Rockwell Automation PowerFlex 7000 User manual

User Manual Original Instructions
PowerFlex 7000 Medium
Voltage AC Drive Air-Cooled
(’B’ Frame)—ForGe Control
Bulletin Number 7000

2Rockwell Automation Publication 7000-UM202H-EN-P - November 2023
PowerFlex 7000 Medium Voltage AC Drive Air-Cooled (’B’ Frame)—ForGe Control User Manual
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.
These labels may also be on or inside the equipment to provide specific precautions.
The following icon may appear in the text of this document.
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).
Identifies information that is useful and can help to make a process easier to do or easier to understand.

Rockwell Automation Publication 7000-UM202H-EN-P - November 2023 3
Table of Contents
Preface
About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Download Firmware, AOP, EDS, and Other Files . . . . . . . . . . . . . . . . . . . . 9
Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
What Is Not in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
General Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Connect to Service and Support and Product Documentation . . . . . . . 11
Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Chapter 1
PowerFlex 7000 Drive Overview Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Rectifier Designs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Cooling Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
Motor Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Simplified Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
2400V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
3300/4160V. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6600V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Functional Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Safe Torque Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
ArcShield Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Basic Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Chapter 2
Power Component Definition
and Maintenance
Control Power Off Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Interlocking. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Control / Cabling Cabinet Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
Voltage-sensing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Replacing the Voltage-Sensing Circuit Board Assembly . . . . . . . . . 34
Input Transient Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Transient Suppression Network (TSN). . . . . . . . . . . . . . . . . . . . . . . . . 35
Surge Arresters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Filter Capacitor Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Filter Capacitors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
Filter Capacitor Mounting Plate. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Replacing Filter Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
Testing Filter Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
Converter Cabinet Components . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
PowerCage Module Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
Resistance Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
SGCT and Snubber Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
SGCT Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64

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Table of Contents
SGCT Anode-to-Cathode (Sharing) Resistance . . . . . . . . . . . . . . . . . 64
Snubber Resistance (SGCT Device) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
Snubber Capacitance (SGCT Device) . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Replacing the SGCT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 69
Replacing Snubber and Sharing Resistor. . . . . . . . . . . . . . . . . . . . . . . 72
Replacing Sharing Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Replacing Snubber Capacitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Silicon Controlled Rectifier PowerCage Modules . . . . . . . . . . . . . . . . . . . 77
SCR Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
SCR Anode-to-Cathode Resistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
SCR Sharing Resistance Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
SCR Gate-to-Cathode Resistance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Snubber Resistance (SCR Device) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
Snubber Capacitance (SCR Device). . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Replacing SCR and SCR Self-Powered Gate Driver Boards
(SPGDB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Uniform Clamping Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Checking Clamping Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Clamping Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Temperature Sensing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Replacing the Thermal Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Replacing Heatsinks/Heatpipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Replacing Heatsinks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Replacing Heatpipes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
PowerCage Gasket . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Replacing PowerCage Gaskets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
Removing the PowerCage Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Self-powered SGCT Power Supply - SPS . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Board Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Testing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Self-Powered Gate Driver Board – SPGDB . . . . . . . . . . . . . . . . . . . . . . . . 101
Board Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Test Points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Terminal/Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Testing Procedure for SCR Self-Powered Gate Driver Board. . . . . . . . 103
Testing Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 103
Fiber Optic Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Air Pressure Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
Replacing the Air Pressure Sensor. . . . . . . . . . . . . . . . . . . . . . . . . . . . 107
DC Link Cabinet Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
DC Link Reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Replacing Ziehl-Abegg Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Replacing Continental/Daltec Fans. . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Impeller Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Installing Impeller Assembly onto Motor Shaft . . . . . . . . . . . . . . . . 126
Fan Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Replacing Air Filters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

