Powerflex® 7000 Medium Voltage Ac Drive - Air-Cooled ("A" Frame)
Powerflex® 7000 Medium Voltage Ac Drive - Air-Cooled ("A" Frame)
Powerflex® 7000 Medium Voltage Ac Drive - Air-Cooled ("A" Frame)
USER MANUAL
(Air-Cooled – “A” Frame)
Bulletin 7000A
Important User Information Solid-state equipment has operational characteristics differing from those of electro-
mechanical equipment. Safety Guidelines for the Application, Installation and Maintenance
of Solid-State Controls (Publication SGI-1.1 available from your local Rockwell Automation
sales office or online at http://literature.rockwellautomation.com describes some
important differences between solid-state equipment and hard-wired electromechanical
devices. Because of this difference, and also because of the wide variety of uses for
solid-state equipment, all persons responsible for applying this equipment must satisfy
themselves that each intended application of this equipment is acceptable.
In no event will Rockwell Automation, Inc. be responsible or liable for any 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.
SHOCK HAZ ARD Labels may be on or inside the equipment (for example, drive or
motor) to alert people that dangerous voltage may be present.
BURN HAZARD Labels may be on or inside the equipment (for example, drive or
motor) to alert people that surfaces may reach dangerous
temperatures.
Chapter 6 Component Definition Setting up the PF 7000 “A” Frame Trending Feature ..........6-105
and Maintenance Environmental Considerations .............................................6-106
(cont.) Hazardous Materials ......................................................6-106
Disposal .........................................................................6-107
Preventive Maintenance Check List ....................................6-108
Operational Maintenance .....................................................6-108
Annual Maintenance ............................................................6-109
Initial Information Gathering ........................................6-109
Physical Checks ............................................................6-109
Control Power Checks (NO Medium Voltage) .............6-111
Final Power Checks before Restarting ..........................6-111
Additional Tasks During Preventive Maintenance .......6-112
Final Reporting ..............................................................6-112
Time Estimations ..........................................................6-113
Tool / Parts / Information Requirements .......................6-114
Appendix B Torque Requirements Torque Requirements for Threaded Fasteners ........................ B-1
Appendix C Drive Logic Command Logic Command Word – Database 2.001................................ C-1
Logic Status Word – Database 2.001 ...................................... C-2
Product Specific Logic Command – Database 2.001 ................. C-3
Logic Command Word – Database 3.001 and later ................ C-4
Logic Status Word – Database 3.001 and later ....................... C-5
Product Specific Logic Command – Firmware 3.001 and 3.002 .. C-6
Product Specific Logic Command – Firmware 3.004 to 5.003 .. C-7
Overview
Who Should Use This Manual This manual is intended for use by personnel familiar with medium
voltage and variable speed solid-state drive equipment. The manual
contains material that will allow the user to operate, maintain, and
troubleshoot the drive system.
What Is Not in this Manual This manual is designed to provide only general information on the
PowerFlex 7000 “A” Frame drive. Therefore customer specific
topics are not presented. These customer specific topics include:
Please note: This manual deals specifically with the PowerFlex 7000
“A” Frame drive. Information on auxiliary cabinetry or special
components we are contracted to supply with the drive will be
contained within the Service Manual you will receive with your
order.
Manual Conventions Symbols are used throughout this manual to indicate specific types
of information.
Who to Call for Commissioning Medium Voltage Support is responsible for Commissioning
Support and activities in our product line.
Introduction The PowerFlex 7000 “A” Frame medium voltage AC drive is part of
the PowerFlex 7000 family of MV drive products.
The design focus is on high reliability, ease of use, and lower total
cost of ownership.
Configuration #1
Base Drive
Optimum installation flexibility with
connection to indoor or outdoor isolation
transformers
Compact packaging for smallest footprint
requirements
New or existing motors
3 Cables in / 3 cables out, for easy installation
Integral cooling fan for VFD
Low line harmonics & high power factor
(with Active Front End)
Fan control power supplied internally
(1-Phase control circuit power supplied by
customer, 120V / 60 Hz, 110V / 50 Hz, 20 amp) Base Drive
Configuration #2
Drive with Integral Isolation Transformer
An integrated system solution for fewer
connections and reduced installation costs
Small system footprint
New or existing motors
3 Cables in / 3 cables out for easy installation
Integral cooling fan for VFD
Low line harmonics & high power factor
(with Active Front End)
Fan control power supplied internally
(1-Phase control circuit power supplied by
customer, 120V/60 Hz, 110V / 50 Hz, 20 amp)
Integral Isolation
Transformer
Configuration #3
Drive with Integral Line Reactor & Input Starter
Elimination of isolation transformer results
in lower losses and saved space
An integrated system solution for fewer
connections and reduced installation costs
New or existing motors
Small system footprint
3 Cables in / 3 cables out, on entire system
for easy installation
Integral cooling fan for VFD
Low line harmonics & high power factor
(with Active Front End)
Internally supplied fan / control power Integral Line Reactor
and Input Starter
Topology The PowerFlex 7000 “A” Frame utilizes a Pulse Width Modulated
(PWM) – Current Source Inverter (CSI) for the machine side
converter as shown in Figure 1.1. 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. Semi-conductor
fuses are not required for the power structure due to the current
limiting DC link inductor.
With 6500 volt 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.
SCRs SGCTs
2U (X1) U (T1)
2V (X2) V (T2)
2W (X3) W (T3)
L- M-
Rectifier Designs There are two offered designs for the front-end rectifier of the
PowerFlex 7000 “A” Frame drive.
6-Pulse Rectifier
a)
b)
c)
The small integral AC line reactor (see Fig. 1.4) provides additional
filtering and current limiting features to a line side short circuit fault.
The line current and voltage waveforms are shown in Figure 1.4. The
line current THD is approximately 4.5%, while line-to-line voltage
THD is approximately 1.5%. (THD of line voltage is a function of
system impedance.) Input power factor with the AFE rectifier is
near unity from 30-100% speed when applied to variable torque
loads.
a)
b)
Figure 1.4 – PWM rectifier (active front-end) and its input current/voltage waveforms
a) Line current
b) Line-to-line voltage at PCC
Motor Compatibility The PowerFlex 7000 “A” Frame 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 (37 °F) higher compared to across the
line operation. Dv/dt in the voltage waveform is less than 10 volts /
microsecond. 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 do not exist with the PowerFlex 7000 “A” Frame. Typical
motor waveforms are shown in Figure 1.5. These motor friendly
waveforms are achieved by utilizing a selective harmonic
elimination (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.
Arms
300.00
200.00
100.00
-100.00
-200.00
-300.00
Vrms
10.00K
7.50K
5.00K
2.50K
Motor voltage 0.00K
-2.50K
-5.00K
-7.50K
-10.00K
100.00 110.00 120.00 130.00 140.00 150.00
TIME (ms)
SGCT Features and Benefits An SGCT is a thyristor with an integrated gate drive. Positioning the
gate drive close to the SGCT as shown in Figure 1.6, creates a low
inductance path that provides more efficient and uniform gating of
the device. As a result, the device is better suited to handle the
fluctuating levels of voltage and current while it is switching on and
off during gating.
An SGCT has low conduction and switching losses, low failure rate,
and double sided cooling for low thermal stress. The SGCT achieves
voltage blocking capability in both forward and reverse directions up
to 6500 volts by a NPT (Non-Punch-Through) structure and nearly
symmetrical pnp transistor in the wafer, while the current is
unidirectional.
Figure 1.6 – SGCT with integrated gate drive (left) and unit cell structure (right)
Description Specifications
Control Power 220/240 V or 110/120 V, 1 phase – 50/60 Hz (20 Amp)
External I/O 16 Digital Inputs, 16 Digital Outputs
50/60 Hz AC or DC
External Input Ratings
120-240 V – 1 mA
50-60 Hz AC or DC
External Output Ratings
30-260 V – 1 amp
Analog Inputs (1) Isolated, (1) Non-isolated, 4-20 mA or 0-10 V
• Analog input 12 Bit (4-20 mA)
• Internal parameter 32 Bit resolution
Analog Resolution
• Serial Communication 16 But resolution ( .1 Hz)
(Digital Speed Reference)
Analog Outputs (1) Isolated, (7) Non-isolated, 4-20 mA or 0-10 V
Communication Interface SCANPort /DPI
Internal ScanPort – 10 ms
Scan Time
Internal DPI – 5 ms
R I/O Lon Works
DeviceNet Can Open
Ethernet RS485 HVAC
Communications Protocols
Profibus RS485 DF1
(Optional)
Modbus RS232 DF1
Modbus + RS232 C
Interbus
Enclosure NEMA 1, IP21
Lifting Device Standard / Removable
Mounting Arrangement Mounting Sill Channels
Epoxy Powder – Paint
Structure Finish Exterior Sandtex Light Grey (RAL 7038) – Black (RAL 8022)
Internal – Control Sub Plates – High Gloss White (RAL 9003)
Interlocking Key provision for customer input Disconnecting Device
Corrosion Protection Unpainted Parts (Zinc Plates / Bronze Chromate)
Fiber Optic Interface Rectifier – Inverter – Cabinet (Warning/Trip)
Door Filter Painted Diffuser with Matted Filter Media
Door Filter Blockage Air Flow Restriction Trip/Warning
Ambient Temperature 0° to 40°C (32°F to 104°F)
Storage and Transportation
-40°C to 70°C (-40°F to 185°F)
Temperature Range
Relative Humidity 95% Non-Condensing
Altitude (Standard) 0 to 3300 ft. (0 to 1000 m)
Altitude (Optional) 0 to 16400 ft. (1001 to 5000 m)
Seismic (UBC Rating) 1, 2, 3, 4
Standards NEMA, IEC, CSA, UL, ANSI, IEEE
SCR’s SGCT’s
2U (X1) U (T1)
1U
2V (X2) V (T2)
1V
2W (X3) W (T3)
1W
L- M-
2400 Volt – 6-Pulse Rectifier, Base Drive with Connection for Remote Isolation Transformer
SCR’s SGCT’s
2U (X1) U (T1)
1U
2V (X2) V (T2)
1V
2W (X3) W (T3)
1W
L- M-
2400 Volt – 6-Pulse Rectifier, Base Drive with Integral Isolation Transformer
SCR’s SGCT’s
LR
U (T1)
L1
V (T2)
L2
W (T3)
L3
2400 Volt – 6-Pulse Rectifier, Base Drive with Integral Line Reactor and Input Starter
(Configurations without Integral Input Starter are available)
SGCT’s SGCT’s
2U (X1) U (T1)
1U
2V (X2) V (T2)
1V
2W (X3) W (T3)
1W
L- M-
2400 Volt – PWM Rectifier, Base Drive with Connection for Remote Isolation Transformer
SGCT’s SGCT’s
2U (X1) U (T1)
1U
2V (X2) V (T2)
1V
2W (X3) W (T3)
1W
L- M-
2400 Volt – PWM Rectifier, Base Drive with Integral Isolation Transformer
SGCT’s SGCT’s
LR
U (T1)
L1
V (T2)
L2
W (T3)
L3
L- M-
2400 Volt – PWM Rectifier, Base Drive with Integral Line Reactor and Input Starter
(Configurations without Integral Input Starter are available)
SCR’s SGCT’s
2U (X1) U (T1)
1U
2V (X2)
V (T2)
1V
2W (X3) W (T3)
1W
L- M-
3300/4160 Volt – 6-pulse Rectifier, Base Drive with Connection for Remote Isolation Transformer
SCR’s SGCT’s
2U (X1) U (T1)
1U
2V (X2) V (T2)
1V
2W (X3) W (T3)
1W
L- M-
3300/4160 Volt – 6-pulse Rectifier, Base Drive with Integral Isolation Transformer
SCR’s SGCT’s
LR
U (T1)
L1
V (T2)
L2
W (T3)
L3
L- M-
3300/4160 Volt – 6-pulse Rectifier, Base Drive with Integral Line Reactor and Input Starter
(Configurations without Integral Input Starter are available)
SGCT’s SGCT’s
2U (X1) U (T1)
1U
2V (X2) V (T2)
1V
2W (X3) W (T3)
1W
L- M-
3300/4160 Volt – PWM Rectifier, Base Drive with Connection for Remote Isolation Transformer
SGCT’s SGCT’s
2U (X1) U (T1)
1U
2V (X2) V (T2)
1V
2W (X3) W (T3)
1W
L- M-
3300/4160 Volt – PWM Rectifier, Base Drive with Integral Isolation Transformer
SGCT’s SGCT’s
LR
U (T1)
L1
V (T2)
L2
W (T3)
L3
L- M-
3300/4160 Volt – PWM Rectifier, Base Drive with Integral Line Reactor and Input Starter
(Configurations without Integral Input Starter are available)
SCR’s SGCT’s
2U (X1) U (T1)
1U
2V (X2) V (T2)
1V
2W (X3) W (T3)
1W
L- M-
6600 Volt – 6-pulse Rectifier, Base Drive with Connection for Remote Isolation Transformer
SCR’s SGCT’s
2U (X1) U (T1)
1U
2V (X2) V (T2)
1V
2W (X3) W (T3)
1W
L- M-
6600 Volt – 6-pulse Rectifier, Base Drive with Integral Isolation Transformer
SCR’s SGCT’s
LR
U (T1)
L1
V (T2)
L2
W (T3)
L3
L- M-
6600 Volt – 6-pulse Rectifier, Base Drive with Integral Line Reactor and Input Starter
(Configurations without Integral Input Starter are available)
SGCT’s SGCT’s
2U (X1) U (T1)
1U
2V (X2) V (T2)
1V
2W (X3) W (T3)
1W
L- M-
6600 Volt – PWM Rectifier, Base Drive with Connection for Remote Isolation Transformer
SGCT’s SGCT’s
2U (X1) U (T1)
1U
2V (X2) V (T2)
1V
2W (X3) W (T3)
1W
L- M-
6600 Volt – PWM Rectifier, Base Drive with Integral Isolation Transformer
SGCT’s SGCT’s
LR
U (T1)
L1
V (T2)
L2
W (T3)
L3
L- M-
6600 Volt – PWM Rectifier, Base Drive with Integral Line Reactor and Input Starter
(Configurations without Integral Input Starter are available)
Control Overview
Line Converter Machine Converter
DC Link
Inductor
Motor fil. Cap.
Motor
Control Control
Faults
Faults
Machine converter
Line
firing angle
Converter
Protection Machine
Motor
Tach. Feedback
Converter
Sync. angle
Faults Protection Model
(SW) Speed
Flux Command
Line Current Idc ref.
Synch Control
Synch.
Transfer
Direct Vector Control The method of control in the PowerFlex 7000 “A” Frame medium
voltage AC drive is called sensorless direct vector control, meaning
that the stator current is divided into torque producing and flux
producing components, allowing the motor torque to be changed
quickly without affecting motor flux. This method of control is used
without tachometer feedback for applications requiring continuous
operation above 6 Hertz and less than 100% starting torque.
Control Hardware The control hardware includes identical drive control boards for
machine and line side complete with up to three fiber optic interface
boards (depending on the voltage and number of switching devices),
signal conditioning boards for machine and line side, customer
interface board and external I/O board. The common drive control
boards are used for the rectifier and inverter, induction or synchronous
drive control, and the two rectifier types (6-pulse, or PWM
Rectifier).
Fiber
Optic
Board
Signal Drive
Fiber
Conditioning Optic Control
Board Board Board
MACHINE MACHINE
Fiber
Optic
Board
Fiber
Optic
Board
Signal Drive
Conditioning Fiber Control
Optic
Board Board Board
LINE LINE
Fiber
Optic
Board
Customer
External I/O
Interface
Board
Board
Operator Interface
Up to five test modes are available including low voltage gate check,
and running at full current without motor connected.
Dimensions / Weights
VFD Total Width
Nominal Line Approx. Weight
Drive Type Maximum
Voltage Millimeters Inches lb (kg)
Current
Configuration #1 – Base Drive 160 2100 82.67 4300 (1955)
2400V 60 Hz or Configuration #2 – Base Drive with Integral Isolation
160 2400 94.49 8300 (3765)
3300V 50 Hz or Transformer
4160V 50/60 Hz Configuration #3 – Base Drive with Integral Line Reactor
160 2400 94.49 9800 (4455)
and Input Starter
Configuration #1 – Base Drive 105 2400 94.49 6500 (2955)
Configuration #2 – Base Drive with Integral Isolation
105 2800 110.24 10000 (4545)
6600V 60 Hz Transformer
Configuration #3 – Base Drive with Integral Line Reactor
105 2800 110.24 7500 (3410)
and Input Starter
Note: Total Depth = 1000 mm (39.37 in.)
Total Height without fan shroud = 2275 mm (89.56 in.)
Total Height with fan shroud = 2583 mm (101.69 in.)
Drive Installation
Safety and Codes WARNING The Canadian Electrical Code (CEC), National
Electrical Code (NEC), or local codes outline
provisions for safely installing electrical
equipment. Installation MUST comply with
specifications regarding wire type, conductor
sizes, branch circuit protection and disconnect
devices. Failure to do so may result in personal
injury and/or equipment damage.
Unpacking and Inspection Before leaving the factory, all drives have been tested both
mechanically and electrically. Immediately upon receiving the drive,
remove the packing and check for possible shipping damage. Report
any damage immediately to the claims office of the common carrier.
After unpacking the material, check the item(s) received against the
bill of lading to assure that the nameplate description of each item
agrees with the material ordered. Inspect the PowerFlex 7000 “A”
Frame drive for physical damage, as stated in the Rockwell
Automation Conditions of Sale.
Transportation and Handling The PowerFlex 7000 “A” Frame drive is shipped on a wooden skid,
which is bolted to the underside of the cabinetry. The drive should
remain bolted to the shipping skid until it is delivered to its final
installation area. Lifting angles are supplied bolted to the top of the
cabinetry. The drive must be kept in an upright position during any
handling. Refer to “General Handling Procedures”, publication
7000-IN002_-EN-P for a more detailed description.
Never attempt to lift or move the drive by any means other than the
methods listed, as structural damage or personal injury could result.
The following methods of handling are recommended:
Overhead Lifting
45.0 Max
2. Carefully ease the shipping platform over the roller pipes until
the drive weight is borne on the roller pipes.
3. The drive can be rolled to its designated location. Steady the load
to prevent tipping.
Storage
Siting of the Drive (cont.) (F) The room in which the equipment is located must be large
enough to accommodate the thermal losses of the equipment
since air conditioning may be required; the ambient
temperature must not exceed that for which the equipment is
rated. The heat created by the drive is directly proportional to
the power of the motor being driven and the efficiency of
equipment within the room. If thermal load data is required
contact the Rockwell Automation Sales office.
(G) The area in which the drive is located should be free of radio
frequency interference such as encountered with some welding
units. This may cause erroneous fault conditions and shut
down the drive.
(H) The equipment must be kept clean. Dust in the equipment
decreases system reliability and inhibits cooling.
(I) Power cable lengths to the motor are virtually unlimited due to
the near sinusoidal voltage and current waveforms. Unlike
voltage source drives, there are no capacitive coupling, dv/dt,
or peak voltage issues that can damage the motor insulation
system. The topology utilized in the PowerFlex 7000 “A” Frame
medium voltage AC drive does not produce dv/dt or peak
voltage problems, and has been tested with motors located up
to 15 kilometers from the drive.
(J) Only personnel familiar with the function of the drive should
have access to the equipment.
(K) The drive is designed for front access and should be installed
with adequate and safe clearance to allow for total door
opening. The back of the unit may be placed against a wall
although some customers prefer back access also.
Generator Note:
ATTENTION Verify that the load is not turning due to the
process. A freewheeling motor can generate
voltage that will be back-fed to the equipment
being worked on.
Installation When the drive has been placed at its installation area, the lag bolts
that fasten the shipping skid to the drive must be removed. The drive
is moved off the shipping skid and the shipping skid can be
discarded.
Position the drive in its desired location. Verify that the drive is on a
level surface and that the position of the drive will be vertical when
the anchor bolts are installed.
Install the hardware from the lifting angles in the tapped holes at the
top of drive; this prevents leakage of cooling air as well as keeping
dust out of the equipment.
When the drive has been placed in its installation area, the converter
door is to be opened and the shock indication labels inspected.
The drive is shipped with a label that records shock levels in excess
of 10G. If these shock levels have been attained, the chevron shaped
window will appear blue in one of the two windows.
If these shock levels have been attained, record the values. There is a
greater possibility of the drive having sustained internal damage if it
has been subjected to physical shock during the shipping and
installation process.
Installation (cont.) If the indicators show that no shock was attained, full inspection and
verification in accordance with the Commissioning process outlined
in Chapter 4 is still essential.
21 mm
(0.8)
On the top of the cabinet with the cooling fan, a sheet metal exhaust
hood is to be installed. The components to make up the exhaust
hood have been packaged and shipped with the drive.
The first step is to remove the protective plate covering the fan
opening on the drive. It is a flat cover plate bolted to the top plate.
Remove the bolts and plate and set aside for re-use.
Flat plate
(Quantity = 1)
Locate the exhaust hood on top of the cabinet per Figure 2.5 and re-
install the original cover plate previously set aside. (Care must be
taken that the notches on the bottom flange are oriented toward the
sides of the drive). Affix assembly to the drive top plate. Tighten all
hardware.
Installation (cont.)
M6 Screw
(Quantity = 12)
Ensure notch
orientation
to sides
1. Remove the protective plate covering the fan opening on the top
of Isolation Transformer cabinet and discard.
2. Locate the cooling fan on top of the cabinet. Position it over the
opening and align the mounting holes and wire harness
connections.
3. Affix the fan to the drive top plate with the M6 thread forming
screws provided.
M6 Screw
(Qty = 12)
Ground Resistor
Hood here
900 mm Converter –
Top Plate for Converter
800 mm Common Mode Choke Cabinet
and Common Mode
Choke Cabinet
External Ducting The PowerFlex 7000’s design allows for its exhaust air to be ducted
outside of the control room. In this case, consideration must be given
to the conditions present in the atmosphere outside the control room.
When externally ducting the exhaust air and bringing in cleansed
outside air, the following requirements must be met:
Cabinet Layout and The following drawings are generic in nature and will not accurately
Dimensional Drawings detail your drive. They are provided here to give you a general
overview of a typical drive.
of Drive
The Dimensional Drawings are order specific and will show the
information outlined.
Drive Layout The following diagrams are presented to show the typical layout of
the three main configurations of the PowerFlex 7000 “A” Frame Drive.
Base Drive
(Configuration # 1)
Figure 2.10 – Structure for Drive with Integral Line Reactor & Input Starter
Cabling Cabinet (Base Drive) The cabling cabinet of the base drive is located in the left hand
section and shows the medium voltage area for customer cable
terminations, three phase fan power transformer, and fuse assemblies
for transformer.
Note: The cabling cabinet for the base drive has the same layout for
6-pulse and PWM rectifiers at 2400-6600 volt ratings.
Current Transformer
Hall Effect Sensor
Current Transformer
Fan Power
Transformer Fuses
Cabling Cabinet (Integral The cabling cabinet of the drive with integral isolation transformer is
Isolation Transformer) located in the left-hand section. The mounting and location of the
isolation transformer is shown along with customer cable termination
locations. The cooling fan for the isolation transformer is located on top.
Note: The cabling cabinet with integral isolation transformer has the
same layout for 6-pulse and PWM rectifiers at 2400-6600 volt ratings.
Fan Housing
Ground Bus
Line Cable
Terminations
Motor Cable
Terminations
Integral Isolation
Transformer
Current Transformers
(CT)
(Front)
(Back)
Cabling Cabinet The cabling cabinet of the drive with integral line reactor and input
(Integral Line Reactor starter is located in the left-hand section. The mounting and location
and Input Starter) of the line reactor and input starter are shown along with customer
cable termination locations. The circulating fans for the cabinet are
located on top.
Note: The cabling cabinet with integral line reactor and input starter
has the same layout for 6-pulse and PWM rectifiers at 2400-6600
volt ratings. This cabinet is also available without integral starter
(see Figure 2.14). The width of the cabinet changes as a function of
the drive voltage ratings.
Current Transformers
Control Power Transformer
AC Line Reactor
Figure 2.13 – Cabling Cabinet with Integral Line Reactor, With Input Starter
Low Voltage
Line Cable Compartment
Terminations
Current
Transformers Motor Cable
Terminations
Fan Power
Transformer
Assembly
AC Line Reactor
Figure 2.14 – Cabling Cabinet with Integral Line Reactor, Without Input Starter
Converter Cabinet The converter cabinet for all configurations of the PowerFlex 7000
“A” Frame drive is located in the middle section. The mounting and
location of Inverter / rectifier modules are shown along with gate
drive power supplies and voltage sensing modules.
Note: The converter cabinet has a similar layout for 6-pulse and
PWM rectifiers. The width of the inverter / rectifier modules changes
as a function of the drive voltage ratings (2400-6600V).
