Rockwell Automation Allen-Bradley PowerFlex 7000 User manual

User Manual
Original Instructions
PowerFlex 7000 Medium Voltage AC Drive Liquid-Cooled
("C" Frame) - ForGe Control
(Using PanelView 550)
Bulletin Number 7000L

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.
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).

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Table of Contents
Preface
Summary of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
What Is Not in this Manual. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Commissioning Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Chapter 1
Overview of Drive Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Liquid Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Benefits of Liquid Cooling Include: . . . . . . . . . . . . . . . . . . . . . . . . . 15
Benefits of the 7000L “C” Frame Liquid-cooled Drive: . . . . . . . 16
Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Rectifier Designs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
18 Pulse Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Active Front End (AFE Rectifier). . . . . . . . . . . . . . . . . . . . . . . . . . . 18
“Direct-to-Drive” Technology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Motor Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
SGCT Features and Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Simplified Electrical Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Control Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Direct Vector Control . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Control Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Chapter 2
Drive Installation Safety and Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Transportation and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Overhead Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Rod or Pipe Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Fork Lift Trucks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Siting of the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Site Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
Joining Shipping Splits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Connect the Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Tools Required (not supplied) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Install CPVC Piping Splices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Connect Power: M+, L+, M-, L- Power Bus . . . . . . . . . . . . . . . . . 42
Control Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Removal of DC Link Choke Turnbuckle Supports . . . . . . . . . . 54

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Table of Contents
Removal of Lifting Angles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Shock Indication Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Installation of Exhaust Air Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Internally mounted fans. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
Externally mounted fans and fan hood . . . . . . . . . . . . . . . . . . . . . . 58
Typical PowerFlex 7000L Drive Structure Layout. . . . . . . . . . . . 59
Control/Cabling Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
Major Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
IEC Component and Device Designation . . . . . . . . . . . . . . . . . . . . . . . 68
Power Wiring Selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
General Notes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Cable Insulation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Power Cabling Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Access the Customer Power Cable Terminations: . . . . . . . . . . . . 71
Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Incoming Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Liquid Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Liquid-to-Air Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Pipe Materials and Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
External Piping to the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
External Piping Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Controlled Siphon into Open-top Reservoir. . . . . . . . . . . . . . . . . . . . . 78
Liquid-to-Liquid Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Power and Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Control Cables. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Encoder Installation Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Information Regarding Termination of Customer Cables. . . . . 86
Grounding Practices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Grounding Guidelines and Practices for Drive Signal and
Safety Grounds. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Grounding Requirements and Grounding Specification for
Customers and Power Integrators. . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Identification of Types of Electrical Supplies – Grounded and
Ungrounded Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Ground Bus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Interlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Chapter 3
Operator Interface Chapter Objectives. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Terminology. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Keypad . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Function (Softkeys) Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Cursor (Selection) Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Data Entry Keys . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
What is a Screen?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94

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Table of Contents
Information Windows . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Accessing/Writing to Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Communication Error . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Languange Changing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
General Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
Operator Interface Power-up Sequence . . . . . . . . . . . . . . . . . . . . . . . . . 99
Top Level Menu . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
How To . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Obtain Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Related Topics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Help on Help . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Modify Operator Interface Operation (Utility) . . . . . . . . . . . . . . . . . 102
Changing Backlight Delay. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Changing Contrast . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Setting Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Setting Date . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Selecting Meters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Viewing Revision Levels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Transfer Data in Memory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 109
Picking an Access Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Select a Parameter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Via Groups . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Via Name. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Via Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Edit Text . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Configure the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Enter/Modify an Access Level . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Drive Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Language Selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Modify Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Numerical Value . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 122
Enumerated Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 124
Bit Encoded Value. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Analog Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 126
Fault Masks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
User Definable External Text. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
PLC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
XIO. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Message Prompting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Store/Retrieve Configuration (NVRAM) . . . . . . . . . . . . . . . . . . 135
Initialize . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Save . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 135
Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Display Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
Custom Group . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 138
View Drive Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 139
View and Reset Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140