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Table of Contents
Chapter 3
Control Component Definition
and Maintenance
Control Power Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Ride-through. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
AC/DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Terminal / Connections Descriptions (Pioneer Power Supply) . . 135
Terminal / Connections Descriptions (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. . . . . . . . . . . . . . . . . . . . . . . . . . 145
Replacing a DC/DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Drive Processor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 148
Replacing the Drive Processor Module. . . . . . . . . . . . . . . . . . . . . . . . 150
Analog Control Board (ACB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Interface Module (IFM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Analog Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Current Loop Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 156
Isolated Process Receiver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 157
Non-Isolated Process Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Auxiliary +24V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Replacing the Analog Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Encoder Feedback Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
Encoder Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
20B-ENC-3 Encoder Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 159
80190-759-01, 80190-759-02 Universal Encoder Interface. . . . . . . . 160
Quadrature Encoder Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Positional Encoder Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 163
External Input/Output Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 164
Replacing the External Input/Output Board. . . . . . . . . . . . . . . . . . . 165
Optical Interface Boards (OIB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Replacing the Optical Interface Board . . . . . . . . . . . . . . . . . . . . . . . . 167
Replace the Optical Interface Base Board . . . . . . . . . . . . . . . . . . . . . 170
Optical Interface Base Board Test Points. . . . . . . . . . . . . . . . . . . . . . 170
Appendix A
Preventative Maintenance
Schedule
Preventative Maintenance Checklist . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Operational Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Annual Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Initial Information Gathering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Physical Checks (NO Medium Voltage and NO Control Power) . . 174
Control Power Checks (No Medium Voltage) . . . . . . . . . . . . . . . . . . 175
Final Power Checks before Restarting . . . . . . . . . . . . . . . . . . . . . . . . 175
Additional Tasks During Preventive Maintenance . . . . . . . . . . . . . 176
Final Reporting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 176

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Table of Contents
Time Estimations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Tool / Parts / Information Requirements. . . . . . . . . . . . . . . . . . . . . . 177
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 178
Appendix B
PowerFlex 7000 Drive Spare
Part Storage Requirements and
Recommendations
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 181
Control Equipment and Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 182
SGCT/SCR/SPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Signal Conditioners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Spare Parts Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Spare Parts Connection Matrix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 185
Power Supply Connection Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Pioneer/Cosel Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
IGDPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
IntelliVAC Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Absopulse AC/DC Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Absopulse DC/DC Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 188
1606 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Control Equipment and Boards Connection Guidelines. . . . . . . . . . . . 189
Analog Control Board (ACB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 189
Power Components Connection Guidelines . . . . . . . . . . . . . . . . . . . . . . 190
SGCT – IGDPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 190
SGCT – SPS Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
SPS Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 191
SCR - SPGDB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Connection Wires Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Appendix C
Torque Requirements Torque Requirements for Threaded Fasteners . . . . . . . . . . . . . . . . . . . . 195
Appendix D
Insulation Resistance Test Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Insulation Resistance Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Insulation Resistance Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Required Equipment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
Appendix E
Environmental Considerations Air Quality Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Hazardous Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Capacitor Dielectric Fluid . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Printed Circuit Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Lithium Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
Chromate Plating. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
In Case Of Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Disposal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205

Rockwell Automation Publication 7000-UM202H-EN-P - November 2023 7
Table of Contents
Appendix F
History of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209

8Rockwell Automation Publication 7000-UM202H-EN-P - November 2023
Table of Contents
Notes:

Rockwell Automation Publication 7000-UM202H-EN-P - November 2023 9
Preface
About This Publication This document provides procedural information for managing daily or
recurring tasks involving the PowerFlex® 7000 medium voltage ‘B’ frame
drives (heatsink and heatpipe models).
Download Firmware, AOP,
EDS, and Other Files Download firmware, associated files (such as AOP, EDS, and DTM), and access
product release notes from the Product Compatibility and Download Center at
rok.auto/pcdc.
Summary of Changes This publication contains the following new or updated information. This list
includes substantive updates only and is not intended to reflect all changes.
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
‘B’ frame drive. This document does not include topics such as:
• Physically transporting or siting the drive cabinetry
• Installing or commissioning procedures
• Spare parts lists compiled for your order.
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
Added warning around energizing isolation transformers 10
Added QR codes for commissioning support 11
Updated filter capacitor replacement instructions 46
Updated main fan replacement procedure to include new main power cable location 117
Added Self-Powered SCR Power Supply (SCR SPGDB) to preventative maintenance schedule 179

