Trip Door Filter Painted Defuser with Matted Filter Media Door Filter Blockage Air Flow Restriction Trip Warning Storag
18. Motor Current Figure 85 Sample waveform PWM drive under full load condition Rockwell Automation Publication 7000 INO12B EN P June 2014 f fi M VS S V 10 mS ff K Gu D4 foOms t 117 Chapter4 Commissioning the Drive Sample waveforms recorded on 18 Pulse Drive running at 75 load Ch1 Line Voltage Ch2 Line Current Ch3 Motor Voltage Ch4 Motor Current Figure 86 Sample waveform 18 Pulse drive at 75 load capacity Synch ronous Tra nsfer When commissioning a drive employing synchronous transfer capture and submit the following waveforms with the commissioning package While measuring the bypass BP contactor closing time e Capture 120V bypass close command from the BP Contactor Close output J1 12 at the ACB refer to electrical drawing for specific wire terminal number e Capture the 9V signal across the bypass contactor vacuum bottles refer to the tech note PF7000_GEN 78 for details s Label the waveforms as BP_Close_Cmd and Actual_ Closure e Save the worksheet as Bypass Contactor Close Delay Table 8 Oscilloscope Settings Oscilloscope Time Base Wave Form Test Point Waveform Label Chan 1 25ms div BP Contactor Close BP Contactor Close BP_Close_Cmd Command Command Chan 2 Actual Closure of BP Across 2K Ohm resistor Actual_Closure connected in series with 9V battery 118 Rockwell Automation Publication 7000 IN012B EN P June 2014 Bypa
19. or a three phase ac supply for an AC brushless machine The drive provides an analog current reference as an input to the field supply The analog current reference has a range of 0 10V where OV corresponds to zero field current and 10V corresponds to maximum field current Adjust the scaling of the analog current reference to achieve a linear relationship between the current reference and the actual field current Failing to do so may result in an unstable flux regulator Adjust the analog output scaling using the following procedure 1 Temporarily assign variable Autotune Lmd in Autotuning to the analog output that controls the field supply e g ACB Port 1 Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 2 Set the analog output scale parameter e g Anlg Out Scale in Analog Output to Maximum analog input of field supply 10V Analog Scale Set Autotune Lmd to a value of 10 00 Confirm the field supply s reference input is at maximum Adjust the analog output scaling parameter if necessary 3 Start the field supply and confirm that the field current goes to its maximum value If necessary adjust the field supply to achieve a field current slightly above rated ATTENTION Applying maximum field current to a stationary machine for an A extended period may damage the exciter Adjust the current as quickly as possible 4 Stop the field supply Assign variable I Field Command
20. 2w Master 240 V3uv 3u Slave 1 20 V3vw 3v Slave 1 140 V3wu 3w Slave 1 260 V4uv 4u Slave 2 20 V4vw 4y Slave 2 100 V4wu 4w Slave 2 220 The test points are measured to either the Analog Ground AGND on the board or the TE ground in the low voltage section Use V2uv as your reference trigger on this waveform and verify all the other test points using the table above It is easier to use zero crossings on your oscilloscope as the reference points when checking the phase shifts Verify the following relationships 1 Vand W in each bridge should be lagging U by 120 and 240 respectively 2 3U 3V and 3W should be lagging 2U 2V and 2W by 20 20 respectively 3 4U 4V and 4W should be leading 2U 2V and 2W by 20 20 respectively Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Figure 72 CH1 is 2Vuv CH2 is 2Vvw CH3 is 2Vwu LeCroy For 60 Hz systems 360 16 7 ms For 50 Hz systems 360 20 ms Refer to Figure 73 for a visual representation of the phasing checks Figure 73 18 Pulse phase sequence 2W Chapter 4 N Ee a eee 4U CNOA NOAA N 1 i 1 1 l N i ON Ne A 1 i 1 o l 4w Rockwell Automation Publication 7000 INO12B EN P June 2014 91 Chapter4 Commissioning the Drive DC Current Test 92 Verify the isolation transformer phasing and
21. 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 gt gt 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 inju
22. DC U2c J21 2 20V DC After testing the drive converters without Medium Voltage and verifying the power supply output values test the SCRs and SGCTs under low voltage control power The following procedures describe the next level of device testing e Gating Test Mode e SCR Firing Test e SGCT Firing Test Rockwell Automation Publication 7000 INO12B EN P June 2014 69 Chapter4 Commissioning the Drive 70 Gating Test Mode The following procedure explains how to enter gating test mode and simulate drive operation by applying gate signals to the SCRs and SGCTs while isolated from medium voltage Prior to starting the drive for the first time perform a gating test to ensure that each device is functional Some drive status I O are active while performing tests in gating test mode If monitoring the drive I O monitored remotely notify process control in advance to avoid confusion A ATTENTION Isolate the drive from medium voltage prior to starting this test 1 Click the Display tab from the operator interface screen 2 Click Access and choose Advanced from the Requested Access pull down menu Figure 53 Password Dialog ii BE Access Filter E _ Requested Access X Monitor z Basic Password Service UK Rockwell Current Access Monitor KA X New Password Change ReEnter Password IS eae SEE m J 3 Type your password and click OK Figu
23. Snubber Circuit for SGCT module with SPS board Cs 1 Rsn 2 Rsn 1 SPS Board Snubber Resistor Anode Rockwell Automation Publication 7000 IN012B EN P June 2014 39 Chapter4 Commissioning the Drive Figure 20 2400V Two Device PowerCage heat sink model Clamp B ae SGCTs Heat sink Module Housing J oe E p gt amp E x Z a 5l gt S S gt 1 i L Temperature r gt Feedback Board ee 9 gt Fo L S RL R _ Clamp Head 2 h oe J 4 ro cl al i gJ T Figure 21 2400V Two Device PowerCage with SPS Boards installed SGCT SPS Mounting Assembly with SGCT Temperature Feedback Board Clamp Head Clamp Base Heat sink SPS Board Mounting Assembly without Temperature Feedback Board Module Housing 40 Rockwell Automation Publication 7000 INO12B EN P June 2014 Commissioning the Drive Chapter 4 Figure 22 3300 4160V Four Device PowerCage heat sink model R Base Matched Set Matched Set Twa SECT Two SGCTs a Heat sink
24. Stp which is too low Motor Starting Torque When starting without an encoder the drive operates in an open loop mode below approx 3 Hz at which point the drive switches to closed loop speed control The starting currents are set by three parameters Torque Command 0 sensorless P 86 Torque Command 1 Sensorless P 87 Torque Command 0 sensorless sets the breakaway torque and Torque Command 1 sensorless is the torque at the transition point from open to closed loop Torque Command Minimum operates in conjunction with Torque Command 1 to minimize speed overshoot at the transition point If you are starting an unloaded but coupled motor or simply auto tuning the default starting torque values may be sufficient to run the motor But the defaults are generally not high enough to start a loaded motor If the motor is uncoupled the default values might be too high reduce the values to 0 10 pu when motor is uncoupled The alternative is to change the operating mode to Uncoupled Mtr Be prepared to have to increase starting torque and ensure Motor Stall faults during initial operation Reaching Specific Load Points Verify the drive can reach rated speed and load Monitor the Torque Reference P 291 and the displayed value of the motor current If you are running into a torque limit the Torque Reference will be running near the Torque Limit Motoring P 84 limit If you are not realizing rated motor current you may increase the Torque L
25. TD002_ EN P Figure 47 DC DC converter PS2 M4 P H M S and nylon shoulder nestor a Mounting Plate E va x Black Insulation DC DC Pa power supply Je Part ID Label 2 L VIEW 2 r LL SL MB HTS VIEW 1 Rockwell Automation Publication 7000 INO12B EN P June 2014 63 Chapter4 Commissioning the Drive SGCT Power Supplies IGDPS Figure 48 Converter Cabinet Components 2400V Ground bus Differential Pressure Sensor Inverter Modules Isolated Gate Driver Power Supplies IGDPS Rectifier IGDPS not required in drives with SPS boards installed Rectifier Modules Note For variations in drive cabinetry such as the heat pipe B Frame or Marine liquid cooled drives please refer to the appropriate Installation Manual for that drive 64 Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 Figure 49 Converter Cabinet Components 3300 4160V Differential Pressure Ground bus Sensor Isolated Gate Driver Power Supplies IGDPS Inverter Modules Rectifier IGDPS not required in drives with SPS boards installed Rectifier Modules Rockwell Automation Publication 7000 INO12B EN P June 2014 65 Chapter4 Commissioning the Drive Figure 50 Converter Cabinet Components 6600V Differential Pressure Ground bus Sen
26. also visit our Knowledgebase at http www rockwellautomation com knowledgebase for FAQs technical information support chat and forums software updates and to sign up for product notification updates For an additional level of technical phone support for installation configuration and troubleshooting we offer TechConnect support programs For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com support Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwellautomation com support americas phone_en html or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact
27. and Components e Installation Manual e Publication 1502 UM050_ EN P Medium Voltage Contactor Bulletin 1502 400 Amp Series D e User Manual e Publication 1502 UM052_ EN P Medium Voltage Contactor Bulletin 1502 400 Amp Series E e User Manual Rockwell Automation Publication 7000 IN012B EN P June 2014 75 Chapter4 Commissioning the Drive Status Indicators Analog 1 0 76 e Publication 1502 UM051_ EN P Medium Voltage Contactor Bulletin 1502 800 A e User Manual If the Medium Voltage contactors or circuit breakers perform as desired stop the drive and perform the same test while operating in remote control Start the drive again and verify that all emergency stops installed in the system function as desired Ensure that all electrical interlocks installed in the system function as desired Make any necessary control wiring modifications at this time and re test the system if necessary Drive status is often feedback to a plant s process control either digitally through the PLC input output feature refer to the relevant PowerFlex 7000 Installation Guides or user Manuals for PLC programming details or through relay logic The following relays are provided with the drive as standard Relay Name Relay Designation Run Contact RUN Fault Contact FLT Warning Contact WRN Ready Contact RDY It is necessary to activate each status indicator used by the customer to ensure that they hav
28. and click Value to open the Analog Output Scale dialog Figure 62 5 Type the new value in the window and click OK 6 Save to NVRAM e Click the Utility tab and click NVRAM s Choose Save and click OK Figure 62 Analog Output Scale window Ere Display Alarms Setup Diagnostics Utility Access Advanced Filter ReadWrite Search Help lt All Parameters gt Feedback Diagnostics Feature Select Anlg Output Motor Ratings Anlg Output7 363 Autotuning Anlg Output8 364 Motor Model Anlg 4 20mAOut rere Ps Ea Anlg Outi Scale Speed Contro Anlg Out2 Scale Speed Profile Anlg Out3 Scale Actuat Mme ae Current Control Anlg Out4 Scale Hs Torque Control Anlg Out5 Scale Ten Yas Flux Control Anlg Out6 Scale adh 1 00 unt Alarm Config Anlg Out7 Scale hi te ai Drive Protection Anlg Out8 Scale Maximum x raad Motor Protection Anlg4 20mA Scale s ile al Sync Xfer Option Encoder Option i The analog outputs from the customer interface boards are stated as 0 10V but in actual fact their outputs are typically 0 025 9 8 or 9 9 V This is due to the rails being loaded down by an attached speed potentiometer or signal conditioner impedance Incorporated signal conditioners usually have 0 10V inputs and 4 20 mA outputs An additional error is incorporated in the signal conditioners so if they are calibrated for 0 10V input there will not be exactly 4 20 mA out Rockwell Automation Publicati
29. bolts This design directs external filtered air through the heat sink slots to dissipate heat from the SGCTs The door filter ensures the heat sink slots stay clear of dust particles SGCT Testing The following steps outline how to verify SGCT semiconductors and all associated snubber components A quick reference to the expected resistance and capacitance values as well as a simple schematic diagram is located in the table below A simple schematic diagram in Figure 18 on page 39 shows how the snubber components are connected across an SGCT SGCT Rating Sharing Resistor Snubber Resistor Snubber Capacitor 1500A 80 kO 6 Q AFE Rectifier 0 2 pf 1500A 80 kO 7 5 Q Inverter 0 2 pf 800A 80 kO 100 0 1 pf 400A B0 kO 15 Q AFE Rectifier 0 1 pf 400A 80 kO 17 5 Q Inverter 0 1 pf 1 2400V drives will not have a sharing resistor on devices Rockwell Automation Publication 7000 INO12B EN P June 2014 45 Chapter 4 Commissioning the Drive 46 Resistance value between two heat sinks is sharing resistance in parallel with anode cathode resistance Table 1 SGCT snubber resistance values SGCT Resistance Measurement Measured Resistance Inverter Rectifier AFE only SGCT Anode Cathode Resistance heat sink to heat sink k Q Lowest Highest Lowest Highest Snubber Resistance Test point Heat sink above Q Lowest Highest Lowest Highest Snubber Capacitance Test Poi
30. cathode test S Resistance value between two heat sinks is Anode to Cathode resistance L TA A F T sa TNE Bas 4 oT eA kes LL LLE CF LF U U UP Q w TRE E II A N eens EN L d ar Y S A good SCR and circuit should read between 22 24 kQ An SCR that has failed from anode to cathode will commonly produce a resistance value of 0 for a shorted device or COQ for an opened device Unlike the SGCT it is highly irregular for an SCR to have a partially shorted device If an SCR is found to be out of tolerance refer to publication 7000 UM202_ EN P for detailed instructions on how to replace the SCR assembly Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 SCR Sharing Resistance Test To test the sharing resistor of an SCR module 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 s
31. in house and on site product training Rockwell Automation Publication 7000 IN012B EN P June 2014 Topology Chapter 2 PowerFlex 7000 Overview The PowerFlex 7000 is a general purpose stand alone medium voltage drive that controls speed torque direction starting and stopping of standard asynchronous or synchronous AC motors It works on numerous standard and specialty applications such as fans pumps compressors mixers conveyors kilns fan pumps and test stands in industries such as petrochemical cement mining and metals forest products power generation and water waste water The PowerFlex 7000 meets most common standards from the National Electrical Code NEC International Electrotechnical Commission IEC National Electrical Manufacturers Association NEMA Underwriters Laboratories UL and Canadian Standards Association CSA It is available with the world s most common supply voltages at medium voltage from 2400 6600V The design focus is on high reliability ease of use and lower total cost of ownership The PowerFlex 7000 uses a Pulse Width Modulated PWM Current Source Inverter CSI topology This topology applies to a wide voltage and power range The power semiconductor switches used are easy to series for any medium voltage level Semiconductor fuses are not required for the power structure due to the current limiting DC link inductor With 6500V PIV rated power semiconductor devices the num
32. more than one IGDPS in the drive Test Points Expected Value Measured Value IDGPS IGDPS 1 IGDPS 2 IGDPS 3 IGDPS 4 IGDPS 5 IGDPS 6 not used with SPS not used with SPS not used with SPS Plug 8 Pin 1 gt 20V DC Pin 2 Plug 9 Pin 1 gt 20V DC Pin 2 Plug 10 Pin 1 gt 20V DC Pin 2 Plug 11 Pin 1 gt 20V DC Pin 2 Plug 12 Pin 1 gt 20V DC Pin 2 Plug 13 Pin 1 gt 20V DC Pin 2 If a channel fails refer to the troubleshooting section of the manual for a replacement procedure 68 Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 Gating Tests SPS Board LEDs There is one green LED on each of the SPS boards labeled DS1 If the SPS board is healthy the corresponding LED will be illuminated need 1 2 or 3 test power harnesses for 2kV 3 4 kV 6 kV drives respectively If any of the SPS board DS1 LEDs do not illuminate the SPS board is defective The output voltage should be within 20 V 2 Test Points SPS Expected Value Measured Value Ula J21 2 20V DC U1b J21 2 20V DC Uic J2 1 2 20V DC U4a J2 1 2 20V DC U4b J21 2 20V DC U4c J21 2 20V DC U3a J21 2 20V DC U3b J21 2 20V DC U3 J21 2 20V DC U6a J21 2 20V DC U6b J21 2 20V DC U6c J21 2 20V DC U5a J21 2 20V DC U5b J2 1 2 20V DC U5c J21 2 20V DC U2a J21 2 20V DC U2b J21 2 20V
33. selecting the desired parameter from the list The red marker shows the trigger point Figure 71 Plot Sub Menu lolx Home Display Alarms Setup Diagnostics Utility Setup Control View Plot DrvStatus Flag1 InvControl Fiag1 RecControl Flag1 RecControl Flag2 X Speed Reference X Speed Feedback Torque Reference Flux Feedback StatFrqvoltModel Motor Current pu Line Voltage pu Idc Reference Ide Fok Sampled Alpha Rectifier Line Current pu Update Motor Voltage pu 0 717 pu Index 32 Trace Parameters True Value When you finish programming these settings the drive is ready to trend data at the next fault The next test required is to test phase rotation requires that medium voltage be applied to the drive input e Inspect the drive for debris and tools prior to energizing the drive e Re install all protective barriers e Configure the drive to Normal operating mode not System test Rockwell Automation Publication 7000 INO12B EN P June 2014 89 Chapter 4 90 Commissioning the Drive Input Phasing Check There are nine voltage test points on the ACB board that will allow you to look at each voltage level individually Table 3 ACB Test Points and Associated Voltage Signals Test Point Description Isolation Transformer Phase Relationship Secondary Phasing and Bridge oh respect to V2uv V2uv 2u Master 0 V2vw 2v Master 120 V2wu
34. the circuit for potential before servicing the equipment Failure to do so can result in severe injury or death T ATTENTION Live capacitors in circuit Before touching anything ensure that spinning motor can generate a high potential into the drives motor filter T ATTENTION Ensure that the motor is not spinning due to a driven load A capacitors which can result in severe injury or death Refer to local safety guidelines for detailed procedures on how to safely isolate the equipment from hazards Only open the door to the medium voltage cabinets after you successfully complete the lockout and tagout Step Down Transformer Fusing The drive uses transformers to step down medium voltage to low voltage With all sources of power removed from the drive Medium Voltage and Control Power remove the step down transformer fuses from the fuse clips and place them in a safe place outside of the drive cabinet Removing the control power fuses will prevent a separate source of control power from being stepped up to Medium Voltage in the event that the safety interlocks fail to function Fuse and 0 L Protection While referencing the electrical diagrams locate all fuses and overload relays within the drive line up Verify that all installed fuses and overload are the same as indicated by Rockwell Automation Fuses and overload settings are also identified by stickers located on the cabinet structure in close proximity to the fuse or overlo
35. traditional location on the low voltage door of the Variable Frequency Drive VFD A remote mounting plate complete with E Stop push button and HMI is supplied loose for the customer to mount wherever desired The HMI connects to the VFD via a hardwired Ethernet cable There is no functional distance limitation Rockwell Automation Publication 7000 IN012B EN P June 2014 19 Chapter 2 20 PowerFlex 7000 Overview This is ideal for non PLC users wanting to control and monitor remotely e g at the driven machine control room etc Also ideal for customers having policies in place to control access to medium voltage equipment and the associated requirements of PPE when using the operator interface at the VFD etc Locally mounted HMI Similar to the previously existing PanelView 550 the HMI is mounted on the LV door of the VFD There is also a service access port RJ 45 connector on the LV door No HMI supplied A service access port RJ 45 connector is located on the LV door of the VFD Customers use their own laptop as the HMI All programs required to use the laptop as the HMI are stored in the VFD Their laptop is connected to the VFD via a hardwired Ethernet cable when required This is ideal for unmanned sites where a dedicated HMI is not required See Publication 7000 UM201_ EN P for detailed instruction for the HMI Interface Board See Publication 7000 UM151_ EN P for detailed instruction for B Frame drives
