Rockwell Automation Allen-Bradley PowerFlex 7000 User manual

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

2Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022
PowerFlex 7000 Medium Voltage AC Drive Liquid-Cooled (’C’ 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 7000L-UM303F-EN-P - April 2022 3
Table of Contents
Preface
Summary of Changes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
About This Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Download Firmware, AOP, EDS, and Other Files . . . . . . . . . . . . . . . . . . . . 9
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
What Is Not in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Commissioning Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
General Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
Chapter 1
Overview of Drive Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Liquid Cooling. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Benefits of Liquid Cooling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Topology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Rectifier Designs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
18-pulse Rectifier . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Active Front End (AFE Rectifier) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Direct-to-Drive Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Motor Compatibility . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Symmetrical Gate-commutated Thyristor (SGCT) Features and
Benefits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Simplified Electrical Drawings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Control Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Direct Vector Control. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Control Hardware. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Functional Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Safe Torque Off . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Operator Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Basic Configurations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Chapter 2
Drive Installation Safety and Codes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Unpacking and Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Transportation and Handling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Overhead Lifting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
Rod or Pipe Rollers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Fork Lift Trucks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Storage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Siting of the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Site Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Joining Shipping Splits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Connect the Sections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Tools Required (not supplied). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

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Table of Contents
Install CPVC Piping Splices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Connect Power: M+, L+, M-, L- Power Bus . . . . . . . . . . . . . . . . . . . . . 37
Control Wiring Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
Removal of DC Link Choke Turnbuckle Supports . . . . . . . . . . . . . . . 49
Removal of Lifting Angles. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Shock Indication Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Installation of Exhaust Air Hood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
Internally-mounted Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
Externally-mounted Fans and Fan Hood . . . . . . . . . . . . . . . . . . . . . . . 52
Typical PowerFlex 7000L Drive Structure Layout . . . . . . . . . . . . . . . 54
Control/Cabling Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
Major Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
IEC Component and Device Designation. . . . . . . . . . . . . . . . . . . . . . . . . . 60
Power Cabling Access . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 60
Access the Customer Power Cable Terminations. . . . . . . . . . . . . . . . 60
Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Incoming Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Liquid Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Liquid-to-Air Heat Exchangers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Pipe Materials and Layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
External Piping to the Drive. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
External Piping Cleaning. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
Controlled Siphon into Open-top Reservoir. . . . . . . . . . . . . . . . . . . . . . . . 67
Liquid-to-Liquid Heat Exchangers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
Power and Control Wiring . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Control Cables . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Encoder Installation Guidelines. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 71
Information Regarding Termination of Customer Cables . . . . . . . 73
Grounding Practices . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 74
Grounding Guidelines and Practices for Drive Signal and Safety
Grounds . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 75
Grounding Requirements and Grounding Specification for
Customers and Power Integrators. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Identification of Types of Electrical Supplies – Grounded and
Ungrounded Systems . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Ground Bus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Interlocking . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 76
Chapter 3
Power Component Definition
and Maintenance
Control / Cabling Cabinet Components . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Voltage Sensing Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Voltage Sensing Circuit Board Assembly Replacement. . . . . . . . . . . . . . 80
Input Transient Protection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Transient Suppression Network (TSN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
MOV Suppressor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 82
MOV Fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
Transient Suppression Network Fuse Replacement . . . . . . . . . . . . . . . . 84

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Table of Contents
Metal Oxide Varistor Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Surge Arresters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 85
Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Surge Arrester Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Field Test and Care . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Output Grounding Network Capacitor Replacement . . . . . . . . . . . . . . . 88
Ground Filter Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Hall Effect Sensor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Current Transformer Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Filter Capacitor Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Filter Capacitors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 92
Filter Capacitor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 93
Testing Filter Capacitors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 94
Converter Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 95
Converter Cabinet Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 96
PowerCage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 98
SGCT and Snubber Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 100
Checking Clamping Pressure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Clamping Pressure Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Symmetrical Gate Commutated Thyristor Replacement . . . . . . . . . . . 103
Silicon Controlled Rectifier and SCR Self-Powered Gate Driver
Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Detachment of Coolant System from PowerCage Modules . . . . . . . . . 107
Reconnecting the Coolant System to a PowerCage Module . . . . . 110
Chill Block Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Remove the Chill Block Assembly. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 110
Insert the Chill Block Assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
PowerCage Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 112
Snubber Resistors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Testing Snubber Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Sharing Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Testing Sharing Resistors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 114
Snubber and Sharing Resistor Replacement . . . . . . . . . . . . . . . . . . . . . . 115
Snubber Capacitor Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Self-Powered Gate Driver Board – SPGDB . . . . . . . . . . . . . . . . . . . . . . . . 117
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Board Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Test Points Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Terminal/Connections Description. . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Testing procedure for SCR Self-powered Gate Driver Board. . . . . . . . 120
Required Equipment: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Procedure: . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 120
Fiber Optic Cabling . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
DC Link Reactor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 125
Cooling System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Cooling Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Chill Blocks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Coolant Pumps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128
Pump Maintenance and Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . 129

