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PowerFlex 7000
Allen-Bradley PowerFlex 7000 User Manual
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User Manual
Original Instructions
PowerFlex 7000 Medium Voltage AC Drive Air-Cooled
(“B” Frame)—ForGe Control
Catalog Number 7000
2
Table of Contents
Default Chapter
3
Table of Contents
3
Preface
9
Purpose
9
Summary of Changes
9
Who Should Use this Manual
9
General Precautions
10
What Is Not in this Manual
10
Commissioning Support
11
Abbreviations
12
Additional Resources
13
Product Certification
13
Chapter 1 Topology
15
Powerflex 7000 Drive Overview
15
Rectifier Designs
16
Configurations
16
Cooling Technology
18
Motor Compatibility
19
Simplified Electrical Diagrams
20
2400V
20
3300/4160V
21
6600V
22
Functional Safety
23
Safe Torque off
23
Arcshield Technology
24
Operator Interface
25
Basic Configurations
25
Chapter 2 Control Power off Tests
27
Interlocking
27
Power Component Definition and Maintenance
27
Control / Cabling Cabinet Components
29
Voltage-Sensing Assembly
37
Replacing the Voltage-Sensing Circuit Board Assembly
38
Input Transient Protection
39
Transient Suppression Network (TSN)
39
Surge Arresters
43
Filter Capacitor Cabinet
50
Filter Capacitors
50
Replacing Filter Capacitors
51
Testing Filter Capacitors
52
Converter Cabinet Components
54
Powercage Module Overview
59
Resistance Checks
60
SGCT and Snubber Circuit
61
SGCT Testing
67
SGCT Anode-To-Cathode (Sharing) Resistance
68
Snubber Resistance (SGCT Device)
70
Snubber Capacitance (SGCT Device)
71
Replacing the SGCT
73
Replacing Snubber and Sharing Resistor
76
Replacing Snubber Capacitor
80
Replacing Sharing Resistors
82
Silicon Controlled Rectifier Powercage Modules
82
SCR Testing
83
SCR Anode-To-Cathode Resistance
85
SCR Sharing Resistance Test
86
SCR Gate-To-Cathode Resistance
87
Snubber Resistance (SCR Device)
88
Snubber Capacitance (SCR Device)
89
Replacing SCR and SCR Self-Powered Gate Driver Boards
90
(Spgdb)
90
Uniform Clamping Pressure
92
Checking Clamping Pressure
93
Clamping Pressure Adjustment
93
Temperature Sensing
94
Replacing the Thermal Sensor
94
Replacing Heatsinks/Heatpipes
97
Replacing Heatsinks
98
Replacing Heatpipes
99
Powercage Gasket
100
Replacing Powercage Gaskets
102
Removing the Powercage Module
103
Self-Powered SGCT Power Supply - SPS
105
Board Calibration
105
Test Points
105
Testing Equipment
107
Self-Powered Gate Driver Board - SPGDB
108
Board Calibration
108
Test Points
108
Terminal/Connections
109
Testing Procedure for SCR Self-Powered Gate Driver Board
110
Testing Equipment
110
Procedure
110
Fiber Optic Cabling
113
Air Pressure Sensor
114
Replacing the Air Pressure Sensor
115
DC Link and Fan Cabinet Components
115
DC Link Reactor
119
Removing and Replacing Fans
121
Fan Installation
123
Impeller Maintenance
124
Impeller Removal from Motor Shaft
124
Installing Impeller Assembly Onto Motor Shaft
125
Replacing Air Filters
127
Chapter 3 Control Power Components
131
Ride-Through
131
Control Component Definition and Maintenance
131
AC/DC Power Supply
133
Terminal / Connections Descriptions
135
(Pioneer Power Supply)
135
Terminal / Connections Descriptions
136
(Cosel Power Supply)
136
Output Calibration
137
Power Supply Replacement
138
Power Supply Diode Replacement
140
UPS Option
141
Replacing the UPS
143
Low Voltage Control Section
144
DC/DC Power Supply
145
Terminal/Connections Descriptions
146
Replacing a DC/DC Power Supply
147
Drive Processor Module
148
Replacing the Drive Processor Module
150
Analog Control Board (ACB)
152
Status Indicators
156
Interface Module (IFM)
156
Analog Inputs and Outputs
157
Current Loop Transmitter
157
Isolated Process Receiver
158
Non-Isolated Process Outputs
159
Auxiliary +24V Power Supply
159
Replacing the Analog Control Board
160
Encoder Feedback Board
160
Encoder Options
160
20B-ENC-3 Encoder Interface
161
Quadrature Encoder Operation
164
Positional Encoder Operations
165
External Input/Output Boards
167
Replacing the External Input/Output Board
168
Optical Interface Boards (OIB)
169
Replacing the Optical Interface Board
170
Replace the Optical Interface Base Board
173
Optical Interface Base Board Test Points
173
Appendix A
175
B" Frame Drive Specifications
175
Specifications
175
Appendix B Service Duty Rating, Continuous Current Rating and Altitude Rating Code
181
Powerflex 7000 Drive Selection Explanation
181
Annual Maintenance
183
Initial Information Gathering
184
Physical Checks
184
Control Power)
184
Control Power Checks (no Medium Voltage)
185
Final Power Checks before Restarting
186
Additional Tasks During Preventive Maintenance
186
Final Reporting
187
Time Estimations
188
Tool / Parts / Information Requirements
188
Appendix C
183
Operational Maintenance
183
Preventative Maintenance Checklist
183
Overview
190
Appendix D Torque Requirements for Threaded Fasteners
193
Appendix E Insulation Resistance Test
195
Overview
195
Insulation Resistance Test Procedure
196
Required Equipment
196
Procedure
196
Maximum Line Cable Sizes
201
Appendix F Maximum Load Cable Sizes
203
Air Quality Requirements
205
Appendix G Hazardous Materials
206
Capacitor Dielectric Fluid
206
Printed Circuit Boards
206
Lithium Batteries
206
Chromate Plating
207
In Case of Fire
207
Disposal
207
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Allen-Bradley PowerFlex 7000 Specifications
General
Brand
Allen-Bradley
Model
PowerFlex 7000
Category
Controller
Language
English
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