36. type loaded CT 200 100 100 Contact factory Yes DRAG LINE CT 100 200 200 Contact factory Yes EXTRUDERS CT 150 150 100 Contact factory Yes rubber or plastic FANS centrifugal ambient Damper closed VT 25 60 50 Normal No Damper open VT 25 110 100 Normal No FANS centrifugal hot gases Damper closed VT 25 60 100 Normal No Damper open VT 25 200 175 Contact factory No FANS propeller axial VT 40 110 100 Normal No flow GRINDING MILL CT 175 180 100 Contact factory Yes Ball Sag Mill HOISTS CT 100 200 200 Contact factory Yes KILNS rotary loaded CT 250 125 125 Contact factory Yes MIXERS Chemical CT 175 75 100 Contact factory Yes Liquid CT 100 100 100 Heavy Yes Slurry CT 150 125 100 Heavy Yes Solids CT 175 125 175 Contact factory Yes PULPER VT 40 100 150 Contact factory No Rockwell Automation Publication 7000 IN012B EN P June 2014 127 AppendixA General Reference Table 14 Typical Application Load Torque Profiles Continued Application Load Torque Load Torque as Percent of Full Load Drive Torque Required Drive Encoder Required for Profile Service Duty Rating Extra Starting Break away Accelerating Peak Running Torque PUMPS Centrifugal discharge open VT 40 100 100 Normal No Oil field Flywheel cT 150 200 200 Contact Factory Yes Propeller VT 40 100 100 Normal No Fan Pump VT 40 100 100 Norma No Reciprocating Positive CT 175 30 175 Contact factory Yes Displacement Screw type st
37. using the PanelView 550 HMI Rockwell Automation Publication 7000 IN012B EN P June 2014 Before Commissioning Chapter 3 Commissioning Preparations This chapter provides important reference material for commissioning a PowerFlex air cooled medium voltage AC drive including s recommended tools and equipment e safety checks s drive line up data sheets e pre power checks e control power checks Use this document in conjunction with the most recent version of the Rockwell Automation Commissioning Guidelines for MV PowerFlex 7000 A B C Frame Drives with ForGe Control document available to field service engineers Review this information before commissioning the drive line up Record all the information requested in the data sheets which will be useful during future maintenance and troubleshooting exercises Perform the commissioning checks in the order listed Failure to do so may result in equipment failure or personal injury Start up occurs at the customer s site Rockwell Automation requests a minimum of four weeks notice to schedule each start up The standard Rockwell Automation work hours are between 9 00 AM to 5 00 PM EST 8 hr day Monday through Friday not including observed holidays Additional working hours are available on a time and material basis Before commissioning the drive Rockwell Automation recommends the following 1 Meet with the customer before installation to review a t
38. voltage cabling section The Commissioning Guidelines document must include all of the system nameplate data and variable set points as commissioning proceeds Why this Information is Needed When you commission a PowerFlex 7000 B Frame medium voltage AC drive the start up sometimes occurs in an artificial environment There s usually no actual process in operation and no load at least not a full load Therefore the application situation is artificial and this isn t an ideal time to establish parameter baselines to signature the drive After commissioning is complete the drive is at full capacity and realistic load conditions occur parameters such as speed regulation may begin to drift and the drive will not perform as designed to meet processing requirements It is important that you complete the service data in a detailed and accurate manner and that immediately after their completion you submit the data sheets to both the customer and the factory This data is necessary for further modifications on the drive line up once production commences It is common to make modifications to the drive s program some time during the two month period following the drive commissioning This ensures that speed control direction starting and stopping functions are all performing with precision In addition to system modifications the factory will use the data sheet as an indication that the system is running The date on the commis
39. your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature Medium Voltage Products 135 Dundas Street Cambridge ON N1R 5X1 Canada Tel 1 519 740 4100 Fax 1 519 623 8930 Online www ab com mvb Allen Bradley Rockwell Software Rockwell Automation and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 7000 IN012B EN P June 2014 Supersedes Publication 7000 INO12A EN P May 2013 Copyright 2014 Rockwell Automation Inc All rights reserved Printed in Canada
40. 0 UM202_ EN P 4 Only required when drive has PFNI 5 Only required when Remote 1 0 has been provided with the drive 24 Rockwell Automation Publication 7000 IN012B EN P June 2014 Important Note for the Commissioning Engineer Commissioning Preparations Chapter 3 Technical Publications and Manuals Each drive ships with a service binder containing all technical publications required to install use and troubleshoot the drive line up This section describes how to determine what technical publications are required and how to obtain them in the event that the service binder is not available when pre commissioning or when you require additional information e The PowerFlex 7000 Medium Voltage AC Drive Parameters Publication 7000 TD002_ EN P Use this document for parameter details and programming during commissioning or troubleshooting e The PowerFlex 7000 B Frame User Manual 7000 UM202_ EN P Use this document for general information regarding the usage and programming of the operator interface after installation before or after commissioning e Additional Manuals The electrical schematics that ship with the drive should list any additional manual necessary for configuring the drive line up The schematic titled General Notes identifies all required Rockwell Automation publications by publication number IMPORTANT Ensure you also have the latest technical and release notes for the releva
41. 4 113 Chapter4 Commissioning the Drive Figure 81 Sample waveforms 20 deg phase shift between master and 2 slave bridges 1 Wuv CH4 1 V 25ms 2 Vauv CH2 T Vo 25 nis 3 VIuv CH3 1 V 25 ms Verify the phase shift is e V2uv must be 0 e V3uv must be 20 e V4uv must be 20 Harmonic An alysis required Measure the harmonic resonance levels at the input to the drive If you notice considerable distortion in the waveforms you MUST send those waveforms to for PWM drives only MV Support via e mail at mvsupport_technical ra rockwell com and then call 519 740 4790 option 1 to discuss the issue and action plan After hours call 519 503 0346 to talk with MV Tech Support Specialist Outside North America call 1 440 646 3434 and request MV Tech Support Summary e Close all drive input contactors If the drive input contactor configuration is set to NOT RUNNING temporarily change it to ALL FAULTS e Verify the drive is not running when capturing these waveforms e Capture line voltage at ACB test point V2uv and line current at ACB test point I2u e Label the waveforms as V2uv and I2u s Save the worksheet as Harmonics Drive Not Running Table 5 Oscilloscope Settings Label Chan 1 10 ms div Line Voltage Harmonics drive not running Chan 2 Line Current 114 Rockwell Automation Publication 7000 IN012B EN P June 2014 DC Current Test Commissioning the Dr
42. 46 Snubber Capacitance 49 Snubber Circuit Assembly 44 Snubber Resistance 48 Rockwell Automation Publication 7000 IN012B EN P June 2014 Sharing Resistors 38 Heat pipe test points 47 Heat sink test points 46 SGCT Anode to Cathode Resistance 46 SGCT Rating 45 Silicon Controlled Rectifier See SCR Snubber Capacitors 38 SGCT Rating 45 SGCT Test 49 Snubber Resistors 38 Heat pipe test points 47 Heat sink test points 46 SGCT Rating 45 SGCT Test 48 Test Points 46 Speed Regulation 124 Speed Regulator Manual Tuning 103 Splice Kits 33 SPS Board Snubber Circuit Schematic 39 Start Stop Control Circuit 75 Step Down Transformer Fusing 31 Support 10 Symmetrical Gate Commutated Thyristor See SGCT Sync Lead Angle 119 Oscilloscope Settings 119 Synchronous Transfer 118 Oscilloscope Settings 118 Sample Waveforms 120 Sync Lead Angle 119 System Test 74 T T DC Link P 115 Manual Tuning 97 Tagout 30 Three Phase Input 59 Topology 11 Torque Capabilities 126 Torque Requirements 123 Total Inertia 106 Tuning 93 V Voltage waveforms 15 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http www rockwellautomation com support you can find technical manuals technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools You can
43. 60V 4 6 6600V 6 6 Output Current THD 1 49th lt 5 Output Waveform to Motor Sinusoidal Current Voltage Medium Voltage Isolation Fiber Optic Modulation techniques Selective Harmonic Elimination SHE Synchronous Trapezoidal PWM Asynchronous or Synchronous SVM Space Vector Modulation Control Method Digital Sensorless Direct Vector Full Vector Control with Encoder Feedback Optional Tuning Method Auto Tuning via Setup Wizard Speed Regulator Bandwidth 1 10 rad s with standard control 1 20 rad s with HPTC optional Torque Regulator Bandwidth 15 50 rad s with standard control 80 100 rad s with HPTC optional Torque Accuracy with HPTC optional 5 0 1 without Encoder Feedback Speed Regulation 0 01 0 02 with Encoder Feedback Acceleration Deceleration Range Independent Accel Decel 4 x 30 s Acceleration Deceleration Ramp 4x Independent Accel Decel Rates S Ramp Rate Independent Accel Decel 2 x 999 s Critical Speed Avoidance 3 x Independent with Adjustable bandwidth 130 Rockwell Automation Publication 7000 INO12B EN P June 2014 Specifications Appendix B Table 15 General Design Specifications Continued Description Stall Protection Adjustable time delay Load Loss Detection Adjustable level delay speed set points Control Mode Speed or Torque Current Limit Adjustable in Motoring and Regenerative Output
44. CB test points Figure 84 Sample waveform DC test on 18 Pulse drive A V cri CH4 500 mV 2ms 2 Ide1 CH1 2 V 2 me 116 Rockwell Automation Publication 7000 IN012B EN P June 2014 Load Test Commissioning the Drive Chapter 4 After autotuning of the drive run the motor on load and capture the following waveforms at 50 load and at 100 load If the system is not ready for 100 load test then capture the waveforms at the max load you are allowed to run the drive at Also print variables at 50 and 100 load points Before printing variables make sure the drive Access Level is at SERVICE e Capture line voltage amp current waveforms at ACB test points V2uv amp T2u s Label the waveforms as V2uv and I2u e Capture motor voltage amp current waveforms at ACB test points Vuv amp v lw s Label the waveforms as Vuv and Iu e Save the worksheet as Line and Load Voltage and Current Waveforms at 1048 rpm 31 A for example Table 7 Oscilloscope Settings Time Base Oscilloscope chan 1 10ms div Sheet Name Line Voltage Chan 2 chan 3 Chan 4 Wave Form Test Point Waveform Label V2uv V2uv Line Current I2u I2u Motor Voltage Vuv Vuv lu lu see above Motor Current Sample Waveforms Sample waveforms recorded on PWM drive running at full load Ch1 Line Voltage Ch2 Line Current Ch3 Motor Voltage Ch4
45. Commissioning Manual Allen Bradley PowerFlex 7000 Medium Voltage AC Drive Air Cooled B Frame ForGe Control Publication 7000 INO12B EN P Allen Bradley Rockwell Software Automation Important User Information Read this document and the documents listed in the additional resources section about installation configuration and operation of this equipment before you install configure operate or maintain this product Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes laws and standards Activities including installation adjustments putting into service use assembly disassembly and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice If this equipment is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell
46. DC Link connections Put the drive in DC Current Test and monitor variable Alpha Line and Idc feedback while increasing the DC current through the drive rectifier IMPORTANT Access level must be Advanced to perform this test 1 Click the Display tab and click Feature Select from the Group Name column The Feature Select parameters will appear in the right window 2 Click Operating Mode and click Value Select DC Current from the pulldown menu and click OK 3 Click Current Control from the Group Name column Figure 74 The Current Control parameters will appear in the right window 4 Select Idc Test Command and click Value Type 0 1 pu in the New Value field and click OK Figure 74 Current Control Group PF7000 Terminal Home Display Alarms Setup Diagnostics Utility Access Advanced Filter ReadWrite Search Help Idc Reference 0 000 pu Idc Feedback 0 000 pu lt All Parameters gt Idc Error 0 000 pu Feedback Vdc Reference 0 000 Diagnostics Alpha Rectifier 0 0 deg Feature Select CurReg Bandwidth 200 0 rfs Motor Ratings Idc Test Command 0 000 pu Autotuning Idc Ref Step 0 000 pu Motor Model Speed Command T DC Link 0 040 sec 5 Press the drive START button The drive will be pumping 0 1 pu 10 of rated current through the DC link Alpha Rectifier should be approximately 90 92 TIP We can also check the Idc Reference and Idc Feedback on this same screen
47. Figure 24 6600V Six Device PowerCage heat sink model Matched Set Matched Set Clamp Base Three SGCTs Three SGCTs Clamp Head Module Housing Heat sink Temperature Feedback Board Figure 25 6600V Six Device PowerCage with SPS Boards installed Matched Set Clamp Base Mate Three SGCTs Three SGCTs Clamp Head Heatsink SPS Mounting Assembly with SPS Mounting Assembly without Module Temperature Feedback Board Temperature Feedback Board Housing 42 Rockwell Automation Publication 7000 IN012B EN P June 2014 Chapter 4 Commissioning the Drive Figure 26 3300 4160V Four Device PowerCage heat pipe model Module Housing Heat Pipe Support Channel Heat Pipe Assembly a S
48. Flux Speed Regulator with the motor running at constant speed using the following procedure 1 Ensure that the analog reference for the field current has been set up as described previously and that parameter L Total Leakage has been set to the correct value 2 Set parameter Autotune Select in Autotuning to FluxSpeed Reg Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 3 Start the drive The motor accelerates normally up to the speed specified by parameter Autotune Spd Cmd The motor magnetizing inductance is calculated from the magnetizing current reference and the flux feedback and parameter Autotune Lm is set to this value The flux command is then set to a value that should produce rated voltage at rated speed and load The resulting change in the flux level may cause the magnetizing inductance to change This process is repeated until the magnetizing inductance and flux command stabilize If a position encoder is fitted to the motor the angle between the measured flux and the encoder zero is measured and parameter Encoder offset is adjusted to align the encoder with the motor flux The field current reference is then held constant and the response of the flux to changes in stator magnetizing current is measured by stepping Ix command up and down at regular intervals The size of the step in the stator current is specified by parameter Autotune Isd Step The step response meas
49. Frequency Range 0 2 75 Hz Standard 75 Hz 85Hz Optional need specific Motor Filter Capacitor MFC Service Duty Rating Normal Duty Heavy Duty 110 Overload for 1 min every 10 150 Overload for 1 min every 10 min min Variable Torque Load Constant Torque Load Typical VFD Efficiency gt 97 5 AFE gt 98 18 Pulse Contact Factory for Guaranteed Efficiency of Specific Drive Rating Input Power Factor AFE Rectifier 0 95 minimum 10 100 Load IEEE 519 Harmonic Guidelines IEEE 519 1992 Compliant VFD Noise Level lt 85 dB A per OSHA Standard 3074 Regenerative Braking Capability Inherent No Additional Hardware or Software Required Flying Start Capability Yes Able to Start into and Control a Spinning Load in Forward or Reverse Direction Operator Interface 10 Color Touchscreen Cat 2711P T10C4A9 VAC Built in PDF viewer Redesigned PanelView Plus 6 Logic Module with 512 Mb of memory Languages English French Spanish Portuguese German Chinese Italian Russian and Polish Control Power 220 240V or 110 120V Single phase 50 60 Hz 20 A External 1 0 16 Digital Inputs 16 Digital Outputs External Input Ratings 50 60 Hz AC or DC 120 240V 1 mA External Output Ratings 50 60 Hz AC or DC 30 260V 1A Analog Inputs Three Isolated 4 20 mA or 0 10V 250 0 Analog Resolution Analog input 12 Bit 4
50. Idc Reference must be at 0 1 pu and Idc Feedback must be around that same number Verify the Idc error stays around 0 The Idc waveform can be observed from 121 Idc1 on the ACB board The waveform must have an offset of 0 5V for each 0 1 pu of Idc Test Command The waveform must also never have any of the low points between ripples go to OV this indicates a problem with the DC Link cabling See the troubleshooting section for sample waveforms Rockwell Automation Publication 7000 IN012B EN P June 2014 Tuning Procedure Commissioning the Drive Chapter 4 6 Increase Idc Test Command to 0 2 pu and repeat the process e Increase to 0 7 pu in 0 1 pu steps for 18 Pulse e Increase to 0 3 pu in 0 1 pu steps for AFE verifying each level as you increase the current s For the AFE rectifier the Idc test is limited to 0 3 Idc Reference If there is a current meter somewhere on the input to the transformer drive check the current to ensure that it matches expectations for drive performance 7 Decrease the IDC current in increments of 0 1 pu to 0 and stop the drive Return to the Feature Select parameter group and reset Operating Mode to Normal Tune the PowerFlex 7000 B Frame medium voltage drive to the connected motor and load There are three drive functions that require tuning These are listed below in the typical tuning order 1 Rectifier 2 Mtr Impedance 3 FluxSpeedReg Tune the first two functions with the motor sta
51. NT 0 00 100 00 200 00 300 00 Vrms 10 00K 7 50K 5 00K 2 50K VOLTAGE 0 00K 2 50K 5 00K 7 50K 10 00K 100 00 110 00 120 00 130 00 140 00 150 00 TIME ms Rockwell Automation Publication 7000 IN012B EN P June 2014 15 Chapter 2 PowerFlex 7000 Overview Simplified Electrical Diagrams 16 2400V Figure 6 2400V Direct to Drive transformerless AFE rectifier LINE CONVERTER COMMON MODE CHOKE L Me MACHINE CONVERTER 4 B X SGCTs x X SGCTs x x L U gt e e J uT L L 4 e e 4 ga 3 W T3 pO el nt I LT T x X x x x c ae Figure 7 2400V AFE Rectifier with Separate Isolation Transformer REMOTE LINE CONVERTER DC LINK MACHINE CONVERTER STX R r X U X SGCIs X x sects x w o eee l Le UU Vo 2y 2 4 e Wo LW LL J x x ax xX x x ZT L Figure 8 2400V 18 Pulse Rectifier with Separate Isolation Transformer DC LINK ISTX LINE CONVERTER L M MACHINE CONVERTER 4U Z1 Rockwell Automation Publication 7000 IN012B EN P June 2014 PowerFlex 7000 Overview Chapter 2 3300 4160V Figure 9 3300 4160V Direct to Drive transformerless AFE rectifier
52. OK 3 Click Current Control in the Group Name column Select Input Impedance in the Parameter Name column and click Value 4 Set the parameter Input Impedance to an initial value of 0 05 pu Rockwell Automation Publication 7000 INO12B EN P June 2014 95 Chapter4 Commissioning the Drive Figure 75 Current Control Group in Service Level Access Home Display Alarms Setup Diagnostics Utility Access Service Filter ReadWrite Search Help File Parameter lt lt All Parameters gt Feedback Diagnostics Feature Select Drive Hardware Motor Ratings Autotuning Motor Model Speed Command Speed Control Speed Profile Current Control Parameter Name Idc Reference 0 000 pu Idc Feedback 0 000 pu Idc Error 0 000 pu Vdc Reference 0 000 Alpha Rectifier 0 0 deg IdcRefLmt Motor 0 000 pu IdcRefLmt DCTest 0 000 pu IdcRefLmt Autotn 0 000 pu CurReg Bandwidth 200 0 rfs Idc Test Command 0 000 pu Idc Ref Step 0 000 pu T DC Link 0 040 sec Input Impedance 0 0500 pu Feedforward Fil 2 0 Hz 5 Energize the drive by closing the input contactor 6 Record the value of the rectifier input voltage by looking at parameter Rec Input Voltage P 696 for example E 7 For SCR drives set parameter Idc Command Test in Current Control to 0 800 pu For AFE drives set the parameter to 0 300 pu for example L 8 Start the drive and wait for a few seconds for steady state conditions to be establishe