Inverter Modules
Transient
Suppression
Network
Transient Suppression
Network Fuses
Rectifier Modules
Control / DC Link / Fan The control / DC link / fan cabinet for all configurations of the
Cabinet PowerFlex 7000 “A” Frame drive is located in the right section. The
mounting and location of the DC link inductor, line / load side
capacitors, and main cooling fan are shown behind the low voltage
control tub.
Note: The control / DC link / fan cabinet has the same layout for all
drives at 2400-6600 volt ratings.
Fan
Inlet Ring
DC Link
Inductor
Grounding
Network
Capacitors
Motor Filter
Capacitor
Low Voltage Control Tub The low voltage control tub is mounted in front of the DC link
(Located in Control / DC inductor in DC link / fan cabinet of the drive. Refer to Chapter 6,
Link / Fan Cabinet) Component Definition and Maintenance, for complete content details
of the low voltage section.
Note: The low voltage control tub has the same layout for all
PowerFlex 7000 “A” Frame drive ratings.
Hinged
Panel
Drive Control
Board
Signal (Machine)
Conditioning
Boards
Fiber Optic
Interface
Boards
Drive Control
Board (Line)
Hinged
Panel Customer
Interface
Board
(Panel
(Hinged closed)
Panel closed) (PanelPanel
(Hinged opened)
opened)
IEC Component and PowerFlex 7000 “A” Frame electrical drawings use conventions that
Device Designations are based on IEC (International Electrotechnical Commission)
standards, while remaining basically compatible with North
American ANSI (American National Standards Institute) standards.
The symbols used to identify components on the drawings are
international and a full listing of the symbols is given as part of each
PowerFlex 7000 “A” Frame electrical drawing (ED) set. The device
designations used on the drawings and labeling are also listed with
explanations on each drawing set.
Power Wiring Selection The following tables identify general wire selections that will be
encountered when installing the PowerFlex 7000 “A” Frame drive
line-up.
General Notes:
Cable Insulation
Cable Insulation Requirements for 18P and 6P / PWM Drives with Isolation
Transformer
Cable Insulation Rating (kV)
System Voltage (V, RMS) (Maximum Peak Line-to-Ground)
Line Side Machine Side
2400 ≥ 4.1 ≥ 2.2
3000 ≥ 5.12 ≥ 2.75
3300 ≥ 5.63 ≥ 3.0
4160 ≥ 7.1 ≥ 3.8
6000 ≥ 10.8 ≥ 5.5
6300 ≥ 11.4 ≥ 5.8
6600 ≥ 11.8 ≥ 6.0
The following table identifies general wire categories that will be encountered when installing the
PowerFlex 7000 “A” Frame Drive. Each category has an associated wire group number that is used in the
following sections to identify the wire to be used. Application and signal examples along with the
recommended type of cable for each group are provided. A matrix providing the recommended minimum
spacing between different wire groups run in the same tray or separate conduit is also provided.
For Tray: Recommended spacing between different wire groups in the same tray.
For Conduit: Recommended spacing for wire groups in separate conduit – mm (inches).
Wire Wire Signal Recommended Wire Power Power Control Control Signal Signal
Application
Category Group Example Cable Group 1 2 3 4 5 6
Per IEC / NEC
AC Power 2.3 kV, 3∅ Local Codes and In 228.6 228.6 228.6 228.6
1
(> 600V AC) AC Lines Application Tray (9.00) (9.00) (9.00) (9.00)
Requirements
Between 76.2 (3.00)
Conduit Between Conduit
Power
Per IEC / NEC
AC Power Local Codes and In 228.6 228.6 152.4 152.4
2 480V, 3∅
(TO 600V AC) Application Tray (9.00) (9.00) (6.00) (6.00)
Requirements
Between 76.2 (3.00)
Conduit Between Conduit
Per IEC / NEC
115V AC
Relay Logic Local Codes and In 228.6 152.4 228.6 152.4
3 or 115V DC
PLC I/O Application Tray (9.00) (6.00) (9.00) (6.00)
Logic
Requirements
115V AC Power Supplies Between 76.2 (3.00)
Power Instruments Conduit Between Conduit
Control
Per IEC / NEC
24V AC Local Codes and In 228.6 152.4 152.4 228.6
PLC I/O
4 or 24V DC Application Tray (9.00) (6.00) (6.00) (9.00)
Logic Requirements
Between 76.2 (3.00)
Conduit Between Conduit
Belden 8760
Analog Signals 5-24V DC
5 Belden 8770
DC Supplies Supplies
Belden 9460
Digital Power Supplies
(Low Speed) TTL Logic Level
Signal
Pulse Train All signal wiring must be run in separate steel conduit.
Input Belden 8760 A wire tray is not suitable.
Digital
6 Tachometer Belden 9460
(High Speed)
PLC Belden 9463 The minimum spacing between conduits containing different
Communications wire groups is 76.2 mm (3 inches).
Note 1: Steel conduit or cable tray may be used for all PowerFlex 7000 “A” Frame Drive power or control wiring, and steel conduit is required for all PowerFlex
7000 “A” Frame Drive signal wiring. All input and output power wiring, control wiring or conduit should be brought through the drive conduit entry holes of the
enclosure. Use appropriate connectors to maintain the environmental rating of the enclosure. The steel conduit is REQUIRED for all control and signal circuits,
when the drive is installed in European Union countries. The connection of the conduit to the enclosure shall be on full 360 degree and the ground bond at the
junction shall be less than 0.1 ohms. In EU countries this is a usual practice to install the control and signal wiring.
Note 2: Spacing between wire groups is the recommended minimum for parallel runs of 61 m (200 feet) or less.
Note 3: The customer is responsible for the grounding of shields. On drives shipped after November 28/02, the shields are removed from the drive boards. On
drives shipped prior to November 28/02, all shields are connected at the drive end and these connections must be removed before grounding the shield at the
customer end of the cable. Shields for cables from one enclosure to another must be grounded only at the source end cabinet. If splicing of shielded cables is
required, the shield must remain continuous and insulated from ground.
Note 4: AC and DC circuits must be run in separate conduits or trays.
Note 5: Voltage drop in motor leads may adversely affect motor starting and running performance. Installation and application requirements may dictate that
larger wire sizes than indicated in IEC / NEC guidelines are used.
Power Cabling Access The drive is built with provision for either the top or bottom power
cable entry.
Cable access plates are provided on the top and bottom plates of the
connection cabinet identified by the customer specific dimension
drawing (DD).
Cable connections are located behind the medium voltage door of the
Connection/Cabling cabinet. Location of power terminals for
various drive configurations are as indicated in Figures 2.18, 2.19
and 2.21.
In the case of the cabling cabinet with starter, the removal of internal
barriers and duct covers located on the left side of the cabinet may be
required to facilitate the routing of line cables. This can be
accomplished by removing the hardware securing the barrier/cover
and sliding it toward the front of the cabinet for removal. In addition
the fan housing and cover plate (if already installed) located on the
top of the cabinet must be removed to allow routing and termination
of line cables. All barriers/covers must be replaced, by reversing the
above sequence, before applying medium voltage.
Power Connections The installer must ensure that interlocking with the upstream power
source has been installed and is functioning.
The drive is supplied with provision for cable lugs. The power
terminals are identified as follows:
Line/Motor Terminations
The following are input cabinets for 6-pulse and PWM rectifier
drives.
400.0 [15.75]
1000.3 [39.38]
2314.6
[91.12]
1409.4
[55.49]
1180.8
[46.49]
952.2
[37.49]
412.9 [16.26]
SECTION A-A
Figure 2.18 – Dimension Views of 400 mm Base Cabling Cabinet Line and Load Motor Terminals
411.9 [16.22]
284.9 [11.22]
157.9 [6.22]
L1 L2 L3
242.5 [9.55]
Note:
Cable Entry Location
To access line cables,
(Top Load/Motor Entry)
fan housing and assembly
must first be removed.
Motor
Cables
U, V, W
Removable Barrier
for Cable Routing 597.5
100.2
[3.94] [23.52]
2314.6
[91.12] 214.5 [8.44]
2033.2
328.8 [12.94] [80.05]
1324.8
[52.16]
Figure 2.19 – Dimension Views of Cabling Cabinet with Integral Line Reactor and Input Starter
700.00
[27.56]
A B
209.6
[8.25]
480.5 [18.92]
429.0 [16.89]
314.7 [12.39]
189.2 [7.45]
2314.6
[91.12]
Line
Cables
L1,L2,L3
Motor
Cables
U,V,W
A B
Figure 2.20 – Dimension Views of Cabling Cabinet with Integral Line Reactor and without Input Starter
328.3
[12.92]
1U
1V
1W
1998.0
[78.66]
2314.6
1890.0 [91.12]
[74.41]
1782.0
[70.16]
Figure 2.21 – Dimension Views of Cabling Cabinet with Integral Isolation Transformer
Power and Control Wiring Drive line-ups (i.e. Drive and Input Starter) which are delivered in
two or more sections, for ease of handling, will require that the
power and control wiring be re-connected. After the sections are
brought together, the power and control wiring is to be re-connected
as per the schematic drawings provided.
Control Cables
GROUND V (T2)
2V
FILTER
W (T3)
2W
GROUND BUS
Each power feeder from the substation transformer to the drive must
be provided with properly sized ground cables. Utilizing the conduit
or cable armor as a ground is not adequate.
Grounding Practices (cont.) The main grounding conductor(s) should be run separately from
power and signal wiring so that faults:
• do not damage the grounding circuit,
or
• will not cause undue interference with or damage to protection or
metering systems, or cause undue disturbance on power lines.
Ground Bus
The drive ground bus runs along the top of the drive at the front.
The ground bus is accessible at the top of each of the drive
enclosures when the enclosure door is opened (and the low voltage
compartment hinged out in the case of the DC link/fan cabinet). It is
the responsibility of the installer to ensure that the drive is grounded
properly, typically at the point on the ground bus in the cabling
cabinet, close to the line cable terminations.
Interlocking Access to the medium voltage areas of the drive is restricted by the
use of key interlocking for safety.
At installation the key interlocking is set up so that access to the
medium voltage compartments of the equipment can only be made
when the upstream power is locked in the off position.
Additionally, the key interlocking prohibits the upstream power
being applied until the medium voltage drive’s access doors have
been closed and locked shut.
It is the responsibility of the installer to ensure that the key
interlocking is installed properly to the upstream equipment.
Operator Interface
Chapter Objectives This chapter describes how you use the operator interface to modify
and obtain information contained within the drive. In this chapter
you will learn how to:
• Modify information associated with the initial drive setup.
• View: - drive parameters,
- drive status.
• View & Reset Alarm Conditions.
• Request printouts of the information in the drive.
• Perform diagnostic trending.
• Modify the operation of the operator interface.
The chapter deals only with the operation of the operator interface.
Specific references to a particular parameter are only for illustrative
purposes. Refer to Medium Voltage AC Drive Parameters •
Technical Data (Publication 7000-TD001_-EN-P) for information
about the actual 'tags' within the drive and their use.
Terminology Parameter – A memory location within the drive to which data may
be written to or read. Setting a parameter (i.e. writing to it) will
modify how the drive behaves. Prior to using the drive a number of
parameters must be set. Additional parameters may be changed
while the drive is in use in order to adjust its operation, (i.e. the
speed could be changed via a parameter).
XIO – the eXternal Inputs and Output adapters used by the drive to
interface hardwired signals to the drive.
Overview The operator interface used on the PowerFlex 7000 “A” Frame
Medium Voltage Drive is that of the PanelView 550 terminal
(Figure 3.1). This terminal however does not behave as a
PanelView, as only the hardware for the operator interface has been
utilized. The PanelView software has been replaced with unique
software to tailor it to the requirements of the Medium Voltage
Drive, and its faceplate has been modified (Figure 3.1).
1 2
Keypad The keypad of the operator interface consists of two rows of five
function keys (item 1 of Figure 3.1) located below the operator
interface display area (item 4 of Figure 3.1). In the lower right
corner of the operator interface are four keys, which will be referred
to as the cursor keys (item 2 of Figure 3.1). Above the cursor keys
are data entry keys consisting of the numeric values 0-9, a decimal
point (.), a negative (-), a backspace key and a data entry key (item 3
of Figure 3.1).
All keys are of a membrane type. The key is executed upon release.
Along the bottom of the display area is one or two rows of 'Softkeys'.
These 'Softkeys' represent the physical function keys. The function
of the actual keys will vary between displays. The bottom row of
keys (i.e. F6-F10) is always shown. The upper row is shown only if
they are required for keys (F2-F5). Thus a single row of 'Softkeys'
always refers to the keys F6-F10.
Even though the upper row of Softkeys (i.e. F1-F5) may not be
shown on some displays, the F1-HELP key is always active. (F2-F5)
are only active if shown.
The cursor keys are normally used to select an item on the display.
When an item on the display is selected, that item will be displayed
in reverse video. To change the selection, press the key in the
desired direction.
On selection screens having more than one page, the page will
automatically change when the cursor is moved beyond the displayed
list.
Some displays, such as the Utility screen, use these keys to modify
the data value. Pressing the [cursor up] and [cursor down] keys will
change the value by a fine amount, i.e. 1 unit. Using the [cursor left]
and [cursor right] keys will change the value by a course amount, i.e.
10 units.
For entries requiring a HEX value, the keys (cursor up/down) are
used to scroll to the desired HEX value.
For parameters that are comprised of bit fields, the left/right keys are
used to move to the desired bit field. The up and down keys toggle
the bit between its possible states.
All four cursor keys have an auto feature such that after holding the
key for 2 seconds, the key will automatically repeat at a rate of 5
‘presses’ per second.
As the name implies, these keys are used to enter data. Pressing the
keys [0] to [9] will enter the corresponding value into the 'editing
field'. Pressing the [-] key will change the value to a negative
number. Pressing the [.] will allow a fractional value to be entered.
The enter key varies depending on the screen. If you are in the
process of a selection operation, the enter key will accept the
selection and proceed to a different screen based on the selection in
order to complete the operation. If you are in the process of entering
data, the enter key will accept the edited data.
What is a Screen? The operator interface uses menu driven screens to perform various
operations on the drive. You can think of a screen as a window or
template, overlaying data from the drive. The operator interface
combines a screen with the drive data, to formulate what you see on
the display area of the operator interface. Individual screens display
a particular type of data and allow selected operations to be
performed on this data. A number of different screens may be used
while performing a single operation.
Components
Although the data displayed on any particular screen will vary, the
general makeup of a screen is the same for all. Figure 3.2 shows a
typical screen and its components.
Page Number
Screen Name
Selected Item
Softkeys
Heartbeat
The upper left-hand corner contains the name of the screen (i.e.
SELECT GROUP:). Knowing the name of the screen will assist you
in the orientation of the menu system. On some screens to the right
of the screen name, will be the name of the selected item from the
previous screen as shown in Figure 3.3.
Some screens have more than one page associated with them. The
current page number and the number of pages which make up the
data currently being displayed on the screen is shown in the upper
right hand corner, (i.e. showing page 1 of 2 pages).
Along the bottom of the screen are one or two rows of 'Softkeys'
which represent the assignment to the actual function keys. In
Figure 3.2, Softkeys F6-F10 are shown. Pressing F8 will display the
next page of data.
In the very lower right-hand corner is a small dot. This dot indicates
the healthy state of the operator interface terminal. Under normal
conditions this dot will flash at a rate of .5 Hz. During
communication errors, the dot will flash at a rate of .1 Hz.
The remainder of the screen shows the data from the drive. The
presentation of the data is dependent on the screen. Screens that
allow an item to be selected show the current selection in reverse
video. An example of this is shown in Figure 3.2 in which the Speed
Control group is selected.
Information Windows
Accessing/Writing to Drive
When first powered up, the operator interface knows very little about
the information in the drive. As each screen is activated, the
operator interface requests information from the drive, which it will
store within the operator interface for future reference. When the
operator interface requests information from the drive, a window is
used to display a message "Accessing Drive ...". During this time,
the operator interface will not respond to any user input, until the
task at hand is completed. You will notice that subsequent activation
of the same screen for the same data will be much quicker since the
operator interface already has most or all of its required information.
Communication Error
The window for the "Communication Error" can take on two forms.
If a window has already been displayed showing "Accessing Drive"
or Writing to Drive", then the communication error message will be
added to the window already in use. Some screens constantly read
from the drive in order to show real-time data. An example of this is
the 'Top Level Menu’. When a communication error occurs on a
screen showing real-time data, a window is opened showing a box
around the "Communication Error". Two examples of this are
shown in Figures 3.4 and 3.5.
Language Changing
When the language used by the drive changes, (either via the
operator interface or an external device), the operator interface must
do considerable work. The database strings are all invalidated, the
character set for the server is changed and all strings used by the
operator interface are linked to the new language. During this
possibly lengthy process, the “Language Changing ...” message is
displayed.
General Operation
The operations for these latter keys will not be explained within the
description of individual screen operations. They are explained here
and apply equally to all screens.
F1 - Help
F6 - Alarms
The F6 'Softkey' will always get you to the Alarm Summary Screen.
A new alarm will cause this key to flash in reverse video.
F8 - Next Page
F9 - Previous Page
F10 - Exit
When you are viewing any screen other than the Top Level Menu,
this 'Softkey' will return you to the previous screen.
Operator Interface Power-up When the operator interface is powered up or reset, it will go
Sequence through two noticeable operations:
Once the database has been obtained, the operator interface will start
up in one of two modes, depending on to what degree the drive has
previously been configured:
b) Once the drive has been configured through the 'Setup Wizard',
the Top Level Menu, will be displayed from this point forward.
The 'Setup Wizard' can be re-entered via the Setup Menu.
Top Level Menu This screen (Figure 3.6) represents the main menu from which all
other screens (and the operations which they perform) are activated.
To activate an operation, simply press the function key
corresponding to the 'Softkey' shown on the screen. A screen for that
operation will be displayed. Refer to the section entitled "How To:"
for information about the various operations which may be
performed.
How To: The following sections describe how to perform the various operations
on the drive, using the operator interface. Throughout the discussion,
a number of screens will be used to achieve the desired operation. In
many cases, the same screen will be used for more than one operation,
however with possibly different data from the drive.
Obtain Help
Help is obtained for any screen by pressing the [F1] function key.
Figure 3.7 shows the help screen, which is displayed for the Top
Level Menu. After the name of the screen (i.e. HELP:) is the name
of the screen for which help is being accessed. (In this case the name
of the Top Level Menu is REV.) This particular help screen contains
three pages. To view page two, press the [F8] key. Page 2 is displayed.
To return to page 1, press the [F9] key.
You can return to the original screen from which you asked for help
at any time by pressing the [F10] key.
Related Topics
All of the help screens will have additional topics relating to the help
currently being displayed. These topics are highlighted just above
the Softkeys. Additional topics are selected via the [cursor left] and
[cursor right] keys. Figure 3.7 shows the additional topic of
"SOFTKEYS" selected. To access this information, press the [enter]
key.
The help for the additional topic will be displayed as in Figure 3.8 .
As with the original help screen, the related topic help may also have
related topics.
Press the [backspace] key to return to the previous level of help, (i.e.
the previous related topic). To exit help completely press [F10] to
return to the screen from which help was called.
Help on Help
The previous sections described how you can access help for a
particular screen, by pressing the [F1] key while on that screen. This
also applies while in any of the help screens.
Pressing [F1] while in a help screen will give you a help screen
describing how to use the help system. An example of a screen
giving help on the help system is shown in Figure 3.9. As with the
help screens previously described, the screens will contain related
topics.
Modify Operator Interface The utility operation of screens change the characteristics of
Operation (Utility) the operator interface. Within this operation you will:
• Set the clock and calendar
• Change the delay for the display backlight shutoff
• Change the contrast of the display
• Define the meters that will be displayed on the Top Level Menu
• View the revision levels of all software in the drive line-up.
• Transfer data between the operator interface ‘flash’ memory,
‘flash’ memory card and the drive.
• Load a new language module.
You will access the Utility operation from the Top Level Menu by
pressing the [F2] key. This results in the display of the screen shown
in Figure 3.10 .
In all operations on this screen, the value currently being acted upon
is shown in reverse video. Only when the value is in this state, may
it be modified.
The display of the operator interface is only readable with the aid of
a backlight. In order to preserve the life of the lamp that provides
this, the backlighting is automatically shut off after a duration of
inactivity on the keypad. The backlight is restored by pressing any
key. The pressed key will not have any other affect on the operator
interface when pressed with the backlight off.
To change the duration of the delay, press the [F2] key. The current
backlight delay will be shown in reverse video (Figure 3.11). The
value can be adjusted from 0 to 60 minutes. A value of zero (0) will
disable the delay, keeping the light on indefinitely. Press the [cursor
up] or [cursor down] keys to change the value by a resolution of 1
minute. Press the [cursor left] and [cursor right] keys to change the
value by a resolution of 10 minutes. To abort the change, press the
[backspace] key and the setting will return to its original value. To
accept the change press the [enter] key. The backlight delay has
been saved.
Changing Contrast
The contrast controls the horizontal angle to which the display may
be viewed. To change the contrast, press the [F3] key. The current
value of the contrast will be shown in reverse video (Figure 3.12).
Press the [cursor up] or [cursor down] keys to change the value of
the contrast. The screen will change instantly to show the effect of
the change. To abort the change, press the [backspace] key and the
setting will return to its original value. To accept the change, press
the [enter] key. The contrast setting has been saved.
Setting Time
The clock setting controls the time stamp that the drive uses on the
information contained on the alarm summary screen. To change the
time, press the [F5] key. The hour’s position of the clock will be in
reverse video (Figure 3.13). Press the [cursor up] or [cursor down]
keys to change the value by a resolution of 1 unit. Press the [cursor
left] and [cursor right] keys to change the value by a resolution of 10
units. To change the minutes press the [F5] key again and repeat the
procedure. Likewise to change the seconds press the [F5] key again.
Each press of the [F5] key will highlight the next position of the clock.
The highlighted position may be modified via the cursor keys.
To abort the change, press the [backspace] key and the clock will
return to its original time. To accept the change, press the [enter]
key. The new clock setting has been recorded.
Setting Date
The calendar setting controls the date stamp that the drive uses on
the information contained on the alarm summary screen. To change
the date, press the [F4] key. The year position of the calendar will be
in reverse video (Figure 3.14). Press the [cursor up] or [cursor
down] keys to change the value by a resolution of 1 unit. Press the
[cursor left] and [cursor right] keys to change the value by a
resolution of 10 units. To change the month press the [F4] key again
and repeat the procedure. Likewise, to change the day, press the [F4]
key again. Each press of the [F4] key will highlight the next position
of the calendar. The highlighted position may be modified via the
cursor keys.
To abort the change, press the [backspace] key and the calendar will
return to its original date. To accept the change, press the [enter]
key. The new calendar setting has been recorded.
You can not set the day of the week. The operator interface will
determine the day of the week based on the date that you set in the
calendar.
Selecting Meters
The utility screen (Figure 3.10 ) shows the four tags assigned to the
four meters on the 'Top Level Menu'. These can be changed by
pressing the [F8] key. This displays a new screen (Figure 3.15) from
which the selection and text associated with the meter is changed.
To change the tag attach to a meter, use the [cursor up] and [cursor
down] keys to highlight the desired meter and press the [enter] key.
(If nothing happens then you have not gained the required access to
make changes.) Press the [F8] key in order to gain access and refer
to the section entitled Enter/Modify an Access Level .
The changes made do not take affect until you press [F10] and exit
the screen. Any time prior to this you may cancel all of the changes
made after coming to the screen by pressing the [F7] key.
The result of selecting the V Line tag for meter 2 (in our example) is
shown in Figure 3.19 after the METERS screen was exited.
To modify the user definable text string, press the [F8] key. (If
nothing happens then you have not gained the required access to
make changes. Exit to the Top Level Menu screen and refer to the
section entitled Enter/Modify an Access Level .)
Prior to exiting the screen, the string can be returned to its state upon
entry to the screen by pressing the [F7] key.
The next level is 'Basic'. This level and all levels above it allow
changes to be made to any parameter that can be viewed. The
number of parameters viewable increases from the previous level.
This level will be sufficient for configuring and maintaining the
drive for the majority of applications.
The last level intended for normal operation is the 'Advanced' level.
From this level, the drive can be configured in its entirety.
Two additional levels are used for trained service personal and are
only used when physical hardware changes are made to the drive.
Individual PIN numbers protects all levels, except the first. Use the
up/down cursor keys to select the desired access level. Then enter
the PIN value for the given access level and press [enter]. If the
correct PIN was entered, the access level will change.
Refer to Enter/Modify an Access Level for complete information
on the use of Access Levels.
Via Groups
From the SELECT GROUP screen (Figure 3.23), the tag can also be
selected via its name by pressing the [F7] key.
Via Name
When you know the name of the tag that you wish to select but do
not know what group it belongs to or are unsure of the full name, this
method of selection may be appropriate.