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Help for Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Request Printouts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Perform Diagnostic Trending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
Assigning a Trace. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Setting the Trigger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 144
Defining Sample Rate and Positioning . . . . . . . . . . . . . . . . . . . . . 146
Starting the Trace . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Flash Memory Transfers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Format Flash Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
View a Directory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 150
Select a Filename . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Enter a Filename . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Loading Programs (Firmware). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Parameter Transfers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Upload to Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
Download from Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . 154
Upload to Memory Card. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Download from Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Parameter File Format . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Loading Language Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
System Programming . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Advanced Screen Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Communications Statistics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Protocol Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Print Screen. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Memory Dump . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 160
Database Download . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Operator Interface Menu Hierarchy Chart . . . . . . . . . . . . . . . . . . . . . 162
What Does It Show?. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
How Do You Read It? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
Example . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
PCMCIA Memory Card Installation Data . . . . . . . . . . . . . . . . . . . . . 167
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Installing the Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Chapter 4
Commissioning Start-up Commissioning Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Drive Commissioning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Commissioning the Drive . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 170
Pre-Commissioning Responsibilities . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
PowerFlex 7000 ‘C’ Frame Pre-Commissioning Checklist . . . . . . . 171
Receiving and Unpacking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 171
Installation / Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 172
Power Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Drive Line-up Status. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173

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Cooling System Status . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Commissioning Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
Recommended Tools and Equipment . . . . . . . . . . . . . . . . . . . . . . 175
Technical Publications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
PowerFlex 7000 “C” Frame Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
PowerFlex 7000 Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Additional Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176
Resources Required to Complete Drive Commissioning. . . . . . . . . 176
Important Note for Commissioning Engineer . . . . . . . . . . . . . . . . . . 177
Key Steps to Commissioning a PowerFlex 7000 Drive . . . . . . . . . . . 178
PowerFlex 7000 “C” Frame Commissioning Datasheets . . . . . . . . . 179
PowerFlex 7000 “C” Frame Drive Commissioning Checklist . . . . 180
Drive Application Review. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Rockwell Automation Drive Line-up Drawings . . . . . . . . . . . . . 183
Electrical System One-line Diagram. . . . . . . . . . . . . . . . . . . . . . . . 184
Verify One-line Diagram on Site . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Inspect Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Safety Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Lockout Tagout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Step Down Transformer Fusing . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Fuse and O/L Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Installation Review . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Inspect for Shipping Damage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Inspect Cabinets for Debris . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Protective Barriers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Component Grounding. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Information on Splice Kits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Power Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
Liquid-Cooling Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Service Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Why this Information is Needed. . . . . . . . . . . . . . . . . . . . . . . . . . . 190
Customer Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
Control Power Off Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Interlocking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Resistance Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 196
SGCT Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
SGCT Anode-to-Cathode Resistance . . . . . . . . . . . . . . . . . . . . . . 198
Snubber Resistance (SGCT Device). . . . . . . . . . . . . . . . . . . . . . . . 199
Snubber Capacitance (SGCT Device) . . . . . . . . . . . . . . . . . . . . . . 200
SCR Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
SCR Anode-to-Cathode Resistance . . . . . . . . . . . . . . . . . . . . . . . . 201
SCR Sharing Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
SCR Gate-to-cathode Resistance. . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Snubber Resistance (SCR Device) . . . . . . . . . . . . . . . . . . . . . . . . . 204
Snubber Capacitance (SCR Device). . . . . . . . . . . . . . . . . . . . . . . . 205
Control Power Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206