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Pump Maintenance Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
Pump Replacement with Drive Running . . . . . . . . . . . . . . . . . . . . . . 130
Piping, Tubing, and Connectors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Non-Return Valves . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 131
Pressure Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Pressure Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Thermostatic Valve . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 132
Thermostatic Valve Replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 133
Repair Instructions - Element Testing . . . . . . . . . . . . . . . . . . . . . . . . 133
Element Replacing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Heat Exchanger . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 134
Pumping Cabinet Control Power Checks. . . . . . . . . . . . . . . . . . . . . . 136
Fluid Conductivity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 136
Temperature Sensor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
De-ionizing Cartridge and Mesh Filter. . . . . . . . . . . . . . . . . . . . . . . . 137
Addressing High Coolant Conductivity . . . . . . . . . . . . . . . . . . . . . . . 139
Reservoir Circuit . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Fluid Top-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Strainers. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 140
Coolant . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Maintaining Coolant Ratio . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 141
Leakage Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 142
System Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
System Fill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143
System Fill and Air Venting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 145
Normal Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 146
Chapter 4
Control Component Definition
and Maintenance
Control Power Components. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
Ride-through. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 147
AC/DC Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 149
Terminal / Connections Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . 150
Replacement Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 151
UPS Option. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 152
Replace the UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 153
Low Voltage Control Section . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 154
DC/DC Power Supply Description . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 155
Terminal/Connections Descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . 155
Replacement Procedure for DC/DC Power Supply . . . . . . . . . . . . . 156
Drive Processor Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 158
Drive Processor Module Replacement . . . . . . . . . . . . . . . . . . . . . . . . 160
Analog Control Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 162
Light-emitting Diodes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 165
Interface Module (IFM) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Analog Inputs and Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 166
Current Loop Transmitter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Isolated Process Receiver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 167
Non-Isolated Process Outputs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 168

Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022 7
Table of Contents
Auxiliary +24V Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Analog Control Board Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Encoder Feedback Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
Encoder Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 169
80190-759-01, 80190-759-02 Universal Encoder Interface. . . . . . . . 171
Quadrature Encoder Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Positional Encoder Operations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 173
Positional Encoder Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 174
External Input/Output Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 175
External Input/Output Board Replacement . . . . . . . . . . . . . . . . . . . 176
Optical Interface Boards (OIB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 177
Optical Interface Board Replacement. . . . . . . . . . . . . . . . . . . . . . . . . 178
Optical Interface Base Board (OIBB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 180
Replace the Optical Interface Base Board . . . . . . . . . . . . . . . . . . . . . 181
Optical Interface Base Board Test Points. . . . . . . . . . . . . . . . . . . . . . 181
Appendix A
Preventative Maintenance
Schedule
Operational Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 183
Annual Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Initial Information Gathering . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 184
Physical Checks (NO Medium Voltage and NO Control Power) . . 184
Control Power Checks (No Medium Voltage) . . . . . . . . . . . . . . . . . . 185
Final Power Checks before Restarting . . . . . . . . . . . . . . . . . . . . . . . . 186
Additional Tasks During Preventive Maintenance . . . . . . . . . . . . . 186
Final Reporting. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 186
Time Estimations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 187
Tool / Parts / Information Requirements. . . . . . . . . . . . . . . . . . . . . . 187
PowerFlex 7000L Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . 189
General Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Maintenance of Medium Voltage Equipment. . . . . . . . . . . . . . . . . . 192
Periodic Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
Contamination . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 192
High-voltage Testing. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Maintenance after a Fault Condition . . . . . . . . . . . . . . . . . . . . . . . . . 193
Part-specific Notes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Cooling-fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Operating Mechanisms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 193
Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Vacuum Contactors. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Power Cable and Control Wire Terminals . . . . . . . . . . . . . . . . . . . . . 194
Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Batteries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Pilot Lights. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 194
Solid-state Devices. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195
Locking and Interlocking Devices . . . . . . . . . . . . . . . . . . . . . . . . . . . . 195

8Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022
Table of Contents
Appendix B
PowerFlex 7000 Drive Spare
Part Storage Requirements and
Recommendations
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 197
Control Equipment and Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 198
SGCT/SCR/SPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Signal Conditioners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Ethylene Glycol. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 199
Spare Parts Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 200
Spare Parts Connection Matrix. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 201
Power Supply Connection Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
Pioneer/Cosel Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
IGDPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 202
IntelliVAC Control Module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Absopulse AC/DC Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 203
Absopulse DC/DC Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 204
1606 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Control Equipment and Boards Connection Guidelines. . . . . . . . . . . . 205
Analog Control Board (ACB) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 205
Power Components Connection Guidelines . . . . . . . . . . . . . . . . . . . . . . 206
SGCT – IGDPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 206
SGCT – SPS Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
SPS Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 207
SCR - SPGDB. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 208
Connection Wires Size . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 209
Appendix C
Torque Requirements Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 211
Appendix D
Insulation Resistance Test PowerFlex 7000L Insulation Resistance Test . . . . . . . . . . . . . . . . . . . . . . 213
Equipment Required. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 214
Appendix E
Environmental Considerations Hazardous Materials . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Capacitor Dielectric Fluid. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Printed Circuit Boards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Lithium Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 217
Chromate Plating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
In Case Of Fire. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Disposal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 218
Appendix F
History of Changes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 219
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 221

Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022 9
Preface
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.
About This Publication This document provides procedural information for managing daily or
recurring tasks involving the PowerFlex® 7000 medium voltage ‘C’ frame
drives.
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.
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.
Topic Page
Removed the following sections:
• Technical specifications
• Catalog number explanation
• Line and load cable sizes
• Cable considerations
• Torque capabilities
These sections moved to PowerFlex 7000 Medium Voltage AC Drives Technical Data,
publication 7000-TD010.
N/A
Removed typical application Load torque profile table. This was moved to PowerFlex
Medium Voltage AC Drives Selection Guide, publication PFLEX-SG003 N/A
Updated operator interface section to account for eHIM 26
Updated Pump Maintenance Guidelines 129
Changed conductivity switch measurements to µS/cm from µS/cm3136
Added instruction around adding ethylene glycol with corrosion inhibitor to the reservoir 139
Added instruction on topping up fluid to not cause trip fault 140
Specified that ethylene glycol may contain approved corrosion inhibitors 141
Added appendix detailing spare part storage requirements 197
Changed Preventative Maintenance Schedule to replace pump seal every two years 190, 191

10 Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022
What Is Not in This Manual This manual provides information specific to the maintenance of the
PowerFlex® 7000 ‘A’ frame drive. The manual excludes topics such as:
• Dimensional and electrical drawings that are generated for each
customer order.
• Spare part lists compiled for each customer order.
• Human Machine Interface (HMI) operation and configuration.
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
Commissioning Support After installation, Rockwell Automation medium voltage support is
responsible for commissioning support and activities in the PowerFlex 7000
product line.
• Phone: [phone]
• Option 1 for technical and option 4 for commissioning questions
[email protected] or
[email protected]
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

Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022 11
General Precautions
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 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: 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.
• 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.

12 Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022
Abbreviations This table contains abbreviations used throughout this document.
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
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

Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022 13
Additional Resources These documents contain additional information concerning related products
from Rockwell Automation.
You can view or download publications at rok.auto/literature.
Resource Description
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
PowerFlex 7000 Medium Voltage AC Drive (ForGe Control) - Troubleshooting
Guide, publication 7000-TG002 Provides a list of fault messages, warning messages, spare parts, fault codes, warning
codes, and suggested actions
PowerFlex 7000 Medium Voltage AC Drive (Firmware Version 11.xxx) - ForGe
Control, publication 7000-TD002 Provides a functional description, parameter descriptions, drive logic and command status,
and critical faults
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.

14 Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022
Notes:

Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022 15
Chapter 1
Overview of Drive
Introduction The PowerFlex® 7000 drive 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 7000L liquid-cooled drives
meet applications ranging from 3000…9000 horsepower (2240…6715 kW).
The PowerFlex 7000L drive is a general purpose standalone medium voltage
drive that controls speed, torque, direction, starting, and stopping of standard
asynchronous or synchronous AC motors. The drive 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 wastewater.
The PowerFlex 7000L drive is a global product that adheres to the most
common standards from NEC, IEC, NEMA, UL, and CSA. The drive is available
with the world’s most common supply voltages at medium voltage, from
2400…6600V.(a)
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 uses a closed loop system to
cool the converter main power components and the integral DC link inductor.
Benefits of Liquid Cooling
• 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
• Completely integrated medium voltage (MV) drive package reduces
customer installation costs and start-up time.
• Higher power rating capability (up to 9000 hp / 6715 kW)
• 18-pulse and active front end (AFE) rectifiers for low harmonic solutions
that meet IEEE 519-2004 Harmonic Guidelines
• Motor-friendly current and voltage output waveforms for use with
standard new and existing motors
- Inverter duty motors not required
(a) For 2400V and 3300V designs, contact factory.