Using the cursor keys, select (i.e. reverse video) the letter with which
the desired tag starts with. The [cursor up] and [cursor down] keys
move vertically within a column, the [cursor left] and [cursor right]
key move laterally within the rows. When the appropriate letter has
been selected, press the [enter] key.
All tags which begin with that letter, and are appropriate for the
operation on which the selection is being performed, will be
displayed as in Figure 3.26. Using the [cursor up] or [cursor down]
keys, and if required the [F8] and [F9] keys to change the page,
select the desired tag. Press the [enter] key and the selected tag will
be used to continue the operation for which the selection process was
being used.
From the SELECT LETTER screen (Figure 3.25) the tag may also
be selected via a code by pressing the [F5] key.
Via Code
Use the data entry keys [0]-[9] to enter the desired code on the
SELECT CODE screen (Figure 3.27). The entered code may be
edited using the [backspace] key. Press the [enter] key.
The screen will display one of two formats. If the code you entered
was valid, it will show the name of the tag associated with the code
(Figure 3.28). This allows you to verify that this was the tag that you
intended to select with the code before proceeding. If correct, press
the [enter] key. If incorrect, immediately repeat the process by
typing in another code. If the tag code was not valid, a message
indicating such is displayed as in Figure 3.29.
When the [enter] key is pressed for a valid tag code (i.e. Figure 3.28)
the selected tag will be used to continue the operation for which the
selection process was being used if that tag is appropriate for the
operation. For example: if you are performing a parameter
modification operation, but have selected a read-only parameter tag
code, you will be unable to exit the screen with this read-only
parameter. The screen will display this information, along with the
tag's current value, such as shown in Figure 3.30. Re-enter a tag
code for a parameter or press [F10] to return to the previous screen
without making a selection.
The operator interface's keypad does not contain any alpha keys to
allow direct input of the characters. This section will describe the
operation for which characters may be entered.
The screen shown in Figure 3.31 is typical of all screens using the
edit text operation. All screens have the F3, F4 and F5 keys in
common (if applicable). Once in the 'editing field' all operations are
performed on the character in reverse video.
Pressing the [cursor left] and [cursor right] keys will move to the
next character position in the string. Pressing the [cursor up] and
[cursor down] keys will cycle through the characters contained in a
set, each time the key is pressed. Note that when the first member of
a set is displayed, pressing [cursor down] will wrap around to the last
member of the set.
There are four sets of characters available. Press the [F3] key to
cycle among the sets. The sets consist of:
a) the upper case letters A-Z.
b) the lower case letters a-z.
c) the numbers 0-9 and the characters '.' and '-'.
d) the characters: space _ ( ) [ ] { } < > | @ # $ % & * ! ^ + = ; : ?
A special set consisting of A-Z, 0-9 and the underscore character are
used for filenames and cannot be selected via the [F3] key or
modified by the [F5] key.
When a letter is in the editing field, pressing the [F5] key may
change its case.
To delete the entire string (i.e. fill it with spaces), press the [F4] key.
To abort the changes to the string being edited press the [backspace]
key. This will restore the string to its contents when the screen was
first entered.
Note: The characters entered may only be valid for the currently
selected language. Any characters used which are unique for a
given language (i.e. other than the four sets defined above) can only
be meaningfully displayed in the selected language, because other
languages do not contain the appropriate display characters.
Configure the Drive In order to tailor the drive to your motor and application, a number
of elements must be defined in the drive. The section describes how
you will set or 'configure' these elements of the drive, via this
operator interface. You will learn how to:
• Change a parameter setting.
• Assign a parameter to an Analog Port.
• Selectively enable or disable (i.e. Mask) certain faults.
• Define your own faults attached to external inputs.
• Configure the XIO
• Define the information sent to your optional PLC connection.
• Save and Restore your settings in the drive.
• Select an alternate language (if previously loaded in operator
interface).
There are two methods to configure the drive. This section defines
the more complete method to configure the drive for any application.
The drive may also be configured for the majority of applications by
using the Setup Wizard. The Setup Wizard can be entered from the
"SETUP" screen by selecting the 'Setup Wizard' from the list of
options and pressing [enter].
The default level, 'Monitor' does not have a PIN associated with it.
With this Access Level, the drive configuration can be viewed, but
no changes are allowed to the parameters. In addition to providing
the protection, the Access Levels also filter out the amount of
information that can be viewed at each level. On any level, other
than 'Monitor', any information that can be viewed may also be
modified.
The value may be edited by using the [backspace] key. When the
value has been typed in, press the [enter] key. If the correct PIN was
entered, the access level of the operator interface will change as
shown in Figure 3.34 . If the incorrect value was entered, the
operator interface will remain at the current access level.
The default value for the password (PIN) of the 'Basic' and
'Advanced' levels is zero (0), or simply pressing the [enter] key. This
value can be changed from the ACCESS screen. First use the
up/down cursor keys to select the level for which you wish to modify
the PIN. Press the [F9] key. The typical PASSWORD CHANGE
screen shown in Figure 3.35 is displayed, showing the Access Level
for which the new PIN will be applied to.
Enter the current PIN value via the data keys [0]-[9] and press the
[enter] key. As in the ACCESS screen, the entered value is shown via
placeholders and may be edited with the [backspace] key.
If you entered the correct PIN, the screen now asks you for the new
PIN. Type in the new PIN value using the data entry keys [0]-[9]
followed by the [enter] key. The screen now asks you to verify the
new PIN. Type in the new PIN again followed by the [enter] key as
shown in Figure 3.36.
At the end of the operation you will see a status as shown in either
Figures 3.36, 3.37 or 3.38 depending on whether you successfully
changed the PIN, incorrectly entered the existing PIN or incorrectly
verified the new PIN.
You will access the "SETUP" screen from the Top Level Menu by
pressing the [F8] key. This will result in the typical screen shown in
Figure 3.39 .
The Current Access level is shown. If it states 'Monitor' then you are
restricted to only viewing the basic drive setup. You cannot make
any changes. You must be in at least the 'Basic' access level in order
to modify any of the drive parameters, and you may only modify the
parameters for which you can view at the given access level.
Language Selection
Modify Parameters
Numerical Value
– the name of the parameter for which you are making the changes
(i.e. Rated motor volt).
– the tag code for the parameter, (i.e. 22).
– the minimum and maximum allowable limits to which the
parameter must be set, (i.e. 4000 to 4160).
– the units in which the parameter data is being displayed
– the actual value of the parameter contained in the drive.
Having gained access, use the data entry keys [0]-[9] to enter the
new value. The [-] key can be typed at any time to enter a negative
value. The [.] key is used to enter a decimal point for fractional
values. The entered new value can be edited by pressing the
[backspace] key. This key will delete the right most character (i.e.
number, decimal point or negative sign) shown on the screen. Press
the [enter] key to accept the new value as shown in Figure 3.43. If
the new value that you entered is outside the limits defined, the new
value will not change. For example: If you entered 900 when the
minimum value was 4000, the new value will still show 4100.
The value may be edited the same as a value entered from the
numeric keypad.
The new value is not sent to the drive until you exit the screen with
the [F10] key. Prior to this you can modify the new value by
repeating the above procedure, or you can cancel the change by
pressing the [F7] key. The CANCEL operation returns the new
value to that of the actual value.
Enumerated Value
Use the up/down cursor keys to scroll onto these additional options.
Press the [enter] key to accept the new value as shown in Figure
3.47.
The new value is not sent to the drive until you exit the screen with
the [F10] key. Prior to this you can modify the new value by
repeating the above procedure, or you can cancel the change by
pressing the [F7] key. The CANCEL operation returns the new
value to that of the actual value.
Having gained access, press the left/right cursor keys to move to the
various bits within the parameter. As each bit is selected, the name
of the bit is displayed. Use the up/down arrow keys to toggle the
state of the bit.
The new value is not sent to the drive until you exit the screen with
the [F10] key. Prior to this you can modify the new value by
repeating the above procedure, or you can cancel the change by
pressing the [F7] key. The CANCEL operation returns the new
value to that of the actual value.
Analog Ports
The changes made do not take affect until you press [F10] and exit
the screen. Any time prior to this you may cancel all of the changes
made after coming to the screen by pressing the [F7] key.
Fault Masks
To change the state of the mask, use the [cursor up] or [cursor down]
keys to select the desired fault and press the [enter] key. Each press
of the [enter] key will toggle the state of the mask as shown in Figure
3.51. (If nothing happens, you do not have proper access to the
drive. Exit to the SETUP screen and refer to the section entitled
Enter/Modify an Access Level to gain access).
Figures 3.50 and 3.51 show all fault masks regardless of their current
state. The fault masks can be viewed according to their state by
pressing the [F7] key on the FAULTS SETUP screen. This will
display the FAULTS OVERVIEW screen, typical of Figures 3.52
and 3.53.
The state of the fault masks which you are currently viewing is
defined to the right of the screen name, i.e. FAULTS OVERVIEW:
DISABLED or FAULTS OVERVIEW: ENABLED. To change the
state of fault masks currently displayed, press the [F7]. Each press of
the [F7] key will toggle the screen to show the masks in the other state.
The changes to the fault masks do not take affect until the screen is
exited via the [F10] key, i.e. exiting the FAULTS OVERVIEW will
change the masks in the drive as will exiting the FAULTS SETUP
screen. In our example, exiting the FAULTS OVERVIEW screen
and returning to the FAULTS SETUP screen now shows the “AC
O/V” mask as being ON (Figure 3.56).
To modify the text attached to a particular fault input, use the [cursor
up] and [cursor down] keys to select the desired input. To modify
the text, press the [cursor right] key. (If nothing happens then you
have not gained the required access to make changes. Exit to the
SETUP screen and refer to the section entitled Enter/Modify an
Access Level to gain access). The first character position of the
string will be in reverse video as shown in Figure 3.58. Refer to the
section entitled "Edit Text". When editing is complete, the screen
will appear as in Figure 3.59.
The changes made do not take affect until you press [F10] and exit
the screen. Any time prior to this you may cancel all of the changes
made after coming to the screen by pressing the [F7] key.
PLC
This will display a screen as shown in Figure 3.60 or 3.61. The PLC
setup consists of eight words of input and eight words of output.
These are shown on separate screens. The type of PLC word being
viewed is defined to the right of the screen name, i.e. PLC SETUP:
INPUTS or PLC SETUP: OUTPUTS. To switch to the other screen,
press the [F8] key. Each press of the [F8] key will toggle the screen
to show the other set of words.
The layout of the PLC 'rack' is dependent on the DIP switch settings
on the RIO adapter, (refer to the appropriate manual for information
on the following adapters and their use: 1203-GD1, 1203-GK1,
1203-CN1, 1203-GD2, 1203-GK2, 1203-GK5, 1203-GU6, 1203-
SM1 and 1203-SSS). Tags are assigned to rack module locations in
pairs. These pairs are referred to as links and consist of two input
and two output words. There are a total of four links that can be
assigned to the RIO adapter.
The screens show the current tags and their tag code, which are
associated with each of the links. To change the tag attached to a
link, use the [cursor up] and [cursor down] keys to highlight the
desired link and press the [enter] key. (If nothing happens then you
have not gained the required access to make changes. Exit to the
SETUP screen and refer to the section entitled Enter/Modify an
Access Level to gain access).
The changes made do not take affect until you press [F10] and exit
the screen. Any time prior to this you may cancel all of the changes
made after coming to the screen by pressing the [F7] key.
XIO
Message Prompting
All the changes you made while you were configuring the drive are
stored in volatile memory of the drive. This means that when power
to the drive is lost, so will be the changes. To permanently store the
changes, the contents of the memory must be stored to NVRAM
memory.
When you exit a group of screens on which you have changed the
drive data, you will be prompted as in Figure 3.62 to save the data.
If you wish to save the data, press [F8] 'Yes' and the NVRAM screen
(refer to Store/Retrieve Configuration) will be entered (Figure
3.63). If you wish the data to reside as temporary data in RAM only,
press [F9] 'No'. Pressing [F10] Exit will return you to the screen
from which you previously exited.
Note that the data can still be saved at a later time by accessing the
NVRAM screen directly from the Top Level Menu. Refer to
Store/Retrieve Configuration.
To access the memory functions, press [F5] on the Top Level Menu.
Within this screen it is possible to perform three operations on the
memory of the drive. To perform these operations you must have the
proper access to the drive. Refer to the section entitled
Enter/Modify an Access Level .
Initialize
The screen then will ask you to confirm the operation. Press the [F8]
key to proceed, or the [F9] key to abort. Performing an initialization
will overwrite the data currently in the drive. Previous changes that
were saved to NVRAM will not be affected.
Save
The changes that you have made to the drive data must be saved if
you do not want to lose the data when the drive is powered off. To
save the changes, press the [F5] key (Figure 3.65).
To confirm the operation, press the [F8] key to proceed, or the [F9]
key to abort. Saving the data will overwrite the previously stored
data in the NVRAM.
Load
The changes that you stored in NVRAM are automatically used each
time the drive is powered up. If you make changes to the data in the
drive (without saving) and then wish to use the previously stored
data, press the [F4] key (Figure 3.66).
To confirm the operation, press the [F8] key to proceed, or the [F9]
key to abort. Loading the data will overwrite the data currently
being used by the drive.
Display Parameters The parameters of the drive can be displayed, continually showing
the value contained in the drive. From the Top Level Menu, press the
[F4] key. The DISPLAY GROUP screen of Figure 3.67 is displayed.
The screen shows one or more pages of groups that can be displayed.
The number of groups displayed depends on the current access level.
Using the [cursor up] and [cursor down] keys select the group you
wish to display and press the [enter] key (Figure 3.68).
The left side of the pair shows the name of the bit, while the right
side shows the current value of the bit within the parameter.
All of these values are updated from the drive on a continual basis.
Custom Group
From the DISPLAY GROUP screen (Figure 3.67) you can select a
group which you have custom defined by pressing the [F7] key. This
custom group contains selected tags from one or more other groups,
arranged by you onto a single screen for more convenient viewing
(Figure 3.71).
To assign a tag to the display, use the [cursor up] and [cursor down]
keys to highlight the desired item position and press the [enter] key.
This will begin the selection process of a tag as described in the
section entitled "Select a Parameter". When you have completed
the selection process, the selected tag will be assigned to the item, as
in Figure 3.72. To remove a tag from the highlighted item, press the
[delete] (Backspace) key.
The changes take affect immediately, however are not saved until
you press [F10] and exit the screen. Any time prior to this you may
cancel all the changes made after coming to the screen by pressing
the [F7] key.
View Drive Status The status of the drive is viewed by pressing the [F7] key from the
Top Level Menu. This screen, shown in Figure 3.73, constantly
displays the latest status of the drive.
View & Reset Alarms All drive faults and warnings are logged to their respective queues.
Collectively the faults and warnings are referred to as "Alarms".
When a new alarm occurs, the F6 key on any screen will begin to
flash in reverse video. Pressing the [F6] key on any screen will bring
you to the screen as shown in Figure 3.74.
The screen shows the current status of the drive, as well as the last
active Fault that tripped the drive and any pending warning. (The
screen only shows a fault and/or warning if the drive is still in the fault
and/or warning state. This is independent of the content of the queues.)
Note: Terminal FRN > 4.005.
To acknowledge the alarm(s), press the [F6] key. This will cause the
F6 key to cease flashing and return to normal video. (If a new alarm
were to occur, the F6 key would again flash in reverse video).
To reset the drive, press the [F7] key. This operation will reset any
latched faults in the drive. This has no action upon either the Fault or
Warning queues. If some faults still exist, they will return as new faults.
Faults and Warnings are stored into separate queues. Both work
similar, thus only the fault queue will be discussed. To access the fault
queue, press the [F9] softkey from the ALARM SUMMARY screen.
A screen typical of Figure 3.75 will be shown. The screen shows all
faults in chronological order as they have occurred. A timestamp
gives the date and time that the fault occurred. The most recent fault
occurs at the top of the list. Use the [F8] and [F9] keys to shift to
other pages if required. Entries are not removed from the queue until
the queue is cleared with the [F7] key. If the queue becomes full, the
oldest entries are discarded to make room for newer faults.
Request Printouts When the drive contains the optional printer, you can obtain hard
copies of the data that you are able to view on the terminal. The
printouts are requested from the PRINTER screen. Press [F3] while
displaying the Top Level Menu.
The printer can automatically print out the alarms as they occur.
This feature is selected as one of the report formats. In the Figure
3.78, the "AUTO - ON" indicates that this feature is currently
enabled. To disable the feature, use the [cursor down] key to select
the text, and press the [enter] key. The text will change to "AUTO -
OFF" (if a printer is attached). The automatic alarm printout feature
is now disabled. Pressing the [enter] key again while selected will
enable the feature.
Perform Diagnostic Trending The diagnostic trending operation of screens allows you to capture
the relationships of a number of parameters over a period of time.
Within this operation you will:
• Define the Parameters to which the Trend Apply
• Define the Trigger Condition to Begin the Trend
• Define the Sampling Rate and position of the Trigger
• View the results of the Trend
You will access the Diagnostic Trend operation from the Top Level
Menu by pressing the [F9] key. This results in the display of the
screen shown in Figure 3.79.
If data has already been captured, a time stamp indicating the last
time the given trigger has occurred. This captured data can be
viewed by pressing the [F9] softkey.
To define a trend, press the [F8] key to display the setup screen,
shown in Figure 3.80.
Assigning a Trace
To assign a tag to a trace, use the [cursor up] and [cursor down]
keys. Highlight the desired trace and press the [enter] key. Since
there are more traces then can be seen on a single screen, use the
up/down arrow keys to extend the list to the additional traces on the
screen. (If nothing happens then you have not gained the required
access to make changes. Press the [F8] key and refer to the section
entitled Enter/Modify an Access Level to gain access).
Once you have assigned a tag to Trace 1, you may proceed to set the
trigger value. Three items of information are required, the trigger
type, the trigger condition and the trigger value. These are selected
for modification by pressing the [F9], [F2] and [F3] keys
respectively. (If nothing happens then you have not gained the
required access to make changes. Press the [F8] key and refer to the
section entitled Enter/Modify an Access Level to gain access).
The trigger condition and trigger value are set with the [F2] and [F3]
keys respectively. When the respective field is in reverse video, that
field may be modified.
Trigger Conditions:
= Equal to
N= Not Equal to
> Greater than
< Less than
+ Boolean OR
N+ Boolean NOR
& Boolean AND
N& Boolean NAND
The value (data) is set through the use of the numerical keypad. Use
the data entry keys [0]-[9] to enter the new value. The [-] key can be
typed at any time to enter a negative value. The [.] key is used to
enter a decimal point for fractional values. The entered new value
can be edited by pressing the [backspace] key. This key will delete
the right most character (i.e. number, decimal point or negative sign)
shown on the screen. Press the [enter] key to accept the new value as
shown in Figure 3.82. If the new value that you entered is outside
the limits defined, the new value will be pegged at the closest limit.
For example: If you entered 900 when the minimum value was 1000,
the new value will show 1000.
The value may be edited the same as a value entered from the
numeric keypad.
Pressing the [F4] key sets the rates at which the samples are taken.
This data field is then modified in the same manner as the trigger
data is entered. Rates can be set from 0 msec (collect as fast as
possible) to 20.000 seconds.
When samples are collected, part of the buffer will store values prior
to the trigger point and the remainder of the buffer will store values
after the trigger. Pressing the [F5] key will allow you to set the
percentage of the trend buffer, allocated to values collected, after the
trigger has occurred. This data field is modified in the same manner
as the trigger data is entered.
The changes do not take affect, and the trend is not started until you
press [F10] and exit the screen. Any time prior to this you may
cancel all the changes made after coming to the screen by pressing
the [F7] key.
When you exit the screen, the trend is started and the screen such as
Figure 3.83 will show the trigger condition and the status. Pressing
the [F7] key on the DIAGNOSTICS screen may also start the trend.
Once the data has started to be collected, the status will show
'triggered' as in Figure 3.84. When the buffer contains a complete
capture, it will show “stopped” (if a single capture), as shown in
Figure 3.85. The time and date at which the trigger occurred is
displayed. The trend buffers may only be viewed when their status is
‘stopped’. If in continuous mode, the capture will stop when the
buffers are viewed. To view the trend buffers, press the [F9] key.
A screen such as Figure 3.86 will be shown. Upon initial entry, the
screen will be positioned to the trigger point, shown by the "T ->". To
view data either side of the trigger point, press the [F8] and [F9] keys.
Changes made to the diagnostic list setup are not permanent unless
they are saved to the NVRAM in the drive. Upon exiting the
DIAGNOSTICS screen (Figure 3.79), you will be prompted to save
the changes to NVRAM. Refer to the section "Message Prompting"
for further details.
Flash Memory Transfers Flash memory is used to store data in a non-volatile environment that
is it is not lost when power is removed. The operator interface
contains flash memory in two forms. The first is built into the
operator interface. This form of flash is used to store the operator
interface’s firmware and parameters from the drive. This
information can also be stored on a removable flash memory card.
This second form of flash allows the data from one drive to be
physically transferred to another drive for loading. All files on the
flash card use a DOS format thus can be read or written by any PC
that contains a PCMCIA drive. Flash memory cards which are
supported are those that contain the following memory chips from
INTEL:
- 28F010
- 28F020
- 28F008SA
- 28F016SA.
These chips are used in the following memory cards available from
Rockwell Automation:
2711-NM11 2711-NM24
2711-NM12 2711-NM28
2711-NM14. 2711-NM216
This section describes how you will transfer information between these
two forms of flash memory and the drive. You will learn how to:
• Format a flash card.
• Look at the directory of files on a flash card containing the DOS
file format.
• Select a program (firmware) from the flashcard and load it into
the operator interface.
• Save the parameters from the drive on the flash card or in the
operator interface.
• Download parameters to the drive from a flash card or that
previously saved in the operator interface.
• Load a language module from the flash card.
You will access the Transfer operations from the Utility screen by
pressing the [F7] key. This results in the display of the screen shown
in Figure 3.87.
From this screen, additional screens are used to perform the various
functions involving the flash memory. The screen shows the current
access level of the operator interface. Any operation that will alter
the contents of the flash memory or of the drive requires the access
level to be something other than 'Monitor'. At the 'Monitor' level you
may view the contents of the flash card. To change the access level,
press the [F8] key. Refer to the section Enter/Modify an Access
Level .
Flash card files have a characteristic unlike normal DOS files. They
can not be modified once written. New files can be added to the
card; however they cannot be selectively removed.
When a new flash card is to be used or all the files removed from an
existing card, the card must first be formatted. Formatting erases all
data on the card and creates a DOS file structure.
To format a card press the [F2] key on the TRANSFER screen. The
screen will appear as in Figure 3.88, indicating the operation you are
about to perform and showing the current status of the operation. (If
nothing happens then you have not gained the required access to
modify the flash memory. Exit to the TRANSFER screen and refer
to the section entitled Enter/Modify an Access Level to gain
access).
The screen will then ask you to confirm the operation. Press the [F8]
key to proceed, or the [F9] key to abort. Performing a format will
overwrite all existing data on the flash card.
View a Directory
When the directory is entered from the TRANSFER screen, all files
will be shown. When entered from one of the operations screens,
only the files that are relevant to the operation being performed will
be shown.
Only the root directory of the card is used, as sub directories are not
supported in the operator interface.
Select a filename
Press the [F10] key to abort the selection operation and return to the
previous screen without continuing with the operation.
Enter a filename
Loading Programs Firmware is the program that is run in the operator interface to
(Firmware) provide all the functionality described in this manual. Firmware is
loaded from the flash card in one of two ways.
b) The user can select from one or more .FMW files on the card and
load the selected firmware into the operator interface. This is the
method that will be described here.
From the TRANSFER screen, press the [F3] key. The operator
interface will enter the DIRECTORY screen from which an existing
firmware filename can be selected or entered. Refer to the sections
entitled “Select a filename” and “Enter a filename”. (If nothing
happens then you have not gained the required access to modify the
flash memory. Exit to the TRANSFER screen and refer to the
section entitled Enter/Modify an Access Level to gain access).
The screen will then ask you to confirm the operation. Press the [F8]
key to proceed, or the [F9] key to abort. Performing a
DOWNLOAD FIRMWARE operation will overwrite the existing
firmware that is currently running.
Pressing the [F3] key may restart an aborted download or one that
failed prior to starting the download. To select or enter a different
filename, press the [F7] key.
• Solid Red - the transfer has failed. Firmware must be loaded via
the method described in a) above. This is achieved by cycling
power to the operator interface or simultaneously pressing the
[cursor left] [cursor right] and [Enter] key at the same time while
the flash card is inserted. If more than one firmware file exists
on the card, the first one will be loaded and this process will need
to be repeated in order to select the firmware file you desire.
Parameter Transfers The parameters used by the drive are stored within the drive itself.
The operator interface is used to review and modify these parameters.
When a Drive Control Board is changed, it is necessary to re-enter
the parameters into the new board. The operator interface can
simplify this process by reading all the parameters from the old
Drive Control Board and storing them either in the operator interface
or on a flash card. When the new board has been installed, the
previously stored parameters are then downloaded to the new board.
