Allen-Bradley PF7000A User manual

PowerFlex 7000 Medium Voltage AC Drives
Publication 7000-TG002J-EN-P
Troubleshooting Guide

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 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.
Labels may also be on or inside the equipment to provide specific precautions.
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.
IMPORTANT
Identifies information that is critical for successful application and understanding of the product.
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).

Rockwell Automation Publication 7000-TG002J-EN-P - March 2015 3
Summary of Changes
This manual contains new and updated information.
New and Updated
Information
This table contains the changes made to this revision.
Topic Page
Added Fault 159 21
Updated STO Gating Flt description 40

4Rockwell Automation Publication 7000-TG002J-EN-P - March 2015
Summary of Changes
Notes:

Rockwell Automation Publication 7000-TG002J-EN-P - March 2015 5
Table of Contents
Preface About this Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Acronyms and Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 1
Fault Messages
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 2
Warning Messages
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Appendix A
Spare Parts
Components and Related Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Appendix B
Fault Codes
Listed Numerically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Appendix C
Warning Codes
Listed Numerically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

6Rockwell Automation Publication 7000-TG002J-EN-P - March 2015
Table of Contents
Notes:

Rockwell Automation Publication 7000-TG002J-EN-P - March 2015 7
Preface
About this Publication This manual contains troubleshooting information for medium voltage
PowerFlex® 7000 drives only.
Who Should Use This Manual This manual is intended for qualified service personnel responsible for
troubleshooting and repairing medium voltage PowerFlex 7000 drives. You
should have previous experience with, and basic understanding of, electrical
terminology, procedures, required troubleshooting equipment, equipment
protection procedures and methods, and safety precautions.
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
You can view or download publications at
http:/www.rockwellautomation.com/literature/. To order paper copies of
technical documentation, contact your local Allen-Bradley distributor or
Rockwell Automation sales representative.
Resource Description
Publication 7000-IN006 PowerFlex 7000 Medium Voltage AC Drive (B Frame) Commissioning - ForGe Control
Publication 7000-IN007 PowerFlex 7000 Medium Voltage AC Drive (B Frame) Installation - ForGe Control
Publication 7000-IN008 PowerFlex 7000 Medium Voltage AC Drive (B Frame) Trans. & Handling - ForGe Control
Publication 7000-IN010 Handling, Inspection, and Storage of Medium Voltage Line Filter Capacitors
Publication 7000-PP002 PowerFlex 7000 Air-Cooled Drives
Publication 7000-QS002 HMI Interface Board Software Updater and Firmware Download Procedure
Publication 7000-TD001 PowerFlex 7000 Medium Voltage AC Drive (Firmware Version 6.xxx) - Classic Control
Publication 7000-TD002 PowerFlex 7000 Medium Voltage AC Drive (Firmware Version 9.xxx) - ForGe Control
Publication 7000-UM150 PowerFlex 7000 Medium Voltage AC Drive (B Frame) - Classic Control
Publication 7000-UM151 PowerFlex 7000 Medium Voltage AC Drive (B Frame) - ForGe Control (Using
PanelView 500)
Publication 7000-UM201 PowerFlex 7000 HMI Offering with Enhanced Functionality
Publication 7000-UM202 PowerFlex 7000 Medium Voltage AC Drive (B Frame) - ForGe Control
Publication 7000-UM203 PowerFlex 7000 Series Safe Torque Off
Publication 7000A-UM150 PowerFlex 7000 Medium Voltage AC Drive (A Frame) - Classic Control
Publication 7000A-UM151 PowerFlex 7000 Medium Voltage AC Drive (A Frame) - ForGe Control (Using
PanelView 550)
Publication 7000L-UM301 PowerFlex 7000 Medium Voltage AC Drive (C Frame) - ForGe Control
Publication 7000L-UM302 PowerFlex 7000 Medium Voltage AC Drive (C Frame) - ForGe Control (Marine)

8Rockwell Automation Publication 7000-TG002J-EN-P - March 2015
Preface
Acronyms and Abbreviations Acronym/ Abbreviation Description
A/D Analog/Digital
A2D Analog to Digital
AC Alternating Current
ACB Analog Control Board
Accel Acceleration
ADC Analog to Digital Converter
Anlg Analog
BW Bandwidth
Cap Capacitor
Ch Channel
Chn Channel
CIB Customer Interface Board
CMC Common Mode Choke
Cmd Command
Conv Converter
CT Current Transformer
Ctctr Contactor
Cur Current
DAC Digital to Analog Converter
DB Dynamic Braking
DC Direct Current
DCB Drive Control Board
DCSL Drive Control and Synchronization Link
DD Dimensional Drawings
Decel Deceleration
DIM Drive Identity Module
Dly Delay
DO Drive Output
DPI Drive Peripheral Interface
DPM Drive Processor Module
DrvIn Drive Input
ED Electrical Drawings
ESP Electric Submersible Pump
Fbk Feedback
Flt Fault
Fltr Filter
FO Fiber-Optic
FOB Fiber-Optic Interface Board
FOI Fiber-Optic Interface
FPGA Field-Programmable Gate Array

Rockwell Automation Publication 7000-TG002J-EN-P - March 2015 9
Preface
Freq Frequency
GND Ground
Gnrl General
HECS Hall Effect Current Sensor
Hi High
HP Horse Power
HW Hardware
ICurrent
IGDPS Isolated Gate Driver Power Supply
Init Initialize
Inv Inverter
IO Input/Output
Isoltn Sw Isolation Switch
LInductance
LLine
LED Light-emitting diode
Liq Liquid
Lo Low
LR Line Reactor
LV Low Voltage
MMachine
Magntz Magnetizing
Max Maximum
Min Minimum
Mstr Master
MTR Motor
NVRAM Non-Volatile Random Access Memory
OC Overcurrent
OL Overload
OP Output
OT Overtemperature
OV Overvoltage
PD Parallel Drive
PF Power Factor
PFC Power Factor Correction
PID Proportional, Integral, Derivative (process control)
PLC Programmable Logic Control
PSD Power Structure Diagnostic
PWM Pulse-Width Modulation
Rect Rectifier
Acronym/ Abbreviation Description

10 Rockwell Automation Publication 7000-TG002J-EN-P - March 2015
Preface
Rot’n Rotation
SCB Signal Conditioning Board
SCR Silicon-Controlled Rectifier
SGCT Symmetrical-Gate Commutated Thyristor
Slv Slave
Spd Speed
SPGD Self-Powered Gate Driver
STO Safe Torque Off
SW Software
Sync Synchronous
Tach Tachometer
TFB Temperature Feedback Board
TFB3 Temperature Feedback Board, 3rd generation
Trp Trip
Trq Torque
TSN Transient Suppression Network
UB Unbalance
UPS Uninterrupted Power Supply
USART Universal Synchronous/Asynchronous Transmitter/Receiver
VVolt
VSB Volt Sensing Board
Wrn Warning
Xfer Transfer
XIO External Input/Output
Acronym/ Abbreviation Description