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Three-Phase Input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Three-Phase Input / Single Phase Input . . . . . . . . . . . . . . . . . . . . 207
Power Supply Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Circuit Board Healthy Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Control Power Transformer (CPT). . . . . . . . . . . . . . . . . . . . . . . . 208
AC/DC Converter (PS1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
DC/DC Converter (PS2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 210
SGCT Power Supplies (IGDPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
IGDPS Board LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Commissioning the Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Heat Exchanger Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 215
Pumping Cabinet Control Power Checks . . . . . . . . . . . . . . . . . . 216
System Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
System Fill and Air Venting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Normal Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Gating Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
Gating Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 220
SCR Firing Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 222
SGCT Firing Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 224
System Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
System Test Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 225
Start/Stop Control Circuit. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 226
Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Analog I/O . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 227
Configurable Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
18 Pulse Phasing Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 231
Line Terminal Resistance Measurements . . . . . . . . . . . . . . . . . . . 232
Application of Medium Voltage . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
Input Phasing Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 233
DC Current Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 235
Tuning Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
1. Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 238
2. Motor Impedance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 243
3. FluxSpeed Regulator [INDUCTION MOTORS] . . . . . . . . 244
4. FluxSpeed Regulator [SYNCHRONOUS MOTORS]. . . . 249
Running the Load . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Motor Starting Torque . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Reaching Specific Load Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 253
Capturing Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Drive Input Voltage Phasing Checks. . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Summary:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 255
Harmonic Analysis
(required for AFE drives only). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
Summary:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 257
DC Current Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Summary:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 258
Load Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 259

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Synchronous Transfer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 261
Chapter 5
Component Definition and
Maintenance
Control / Cabling Cabinet Components. . . . . . . . . . . . . . . . . . . . . . . 265
Voltage-Sensing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 268
Voltage-Sensing Circuit Board Assembly Replacement . . . . . . . . . . 268
Input Transient Protection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 269
Transient Suppression Network (TSN) . . . . . . . . . . . . . . . . . . . . . . . . 270
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
MOV Suppressor. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 270
MOV Fuse. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 271
Transient Suppression Network Fuse Replacement . . . . . . . . . . . . . 272
Metal-Oxide Varistor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 273
Surge Arresters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 274
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 275
Surge Arrester Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 276
Field Test and Care. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 277
Output Grounding Network Capacitor Replacement . . . . . . . . . . . 277
Ground Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 279
Hall Effect Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 280
Current Transformer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . 281
Filter Capacitor Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Filter Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 282
Filter Capacitor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 284
Testing Filter Capacitors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 285
Converter Cabinet Components. . . . . . . . . . . . . . . . . . . . . . . . . . . 287
Converter Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
PowerCage™ . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 289
SGCT and Snubber Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 291
Checking Clamping Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Clamping Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . 292
Symmetrical Gate Commutated Thyristor Replacement. . . . . . . . . 293
Silicon Controlled Rectifier and SCR Self-Powered Gate Driver
Board Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 296
Detachment of Coolant System from PowerCage Modules . . . . . . 299
Reconnecting the Coolant System to a PowerCage Module . . 303
Chill Block Removal and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . 303
Instructions for removing Chill Block assembly . . . . . . . . . . . . . 303
Instructions for inserting Chill Block assembly. . . . . . . . . . . . . . 304
PowerCage Removal and Replacement . . . . . . . . . . . . . . . . . . . . . . . . . 305
Snubber Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 306
Testing Snubber Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Sharing Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 307
Testing Sharing Resistors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 308
Snubber and Sharing Resistor Replacement. . . . . . . . . . . . . . . . . . . . . 309

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Snubber Capacitor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 311
Self-Powered Gate Driver Board – SPGDB. . . . . . . . . . . . . . . . . . . . . 312
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Board Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Test points description. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 312
Terminal/connections description . . . . . . . . . . . . . . . . . . . . . . . . . 313
Testing procedure for SCR self-powered gate driver board . . . . . . . 314
Equipment needed: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Procedure: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 314
Fiber Optic Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 318
DC Link Reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 320
Control Power Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
Ride-Through. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 322
AC/DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 323
Location . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 324
Terminal / Connections Descriptions. . . . . . . . . . . . . . . . . . . . . . 325
Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 326
UPS Option . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 327
UPS Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 328
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 329
Cooling Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Chill Blocks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Coolant Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 330
Pump Maintenance and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . 331
Pump Seal Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 331
Pump Replacement with Drive Running . . . . . . . . . . . . . . . . . . . 332
Piping, Tubing and Connectors . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
Non-Return Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 334
Pressure Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Pressure Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Thermostatic Valve. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Thermostatic Valve Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 335
Repair Instructions - Element Testing . . . . . . . . . . . . . . . . . . . . . . 336
Element Replacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 336
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 337
Fluid Conductivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 338
De-Ionizing Cartridge and Mesh Filter . . . . . . . . . . . . . . . . . . . . . 339
Replacing the Mesh Filters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 340
Reservoir Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Fluid Top-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Strainers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 341
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 342
Maintaining Coolant Ratio. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 343
Leakage Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 344
System Drain. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345