53. PS Inserted all PowerCage drawings with and without SPS installed Added SGCT PowerCage drawings showing SPS and heat pipe test points Added Snubber Resistor drawings showing SPS Added Snubber Capacitor drawings showing SPS Replaced Control Power schematic Inserted new Cosel Power Supply images Updated all cabinet drawings to reflect SPS boards Inserted heat pipe converter cabinet graphics Inserted IGDPS Board LED test point table Inserted SPS Board LED test point table Updated Gating Test section for new HMI Added labels on SCR SPGDB Boards Updated System Test section for new HMI Updated Analog 1 0 section Changed 18 Pulse section to accommodate new HMI Insert Save and Retrieve information Changed DC Current Test to use new HMI Updated Tuning procedure using the new HMI Updated Input Impedance Manual Tuning procedure Added Leakage Inductance footnote Changed Speed Regulator Manual Tuning Induction Motor for new HMI Changed Total Inertia Calculations for clarity Switched all references from Tachometer to Encoder Updated and reformatted all Specifications Added Index Rockwell Automation Publication 7000 IN012B EN P June 2014 133 AppendixC History of Changes Notes 134 Rockwell Automation Publication 7000 IN012B EN P June 2014 Index Numerics 18 Pulse Phasing Test 81 Line Terminal Resistance 81 A AC DC Con
54. Rockwell Automation Publication 7000 IN012B EN P June 2014 13 Chapter2 PowerFlex 7000 Overview 18 Pulse Rectifier with Separate Isolation Transformer For high power constant torque applications and or when the line voltage is higher than the motor voltage a transformer is required for voltage matching The 18 Pulse rectifier uses SCRs instead of the SGCTs used for an AFE rectifier When used for high power and constant torque applications the 18 Pulse rectifier has lower losses than the AFE rectifier making it ideal for the highest power requirements The 18 Pulse isolation transformer provides the required input impedance and addresses common mode voltage just like the separate isolation transformer used with the AFE rectifier However instead of a PWM rectifier switching pattern and a single rectifier bridge the 18 Pulse configuration mitigates line side harmonics through harmonic current cancellation in the isolation transformer phase shifted secondary windings The inverter is the same configuration for all available rectifier options Figure 4 3300 4160V 18 Pulse rectifier with Separate Isolation Transformer REMOTE DC LINK ISTX LINE CONVERTER ix Me MACHINE CONVERTER e RARIS p gsr X um Ue K WTS o i m F L M Cooling Technology These VFDs are supplied with heat sinks for low and mid power configurations and heat pipes for high power configurations While bo
55. Save and Retrieve Diagnostic Configurations Any number of configurations can be saved to any media accessible to the terminal To save a configuration e Click Menu and choose Save s Type the filename and save as file type XML in the dialog To retrieve a saved configuration e Click Menu and choose Load e Select the saved configuration The drive contains a default diagnostic setup This default configuration is loaded by pressing the Menu button and then selecting Default Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 Diagnostic Control The Control tab Figure 69 shows the current status of the data capture and provides a means to control the data capture process Figure 69 Control Sub Menu Home Display Alarms Setup Diagnostics Utility Setup Control View Plot Operating Mode OR Normal Fea Running Last Trigger Unavailable Force Stop a Export Last Trigger will display a time stamp of the last trigger occurrence ifa data capture is available The status of the data capture shows e Stopped e Running e Triggered e Force Triggered Re Arm Arm the trigger if it has stopped Force Unconditionally trigger data collection Stop Abort data collection process This will allow the previous capture to be viewed as once a trigger condition occurs the previously captured data is overwritten Export Not curre
56. Search to open the Search Dialog e Type the Linear number and click Select OR e Type the Partial Name in the Field select from the list of parameters found and click Select Rockwell Automation Publication 7000 INO12B EN P June 2014 83 Chapter4 Commissioning the Drive Figure 66 Search Dialog seans x Linear ca Partial Name Select o Canol Parameters are not plotted by default To plot the parameter select the desired trace and click Plot Click Plot again to remove the trace from the plot Diagnostic Trigger The trigger variable is based on the first trace parameter The trigger type is defined by the drive as e Single the capture is triggered once and must be manually armed again for an additional trigger or e Continuous the capture is re armed each time the drive starts or when manually re armed The trigger condition is set from a pulldown menu and consists of Greater than gt AND amp Less than lt NAND N amp Equal to OR Not Equal to l NOR N The value the trigger condition is being applied to is entered by selecting the data field and then clicking on the Soft Keypad Icon 84 Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 Depending on the type of parameter assigned to trace 1 the following dialogs are possible s Value Parameter Enter the value in the Soft Keypad dialog e Binary Parameter
57. Terminal Resistance Measurements 0 00 eee eee 81 Application of Medium Voltage x vis see 82 Save and Retrieve Diagnostic Configurations 4 86 Diagnostic LZ onreoal 1 a 5 afea aO Tec TTT RTL EE Are 87 Diagnostics VIEW alee a a a aloe ULI Ou ae Madey 88 Di gnostics Plots ee eene Siac ia EE EEEE E 88 Input Phasing Check 90 DE Gutrent Best ise vc ce inicio Ay E EE E 4s 92 Tuning Procedure 4 are S T RTK iena a a Eea 93 Rece a EESE Se NE ule aa TA 94 Motor Tmped ances ona a E E E T deans odes 98 Flux Speed Regulator Induction Moros 00 100 Speed Regulator Manual Tuning Induction Motor 103 Flux Speed Regulator Synchronous Motors see 106 Running the Load 110 Motor Starting Torque se ee e arin taevelsnad oa aware 110 Reaching Specific Load Dons 55so tis cecenievsiees cow eens 110 Captaring Data iss merrier Re REER E RARA Ra 112 Guidelines For Data Capture dre boc Uae ata tee lh 112 Harmonic Analysis required for PWM drives only 5 114 DO Ta Test TTT 115 Load Testucssese cerned OSEE EEES 117 Synchronous Transfer se ae ie E T e R THER aS 118 Bypass Contactor Closures 2552 2s csc esce cine cases lt ha07eeunt 119 Synchronous Transfer Test Verify Sync Lead Angle 119 Live Synchronous T ransber see 120 Appendix A Torque Requirements for Threaded Fasteners sss 123 Ene der Usage oarden ai naka KR A NTR E E RE c 123 When is an Encoder Required 2 74 3 4 cad
58. a reugesinternsane s 29 lAsp cti n Proc s sssi ionni RL E AA Vas Beer eS ES 30 Safety H TT 30 Lockout Tagout aa ZR EaR Te 8 9 pho beh TERE e YZ call 30 Step Down Transformer Fusing e eee ee eves eat enuens 31 Fuse and O L Protection s 31 Installation Review se 31 Inspect for Shipping Damage e e e e e eater vein 32 Inspect Cabinets for Debris s 32 Rockwell Automation Publication 7000 IN012B EN P June 2014 5 Table of Contents Protective Barticts 2 Ha Ah soe i KERE a aS 32 Component Grounding ae hata ee e e mesial th ane eminence 32 Information on Splice Kits ist nod toe eee ae hes tg 33 Power Cabling inensis nani aie iiei a E ata pE EE aa 33 Control Witing SER E kinases Y RN alice Ea RES E N SHR 2 33 Service R re ation a tenet roat neh eabe cantare tute 34 Why this Information is Needed 34 Control Power Off Tests suet scenes ey Uae ae 35 Interlocking warts RY RT adare Rema a dates 35 R sistance e TTT 37 SGCT and Snubber Circuit 2 44 osascse camer tuoypouenss deen reren 39 SGC YT TESNE eh a AET E lo abated te kets blot 45 SGCT Anode to Cathode Sharing Resistance 46 Snubber Resistance SGCT Device rreren 48 Snubber Capacitance SGCT Device 49 Silicon Controlled Rectifier PowerCages see 51 SCR Testing ar ee a aoia a RE ETETA EEEE E E S 52 SCR Anode to Cathode Resistance 0 cece cece cece eeees 54 SCR Sharing Resistance Test ian euelot sec eeoiea ds 2aee elles 55 SCR G
59. ad Ensure the settings match the rating identified on the sticker Replacement fuses have been shipped with the drive in the event that a fuse opens during commissioning Prior to commencing the commissioning of the drive line up it Rockwell Automation recommends re inspecting the equipment installation Identifying errors in the drive installation prior to commencing the commissioning rather than mid way through the process greatly reduces the time required to commission the drive line up Rockwell Automation Publication 7000 INO12B EN P June 2014 31 Chapter 4 Commissioning the Drive 32 Inspect for Shipping Damage Prior to continuing verifying the installation of the equipment open the cabinets to all equipment supplied by Rockwell Automation and inspect each component installed for signs of damage Make any damage claims to the Medium Voltage Business as soon as possible in order to replace the damaged components as quickly as possible See Publication 7000 IN008_ EN P for further information on transportation and handling Inspect Cabinets for Debris Once you complete the safety checks and successfully isolated the drive line up inspect all cabinets in the drive line up for foreign material left behind during the installation Ensure that no tools hardware or wiring debris remain in the drive Note that some electric components used within the drive create magnetic fields that may attract residual metal shavi
60. al 9 What Is Nor in this Manual 9 General Precaitionssei eneren A X XE A AREER ASAE T N 10 Commissioning SUppoTt s s sses at ae cere e e Ree 10 Chapter 2 Topology ioiai ee eee eee re ree 11 Rectifier Designsiosorod resne un ui a a E a 12 Configuration xe e 12 Cooling Technology sse 14 Motor Compatibility ee e dines bs oaeieercmees adda pengs Peareks 15 Simplified Electrical Diagrams ses eee 16 DAQOV See Ha a AEE a e E E E Ha 16 SB 300 41 GOV mr fase de need ees SHA a E ee 17 6600Y iiaae Saran tates ea a ae r a e gee E 18 Operator Interface 22 Sa cael resser t i iA OVE E t aree Eee 19 Basic Configurations sera anra a E E beep SEADETE 19 Chapter 3 Before Commissioning ee e e e 21 Pre Commissioning Responsibilities eee 23 Commissioning Preparation ss 0 25 hi saden tases keds eases Pacents 23 Recommended Tools and Equipment 6 2s00 sees seeees 23 Additional Required Resources i24sceavatsicdcdie Sum atuiaduateoo erates 24 Technical Publications and Manuals 00 ce sees 25 Important Note for the Commissioning Engineer 4 25 Chapter 4 Key Steps to Commission a PowerFlex 7000 Drive 4 27 Drive Application Review 28 Rockwell Automation Drive Line up Drawings 28 Dimensional Drawings sees ee e e e cadvesecadewerses 28 Electrical Drawings see e 29 Electrical System One line Diagram see e 29 Verify One line Diagram on Site n caucde cec
61. al for retrofitting existing motor applications Rockwell Automation Publication 7000 IN012B EN P June 2014 PowerFlex 7000 Overview Chapter 2 Figure 2 3300 4160V Direct to Drive transformerless AFE rectifier LINE CONVERTER COMMON MODE CHOKE MACHINE CONVERTER e L 8 T oe e e X SGCIs X FS Z sgr n FS FN FS x x E ii a SE P P e 4 eee LI 4 gt x x x gt x x ATTAR L M AFE Rectifier with Separate Isolation Transformer For applications when the line voltage is higher than the motor voltage a transformer is required for voltage matching In this case providing an AFE rectifier with a separate isolation transformer is ideal The isolation transformer provides the input impedance replaces the requirement for an integral line reactor and addresses the common mode voltage replaces the requirement for a CMC that is supplied in the Direct to Drive rectifier configuration However the AFE rectifier its operation and advantages are the same as the Direct to Drive configuration Figure 3 3300 4160 AFE Rectifier with separate isolation transformer REMOTE LINE CONVERTER ape PNE MACHINE CONVERTER ISTX 6 6 6 P e Kran Ey X SGCls X FS SGCTs FS x x x ithe 2U x1 v S wod S vg a 1W o meal 4 NUS 7 O z x xX x y UW FR xX x x l Lo o oe 4
62. and L R and D Maximum parameters so that with full reference command inputs the associated Reference command Variables read the desired maximum value The various reference command maximums usually have to be increased above the desired maximum value to compensate for the loading down of their 10 volt input rails by the attached potentiometer or isolator Example SpdCmd Anlg Inp 4 20mA Reference command Input Scaling The customer 4 20 mA speed input is coming to the Current Loop Receiver on the ACB and they want the maximum input to represent 60 Hz 1 Set Reference Command Remote Maximum Ref Cmd R Max for 60 Hz 2 Set the Reference Select parameter to Remote 4 20 mA 3 Have the source supply 20 mA to the drive Verify this with a multimeter connected in series with the current source Ensure that you are in Remote mode with the selector switch and look at the parameter Speed Command In which will represent that 20 mA signal 4 Ensure that it reads 60 Hz If it does not increase the Ref Cmd R Max value until this parameter reads 60 Hz Example SpdCmd DPI Digital Reference command Input Scaling The maximum value for a digital reference command is 32767 the minimum value is 0 Values that are negative or out of bounds will result in the drive slowing down to minimum speed Rockwell Automation Publication 7000 INO12B EN P June 2014 77 78 Chapter4 Commissioning the Drive Analog Outputs Review the
63. application e g ID Fans Assign parameter Speed Error in the Speed Control group to a test point e g ITP1 on the DPM This can be done similarly to the way that the meter assignments were described earlier in the chapter Then it can be displayed on your oscilloscope Adjust the reference command to a value around the middle of the operating speed range Start the drive and wait for it to accelerate to the commanded speed Set parameter Speed Ref Step in Speed Control to 0 8 Hz The drive speed will step up and down by this amount at regular intervals The step of 0 8 Hz corresponds to 0 8V or 800mV on the test point To capture the error set the scope at 200 mV division and 200 msec division Trigger the scope on negative edge as shown in Figure Adjust the value of parameter Total Inertia until the speed rises to approximately 63 of its final value in 1 second as shown in the figure If the response time is too fast it indicates that Total Inertia is set too high and should be decreased If the response is too slow then Total Inertia is set too low and should be increased Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 Figure 79 Speed regulator tuned correctly LeCroy 9 Set parameter SpdReg Bandwidth to the normal operating value Confirm that the response time is equal to the inverse of the speed regulator band
64. armonic Analysis PWM Drives only 114 Live Synchronous Transfer 120 Load Test 117 Sync Lead Angle 119 Synchronous Transfer 118 Overload Protection 31 P Power Supply Tests 60 135 PowerCage 2400V heat sink 40 2400V with SPS 40 3300 4160V heat pipe 43 3300 4160V heat sink 41 3300 4160V with SPS 41 6600V heat sink 42 6600V with SPS 42 Recommended Tools 23 Rectifier 94 Input Impedance Manual Tuning 95 Rectifier Designs 12 18 Pulse Rectifier with Separate Isolation Transformer 14 AFE Rectifier with Separate Isolation Transformer 13 Direct to Drive 12 Resistance Checks 37 SCR Anode to Cathode Resistance 54 SCR Gate to Cathode 56 SCR Sharing Resistance 55 SGCT and Snubber Circuit 39 SGCT Anode to Cathode 46 SGCT Testing 45 Snubber Capacitance SCR 58 Snubber Capacitance SGCT Device 49 Snubber Resistance SCR 57 Snubber Resistance SGCT Device 48 S Safety Tests 30 Sample Waveforms Bypass Contactor Closures 119 DC Current Test 116 Drive Input Voltage Phasing Checks 113 Harmonic Analysis PWM Drives only 115 Live Synchronous Transfer 121 Synchronous Transfer 120 Scaling 77 SCR Anode to Cathode Resistance 54 Firing Test 71 Gate to Cathode Resistance 56 Gating Test 69 PowerCage 51 Sharing Resistance 55 Snubber Capacitance 58 Snubber Circuit Connections 53 Snubber Resistance 57 Selective Harmonic Elimination 15 Service Data 34 SGCT Anode to Cathode 46 Gating Test 69 Sharing Resistance
65. arted dry VT 75 30 100 Normal No Screw type primed discharge CT 150 100 1000 Heavy Yes open Slurry handling discharge CT 150 100 100 Heavy Yes open Turbine Centrifugal deep T 50 100 100 Normal No well Vane type positive CT 150 150 175 Contact factory Yes displacement SEPARATORS AIR VT 40 100 100 Normal No fan type 1 PowerFlex 7000 A Frame suitable only for normal service duty rating 128 Rockwell Automation Publication 7000 IN012B EN P June 2014 Appendix B Specifications ATTENTION In the event of discrepancies between information published in generic manual specifications and those included with your specific design or electrical drawings take the DD or EE ratings as correct values B Frame Drive Specifications Table 15 General Design Specifications Description Motor Type Induction or Synchronous Input Voltage Rating 2400V 3300V 4160V 6600V Input Voltage Tolerance 10 of Nominal Voltage Sag 30 Control Power Loss Ride through 5 Cycles Std gt 5 Cycles Optional UPS Input Protection Surge Arrestors AFE Direct to Drive Metal Oxide Varistor MOV 18 Pulse Input Frequency 50 60 Hz 0 2 Power Bus Input Short circuit 25 kA RMS SYM 5 Cycle Current Withstand 2400 6600V Basic Impulse Level 45 kV 0 1000 m Power Bus Design Copper Tin plated Ground Bus Copper Tin plat
66. ate to Cathode Resistance 0 cece cece ene ee neces 56 Snubber Resistance SCR Device 57 Snubbet Capacitance SCR Device 58 Control Power hestsics beni 4s Stee E ae ex ee ates 59 ThreePh se Input sses awe Rew ad anon netn eae E EEE ke ee tee 59 Three Phase Input Single Phase lnputivces osseous vee ewes ptnees 60 Power Supply Tests tsere pininana inet te eect EE a 60 Circuit Board Healthy Lights oo sese 60 Control Power Transformer CPT B Frame only 61 AC DC Converter PS1 iis yt ecu choline eh oee Col 61 DC DC Converter PS 63 SGCT Power Supplies IGDPS 5 sex ccechcaneek ea delusveeeees 64 IGDPS Board TL EIS adao hl dann te A Rate 68 SPS Board LED T 69 Gating Lests lt 5 ascii a a EA 25557 Fe Rh aa I eens ees 69 Gating West TT 70 SCR Firing Wests ics ean tated be uaa ashes lac 71 SGCT Firing R ai ala hake th Na A Se ttt et ans E 73 System Tes TTT 74 System Test Mode sss rn graag ii iea ad oeii Erias 74 Start Stop Control Creuir esse 75 Sra rns LHC TGO aa ca hacia e Ra RTS RER RA Se StS 76 Analog O dermapen n AE E asia apheuekerteswen EE 76 Analog Inputs 4 4 KT roturas T dA e a aea TI Analog Outputs ss kossi sise rie t AA anes even E E 78 Configurable Alarms eee 80 t8 Pulse TT dnc Veantdv te tel cucu viernes ie aude Jane Vk te 81 Rockwell Automation Publication 7000 IN012B EN P June 2014 General Reference Specifications History of Changes Index Table of Contents Line
67. ated value Speed Regulator Manual Tuning Induction Motor If it is not possible to tune the speed regulator using the auto tune function tune the speed regulator s step response manually using the following procedure To obtain accurate results the load torque must be steady 1 Click the Display tab and click Speed Control from the Group Name column The Speed Control parameters will appear in the right window 2 Click SpdReg Bandwidth and click Value Type 1 0 in the New Value Field and click OK Rockwell Automation Publication 7000 INO12B EN P June 2014 103 Chapter 4 Commissioning the Drive 104 Figure 78 Speed Control Group Home Display Alarms Setup Diagnostics Utility Access Service Filter ReadWrite Search Help File 3 lt All Parameters gt Feedback Diagnostics Feature Select Drive Hardware Motor Ratings Autotuning Motor Model Speed Command Speed Control Parameter Name Value T Units Speed Reference 6 0 Hz Speed Feedback 0 0 Hz Speed Error 0 00 Hz MtrTorque CurCmd 0 000 pu InvTorque CurCmd 0 000 pu Total Accel Time 32 0 sec Total Decel Time 32 0 sec Inertia Type Low Total Inertia 1 00 sec Speed Fbk Mode Sensorless SpdReg Bandwidth 1 0 rls SpdReg Kp 1 00 Parameter hd Set parameter Total Inertia in Speed Control to an initial value of 1 0 sec if it is a low inertial application pumps etc Set the parameter to 5 0 seconds if it isa high inertia