16 Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022
Chapter 1 Overview of Drive
- 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
-Redundantpumpingsystem (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” PowerCage™assembly concept
- Central location for easy access to all main power components
- 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
• Keyed mechanical interlock
- Interlocked with main disconnect means to prevent unsafe access to
medium voltage section

Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022 17
Chapter 1 Overview of Drive
Topology The PowerFlex 7000L drive 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 6500V PIV 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 drive has the additional benefit of inherent regenerative
braking for applications where the load is overhauling the motor (for example,
downhill conveyors), or where high inertia loads (for example, fans) 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 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.
Figure 1 - AFE Rectifier (4160 Volt)
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. IEEE 519-2014
requirements are met in the majority of cases without passive filters; however,
a multi-winding isolation transformer is required to mitigate the low order
harmonics by phase shifting principles.
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.
The line voltage and current harmonics at the input of the 18-pulse drive meet
the harmonic requirements in the IEEE 519-2014 guideline for harmonics. The
18-pulse rectifier consists of one master bridge and two slave bridges and will
always have a total of 18 silicon controlled rectifier (SCR) switching devices.
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-UM303F-EN-P - April 2022
Chapter 1 Overview of Drive
Figure 2 - 18-pulse Rectifier and Input Waveforms
Active Front End (AFE Rectifier)
An 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 519-2014. 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.
The AFE rectifier requires a switching pattern that complies with similar rules
as the inverter. The pattern is 7-pulse selective harmonic elimination (SHE),
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 cut-off
frequency in a region where no harmonics are present. This prevents the
resonance effect of system and/or drive harmonic frequencies with the filter
cut-off frequency. 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 voltage and current
harmonics at the input of the AFE drive meet the harmonic requirements in
the IEEE 519-2014 guideline for harmonics.
Figure 3 - Active Rectifier (PWM) and Input Current/Voltage Waveforms
Line
current
Line-to-line
voltage at PCC
Line Current
Line-to-line
voltage at PCC

Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022 19
Chapter 1 Overview of Drive
Direct-to-Drive Technology Direct-to-Drive technology allows you to:
• connect supply power directly to the drive without an Isolation
Transformer
• connect a new or existing motor directly to the drive without extra motor
filtering.
Most MV 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.
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 AFE 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 drive with Direct-to-Drive technology is typically smaller
and lighter than drive technologies that use isolation transformers. Isolation
transformers represent 30…50% of a drive system size and 50…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 drive the simplest to install.

20 Rockwell Automation Publication 7000L-UM303F-EN-P - April 2022
Chapter 1 Overview of Drive
Motor Compatibility The PowerFlex 7000L 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. Dv/dt in the
voltage waveform is less than 10V/μs. The peak voltage that the motor
insulation will see is the rated motor RMS voltage divided by 0.707. Reflected
wave and dv/dt issues often associated with VSI (voltage source inverter)
drives are a non-issue with the PowerFlex 7000L drive. Typical motor
waveforms are shown in Figure 4. These motor friendly waveforms are
achieved by utilizing a SHE pattern in the inverter to eliminate major order
harmonics, in conjunction with a small output capacitor (integral to the drive)
to eliminate harmonics at higher speeds.
Standard motors are compatible without derating, even on retrofit
applications.
Motor cable distance is virtually unlimited. This technology has been tested,
controlling motors up to 15 km (9.3 miles) away from the drive.
Figure 4 - Motor Waveforms at Full Load, Full Speed
Symmetrical Gate-
commutated Thyristor
(SGCT) Features and
Benefits
Positioning the gate drive close to the SGCT (Figure 5), creates a low
inductance path that provides more efficient and uniform gating of the device.
As a result, the device is better suited than a conventional GTO to handle the
fluctuating levels of voltage and current while it is switching on and off during
gating.
An SGCT has similar characteristics to an integrated gate-commutated
thyristor (IGCT) (used on some VSI drives), including low conduction and
switching losses, low failure rate, and double sided cooling for low thermal
stress. However, the SGCT achieves voltage blocking capability in both forward
and reverse directions up to 6500V by a NPT (Non-Punch-Through) structure
and nearly symmetrical pnp transistor in the wafer, while the current is
unidirectional. Unlike many VSI topologies that use IGBTs, the
semiconductors used in the PowerFlex 7000L feature a non-rupture, non-arc
failure mode. In the unlikely event of a device failure, the fault would be
contained within the device.
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
)
140.00 150.0
0
Arms
Vrms
Motor Current
Motor Voltage