Rockwell Automation Publication 7000L-UM301F-EN-P - March 2020 11
Table of Contents
Low Voltage Control Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 345
DC/DC Power SupplyDescription . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 346
Terminal/Connections Descriptions. . . . . . . . . . . . . . . . . . . . . . . 347
Replacement Procedure for DC/DC Power Supply . . . . . . . . . 348
Printed Circuit Board Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 349
IO Connectors on Control Boards. . . . . . . . . . . . . . . . . . . . . . . . . 349
Drive Processor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 350
Drive Processor Module Replacement . . . . . . . . . . . . . . . . . . . . . . 352
Instructions to Replace the Drive Processor Module. . . . . . . . . 352
ACB Analog Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 354
LEDs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
Interface Module (IFM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
Analog Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 358
Current Loop Transmitter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
Isolated Process Receiver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 359
Non-Isolated Process Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 360
Auxiliary +24V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 361
ACB Analog Control Board Replacement . . . . . . . . . . . . . . . . . . 361
Tachometer Feedback Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Encoder Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 362
Quadrature Encoder Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . 365
Positional Encoder Operations . . . . . . . . . . . . . . . . . . . . . . . . . . . . 366
Positional Encoder Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 367
External Input/Output Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 368
External Input/Output Board Replacement . . . . . . . . . . . . . . . . 369
Optical Interface Boards (OIB). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 370
Optical Interface Board Replacement . . . . . . . . . . . . . . . . . . . . . . 371
Optical Interface Base Board (OIBB) . . . . . . . . . . . . . . . . . . . . . . . . . . 373
Optical Interface Base Board Test Points . . . . . . . . . . . . . . . . . . . 374
Downloading Firmware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 375
PowerFlex 7000 in Download Mode . . . . . . . . . . . . . . . . . . . . . . . 378
Reloading the Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 381
Setting Elapsed Time . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 382
Downloading the Terminal Firmware. . . . . . . . . . . . . . . . . . . . . . . . . . 383
Using Flash Memory Card . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
DOSFWDL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 383
Method. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
Setting up Diagnostic Trending . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 384
Diagnostic Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
Setting up the Trend. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 385
Printing (Uploading) Data from the Drive . . . . . . . . . . . . . . . . . . . . . 391
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 391
Creating an empty notepad (.txt) file . . . . . . . . . . . . . . . . . . . . . . . 392
Setting up HyperTerminal Connection . . . . . . . . . . . . . . . . . . . . 394

12 Rockwell Automation Publication 7000L-UM301F-EN-P - March 2020
Table of Contents
Uploading the Data from the drive. . . . . . . . . . . . . . . . . . . . . . . . . 396
Printing (Uploading) Control Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . 399
Set up HyperTerminal connection . . . . . . . . . . . . . . . . . . . . . . . . . 400
Printing Control Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 401
Environmental Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Hazardous Materials. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 403
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Preventive Maintenance Check List . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Operational Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 405
Annual Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Initial Information Gathering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 406
Physical Checks (NO Medium Voltage and NO Control
Power) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 407
Control Power Checks (No Medium Voltage) . . . . . . . . . . . . . . 408
Final Power Checks before Restarting . . . . . . . . . . . . . . . . . . . . . . 408
Additional Tasks During Preventive Maintenance . . . . . . . . . . 409
Final Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 409
Time Estimations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 410
Tool / Parts / Information Requirements. . . . . . . . . . . . . . . . . . . 410
Appendix A
Catalog Number Explanation PowerFlex 7000 Drive Selection Explanation . . . . . . . . . . . . . . . . . . . 415
Service Duty Rating, Continuous Current Rating & Altitude
Rating Code . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 415
When is an Encoder Required? . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 416
PowerFlex 7000 Drive Performance (Torque Capabilities) . . . . . . 417
Glossary of Terms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 418
Appendix B
Torque Requirements for
Threaded Fasteners
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 421
Appendix C
Meggering Drive Meggering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
Meggering the PowerFlex 7000. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 423
Equipment Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 424
Appendix D
Preventative Maintenance
Schedule
PowerFlex 7000 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . 429