The flash card provides an added benefit when more than one drive
is using the same set of parameters. Parameters can be entered on
the first drive, then uploaded and stored on the flash card. The flash
card may then be taken to the remaining drives and the parameters
downloaded to those drives.
Note: This feature does not replace the saving of parameters to the
Drive NVRAM, refer to section Store/Retrieve Configuration.
After downloading parameters, they must still be saved within the
drive in order to make them permanent.
The parameters are read from the drive and stored in the operator
interface by pressing the [F5] key. The screen will appear as in
Figure 3.93, indicating the operation you are about to perform. The
screen will then ask you to confirm the operation. Press the [F8] key
to proceed, or the [F9] key to abort. Performing a “DRIVE TO
MEMORY” transfer will overwrite any previous parameters stored
within the operator interface.
The parameters are read from the drive and stored on a memory card
by pressing the [F4] key. The operator interface will enter the
DIRECTORY screen in which a parameter filename can be entered.
Refer to the section entitled “Enter a filename”. When the filename
has been obtained, the TRANSFER: PARAMETERS screen such as
that in Figure 3.94 will be displayed, showing the filename,
indicating the operation you are about to perform and showing the
current status of the operation.
The screen will then ask you to confirm the operation. Press the [F8]
key to proceed, or the [F9] key to abort. Pressing the [F4] key may
restart an aborted transfer or one that failed. To select or enter a
different filename, press the [F7] key.
The parameters are read from a memory card and written to the drive
by pressing the [F2] key. The operator interface will enter the
DIRECTORY screen from which an existing parameter filename can
be selected or entered. Refer to the sections entitled “Select a
filename” and “Enter a filename”. When the filename has been
obtained, the TRANSFER: PARAMETERS screen similar to that
shown in Figure 3.94 (except the operation will show “FILE TO
DRIVE”) will be displayed, showing the filename, indicating the
operation you are about to perform and showing the current status of
the operation.
The screen will then ask you to confirm the operation. Press the [F8]
key to proceed, or the [F9] key to abort. Pressing the [F4] key may
restart an aborted transfer or one that failed. To select or enter a
different filename, press the [F7] key.
The parameter file stored on the flash card is in a DOS file format.
This parameter file can be created off-line on a PC using any ASCII
text editor and then written to the memory card via a PCMCIA Card
Drive.
a) First Line:
– a revision number followed by a semi-colon (;). Number is
not important.
– the date followed by a semi-colon, i.e. 01/01/1996. Date is
not important.
– the time followed by a semi-colon, i.e. 12:01:01. Time is not
important.
b) Remaining Lines:
– each line contains one parameter. The line consists of the
linear parameter number followed by a semi-colon, and the
parameter value followed by a semi-colon. i.e.
1;0;
2;0;
5;2;
Loading Language Modules In order to use a language in the operator interface, it must first be
loaded into the operator interface from the flash card.
From the TRANSFER screen, press the [F5] key. The operator
interface will enter the DIRECTORY screen, from which an existing
language module filename can be selected or entered, Figure 3.95.
Refer to the sections entitled “Select a filename” and “Enter a
filename”. (If nothing happens then you have not gained the required
access to modify the flash memory. Exit to the TRANSFER screen
and refer to the section entitled Enter/Modify an Access Level to
gain access).
The screen will then ask you to confirm the operation. Press the [F8]
key to proceed, or the [F9] key to abort. If an attempt to download a
language module that already exists is made, the transfer will fail.
Pressing the [F5] key may restart an aborted download or one that
failed. To select or enter a different filename, press the [F7] key.
System Programming The firmware for the complete drive system may be updated via
serial port #2 on the Customer Interface Board. Pressing the [F9]
key from the transfer screen will place the drive system into
download mode.
Advanced Screen Operations A number of advanced functions have been incorporated into the
operator interface. These operations are not required to operate the
drive. They are meant as service tools for trained technicians and
have been included here only for completeness.
All operations are accessed via a two key sequence.
Communications Statistics
The screen, depicted in Figure 3.98 shows statistics involving the
serial communications between the operator interface and the drive
as well as the contents of the transmit and receive buffers. It is
called from any screen (except the PRINTER screen), by pressing
the [F10] key and the [cursor down] key at the same time.
Protocol Analyzer
The protocol analyzer is accessed from the COMMUNICATIONS
screen by pressing the [F7] key. The screen shows the data and the
relationship of the data exchanged between the operator interface and
the drive board. This data can be displayed in either one of two
formats:
– the data shown in hexadecimal (Figure 3.99 )
– the data shown as a mixture (Figure 3.100) of:
a) control characters
b) printable ASCII characters
c) hexadecimal data.
Pressing the [F7] key changes the format of the displayed data. When
data is shown as a mixture, a particular value is displayed based on the
priority defined above, (control characters is highest).
Print Screen
The operation is initiated from any screen by pressing the [F10] key
and the [cursor right] key at the same time. The screen will clear and
a message will indicate that the screen is being printed as well as the
percentage completed. When complete, the original screen will
return.
Memory Dump
The initial screen, (Figure 3.101) shows the data segment by default.
Each screen shows the segment (in hex) which is being viewed. In
the left column is the starting address (in hex) for the row of data.
Eight bytes of data are shown in Hex, followed by the equivalent 8
ASCII characters (if relevant). Additional data within the segment is
viewed by pressing the [F8] and [F9] keys.
To change the segment and/or offset being viewed, press the [F7]
key. A display similar to Figure 3.102 will be shown. Each
successive press of the [F7] key toggles between highlighting the
segment and offset value. The highlighted value is the field that is
currently being edited.
The segment:offset address is edited via the numeric keypad and the
arrow keys. All values of [0...9] can be entered directly via the
numeric keypad. To enter a value of [A...F], the [cursor up] and
[cursor down] keys must be used to cycle through the possible
values. Note that the value [0...9] can also be entered via this
method. Once a digit has been entered via the arrow keys, it must be
accepted by means of the [cursor right] key.
The value may be edited via the [cursor left] key, which acts as a
backspace to remove the last digit entered. The value is accepted by
pressing either the [enter] or [F7] key. The edited segment:offset can
be aborted by pressing the [delete] key. To accept the segment:offset
value entered, press the [enter] key. The screen will show the data at
the entered address, as shown in Figure 3.103.
Database Download
This screen will always return to the screen from which the
download was requested.
Operator Interface Menu The screens of the operator interface are used to form a menu driven
Hierarchy Chart system to access the various operations in the drive. The hierarchy
of this menu system is shown in Figures 3.104 and 3.105.
Each of the boxes represents a screen and contains the screen name.
From a particular screen, a downward arrow shows what other
screens can be displayed and which function key is required to move
to that screen. Pressing exit [F10] on the screen will move you in the
opposite direction, returning you to the screen from which you came.
A lateral arrow shows to which screen you can move by pressing the
[enter] key while making a selection. Again pressing exit [F10] on
the screen will move you in the opposite lateral direction, returning
you to the screen from which you came.
For sake of clarity, the soft function key calls to the HELP operation
and the ALARMS screen have not been shown. It is implied that all
screens have this ability via the F1 and F6 keys respectively.
Example
To change the parameter, you must have the proper access to it. If
required press the [F8] key to display the ACCESS screen, as
represented by the symbol P. Obtain the access from this screen and
press [F10] to exit. This will return you to the MODIFY
PARAMETER screen. When you are finished with this screen, press
[F10] exit and you will be returned to the SELECT screen (via
symbols M and T). Pressing [F10] again will return you to the
DISPLAY screen (via the symbol D). Successive presses of the
[F10] key will return you to the DISPLAY GROUP and finally to
either the MAINMENU or the MESSAGE screens.
If you have changed any data in the drive, the [F10] Exit key will
bring up the MESSAGE screen. The message will remind you that
the changes made in the drive are only temporary, unless saved to
NVRAM. If you desire the data to be temporary, press [F9] 'No' and
you will continue onto the MAINMENU. If you press [F8] 'Yes', the
NVRAM screen is entered, from which you can save the data.
Exiting the NVRAM screen returns you to the MAINMENU.
Pressing the [F10] Exit key on the MESSAGE screen will return you
to the DISPLAY GROUP screen.
E H
F3-Print F2-Utility F7-Status F5-NVRAM F1-Help
Printer: Utility: Status: NVRAM: Help:
F8-Access F8-Text
P Q
Drive Text:
R
F7-List G
Select Letter: Select List:
Note: All screens have access to the F1-Help and F6-Alarm
F5-Code key. They are not shown on the diagram in order to
Select Code: T improve clarity.
Operator Interface
MainMenu:
Continued from Page 1
Q F8-Yes F9-No
A E Q P
R
F8-Setup F6-Alarms Message: F10-Access
Setup: Alarm Summary: F10-Exit Access:
Operator Interface
F7-Custom F7-Modify
T S Display Custom: D T M F10 & < Memory
Fault Masks
F10 & ^ Obtain Database
PLC
Parameters
T S M PLC Setup: S T
Note: All screens have access to the F1-Help and
Modify Parameter F8-Toggle F6-Alarm key. They are not shown on the
Setup Wizard diagram in order to improve clarity.
F8-Access
P
PF7000 Terminal Menu Tree Page 2 of 2
1. Locate the vertical card slot on the back of the operator interface.
See Figure 3.106.
CARD SLOT
COMMUNICATION CABLE
2. Position the card vertically so the key slot is facing the right side
of the operator interface.
KEY SLOT
3. Insert the card into the card slot and push until the card is firmly
seated.
WARNING Do not force the card into the slot. Forcing the
card into the slot may damage the connector
pins.
Commissioning
Drive Commissioning
Notwithstanding the safety references here, all local codes and safety
practices are to be utilized when working on this product.
2. Installation / Mounting
Initials Date
The drive is securely fastened in an upright position, on a level
surface. Seismic zones require special fastenings. Consult Factory.
Lifting Angles have been removed.
Bolts have been inserted into original location on top of drive
(leakage of cooling air).
All contactors and relays have been operated manually to verify
free movement.
4. Control Wiring
Initials Date
All low voltage wiring entering the drive is labeled, appropriate
wiring diagrams are available, and all customer interconnections
are complete.
If a tachometer is used, the tachometer must be isolated from the
motor frame. The tachometer cables should be routed in grounded
steel conduit for electrical noise suppression, and the conduit must
be grounded at junction box but left isolated from the tachometer
with an insulated bushing.
The tachometer cable shield to the drive is connected to the ground
bus at the drive end only.
All AC and DC circuits are run in separate conduits.
All wire sizes used are selected by observing all applicable safety
and CEC / NEC / IEC regulations.
Remote I/O Interface is properly configured / active.
All 3-phase control wiring is with in specified levels and has been
verified for proper rotation, UVW.
All single-phase control wiring is within specified levels and has
grounded neutrals.
NOTES OR COMMENTS:
Commissioning Preparation The following section identifies all the tools and resources required
to successfully commission a PowerFlex 7000 “A” Frame drive line-
up. In addition, it identifies how to obtain the required equipment in
the event that it is not readily available prior to commissioning the
drive. It is recommended that all items listed below be obtained prior
to attempting to commission the drive. Ensure that the contents of
this section are reviewed and that the use of the equipment described
within are understood prior to commencing commissioning of the
drive. If further support or additional information is required, contact
your local Rockwell Automation service office or Medium Voltage
Support at (519) 740-4790.
Hand Tools
• Metric and Imperial wrenches, sockets, and Hex keys
• Torque wrench
• Assortment of screw drivers
• Assortment of electrical tools (wire strippers, electrical tape,
crimpers, etc.)
Electrical Equipment
• High voltage gloves – 10 kV insulation rating (minimum)
• Approved high voltage potential tester – 10 kV rating (minimum)
• Anti-static strap
Test Equipment
• 100 MHz oscilloscope with at least 2 channels and memory
• 600-Volt (1000V rating) digital multimeter with assorted clip leads
• 5000 Volt megohmmeter
* Only required when Remote I/O has been provided with the drive.
** Only required when PLC has been provided with the drive
Technical Publications Each drive is shipped with a service binder containing all technical
publications required to commission and troubleshoot the drive line-
up. This section describes how to determine what technical
publications are required and how to obtain them in the event that the
service binder is not available at the time of commissioning or
additional information is required.
PowerFlex 7000 “A” Frame The PowerFlex 7000 “A” Frame manual will be required during
Manual drive commissioning to guide you through each commissioning
procedure. Copies of the manual or new revisions of the manual can
be requested from your local Rockwell Automation Office.
PowerFlex 7000 Parameters The PowerFlex 7000 Technical Data publication for Parameters is
also required for Commissioning and Troubleshooting. Refer to
7000-TD001_-EN-P for the latest firmware revision.
Additional Manuals Any additional manual required to configure the drive line-up can be
identified on the Electrical Schematics. The schematic titled
“General Notes” identifies all required Rockwell Automation
Publications by publication number.
Resources Required to Complete Prior to attempting to commission the drive ensure you have the
Drive Commissioning following:
• Self powered gate driver board power supply cable (supplied
with SCR rectifier drives only)
• Rockwell Automation electrical diagrams (ED) and dimensional
diagrams (DD)
• PLC program (if supplied with a PLC)
• Commissioning data sheets
• All required manuals
It is recommended that this checklist be photocopied so as that it is readily available while performing
drive commissioning.
Drive Application Study Rockwell Automation prints provided with Drives System.
Review Study the system one-line diagram and identify all sources of power.
Verify one-line diagram. Trace power cables back to their sources and
verify that equipment tag ID numbers agree with the customer’s one-
line diagram.
Inspect the process for hazards. Verify that the load is not turning due
to process (A freewheeling motor may generate voltage).
Safety Tests Lock out and tag all sources of power as per OSHA guidelines.
Test for voltage potential in cabinet with appropriate safety equipment.
Remove step down CPT or PT fuses and place them in a safe place
outside of the drive cabinet (To be done with control power off).
Check fuse and O/L values and compare them to the values specified
on the schematic diagrams.
Converter Tests Confirm that SCR and SGCT gating pulse sequence is correct for all
devices.
System Tests
Perform a system test with low voltage control/test power.
Prove all protection functions as desired.
Verify that all emergency stop devices function.
Calibrate the analog I/O.
Verify that the fans are operating properly (when applicable).
Power Tests
Measure input contactor drop out time. (2-cycle advance warning
needed if input contactor is not part of drive line-up)
Verify that line voltage is at rated value.
Verify harmonic by checking voltage and current waveforms at SCBL
board (PWM only)
Review drive program settings for operating at reduced load.
Perform an IDC Test.
Autotune
Program the drive for operation at full load.
Run drive at rated load and rated speed, and record data.
Capture waveforms of voltages and currents on the line and motor sides.
Paperwork Print DRIVE SETUP, which gives all parameters, firmware revisions,
PLC links, etc.
Complete the Commissioning Data Sheets.
Mark up modified electrical drawings.
Add revision notes to modified PLC program.
Have the customer sign sign-off document.
Provide customer with parameter settings, marked-up drawings,
commissioning package, PLC program and Field Report.
Forward PLC program, modified drawings, Commissioning Package
and Field report to Medium Voltage Product Support.
Drive Application Review In order to ensure trouble free commissioning, it is necessary for all
involved in the start-up to familiarize themselves with the drive line-
up and application. Service on the equipment should not be
performed without a clear understanding of how the equipment has
been designed to function and how the equipment has been applied.
If questions arise that have not been addressed within this manual,
they can be addressed by contacting your local GMS office or by
contacting Medium Voltage Support directly.
Dimensional Drawings
Power cable termination locations
Ground bus locations
Shipping split locations
Control and medium voltage power ratings
Drive options
Remote I/O protocol
PLC options
Motor and load specifications
Drive power component selection ratings
Heat exchanger ratings, connections
Electrical Drawings
Contactor locations (electrically)
Drive topology
General notes
Cable insulation ratings
Symbol table
Component designations
If the dimensional and electrical prints are not available, a copy can
be sent from the factory. In addition, if the drawings require changes
to accurately suit the installation and application of the system,
please fax or e-mail them to the factory so they may be revised.
Inspect Process
Lockout/Tagout
Prior to opening the doors to the drive line-up cabinets, proper lockout
tagout procedures must be performed to ensure that the working
environment is safe. In addition, the equipment must be tested for
potential prior to servicing the equipment. Even though the input to the
drive may be open, it is still possible for potential to be present.
The door to the medium voltage cabinets can only be opened after
the lockout/tagout are successfully completed.
Replacement fuses have been shipped with the drive in the event that
a fuse opens during commissioning.
Once the safety checks have been completed and the drive line-up
has been successfully isolated, inspect all cabinets in the drive line-
up for foreign material left behind during the installation. Ensure that
no tools, hardware or wiring debris have been left in the drive. Note
that some electric components used within the drive create magnetic
fields that may attract metal shavings left behind if drilling or metal
cutting was required during the installation process. Ensure that all
metal shavings have been removed from the cabinet and take care
not to get shavings into the cabinets if drilling or cutting is required
during drive installation.
Protective Barriers
Component Grounding
Verify that the drive and all its associated equipment have system
power ground cabling installed and that the cables are terminated at
both ends. Power cable shield grounds are to be terminated at both
ends. Ensure that all grounding hardware is sufficiently torqued (See
Appendix B "Torque Requirements"). All drive line-up components
(Drives, Switcher, Motors, Transformers and Reactors) must be
grounded to the installations ground grid.
The drive line-up may have been shipped in sections. Verify that the
bus splice kits provided in this circumstance are installed and
properly torqued at shipping split locations.
Power Cabling
All customer power and control wiring required for drive line-up
installation have been identified on the electrical drawings by a
dashed line (See electrical drawing – General Notes, for additional
information).
Verify that all cables are terminated on each end and are sufficiently
torqued (see Appendix B "Torque Requirements").
Verify that the cable installed meets the recommended power rating
outlined in the electrical drawings and installation section of the
manual. Ensure that the cable terminations are stress coned if
required.
Control Wiring
Ensure factory jumpers installed and marked with notes “to remove
if remote equipment installed” have been removed.
Perform a tug test on all control cables to ensure that they are
securely fastened, and check each plug and connector to ensure it is
properly seated in its socket.
Service Data This section of the commissioning chapter has been included in this
manual so that all of the system nameplate data and variable set
points can be captured as commissioned.
These data sheets will be archived at the factory for future reference.
Customer Information
COMPANY
ADDRESS
SERVICE CONTACT
Control Cell
MAX VOLTS Hz
Power Cell
UNIT SERIES Hz BIL (kV) CURENT (Amps) RECTIFIER TYPE
VOLTS Hz KVAR
VOLTS Hz KVAR
DC Link
MANUFACTURER SERIAL NO. MODEL
Input Magnetics
CONFIGURATION: MANUFACTURER MODEL NO. SERIAL NO.
LINE ISOLATION
REACTOR T TRANSFORMER T
KVA / CURRENT TEMP. RISE IMPEDANCE
VOLTAGE:
PRIMARY: SECONDARY:
Miscellaneous Information
Auxiliary Cooling Blower Motor (if any)
HP/KW: VOLTS: PHASE:
FLC: RPM: S.F.:
MANUFACTURER: MODEL: FRAME SIZE:
Drives Source of Control Power
LIGHTING PANEL OTHERS:
UPS:
NUMBER: (SPECIFY)
Environmental conditions
OTHERS:
AIR CONDITIONED T FAN FORCED AIR T (SPECIFY)
Other Pertinent Information
DCB M 80190-239-
CIB 80190-319-
UPS ---
PRINTER ---
X PV Firmware is located on a sticker on the back of the unit; PV Software is located on the main display screen.
Y The drive can have more than one of this circuit board.
DCB M 80190-239-
CIB 80190-319-
SGCT -- ---
SCR -- ---
PS1 Y
80026-172- ---
[AC/DC Converter]
PS2
80026-173- ---
[DC/DC Converter]
PS4
80026-096- ---
[24V DC Power supply]
X PV Firmware is located on a sticker on the back of the unit; PV Software is located on the main display screen.
Y The drive can have more than one of this circuit board.
Control Power Off Tests The following checks listed in this section of the chapter should be
performed prior to applying control power to the drive. It is
recommended that these checks be completed in the sequence that
they have been presented in this chapter.
Interlocking
Grease marks
from dead bolt pins Adjust dead bolt counterpart
so that grease marks from
pins hit here.
1. Lock out and isolate the drive from medium voltage. Verify with
a hot stick that there is no medium voltage present.
3. Open the doors of the cabinet and inspect the key assembly.
Place high visibility grease on the pins of the dead-bolt
counterpart. The factory recommends using yellow torque
sealant, however if it is unavailable almost any grease will do.
(See Figure 4.1)
Place grease on
dead bolt pins here.
4. Bolt the cabinet door closed so the pins on the dead bolt
counterpart make contact with the dead bolt assembly. Doing so
should leave two marks of torque sealant or grease on the
assembly where the pins made contact (See Figure 4.1 – Dead
bolt assembly).
6. Clean the torque seal/grease from the key interlock once finished
aligning the counterpart.
Once properly aligned, the key should turn freely when the cabinet
door is fully bolted shut. If the key does not function when the door
is tightly bolted closed, adjustments will have to be made to the
depth of the counterpart. This can be done by adding shims on the
landing plate where the counterpart is mounted.
Resistance Checks Prior to applying control power to the drive, power semiconductor
and snubber circuit resistance measurements must be taken. Doing so
will ensure that no damage has occurred to the converter section
during shipment. The instructions provided below detail how to test
the following components:
SGCT Testing
Measured Resistance
SGCT Resistance Measurement
Inverter Rectifier (PWM only)
SGCT Anode-Cathode Resistance __________ – __________ kΩ __________ – __________ kΩ
(Heatsink to heatsink) (Lowest) (Highest) (Lowest) (Highest)
Snubber Resistance __________ – __________ Ω __________ – __________ Ω
(Test Point – Heatsink above) (Lowest) (Highest) (Lowest) (Highest)
Snubber Capacitance __________ – __________ µF __________ – __________ µF
(Test Point – Heatsink on Right) (Lowest) (Highest) (Lowest) (Highest)
Measure resistance
between heatsink
and test point.
Measure capacitance
between heatsink
and test point.
SCR Testing
The following steps outline how to verify SCR semiconductors and
all associated snubber components. A quick reference to the
expected resistance and capacitance values as well as a simple
schematic diagram is located in below:
Sharing Resistance
To Gate
Snubber Capacitor Driver Board
Snubber Resistance
Testpoint
Heatsink Heatsink
An SCR that has failed from anode to cathode will commonly produce
a resistance value of 0 for a shorted device or ∞ Ω for an opened
device. Unlike the SGCT, it is highly irregular for an SCR to have a
partially shorted device. If an SCR is found to be out of tolerance,
refer to Chapter 6 – Component Definition and Maintenance for
detailed instructions on how to replace the SCR assembly.
Sharing Resistance
To Gate
Snubber Capacitor Driver Board
Snubber Resistance
Testpoint
Heatsink Heatsink
Sharing Resistance
To Gate
Snubber Capacitor Driver Board
Snubber Resistance
Testpoint
Heatsink Heatsink
Control Power Tests Prior to energizing the drive, verify that the control power being
fed into the input breakers are rated as designated on the
electrical diagram.
phase CONVERTER
+12V - REM I/O
+15V - TACH
Grounded
neutral +24V - PRINT,I/O
CB1
120 V Single phase 20V
AC/DC ISOLATED
(Customer supplied
converter GATE DRIVER
or off CPT in input 20V
56V POWER SUPPLY 6
starter section)
1500W
C hold-up
Fan
4
3phase
(Fed from AC DC
Medium voltage) FAIL FAIL
Three phase voltage for the “A” frame cooling fan comes from the
medium voltage feed on the load side of the input contactor. On
isolation transformer drives, the fan power is tapped off the
transformer secondary. On line reactor drives, the fan power is
supplied by a separate medium voltage/low voltage transformer.
This means you will not be able to verify the fan voltage until the
medium voltage is applied later in commissioning.
Every PowerFlex 7000 “A” Frame drive will be supplied with one
AC/DC converter.
Ensure the output of the supply is 56V DC. Refer to the Component
Definition and Maintenance section (Chapter 6) if adjustment is
necessary.
Control signals
Earth
Line
Neutral
TOP DC outputs
VIEW
FRONT
VIEW
If any values are out of the expected range, a bad DC/DC converter
is suspect. For additional information on how to troubleshoot the
DC/DC converter, refer to the troubleshooting section of the manual
(Chapter 7).
M4 (P.H.M.S.) and
nylon shoulder washer
Mounting Plate
Black Insulation
Part ID Label
DC/DC
Power Supply
DC Power
good indicator light VIEW “2”
M6 (H.H.T.R.S.)
