Rockwell Automation PowerFlex 7000 User manual

Page 1 of 17 Tech Note for PSA 2012-01-001 PF7000_GEN-95
Medium Voltage Support – Technical Services Update Product Update Number:
PF7000_GEN-95
Title:
Product Service Advisory PSA 2012-01-001 Tech Note
(Supersedes PSA 2011-05-001 and PSA 2010-02-001 Tech Notes)
•Classic Control Users
Issued By: Date: Products Affected
Carlos Siri March 2, 2012 Active Front End (AFE) Rectifier
PowerFlex 7000 VFD
(7000A, 7000B, 7000L)
•Classic Control
Reviewed By: Date:
Manish Pande March 5, 2012
Fred Jason
Only personnel who have been trained and understand the PowerFlex 7000 MV Variable
Frequency Drive (VFD) and the Bulletin 1500 product line can work on this equipment.
Appropriate PPE and applicable safety procedures must be followed at all times.
Please refer to the attached sheets.
Please submit any questions you have about this document to:
Rockwell Automation Canada Inc.
135 Dundas Street
Cambridge, Ont.
N1R 5X1
Attn: Medium Voltage Support
Phone: [phone] (Option 1 for MV Technical Support)
Fax: [phone]
Email: [email protected]
NOTE: The original Customer Letter and subsequent updates mailed/posted refer to Firmware Versions
5.006 through 6.001. In firmware version 6.002 or higher, the Line Filter Capacitor protection method is
upgraded to provide better detection and annunciation, more robust lockout and password reset
functionality, as well as higher immunity to nuisance trips. Please download and install Firmware Version
6.002 or higher per Product Safety Advisory (PSA) 2012-01-001 located on
http://www.rockwellautomation.com/knowledgebase, as ID number 221486.

Page 2 of 17 Tech Note for PSA 2012-01-001 PF7000_GEN-95
QUESTIONS / SITUATIONS: (problem/issue/product change/etc.)
1. The PSA states a requirement to download and install 6.002 or higher firmware for Classic Control Users. How do I
install the firmware? … refer to Page 3
2. If the VFD Operator Interface annunciates a fault where there is a potential for a Line Filter Capacitor (LFC) failure,
what steps need to be taken to inspect and test the LFCs? … refer to Page 13
3. What is the reset process for a “Line Cap Failure” fault, when using VFD firmware 6.002? … refer to Page 14
SUMMARY:
PSA 2012-01-001 had been released by Rockwell Automation. This Tech Note is to guide the customer or field engineer
through the implementation process and gives instructions how to respond to the requirements of the PSA:
explains how to install the Firmware upgrade requirements for a PowerFlex 7000 VFD on the Classic Control
platform (must be updated to Firmware Version 6.002 or higher)
states the required actions in the event of tripping of the VFD on a fault where there is the potential for LFC failure
explains the “Line Cap Failure” fault lockout and password reset process
INTRODUCTION:
IMPORTANT: This document is valid for PowerFlex 7000 drive with Firmware revision 6.002 or higher, for the Classic Control
platform. For Forge Control platform users refer to the specific Forge Control Tech Note (PF7000_4th Gen_GEN-24)
Per the Product Service Advisory (PSA 2012-01-001) it is mandatory to upgrade the drive Firmware in all AFE PowerFlex
7000 VFDs on the Classic Control platform to the latest revision level (must be Firmware Version 6.002 or higher).
Installation Note:
To upgrade/download Firmware, the VFD needs to be stopped and isolated from Medium Voltage. Make sure you have all the
necessary hardware and Firmware before proceeding to download the Firmware. If any additional help or guidance is required,
after reading this Tech Note, please call your local RA office or Rockwell Automation Customer Support for clarifications.
Firmware Improvements:
In Firmware version 6.002 and higher, “Line Cap Failure” fault (Fault Code 174) with an improved detection algorithm has
been implemented to determine if the potential for LFC failure exists. This fault provides alternating flashing messages of
“CheckDriveInput”, “Check Line Cap”, and “DoNotApplyMV” to the operator and does not allow a reset of the fault unless a
specific resetting procedure is followed. This alarm indicates that the potential for LFC failure exists, requiring all necessary
checks and troubleshooting steps to be carried out before re-energizing the VFD, as described in the Classic User Manual -
Component Definition and Maintenance chapter (chapter 6). Some of the important steps are duplicated here for a quick
reference.
The improved control algorithm for “Line Cap Failure” fault in Firmware versions 6.002 or higher includes the following:
-New and more robust method for resetting “Line Cap Failure” fault.
-New approach of Area Under Curve (AUC) with inverse-time characteristics for faster failure detection, to mitigate
severe damage to LFCs
-New approach of Accelerated Area Under Curve (AAUC) for detecting “Line Cap Failure” fault promptly upon a fault
incident followed by opening the VFD input contactor and disabling VFD gating