Rockwell Automation Publication 7000L-UM301F-EN-P - March 2020 13
Preface
Summary of Changes This table contains the changes made to this revision.
This document provides procedural information for managing daily or recurring
tasks involving the PowerFlex® 7000L medium voltage ‘C’ frame drives. This
document also includes specific information regarding customer responsibilities
prior to commissioning.
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 regular operation and maintenance of the drive system.
What Is Not in this Manual This manual provides information specific to maintaining the PowerFlex 7000
“C” Frame drive. It does not include topics such as:
• Dimensional and electrical drawings generated for each customer’s order
• Spare parts lists compiled for each customer’s order
Please refer to the following documents for additional product detail or
instruction relating to PowerFlex 7000 “C” Frame drives:
• Drive-specific Technical Specifications
• Transportation and Handling Procedures: receiving and handling
instructions for Medium Voltage variable frequency drive and related
equipment
• Drive-specific Technical Data: additional troubleshooting, parameters,
and specification information for MV variable frequency drives
Rockwell Automation provides the site- and installation-specific electrical and
design information for each drive during the order process cycle. If they are 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:
• “A” Frame for lower power air-cooled configurations (up to approximately
1250 hp/933 kW)
• “B” Frame for higher-power, air-cooled configurations (standard or
heatpipe models)
• “C” Frame for all liquid-cooled configurations
Topic Page
Changed input frequency to ±5% 23
Added warning for motor filter capacitors and indicative fault codes 283
Changed inspect to replace for power devices in year 12 431

14 Rockwell Automation Publication 7000L-UM301F-EN-P - March 2020
Preface
General Precautions
Commissioning Support After installation, Rockwell Automation Medium Voltage Support is responsible
for commissioning support and activities in the PowerFlex 7000 product line.
Contact Rockwell Automation commissioning services by phone at 519-740-
4100; request the Medium Voltage Support – Project Manager.
Rockwell Automation support includes, but is not limited to:
• quoting and managing product on-site start-ups
• quoting and managing field modification projects
• quoting and managing customer in-house and on-site product training
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
You can view or download publications at
http://www.rockwellautomation.com/global/literature-library/overview.page.
To order paper copies of technical documentation, contact your local
Allen-Bradley distributor or Rockwell Automation sales representative.
ATTENTION: This drive contains ESD (Electrostatic Discharge) sensitive parts
and assemblies. Static control precautions are required when installing,
testing, servicing or repairing this assembly. Component damage may result
if ESD control procedures are not followed. If you are not familiar with static
control procedures, reference Allen-Bradley publication 8000-4.5.2,
“Guarding Against Electrostatic Damage”or any other applicable ESD
protection handbook.
ATTENTION: An incorrectly applied or installed drive can result in
component damage or a reduction in product life. Wiring or application
errors, such as, undersizing the motor, incorrect or inadequate AC supply, or
excessive ambient temperatures may result in malfunction of the system.
ATTENTION: Only personnel familiar with the PowerFlex 7000 Adjustable
Speed Drive (ASD) and associated machinery should plan or implement the
installation, start-up and subsequent maintenance of the system. Failure to
comply may result in personal injury and/or equipment damage.
Resource Description
Industrial Automation Wiring and Grounding Guidelines,
publication 1770-4.1
Provides general guidelines for installing a Rockwell
Automation industrial system.
Product Certifications website, http://
www.rockwellautomation.com/global/certification/
overview.page
Provides declarations of conformity, certificates, and
other certification details.

