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PowerFlex 7000 Medium Voltage AC Drive Air-Cooled (B Frame) - ForGe Control (Using PanelView 500)

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PowerFlex® 7000 Medium Voltage AC Drive Air-Cooled (“B” Frame)—ForGe Control(Using PanelView 550)Publication 7000-UM151E-EN-PBulletin 7000 User ManualImportant User InformationSolid-state equipment has operational characteristics differing from those of electromechanical equipment. Safety Guidelines for the Application, Installation and Maintenance of Solid State Controls (publication SGI-1.1 available from your local Rockwell Automation sales office or online at http://www.rockwellautomation.com/literature/) describes some important differences between solid-state equipment and hard-wired electromechanical devices. Because of this difference, and also because of the wide variety of uses for solid-state equipment, all persons responsible for applying this equipment must satisfy themselves that each intended application of this equipment is acceptable.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 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.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.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.SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous voltage may be present.BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may reach dangerous temperatures.ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).IMPORTANTIdentifies information that is critical for successful application and understanding of the product.Rockwell Automation Publication 7000-UM151E-EN-P - January 20133Summary of ChangesThis manual contains new and updated information since the last edition of the PowerFlex 7000 “B” Frame AC Drive User Manual.New and Updated InformationThis table contains the changes made to this revision.TopicPageInserted PanelView 550 subtitleFront CoverInserted ArcFlash warning24Rockwell Automation Publication 7000-UM151E-EN-P - January 2013Summary of ChangesRockwell Automation Publication 7000-UM151E-EN-P - January 20135Table of ContentsImportant User InformationWho Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11What Is Not in this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11Manual Conventions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12Commissioning Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13PowerFlex 7000 OverviewTopology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15Rectifier Designs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16Motor Compatibility. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17Simplified Electrical Diagrams. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182400V with AFE Rectifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183300/4160V with AFE Rectifier. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196600 V with AFE Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21Component Definition and MaintenanceControl / Cabling Cabinet Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 23Voltage-Sensing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29Replacing the Voltage-Sensing Circuit Board Assembly. . . . . . . . . . 29Input Transient Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30Transient Suppression Network (TSN) . . . . . . . . . . . . . . . . . . . . . . . . 31Surge Arresters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35Filter Capacitor Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Filter Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42Testing Filter Capacitors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44Converter Cabinet Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45Converter Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48PowerCage™. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49SGCT and Snubber Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52Uniform Clamping Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53Temperature Sensing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56Replacing the Symmetrical Gate Commutated Thyristor . . . . . . . . 58Replacing Silicon Controlled Rectifier and SCR Self-Powered Gate Driver Boards (SPGDB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60Replacing Heatsinks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63PowerCage Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65Replacing PowerCage Gaskets. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66Removing the PowerCage. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67Snubber Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68Testing Snubber Resistors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69Replacing Snubber and Sharing Resistor. . . . . . . . . . . . . . . . . . . . . . . . 69Sharing Resistors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73SGCT PowerCages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74Replacing Sharing Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75SCR PowerCages. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75

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