10 Rockwell Automation Publication 7000-UM202H-EN-P - November 2023
Preface
General Precautions
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 Variable
Frequency Drive (VFD) or Adjustable Speed Drive (ASD) and associated
machinery should plan or implement the installation, startup, and subsequent
maintenance of the system. Failure to comply may result in personal injury
and/or equipment damage.
ATTENTION: It is not recommended to repeatedly energize transformers.
Transformer energization results in high inrush current (10…15 times the rated
transformer current). Energizing a transformer multiple times in a short
period of time, may subject the transformer windings and winding insulation
to destructive thermal and electromechanical stress, due to the repetitive
high inrush current. This energization limitation is similar to limiting the
number of motor starts per hour to reduce thermal stress on a motor. The
typical inrush current for a motor is much lower (six times the motor full-load
current) making the energization limitation for an isolation transformer even
more important.
For applications where the motor must be started frequently, PowerFlex
medium voltage drives should be left in the 'Drive Ready' mode. The input
contactor/breaker remains closed in this mode (that is, medium voltage
remains present on the transformer) and the drive will start, run, and stop the
motor when required, without the need to energize and de-energize the drive
isolation transformer.
ATTENTION: To keep arc resistant structural integrity, if applicable, the
following rules must be followed:
• The pressure relief vent may not be tampered with, and it is not to be used as
a step.
• No unapproved alterations can be made to the enclosure.
• All covers, plates, and hardware removed for installation or maintenance
purposes must be re-installed and properly secured. Failure to do so voids the
arc resistant structural integrity.
• Power cable entry points are to be treated as the boundary to a hazardous
location and must be sealed accordingly. Failure to do so voids the arc
resistant structural integrity.
• A plenum or chimney must be used to direct the arc flash energy to a suitable
location. Failure to do so voids the arc resistant structural integrity. See
publication 7000-IN007.
• All wiring between the low voltage panel and the power cell must be routed
through a suitable cable gland to ensure flames and gases are not transmitted
into this area (as fitted from factory).
• The medium voltage doors must be properly secured using the handle
mechanism (if provided), the key interlock (if provided), and the door bolts.
Failure to do so voids the arc resistant structural integrity.

Rockwell Automation Publication 7000-UM202H-EN-P - November 2023 11
Preface
Connect to Service and
Support and Product
Documentation
Scan the left QR code to get connected to your Regional Customer Care Group.
Scan the right QR code to get connected to the PowerFlex 7000 Medium
Voltage Drive product page, where you can access user manuals, technical
specifications, firmware manuals, and more.
Abbreviations This table contains abbreviations used throughout this document.
Global
Customer Care
Technical
Documents
Table 1 - Abbreviations
Abbreviation Description
ACB Analog Control Board
AFE Active Front End
ASD Adjustable Speed Drive
CMC Common Mode Choke
CSI Current Source Inverter
CT Current Transformer
DMM Digital Multimeter
DPM Drive Processor Module
HECS Hall Effect Current Sensor
HMI Human Machine Interface
HPTC High Performance Torque Control
IFM Interface Module
IGDPS Isolated Gate Driver Power Supply
LV Low Voltage
MOV Metal-oxide Varistor
MV Medium Voltage
GN Grounding Network
OIB Optical Interface Board
OIBB Optical Interface Base Board
PIV Peak Inverse Rating
PLC Programmable Logic Controller
PWM Pulse Width Modulated
SCB Signal Conditioning Board
SCR Silicon-controlled Rectifier
SGCT Symmetrical Gate Commutated Thyristor
SHE Selective Harmonic Elimination
SIL Safety Integrity Level
SPGDB Self-powered Gate Driver Board