Page 3 of 17 Tech Note for PSA 2012-01-001 PF7000_GEN-95
In the event of the VFD tripping on “Line Cap Failure”, the flashing messages as described previously would appear on the
Main Screen as well as on the Alarm Screen across the STATUS line. The VFD will prevent resetting the fault and clearing the
Fault Queue. You must verify the integrity of LFCs, i.e. testing for internal failure and inspecting for visible signs of
physical damage (bulging case or oil leaks) before attempting to re-energize the VFD. For testing LFCs, follow the
instructions outlined later in this document.
ANSWERS:
Answer #1: Downloading and Installing the VFD Firmware
Introduction
With the introduction of the PowerFlex 7000 Medium Voltage VFD, all VFD control functions are loaded on the Drive Control
Boards (DCBs) with firmware via a serial connection on the Customer Interface Board (CIB) via the serial port (J8) on the CIB.
The firmware for all participating boards in the system is packaged into a single file (with the extension .XFW) and downloaded
to the drive using the XMODEM protocol. This protocol is readily available on Windows based PC systems in the form of
HyperTerminal.
The latest Firmware files and the associated Tech Notes are available on
http://www.ab.com/support/abdrives/webupdate/powerflex7000.html and the Medium Voltage intranet site, or can be obtained
from Medium Voltage Product Support. When upgrading Firmware it is imperative that you review all of the associated
Firmware release notes as they contain critical information that must be followed (please review applicable release notes in
addition to any intermediary release notes). Failure to do so may result in equipment damage or render the VFD temporarily
inoperable.
Overview
From the point of view of On Board Programming (OBP) or downloading Firmware to the drive boards, there are currently
three control boards which can participate:
Inverter DCB (Drive Control Board – Machine)
Rectifier DCB (Drive Control Board - Line)
Customer Interface Board (CIB)
When the system is powered up, the three control boards communicate with each other and execute the Application Code
contained in the on-board flash memory. If any single board does not have valid Firmware, then the entire system will drop
into a download mode. In the download mode the system is waiting to receive a Firmware download via the serial port (J8) on
the CIB. This port is normally used by the printer, if supplied.
The system may also be placed into download mode from the drive Terminal. To do this, refer to the section “Download
Mode” described in the following section.
Any drive that is shipped with no Firmware, or any drive that has new DCB or CIB installed with none or incompatible
Firmware (a repair situation) will automatically go into Firmware download mode on power-up. Otherwise you have to put the
system into download mode using Terminal as explained in the following section.

Page 4 of 17 Tech Note for PSA 2012-01-001 PF7000_GEN-95
Preparation for Downloading Firmware
Required
Boot Code
-Verify that the boot code rev. level is 2.001 or higher. (The boot code chips are located on DCBs and CIB).
-If the boot code rev. level is lower than 2.001, then all three chips must be replaced with boot code 2.005.
PLC
-If your system has a PLC communicating with the VFD, and the VFD Firmware is from an earlier version than 3.004,
then you would need to update the Logic Command word (bits 6-7) in the PLC as explained in Appendix C of the
user manual.
Firmware 3.004 and higher - P257 “Logic Command” bits 6 and 7.
Firmware earlier than 3.004 - P257 “Logic Command” word bits 6 and 7.
LAPTOP: loaded with Windows HyperTerminal program.
NULL-MODEM CABLE: with a 9-pin female connector for the laptop serial port, and a 9- pin male connector for the
CIB Communication Port (J8). (A serial cable with pins 2-3 swapped at one end will also work)
DRIVE FIRMWARE FILE: Latest copy (filename.XFW)
VFD Access level must be at least ‘Advanced’ or higher (Service or Rockwell).