Rockwell Automation Publication 7000L-UM301F-EN-P - March 2020 15
Chapter 1
Overview of Drive
Introduction The PowerFlex® 7000 represents the third generation of medium voltage drives at
Rockwell Automation. The PowerFlex 7000 medium voltage AC drive is part of
the PowerFlex family of AC drive products. The Allen-Bradley® PowerFlex family
of Drives incorporates leading-edge technology, embedded communications, and
significant commonality across multiple platforms, networks, operator interface
programming and hardware. Designed for end users, solution providers and
OEMs, PowerFlex 7000 liquid-cooled drives meet applications ranging from
3000...9000 horsepower (2240...6715 kW).
The PowerFlex 7000L is a general purpose stand alone medium voltage drive that
controls speed, torque, direction, starting, and stopping of standard
asynchronous or synchronous AC motors. It is intended for use on a host of
standard and specialty applications such as fans, pumps, compressors, mixers,
conveyors, kilns, fan-pumps, and test stands. Primary industries for these
applications include petrochemical, cement, mining and metals, forest products,
power generation, and water / waste water.
The PowerFlex 7000L is a global product that adheres to the most common
standards from NEC, IEC, NEMA, UL, and CSA. It is available with the world’s
most common supply voltages at medium voltage, from 2400...6600 volts.(1)
The design focus is on high reliability, ease of use, and lower total cost of
ownership.
Liquid Cooling The PowerFlex 7000L “C” Frame liquid-cooled drive utilizes a closed loop
system to cool the converter main power components and the integral DC link
inductor.
Benefits of Liquid Cooling Include:
•Smaller drive dimension compared to air-cooled drives of similar rating
•Higher power rating capability
•Quiet operation in control room
•Low loss rejection to the control room reduces air conditioner loading
•Majority of losses rejected outside the control room via a liquid-to-air or
liquid-to-liquid type heat exchanger
(1) For 2400V and 3300V designs, contact factory.

16 Rockwell Automation Publication 7000L-UM301F-EN-P - March 2020
Chapter 1 Overview of Drive
Benefits of the 7000L “C”Frame Liquid-cooled Drive:
•Completely integrated MV drive package reduces customer installation
costs and start-up time.
•Higher power rating capability (up to 9000 hp / 6715 kW)
•18 Pulse and AFE rectifiers for low harmonic solutions that meet IEEE
519-1992 Harmonic Guidelines
•Motor friendly current and voltage output waveforms for use with
standard new and existing motors
–Inverter duty motors not required
–Motor temperature derating not required
–No additional dv/dt or peak voltage stress to motor insulation system
–Tested up to 15 kilometers (9.3 miles) cable distance between drive and
motor
•Spacious cable termination cabinet for ease of use by installation
contractor
•Cable termination stabs accommodate:
–3 cables in / 3 cables out (Direct-to-Drive™ or AFE rectifier)
–9 cables in / 3 cables out (18 Pulse)
–Top or bottom entry and exit of line and load cables
•90% of drive losses are rejected outside the control room
•Integral liquid-cooled DC link inductor reduces overall dimension and
eliminates external interwiring.
•Integral pumping panel includes:
–Line supply c/w disconnect and fusing
–Closed loop coolant system
–Iron and chloride free liquid ethyl-glycol / deionized water mixture
–Low conductivity coolant (1-2 micro-Siemens / cm3)
–Isolated from medium voltage
–Fully serviceable low voltage compartment isolated from medium
voltage power
–Monitors coolant temperature, flow, level, conductivity, and pressure
–Redundant pumping system (optional)
–Automatic pump change over on pump failure
–1/2 turn valves with quick disconnect couplers for pump replacement
when drive is operating
–Full drip tray to contain any spilled coolant
–Drain and fill pump for convenient filling
–Industrial schedule 80 CPVC piping for pump panel, headers and
manifolds (no condensation possibility)
–Control hardware for cycling of main / redundant cooling pumps and
heat exchanger fans
• “Plug and play” Power Cage concept
–Central location for easy access to all main power components