68. ating Mode Value changes to System Test Figure 59 Figure 59 System Test Mode Ld Home Display Alarms Setup seene Utility Access Advanced Filter ReadWrite Search Help Parameter Name Value Units Operating Mode System Test Speed Ref Select PFNetServer TorqueRef Select None Ref Command Loss Fault Coast Speed 2 0 Hz Auto Restart Dly 0 0 sec lt All Parameters gt Feedback Diagnostics Feature Select TIP You can check the entire system without medium voltage As long as all the contactors have test power you can start stop E Stop trigger faults check remote 10 check PLC inputs and verify other functions ATTENTION Ensure that the drive is no longer running in system test mode A prior to applying medium voltage to the drive line up Failure to do so may result in equipment damage Once the drive is in System Test mode ensure that the stop start circuit functions as desired If necessary review the electrical schematic drawings prior to performing this test to better understand the control circuit Start the drive in local control while observing the system vacuum contactors or customer supplied circuit breakers If you must troubleshoot Rockwell Automation medium voltage switchgear refer to the following publications e Publication 1500 UM055_ EN P Medium Voltage Controller Bulletin 1512B Two High Cabinet 400 Amp e User Manual e Publication 1503 IN050_ EN P OEM Starter Frame
69. ber of inverter components is minimal For example only six inverter switching devices are required at 2400V 12 at 3300 4160V and 18 at 6600V The PowerFlex 7000 also provides inherent regenerative braking for applications where the load is overhauling the motor e g downhill conveyors etc or where high inertia loads e g fans etc are quickly slowed down The drive uses Symmetrical Gate Commutated Thyristors SGCTs for machine converter switches SGCTs for Active Front end AFE rectifier configurations for the line converter switches and Silicon controlled Rectifiers SCRs for 18 Pulse rectifier configurations The PowerFlex 7000 provides a selectable option for enhanced torque control capabilities and increased dynamic control performance This High Performance Torque Control HPTC feature delivers 100 torque at zero speed and provides torque control through zero speed with smooth direction transition Rockwell Automation Publication 7000 INO12B EN P June 2014 11 Chapter2 PowerFlex 7000 Overview Rectifier Designs 12 Configurations The PowerFlex 7000 offers three rectifier configurations for B Frame drives e Direct to Drive AFE rectifier with integral line reactor and Common Mode Choke e AFE rectifier with separate isolation transformer s 18 Pulse rectifier transformerless AFE rectifier with separate isolation transformer Direct to Drive Direct to Drive M technology does not require an i
70. blication 7000 IN012B EN P June 2014 Appendix A General Reference Torque Requirements for Unless otherwise specified use the following values of torque in maintaining the equipment Threaded Fasteners amp Diameter Pitch Material Torque N m Torque lb ft M2 5 0 45 Steel 0 43 0 32 M4 0 70 Steel 1 8 1 3 M5 0 80 Steel 3 4 25 M6 1 00 Steel 6 0 44 M8 1 25 Steel 14 11 M10 1 50 Steel 29 21 M12 1 75 Steel 50 37 M14 2 00 Steel 81 60 1 4 20 Steel S A E 5 12 9 0 3 8 16 Steel S A E 2l 27 20 Encoder Usage When is an Encoder Required An encoder is required under the following conditions 1 When speed regulation accuracy must be between 0 01 0 02 of nominal speed 2 When the zero speed breakaway torque needed is greater than 90 of continuous running torque 3 When continuous running speed is greater than or equal to 0 1 Hz but less than 6 Hz 4 For minimizing restart times using the flying start capability in forward or reverse direction 5 At any time when high performance torque or speed control mode HPTC is enabled Rockwell Automation Publication 7000 INO12B EN P June 2014 123 Appendix A 124 General Reference Table 11 PowerFlex Speed Regulation Encoder Frequency Output lt 6 Hz 6 15 Hz gt 15 Hz Without Encoder Not applicable 0 1 0 1 With Encoder 0 02 0 01 0 01 With Encoder and HPTC 0 01 0 01 0 01 mode enabled Notes
71. cal locations of the same circuit Disconnect the 2 pole plug to the Gate Driver board marked TB1 on the circuit board Measure the resistance from the point of the plug that connects to the point labeled V SENSE on the Gate Driver board to the anode side heat sink A value of 80 kO indicates a good sharing resistor Figure 36 Snubber Circuit for SCR Rectifier Module s 1 Rsn 1 s 2 Anode Cathode Rockwell Automation Publication 7000 IN012B EN P June 2014 51 Chapter4 Commissioning the Drive Figure 37 Snubber Circuit Assembly for SCR Rectifier Module Rsh Rsn 2 5 1 s 2 Rsn 1 Anode Pa Cathode SCR Testing The following procedure verifies SCR semiconductors and all associated snubber components For quick reference to the expected resistance and capacitance values refer to Table 2 below A simple schematic diagram in Figure 38 shows the snubber component connections across an SGCT Table 2 SCR Snubber Circuit Resistance and Capacitance Values SCR Rating Sharing Resistance Snubber Resistance Snubber Capacitance 350 400 815 A 80 kO 0 5 uf 52 Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 Figure 38 SCR snubber circuit connections
72. cing 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 i ATTENTION This drive contains ESD Electrostatic Discharge sensitive parts damage or a reduction in product life Wiring or application errors such as undersizing the motor incorrect or inadequate AC supply or excessive ambient temperatures may result in malfunction of the system f ATTENTION An incorrectly applied or installed drive can result in component 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 i ATTENTION Only personnel familiar with the PowerFlex 7000 Adjustable After installation Rockwell Automation Medium Voltage Support is responsible for commissioning support and activities in the PowerFlex 7000 product line Phone 519 740 4790 Option 1 for technical and option 4 for commissioning questions MVSupport_technical ra rockwell com or MVSupport_services ra rockwell com Rockwell Automation support includes but is not limited to e quoting and managing product on site start ups e quoting and managing field modification projects e quoting and managing customer
73. d 9 Record the value of the rectifier input voltage by looking at parameter Rec Input Voltage P 696 for example V 10 Calculate the value of input impedance for AFE drives bee Vino a Vint Tact Cin Ving Vini C is the value of input filter capacitor given by Line Filter Cap P 133 11 Calculate the value of input impedance for SCR drives a 3Ving Vini in Lj C 12 Stop the drive Set the Operating Mode parameter to Normal and Idc Command Test to zero 96 Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 T DC Link P 115 Manual Tuning Determine an appropriate value for the T DC Link parameter from the current regulator step response while operating in DC Current test mode Use the following procedure 1 Ensure you set all parameters in the Drive Hardware and Motor Ratings groups to the correct values Otherwise the calculated value of parameter T DC Link in Current Control will be incorrect 2 Set parameter Operating Mode in the Feature Select to DC Current to enter the test mode 3 Set parameter Idc Test Command in Current Control to 0 225 pu for AFE rectifier drives and 0 400 pu for SCR drives 4 Set parameter CurReg Bandwidth in Current Control to 100 rad s A lower than the normal bandwidth makes the step response easier to measure 5 Set parameter T DC Link in Current Control to 0 020 sec which is at the low end of the normal range of values a
74. d Control is set equal to Autotune Inertia and calculate regulator gains If the auto tuning fails then a warning is issued indicating the cause of the failure Following are the list of possible warnings L Magnetize Low indicates that the measured value of magnetizing inductance is less than 1 0 pu This warning indicates an unusually low value of magnetizing inductance This may occur if the motor is much larger than the drive and the nameplate parameters do not correspond to the actual motor ratings L Magnetize High indicates that the measured value of magnetizing inductance is greater than 10 0 pu This warning indicates an unusually high value of magnetizing inductance This may occur if the motor is much smaller than the drive and the nameplate parameters do not correspond to the actual motor ratings Tune the flux regulator using the manual method described below T Rotor Low indicates that the calculated value of rotor time constant is less than 0 2 seconds This is caused by a value of Lm Rated or Rated Motor RPM which is too low T Rotor High indicates that the calculated value of rotor time constant is greater than 5 0 seconds This is caused by a value of Lm Rated or Rated Motor RPM which is too high Regulator Limit indicates that the torque command was greater than Trq Limit Motoring or Trq Limit Braking The measured inertia value is invalid Set the Autotune Trq Stp or Autotune Spd Cmd parameter toa lower valu
75. d test point LN T Snubber test point Heatsink Heatsink o 48 Figure 33 Snubber Resistor Test with SPS Board Resistance Value between two heat sinks is sharing resistance in parallel with Anode Cathode Resistance Sharing Resistor Snubber Snubber Resistor Capacitor SPS Board 1 2 J1 L Test Point SGCT Y Resist lue bet esistance value between nesaat em heat sink and test point is Snubber Resistance Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 Refer to Table 1 on page 46 to determine the appropriate snubber resistance value for the current rating of the SGCT used If the resistor is found to be out of tolerance refer to publication 7000 UM202_ EN P for detailed instructions on replacing the snubber resistor assembly Snubber Capacitance SGCT Device Turn the multimeter from the resistance to capacitance measurement mode Verify the snubber capacitor by measuring from the test point to the heat sink adjacent to the right for standard rectifiers or from heat sink to heat sink For SPS rectifiers measure from the test point to pin 1 of the Phoenix connector that plugs into J1 of the SPS board disconnect the J1 connector from the SPS board first Figure 34 Snubber Capacitor Test
76. device damage will occur to the Digital 1 0 board and possibly weld the equipment s 0 ATTENTION Do not short the lifted wire to ground when testing the circuit or trip contact 80 Rockwell Automation Publication 7000 IN012B EN P June 2014 18 Pulse Phasing Test Commissioning the Drive Chapter 4 Prior to applying medium voltage and running the drive it is important to verify the phase rotation on the input of all 18 Pulse drives The following tests do not need to be performed on AFE rectifier drives unless they incorporate synchronous transfer s Line Terminal Resistance Measurements e Application of Medium Voltage Power Compare the voltage feedback from all 9 test points in the ACB board to ensure proper phasing Failure to perform the recommended tests will result in poor drive performance and may result in drive converter damage Line Terminal Resistance Measurements Measuring the resistance between the drive line cable terminals will quickly identify if there is inter wiring between the 0 20 and 20 bridges in the isolation transformer Figure 63 Line terminal designations
77. devices Normal gating test mode fires the inverter at the output frequency corresponding to the active reference speed command Prior to applying medium voltage verify the entire low voltage control circuit to ensure the drive operates as expected Failure to perform this test may result in damage to the drive or process in the event that the control does not operate as expected This section of the manual provides instruction for the following five tests e System Test Mode e Start Stop Contactor Control e Status Indicators e AnalogI O e Configurable Alarms System Test Mode This test mode enables the drive to operate the drive s low voltage control circuit without medium voltage present Drive status I O is active while performing tests in this mode If monitoring the drive I O remotely notify process control in advance to avoid confusion You must have advanced access permissions on the drive to perform this 0 ATTENTION Isolate the drive from medium voltage prior to starting this test operation Rockwell Automation Publication 7000 INO12B EN P June 2014 Start Stop Control Circuit Commissioning the Drive Chapter 4 1 Click the Display tab and select Feature Select from the Group Name column The group parameters show in the right window 2 Select Operating Mode and click Value to open the Operating Mode dialog Figure 55 3 Select System Test from the New Value pulldown menu and click OK The Oper
78. e _0 wed yom l RL two 2 T l W T3 oer Figure 14 6600V 18 Pulse Rectifier with Separate Isolation Transformer DC LINK ISTX LINE CONVERTER L M MACHINE CONVERTER uea J a AV Z2 x 4W Z3 SGCTs b4 3V Y2 3W Y3 2U X1 2V K2 ba PRA L M 18 Rockwell Automation Publication 7000 IN012B EN P June 2014 Operator Interface PowerFlex 7000 Overview Chapter 2 The HMI Interface Board is an HMI enabling device for the PowerFlex 7000 drive It allows the user to acquire all the necessary executable tools documentation and reports required to commission troubleshoot and maintain the drive Via the HMI Interface Board the user can choose the style and size of the desired Windows based operator terminal to interact with the drive e g Panel View CE terminal laptop or desktop computer The HMI Interface Board removes past issues with compatibility between the drive and configuration tools as all the necessary tools are acquired from the drive The HMI Interface Board is well suited for applications that require remote placement of the operator terminal and remote maintenance Figure 15 Operator Interface SPF 1000 Terminal Home Display Alarms Setup Diagnostics Utility 4 ls C nan Basic Configurations There are three basic configurations for the HMI Interface Board Remote mounted HMI The HMI is not mounted in the
79. e and Transportation 40 70 C 40 185 F Temperature Range Relative Humidity Max 95 non condensing Altitude Standard 0 1000 m 0 3300 ft Altitude Optional 1001 5000 m 0 16 400 ft Seismic UBC Rating 1 2 3 4 Standards NEMA IEC CSA UL ANSI IEEE 1 Voltage Sag tolerance is reduced to 25 when control power is supplied from medium voltage via CPT 2 MOVs are used for 18 Pulse Surge arrestors are used for AFE Direct to Drive configurations 3 Short circuit fault rating based on input protection device contactor or circuit breaker 4 BIL rating based on altitudes lt 1000 m 3300 ft Refer to factory for derating on altitudes gt 1000 m 5 Optional 6 Under certain conditions power system analysis will be required Rockwell Automation Publication 7000 IN012B EN P June 2014 7000 INO12A EN P May 2013 Appendix C History of Changes This appendix summarizes the revisions to this manual Reference this appendix to determine what changes have been made across multiple revisions Change Removed all PanelView 550 content Linked referenced documents to Literature Library Changed sample waveform images to white background Built all equations using appropriate tools Updated Operator Interface section to reflect new HMI Inserted UPS battery option Consolidated resistance checks section Added Snubber Circuit for SGCT schematic with S
80. e and repeat the test Tuning abort indicates that the deviation in motor speed was greater than 10 Hz The measured inertia value is invalid Set Autotune Trq Stp to a lower value and repeat the test Inertia high indicates that the measured total inertia is greater than 20 seconds This warning indicates an unusually high inertia value For a very high inertia load such as a large fan this may be a valid result set Total Inertia manually to equal Autotune Inertia However a high inertia measurement might also indicates that the Autotune Trq Stp value is too low 102 Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 Flux Regulator Manual Tuning Induction Motor 1 Adjust the reference command to a value between 25 40 Hz 2 If possible run the motor loaded not uncoupled 3 Start the drive and wait for it to accelerate to the commanded speed 4 Record the value of parameter Lm Measured P 134 in Motor Model 5 Stop the drive 6 Set parameter Lm Rated in Motor Model to the recorded value of Lm Measured 7 Verify that the measured value is FLA wh Mag wpa Where FLA Motor Full Load Amps and NLA Motor No Load Amps 8 Calculate an approximate value of the rotor time constant using the LmRated following formula Tisa RatedSlip SyncRPM RatedRPM Where RatedSlip 2nFreqmotor x SyncRPM Set the parameter T Rotor in Motor Model to the calcul
81. e connected their control to the drive correctly This can be achieved by changing the drive status ready faulted warning etc It is possible to configure all of the drive s analog inputs and outputs without running the motor The following information describes how to set up the following drive features e Analog Inputs Analog Reference Command Input Scaling Local Remote Minimum Setting Maximum Setting Digital Reference Command Input Scaling Digital e Analog Outputs All of the Analog I O connections occur on the ACB Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 Analog Inputs e Analog Command Input Scaling Prior to commencing the reference command input scaling it is necessary to ensure that the reference command input selection has been configured as desired This requires setting Speed Reference Select P 7 to the appropriate input source Torque Reference Select is P 401 Set the utilized Reference Command minimum SpdCmd Pot L SpdCmd Anlg Inp R and SpdCmd DPI D to the desired value The minimum reference command input setting on a drive without an encoder is 6 Hz Without encoder control do not set the reference command minimum parameter below 6 Hz A control with encoder feedback will allow a minimum speed of 1 Hz With encoder control do not set the reference command minimum parameter below 1 Hz Set the utilized Reference comm
82. e ets ins 123 PowerFlex 7000 Drive Performance Torque Capabilities 126 Glossary OF Terms cucuta svat Ae eta toot el shee ele so Uo hie 126 Appendix B B Frame Drive Specifications e 129 Appendix C 7000 IN012A EN P May 2015 133 Rockwell Automation Publication 7000 IN012B EN P June 2014 7 Table of Contents Notes 8 Rockwell Automation Publication 7000 IN012B EN P June 2014 Chapter 1 Important User Information This document provides procedural information for commissioning the PowerFlex 7000 medium voltage B Frame drives heat sink and heat pipe models Who Should Use This Manual This manual is intended for use by personnel familiar with medium voltage and solid state variable speed drive equipment The manual contains material that enables Rockwell Automation field service engineers to commission the drive system What Is Not in this Manual This manual provides information specific to commission the PowerFlex 7000 B Frame drive It does not include topics such as e Physically transporting or siting the drive cabinetry e Installation and pre commissioning procedures e Meggering safety procedures e Dimensional and electrical drawings generated for each customer s order e Spare parts lists compiled for each customer s order e Trouble shooting potential usage problems Please refer to the following documents for additional product detail or instruction relating to PowerFlex 7000
83. e motor nameplate parameters do not correspond to the actual motor ratings Because of the design of the motor this method of measuring leakage inductance does not produce a valid result Obtain the leakage inductance from the motor data sheet or if this is not possible set the L Total Leakage parameter to its default value of 0 20 pu 1 LLeakage as where FLA Motor Full Load Amps LRA Motor Locked Rotor Amps Rockwell Automation Publication 7000 INO12B EN P June 2014 99 Chapter4 Commissioning the Drive s L Leakage High indicates that the measured leakage inductance is greater than 0 35 pu Possible causes are The inductance of long motor cables is increasing the apparent leakage inductance of the motor In this case the measured leakage inductance is probably correct The motor is very small leakage inductance generally increases with decreasing motor size Because of the design of the motor this method of measuring leakage inductance does not produce a valid result Obtain the leakage inductance from the motor data sheet or if this is not possible set the L Total Leakage parameter to its default value of 0 20 pu Flux Speed Regulator Induction Motors This method combines the auto tuning of the Flux and Speed regulator in a single step It calculates parameters Lm Rated P 131 T Rotor P 132 in Motor Model Group and Total Inertia P 82 in Speed Control group IMPORTANT For synchronou