Page 5 of 17 Tech Note for PSA 2012-01-001 PF7000_GEN-95
Here is a typical pin out of a complete null-modem cable.
Although the above cable will work, only a cable with pin connectors 2, 3 and 5 is all that is required.
Saving Original Settings
Ensure the parameters are saved to NVRAM, and saved to the Operator Interface Terminal, and saved to any other external
source such as the Flash Card, DriveTools, or printed to a hardcopy.
Press [F10] (ACCESS), and highlight Advanced. Press [Enter], or enter the password value (if password required) and you
should have Advanced level access.
Press [F10] (EXIT), and then [F5] for NVRAM. Press [F5] (SAVE), and [F8] (YES). The parameters should now be saved to
NVRAM. Press [F10] again (EXIT).

Page 6 of 17 Tech Note for PSA 2012-01-001 PF7000_GEN-95
To save to the Operator Interface Terminal and Flash Card, Press [F2] (UTILITY), [F7] (TRANSFER), and [F4]
(PARAMETERS). You should now be on the following screen:
To save parameters to the Operator Interface Terminal, press [F5] (DRV>MEM). To save to the Flash Card, you must first
insert the card in the terminal. Remove the back cover and insert the card in the slot on the terminal. It can only go in one way.
Then press [F4] (DRV>CRD).
Saving to the card means that you will have to choose a file name. Use the Up and Down arrows to select the character, and
then use the Right arrow to go to the next character. Press the [Enter] key when finished.
Press [F8] (YES), and the parameters will be transferred to the card. Press [F10] (EXIT).
Download Mode
If the drive is running, you will not be able to place it into Firmware download mode. Ensure the drive is stopped, and the E-
Stop is pressed. This is just a precaution, as all versions of Firmware 2.xxx and later will not allow you to attempt a Firmware
download while running.
To place the drive in Firmware download mode, you should be in the UTILITY - TRANSFER screen.
This time press [F9] (SYSTEM), and a screen will appear telling you that you are in download mode.

Page 7 of 17 Tech Note for PSA 2012-01-001 PF7000_GEN-95
When the system is in download mode, the status of LEDs on CIB labeled OBP1 (D1), and on two DCBs labeled D1, provide
indication of the Firmware download process. These LEDs are bicolor and may flash at different rates to indicate the current
condition. The following illustrates the states of LEDs:
Solid Green – the Application Firmware is running. The system is not in download mode.
Green 0.25Hz – the board is in download mode
Green 0.5Hz – the board is in download mode and is currently being flashed with new Firmware
After putting the VFD in download mode, the following is displayed on the VFD terminal:
If you press any Key after this message the Terminal will show:
COMMUNICATION ERROR
Method to Download Firmware
The following illustrates how to download Firmware on the PF7000 VFD. The method involves two steps, which are explained
below:
Step 1: Configuring HyperTerminal Connection
-Run HyperTerminal program
-The ‘Connection Description’ window will pop up. Enter any name for new connection in the Name field as shown
below, and then click OK.

Page 8 of 17 Tech Note for PSA 2012-01-001 PF7000_GEN-95
-From ‘Connect to’ window, select COM1 from the dropdown list as shown below, and then click OK.
-At the ‘COM1 Properties’ window, set port settings as shown below and then click OK.
-Now, close HyperTerminal program. A message box will pop as shown below. Click Yes.

Page 9 of 17 Tech Note for PSA 2012-01-001 PF7000_GEN-95
-You will be prompted to save the connection that you just created. Click Yes. This will close the HyperTerminal
program.
The first step is complete. Now, you are ready to download the Firmware into the drive. For this you need to follow the steps
as outlined below.
Step 2: Downloading the Firmware
-Connect the null-modem cable between your laptop’s serial port and the serial port ‘J8’ on the CIB.
-Place the drive in download mode, if it was not already in download mode. Refer to “Download Mode” described
above.
-Restart HyperTerminal program. When you see the ‘Connection Description’ window, click Cancel.
-From the File menu, click Open… The Open window will appear. Locate the HyperTerminal Connection that you
created earlier, and then click Open.

Page 10 of 17 Tech Note for PSA 2012-01-001 PF7000_GEN-95
-If the drive is in download mode, the character Cwill appear every 3 seconds inside the HyperTerminal window.
-At the HyperTerminal window, click on Transfer menu and select ‘Send file…’. The ‘Send File’ window will appear
as shown below:
-At the Send File window, click Browse button and locate the Firmware file saved in your laptop. The Firmware file
must have .XFW filename extension.
-Under Protocol, click the arrow on the right to open the dropdown list. Select Xmodem from the list and then click on
Send button. This will start the download process, and a window similar to the one shown below will appear showing
download progress.