Rockwell Automation Publication 7000L-UM301F-EN-P - March 2020 17
Overview of Drive Chapter 1
–Common modular design for rectifier / inverter
–Same concept as air-cooled drive for front access, easy component
replacement, and no special tools
–5...10 minutes to replace main power devices
–No need to remove any cooling lines for device replacement
–Reduced manufacturing time for faster delivery and lower cost
•Keyedmechanicalinterlock
–Interlocked with main disconnect means to prevent unsafe access to
medium voltage section
Topology The PowerFlex 7000L utilizes a Pulse Width Modulated (PWM) – Current
Source Inverter (CSI) for the machine side converter as shown in Figure 1. This
topology offers a simple, reliable, cost effective power structure that is easy to
apply to a wide voltage and power range. The power semiconductor switches
used are easy-to-series for any medium voltage level. Semiconductor fuses are not
required for the power structure due to the current limiting DC link inductor.
With 6500VPIV rated power semiconductor devices, the number of inverter
components is kept to a minimum. For example, only six inverter switching
devices are required at 2400V, 12 at 3300-4160V, and 18 at 6600V.
The PowerFlex 7000L has the additional benefit of inherent regenerative braking
for applications where the load is overhauling the motor (i.e. downhill conveyors,
etc.), or where high inertia loads (i.e. fans, etc.) need to be slowed down quickly.
Symmetrical Gate Commutated Thyristors (SGCTs) are used for machine
converter switches. Silicon-controlled rectifiers (SCRs) (for 18 Pulse) or SGCTs
(for AFE rectifiers) are used for the line converter switches. An AFE
configuration is shown in Figure 1.
The PowerFlex 7000L 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.
Figure 1 - AFE Rectifier (4160 Volt)
2U (X1)
2V (X2)
2W (X3)
SGCT’s
LINE CONVERTER DC LINK
L+ M+
SGCT’s
MACHINE CONVERTER
U (T1)
V (T2)
W (T3)
L- M-
1U
1V
1W
LR

18 Rockwell Automation Publication 7000L-UM301F-EN-P - March 2020
Chapter 1 Overview of Drive
Rectifier Designs There are two offered designs for the rectifier of the PowerFlex 7000L drive.
18 Pulse Rectifier
An 18 Pulse phase controlled rectifier is shown in Figure 2. In an 18 Pulse
configuration, the IEEE 519-1992 requirements are met in the majority of cases
without the need for passive filters; however, a multi-winding isolation
transformer is required to mitigate the low order harmonics by phase shifting
principles. The 18 Pulse solution is superior to 6- or 12-pulse offerings in terms of
lowering line side harmonics.
Isolation transformers are available in indoor dry type, cast coil, and outdoor oil-
filled designs for maximum flexibility in dealing with floor space, installation
costs, and control room air conditioner loading. (Refer to Specification 80001-
005, Rectifier Duty Transformers, for more details on transformer requirements
and features.)
Sample line current and voltage are also shown in Figure 2. The THD of line
current is approximately 5.6%, while the THD of line voltage (line-to-line) is
approximately 2.0%. (THD of line voltage is a function of system impedance.)
The 18 Pulse rectifier consists of one master bridge and two slave bridges and will
always have a total of 18 SCR switching devices.
Figure 2 - 18 Pulse Rectifier and its input waveforms
Active Front End (AFE Rectifier)
An active front end (AFE rectifier) suitable for the PowerFlex 7000L topology is
also commonly called a PWM rectifier. This is particularly attractive since it does
not require an isolation transformer to meet IEEE 519-1992. Most available
technologies in today’s MV market require a multi-winding transformer to
mitigate the unwanted harmonics by phase shifting the transformer secondary
windings. Depending on the topology, the transformer can have up to 15 sets of
secondary windings. Elimination of the isolation transformer reduces capital and
installation costs, saves on valuable floor space, and increases overall system
efficiency.
Line
current
Line-to-line
voltage at PCC