84. e to be made to the depth of the counterpart This can be done by adding shims on the landing plate where the counterpart is mounted Prior to applying control power to the drive power semiconductor and snubber circuit resistance measurements must be taken Doing so will ensure that no damage has occurred to the converter section during shipment The instructions provided below detail how to test the following components e Inverter or AFE Rectifier Bridge Anode to Cathode Resistance Test Sharing Resistor and SGCT Snubber Resistance Test Snubber Resistor Snubber Capacitance Test Snubber Capacitor e SCR Rectifier Bridge Anode to Cathode Resistance Test Sharing Resistor and SCR Gate to Cathode Resistance Test SCR Snubber Resistance Test Snubber Resistor Snubber Capacitance Test Snubber Capacitor ATTENTION Before attempting any work verify that the system has been locked out and tested to have no potential Rockwell Automation Publication 7000 INO12B EN P June 2014 37 Chapter 4 Commissioning the Drive 38 Snubber Resistors Snubber resistors connect in series with the snubber capacitors Together they form a simple RC snubber that connects across each thyristor SCR or SGCT The snubber circuit reduces the dv dt stress on the thyristors and reduces the switching losses The snubber resistors connect as sets of various wire wound resistors connected in parallel The number of resistors
85. ed 6 x 51 mm a x 2 in Customer Control Wire Way Separate and Isolated Input Power Circuit Protection Vacuum Contactor with Fused Isolating Switch or Circuit Breaker Output Voltage 0 2400V 0 3300V 0 4160V 0 6000V 0 6300V 0 6600V Inverter Design PWM Inverter Switch SGCT Inverter Switch Failure Mode Non rupture Non arc Inverter Switch Failure Rate FIT 100 per 1 Billion Hours Operation Inverter Switch Cooling Double Sided Low Thermal Stress Inverter Switching Frequency 420 440 Hz Rockwell Automation Publication 7000 INO12B EN P June 2014 129 AppendixB Specifications Table 15 General Design Specifications Continued Description Number of Inverter SGCTs Voltage SGCTs per phase 2400V 2 3300V 4 4160V 4 6600V 6 Inverter PIV Rating Voltage PIV each device Total PIV Peak Inverse Voltage 2400V 6500V 6500V 3300V 6500V 13 000V 4160V 6500V 13 000V 6600V 6500V 19 500V Rectifier Designs Direct to Drive transformerless AFE rectifier AFE with separate isolation transformer 18 Pulse with separate isolation transformer Rectifier Switch SCR 18 Pulse SGCT AFE Rectifier Rectifier Switch Failure Mode Non rupture Non arc Rectifier Switch Failure Rate FIT 50 SGCT 100 SCR per 1 Billion Hours Operation Rectifier Switch Cooling Double Sided Low Thermal Stress Number of Rectifier Devices per phase Voltage AFE 18 Pulse 2400V 2 6 3300V 4 6 41
86. electrical schematics to understand which meters or signals the user expects out of the analog output ports on the ACB Board IMPORTANT _ To assign a parameter to an analog output verify you have Advanced access to drive operations 1 Click the Display tab and select Analog Outputs from the Group Name column Figure 60 Figure 60 Analog Outputs group Hom in Alarms Setup Setup D Diagnostics Utility ty suj Advanced Analog Outputs XIO Metering Thermal Protectn IP Address 127 0 0 1 2 Select the desired output in the Parameter Name column Click Value to open the Analog Output dialog Figure 61 Figure 61 Analog Output Window Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 3 Type new value in the New Value Field and click OK Scaling factors for the four Meter Port and the three ACB Port outputs are in the Analog Outputs list All parameters are scaled to 0 10V with 0 being the minimum value and 10V the maximum value Scaling parameters i e Anlg Port2 Scle change the scaling Refer to the Installation or Technical Data Guides for more information on programming parameters IMPORTANT The minimum value for certain parameters is a negative number In that case the minimum value of the parameter 10V is scaled to OV output and the maximum value is scaled to 10V output 4 Select the appropriate Analog Scale parameter
87. eral Reference PowerFlex 7000 Drive Performance Torque Capabilities Glossary of Terms 126 The PowerFlex 7000 drives have been tested on a dynamometer to verify performance under locked rotor accelerating and low speed high torque conditions Table 13 shows the PowerFlex 7000 drive torque capabilities as a percent of motor rated torque independent of the drive s momentary overload conditions Table 13 PowerFlex 7000 Drive Torque Capabilities Parameter Breakaway Torque 7000 Torque Capability without Encoder of Motor Rated Torque 90 7000 Torque Capability with Encoder of Motor Rated Torque 150 7000 Torque Capability with Encoder and High Performance Torque Control HPTC 150 Accelerating Torque 90 0 8 Hz 140 0 8 Hz 125 9 75 Hz 140 9 75 Hz 150 0 75 Hz Steady State Torque 125 9 75 Hz 100 1 2 Hz 140 3 60 Hz 150 0 60 Hz U Max Torque Limit 150 150 1 Drive will require over sizing to achieve greater than 100 continuous torque 150 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 e T acceleration to
88. from the measured current and flux feedback Set the Autotune L Magn parameter to this value Set the flux command to a value that should produce rated voltage at rated speed and load The resulting change in the flux level may cause the magnetizing inductance to change Repeat the process until the magnetizing inductance and flux commands stabilise 4 After completing the flux regulator tuning the drive waits for a few seconds and adds a sinusoidal perturbation specified by parameter Autotune Trq Stp to the torque command causing the speed to vary After the initial transient has decayed this usually takes a few seconds measure the variation in torque and speed and calculate the Total Inertia Remove the torque perturbation and the drive performs a normal stop Rockwell Automation Publication 7000 INO12B EN P June 2014 101 Chapter4 Commissioning the Drive Set the Autotune L Magn P 221 parameter to measure magnetizing inductance Set the FlxCmd RatedLoad parameter in the Flux Control Group to a value that produces rated voltage at rated speed and load Calculate the value of parameter Autotune T Rotor from parameters Lm Rated and Rated Motor RPM which gives the rated slip If the auto tuning is successful the Lm Rated P 131 in Motor Model is set equal to the Autotune L Magn the T Rotor P 132 in Motor Model is set equal to Autotune T Rotor and recalculate the flux regulator gains and the Total Inertia P 82 in Spee
89. fy 20 deg phase shift between the Master and two Slave windings for each phase voltage and capture the waveforms at ACB test points Slave 1 winding V3uv V3vw V3wu Slave 2 winding V4uv V4vw V4wu s Label the waveforms as V2uv V2vw and V2wu etc e Save the worksheet as Input Phasing Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 Table 4 Oscilloscope Settings Oscilloscope Time Base Wave Form Test Point Waveform Sheet Name Label Chan 1 5 ms div 2U Line Voltage V2uv V2uv Input phasing Chan 2 2V Line Voltage V2vw V2vw Chan 3 2W Line Voltage V2wu V2wu Use the same settings on the oscilloscope when capturing waveforms for the two Slave bridges If you are using a 2 channel oscilloscope then first capture two waveforms and move them onto a wavestar worksheet and after that capture the remaining waveforms and move them onto the same wavestar worksheet Sample Waveforms Sample Waveforms captured on ACB test points showing incoming line voltage phasing Ch1 V2uv red Ch2 V2vw yellow Ch3 V2wu blue Figure 80 Sample waveforms incoming line voltage phasing Sample waveforms captured on ACB test points showing 20 deg Phase Shift between Master and two Slave Bridges Ch1 Master V2uv red Ch2 Slave 1 V3uv yellow Ch3 Slave 2 V4uv blue Rockwell Automation Publication 7000 INO12B EN P June 201
90. haring resistor Measure the resistance between the red wire of the plug and the heat sink to the left A value of 80 k ohms indicates a healthy sharing resistor Figure 40 SCR sharing resistance test Q mA TT l MSS U f S gt l j eal ass aN ii Mi ee LO a Resistance between heat sink and red wire at plug is sharing resistance Rockwell Automation Publication 7000 INO12B EN P June 2014 55 Chapter 4 56 Commissioning the Drive SCR Gate to Cathode Resistance One test that can be performed on SC R that cannot be performed on SGCTs is a Gate to Cathode Resistance Test Performing a Gate to Cathode resistance measurement will identify damage to an SCR by revealing either an open or shorted gate to cathode connection To test an SCR from gate to cathode disconnect the SCR gate leads from the self powered gate driver board and measure the gate to cathode resistance on the SCR firing card Phoenix connector Figure 41 SCR gate to cathode test
91. he Rockwell Automation start up plan b the start up schedule c the drive s installation requirements 2 Inspect the drive s mechanical and electrical devices 3 Perform a tug test on all internal connections within the drive and verify wiring 4 Verify critical mechanical connections for proper torque requirements Rockwell Automation Publication 7000 IN012B EN P June 2014 21 Chapter3 Commissioning Preparations 5 Verify and adjust mechanical interlocks for permanent location 11 12 13 Confirm all inter sectional wiring connections Re verify control wiring from any external control devices such as PLCs etc Confirm cooling system is operational Verify proper phasing from isolation transformer to drive 10 Confirm drive cabling to motor isolation transformer and line feed Confirm test reports indicating megger hipot test is complete on line and motor cables Control power checks to verify all system inputs such as starts stops faults and other remote inputs Connect the UPS battery cables IMPORTANT Ifthe UPS has not been charged in six months since the date of shipment contact Rockwell Automation Applying power and tuning or performance testing the drive are part of the actual commissioning process not part of the preparation Note Appropriate customer operations staff must be on site with Rockwell Automation commissioning personnel to participate in the system start u
92. iagram and locate it within the terminal blocks in the drive Examine it to verify that the cable insulation has not been tightened into the terminal Verify that all connections have proper continuity Ensure factory jumpers installed and marked with notes to remove if remote equipment installed have been removed Inspect the control cable routing to ensure that DC control wiring and AC control wiring are separated from each other Routing them together in the same bundle wire way or conduit may induce unwanted noise in the drive control In the overhead cable tray provided at the front of the drive ensure that the AC control DC control and fiber optic cables remain isolated from each other by the available dividers Rockwell Automation Publication 7000 INO12B EN P June 2014 33 Chapter4 Commissioning the Drive Service Data 34 Inspect for additional control not shown on the electrical diagram Determine its purpose mark the changes on the electrical diagram and send the prints to the factory for future reference Perform a tug test on all control cables to ensure that they are securely fastened and check each plug and connector to ensure it is properly seated in its socket ATTENTION Ensure that there is sufficient clearance between the installed control wiring to the control cabinet and components carrying medium voltage Verify that closing the low voltage door does not swing the low voltage cables into the medium
93. idge Ontario NIR 5X1 Canada MV Support Contact Info Office Hours 9 00 a m 5 00 p m EST Monday to Friday Phone 1 519 740 4790 Option 1 for Tech Support Option 2 for MV Parts After Hours Support 5 00 p m 9 00 a m EST 365 days To ensure trouble free commissioning it is necessary for all involved in the start up to familiarize themselves with the drive line up and application Do not service the equipment without a clear understanding of the equipment s functional design and the equipment s particular application If questions arise that are not addressed within this manual contact your local GMS office or Medium Voltage Support directly Rockwell Automation Drive Line up Drawings Prior to performing any service work on the drive line up study and understand the electrical and dimensional drawings provided with the equipment These drawings contain detailed information and instructions required for commissioning and installation of the equipment including the following Dimensional Drawings s Power cable termination locations s Ground bus locations e Shipping split locations e Control and medium voltage power ratings e Drive options e Remote I O protocol e PLC options e Motor and load specifications e Drive power component selection ratings e Heat exchanger ratings connections Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 Electrical Draw
94. imit Motoring slightly If increasing the Torque Limit Motoring does not help to increase the motor amps and speed then the drive is most likely running out of input voltage Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 Monitor the Line Voltage pu P 135 and increase the tap setting on the drive feed if the measured value is less than 1 03 pu It is desirable to have Line Voltage pu read in the 1 03 to 1 07 pu range Alpha Rectifier P 327 should be greater than 15 while running at rated speed and load indicating how far forward the rectifier is phased The input voltage should be increased by tapping up the transformer Fill in the following table with data from the various load points If possible capture the running parameters with the printer DriveTools or Hyperterminal as a substitute for recording the data in the table below This should be forwarded with all commissioning data back to Product Support for future reference TEST Motor Drive Drive Variables Operating Point Speed AMPS Volts Speed Speed FluxRef Torque IDC IDC Alpha Alpha Inverter Rectifier RPM Vline Ref Hz Fdbk pu Ref pu Ref Fdbk Machine Line heat heat Hz pu pu degrees degrees sink sink Temp Temp I 1 25 2 50 3 75 4 100 5 __ 6 __ 7 __ 8 __ 9 __ 10 __ 11 Da
95. in Flux Control to the analog output used to control the field supply e g ACB Port 1 The setup of the field current reference is complete and you can proceed with the tuning of the FluxSpeed regulator Flux Speed Reg Auto tuning Synchronous Motor The following parameters determine the Flux Speed regulator tuning for a synchronous machine s FlxReg Bandwidth in Flux Control s Lm Rated in Motor Model s T Rotor in Motor Model s Lmd in Motor Model e SpdReg Bandwidth in Speed Control e Total Inertia in Speed Control The Flux Speed Regulator tuning function calculates parameters Lm Rated P 131 T Rotor P 132 in Motor Model Group and Total Inertia P 82 in Speed Control group This is combined Auto tuning for Flux and Speed regulator During this autotune step the motor will run at speed set in auto tune speed Cmd The default setting is 30 Hz Make sure the motor rotates during this autotune Motor rotation must be verified either physically or monitoring FlxFbk VoltModel P 342 It is possible that stall condition may calculate wrong tuning parameters If It happens make sure the tuning parameters Lm rated T rotor Total Inertia are set to default before starting this tuning again Rockwell Automation Publication 7000 INO12B EN P June 2014 107 Chapter 4 Commissioning the Drive 108 Flux Regulator Set Flux Regulator Bandwidth to the default value for almost all applications Lm Rated Lmd T R
96. in parallel depends on the type of the thyristor and the configuration and frame size of the drive Snubber Capacitors Snubber capacitors are connected in series with the snubber resistors Together they form a simple RC snubber that is connected across each thyristor SGCT The purpose of the snubber circuit is to reduce the voltage stress dv dt and peak of the thyristor and to reduce the switching loss Sharing Resistors Sharing resistors provides equal voltage sharing when using matched devices in series Please note SGCT PowerCages for 2400V systems do not need matched devices and have no sharing resistor SCR PowerCages always have sharing resistors even if matched devices are not necessary Sharing resistors in SCR PowerCages provide a diagnostic function Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 SGCT and Snubber Circuit With all power semiconductors or thyristors the SGCT requires a snubber circuit The snubber circuit for the SGCT consists of a snubber resistor in series with a snubber capacitor Figure 18 shows the snubber circuit Figure 28 shows the physical locations of the same circuit Measure the resistance across two adjacent heat sinks A value between 60 kQ and 75 kQ indicates a good sharing resistor Figure 18 Snubber Circuit for SGCT module Cs 1 Rsn 2 Rsh Cs 2 Rsn 1 Snubber Resistor Anode Test Cathode Heatsink Heatsink Figure 19
97. ings e Contactor locations electrically e Drive topology e General notes e Cable isolation ratings e Symbol table e Component designations Device Designations Color Designations Wire No Designations SGCT Designations Ribbon Cable Designations Location of Relay and Location of Relays Drawing Location Contactor Contacts References e Customer power and control wiring locations electrically e Control and medium voltage power ratings e Fuse ratings and locations electrically If the dimensional and electrical prints are not available request copies from the factory In addition if the drawings require changes to accurately suit the installation and application of the system please fax or e mail them to the factory for revision Electrical System One line Diagram After reviewing the Rockwell Automation electrical and dimensional drawings obtain a copy of the electrical system one line drawing to help identify all relevant equipment tag identification names and numbers Study the system for power sources and parallel paths of medium voltage power to the drive Retain a copy of the one line diagram for the drive commissioning and if possible send a copy to the Medium Voltage division for archiving and use in the event of future customer assistance requests Verify One line Diagram on Site After reviewing all documentation perform an on site inspection of the drive While referencing the one line diagram and Rockwell A
98. ive Chapter 4 Sample Waveforms Sample waveforms captured on ACB test points under Drive Not Running Condition Ch1 V2uv red Ch2 I2u yellow Figure 82 Sample waveform SCBL test points drive not running Make sure the Diagnostic Trend has been setup and is armed Run the DC Test with Idc Command Test P119 set to 0 1 pu Increase Idc Command Test from 0 1 to 0 3pu for AFE drives or from 0 1 to 0 7pu for 18 Pulse drives in steps of 0 1pu At each step verify DC link current regulation by monitoring Idc Error P323 and Alpha Line P327 Capture DC link voltage waveform at ACB test point Vdcr1 and DC link current waveform at ACB test point Idc1 at 0 3pu for AFE drives or at 0 7pu for 18 Pulse drives Label the waveforms as Vdcr1 and Idc1 Save the worksheet as DC Test 0 3pu for AFE drives or DC Test 0 7pu for 18 Pulse drives Table 6 Oscilloscope Settings Label 2ms div DC Link Voltage DC Test DC Link Current Rockwell Automation Publication 7000 INO12B EN P June 2014 115 Chapter4 Commissioning the Drive Sample Waveforms Sample waveforms of DC Test recorded on a PWM drive Idc Cmd Test 0 2pu Ch1 Vdcr1 yellow Ch2 Idc1 blue at ACB test points Figure 83 Sample waveform DC test on PWM drive C Test gt Test Sample waveforms of DC Test recorded on 18 Pulse Drive Idc Cmd Test 0 5pu Ch1 Vderl yellow Ch2 Idc1 blue at A