12 Rockwell Automation Publication 7000-UM202H-EN-P - November 2023
Preface
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
You can view or download publications at rok.auto/literature.
SPS Self-powered SGCT Power Supply
STO Safe Torque Off
TSN Transient Suppression Network
UPS Uninterruptible Power Supply
VFD Variable Frequency Drive
VSB Voltage Sensing Board
VSI Voltage Source Inverter
XIO External Input/Output
Table 1 - Abbreviations (Continued)
Abbreviation Description
Resource Description
PowerFlex 7000 Medium Voltage AC Drives Technical Data,
publication 7000-TD010.Provides technical specifications, standards and certifications, product selection tables,
cable considerations, torque capabilities and drive dimensions.
PowerFlex Medium Voltage AC Drives Selection Guide,
publication PFLEX-SG003
Provides information to correctly select the appropriate drive for your application. Includes
typical application load torque profiles, drive options, catalog number explanation, and
features.
PowerFlex 7000 Medium Voltage AC Drive (A Frame) - ForGe Control,
publication 7000A-UM200
Provides detailed information on hardware replacement, overview, control and power
component definition, maintenance and specifications for air-cooled medium voltage
variable frequency drives
PowerFlex 7000 Medium Voltage AC Drive (B Frame) Installation - ForGe
Control, publication 7000-IN007 Provides detailed installation and precommissioning procedures and information
PowerFlex 7000 Medium Voltage AC Drive (B Frame) Transportation and
Handling - ForGe Control, publication 7000-IN008 Provides receiving and handling instructions for Medium Voltage variable frequency drive
and related equipment
PowerFlex 7000 Medium Voltage AC Drive (C Frame) - ForGe Control,
publication 7000L-UM303
Provides detailed information on hardware replacement, overview, control and power
component definition, maintenance and specifications for liquid-cooled medium voltage
variable frequency drives
PowerFlex 7000 HMI Offering with Enhanced Functionality,
publication 7000-UM201 Provides detailed information to configure, set up, operate, update and troubleshoot the PowerFlex 7000 HMI Interface Board
HMI Interface Board Software Updater and Firmware Download Procedure,
publication 7000-QS002 Provides quick start information on updating HMI Interface Board software
EtherNet/IP Network Devices User Manual, ENET-UM006 Describes how to configure and use EtherNet/IP devices to communicate on the EtherNet/IP
network.
Ethernet Reference Manual, ENET-RM002 Describes basic Ethernet concepts, infrastructure components, and infrastructure features.
System Security Design Guidelines Reference Manual, SECURE-RM001 Provides guidance on how to conduct security assessments, implement Rockwell
Automation products in a secure system, harden the control system, manage user access,
and dispose of equipment.
UL Standards Listing for Industrial Control Products,
publication CMPNTS-SR002 Assists original equipment manufacturers (OEMs) with construction of panels, to help ensure
that they conform to the requirements of Underwriters Laboratories.
American Standards, Configurations, and Ratings: Introduction to
Motor Circuit Design, publication IC-AT001 Provides an overview of American motor circuit design based on methods that are outlined in the NEC.
Industrial Components Preventive Maintenance, Enclosures, and Contact
Ratings Specifications, publication IC-TD002 Provides a quick reference tool for Allen-Bradley industrial automation controls and
assemblies.
Safety Guidelines for the Application, Installation, and Maintenance of
Solid-state Control, publication SGI-1.1
Designed to harmonize with NEMA Standards Publication No. ICS 1.1-1987 and provides
general guidelines for the application, installation, and maintenance of solid-state control in
the form of individual devices or packaged assemblies incorporating solid-state
components.
Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system.
Product Certifications website, rok.auto/certifications. Provides declarations of conformity, certificates, and other certification details.

Rockwell Automation Publication 7000-UM202H-EN-P - November 2023 13
Chapter 1
PowerFlex 7000 Drive Overview
The PowerFlex™ 7000 drive is a general-purpose, standalone, medium voltage
drive that controls speed, torque, direction, starting, and stopping of standard
asynchronous or synchronous AC motors. This drive 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 drive meets most common standards from these
organizations:
• National Electrical Code (NEC)
• International Electrotechnical Commission (IEC)
• National Electrical Manufacturers Association (NEMA)
• Underwriters Laboratories (UL)
• Canadian Standards Association (CSA).
The drive is available with the world’s most common supply voltages at
medium voltage, from 2400…6600V. The design focuses on high reliability,
ease of use, and lower total cost of ownership.
Topology The PowerFlex 7000 drive 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 number 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 drive also provides inherent regenerative braking for
applications where the load is overhauling the motor, or where high inertia
loads are quickly slowed down. The drive uses the following:
• Symmetrical gate commutated thyristors (SGCTs) for machine converter
switches
• SGCTs for active front-end (AFE) rectifier configurations for the line
converter switches
• Silicon-controlled rectifiers (SCRs) for 18-pulse rectifier configurations
The PowerFlex 7000 drive 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.