Rockwell Automation Publication 7000L-UM301F-EN-P - March 2020 19
Overview of Drive Chapter 1
The AFE rectifier requires a switching pattern that complies with similar rules as
the inverter. The pattern, used for the example shown in Figure 3, is a 42-pulse
selective harmonic elimination (SHE) pattern, which eliminates the 5th, 7th and
11th harmonics. The integral input capacitors are designed to reduce the current
harmonics of the higher order. The filter transfer function technique is used to
place the filter break frequency in a region where no harmonics are present. This
prevents the excitation of system harmonic frequencies. Other factors that are
considered when designing the filter are the input power factor and the
requirement on Total Harmonic Distortion (THD) of input current and voltage
waveforms.
The AFE rectifier is ideal when a distribution transformer is required to step
down the distribution voltage to match the VFD and motor voltage. The rectifier
input current, the rectifier terminal voltage and the line current and voltage
waveforms are shown in Figure 3. The line current THD is approximately 4.5%,
while line-to-line voltage THD is approximately 1.5%. (THD of line voltage is a
function of system impedance.) Input power factor with the AFE rectifier is
equal to or greater than 0.98 for the typical speed and load range when applied to
variable torque loads.
Figure 3 - Active rectifier (PWM) and its input current/voltage waveforms
“Direct-to-Drive” Technology The PowerFlex 7000L with “Direct-to-Drive” technology allows you to:
•connect supply power directly to the drive without an Isolation
Tra ns f o rm er
•connect a new or existing motor directly to the drive without extra motor
filtering.
Most Medium Voltage Drive Manufacturers use multi-winding isolation
transformers to mitigate unwanted harmonics by phase shifting the transformer
secondary windings. Depending on the topology, the transformer can have up to
15 sets of secondary windings. The disadvantages to this method are the high
degree of drive and transformer complexity, a very high component count and
many interconnecting cables and connection points. This leads to much higher
maintenance requirements and lower reliability.
Line
current
Line-to-line
voltage at PCC

20 Rockwell Automation Publication 7000L-UM301F-EN-P - March 2020
Chapter 1 Overview of Drive
Manufacturers also use isolation transformers to protect motors from Common
Mode Voltage stress. When transformers are used they allow the motor neutral
point to be connected to ground, but with this method, the common mode
voltage that would otherwise be impressed on the motor is impressed on the
transformer. The disadvantage to this method is that increased transformer
insulation and increased cable insulation is required between the transformer and
the drive so it can withstand the common mode voltage stress.
Rather than use an Isolation Transformer, the “Direct-to-Drive” Active Front
End uses the semiconductor switching pattern to reduce line current harmonics
to levels that comply to the world’s most accepted harmonic standards. The
Active Front End is the best method of harmonic cancellation because it does not
suffer from complexity and high component count like multi-pulse drive
topologies do.
“Direct-to-Drive” technology produces virtually no common mode voltage so it
is suitable for new or existing motors and imposes no stress on the drive input.
The advantage of “Direct-to-Drive” technology over an Isolation Transformer is
that no extra insulation is required in the motor, in the motor cables or in the line
cables.
In addition to mitigating Common Mode Voltage, “Direct-to-Drive” technology
mitigates dv/dt or Reflected Wave Voltage Stress on motors.
The simplicity of its design results in a lower initial capital investment, lower
operating cost, lower installation cost and lower maintenance cost relative to
drives that require isolation transformers.
The PowerFlex 7000L with “Direct-to-Drive” technology is typically smaller and
lighter than drive technologies that use Isolation Transformers. Isolation
Transformers represent 30 to 50% of a drive system size and 50 to 70% of the
system’s weight. This means that there is no interwiring between drive and
transformer (for external transformer configurations). This makes the PowerFlex
7000L the simplest to install.