99. key should turn easily if any force is required to turn the key the deadbolt alignment requires adjustment Open the doors of the cabinet and inspect the key assembly Place high visibility grease on the pins of the deadbolt counterpart The factory recommends using yellow torque sealant however if it is unavailable almost any grease will do See Figure 17 Figure 17 Deadbolt counterpart mounted to cabinet Aye 0 oR O Place grease on deadbolt pins here Rockwell Automation Publication 7000 IN012B EN P June 2014 Resistance Checks Commissioning the Drive Chapter 4 4 Bolt the cabinet door closed so the pins on the dead bolt counterpart make contact with the deadbolt assembly Doing so should leave two marks of torque sealant or grease on the assembly where the pins made contact see Figure 16 on page 36 5 Slightly loosen the adjustment bolts on the counterpart and make the necessary movements on the counterpart to ensure that the pins align with the landing plates on the deadbolt assembly As the amount of counterpart movement required is an estimate it may take a couple attempts to properly align the assembly 6 Clean the torque seal grease from the key interlock once finished aligning the counterpart Once properly aligned the key should turn freely when the cabinet door is fully bolted shut If the key does not function when the door is tightly bolted closed adjustments will hav
100. l 12 __ Rockwell Automation Publication 7000 INO12B EN P June 2014 111 Chapter4 Commissioning the Drive Capturing Data 112 IMPORTANT Once you complete the final commissioning procedures and the drive is running CAPTURE ALL DRIVE DATA for future reference The last step should be to upload black box data from the DPM This captures all parameters regardless of the user access level the various firmware revisions the exploded fault masks the PLC links and the Analog configuration Always upload the seven files from the black box The Variables csv file should be taken with the drive running with MV All of this information is necessary as reference to address future customer issues Guidelines For Data Capture This section provides some guidelines for capturing required commissioning data and setting up oscilloscope to capture the waveforms Some sample waveforms have been included for reference purpose Drive Input Voltage Phasing Checks After applying medium voltage to the drive perform an input voltage phasing check Summary e Drive input contactor should be closed If the drive input contactor configuration is set to NOT RUNNING you will have to temporarily change it to ALL FAULTS s Ensure that the drive is not running when capturing these waveforms e Capture the three line voltage waveforms at ACB test points Master winding V2uv V2vw amp V2wu e In the case of 18 Pulse drive veri
101. l reaching the end of the middle stack Then the left device in the bottom stack fires and the pattern continues to the last device when it returns to the top This tests for correct fiber optic cables connected to the corresponding devices During commissioning it is not necessary to use an oscilloscope for SCR firing tests although it is required if SCR firing problems occur taken out of Test Mode prior to applying Medium Voltage Failure to do so may T ATTENTION Ensure that the test cable is removed from the drive and that it is result in personal injury or equipment damage SGCT Firing Test Unlike the SCR Self powered gate driver board the SGCT has an integrated firing circuit mounted on the device This circuit derives power from the SGCT Power Supplies IGDPS or from the SPS boards which require a test harness You can monitor the lights on the firing circuit without putting the drive into gating test mode There are four LEDs on the firing card Figure 58 harness from all of the SPS boards and remove the SPS test harness from the power converter cabinet Do NOT leave the SPS test harness in the power converter cabinet Reconnect all of the SGCT snubber connections to the J1 connectors on the SPS boards T WARNING When testing with the SPS harness is complete remove the test Figure 58 SGCT healthy LEDs SPS board not shown for clarity SGCT SGCT LED 4 Green LED 3 Green 7
102. lication 7000 TD002_ EN P for information on troubleshooting Control Power Transformer CPT B Frame only A control power transformer is supplied only in certain drive configurations If there is no control transformer supplied in the drive being commissioned please disregard the following information on setting the control voltage output level Measure the control voltage level at the secondary of the control power transformer located in the DC link low voltage cabinet of the drive Ensure that the output of the transformer matches the specification on the electrical schematics You can adjust the value of the output by changing the taps on the control transformer Disconnect the power at the disconnect switch prior to attempting to change the control transformer tap setting AC DC Converter PS1 Every PowerFlex 7000 A or B Frame drive has at least one AC DC power supply As the number of devices increases or to provide a redundant power supply the number of installed AC DC power supplies may increase The electrical schematics provided by Rockwell Automation identify the number of AC DC power supplies in the drive being commissioned Ensure the output of the AC DC power supply is 56V DC To make adjustments see Publication 7000 UM202_ EN P Rockwell Automation Publication 7000 INO12B EN P June 2014 61 Chapter4 Commissioning the Drive Figure 45 Terminal locations on AC DC power supply Pioneer
103. lled in the drive are accurately programmed in drive parameter settings Perform system test and verify operation of the drive and the associated controls Remove any jumpers used during system test Inspect the drive line up and ensure that no tools are left inside the cabinets before closing them Apply medium voltage and complete incoming line phasing checks and take harmonic measurements Perform DC test Ensure that the Diagnostic Trend is setup and ready before attempting the DC test Perform Stationary Autotune tests first 2 autotune tests Bump the motor for rotation check Complete Rotating Autotune tests last autotune test Save the parameters in NVRAM and also transfer them from drive to memory and also print the drive setup to your laptop Start the drive in normal operation print variables and capture waveforms Complete commissioning documentation Rockwell Automation Publication 7000 INO12B EN P June 2014 27 Chapter4 Commissioning the Drive Drive Application Review 28 Medium Voltage Product Support MUST complete and return the commissioning datasheets to the Rockwell Automation Canada Cambridge office immediately upon completion of the drive system commissioning The most recent datasheets are available in the Commissioning Guidelines for MV PowerFlex 7000 A B C Frame Drives document available to field service engineers on the Intranet ROCKWELL AUTOMATION CANADA 135 Dundas Street Cambr
104. mission a PowerFlex 7000 B Frame drive In addition it identifies how to obtain the required equipment in the event that it is not readily available prior to commissioning the drive It is recommended that all items listed below be obtained prior to attempting to commission the drive The contents of this section must be reviewed and that the uses of the equipment described within are understood prior to commissioning of the drive If support or additional information is required contact your local Rockwell Automation service office or Medium Voltage Support at 519 740 4790 Recommended Tools and Equipment Hand Tools e Metric and Imperial wrenches sockets and Hex keys s Torque wrench e Assortment of screw drivers e Assortment of electrical tools wire strippers electrical tape crimpers etc Electrical Equipment e High voltage gloves 10 kV insulation rating minimum e Approved high voltage potential tester 10 kV rating minimum e Anti static strap Test Equipment s 100 MHz or higher oscilloscope with at least two channels and memory e 600V 1000V rating digital multimeter with assorted clip leads e Megohmmeter with selectable voltage 2500 5000V Rockwell Automation Publication 7000 INO12B EN P June 2014 23 Chapter3 Commissioning Preparations Computer Requirements and Software Laptop computer 486 or higher installed with Microsoft MS Windows Microsoft HyperTerminal Provided with MS Windows Rock
105. n 7000 INO12B EN P June 2014 59 Chapter 4 60 Commissioning the Drive Three Phase Input Single Phase Input This configuration has one source of control power e Three phase control power for fan operation which is also converted to single phase control power to operate the Interface power supplies I O and additional auxiliaries Similar to the three phase configuration the input power for the fan and control must be verified at the primary of DS1 If the ratings match the designation on the electrical schematic it is acceptable to apply control power to the drive by closing CB1 and DS1 Take necessary measures to rectify the control power levels in the event that they do not meet the design specifications Power Supply Tests The variety of components installed within the PowerFlex 7000 B Frame requires a versatile control distribution design As a result there are many power supplies incorporated within the drive design The following section describes how to verify that all power supplies installed within the drive are functioning as designed Circuit Board Healthy Lights Once all sources of control power have been verified and proven to be within specified levels close the low voltage input breaker CB1 and Disconnect Switch DIS doing so will apply control power to the drive Observe the healthy lights on all drive control boards to ensure that the unit has passed all power up self tests The followi
106. n sections verify that the bus splice kits provided in this circumstance are properly installed and torqued at shipping split locations Power Cabling Ensure that all customer power and control wiring required for drive line up installation are identified on the electrical drawings by a dashed line see your electrical drawing s General Notes for additional information ATTENTION Power cabling should be installed in accordance with local codes and guidelines The information in this section is to be used as reference only and is not intended to replace practices outlined in the electrical code Trace the power cabling from termination point to termination point while examining the cable and its routing for mechanical damage sharp bend radiuses and sources of induced noise and heat Ensure that the power cabling is sufficiently braced so as to contain the cabling in the event of a ground fault situation Verify that all cables are terminated on each end and are sufficiently torqued see Torque Requirements for Threaded Fasteners on page 123 Verify that the cable installed meets the recommended power rating outlined in the electrical drawings and installation section of the manual Ensure that the cable terminations are stress coned if required Verify that the customer power cables have been Hi Potted or meggered and read a sufficient insulation value Identify all customer required control wiring detailed on the electrical d
107. nd should produce an under damped response 6 Assign parameters Idc Reference and Idc Feedback in the Current Control group to 2 DPM test points e g RTP1 and RT P2 This process is similar to the meter assignments described earlier Use an oscilloscope to view the results 7 Start the drive Set parameter Idc Ref Step in Current Control to 0 075 pu for AFE rectifier drive and 0 200 pu for SCR drives The dc link current will step up and down by this amount at regular intervals 8 Adjust the scope to trigger on the rising edge of the dc current reference and observe the dc current feedback on the other channel The step response may have noticeable overshoot indicating that the dc link time constant is too low 9 Adjust the T DC Link parameter until the current feedback rises to 63 of its final value in 10 ms as shown in Figure 76 and Figure 77 The overshoot should reasonably small Increasing T DC Link causes the rise time to increase Since the desired step response is slightly under damped do not increase the T DC Link beyond the value at which the overshoot disappears Rockwell Automation Publication 7000 INO12B EN P June 2014 97 Chapter4 Commissioning the Drive Figure 76 Current regulator tuned incorrectly Figure 77 Current regulator tuned correctly LeCroy Idc Feedback ai e _ _ n BLE te ee EEFI S G G H d
108. ng because its value is determined by the impedance of the input transformer and harmonic filter if present TDC Link Three parameters control current regulator tuning two in the Current Control group and one in the Drive Hardware group e Current regulator bandwidth CurReg Bandwidth s DC Link time constant T DC Link e DC Link inductance in per unit DCLnk Induct pu Inductance DCLnk Induct pu is calculated from its nameplate rating the current regulator bandwidth should be set to its default value of 200 rad s and only T DC Link is unknown and must be measured Although the current regulator was tuned during factory test it should be retuned during commissioning because the dc link time constant is affected by the impedance of the drive input transformer The following auto tune procedure is used to complete the rectifier side tuning 1 Ensure that the parameters in the Drive Hardware and Motor Ratings groups have been set to the correct values 2 Set parameter Autotune Select in the Autotuning parameter group to Rectifier The drive will go into DC Current test mode The current regulator bandwidth is set to Autotune Idc BW P 212 Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 3 Start the drive The dc current will increase to 0 2pu and stay at that level for couple of seconds The drive records the data under this condition and then ramps up to approximately rated curre
109. ng table identifies the LEDs that should be illuminated assuming the drive passes all self tests and is in a ready state Component LED Activities AC DC Converter Power Supply No Healthy LEDs Provided DC DC Converter Power Supply No Healthy LEDs provided Isolated Gate Driver Power Supply IGDPS 1 Green LED per section of Power Supply No Label SPS Power Supply DS1 1 Green LED per SPS board SGCT Integrated Firing Card LED 4 Green LED 3 Green LED 1 Red Analog Control Board ACB 2 Green LEDs Healthy Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 Component LED Activities DPM LED 6 Green LED 9 Green LED 7 Green LED 11 Green External 1 0 Various YELLOW Surface Mounted LEDs based on 1 0 status Remote 1 0 Adapter LED configuration will change based on adapter Refer to the adapter user s manual to identify the state the adapter is in Operator Interface Terminal Displays Boot Sequence Communications Error will occur in a fault situation A small flashing indicator in bottom right corner indicates good communication 1 Number of supplies varies based on drive configuration 2 It is normal for the operator interface to show a Comm Error message until the DPM has finished the boot up sequence 3 After boot up sequence is completed Failure of LED to illuminate indicates a problem with the power up self test Refer to Pub
110. ngs if the customer required any drilling or metal cutting during the installation process Clear all metal shavings from the cabinet and take care not to get shavings into the cabinets if you do any further drilling or cutting Protective Barriers In confined spaces installation electricians often remove protective barriers to create more space within the cabinets Ensure that you re install all protective barriers removed during installation Failure to re install a protective barrier may result in equipment damage or personal injury Component Grounding Verify that the drive and all its associated equipment have system power ground cabling installed and that the cables are terminated at both ends Terminate power cable shield grounds at both ends Ensure that all grounding hardware is sufficiently torqued see Torque Requirements for Threaded Fasteners on page 123 Ground all drive line up components drives switcher motors transformers and reactors to the installation s ground grid In drive line ups supplied with isolation transformers leave the secondary of the isolation transformer floating so the drive line up can reference system ground from the upstream distribution transformer Failure to do so may result in unreliable drive operation Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 Control Wiring Information on Splice Kits If the drive line up was shipped i
111. nt heat sink on Right pF Lowest Highest Lowest Highest SGCT Anode to Cathode Sharing Resistance The anode cathode resistance check measures the parallel combination of the sharing resistor and SGCT anode cathode resistance The sharing resistor has a resistance much lower than that of a good SGCT so the measurement will be slightly less than the resistance of the sharing resistor A measurement between 60 kO and 75 kQ indicates the SGCT is in good condition and that wiring to the SGCT is correct If the SGCT fails it will be in the shorted mode 0 Q The anode to cathode resistance check will be 0 Q There is a test point 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 Place one probe of the multi meter on the test point and the other probe on the appropriate heat sink to determine the value of the resistor or capacitor See Figure 29 Figure 29 SGCT PowerCage Resistance value between heat sink and test point is snubber resistance Yin T DANARI lt Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 Figure 30 Resistance Measurements SGCT PowerCage with SPS Board Mounting Assembly Resistance value between two heat sinks is sharing resistance in parallel with anode cathode resis
112. nt After staying at the level for couple of seconds the drive will again record the measured data and then ramp the current to zero The current regulator bandwidth is set back to the original value From the recorded data the drive will calculate the Autotune L Input P 217 and Autotune T DCLnk P 218 At the end of the tuning Input Impedance is set to Autotune L Input and T DC Link is set to Autotune T DCLnk During tuning if the values are determined to be out of range the drive will issue warnings indicated below Try to tune the drive again but if the warnings persist verify the result by tuning the drive manually You may encounter one or more of the following warnings during Rectifier tuning e L Input Low indicates that the measured L Input is less than 0 02 pu The L Input must be tuned using the manual method described below e L Input High indicates that the measured L Input is greater than 0 5 pu The L Input must be tuned using the manual method described below s TDC Link Low indicates that the measured dc link time constant is less than 0 020 second The step response of the current regulator should be checked using the manual method described below Input Impedance Manual Tuning 1 Click the Display tab and click Feature Select from the Group Name column The Feature Select parameters will appear in the right window 2 Click Operating Mode and click Value Select DC Current from the pulldown menu and click
113. nt drive firmware before proceeding with commissioning Check the most recent version of the Commissioning Guide for a list of updated Tech Notes available in the MV intranet site The commissioning engineer should review this commissioning package and follow the defined steps to commission PowerFlex 7000 drive s It is the responsibility of the commissioning engineer to complete all datasheets included in this package and collect any other relevant information that may not have been included in the package Important guidelines for capturing waveforms are also included in the package for quick reference These must be reviewed and followed properly by the commissioning engineer Anything that is not clear please contact MV Tech Support for assistance Phone 519 740 4790 Option 1 for technical and option 4 for commissioning questions MVSupport_technical ra rockwell com or MVSupport_services ra rockwell com After successful commissioning of the drive the commissioning engineer is required to return the completed commissioning package along with his field service reports to the project manager within one week after completion of job If job is not completed and some data collected it must be sent to project manager within one week after leaving the site The items listed below MUST be included when submitting the commissioning package Rockwell Automation Publication 7000 INO12B EN P June 2014 25 Chapter3 Commissioning Preparation