14 Rockwell Automation Publication 7000-UM202H-EN-P - November 2023
Chapter 1 PowerFlex 7000 Drive Overview
Rectifier Designs Configurations
The PowerFlex 7000 drive offers three rectifier configurations for ‘B’ frame
drives:
• Direct-to-Drive™ (AFE rectifier with integral line reactor and CMC)
• AFE rectifier with separate isolation transformer
• 18-pulse rectifier with separate isolation transformer
Direct-to-Drive
Direct-to-Drive technology does not require an isolation 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 that are used are SGCTs. Unlike the diodes that are 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, similar to the
control philosophy of the inverter. The gating algorithm uses a specific
42-pulse switching pattern called selective harmonic elimination (SHE) to
mitigate the 5th, 7th, and 11th harmonic orders.
Figure 1 - Typical PWM Switching Pattern, Line Voltage Waveform
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 configuration delivers
excellent line-side harmonic and power factor performance to meet IEEE 519-
1992 requirements and other global harmonic standards in virtually all cases.
This setup also provides a simple, robust power structure that maximizes
uptime by minimizing the number of discrete components and the number of
interconnections required.
A CMC mitigates the common mode voltage seen at the motor terminals, so
standard (non-inverter duty rated) motors and motor cables can be used. This
technology is ideal for retrofitting existing motor applications.

Rockwell Automation Publication 7000-UM202H-EN-P - November 2023 15
Chapter 1 PowerFlex 7000 Drive Overview
Figure 2 - 3300/4160V Direct-to-Drive (Transformerless AFE Rectifier)
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 (indoor and outdoor
transformer versions are offered). The isolation transformer replaces the
requirement for an integral line reactor and 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
SGCTs
LINE CONVERTER OMMON MODE CHOKE
C
L+ M+
SGCTs
MACHINE CONVERTER
U(T1)
V(T2)
W(T3)
L- M-
LR
SGCTs
LINE CONVERTER DC LINK
L+ M+
SGCTs
MACHINE CONVERTER
U(T1)
V (T2)
W(T3)
L- M-
2U (X1)
2V (X2)
2W (X3)
1U
1V
1W
ISTXISTX
REMOTE

16 Rockwell Automation Publication 7000-UM202H-EN-P - November 2023
Chapter 1 PowerFlex 7000 Drive 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
(indoor and outdoor transformer options are available). The 18-pulse rectifier
uses SCRs instead of the SGCTs used for an AFE rectifier. When used for high
power constant torque applications, the 18-pulse rectifier has lower losses than
the AFE rectifier, making 18-pulse 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
Cooling Technology These VFDs are supplied with heatsinks for most configurations and heatpipes
for the highest-power AFE configurations. While both configurations draw
heat away from the semiconductors, heatpipes are bigger, more efficient, and
require larger fans and airflow.
Information and graphics in this manual show both configurations.
LINE CONVERTER
L- M-
DC LINK
L+ M+ MACHINE CONVERTER
U (T1)
V (T2)
W (T3)
4U (Z1)
4V (Z2)
4W (Z3)
ISTX
SCRs
3U (Y1)
3V (Y2)
3W (Y3)
2U (X1)
2V (X2)
2W (X3)
SGCTs
LINE CONVERTER
L- M-
DC LINK
L+ M+ MACHINE CONVERTER
U (T1)
V (T2)
W (T3)
4U (Z1)
4V (Z2)
4W (Z3)
ISTX
SCRs
3U (Y1)
3V (Y2)
3W (Y3)
2U (X1)
2V (X2)
2W (X3)
SGCTs
REMOTE
1U
1V
1W

Rockwell Automation Publication 7000-UM202H-EN-P - November 2023 17
Chapter 1 PowerFlex 7000 Drive Overview
Motor Compatibility The PowerFlex 7000 drive 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 50 V/μs. 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 VSI drives are a non-
issue with the drive. Figure 5 shows typical motor waveforms. The drive uses a
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 at Full Load, Full Speed
300.00
200.00
100.00
0.00
-100.00
-200.00
-300.00
10.00K
7.50K
5.00K
2.50K
0.00K
-2.50K
-5.00K
-7.50K
-10.00K
100.00 110.00 120.00 130.00
TIME (ms)
140.00 150.00
Arms
Vrms
CURRENT
VOLTAGE