VIEW “1”
Inverter Modules
Isolated
Gate Drive
Power
Supplies
(IGDPS)
Transient
Suppression
Network
Transient
Suppression
Network Fuses
Rectifier
Modules
Inverter Modules
Transient
Suppression
Network
Transient Suppression
Network Fuses
Rectifier Modules
Inverter Modules
Isolated
Gate Drive
Power
Supplies
(IGDPS)
Transient
Suppression
Network
Transient
Suppression
Network Fuses
Board LEDs
One operational green LED on each of the 6 outputs, visible from the
input ends of the unit that detects failed 20V output.
There may be more than one IGDPS. Record voltages for all of them.
Gating Tests Once the drive converters have been tested without Medium Voltage
and all the power supply output values have been verified, it is
necessary to test the SCRs and SGCTs under low voltage control
power.
If the results of the tests are not as described in the section below,
refer to Chapter 6 – Component Definition and Maintenance, for
detailed information on how to troubleshoot problems in the
converter section of the drive.
Some drive status I/O will be active while performing tests in Gating
Test Mode. If the drive I/O is monitored remotely, process control
should be notified in advance to avoid confusion.
In normal operation, the SCR firing cards derive their power from a
voltage divider network that steps down the medium voltage to 20
volts maximum. As it is necessary to perform this test while isolated
from medium voltage, a secondary source of power has to be
provided to power the firing cards.
Plug the 4-pin Phoenix connector on the test cable into the DC/DC
converter terminal labeled P3. The other 3-pin connectors plug into
the SCR self powered gate drive board terminals labeled TB3 – Test
Power (See Figure 4.19 – Self-Power Gate Driver Board Test Power
Terminal).
LED
Put the drive in Gating Test Mode and the rectifier will automatically
go into Test Pattern gating mode.
LED 1 – Gate Pulse (Orange) should light up and pulsate at the
frequency that the device is firing. All the other LEDs will light up
as the firmware sends a gating signal to every SCR.
The Gating Test fires the individual devices one at a time, in what is
described as a Z-pattern. Basically, for each section, the Top Left
device will turn on for 2 seconds, then turn off. The next device to
the right will turn on for 2 seconds, and the pattern will continue.
When you reach the end of the first stack of devices, the right device
in the middle stack down will fire and the pattern continues right to
left until the end of the middle stack is reached. Then the left device
is the bottom stack will fire and the pattern will continue to the last
device, where it will then return to the top. This is a test to show that
the correct fiber optic cables are going to the corresponding devices.
Normal gating test mode should not be attempted for SCR rectifiers
as the test power from the power supply to the SPGD boards through
the wiring harness does not have sufficient current to drive all of the
boards at once.
Unlike the SCR Self-powered gate Driver Board, the SGCT has an
integrated firing circuit mounted on the device. The power for this
circuit is derived from the SGCT Power Supplies (IGDPS), and
preliminary observations are possible by monitoring the healthy
lights on the firing circuit without putting the drive into gating test
mode. There are 4 LEDs on the firing card. The following diagram
illustrates the location of the LEDs:
SGCT SGCT
LED 4 (Green)
LED 3 (Green)
LED 2 (Yellow)
LED 1 (Red)
System Test Prior to applying medium voltage, it is necessary to verify the entire
low voltage control circuit to ensure the drive operates as desired.
Failure to perform this test may result in damage to the drive or
process in the event that the control does not operate as expected. This
section of the manual provides instruction for the following five tests:
• System Test Mode
• Start/Stop Contactor Control
• Status Indicators
• Analog I/O
• Configurable Alarms
Drive status I/O will be active while performing tests in System Test
Mode. If the drive I/O is monitored remotely, process control should
be notified in advance to avoid confusion.
Once the drive is in System Test mode, ensure that the stop/start
circuit functions as desired. It may be necessary to study the
electrical schematic drawings, prior to performing this test, in order
to understand the control circuit.
Start the drive in local control while observing the system vacuum
contactors or customer supplied circuit breakers. If troubleshooting is
required in Rockwell Automation medium voltage switchgear,
additional information is available in the following publications:
• Publication 1500-UM055_-EN-P, Medium Voltage Controller,
Bulletin 1512B, Two-High Cabinet, 400 Amp • User Manual
• Publication 1503-IN050_-EN-P, OEM Starter Frame and
Components • Installation Manual
• Publication 1502-UM050_-EN-P, Medium Voltage Contactor,
Bulletin 1502, 400 Amp (Series D) • User Manual
• Publication 1502-UM052_-EN-P, Medium Voltage Contactor,
Bulletin 1502, 400 Amp (Series E) • User Manual
• Publication 1502-UM051_-EN-P, Medium Voltage Contactor,
Bulletin 1502, 800 Amp • User Manual
Start the drive again and verify that all emergency stops installed in
the system function as desired. Ensure that all electrical interlocks
installed in the system function as desired. Make any necessary
control wiring modifications at this time and re-test the system if
necessary.
Status Indicators
Analog I/O
Analog Inputs
• Analog Command Input Scaling
Example:
The customer 4-20mA speed input is coming to the Current Loop
Receiver on the Customer Interface Board, and they want the
maximum input to represent 60 Hz.
Analog Outputs
Note: There are certain parameters whose minimum value is a negative number. In that
case, the minimum value of the parameter (-10V) is scaled to 0V output and the
maximum value is scaled to 10V output.
The analog outputs from the customer interface boards are stated as 0
to 10 volts, but in actual fact their outputs are typically 0.025 to 9.8 or
9.9 V. This is due to the rails being loaded down by an attached
speed potentiometer or signal conditioner impedance. Incorporated
signal conditioners usually have 0 to 10-volt inputs and 4 to 20 mA
outputs. An additional error is incorporated in the signal conditioners,
so if they are calibrated for 0 to 10 volts input, there will not be
exactly 4 to 20 mA out.
Configurable Alarms
The external faults can be tested by lifting the wires to all external
warning / fault inputs while running in system test mode. These
wires are terminated at the external I/O boards. Opening the circuit at
any point will verify the external fault’s configuration and
functionality. However, it is preferable to actually force the trips
from the source. If that is not possible, then an acceptable alternative
is to lift the wire at the protective device.
Application of Medium Voltage Before running the drive on Medium Voltage, it is a good idea to set
up the diagnostic trending feature to capture any information in the
event of a fault during commissioning. REMEMBER TO RESET
THE TRENDING BEFORE LEAVING THE DRIVE IN
PRODUCTION.
The length of the trend buffer can be set to 100 or 1000 samples.
From the main menu, press the Diagnostics Key (Diags [F9]). This
key enters the user into the Diagnostics Menu. The Options within
the Diagnostics Menu are listed as follows:
RE-ARM
D_SETUP
VIEW
Re-Arm
The re-arm function clears the memory buffer, which contains the
data stored from the previous trend. It is necessary to reset the
trending feature in order for a second trigger to occur, unless you
have continuous trigger enabled.
Diagnostic Setup
Post The percentage of the list which will occur after the
trigger point. Any value between 0 and 100% may be
used.
Cond Defines the Condition that will cause the trigger. The
possible options are:
= Equal to + Boolean OR
N= Not Equal to N+ Boolean NOR
> Greater than & Boolean AND
< Less than N& Boolean NAND
View
The view feature is used to observe the samples recorded during the
last diagnostic trend.
The sample rate is to be set at 0 msec. This will default to the fastest
sample rate. 20% of the samples should be recorded after the trigger.
The single trigger should occur when any fault occurs.
The next test required to test phase rotation requires that medium
voltage be applied to the drive input. Ensure that the drive is
thoroughly inspected for debris and tools prior to energizing the
drive. Furthermore, ensure that all protective barriers have been
re-installed before continuing. Ensure that you have taken the drive
out of System Test mode and have returned to Normal operating
mode.
All of these test points can be measured to either the Analog Ground
on the board or the TE ground in the low voltage section. You can
use Vab1-Out as your reference (trigger on this waveform) and
verify all the other test points using the table above. It is easier to
use zero crossings on your oscilloscope as the reference points when
checking the phase shifts.
2>
V ABX-OUT
1>
V BCX-OUT
1) Ref A: 5 Volt 2 ms
2) Ref B: 5 Volt 2 ms
DC Current Test The following test will assist in verifying the isolation transformer
phasing, as well as verifying DC Link connections. It involves
putting the drive in DC Current Test and monitoring variable Alpha
Line and IDCP test point while increasing the DC current through
the drive rectifier. The following instructions detail how to run DC
current test:
Press the start button and the drive should start running, pumping 0.1 pu (10%) of rated
current through the DC link. Alpha Line should be approximately 90°-92°.
The Idc waveform can be observed from TP68 (IDCP) on the SCB-L. There are 2 IDCP test
points with TP68 being the unfiltered version. The test point should show 6 ripples per cycle
for a 6-pulse drive. The waveform should have an offset of 0.5V for each 0.1pu of Idc Test
Command. The waveform should also never have any of the low points between ripples go
to 0V. This would indicate a problem with the DC Link cabling. See the troubleshooting
section for sample waveforms.
Tuning Procedure The PowerFlex 7000 “A” Frame medium voltage drive must be
tuned to the motor and load to which it is connected. There are six
drive functions that require tuning. These are listed below in the
order in which they are usually performed:
1. Commutation Inductance
2. Current Regulator
3. Motor stator resistance
4. Motor leakage inductance
5. Flux Regulator
6. Speed Regulator
The first four functions can be tuned with the motor stationary, but
the tuning of the flux and speed regulators requires the motor to rotate.
1. Commutation Inductance
(Required for all drives with 3.004 firmware or later. On earlier
revisions, it is required only for 6-pulse SCR drives.
The commutation inductance is used in the hardware reconstruction
of the line voltage to compensate for commutation notches. It is also
used in the calculation of the line converter retard limit to ensure
proper operation under all conditions of line voltage and load current
when regenerating. If the commutation inductance parameter is not
correctly adjusted, the resulting distortion in the reconstructed line
voltage may cause line synchronization faults.
5. Start the drive. The dc link current will rise to 0.4 pu.
Commutation notches will appear in the unfiltered line voltage
VAB1-OUT as shown in the figure. Some distortion will appear
in the reconstructed voltage FAB1 around the zero crossings.
7. Record the values of the parameters "V line average", and "Idc
reference” in “Current control”
10. Set parameter "Idc command test" to 0.800 pu. The dc current
will increase and the commutation notches will become much
larger.
13. Stop the drive. Set parameters “Operating mode” to normal and
"Idc command test" to zero.
2. Current Regulator
The tuning of the current regulator is controlled by three parameters
– two in the “Current Control" group, and one in the “Drive
Hardware” group:
1. “Curreg bandwidth”
2. "T dc link"
3. "L dc link”
The current regulator bandwidth is set back to its normal value and
parameter "Autotune select" is set to Off. Parameter "Autotune Tdc"
indicates the results of the test. If the test is successful, parameter "T dc
link" in "Current Control" is set equal to "Autotune Tdc". If the test
fails, then parameter "T dc link" is not changed and a warning is issued
indicating the cause of the failure:
7. Start the drive. The dc link current will rise to 0.4 pu.
10. Adjust parameter "T dc link" until the current feedback rises to
about 63% of its final value in 10 ms as shown in the figure. The
overshoot should now be quite small. Increasing “T dc link“
causes the rise time to increase. Since the desired step response
is slightly underdamped, “T dc link“ should not be increased
beyond the value at which the overshoot disappears.
12. Set parameter "Idc ref step" to zero. The dc link current will
return to a steady level of 0.4 pu.
13. Stop the drive. Set parameters Operating Mode to Normal, and
Idc Command Test to 0.
3. Stator Resistance
The motor current then jumps up to approximately 0.10 pu for less than
a second and the drive shuts off. This test produces a small amount of
motor torque and some rotation may occur.
4. Leakage Inductance
1. The motor is much larger than the drive and the motor
nameplate parameters do not correspond to the actual motor
ratings. In this case, the measured leakage inductance is
probably correct and parameter "L total leakage" should
manually be set equal to "Autotune Ls".
5. Flux Regulator
The other aspect of flux control is the variation of motor flux with
speed. This is determined by two parameters:
1. Base speed in "Flux Control"
2. Flux command base speed in "Flux Command"
In most applications, the motor runs at constant flux below rated speed
and constant voltage above rated speed. The motor flux is normally set
to a level that provides rated voltage at rated speed and full load. The
flux level required to achieve this is a function of the motor parameters.
The flux regulator Autotuning determines a value of rotor flux that
should provide rated motor voltage at full load and rated speed, and sets
the flux command parameter to this value.
The flux regulator is tuned with the motor running at constant speed
using the following procedure:
1. Ensure that parameters "Rated motor rpm" in "Motor Rating" and
"L total leakage" in "Motor Model" are set to the correct value.
2. Set parameter "Autotune select" in "Autotuning" to Flux Reg.
3. Start the drive. The motor accelerates normally up to the speed
specified by parameter "Autotune spd cmd". The motor
magnetizing inductance is calculated from the measured current
and flux feedback and parameter "Autotune Lm" is set to this
value. The flux command is then set to a value that should produce
rated voltage at rated speed and load. The resulting change in the
flux level may cause the magnetizing inductance to change. This
process is repeated until the magnetizing inductance and flux
commands stabilise. The drive then performs a normal stop.
L magnetizing
T rotor =
Rated slip in rad/sec
Where,
(synchronous speed in rpm – rated speed in rpm)
Rated slip in rads/sec = 2πf X
Synchronous speed in rpm
Set the parameter "T rotor" in "Motor Model" to the calculated value.
Before the flux regulator can be tuned, the analog output for the field
current reference must be set up.
2. Set the analog output scale parameter (e.g. Analog CIB Port 1
Scale) in “Analog Parameters” to:
4. Start the field supply and confirm that the field current goes to its
maximum value. If necessary, adjust the field supply to achieve a
field current slightly above rated.
The other aspect of flux control is the variation of motor flux with
speed. This is determined by two parameters:
1. Base speed in “Flux Control”
2. Flux Command Base Speed in "Flux Command"
In most applications, the motor runs at constant flux below rated speed
and constant voltage above rated speed. The motor flux is normally set
to a level that provides rated voltage at rated speed and full load. The
flux level required to achieve this is a function of the motor parameters.
The flux regulator autotuning determines a value of rotor flux that
should provide rated motor voltage at full load and rated speed and sets
the flux command parameter to this value.
The flux regulator is tuned with the motor running at constant speed
using the following procedure:
1. Ensure that the analog reference for the field current has been set
up as described previously, and that parameter “L total leakage”
has been set to the correct value.
4. The field current reference is then held constant and the response
of the flux to changes in stator magnetizing current is measured
by stepping “Ix command” up and down at regular intervals.
The size of the step in the stator current is specified by parameter
“Autotune Isd Step”. The step response measurement takes
about 3 minutes. When the measurement is complete, the drive
performs a normal stop.
T rotor low – indicates that the calculated value of rotor time constant
is less than 0.1 seconds
T rotor high – indicates that the calculated value of rotor time constant
is greater than 5.0 seconds.
6. Speed Regulator
Reg in limit - indicates that the torque command was greater than
"Torque limit motoring" or "Torque limit braking". The measured
inertia value is invalid. Parameter "Autotune trq stp" or parameter
"Autotune spd cmd" must be set to a lower value and the test
repeated.
7. Adjust the value of parameter "Total inertia" until the speed rises
to approximately 63% of its final value in 1 second as shown in
the figure. If the response time is too fast, it indicates that “Total
inertia” is set too high and should be decreased. If the response
is too slow, then “Total inertia” is set too low and should be
increased.
9. Set parameter "Speed ref step" to zero and stop the drive.
Total inertia = total inertia of motor & load in kg-m2 X ( rated speed in rad/ sec)2
rated power in watts
or
Total inertia = 6.21 x 10-7 total inertia of motor and load in lb-ft2 X ( rated speed in rpm)2
rated power in hp
If there is a gearbox between the motor and load, the inertia of the load
must be referred to the motor side of the gearbox.
Verify the drive can reach rated speed and load. Monitor the Torque
Reference (P291) and the displayed value of the motor current. If
you are running into a torque limit the Torque Reference will be
running near the Torque Limit Motoring (P84) limit. If you are not
realizing rated motor current you may increase the Torque Limit
Motoring slightly. If increasing the Torque Limit Motoring does not
help to increase the motor amps and speed then the drive is most
likely running out of input voltage.
Monitor the V Line Average (P135), and increase the tap setting on
the drive feed if the measured value is less than 1.03 pu. It is
desirable to have V Line Average read in the 1.03 to 1.07 pu range.
Alpha Line (P327) should be greater than 15° while running at rated
speed and load, indicating how far forward the rectifier is phased.
The input voltage should be increased by tapping up the transformer.
Fill in the following table with data from the various load points. If
possible, capture the running parameters with the printer,
DriveTools, or Hyperterminal as a substitute for recording the data in
the table below. This should be forwarded with all commissioning
data back to Product Support for future reference.
Figure 4.21 – DC Current Test @ .3 pu: Idcp (1) vs. Vdc_Avg (2)
Figure 4.22 – Running Full Speed/Full Load: Line Side; Vab1_out (1) vs. Ia1_out (2)
Figure 4.23 – Running Full Speed/Full Load: Line Side; Vab1_out (1) vs. Idcp (2)
Figure 4.24 – Running Full Speed/Full Load: Motor Side; Vab1_out (1) vs. Ia3_out (2)
Figure 4.25 – Running DC Current Test Mode: .80 pu: Idcp (1) vs. Vdc_Avg (2)
Figure 4.26 – Running Full Speed, 90% Load: Line Side; Vab1_out (1) vs. Ia1_out (2)
Figure 4.27 – Running Full Speed, 90% Load: Line Side; Vab1_out (1) vs. Ia1_out (2)
Figure 4.28 – Running Full Speed, 90% Load: Line Side; Vab1_out (1) vs. Idcp (2)
Figure 4.29 – Running Full Speed, 90% Load: Motor Side; Vab1_out (1) vs. Ia3_out (2)
Capturing Data When all of the final commissioning procedures are completed and
the drive is running, it is VERY IMPORTANT TO CAPTURE ALL
THE DRIVE DATA for future reference.
The last step should be to PRINT --> DRIVE SETUP. This will
print all the parameters (regardless of the user access level), the
various firmware revisions, the exploded fault masks, the PLC links,
and the Analog configuration.
MOTOR/DRIVE
OPERATING DRIVE VARIABLES
POINT
TEST #
Alpha Inverter Rectifier
%SPEED VOLTS Speed Ref Speed Fdbk Flux Ref Torque Ref I DC Ref I DC Fdbk Alpha Line
AMPS Machine Heatsink Heatsink
/ RPM (Vline) (Hz) (Hz) (pu) (pu) (pu) (pu) (degrees)
(degrees) Temp (°C) Temp (°°C)
1 25%/___
2 50%/___
3 75%/___
4 100%/___
5 ___%/___
6 ___%/___
7 ___%/___
8 ___%/___
9 ___%/___
10 ___%/___
11 ___%/___
12 ___%/___
cap cap
Motor
Motor
voltage
Source Motor
current
Speed
Line Command
current
Machine side
Line side feedback Machine
feedback and Protection Tach
and gating
Line voltage gating Feedback
Speed
Faults Reference
Alpha Alpha
line machine
Flux angle
Line
Protection Idc Feedback Slip freq
Current Motor Speed
Control Model Stator freq Control
Faults Sync
Transfer
Flux feedback
Iy command
Ix command
Speed Command The function of Speed Command block is to select one of the 13
possible speed command inputs. Parameter Reference Select (2) in
conjunction with Local/Remote selector switch is used to define the
speed command input Speed Command In (276). When the selector
switch is in Local position, the default speed command is the Analog
Speed Potentiometer typically mounted on the LV panel. When the
selector switch is in Remote position, the parameter Reference Select
defines the source of speed command. The options available are:
3 analog inputs (Speed Pot, Remote 0-10V,
Current Loop: 4-20mA or 0-20mA)
3 Preset speed commands
6 DPI/SCANport commands
1 Preset jog speed command
The above speed commands are used when the drive is in Normal
mode of operation. However PF7000 has many special modes of
operation e.g. test modes or auto-tuning for which different speed
commands are selected. Table 5.A summarizes the speed command
during these special modes.
Speed Command (cont.) Three skip speeds Skip Speed 1(50), Skip Speed 2 (51), Skip Speed 3
(52) are provided to prevent the drive from continuously operating at
a certain speed. This feature is sometimes needed to avoid
mechanical vibrations occurring in a drive system at certain speeds.
The skip speed zone around each Skip Speed is specified by the
parameter Skip Spd Band1 (53), Skip Spd Band2 (54), Skip Spd
Band3 (55) If the desired Speed Command lies in a given skip speed
zone, the Speed Command is clamped to the lowest value in the
zone. E.g. if Skip Speed 1 is 45 Hz with Skip Spd Band1 as 1 Hz,
then the skip speed range extends from 44.5Hz to 45.5Hz. If the
desired speed command is set to 45 Hz, then the drive will avoid this
speed and run at 44.5Hz.
The final stage in processing the command is the whether the drive
has been requested to run forward or reverse. The sign is changed if
reverse rotation is selected or is set to zero if there is no run request.
Speed Reference The function of the Speed Reference block is to determine the Speed
Reference (278) from the desired Speed Command (277). PF7000
provides two options:
• S-curve
• Linear Ramp
Example
If S curve Acc1 is set for 20sec with 20% in S-curve Percent, then
the total acceleration time is increased by 0.2 x 20 = 4 seconds. The
total acceleration time will now be 24 seconds with 4 seconds in the
non-linear portion of the S-curve. Since the curve is symmetrical,
each of the segments will be of 2 seconds duration.
Ramp Speed4
(76)
Ramp Speed3
(75)
Ramp Speed2
(74)
Ramp Speed1
(73)
Speed Control The function of the speed control block is to determine the torque-
producing component (Isq) of the stator current (Is). The inputs to the
block are the Speed Reference (278) from the speed ramp and the
Stator Freq (448) and Slip Frequency (343) from the motor model. If
drive is installed with an optional tachometer, then the motor speed
is determined by counting the tach pulses.
In Sensorless mode, the drive uses Trq Command 0 (86) and Trq
Command 1 (87) for an open loop start up. At frequencies greater
than 3Hz, the drive closes the speed loop and disables the open loop
start mode. In Pulse Tach mode, the drive is always in closed loop.
The maximum torque a drive can deliver in motoring mode is
determined by Trq Lmt Motoring (84). In regenerative mode the
torque is limited to Trq Lmt Braking (85). It should be noted that at
speeds above the Base Speed (98), the motor torque capability is de-
rated and varies in inverse proportion to the speed.
Flux Control The function of the flux control block (Figure 5.5) is to determine the
magnetizing component (Isd) of the stator current (Is) needed to
maintain the desired flux profile in the motor. The inputs are Flux
Feedback (306) and Stator Freq (448) from the motor model, Speed
Feedback (289) and Torque Reference (291) from the speed control
block and the measured voltage at the input of the bridge Vline
Bridge (696).
The flux profile in the drive is adjusted by the parameters Flx Cmd
No Load (103) and Flx Cmd Base Spd (100). Using these parameters,
Flux Reference is adjusted linearly with the desired Torque
Reference. At light loads motor flux is decreased allowing reduction
in losses while full flux is produced at rated load. The maximum flux
reference is limited to Flux Cmd Limit (623). This limit is dependent
on the input voltage Vline Bridge and the motor speed (Speed
Feedback). If the drive operates at reduced line voltage, then Flux
Reference is reduced. Also if the motor is running above the Base
Speed, the flux profile is made inversely proportional to the speed of
the motor resulting in the field weakening or the constant power
mode of operation of the drive. This is accompanied by a decrease in
the motor torque capability.
Isd Command 0
(308)
Speed Feedback Base Speed
(289) (98) EXCITATION
FLUX CURRENT
Flx Cmd Base Spd (100) Flux Isd LIMIT
REGULATOR
Reference Flux Error Command 1 1.0
+
Flx Cmd No Load (103) (305) + (307) (309) + Isd Command
(310)
Torque Reference 291) - -1.0
FLUX
LIMIT
Flux Control for Synchronous Most of the magnetization for a synchronous motor is supplied by
Motor the rotor field winding, unlike an induction motor where all of the
magnetizing current is supplied through the stator. However, control
of the motor flux through the field current is very slow because of
the large time constant of the dc field winding and the current and
voltage limitations of the field supply. To obtain sufficiently fast
response from the flux regulator the magnetizing current is split into
transient and steady state components, with the steady state
component supplied through the rotor and the transient component
through the stator.
The additions to the flux control required for synchronous machines
are shown in the block diagram (Figure 5.6). The portion of the
motor filter capacitor current supplied by the drive is then added to
determine Ix Command, which is the magnetizing component of the
dc link current command.
Parameter Icd Command Gain (107) determines how the motor filter
capacitor current is split between the motor and the drive. When this
parameter is set to its minimum value of 0.0, all the capacitor current
is supplied by the drive. The line current is higher than the motor
current and the motor operates at approximately unity power factor.