114. ntly active Rockwell Automation Publication 7000 INO12B EN P June 2014 87 Chapter 4 Commissioning the Drive Diagnostics View Captured data is shown in a table with each column representing a trace Figure 70 For binary data select the desired capture point row and click the column header to decode the value Figure 70 View Sub Menu CEO Hl x Home Display Alarms Setup Diagnostics Utility The collection point at which the trigger condition occurred will be highlighted in red Diagnostics Plot The Plot tab Figure 71 shows relationships and trends amongst the captured data Trace parameters which were selected on Setup tab are automatically plotted when the Plot tab is selected To add or remove additional parameters from the plot e Select the desired parameter and click the X column header e Click Update to redraw the new plot Colors assigned to the parameter name correspond to the colors used in the plot All values in the plot are normalized Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 To see the true value of a captured point even if it is not plotted e Select the desired parameter from the list e Click on the graph at the point where the desired value is sought The location is marked by a white marker and the true value is shown at the bottom of the plot Other parameter values can be read without moving the marker point by
115. on 7000 INO12B EN P June 2014 79 Chapter4 Commissioning the Drive Next calibrate the external 4 20 mA signal conditioners 1 Seta digital multimeter to mA and place it in line with the signal conditioners If the output of the conditioner is terminated use the meter as a load 2 Assign a parameter to the Analog Output port you are calibrating This parameter must be configurable from minimum to maximum for test purposes only for example IDC Command Test See previous page on assigning an output 3 Set IDC Command Test to 0 000 pu This is the minimum Adjust the Zero adjustment screw on the isolator to read 4 mA 4 Set IDC Command Test to 1 500 pu This is the maximum Adjust the Span adjustment screw on the isolator to read 20 mA 5 Repeat the process until you complete the adjustments 6 Set IDC Command Test to 0 750 pu to ensure you read 12 mA Half scale Set IDC Command Test to 0 000 pu 7 Assign the required parameter to the Analog Output port we have calibrated 8 Save all changes to NVRAM Configurable Alarms Test the external faults by lifting the wires to all external warning fault inputs while running in system test mode These wires terminate at the Digital I O boards Opening the circuit at any point will verify the external fault s configuration and functionality However it is preferable to actually force the trips from the source If that is not possible lift the wire at the protective
116. otor and Total Inertia are usually unknown and must be measured Although these motor parameters change with different operating conditions the variations do not significantly affect the operation of the flux regulator The other aspect of flux control is the variation of motor flux with speed This is determined by two parameters e Base Speed in Flux Control s FlxCmd RatedLoad in Flux Control In most applications the motor runs at constant flux below rated speed and constant voltage above rated speed The motor flux is normally set to a level that provides rated voltage at rated speed and full load The flux level required to achieve this is a function of the motor parameters The flux regulator auto tuning determines a value of rotor flux that should provide rated motor voltage at full load and rated speed and sets the flux command parameter to this value Speed Regulator For more details refer to Speed Regulator Manual Tuning Induction Motor on page 103 Ifa position encoder is fitted to the motor the FluxSpeed regulator auto tuning is performed with the encoder feedback turned off because it is assumed that the encoder has not been aligned with the rotor axis yet Since less starting torque is produced with the encoder feedback off this test should be performed with reduced load The encoder offset measurement is also most accurate with no load on the motor Flux Speed Regulator Auto tuning Synchronous Motor Tune the
117. p procedures ATTENTION Servicing energized industrial control equipment can be hazardous Severe injury or death can result from electrical shock burn or unintended actuation of control equipment Hazardous voltages may exist in the cabinet even with the circuit breaker in the OFF position Rockwell Automation recommends that you disconnect or lock out control equipment from power sources and confirm discharge of stored energy in capacitors If it is necessary to work in the vicinity of energized equipment follow the safety related work practices of NFPA 70E Electrical Safety Requirements for Employee Work Places In addition to the safety references here follow all local codes and safety practices when working on this product susceptible to damage or destruction by static charges Personnel working near 0 ATTENTION The CMOS devices used on the control circuit boards are Static sensitive devices must be appropriately grounded 22 Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning Preparation Commissioning Preparations Chapter 3 Pre Commissioning Responsibilities The customer must complete the pre commissioning checklist refer to the Publication 7000 IN007_ EN P for the customer s full pre commissioning checklist as well as sign off dates and signatures indicating completion of the required tasks The following section identifies all the tools and resources required to successfully com
118. re 53 You are now granted Advanced Access 4 Select Feature Select from the Group Name column The group parameters are now listed on the right side Figure 54 Figure 54 Feature Select Group Home Display Alarms Setup Diagnostics Utility Access Advanced Filter ReadWrite Search Help l me Parameter Name Value Units Operating Mode Normal Speed Ref Select PFNetServer lt All Parameters gt TorqueRef Select None Feedback Ref Command Loss Fault Diagnostics Feature Select Coast Speed 2 0 Hz Auto Restart Dly 0 0 sec Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 5 Select Operating Mode and click Value to open the Operating Mode dialog Figure 55 Figure 55 Operating Mode window DA JPF7000 Terminal 7 Home Display Alarms Setup Diagnostics Utility Access Advanced Filter ReadWrite Search Help E File Parameter lt Units Normal GroupName peed Ref Select PFNetServer lt All Parameters gt TorqueRef Select None Feedback Ref Command Loss Fault Diagnostics Coast Speed 2 0 Hz Feature Select Auto Restart Dly 0 0 sec Motor Ratings Input Ctctr Cfg All Faults Autotuning InpCtctr OpenDly 0 0 min Motor Model Output Ctctr Cfg SG k Speed Command SpecialFeatures1 Speed Control SpecialFeatures2 Appl Speed Profile SpecialFeatures3 actuat Ward T ere Current Control Load Lo
119. replacement procedure Rockwell Automation Publication 7000 INO12B EN P June 2014 57 Chapter4 Commissioning the Drive Snubber Capacitance SCR Device Turn the multimeter from the resistance to capacitance measurement mode Proceed to verify the snubber capacitor by measuring from the test point and the white wire at the 2 pole device snubber plug labeled snubber Figure 43 Snubber capacitance test Heatsink Resistance value between test point and white wire at 2 hole plug is snubber capacitance Sharing Resistor gt Snubber Snubber Resistor Capacitor To Gate Driver Board Fa Test Point Heatsink ae ta To test the snubber capacitance disconnect the plug of the self powered gate driver board labeled SHARING and SNUBBER The resistance between the white wire of the plug and the Test Point to its left is the snubber capacitance Refer to Table 2 on page 52 to determine the appropriate snubber capacitance value for the current rating of the SCR used Read the actual snubber capacitor value shown in the table If the capacitor is out of tolerance refer to publication 7000 UM202_ EN P for the snubber capacitor replacement procedure 58 Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 Control Power Tests Customer Supplier 120V Although there are a variety of options available to customers that
120. rque in Nem lbe fc e W force N or kgf Ib e K gyration radius m ft e WK total system inertia kg fx m Ibeft that the motor must accelerate including motor gear box and load e t time s to accelerate total system load Steady State Torque Continuous operating torque required to control the load without instability Torque Limit An electronic method of limiting the maximum torque available from the motor The software in a drive typically sets the torque limit to 150 of motor rated torque Rockwell Automation Publication 7000 IN012B EN P June 2014 General Reference Appendix A Table 14 Typical Application Load Torque Profiles 1 Application Load Torque Load Torque as Percent of Full Load Drive Torque Required Drive Encoder Required for gita Break away Accelerating Peak Running vee ae 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 opened VT 40 110 100 Normal No CHIPPER w00D CT 50 40 200 Contact factory No starting empty COMPRESSORS Axial vane loaded VT 40 100 100 Normal No Reciprocating starting CT 100 100 100 Contact factory Yes unloaded CONVEYORS Armored face cT 175 150 200 Contact factory Yes Belt type loaded CT 150 130 100 Heavy Yes Drag type CT 175 150 100 Contact factory Yes Screw
121. ry 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 New and Updated Information This manual contains new and updated information Summary of Changes This table summarizes the changes made to this revision Topic Page Added HPTC information to Topology section i Added additional SPS test harness warning 73 Updated When is an Encoder Required section and table 123 Replaced Encoder Selection table 125 Added HPTC information to Drive Torque Capabilities table 126 Updated Typical Application Load Torque Profiles 127 Updated Speed Regulator Bandwidth 130 Updated Torque Regulator Bandwidth 130 Inserted Torque Accuracy with HPTC 130 Added Polish to list of available Languages 131 Added Dual port Ethernet IP to Communications Protocols 132 Rockwell Automation Publication 7000 IN012B EN P June 2014 Summary of Changes Notes 4 Rockwell Automation Publication 7000 INO12B EN P June 2014 Important User Information PowerFlex 7000 Overview Commissioning Preparations Commissioning the Drive Table of Contents Chapter 1 Who Should Use This Manu
122. s 10 All checklists and tables in this document commissioning checklist customer data motor data daily service summary etc Harmonics waveforms must be captured on AFE drives under drive not running and full load conditions DC current test waveforms dc voltage and dc current and variables while running DC test Load Test waveforms line and load voltage and current waveforms at 50 and 100 load or whatever maximum load and speed allowed by the customer Final drive parameter settings and variables running motor at max speed and load 6 Modified PLC program if applicable 7 8 9 Synchronous transfer waveforms for synchronous transfer applications Starting with and without load profile for conveyor applications Marked up drawings Summary of issues failures encountered during commissioning All documents and data files waveforms parameter settings variables trend data etc intended for submission must be properly named labeled and organized IMPORTANT Ifthe commissioning datasheets submitted by the commissioning engineer are incomplete and or the required commissioning data such as harmonic waveforms dc test waveforms sync xfer waveforms etc are not captured correctly or the required data is missing then it can delay the processing of expense invoices submitted by the engineer IMPORTANT While the Field Service Engineer FSE is still at the site he MUST send the
123. s motors please refer Flux Speed Regulator Synchronous Motors on page 106 During this auto tune step the motor will run at speed set in Autotune Spd Cmd The default setting is 30 Hz Ensure the motor rotates during this auto tune Verify motor rotation physically or by monitoring FlxFbk VoltModel P 342 Stall condition may calculate wrong tuning parameters If it happens ensure you set the tuning parameters Lm Rated T Rotor and Total Inertia to default before re starting this tuning Flux Regulator Three parameters determine tuning for the flux regulator in an induction motor e FlxReg Bandwidth in Flux Control s Lm Rated in Motor Model s T Rotor in Motor Model Set FlxReg Bandwidth to the default value of 10 r s for almost all applications Lm Rated and T Rotor are usually unknown measure them individually Both of these motor parameters change substantially with different operating conditions but the variations do not significantly affect the operation of the flux regulator 100 Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 The other aspect of flux control is the variation of motor flux with speed determined by two parameters e Base Speed in Flux Control e FlxCmd RatedLoad in Flux Control In most applications the motor runs at constant flux below rated speed and constant voltage above rated speed The motor flux normally operates at a level that provides rated
124. sioning data sheets indicates to the factory the date that the system started up and will be used to commence the product warranty In the unlikely event the system is not operating as designed it will be possible to trend performance between similar applications and topologies In the event a product notification or recall is required the factory uses the datasheets to identify if the customer falls under the definition for an update Rockwell Automation Publication 7000 IN012B EN P June 2014 Control Power Off Tests Commissioning the Drive Chapter 4 The factory archives data sheets for future reference Perform the following checks before applying control power to the drive Rockwell Automation recommends that you complete these checks in the sequence they are presented here Interlocking When the input contactor option is purchased a key interlock is provided to prevent access to the medium voltage compartments of the drive unless the input isolation switch is locked in the open position Where the input switching device is provided by others Rockwell Automation will provide a key interlock on the medium voltage compartment of the drive and a matching interlock for installation by others on the upstream device The interlock must be installed in a manner that ensures the power to the drive is off and the drive is electrically isolated whenever the key is freed Although key interlocks shipped with all medium voltage equipmen
125. solation transformer or multiple rectifier bridges as in Voltage Source Inverter VSI topologies offered by others The approach is completely different Instead of multiple uncontrolled rectifiers a single AFE rectifier bridge is supplied The rectifier semiconductors used are SGCTs Unlike the diodes used in VSI rectifier bridges SGCTs are turned on and off by a gating signal A PWM gating algorithm controls the firing of the rectifier devices very similar to the control philosophy of the inverter The gating algorithm uses a specific 42 pulse switching pattern Figure 1 called Selective Harmonic Elimination SHE to mitigate the 5th 7th and 11th harmonic orders Figure 1 Typical PWM switching pattern line voltage waveform Vine Time ms A small integral line reactor and capacitor addresses the high harmonic orders 13th and above and provides virtually sinusoidal input voltage and current waveforms back to the distribution system This delivers excellent line side harmonic and power factor performance to meet IEEE 519 1992 requirements and other global harmonic standards while still providing a simple robust power structure that maximizes uptime by minimizing the number of discrete components and the number of interconnections required A Common Mode Choke CMC mitigates the common mode voltage seen at the motor terminals so standard non inverter duty rated motors and motor cables can be used making this technology ide
126. sor Isolated Gate Driver Power Supplies Inverter Modules IGDPS Rectifier Modules Rectifier IGDPS not required in drives with SPS boards installed 66 Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 Figure 51 Converter Cabinet 3300 4160V heat pipe model Inverter modules Ground bus Isolated Gate Driver Isolated Gate Power Supplies Driver Power IGDPS Supplies IGDPS Rectifier modules Figure 52 Converter Cabinet 6600V heat pipe model Inverter modules Isolated Gate Isolated Gate Driver Power Driver Power Supplies Supplies IGDPS IGDPS Rectifier modules Rockwell Automation Publication 7000 INO12B EN P June 2014 67 Chapter 4 Commissioning the Drive The circuitry for the IGDPS is encapsulated in epoxy As a result the module cannot be field repaired and there are no test points or adjustments available on this board If one of the six isolated 20V output fails you must replace the entire board IGDPS Board LEDs There is one green LED on each of the six output channels of IGDPS If the IGDPS is healthy then all six LEDs are active If any of the LEDs in not ON then the IGDPS might be defective replace it immediately Record the output measurements in the relevant Commissioning Guide data sheet to ensure all six outputs in each IGDPS are functioning The output voltage should be within 20V 2 There may be
127. ss Contactor Closures Sample Waveforms Commissioning the Drive Chapter 4 Ch1 Bypass Contactor Close Command BPC output at ACB J 1 12 amp 402 Ch2 Actual Closure of Bypass Contactor using 9V battery across contactor vacuum bottles Figure 87 Sample waveform Bypass contactor closures ae ee Sy A Ak i oe T anen ME E Tr H 4 E E H H 1 p da eu 5 V 25 ma 1 UFO ENF 2 V TR gs LAL ii IH TY y L ln ji DI I i IE N Hl Jersi salisi Coil Synchronous Transfer Test Verify Sync Lead Angle While simulating a synchronous transfer to determine the best lead angle e ensure you have configured and armed the Diagnostic Trend e capture motor voltage at ACB test point Vuv amp bypass voltage at ACB test point Vuvs e capture and trigger on falling edge of the DC Link current waveform at ACB test point Idc1 s label the waveforms as Vuv Vuvs and Idc1 e save the worksheet as Drift 15 Degree Lead Angle for example Table 9 Oscilloscope Settings Oscilloscope chan 1 Chan 2 Chan 3 Rockwell Automation Publication 7000 INO12B EN P June 2014 Time Base 10ms div Wave Form Test Point Waveform Label DC Link Current Idc1 Idc1 Motor Voltage Vuv Vuv Bypass Line Vuvs Vuvs Voltage 119 Chapter4 Commissioning the Drive Sample Wa
128. ss Detect 2 Torque Control NetSrvr FitActin Ne Value C Flux Control NetSrvr MPntCntl Bee mera Alarm Config Passcode 0 Drive Protection Passcode 1 Motor Protection Passcode 2 Sync Xfer Option Passcode 3 Encoder Option A 6 Choose Gate Test from the New Value pull down menu and click OK The operating mode value changes to Gate Test Figure 56 Figure 56 Gate Test Mode z3 PF77000 Terminal Home Display Alarms Setup Diagnostics Utility Access E m Operating Mode Advanced Filter ReadWrite Z Fie Parameter Parameter Name Value Unis Search Help Gate Test ATTENTION Ensure that the drive is no longer running in test mode prior to applying medium voltage to the drive line up Failure to do so may result in equipment damage SCR Firing Test In normal operation the SCR firing cards derive their power from a voltage divider network that steps down the medium voltage to 20V DC maximum As it is necessary to perform this test while isolated from medium voltage you need a secondary power source for firing cards Rockwell Automation Publication 7000 IN012B EN P June 2014 71 Chapter 4 72 Commissioning the Drive Each drive has a power cable that supplies 15V DC from an AC DC power supply to the firing cards SPGDB This cable has one input you can connect to an AC source 120 240V 50 60 Hz and 18 sets of outputs you can connect to the SCR self powered gate dri
129. t are aligned in the factory they often move out of position during shipping or are often misaligned when the cabinet is set down on an uneven floor The following instructions will assist the field engineers in quickly and accurately aligning the deadbolt key interlock with its counterpart hazardous Severe injury or death can result from electrical shock burn or unintended actuation of control equipment Hazardous voltages may exist in the cabinet even with the circuit breaker in the off position Recommended practice is to disconnect or lock out control equipment from power sources and confirm discharge of stored energy in capacitors If it is necessary to work in the vicinity of energized equipment the safety related work practices of NFTA 70E Electrical Safety requirements for Employee Work places must be followed 0 ATTENTION Servicing energized industrial control equipment can be Rockwell Automation Publication 7000 IN012B EN P June 2014 35 Chapter 4 36 Commissioning the Drive Figure 16 Deadbolt assembly mounted to door Grease marks from deadbolt pins Adjust deadbolt counterpart so that grease marks from pins hit here Lock out and isolate the drive from medium voltage Verify with a hot stick that there is no medium voltage present Determine that the key interlock is correctly aligned by securely bolting the medium voltage doors of the cabinet closed and removing the key from the lock The