18 Rockwell Automation Publication 7000-UM202H-EN-P - November 2023
Chapter 1 PowerFlex 7000 Drive Overview
Simplified Electrical
Diagrams 2400V
Figure 6 - 2400V – Direct-to-Drive (Transformerless AFE Rectifier)
Figure 7 - 2400V – AFE Rectifier with Separate Isolation Transformer
Figure 8 - 2400V – 18-pulse Rectifier with Separate Isolation Transformer
SGCTs
LINE CONVERTER
L+ M+
SGCTs
MACHINE CONVERTER
U(T1)
V(T2)
W(T3)
L- M-
LR
OMMON MODE CHOKE
C
SGCTs
LINE CONVERTER DC LINK
L+ M+
SGCTs
MACHINE CONVERTER
U (T1)
V (T2)
W (T3)
L- M-
2U (X1)
2V (X2)
2W (X3)
1U
1V
1W
ISTXISTX
REMOTE
LINE CONVERTER
L- M-
DC LINK
L+ M+ MACHINE CONVERTER
U (T1)
V (T2)
W (T3)
4U (Z1)
4V (Z2)
4W (Z3)
ISTX
SCRs
3U (Y1)
3V (Y2)
3W (Y3)
2U (X1)
2V (X2)
2W (X3)
SGCTs
LINE CONVERTER
L- M-
DC LINK
L+ M+ MACHINE CONVERTER
U (T1)
V (T2)
W (T3)
4U (Z1)
4V (Z2)
4W (Z3)
ISTX
SCRs
3U (Y1)
3V (Y2)
3W (Y3)
2U (X1)
2V (X2)
2W (X3)
SGCTs
1U
1V
1W
REMOTE

Rockwell Automation Publication 7000-UM202H-EN-P - November 2023 19
Chapter 1 PowerFlex 7000 Drive Overview
3300/4160V
Figure 9 - 3300/4160V – Direct-to-Drive (Transformerless AFE Rectifier)
Figure 10 - 3300/4160V – AFE Rectifier with Separate Isolation Transformer
Figure 11 - 3300/4160V – 18-pulse Rectifier with Separate Isolation Transformer
SGCTs
LINE CONVERTER
L+ M+
SGCTs
MACHINE CONVERTER
U(T1)
V(T2)
W(T3)
L- M-
LR
OMMON MODE CHOKE
C
SGCTs
LINE CONVERTER DC LINK
L+ M+
SGCTs
MACHINE CONVERTER
U(T1)
V (T2)
W(T3)
L- M-
2U (X1)
2V (X2)
2W (X3)
1U
1V
1W
ISTXISTX
REMOTE
LINE CONVERTER
L- M-
DC LINK
L+ M+ MACHINE CONVERTER
U (T1)
V (T2)
W (T3)
4U (Z1)
4V (Z2)
4W (Z3)
ISTX
SCRs
3U (Y1)
3V (Y2)
3W (Y3)
2U (X1)
2V (X2)
2W (X3)
SGCTs
LINE CONVERTER
L- M-
DC LINK
L+ M+ MACHINE CONVERTER
U (T1)
V (T2)
W (T3)
4U (Z1)
4V (Z2)
4W (Z3)
ISTX
SCRs
3U (Y1)
3V (Y2)
3W (Y3)
2U (X1)
2V (X2)
2W (X3)
SGCTs
REMOTE
1U
1V
1W

20 Rockwell Automation Publication 7000-UM202H-EN-P - November 2023
Chapter 1 PowerFlex 7000 Drive Overview
6600V
Figure 12 - 6600V – Direct-to-Drive (Transformerless AFE Rectifier)
Figure 13 - 6600V – AFE Rectifier with Separate Isolation Transformer
Figure 14 - 6600V - 18-pulse Rectifier with Separate Isolation Transformer
SGCTs
LINE CONVERTER
L+ M+
SGCTs
MACHINE CONVERTER
U(T1)
V(T2)
W(T3)
L- M-
LR
OMMON MODE CHOKE
C
SGCTs
LINE CONVERTER DC LINK
L+ M+
SGCTs
MACHINE CONVERTER
U (T1)
V (T2)
W (T3)
L- M-
2U (X1)
2V (X2)
2W (X3)
1U
1V
1W
ISTXISTX
REMOTE
LINE CONVERTER
L- M-
DC LINK
L+ M+ MACHINE CONVERTER
U (T1)
V (T2)
W (T3)
4U (Z1)
4V (Z2)
4W (Z3)
ISTX
SCRs
3U (Y1)
3V (Y2)
3W (Y3)
2U (X1)
2V (X2)
2W (X3)
SGCTs
LINE CONVERTER
L- M-
DC LINK
L+ M+ MACHINE CONVERTER
U (T1)
V (T2)
W (T3)
4U (Z1)
4V (Z2)
4W (Z3)
ISTX
SCRs
3U (Y1)
3V (Y2)
3W (Y3)
2U (X1)
2V (X2)
2W (X3)
SGCTs
1U
1V
1W
REMOTE