When this parameter is set to its maximum value of 1.0, the motor
supplies all the capacitor current. The line current is less than the
motor current and the motor operates at a lagging power factor with
reduced field current.
CAP CURRENT
CALCULATOR
+
L Magnetizing L Total Leakage
+ + Ix command
(130) (130) (312)
-
Motor Filter Cap LOW PASS
(128) FILTER
- L magnetizing Lmd
+ (131) (418)
Isd command (310) I Field Command (314)
Current Control The function of the current control block (Figure 5.7) is to determine
the firing angles for the converters Alpha Line (327) and Alpha
Machine (328). The inputs are the torque (Iy Command) and flux
producing (Ix Command) components of the dc link current
command from the speed control and flux control blocks
respectively, and the measured dc link current Idc Feedback (322).
DC LINK
CURRENT
Ix Command REGULATOR LIMITER
(312) Idc Error Vdc Reference
Idc Reference Vdc Error Alpha Line
(321) + (323) + (326) (327)
(332) -
Iy Command x 2+y 2 cos -1
(294) - + 1
Idc feedback
(322)
Line Converter Feedback The function of the line converter feedback block is to process (scale
and filter) the line side voltage and current feedback signals before
being sampled by the drive control software. It represents most of
the analog portion of the line side Signal Conditioning Board
(SCBL) and the Drive Control Board. The line converter Voltage
Feedback Board (VFB) provides a total of six voltage feedback
signals representing the three ac (Va1, Vb1, Vc1), two dc (Vdc+, Vdc-) and
one line side filter capacitor voltages referenced to ground. The
three line-to-ground voltages are subtracted from each other to
produce the three line to line voltages (Vab1-out, Vbc1-out, Vca1-out). These
line voltages are filtered (Vab1, Vbc1, Vca1) and sampled by software
for synchronization and protection. The two dc voltages are
subtracted to determine the line side dc link voltage (Vdc), which is
used for hardware dc link over-voltage protection. In PWM drives,
the neutral point of the line filter capacitor is measured (Vn) and used
for line side neutral over-voltage protection.
Machine Converter Feedback The function of the machine converter feedback block is to process
(scale and filter) the raw voltage and current feedback signals to the
form required by the drive control software. It represents most of the
analog portion of the machine side Signal Conditioning Board
(SCBM) and the Drive Control Board. The machine converter VFB
provides a total of six voltage feedback signals representing the three
ac (Va1, Vb1, Vc1), two dc (Vdc+, Vdc-) and one machine side filter
capacitor neutral voltage referenced to ground. The motor line to
ground voltages are subtracted from each other and filtered to
produce the three motor line to line voltages (Vab1, Vbc1, Vca1).
The motor line voltages and currents are further used to calculate the
motor flux (Fab, Fbc, Fca) using a hardware analog model. The
measured flux (Vd and Vq) is then used in the motor model block
(described in the next section) for synchronization and drive control.
Motor Model The function of the motor model block (Figure 5.8) is to determine
the rotor flux position (Flux Angle), flux feedback (Flux Feedback),
applied stator frequency (Stator Freq), slip frequency (Slip
Frequency) and motor operating variables like stator current (I
Stator), stator voltage (V Stator), torque (Torque), power (Motor
Power) and power factor (Mtr Pwr Factor).
Motor Currents
I Stator (340)
3 I sq (339) V Stator (344)
VECTOR MOTOR
ROTATOR V sd (690) OPERATING Motor Power (346)
Motor Voltages
V sq (691) VARIABLES Mtr Power Factor (692)
3 Torque (345)
Functional Description
Line/Machine Converter Except for the dc link over-current, line side dc link over-voltage and
Protection machine side dc link over voltage, the drive protection is customer
configurable in the software. Adjustable parameters specifying the
trip level and time delay are provided for each fault (see Medium
Voltage AC Drive Parameters, Publication 7000-TD001_-EN-P).
A detailed list of all the faults and warnings (alarms) is provided in
Chapter 7 (Troubleshooting).
For Class 2 faults the motor is brought to a normal stop before the
gating is disabled and the contactors opened. Typical examples of
Class2 faults are motor overload, drive overload and loss of load.
For most Warnings no action is taken and drive maintains its normal
operation. A warning could be an indication of a problem in drive
e.g. an Air Filter warning is an indication of a blocked air filter. In
addition there are a few warnings in the drive that may cause
momentary interruption in the operation of the drive e.g. Master UV,
Line Loss or Bus Transient. The action taken is similar to a Class1
fault and the normal operation is resumed once the transient
condition has disappeared. If a drive experiences Master UV or Line
Loss, then Auto Restart Dly (3) should be set to a non-zero value in
order to resume normal operation.
Power Semiconductor The PowerFlex 7000 drive tests for the failure of the power
Diagnostics semiconductors (SCRs or SGCTs) before running and while running.
The method used to detect failed devices is different for starting
(offline diagnostics) and for running (on-line diagnostics), but the
same hardware is used in both situations. The drive control receives
a feedback signal via a fiber-optic cable from each device gate
driver, which can indicate whether or not it is healthy. SCR
diagnostics are based on sensing the voltage across the device while
SGCT has smart diagnostics built in the gate driver board. The
feedback and the gating have a certain relationship when the device
is healthy or failed. This is shown in Figure 5.10. The following
section describes the diagnostics in detail. The description applies to
all 6P, 18P and PWM PowerFlex 7000 drives.
Diagnostic Diagnostic
feedback high feedback low
No gating received
1
0 LIGHT
No diagnostic feedback
1
0 NO LIGHT
Power
• Semiconductor SCR Rectifier Active Off-Line Diagnostics
Diagnostics (cont.) In the active diagnostic test, each device is gated at maximum
blocking voltage. For a healthy SCR, the feedback will normally
change from high to low when gated. However the drive will
receive a high state both before and after gating if the device is
open-circuited, there is an incomplete gating fiber-optic path or a
damaged gate driver. When this occurs the drive will issue an
Offline OC fault for the device. If the drive receives a low signal
in both states, there may be shorted device or an incomplete
feedback fiber optic. If this occurs drive will issue an Offline SC
fault for the device. Failed or open-circuited snubber connections
will shift the device blocking voltage (when not running) which
may case either fault to appear. It should be noted that during the
active diagnostics stage a dc link voltage which is close to rated
voltage will appear due to interaction with the snubber circuit.
Shortly after the drive fires an SCR it checks the feedback from the
gate driver boards. If the feedback shows that the device did not fire
the drive considers that the device may be open-circuited and starts a
timer. If the fault persists for 6 cycles, the drive generates an Online
OC fault. As with the short circuit fault, each device has its own
timer, however the delay is not adjustable.
Test Modes The PowerFlex 7000 AC drive is provided with test modes to check
the functionality of the drive during commissioning. These test
modes are selected using the parameter Operating Mode in the
Feature Select group. When Test Mode is set to the default value of
Normal, the drive is in the normal operating mode. The parameter
cannot be changed while the drive is running.
Setting Inv Gating Test to Test Pattern will fire the inverter devices
in a sequential Z pattern at a low frequency (1Hz) and is verified by
observing the LEDs on the SGCT gate driver board. Setting Inv
Gating Test to Time Pattern or Normal Gate will result in the
inverter devices firing as in normal mode of operation. The
frequency of the gating is controlled by parameter Speed Command
In (276). Setting Inv Gating Test to Off stops the inverter test gating
sequence.
To test the line converter and to tune the dc link current regulator and
the line commutating impedance, the drive Operating Mode is
selected as DC Current. In this test mode, the line converter
operates normally, but the machine converter gating is modified to
gate both the positive and negative legs in the same phase in order to
short-circuit the dc link current through the machine converter. The
short circuit current is slowly rotated among the three phases with
overlap between phases to ensure that an open circuit does not occur
during commutation. There is no current in the motor and the output
contactor (if installed in the drive) is opened). The dc current
command is set equal to the value specified by parameter Idc
Command Test (119) in the Current Control group. In this test mode
the line converter firing angle Alpha Line (327) will be close to 90
degrees. This is because it takes very small dc voltage to build
current in a shorted dc link.
Setting Operating Mode to System Test selects the system test mode.
This mode is used to test the drive as a system, including interfaces
with external devices such as programmable controllers, without
applying power to the drive or motor. The drive behaves as if it was
running normally but device gating disabled. Since the input, output,
and bypass contactors operate normally in this mode, it must be
ensured that the drive and motor are isolated from medium voltage.
If the drive detects medium voltage in this test mode, a fault MV in
SystemTest is issued and the input contactor is opened.
Setting Operating Mode to Open Circuit, selects the open circuit test
mode. This mode is used to test the drives at rated output voltage
and frequency without connecting it to a motor. In open circuit test
mode, ac current sufficient to produce rated voltage at the drive
output is forced through the output filter capacitors. When the drive
is started in this mode, it ramps up to rated frequency and
synchronizes its output voltage with the line voltage. The current
reference is set to a value that will produce voltage at the drive
output set by the parameter Flx Cmd Base Spd (100).
This feature is available in firmware release 4.001 and higher for drives running induction
motors only.
Flying Start (Induction Motor) Using this feature, the PowerFlex 7000 AC drive is capable of
restarting a motor that is not stationary but is already rotating. In
normal operation, the output of the drive is synchronized with the
motor flux, which is derived from the stator voltage and current
feedback. If there is no motor current, then whether the motor is
rotating or stationary, it does not generate any significant voltage and
it is not possible to determine the stator frequency. If there is no
detectable stator voltage, the drive assumes that the motor is
stationary, because this is the most likely case. Therefore, when the
drive is started, the frequency starts from an initial value of zero and
ramps up until motor flux is detected. Significant flux is created in
the motor only when the slip frequency (i.e. the difference between
the applied stator frequency and rotor frequency) is small. When the
drive is started with the motor stationary, the initial slip frequency is
small and the motor flux builds up fairly quickly. But, if the motor is
already spinning, then very little flux will be induced until the stator
frequency is quite close to the rotor frequency, at which time the
motor flux will suddenly rise to a level sufficient for the drive to
detect and synchronize to. If the drive reaches the commanded speed
without detecting any motor flux, then it will trip on a motor stall
fault. There are four possible causes of a motor stall when starting:
1. The motor has pulled out and stalled during starting due to
insufficient torque. The remedy for this is to increase the value
of some or all of the parameters Trq Command 0, Trq Command 1
and Accel Time 1.
2. The motor was already rotating but the flying start failed because
the drive passed through the low slip region too quickly to allow
the motor flux to build up. The solution to this problem is to
increase the value of parameter Accel Time 1. Most medium
voltage motors have a rotor time constant in the range of 1 to 5
seconds, and it can take a few seconds for the flux to rise to a
detectable level. Until flux is detected, the drive does not use the
normal speed ramp but continues to accelerate at the rate defined
by parameters Accel Time 1 and Ramp speed 1.
Flying Start (Synch Motor) With a synchronous motor, flying start is much quicker and more
reliable because a detectable stator voltage is produced whenever the
field is applied and the motor is rotating, even with zero stator current.
When the drive is started, rated field current is applied to the motor
but the stator current remains at zero until the end of the ramp start
delay to allow the rotor flux to build up. If the stator frequency is
greater than about 2 Hz, sufficient stator voltage is generated to
allow the drive to detect the speed and direction of the motor and
synchronize itself to the motor flux. If the flux feedback does not
reach the level specified by parameter Flux minimum (156) the drive
assumes that the motor is stationary and starts from zero frequency.
Dividing the number of tach pulses by the sampling period yields the
tach output frequency, from which the shaft speed can be calculated
using the tach pulses per revolution (ppr) specified by parameter
Tach pulse/rev (234). The tach resolution determines the minimum
motor speed that can be measured. If high starting torque or very low
speed operation is required, a high resolution such as 1024 or 2048 ppr
must be provided. Otherwise, a low resolution such as 240 or 360 ppr
is adequate.
The analog flux signal is not usable for stator frequencies less than
about 3 Hz. To control flux and torque at low speeds, the PowerFlex
7000 drive switches to current model based on indirect vector control.
With indirect control, the position of the rotor flux is not directly
measured but is indirectly predicted by adding the calculated slip
angle to the measured rotor angle. The rotor angle is obtained by
integrating the output of the pulse tach (the zero position is arbitrary).
The slip frequency required to provide the desired flux and torque is
calculated by the motor model. The slip frequency is integrated to
get the slip angle and added to the measured rotor angle to obtain the
flux angle. Indirect control can be used at any speed, but its weakness
is that the calculated slip is sensitive to errors in the motor parameters.
Errors in slip frequency increase the coupling between flux and
torque which adversely affects the stability of the flux control. Since
large motors generally have lower magnetizing current and lower
slip than small motors, they are more sensitive to parameter errors
(i.e. a small error in slip produces a large error in torque and flux).
Because of its salient pole construction, the position of the rotor flux
in a synchronous machine is not arbitrary but is determined by the
physical position of the rotor. A synchronous machine therefore
requires an absolute position encoder instead of an incremental
encoder for indirect vector control. The encoder must also be aligned
with the direct axis of the rotor. To avoid having to physically align
the encoder, an offset angle specified by parameter Encoder Offset
(644) is added to the encoder output to compensate for the difference
between the encoder zero and the direct axis of the rotor. Parameter
Enc Direction (643) is provided to reverse the encoder rotation in
software if it does not match the rotation of the motor. There is no
parameter to specify the encoder resolution; it is inferred from the
number of motor poles.
Bypass contactor
PF7000
CONTROL
Bypass bus
Transfer to Bypass
Synchronous Transfer 3. When the phase error between the motor voltage and bypass
(cont.) voltage has remained less than the value specified by parameter
Sync Error Max (228) for the time interval specified by
parameter Sync Time (229) the drive activates its bp contactor
close output.
4. After a time delay specified by Sync Off Delay (227) the drive
shuts off. It is important that this parameter is set to the correct
value. This should be at least 1 cycle less than the contactor
closing time. If this time delay is set too short, the motor voltage
could drift out of phase with the bypass voltage. If the time delay
is set too long, a drive overcurrent fault may occur because the
drive is unable to control its output voltage and frequency once
the bypass contactor has closed.
Current Transformer
Hall Effect Sensor
Current Transformer
Control Power
Transformer Fuses
Fan Housing
Top Cable Entry
and Exit locations
Ground Bus
Line Terminals
Load Terminals
Integral Isolation
Transformer
Current Transformers
(CT)
(Front)
(Back)
AC Line Reactor
Figure 6.3 – Cabling Cabinet with Integral Line Reactor, with Input Starter
Low Voltage
Line Cable Compartment
Terminations
Motor Cable
Terminations
Fan Power
Transformer
Assembly
AC Line Reactor
Figure 6.4 – Cabling Cabinet with Integral Line Reactor, without Input Starter
2. Note the location of all wires and the orientation of the Hall Effect
sensor. For quick reference when checking the orientation of the
Hall Effect sensor, look for the white arrow.
Detail A Detail A
Detail B Detail B
Detail A
Hall Effect Sensor
Hall Effect Sensor See Detail B
See Detail B
Figure 6.5 – Hall Effect Sensor located within cabinet with detail
2. Note the location of all wires and the orientation of the CT. For quick
reference when checking the orientation of the CT, look for the white dot.
Detail A
Detail B
Current Transformer (CT) Current Transformers (CT)
Current Transformer (CT)
See Detail B
Inverter Modules
Transient
Suppression
Network
Transient Suppression
Network Fuses
Rectifier Modules
Converter Cabinet The converter cabinet contains three rectifier modules and three inverter
modules. Figure 6.7 shows a 3300/4160 V converter with a PWM
Rectifier.
Thermal sensors are installed on the top module of the inverter and
rectifier. The exact location depends on the drive configuration.
Voltage-Sensing Assembly The voltage-sensing assembly consists of two voltage sensing boards,
mounting plate and protective cover. Each voltage sensing assembly has
six independent channels which convert voltages up to 10800V (7.2kV @
1.5 pu) down to low voltage levels which can be used by the PowerFlex
7000 “A” Frame control logic (i.e. Signal Conditioning Board - SCB). For
drives that require the synchronous transfer option, one extra assembly is
used. This extra assembly uses a separate connector to output the transfer
voltages directly to the SCB board.
Below is a table of the input voltage ranges for each of the input terminals
on the voltage-sensing board. There are four separate inputs taps for each
of the six independent channels. This assembly has been designed to
operate at a nominal input voltage of up to 7200V with a continuous 40%
overvoltage. The output voltages are scaled to provide close to 10V peak
for a 140% input voltage at the high end of each of the voltage ranges.
Each of the channels has only four taps, thus they must be used to provide
a range of input voltages and software will be used to provide a given
amount of gain so that 140% will correspond to the maximum numerical
value of the analogue to digital converter.
MOV Suppressor
The transient suppressors used in the module are heavy-duty metal oxide
varistors or MOVs. Varistors are voltage dependent, nonlinear resistors.
They have symmetrical voltage/current characteristics similar to back-
to-back connected Zener Diodes. The varistor has very high resistance
below its voltage rating and appears as an open circuit.
The leakage current through the device would be very small in this region.
When a voltage transient occurs in which the voltage exceeds the ‘knee’
in the curve, the varistor resistance changes from its high state by several
orders of magnitude to a very low level. The voltage will be essentially
clamped for a change in current of several orders of magnitude. This can
be seen in Figure 6.9.
High Short
Resistance Circuit
Region Voltage Clamping Region Region
log scale
VOLTAGE
(VOLTS)
-8 -7 -6 -5 -4 -3 -2 -1 0 2 3 4 5
10 10 10 10 10 10 10 10 10 10 10 10 10 10
CURRENT (AMPERES) - log scale
When the MOV is clipping the voltage transient, the energy of the
transient is being absorbed by the MOV. The varistor has a limited
energy absorbing capability and generally there is not enough time for the
heat generated to be conducted out of the device. The MOV is sized
based on the steady-state voltage rating, the energy in the transient, and
the repetition rate of the transients. A critical element in the MOV
selection and protection offered is the impedance in the line supplying the
transient. This impedance will be mainly that provided by the Isolation
Transformer or the AC Line Reactor on the input of the drive. That is
why an impedance level is specified for these input devices.
MOV Fuse
In series with each of the Phase MOVs is a medium voltage fuse. As seen
in Figure 6.12, these fuses are located on the assembly. The fuses are
mounted on the assembly (on the Line Terminal Module).
The fuses provide overload protection for the conductors feeding the
suppression network (and overcurrent protection if a short circuit occurs
on the downstream side of the fuse.) These conductors will normally have
a much smaller current carrying capacity than the drive input conductors
and thus will not be protected by the drive input fuses. The fuses also
serve to isolate a failed MOV. Varistors initially fail in a short-circuited
condition. The high follow-through current will open the fuse and remove
the MOV from the circuit.
The fuses used are E-rated current limiting fuses with a high interrupting
rating. Because they are current limiting, they will limit both the
magintude and duration of fault currents. They are small dimension,
ferrule-type fuses with a fiberglass body, and mount in standard fuse clips.
Transient Suppression
Network – TSN (cont.)
Suppressor
Ground MOV
Suppressor
Phase MOV
U V W
Suppressor
Ground MOV
Suppressor
Phase MOV
Suppressor
Phase MOV
U V W
Two sizes of fuses (5 kV, 7.2 kV) are available within the Transient
Suppression Network (TSN) located inside the connection cabinet.
2. Fuses are held in a place with a fuse clip. To remove the fuse pull
firmly.
3. To replace the fuse, hold it in position and push firmly until the fuse is
seated within the fuse clip. Install fuses so that the rating is visible,
and the rivets are not against the clips.
Location of ground
Varistors
Connecting Links
Varistors
Location of 5 kV fuses
Transient Suppression
Network – TSN (cont.)
Location of ground
Connecting Links
Varistors
Varistor Replacement
Varistors are part of the Transient Suppression Network located within the
converter cabinet. The “A” Frame drive contains one varistor panel.
1. Ensure there is no power to the equipment.
All drives have six PowerCages, three rectifier modules and three inverter
modules. There are two types of rectifiers: PWM and 6-pulse SCR.
PWM type rectifiers use SGCTs as semi-conductors.
SCR type rectifiers use SCRs as semi-conductors.
The inverter module is the module that contains the SGCT power device
necessary for producing the motor voltages and currents. There are three
inverter modules in each drive; the number of SGCTs per module depends
on the voltage rating of the motor. To understand a module, a description
of a single SGCT and its peripheral equipment is all that is required.
Clamp head
Module housing Temperature
sensing board
SGCT and Snubber Circuit As with all power semi-conductor or thyristors, the SGCT must have a
snubber circuit. The snubber circuit for the SGCT is comprised of a
snubber resistor in series with a snubber capacitor.
SHARING
RESISTOR
SNUBBER SNUBBER
RESISTOR CAPACITOR
TEST
POINT
SGCT
HEAT HEAT
SINK SINK
The cooling requirements of the SGCT are achieved by placing the SGCT
between two forced air-cooled heatsinks, one heatsink on the anode and
the other heatsink on the cathode. The clamp assembly on the right hand
side of the inverter module generates these forces.
External filtered air will be directed through the slots of the heatsinks to
carry away the generated heat from the SGCTs. The door filter is
necessary to ensure the slots on the heatsinks do not get plugged.
Uniform Clamping Pressure It is very important to maintain proper pressure on the thyristors. Follow
this procedure whenever changing devices, or whenever the clamp is
loosened completely.
2. Torque the heatsink bolts to 13.5 N-m (10 ft-lb.) and then loosen each
bolt two complete turns.
3. Tighten the clamp to the proper force until the indicating washers can
just be turned by the fingers with some resistance.
4. Torque the heatsink bolts to 13.5 N-m (10 ft-lb.) starting with the
center heatsink and moving outward alternating left to right.
Checking Clamping Pressure Periodically, the clamping force in the PowerCage should be inspected.
Ensure there is no power to the equipment.
Disc Springs
Pressure Pad
If proper force (as designated on the clamp head block) is applied to the
clamping assembly, the indicating washer should just be able to rotate
with fingertip touch. The indicating washer should not rotate freely.
Some force will need to be applied with your fingertips.
Temperature Sensing Thermal sensors are located on one heatsink in the rectifier and one
heatsink in the inverter. The thermal sensors are mounted on the heatsink
with the temperature feedback circuit board.
8. Disconnect the plug that connects the thermal sensor to the circuit
board.
9. Remove the screw that attaches the thermal sensor to the heatsink.
10. Replace with the new thermal sensor and cable assembly.
11. Note there is a small voltage difference between the thermal sensor
and its heatsink. For proper function, it is essential to mount the small
insulating pad between the thermal sensor and the heatsink and the
insulating bushing between the thermal sensor mounting screw and
the thermal sensor (see Figure 6.20).
12. Replacement of the heatsink with the new thermal sensor is in the
reverse order of removal.
13. Follow procedure “Uniform Clamping Pressure” to ensure the
heatsinks are clamped to a uniform pressure.
Insulating bushing
Mounting pad
Temperature feedfack
circuit board
Mounting screw
Thermal sensor
and cable assembly
Symmetrical Gate The Symmetrical Gate Commutated Thyristor (SGCT or device) with
Commutated Thyristor attached circuit board is located within the PowerCage assembly.
Replacement
SGCTs must be replaced in matched sets:
• 4160V systems use sets of 2
• 6600V systems use sets of 3
The SGCT and associated control board are a single component. There
will never be a time when the device or the circuit board will be changed
individually. There are 4 LEDs on the SGCT, and the following table
describes their functions:
10. Slide the SGCT into place until the mounting brackets contact the
surface of the heatsink.
13. Connect the power cable and fiber optic cables (ensure the bend
radius is not exceeded).
Silicon Controlled Rectifier The method for replacing the Silicon Controlled Rectifier (SCR) is almost
and SCR Self-Powered Gate identical to that of the SGCT. The one exception is that the SCR and
circuit board can be replaced independently of one another.
Driver Board Replacement
1. Ensure there is no power to the equipment.
5. Loosen the 2 captive screws with a long Phillips screwdriver until the
circuit board is free. It may be necessary to adjust the position of the
heatsinks to allow free movement of the SCR.
8. Loosen the tie wrap holding the G-C wire in place, and remove the
device from the assembly.
9. Install the new device in the same position and using the same
orientation as the original SCR, and firmly secure the G-C wires with
the same tie wrap.
10. Connect the Gate-Cathode phoenix connector to the Gate Driver
Board.
11. Apply a thin layer of Electrical Joint Compound ( Alcoa EJC No.2 or
approved equivalent ) to the contact faces of the new SCRs to be
installed. The recommended procedure is to apply the compound to
the pole faces using a small brush and then gently wiping the pole
face with an industrial wipe so that a thin film remains. Examine the
pole face before proceeding to ensure that no brush bristles remain.
13. Pull the 4 plastic clips that secure the SCR SPGD Board to the glastic
assembly. Retain the hardware.
14. Install the new SCR SPGD Board in the assembly with the 4 plastic clips
and use the screws to secure the board to the metal bracket.