130. tance Resistance value between heat sink and test point is snubber resistance Snubber Test Point Resistance between heat sink and test point is snubber resistance Resistance between two heat sinks is sharing resistance in parallel with anode o o o cathode resistance Rockwell Automation Publication 7000 IN012B EN P June 2014 47 Chapter4 Commissioning the Drive Snubber Resistance SGCT Device Access to the snubber resistor is not required to test the resistance The snubber circuit test point is located within the PowerCage under the heat sinks For each device there is one test point To verify the resistance measure the resistance between the test point and the heat sink above Figure 32 Snubber resistor test O Sharing Resistor r 4 e ol T Ld r Snubber Snubber O lI Resistor Capacitor E ST 2 as B gt 2 S S oa S E DO E 4 O A T a SS 0 T Sse SSS Test Point 1 EE O sect ji Measure resistance IP between heat sink an
131. th configurations draw heat away from the semiconductors heat pipes are bigger more efficient and require larger fans and airflow Information and graphics in this manual show both configurations 14 Rockwell Automation Publication 7000 IN012B EN P June 2014 PowerFlex 7000 Overview Chapter 2 Motor Compatibility The PowerFlex 7000 achieves near sinusoidal current and voltage waveforms to the motor resulting in no significant additional heating or insulation stress Temperature rise in the motor connected to the VFD is typically 3 C 5 5 F higher compared to across the line operation Voltage waveform has dv dt of less than 10 V us The peak voltage across the motor insulation is the rated motor RMS voltage divided by 0 707 Reflected wave and dv dt issues often associated with voltage source inverter VSI drives are a non issue with the PowerFlex 7000 Figure 5 shows typical motor waveforms The drive uses a selective harmonic elimination SHE pattern in the inverter to eliminate major order harmonics plus a small output capacitor integral to the drive to eliminate harmonics at higher speeds Standard motors are compatible without de rating even on retrofit applications Motor cable distance is virtually unlimited Rockwell Automation has tested this technology for controlling motors up to 15 km 9 3 mi away from the drive Figure 5 Motor waveforms full load full speed 300 00 200 00 100 00 CURRE
132. tionary but third function requires the motor to rotate In case the drive cannot complete the tuning you must tune it manually IMPORTANT You require a minimum of SERVICE level access to complete manual tuning If you do not have SERVICE level access please contact the factory Confirm the following tuning parameter default values s Input Impedance P 140 e TDC Link P 115 s R Stator P 129 s L Total Leakage P 130 s Lm Rated P 131 s T rotor P 132 s Total Inertia P 82 s Lmd P 418 Rockwell Automation Publication 7000 INO12B EN P June 2014 93 Chapter 4 Commissioning the Drive 94 Rectifier The Rectifier tuning function calculates parameter Input Impedance P 140 and T DC Link P 115 in Current Control group Input Impedance Input Impedance is used in the software reconstruction of the line voltage to compensate for the drop in the line impedance It is also used in the calculation of the line converter retard limit for SCR rectifiers to ensure proper operation under all conditions of line voltage and load current If the Input Impedance parameter is not correctly adjusted the resulting error in the reconstructed line voltage may cause line synchronization faults and incorrect reading of the incoming line voltage The Input Impedance parameter is tuned with the drive operating in the dc current test mode Although the Input Impedance was tuned during factory test it must be retuned during commissioni
133. ub menus used to e Configure the diagnostic setup e Provide operation status of the data collection e View collected data in tabular format s Plot collected data Diagnostics Setup To change a parameter 1 Click the Diagnostics tab and click the Setup tab in the sub menu to view the 16 parameters traces as shown in Figure 64 82 Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 Figure 64 Diagnostics screen PF7000 Terminal Home Display Alarms TEA Utility Access Advanced Filter ReadWrite Search Help Setup Control View Plot Parameter Linear Plot Trigger Type Continuous gt Torque Reference 291 Flux Feedback 306 Menu _Accept_ StatFrqVoltModel 485 10 Motor Voltage pu 554 11 Motor Current pu 555 12 Line Voltage pu 135 i DrvStatus Flag 569 DrvStatus Flag1 Hex 2 InvControl Flagi 265 for EI 3 RecControl Flagi 264 P 4 RecControl Flag2 160 ae K 5 Speed Reference 278 om i 6 Speed Feedback 289 IGA 7 8 9 13 Idc Reference 321 14 Idc Fbk Sampled 329 15 Alpha Rectifier 327 16 Line Current pu 122 2 Select the desired parameter in the Parameter column and press Linear to open the Soft Keypad dialog Figure 65 Type in the new parameter value Figure 65 Soft Keypad Dialog xl _ DoD A S BED EHE Parameters can also be selected for assignment by using the Search button e Click
134. urement takes about 3 minutes During this step parameter Lmd T Rotor Lm Rated will be calculated When the motor speed has settled at the commanded value a sinusoidal perturbation specified by parameter Autotune Trq Stp is added to the torque command causing the speed to vary After the initial transient has decayed this usually takes a few seconds the variation in torque and speed are measured and used to calculate the total inertia The torque perturbation is then removed and the drive performs a normal stop Parameter FlxCmd RatedLoad in Flux Control is set to a value calculated to produce rated voltage at rated speed and load The value of parameters Autotune T rotor and Autotune Lmd are calculated from the step response data If the flux regulator auto tuning is successful then parameter Lm Rated in Motor Model is set equal to Autotune L Magn parameter T Rotor in Motor Model is set equal to Autotune T Rotor and parameter Lmd in Motor Model is set equal to Autotune Lmd Parameter Total Inertia P 63 in Speed Control is set equal to Autotune Inertia If the flux regulator auto tuning fails a warning indicates the cause of the failure s L Magnetize Low indicates that the measured value of magnetizing inductance is less than 1 0 pu This warning is intended to draw attention to an unusually low value of magnetizing inductance The most likely cause is incorrect scaling of the analog field current reference e L Magnetize High
135. utomation prints identify all the locations of the components within the drive line up by their tag identification name or number Trace the power cables from point to point while following the electrical diagrams Note and review any discrepancy between the physical installation and the electrical prints prior to commissioning the drive Rockwell Automation Publication 7000 INO12B EN P June 2014 29 Chapter 4 30 Commissioning the Drive Inspection Process Before commissioning the drive line up you must inspect the process to which the drive is applied This step is not only important as a means of identifying and understanding how the equipment design adapts to the customer s application but also to identify any potential hazards Review the process and identify any necessary measures to ensure that commissioning the equipment will not expose anyone to hazardous situations or in any way do damage to the equipment involved in the application freewheeling motor can generate voltage that will be back fed to the equipment being serviced Take all action necessary to ensure that motor regeneration into the drive does not occur while the equipment is being serviced 0 ATTENTION Verify that the load is not turning due to the process A Safety Tests Complete this section of the commissioning chapter to ensure that the commissioning continues in an environment safe to all those involved in servicing the drive line up Complete e
136. veforms Synchronous Transfer Test to verify Sync Lead Angle 50Hz System Ch1 Idcl yellow Ch2 Vuv blue Ch3 Vuvs red Figure 88 Sample waveform Synchronous transfer test gt 40 ms K 547522e 006 ps raa yidet CH1 2 V 10 m 2 Vuv CH2 4 Y 10m 3 Vuvs CH3 4 Y 10 nis Live Synchronous Transfer While performing a live synchronous transfer 1 Capture motor voltage at ACB test point Vuv amp bypass voltage at ACB test point Vuvs 2 Capture and trigger on falling edge of the DC Link current waveform at ACB test point Idc1 3 Label the waveforms as Vuv Vuvs and Idc1 4 Save the worksheet as Synch on Motor 01 for example Table 10 Oscilloscope Settings Oscilloscope Time Base Wave Form Test Point Waveform Label Chan 1 10ms div DC Link Current Idc1 Idc1 Chan 2 Motor Voltage Vuv Vuv Chan 3 Bypass Line Vuvs Vuvs Voltage 120 Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 Sample Waveforms Live Synchronous Transfer Capture 50Hz System Ch1 Idc1 yellow Ch2 Vuv blue Ch3 Vuvs red Figure 89 Sample waveform Live synchronous transfer dk 20 de X 6 47622e 006 ps bru LI V NL y 2 Vuv CH2 4 10mg 3 Vuus CH3 4 Y 10 ms Rockwell Automation Publication 7000 IN012B EN P June 2014 121 Chapter4 Commissioning the Drive Notes 122 Rockwell Automation Pu
137. ver boards Plug the AC power connector on the test cable into an appropriate AC source The other eighteen 3 pin connectors plug into the SCR SPGDB board terminals labeled TB3 Test Power see Figure 57 The number of eighteen 3 pin connectors used depends on the voltage and configuration of the drive rectifier section Figure 57 Self Powered Gate Driver Board Test Power Terminal TB3 Test power connection D e 9 0 OP1 OT1 Fiber optic transmitter and receiver TB2 Temperature sensor power connection TP9 ma TP8 TP7 TPG gt TB4 Gate and cathode N thyristor connection TPS _ le TP4 TP3 LED PR qs TB1 Snubber connection r Ole TP2 TP1 Put the drive in Gating Test Mode and the rectifier automatically enters Test Pattern gating mode LED 1 Gate Pulse Yellow should light up and pulsate at the same device firing frequency The other LEDs light up as the firmware sends a gating signal to every SCR There is also a Gating Test that fires the individual devices one at a time in what is described as a Z pattern For each section the Top Left device turns on for 2 seconds then turns off The next device to the right turns on for 2 seconds and the pattern continues Rockwell Automation Publication 7000 IN012B EN P June 2014 Commissioning the Drive Chapter 4 At the end of the first stack of devices the right device in the middle stack down fires and the pattern continues right to left unti
138. verter 61 ACB Test Points 90 Analog Inputs Outputs 76 Scaling 77 Bypass Contactor Closures 119 C Commissioning Package 25 Configurable Alarms 80 Control Power Off Tests 35 Tests 59 Transformer 61 Control Wiring 33 Cooling Technology 14 D Data Capture 112 DC Current Test 92 115 Oscilloscope Settings 115 Sample Waveforms 116 Diagnostics 82 Setup 82 Trigger 84 Disconnect Switch 60 Drive Input Voltage Phasing Checks 112 Oscilloscope Settings 113 Sample Waveforms 113 E Encoder Usage 123 F Field Current Reference 106 Firing Test 71 Flux Speed Regulator 100 Flux Regulator 100 Flux Regulator Manual Tuning 103 Speed Regulator 101 Fuse Protection 31 Rockwell Automation Publication 7000 IN012B EN P June 2014 G Gating Tests 69 Harmonic Analysis PWM Drives only 114 Oscilloscope Settings 114 Sample Waveforms 115 Heat pipe PowerCage Components 43 Snubber Circuit Assembly 44 Snubber test point 47 Heat sink Snubber test point 46 Input Phasing Check 90 Inspection 30 Interlocking 35 K Key interlock 35 L Line Terminal Resistance Measurements 81 Live Synchronous Transfer 120 Oscilloscope Settings 120 Sample Waveforms 121 Load Test 117 Oscilloscope Settings 117 Lockout 30 Low Voltage Input Breaker 60 M Motor Compatibility 15 Motor Impedance 98 0 Operator Interface 19 Basic Configurations 19 Oscilloscope Settings 115 Drive Input Voltage Phasing Checks 113 H
139. very point in this section prior to continuing with the drive commissioning Ensure that you perform the drive commissioning in accordance with local safety standards hazardous Severe injury or death can result from electrical shock burn or unintended actuation of control equipment Hazardous voltages may exist in the cabinet even with the circuit breaker in the off position Recommended practice is to disconnect or lock out control equipment from power sources and confirm discharge of stored energy in capacitors If it is necessary to work in the vicinity of energized equipment the safety related work practices of NFTA 70E Electrical Safety requirements for Employee Work places must be followed T ATTENTION Servicing energized industrial control equipment can be ATTENTION Before attempting any work verify the system has been locked out and tested to have no potential Lockout Tagout Prior to opening the doors to the drive line up cabinets ensure you use proper lockout tagout procedures to ensure that the working environment is safe In addition test the equipment for potential prior to servicing the equipment Even though the input to the drive may be open it is still possible for potential to be present Rockwell Automation Publication 7000 IN012B EN P June 2014 Installation Review Commissioning the Drive Chapter 4 the drive is isolated from medium voltage and wait five minutes for the capacitors to discharge Test
140. voltage at rated speed and full load The flux level required to achieve this is a function of the motor parameters The flux regulator auto tuning determines a value of rotor flux that should provide rated motor voltage at full load and rated speed and sets the flux command parameter to this value Speed Regulator Two parameters in the Speed Control group determine the speed regulator tuning e SpdReg Bandwidth s Total Inertia Set Parameter SpdReg Bandwidth to a value determined by the requirements of the application Total Inertia is usually unknown measure it separately The auto tuning determines the total inertia by measuring the change in speed that occurs when a low frequency sinusoidal torque perturbation is applied to the motor Load torque does not affect the inertia measurement as long as the drive does not hit torque limit Do not disconnect the driven load from the motor you are measuring the total inertia of motor and load Use the following procedure to auto tune FluxSpeed Reg Induction Motor 1 Ensure that parameters Rated Motor RPM in Motor Ratings and L Total Leakage in Motor Model have the correct value Ensure that parameters Autotune Spd Cmd and Autotune Trq Stp in Autotune use default values 2 Set the Autotune Select parameter in Autotuning to FluxSpeed Reg 3 Start the drive The motor accelerates normally up to the speed specified by parameter Autotune Spd Cmd Calculate the motor magnetizing inductance
141. well Automation Software RS drive tools Optional RS Logix Required computer cables 9 Pin Null Modem 9 Pin Serial Ethernet cable Remote I O SCANport DeviceNet PLC Communications Cable Addition al Required Prior to scheduling your drive commission ensure you have the following Resources Functional specifications for the drive to be commissioned generally available from the online MV Literature Library Any commissioning notes for this customer installation available from the Rockwell Automation Application Specialist or Project Manager Self powered gate driver board test power cable wire harness Part no 80018 298 51 supplied with SCR rectifier drives only SPS test power cable wire harness part no 80018 695 51 supplied with SPS rectifier drives only Rockwell Automation electrical and mechanical diagrams for each drive also available through ShopView SAP PLC program if supplied with a PLC materials available from the MV intranet website using the order number as a reference Commissioning data sheets All required manuals see below for list If any of the above information is not available prior to the time of commissioning please contact the Rockwell Automation Project Manager or the factory 1 Only required if drive does not have PFNI PowerFlex 7000 Netserver Interface 2 Only required when PLC has been provided with the drive 3 Refer to Publication 700
142. width and that there is minimal overshoot For example if the speed regulator bandwidth is set to 2 rad s the speed should rise to 63 of its final value in 0 5 second 10 Set parameter Speed Ref Step to zero and stop the drive Rockwell Automation Publication 7000 IN012B EN P June 2014 105 Chapter 4 106 Commissioning the Drive Calculating Total Inertia If you cannot measure the system inertia calculate it if you know the motors inertial moment motor and load The value of parameter Total Inertia is the time required to accelerate the motor and load to rated speed when applying the rated torque Use the following formulas for either metric or imperial calculations Metric Te R H where Total inertia s s Tu Total inertia of motor and load in kgem e Ru Rated speed in rad s e Py Power in watts Imperial 34 T S Total inertia s 6 21 x 10 where I s T Total inertia of motor and load in Ibeft2 e S lt Rated speed in rpm e Di Power in Hp If there is a gearbox between the motor and load refer the inertia of the load to the motor side of the gearbox Flux Speed Regulator Synchronous Motors IMPORTANT Before tuning the FluxSpeed regulator you must configure the analog output for the field current reference Configuring the Field Current Reference Use a current regulated field supply to excite the synchronous motor either a dc supply for a slip ring or DC brushless machine
143. will affect the control power distribution within the drive the input will always be as illustrated below Figure 44 Control power distribution 1 ph o Line Filter gt AC DC Converter C Hold up B gt Operator Interface Printer Relays gt 5V LOGIC gt 15V LOGIC 56V DC G DC DC CONVERTER LK 24V HECS OOW 1000W R SR gt 24V ISOLATORS gt 24V XI0 DC Fail SENSE CABLE 20V Isolated Gate Driver Power Supply 20V Inverter only for SPS drives IMPORTANT Prior to energizing the drive verify that the control power feeding into the input breakers is rated as designated on the electrical diagram Three Phase Input In the 3 phase input configuration the customer supplies 3 phase control power into the disconnect switch Labeled DS1 on the Electrical Schematics From that point the power is distributed to the 3 phase fan and to the power supplies through a single phase CPT The output of the single phase CPT powers all the power supplies and controls within the drive The 3 phase control should be measured at the input to DS1 If the rating matches the designation on the electrical schematic it is acceptable to apply control power to the drive Take necessary measures to rectify the control power level in the event that it does not meet the design specifications Rockwell Automation Publicatio
144. y render test results invalid It is not necessary to lock the rotor 2 Set the Autotune Select parameter in Auto tuning to Motor Impedance 3 Start the drive In the first half of the test the output frequency is zero the dc current increases to 0 6pu for a few seconds to calculate R Stator then decreases to zero 4 In the second half of the step the output frequency increases to rated frequency with the de current equal to 1 0 pu for a few seconds This test may produce a small amount of motor torque and some rotation may occur This step calculates the L Total Leakage Decrease the current and set the Autotune Select parameter to Off 5 At the end of the R Stator tuning the R Stator P 129 in Motor Model is set equal to Autotune R Stator If the test fails or the values are out of range the interface prompts with a warning indicating the cause of the failure 6 At the end of the L Leakage tuning the L total leakage P 130 in Motor Model equal to Autotune LLeakage If the test fails the interface prompts with a warning The following warnings may occur during this test e R stator High this is probably caused by extremely long motor cables increasing the apparent stator resistance of the motor The drive cannot operate with stator resistance greater than 0 50 pu e L Leakage Low indicates that the measured leakage inductance is less than 0 10 pu Possible causes are The motor is much larger than the drive and th

PowerFlex 7000 Medium Voltage AC Drive Air-Cooled

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