15. Clean the heatsink with a soft cloth and rubbing alcohol.
16. Slide the SCR and SCRGD Board back into place until the mounting
bracket makes contact with the heatsink. Use the Phillips screwdriver
to tighten the assembly to the heatsink.
18. Connect the control power cable and the fiber optic cables, ensuring
that the bend radius is not exceeded.
Heatsink Replacement The PowerFlex drive uses an aluminum or copper heatsink, depending on
the drive rating.
Heatsink
2. Remove the load from the clamp head per the procedure on page
6-19.
3. Completely remove the SGCT or SCR from the heatsink that is being
replaced per the instructions on pages 6-22 to 6-27.
4. There are 2 bolts that secure the heatsink to the PowerCage. They are
13-mm bolts, and should be removed using several extenders to get
the socket wrench out past all the sensitive gate driver boards.
5. Loosen the two bolts and carefully remove the heatsink from the
PowerCage.
7. Replace the SGCT or SCR per the instructions on pages 6-22 to 6-27.
PowerCage Gasket To ensure all air movement is through the slots of the heatsinks, all
possible air leaks have been sealed with a rubber gasket. This gasket is
placed between the surface of the PowerCage and heatsink module. It is
necessary to have the gasket in place to ensure proper cooling of the
SGCTs or SCRs is maintained.
Power connection
Resistors
Gasket
PowerCage housing
Power connection
The gaskets do not normally require replacement, but in the event that
they become damaged, they may require replacement.
Pull all the material possible off by hand. Scrape off as much material as
possible with a sharp knife. Do not score the PowerCage with the knife.
All the material will not come off! Remove as much as possible to leave
an even surface to bond to. Clean away any loose pieces of gasket. Then
proceed with installation of the gasket.
The PowerCage must be cleaned with Spray Nine (another all purpose
household cleaner could be used). Do not spray onto the PowerCage as it
promotes electrical tracking. Apply the cleaner to a paper towel and wipe
the surface of the PowerCage where the gasket will be applied. Liberally
spray the surface with distilled water. Wipe the surface with a clean paper
towel.
Position the gaskets ensuring the gasket is oriented correctly. The gasket
should be centered over the opening for the heatsinks with the narrow end
positioned closest to the test points. The porous surface of the gasket
should be applied to the PowerCage. The gasket will bond almost
immediately. Apply some pressure to the gasket for 15-30 seconds.
After all the gaskets have been placed check to see that the gasket has
bonded properly. Repair any loose areas.
3. Remove the 13-mm bolts in the two flanges that connect the heatsink
to the PowerCage, then remove the heatsink from the PowerCage.
This will reduce the weight of the PowerCage making it easier to
handle.
4. To detach the PowerCage itself, the bolts on the outer flange need to
be removed. Carefully lift the PowerCage down, placing the forward
face down. Do not overtorque these bolts when replacing the
PowerCage.
Snubber Resistors Snubber resistors are connected in series with the snubber capacitors.
Together they form a simple RC snubber that is connected across each
thyristor (SCR or SGCT). The purpose of the snubber circuit is to reduce
the dv/dt stress on the thyristors and to reduce the switching losses. The
snubber resistors are connected as sets of various wire-wound resistors
connected in parallel. The number of resistors in parallel depends on the
type of the thyristor and the configuration and frame size of the drive.
Snubber and Sharing The snubber and sharing resistors are part of the resistor assembly located
Resistor Replacement behind the PowerCage.
1. Remove the PowerCage as outlined in “PowerCage Removal”.
2. Note the connection of the leads for correct replacement.
3. Detach the leads located on the bottom of the resistor assembly.
Snubber Capacitor
4. Remove the push nuts on the end of the retaining rod. Pinch the clip
together and pull off. Pull out the retaining rod.
Retaining rod
Extract
retaining rod.
Push Nut
Retaining Rod
Resistor Bank
Sharing Resistors Sharing resistors provide equal sharing of the voltage when matched
devices are used in series. SGCT PowerCages for 2400V systems do not
need matched devices and have no sharing resistor.
SGCT PowerCages
Rsh
Cs-2 Rsn-1
Anode
Cathode
Rsn-2
Rsh
Cs-1
Anode
Rsn-1
Cs-2
Cathode
SCR PowerCages
The snubber circuit is shown in Figure 6.31. Disconnect the 2-pole plug
to the Gate Driver Board that is marked TB1 on the circuit board. Measure
the resistance from the point of the plug that connects to the point labeled
V.SENSE on the Gate Driver Board to the anode side heatsink. A value
of 80 kΩ indicates a good sharing resistor.
Rsn-2
Cs-1
Rsh
Rsn-1 Cs-2
TP
Cathode
To gate driver board
Anode
Rsn-2
Rsh
Cs-1
Rsn-1
Cathode
Anode
Cs-2 TP
Resistance Measurements
The anode-cathode resistance check will measure the parallel combination
of the sharing resistor and SGCT anode-cathode resistance. The sharing
resistor has a resistance much lower than a good SGCT, thus the
measurement will be slightly less than the resistance of the sharing
resistor. A measurement between 60 kΩ and 75 kΩ indicates the SGCT is
in good condition and that wiring to the SGCT is correct. If the SGCT
fails, it will be in the shorted mode, 0 Ω. The anode to cathode resistance
check will be 0 Ω.
The SPGDB receives its command from the drive processor, via a light
signal, which is transmitted through a fiber optic cable. The power source
for the SPGDB is from the snubber network of the SCR, a patent pending
design of Rockwell Automation. This unique design gives the SPGDB
the ability to conserve the amount of energy that it supplies to the SCR.
This reduces the amount of energy required by the drive to operate, thus
making the drive more efficient.
Also, this board will determine the health of the SCR. It has the hardware
necessary to diagnose the condition of the SCR. This status is relayed to
the processor via a fail-safe light signal transmitted through a fiber optic
cable.
Board Calibration
TP1 – SCR gate output (attach oscilloscope between TP1 and TP2 to see
gating pulses)
TP2 – SCR cathode output
TP3 – Common reference point for all other test point measurements,
except for TP1, which uses TP2 as its reference point
TP4 – The positive 20 V rail used for the SPGDB operation
TP5 – The positive 5 V rail used for the SPGDB operation
TP6 – The sense voltage taken from the sense resistor across the SCR
being controlled
TP7 – Trigger signal, which remains active for a fixed period of time
after the SCR being controlled, has turned on and the voltage
across it has collapsed
TP8 – Internal gating signal that indirectly turns on the SCR that is being
controlled
TP9 – Gating signal received from the commanding drive control board,
through the appropriate fiber optic cable
The yellow LED (LED 1) on the SGPDB indicates that the SCR being
controlled has a gating current flowing which is used to turn the SCR on.
Thermal sensing
connection
TP9
TP8
TP7
TP6 Gate and cathode
thyristor connection
TP5
TP4
TP3
LED
TP1
Terminal/connections description
Procedure:
1. Connect a clamped ABB #5STP03D6500 SCR to the gate-cathode
leads of the SPGDB board (TB4-1/TB4-2).
2. Attach a temperature sensor board to the TB2-1/TB2-2 terminals.
3. Apply +15V test power to terminals TB3-1 and TB3-3 (TB3-1 is at
+15V while TB3-3 is the +15V return). Leave TB3-2 open.
4. Measure TP4 to TP3, which should be +14.4V, +/-100mV.
5. Measure TP5 to TP3, which should be +5.0V, +/- 250mV.
6. Measure TB2-1 to TB2-2, which should be +14.4V, +/-100mV.
7. Measure the voltage at U4-pin2 to COM, which should be +1.0V,
+/- 100mV.
8. Measure the voltage at U4-pin3 to COM, which should be 0V.
9. Measure the voltage at U4-pin7 to COM, which should be +3.6V,
+/- 100mV.
10. Verify that the OT1 LED is off.
11. Measure TP7 to TP3, which should be 0V.
12. Measure TP9 to TP3, which should be +5.0V, +/- 250mV.
13. Measure TP8 to TP3, which should be 0V.
14. Measure TP1 to TP2, which should be 0V.
15. Connect a jumper between TB3-1 and TB3-2 and verify that the
voltage at TP6 is +2.2V, +/-100mV.
16. Apply a 60Hz, 33% duty cycle signal to the OP1 fiber optic input.
17. Verify that the diagnostics transmitter LED, OT1, is on.
18. Verify that the signals at TP9 and TP8 are as shown in Fig. 6.35.
19. Verify that the signal between TP1 and TP2 is as shown in Figures
6.36 and 6.37.
20. Remove the jumper between TB3-1 and TB3-2.
21. Apply a constant fiber optic signal to the OP1 input.
22. Apply a 60 Hz, 33% duty cycle signal, at a 0 to +2V level, between
the TB1-2 input and COM. Verify the signals in Figures 6.38 and
6.39. Note that in Figure 6.39 there should be a 220 µS, +/-20 µS time
between the rising edge of the U4-pin7 pulse and the falling edge of
the TP7 signal.
Fiber Optic Cabling The equipment is provided with fiber optic cabling as a means of
interfacing the low voltage control to the medium voltage circuits. The
user of the equipment should never need to change the routing of the fiber
optic cables.
Each end of a fiber optic cable is provided with a connector that plugs and
latches into its respective location on a circuit board. To disconnect a fiber
optic cable, depress the ridged plastic tab at the end connector and pull.
To install a fiber optic cable insert the fiber optic port of the circuit board
so that the plastic tab latches into place.
If the user finds it necessary to replace fiber optic cables, great care must
be taken to prevent the cables from becoming strained or crimped as a
resulting loss in light transmission will result in loss in performance.
The minimum bend radius permitted for the fiber optic cables is
50 mm (2.0 inches).
When installing the fiber optic cable, the colour of the connector at the
end of the cable must match the colour of the connector socket on the
circuit board.
Duplex Simplex
5.0 meter 5.0 meter
5.5 meter 6.0 meter
6.0 meter 10.0 meter
6.5 meter
7.0 meter
There is one duplex fiber optic for each thyristor, which manages gating
and diagnostic functions. The healthy status of the thyristor is determined
by the circuitry on the respective driver boards. This information is then
sent to the main processor via a fail-safe light signal in the fiber optic. The
firing command for the thyristor is initiated by the main processor and
transmitted to the appropriate gate driver board via the gating fiber optic.
Air Pressure Sensor An air pressure sensor is located in both the converter cabinet and the
integral rectifier transformer cabinet (if applicable). In both cases, it is
located in the upper left-hand quadrant of the cabinet.
Mounting screw
Wire terminals
The air pressure sensor measures the difference in air pressure between
the front and rear of the converter modules/integral rectifier transformer.
A small direct current voltage signal is transmitted to the control circuits.
In the event of reduced fan performance or air blockage for either the
converter or the transformer, the measured differential pressure will be
reduced and a warning message will appear on the console. A likely
cause of the warning message would be laden filters at the inlet.
2. Disconnect the clear tube on the low pressure port. Remove the two
mounting screws of the sensor.
3. Check the integrity of the sealant that has been applied where the
clear tubing passed through the sheet metal barrier.
Low voltage
Control Tub
Retaining
Hardware
Fan
AC/DC
Power
Supply
Inlet Ring
Figure 6.41 – DC Link and Fan cabinet Figure 6.42 – DC Link and Fan Cabinet
with low voltage control tub shown with low voltage control tub removed
When the door is opened, control components are accessible. Behind the
low voltage swing-out panel is the medium voltage compartment where
the DC link and fan are located.
The D.C. link is mounted on the floor plate of the cabinet above the
capacitors.
Power connections are made to the inductor via its flexible leads. There
are four power connection points labeled L+, L-, M+, and M-.
The D.C. link is equipped with thermal protection for the windings.
The primary elements of the fan are the inlet ring, impeller and motor.
The inlet ring is stationary and must not contact the rotating impeller.
Mounted on top of the cabinet is an air exhaust hood. The exhaust hood
must be installed to prevent foreign objects entering the drive.
Important!
Torque on capacitor terminals
3,4 Nm (30 lb-in) maximum
Reactor Transformer
Capacitors
Filter Capacitors
Filter capacitors are used on the motor side for all drives. The PWM
rectifier option also includes filter capacitors on the line side. Refer to
Figure 6.42 (DC Link and Fan Cabinet with control panel removed).
The filter capacitors are three-phase four-bushing units and “oil-filled”.
The three-phase capacitors are comprised of internal single-phase units
that are connected in a Y configuration. The neutral point of the Y is
connected to the fourth bushing, which is accessible and can be used for
neutral point voltage measurement or other protection/diagnostics purposes.
Depending on the drive configuration, the fourth bushing may or may not
be connected to circuitry. The metal cases of the capacitors are grounded
through a stud on the capacitor housing.
Generator Note:
WARNING Verify that the load is not turning due to the
process. A freewheeling motor can generate
voltage that will be back-fed to the equipment
being worked on.
DC Link Reactor The DC Link maintains a ripple-free current between the rectifier and the
Replacement inverter.
The DC link reactor does not normally require service. In the event of its
replacement, it must be ensured that Rockwell Automation approves the
replacement link.
The link has been constructed to ensure that it is cooled by air drawn
through its coils.
1. Ensure that source power to the drive is locked out and that the filter
caps are fully discharged.
2. Access to the DC link is gained by opening the door to the DC link
cabinet and removing screws that retain the vertical sheet metal
barrier and low voltage panel in front of the DC link. Swing the low
voltage panel to the left and disassemble the closing barriers located
on the left and right-hand side of the panel by removing the nuts and
washers which secure them to the sides of the structure.
Note: In some instances, depending on the size of the DC link, it may
be necessary to completely remove the low voltage panel from the
drive cabinet. This can be accomplished by lifting the panel off its
hinges and shifting or rotating it to a position where it does not
obstruct the opening to the DC link cabinet. Ensure that equipment
used to lift and support the panel during DC link replacement is
adequate for this purpose.
3. Disconnect the 4 power connections. The DC link is equipped with
flexible power leads.
4. Disconnect wires at terminal block on DC link for thermal switch.
5. Remove the hardware that secures the DC link.
6. Disconnect the ground connection.
The DC link is heavy and has provision for lifting with forks of a lift
truck.
The installer must ensure that the flexible DC link leads are connected to
the appropriate terminal and routed so that electrical clearances are
maintained. You must also verify that the nameplate ratings are the same
or appropriate for the drive system. A different DC link will require
different parameter settings.
Fan Replacement There are several models of cooling fans used in PowerFlex “A”
Frame drives. Differing fan types may be used in the various
locations throughout the drive.
DC Link Section
The fan consists of a motor and impeller assembly. To replace the
fan it is necessary to remove the fan exhaust hood. See Figure 6.47.
Safety Notes
Fan replacement requires working at a significant height from the floor.
Care should be taken to make a suitable platform from which to work.
The fan motor weighs approximately 45 kg (100 lbs) and will require
suitable lifting provision. Ensure that fan power is locked out during fan
maintenance.
Remove the eight nuts that secure the motor frame to the sidesheets of the
cabinet. Disconnect the power leads to the motor. Note the terminal
locations so that proper fan rotation is maintained.
To extract the fan, lifting hooks are placed in the holes of the motor
mounting brackets and the assembly is withdrawn vertically from the
cabinet. Do not support the assembly on the impeller or damage may result.
Fan motor
Lifting points (4)
Mounting holes
Fan impeller
Inlet ring
Mounting bracket
Fan Installation
Care must be taken in handling of the fan as its balance could be affected
by poor handling.
Cross Channel
Fan
Inlet Ring
1. Remove the top plate of the ventilation housing and label fan supply
leads before disconnecting.
2. Remove the bolts retaining the cross channel and withdraw the fan
and channel from housing.
Ventilation Cover
Terminal Blocks
Fans
1. Remove the top ventilation cover from the exterior of the cabinet.
3. Unplug or disconnect fan leads from terminal blocks and replace fan.
Safety notes
The impeller is fragile. Do not allow the impeller to support the weight of
the motor.
If vertical, the impeller and bushing may fall when loosening capscrews.
Physical injury or component damage may result.
D E C
DO NOT LUBRICATE
CAPSCREWS, BORE,
OR BUSHING BARREL
B
A – Taper surfaces
B – Capscrews A
C – Split in Taper Bushing
D – Key
E – Threaded Hole for Separating Tapers
1. Record the distance from the end of the motor shaft to the bushing.
The new impeller must be installed in the same location. Failure to do
so will result in gaps between the impeller and the intake ring
resulting in loss of air flow, or rubbing of the impeller against the inlet
ring or motor assembly during operation.
3. Thread the capscrews by hand into the two threaded holes in the
bushing flange.
4. Tighten each bolt part of a turn successively, to push the impeller off
the bushing. Screwing down the capscrews into these holes will force
the bushing away from the impeller hub, releasing the compression on
the shaft. Be careful that the impeller does not fall as the clamping
force is released.
5. Pull the bushing off the shaft and remove the impeller. If the
assembly has been in place for some time, it may be necessary to use
a wheel puller to remove the bushing. Never use a wheel puller on
the impeller.
The fan impeller is held onto the motor shaft with a split tapered bushing.
This bushing is positioned on the motor shaft and through the center of
the impeller. Capscrews, when tightened to 10.2 N-m (7.5 ft-lbs.), lock
the bushing onto the motor shaft and the impeller to the bushing.
The bushing barrel and the bore of the impeller are tapered which assures
concentric mounting and keeps the impeller running evenly.
The capscrews, when tightened, lock the bushing in the impeller and over
the motor shaft.
The bushing is split down the middle, so that when the locking capscrews
force the bushing into the tapered bore in the impeller assembly, the
bushing will grip the shaft with a positive clamping fit.
The impeller and bushing assembly have keyways that line up with the
shaft and are held in place with compression.
To Assemble:
1. Make sure the shaft and keyway are clean and smooth. Clean the
shaft and bore with rubbing alcohol or non oily solvent. Check the
key size with both the shaft and bushing keyways.
2. Put the capscrews through the clearance holes in the bushing and put
the bushing loosely into the impeller, lining up the screws with the
threaded holes on the impeller hub. Do not press, drive or hammer
the bushing into the bore.
3. Start the capscrews by hand, turning them just enough to engage the
threads. Do not use a wrench at this time. The bushing should be
loose enough in the impeller to move freely.
4. Slide the impeller and bushing assembly onto the motor shaft,
ensuring the same distance from the end of the shaft to the bushing as
in step 1 of impeller removal.
5. Fit the key into keyway. Do not force impeller and bushing onto
shaft. If they do not fit easily, check the shaft, bushing and key sizes.
7. Peen the end of the motor shaft at the keyway with a chisel or center
punch to prevent the key from falling out of position.
Fan Balance
The isolation transformer fan motor and impeller is an integral unit and
cannot be serviced separately.
Inlet Ring Removal and The inlet ring is the large circular part located beneath the fan impeller.
Replacement It is positioned such that the impeller sits outside but does not touch the
ring. The ring sits inside the impeller 10 mm (0.40 inches). Refer to the
cutaway view of fan impeller and bushing (Figure 6.50).
Safety Notes
This procedure will require coming in contact with the internal electrical
connectors and devices. It is EXTREMELY important that ALL
POWER BE REMOVED FROM THE DRIVE! Failing to do so may
result in serious injury or death.
Precautions must be taken to prevent the inlet ring from falling after all of
the bolts have been removed.
Procedure
1. Remove bolts and swingout low voltage panel (see Fig. 6.41).
2. Remove bolts from the inlet ring being careful not to allow the ring to
fall.
3. Remove inlet ring via the bottom access panel by moving it around
the DC link and diagonally out the door. Shifting of the DC link may
be required.
4. To install the new ring, reverse the above procedure. Rotate the fan
impeller by hand to ensure that there is no contact with the inlet ring.
Move the ring and retighten bolts to eliminate interference.
5. Replace all panels and barriers opened or removed during inlet ring
replacement.
Replacement of Air Filters Air filters are located at the cooling air intake grille mounted on the door
in front of the converter, line reactor and transformer cabinets.
Note that if the drive is running, the filter must be replaced as soon as
possible so that foreign material is not drawn into the drive.
Care must be taken in removing the filter, to prevent dirt that has
accumulated on the inlet side of the filter from being sucked into the drive.
It may be difficult to remove the filter material without tearing it due to
the suction at the air inlet.
When replacing with a new filter, the filter must be provided by Rockwell
Automation or approved for use by Rockwell Automation. Replacement
of the filters is performed in the reverse order of its removal. Check that
there are no openings that would allow foreign matter to enter the drive.
Retaining Hardware
Filter
Control Power Components There are two configurations in which control power will be distributed
for the drive. The different methods are dependent on what drive option
the customer has chosen:
1. Integrated Line Reactor Drive with Integral Starter (refer to Figure 6.54)
2. Remote Transformer and Starter (refer to Figure 6.55)
3. Integrated Line Reactor Drive with Remote Starter (refer to Figure 6.55)
4. Integrated Transformer Drive (refer to Figure 6.56)
Ride-Through
Figure 6.54 illustrates the control power distribution for 6-pulse and PWM
drives with integral starter/line reactor.
Printer
Creator Interface
Relays
+5V - LOGIC
120V +/-15V - LOGIC
AC/DC
+/-24V – HALL EFFECT
1-ph Converter DC/DC +12V - REM I/O
56 V DC Converter +15V - TACH
1500 W +24V I/O
+15V SPGDB Test Power
and pressure transducer
380V 50Hz
or 20V Isolated
460V 60Hz Gate Driver
3-ph 20V
Power Supply*
VFD Fan
* Up to 6 supplies depending on voltage and rectifier type
Control Power Components Figure 6.55 illustrates the control power distribution for 6-pulse and
(cont.) PWM drives with remote transformer/starter or integrated line reactor
with remote starter.
Printer
Operator Interface
Relays
380V 50Hz
or 20V Isolated
460V 60Hz Gate Driver
3-ph 20V
Power Supply*
VFD Fan
* Up to 6 supplies depending on voltage and rectifier type
Figure 6.56 illustrates the control power distribution for 6-pulse and
PWM drives with integral transformer and remote starter.
Printer
Operator Interface
Relays
Tx Fan
20V Isolated
Gate Driver
380V 50Hz 20V
Power Supply*
or
440V 60Hz
3-ph
VFD
VFD
Fan
* Up to 6 supplies depending on voltage and rectifier type
AC/DC Power Supply The load demands on the AC/DC converters are the DC/DC converter and
up to six IGDPS modules. The DC/DC is a fixed load; however, the
quantity of IGDPS modules will vary depending upon the drive
configuration.
Description
The AC/DC power supply accepts single phase voltage and produces a
regulated 56Vdc output for the DC/DC power supply and the HV IGDPS
modules for the SGCTs. The input and output voltages are monitored and
fail signals are annunciated upon either voltage going below a pre-set
level.
DC/DC
Single phase Power
95-265V ac AC/DC Supply
47-63 Hz Power Supply
0.95 PF @ 1500 W 56V, 1500 W
HV IGDPS
Power
Supply
4
AC DC
FAIL FAIL
Location
The AC/DC power supply is located in the low voltage panel
in the far right-hand section of the drive. A typical low voltage
compartment is shown in Figure 6.58.
TOP DC outputs
VIEW
FRONT
VIEW
Replacement Procedure
1. Ensure control power has been isolated and locked out.
2. Disconnect the terminals at the unit.
3. Remove the two M6 bolts per Figure 6.60.
4. Extract the power supply complete with bracket from the drive.
5. Remove the bracket from the failed power supply (four M4 screws
and nylon shoulder washers).
6. Attach bracket to replacement power supply.
Note: Make sure the Black Insulation is between the AC/DC power
supply and the mounting plate.
7. Repeat Steps 5, 4, 3, 2 and 1 in this order to replace the unit (see
Figure 6.60).
8. Reapply control power and verify voltage levels.
Black
Insulation
Bracket
M6 Bolts
Low Voltage
Swing-out Tub
Low Voltage Control Section The low voltage control section houses all of the control circuit boards,
relays, Operator Interface Terminal, DC/DC power supply, and most other
low voltage control components. Refer to Figure 6.61 for a generic
representation of a low voltage tub arrangement.
Drive Control
Board
Signal (Machine)
Conditioning
Boards
Fiber Optic
Interface
Boards
Drive Control
Board (Line)
Customer
Interface
Board
Due to the critical nature of the DCB Logic power source, the DC/DC
power supply has been designed to provide redundancy for these voltages.
Each of the DCB Logic outputs is supplied internally with two separate
sources of power. In the event of one failing, the other power supply will
be automatically switched in to provide the output power.
SPGDB TEST POWER ON – The +15V output on COM4 will have its
load current monitored. This open collector output goes from low to high
when the load current exceeds 20 mA. The purpose of this signal is to
inform the user that the test harness for the SCRs is still attached to the
DC/DC converter.
Terminal/connections descriptions
M4 (P.H.M.S.) and
nylon shoulder washer
Mounting Plate
Black Insulation
Part ID Label
DC/DC
Power Supply
DC Power
good indicator light VIEW “2”
M6 (H.H.T.R.S.)
VIEW “1”
Printed Circuit Board The replacement of printed circuit boards should be handled in a careful
Replacement and deliberate manner.
There are some basic precautions that should be taken. They include the
following:
Remove all power to the drive.
Do not remove the replacement board from the anti-static bag until
necessary.
Use anti-static wrist strap, grounded in the Low Voltage Control
Section
Drive Control Boards There are two Drive Control Boards (DCBs) in the Low Voltage Control
Section. There is one board to control the Rectifier or Line-Side devices
(DCB-L) and one board to control the Inverter or Machine-Side devices
(DCB-M). These boards are the same and are interchangeable. The
DCB-M is the top board. The DCB-L is the middle board, directly
connected to the Customer Interface Board (CIB).
These boards are responsible for all of the drive control processing and
store all of the parameters used for the drive control. They are
programmed at the same time that the CIB is programmed, through a null-
modem cable and the CIB (J8) port.
There is a Status LED on the DCB, labeled D1. The following Table
illustrates the states of the LED. Except where specific boards are
mentioned in the Condition description, this table is applicable to all
Circuit Boards in the Control Section.
The DCB-L, DCB-M, and CIB are all connected together using solid plug
connections. This means that the best way to change any of the boards
without physically stressing the connections and boards is to remove all 3
from the drive and change the board externally.
1. Record all drive setup information using any of the options above, if
possible.
2. Ensure that all medium voltage and control voltage power to the drive
is isolated and locked out.
3. Loosen the two metal tabs on the top and bottom right of the panel on
which the SCB-L and SCB-M are mounted. The panel is hinged on
the right side, and should swing open to allow access to the DCB-L,
DCB-M and CIB boards. There is no need to remove any connections
from the SCB.
4. Note and mark the location and orientation of all the ribbon cables,
plugs and connectors into the DCB-L, DCB-M and CIB. Use the
electrical drawing as a reference.
5. Using your static strap, disconnect the fiber optic cables from the
sheet metal by cutting the tie-wraps. The purpose is to create enough
slack to allow the FOI Boards to be moved slightly out of the way,
allowing access to remove the boards. Use great care when handling
Fiber Optics, as any damage can affect transmission capabilities.
Fiber Optic
Interface
Boards
Customer Interface
Board
6. Remove the Fiber Optic Interface (FOI) Boards from the DCBs.
There are standoffs and pins from the DCB that slide into the FOI
boards, but they are physically attached only using the standoff
connectors, and you have to be firm, but CAREFUL, in freeing the
FOI boards.
7. There are numerous plastic clips holding all 3 boards to the plate.
Loosen the connectors and remove all 3 boards as one unit. If you
need to place the boards on a surface, ensure you have a static pad to
protect the boards.
8. Separate the boards and replace the damaged DCB with the new part.
Verify the part number is the same, and note the revision letters.
9. Follow Steps 7-3 in reverse to re-install the boards back into the low
voltage control cabinet.
10. Apply control power to the drive. The DCBs are shipped with no
firmware installed, so the drive will automatically go into download
mode. Install firmware in the drive following the guidelines in
‘Installing Firmware’.
Customer Interface Board The Customer Interface Board (CIB) is the hub for all control-level
signals external to the drive. Analog I/O, External Fault signals (through
the XIO board), ScanPort/DPI communication modules, Remote I/O,
terminal interface, printers, modem, Drive Identity Module, and other
external communication devices are routed through this board.
LEDs
The PowerFlex 7000 “A” Frame offers one isolated process current loop
transmitter and one isolated process current loop receiver, embedded into
the control. These are accessible on the CIB.
Each of these can be configured independently as either 0-20mA or
4-20mA. (Refer to Programming Manual).
The following information will show the connections for each.
Isolated
DC/DC +15V
Converter
DSP
+5V
FPGA
D/A
J4A
1
Current
Optical Boost
Interface 2
3
4
J4A Ia
1
2
3
4 SHLD
The receiver can accept either 0-20mA or 4-20mA inputs from an external
transmitter. The transmitter must have a minimum loop compliance of 5V
to satisfy the input impedance of 250 ohms.
J4B
3 Isolated
+15V @ 2W DC/DC
4 Converter DSP
FPGA
1 A/D
250R x1 u1
Buffer
Isolation
Amplifier
2
The receiver can accept either 2-wire or 4-wire transmitters, and therefore
the connections to this port are dependent on the type of external
transmitter used. The figure below shows the recommended connections.
Again, the type of shielded cable used is application specific as per the
transmitter.
CIB
J4B
Out 1 CIB Supplied Power
RTN 2 (Sourcing)
VPP 3
4
2-Wire Transmitter
CIB
J4B
VPP 1 User supplied power
Out
DC 2 (Sinking)
RTN 3
GND 4
4-Wire Transmitter
LEDs
There are 5 LEDs on the CIB, labeled D1 to D5. They are designated as
follows:
LED Designation Description
D1 OBP1 This LED is similar in function to D1 on the DCB. It is
the On-Board Programming LED, and the DCB table
should be used to evaluate the status of the LED
D2 MOD A ScanPort Communication Status LED
- Flashing Red – All valid adapters are Lost
- Flashing Red/Green – At least one, but not all,
of the valid adapters are lost
- Green – All valid adapters are OK
- Off – No adapters are connected or active
D3 MOD B DPI Communication Status LED
- Flashing Red – All valid adapters are Lost
- Flashing Red/Green – At least one, but not all,
of the valid adapters are lost
- Green – All valid adapters are OK
- Off – No adapters are connected or active
D4 XIO LINK XIO Link Status LED
- Solid Green – XIO #1 has been configured and
detected
- Off – XIO #1 either is not configured or not detected
D5 HEALTHY The healthy LED will be green as long as all control
voltages on the CIB are OK, and the CIB Watchdog is
operating correctly
1. Record all drive setup information using any of the options above, if
possible.
2. Ensure that all medium voltage and control voltage power to the drive
is isolated and locked out.
3. Loosen the two metal tabs on the top and bottom right of the panel on
which the SCB-L and SCB-M are mounted. The panel is hinged on
the right side, and should swing open to allow access to the DCB-L,
DCB-M and CIB boards. There is no need to remove any connections
from the SCB.
4. Note and mark the location and orientation of all the ribbon cables,
plugs and connectors into the DCB-L, DCB-M and CIB. Use the
electrical drawing as a reference.
5. Using your static strap, disconnect the fiber optic cables from the
sheet metal by cutting the tie-wraps. The purpose is to create enough
slack to allow the FOI Boards to be moved slightly out of the way,
allowing access to remove the boards. Use great care when handling
Fiber Optics, as any damage can affect transmission capabilities.
6. Remove the Fiber Optic Interface (FOI) Boards from the DCBs.
There are standoffs and pins from the DCB that slide into the FOI
boards, but they are physically attached only using the standoff
connectors, and you have to be firm, but CAREFUL, in freeing the
FOI boards.
7. There are numerous plastic clips holding all 3 boards to the plate.
Loosen the connectors and remove all 3 boards as one unit. If you
need to place the boards on a surface, ensure you have a static pad to
protect the boards.
8. Separate the boards and replace the damaged CIB with the new part.
Verify the part number is the same, and note the revision letters.
9. Follow Steps 7-3 in reverse to re-install the boards back into the low
voltage control cabinet.
10. Apply control power to the drive. The CIBs are shipped with no
firmware installed, so the drive will automatically go into download
mode. Install firmware in the drive following the guidelines in
‘Installing Firmware’.
Signal Conditioning Boards The Signal Conditioning Boards (SCB) receive all of the Analog Signals
from the drive’s internal components. This includes the current and
voltage feedback signals. The boards also have isolated Digital I/O for
fan status, e-stops, and contactor control and status feedback. All of the
test points for the currents, system voltages, control voltages, and flux are
on these boards.
The following table illustrates the most commonly used test points.
There is a separate SCB for each DCB, and they are labeled SCB-L and
SCB-M. These boards are NOT the same and therefore not
interchangeable. They are separate part numbers. The main reasoning for
the difference is that Current Feedback from the Line-Side Current
Transformers and Current Feedback from the Machine-Side Hall Effect
sensors requires different scaling resistors. These resistors are mounted
directly on the boards for drives with lower current requirements. A drive
with higher current requirements may require an external parallel resistor
connected across the CT/Hall Effect sensor input plug connector.
There are two LEDs on the SCB labeled D2 and D3. D2 is the ±15V DC
voltage-OK signal, and D3 is the +5V DC voltage-OK signal.
1. Ensure that all medium voltage and control voltage power to the drive
is isolated and locked out.
2. Note and Mark the location and orientation of all the ribbon cables,
plugs, and connectors into the SCB-L or SCB-M. Use the electrical
drawing as a reference.
3. Using your static strap, disconnect all of the connections.
4. Remove the SCB from the low voltage control cabinet. Verify that
the new part number matches the part number on the old SCB.
Installing the SCB-L in the place of the SCB-M (or the opposite) can
result in serious damage to the drive as the feedback scaling will be
wrong.
5. Install the new SCB in the low voltage control cabinet.
6. Reconnect all plug connections and verify the locations.
7. Apply Low Voltage power and complete a System Test and Medium
Voltage tests to ensure the new board functions properly.
External Input/Output Boards The External Input/Output (XIO) Boards are connected through a network
cable (CAN Link) to the Customer Interface Board. This cable may be
connected to either XIO Link A (J4) or XIO Link B (J5). The XIO board
handles all external Digital Input and Output signals and sends them to the
CIB through the cable. There are 16 Isolated Inputs and 16 Isolated
Outputs on the card, and they are used for Runtime I/O including Start,
Stop, Run, Fault, Warning, Jog, and External Reset signals. The boards
also handle the standard drive fault signals (Transformer/Line Reactor
Overtemperature, DC Link Overtemperature, etc.) and several spare
configurable fault inputs. There is an option in software to assign each
XIO a specific function (General IO, External IO or Liquid Cooling).
OUTPUTS
16 15 14 13 12 11 10 9 8 7 6 5 4 3 2 1
LEDS
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16
INPUTS
The standard drive comes with one XIO board, although additional boards
can be paralleled through the same type of CAN Link connection, from
XIO Link B (J5) on the first board to XIO Link A (J4) on the second
board, and so on. Specific applications may require the additional inputs
and outputs. U6 on the XIO board displays the XIO address. LED DI
indicates the status of the board. The following table illustrates the
possible states.
1. Ensure that all medium voltage and control voltage power to the drive
is isolated and locked out.
2. Note and Mark the location and orientation of all the plugs, cables,
and connectors into the XIO board. Use the electrical drawing as a
reference.
3. Using your static strap, disconnect all of the connections.
4. Remove the XIO board assembly from the low voltage control
cabinet. The XIO board mounts on a DIN rail, so a special
3-piece assembly is used to secure the board. The assembly does
not come with the new board, so the old board needs to be removed
from the assembly and the new board installed in its place.
5. Install the new XIO board assembly in the low voltage control
cabinet.
6. Reconnect all connections and verify the locations.
7. Apply Low Voltage power and complete a System Test and Medium
Voltage tests to ensure the new board functions properly.
Fiber Optic Interface Boards The Fiber Optic Interface (FOI) Boards are the interface between the
Drive Control Boards and the Gate Driver circuitry. The drive control
decides which device to fire, and sends an electrical signal to the FOI
boards. The FOI board converts that electrical signal to an optical signal,
which is transmitted via fiber optics to the gate driver cards. Typically,
the Transmit ports are Black and the Receive ports are Blue. The gate
driver accepts that signal and turns the device on and off accordingly.
The diagnostic fiber optic signals work the same way, but the source is the
gate driver boards and the destination is the drive control boards.
The FOI boards are mounted directly on the DCBs using two parallel 14-
pin connectors for the electrical connection, and plastic clips to provide
the mechanical strength. Each FOI board can handle the Firing and
Diagnostic duplex fiber optic connector for 6 devices, whether they are
SCRs or SGCTs. Physically, on the Drive Control Boards, there is
provision for 18 devices for the inverter and the rectifier. This is enough
capacity to handle the highest rated drive that we currently produce. The
top FOI board on the DCB is for the ‘A’ devices, the middle FOI board on
the DCB is for the ‘B’ devices, and the bottom FOI board on the DCB is
for the ‘C’ devices.
Each FOI board also has an input for a signal from a Thermistor Feedback
Board. The quantity and location of thermistor connections is dependant
on the drive configuration. Typically there is one thermistor from the
Line Converter and one thermistor from the Machine Converter, each
going into the respective FOI board in the ‘A’ position. However some
drive configurations only require one thermistor feedback connection.
For more information, see the drawings supplied with your drive. The
alarm and trip setpoints for each of these signals is programmable in
software.
There are 3 LEDs on the FOI board, and the following table illustrates the
status and description for the LED states:
1. Ensure that all medium voltage and control voltage power to the drive
is isolated and locked out.
2. Note and mark the location and orientation of all the fiber optic
cables. Use the electrical drawing for reference.
3. Using your static strap, disconnect all of the connections.
4. Remove the FOI board from the DCB. There are four standoffs that
snap into place on the FOI, and they need to be carefully handled
when disconnecting the boards. There is also the 28-pin connection
between the boards, and this connection should be handled carefully
as you do not want to bend the pins.
5. Install the new FOI on the DCB. Ensure the standoffs snap into place.
6. Reconnect all fiber optic connections and verify the locations.
7. Apply Low Voltage power and complete a System Test and Medium
Voltage tests to ensure the new board functions properly.
With the introduction of the PowerFlex 7000 Medium Voltage Drive, all
drive control functions are loaded on the Drive Control Boards (DCBs)
with firmware via a serial connection on the Customer Interface Board
(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 and the associated release notes are available on the
Medium Voltage intranet site, or can be obtained from Medium Voltage
Product Support.
Overview
Communications Board
Rectifier DCB (Drive Control Board - Line)
Inverter DCB (Drive Control Board – Machine)
When the system is powered up, the three control boards communicate
amongst themselves 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. This can only be accomplished if you have obtained a
minimum of ‘ADVANCED’ level access. Once that has been obtained,
from the main screen selecting UTILITY-TRANSFER-SYSTEM will
place the drive into download mode.
Ensure the parameters are saved to NVRAM, and saved to the Operator
Preparation for
Interface Terminal, and saved to any other external source such as the
Downloading Firmware Flash Card, DriveTools, or printed to a hardcopy.
Hit F10 (Access), and highlight Advanced. Press Enter and you should
have Advanced level access.
Hit F10 to Exit, and then F5 for NVRAM. Press F5 for SAVE, and F8 for
YES. The parameters should now be saved to NVRAM. Press F10 again
to EXIT.
Preparation for To save to the Operator Interface Terminal and Flash Card, Press F2
Downloading Firmware (UTILITY), F7 (TRANSFER), and F4 (PARAMETERS). You should
now be on the following screen:
(cont.)
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 for YES, and the parameters will be transferred to the card.
Press F10 to EXIT.
Setting Up Hyperterminal
Next select the "Advanced" button and de-select the "Use FIFO Buffers".
Now select OK all the way back to the main HyperTerminal screen.
Connect a ‘null modem’ serial cable between your computer's serial port
and the serial port marked 'J8' on the CIB. Only pins 2,3 and 5 are used in
the connection. Typically 2 and 3 are reversed on a null modem
connection.
This time press F9 for SYSTEM, and a screen will appear telling you that
you are in download mode, and to recycle control power once the
download is complete. On the Hyperterminal Screen, you should now see
the letter ‘C’ appear every 3 seconds, indicating that your cable is good
and you are communicating.
From Hyperterminal, on the top menu bar, select Transfer, then File. The
following screen will appear:
Ensure you choose XModem as the protocol, and then click the Browse
button. Find the appropriate location of the firmware file, which will be a
file with the ‘.XFW’ extension. Then to download, press the Send button.
As the firmware downloads, you may see a retry error each time the
system switches from one board to the next. This only occurs on older
versions of firmware. You will also note the number of packets will stop
incrementing during this time. This is normal. When the download is
complete, the ‘Xmodem file send’ screen will disappear and a status
message will be displayed. This should be "Download Successful". Then
the ‘C’s will continue.
At this point the PF7000 drive system is still in download mode. Cycle
power to the drive control boards using the isolation switch for the Fan
Power on the right side of the drive. Wait approximately 10 seconds
before reapplying power.
Reloading the Parameters Once power is reapplied, the drive may come up will all the parameters
from NVRAM. But if you have upgraded the firmware from one main
revision level to another (i.e. 2.002 to 3.001), the NVRAM will be
cleared. All other information such as operating hours, external fault
messages, specific drive name, trending setup, etc. are also cleared. If you
have upgraded the firmware from one minor revision level to another (i.e.
3.002 to 3.004), the NVRAM will still be intact.
For major revision level upgrades, the majority of the parameters that
were stored in the Operator Interface or other external means can still be
used, but there may be things such as new parameters, changed scaling on
an existing parameter, or added functionality to existing parameters that
may have to be addressed. IT IS IMPORTANT TO REFER TO THE
RELEASE NOTES BEFORE UPGRADING FIRMWARE.
To reload the parameters from the Operator Interface, once again obtain
ADVANCED level access.
You can also transfer from the Card to the Drive using F2 (CRD>DRV),
and the difference is that you will first get a screen asking you to choose
from all the available parameter listings on the card. Select the one you
want using the arrow keys, and press Enter. Then you can press F8 for
Yes and transfer the parameters. Once the parameters are transferred,
press the F10 (EXIT) key to get back to the main screen.
Reloading the Parameters It is important to go through the parameters and ensure the settings are
(cont.) proper for the drive. New parameters may need to be changed for the
specific drive application, and this should be understood from reviewing
the release notes beforehand. You should also correct any information
such as the drive name, the operating hours, or the external fault text, if
present.
Then cycle control power one more time, and the drive should come up
with no faults or warnings, and the drive will be ready to run. At this
point you may also want to save the parameters to the Operator Interface
terminal, the Flash Card, via Hyperterminal, via software, or as a
hardcopy. This will provide a record of the new settings.
HyperTerminal can also be used to load new languages into the drive
system. This is accomplished by connecting a serial cable between the PC
and the serial port J46 on the DCB, which is adjacent to the CIB. The use
of HyperTerminal and the Configuration settings are the same as that used
to download new firmware.
Programming the Terminal The terminal used on the PowerFlex7000 “A” Frame drive is capable of
participating in the firmware download using HyperTerminal only if it
already has previous drive terminal software loaded. If it lacks the
software, it does not have the necessary information to communicate with
the CIB and must be programmed first.
In this case, the appropriate firmware file with the extension .FMW must
either be copied to a PCMCIA Flash Memory Card (ATA) or downloaded
serially using the DOSFWDL.exe program. All the necessary files and
instructions are available on the Product Support Intranet site.
Power off the Terminal and insert the memory card. Apply power to the
terminal. The terminal on powerup will sense new firmware and download
it from the card. You will see a series of codes on the screen (2 – 20 – 21)
and then the drive application firmware will start. This process may take
several minutes. When the download is finished, remove the card from
the terminal. (If you leave the card in the terminal, it will reload the
firmware each time the terminal is powered up).
DOSFWDL
This is a program that copies the .FMW file out the serial port of the PC to
the serial port of the terminal. Disconnect the terminal's cable from the
CIB and connect it to your PC. Make sure the terminal is powered off.
Start the DOSFWDL program and select the appropriate COM port and
the applicable .FMW file. When the program displays the "Sending
Request" message, turn on the power for the terminal. (Note: the terminal
must be off before starting the DOSFWDL program).
The program will then indicate the status of the download. When
complete, remove the serial cable from the PC and reconnect it to the CIB
board port J7.
Setting up the PowerFlex The trending setup is best illustrated through an example:
7000 “A” Frame Trending
Feature Trend Read-Only Parameters:
1 – Status Flag (569)
2 – Alpha Line (327)
3 – Speed Feedback (289)
4 – Torque Reference (291)
5 – IDC Reference (321)
6 – IDC Feedback (322)
7 – I Stator (340)
8 – V Stator ( 344 )
The sample rate is to be set at 0 msec. This will default to the fastest
sample rate. 20% of the samples should be recorded after the trigger. The
single trigger should occur when any fault or warning occurs.
Once these settings have been programmed the drive is ready to trend.
Now the drive will trend data at the next fault.
The fluids used in the filter capacitors and the snubber capacitors are
generally considered very safe and are fully sealed within the
capacitor housings. Shipping and handling of this fluid is not
restricted under any regulations. In the unlikely event that capacitor
fluid leaks out, avoid ingestion or contact with skin or eyes as slight
irritation could result. Rubber gloves are recommended for handling.
• Chromate Plating
Some sheet steel and fasteners are plated with zinc and sealed with a
chromate-based dip (gold-coloured finish). Shipping and handling of
chromate plated parts is not restricted under any regulations, however,
chromate is considered a hazardous substance. Chromate plated parts
must be disposed of according to local regulations and must not be
disposed of with general landfill refuse.
• In Case Of Fire
Disposal
Preventive Maintenance The preventive maintenance activities on the PF7000 Air-Cooled Drive
Check List (“A” Frame or “B” Frame) can be broken down into two categories:
• Operational Maintenance – can be completed while the drive is
running.
• Annual Maintenance – should be completed during scheduled
downtime.
Operational Maintenance This process really involves only one task: Changing or Cleaning the Air
Filters. The PF7000 drives require consistent, unrestricted airflow to keep
the power devices cool. The air filter is the main source of blockage in
the air path.
The drive will provide an air filter alarm whenever the pressure
differential across the devices drops to a drive-specific level. Referring to
the Air Filter Block parameter, this can be anywhere from 7% to 17%
blocked, depending on the heatsink and device configuration. This may
seem like a small number, but it takes significant blockage to begin to
lower the voltage from the pressure sensor. The percentage is a measure
of voltage drop, and should not be viewed as a percentage of the opening
that is covered. They are not related linearly.
This can be done while the drive is running. Refer to User’s Manual,
Chapter 6 – Component Definition and Maintenance for a detailed
description of the process.
Annual Maintenance As the name implies, these maintenance tasks should be performed on an
annual basis. These are recommended tasks, and depending on the
installation conditions and operating conditions, you may find that the
interval can be lengthened. For example, we do not expect that torqued
power connections will require tightening every year. Due to the critical
nature of the applications run on MV drives, the key word is preventive.
Investing approximately 8.0 hours per year on these tasks is time well
spent in adding insurance against unexpected downtime.
¾ Carry out the integrity checks on the signal ground and safety
grounds.
Annual Maintenance ¾ Check for any visual/physical evidence of damage and/or degradation
(cont.) of components in the low voltage compartments.
This includes Relays, Contactors, Timers, Terminal connectors,
Circuit breakers, Ribbon cables, Control Wires, etc.; Causes could be
corrosion, excessive temperature, or contamination.
Clean all contaminated components using a vacuum cleaner (DO
NOT use a blower), and wipe clean components where appropriate.
¾ Carry out the physical inspection and verification for the proper
operation of the contactor/isolator interlocks, and door interlocks.
¾ Carry out the physical inspection and verification for the proper
operation of the key interlocks.
¾ Carry out the cleaning of the fans and ensure that the ventilation
passages are not blocked and the impellers are freely rotating without
any obstruction.
Annual Maintenance ¾ Check clamp head indicator washers for proper clamp pressure, and
(cont.) adjust as necessary.
Refer to page 6-18, “Uniform Clamping Pressure” and “Checking
Clamping Pressure” for details on proper clamp pressure.
¾ Apply Control power to the PowerFlex drive, and test power to all of
the vacuum contactors (input, output, and bypass) in the system,
verifying all contactors can close and seal in.
Refer to Publication 1502-UM050_-EN-P for a detailed
description of all contactor maintenance.
¾ Verify all single-phase cooling fans for operation.
This includes the cooling fans in the AC/DC Power supplies and
the DC/DC converter.
¾ Verify the proper voltage levels at the CPT (if installed), AC/DC
Power Supplies, DC/DC converter, isolated gate power supply boards.
Refer to User’s Manual, Chapter 4 – Commissioning for
appropriate procedures/voltage levels for the above checks.
¾ Verify the proper gate pulse patterns using Gate Test Operating Mode.
¾ If there have been any changes to the system during the outage, place
the drive in System Test Operating Mode and verify all functional
changes.
Final Reporting
Note: ** indicates that the time may not be required depending on the
nature of the maintenance and the condition of the drive system. These
times are only estimations.
Tools
100 MHz Oscilloscope with minimum 2 Channels and memory
5kV DC Megger
Digital Multimeter
Torque Wrench
Laptop Computer with Relevant Software and Cables
Assorted Hand Tools (Screwdrivers, Open Ended Metric Wrenches,
Metric Sockets, etc.)
5/16 Allen Keys
Speed Wrench
Feeler Gauge
Vacuum Bottle Checker or AC-Hipot
Minimum of 15kV Hotstick / Potential Indicator
Minimum of 10kV Safety Gloves
Vacuum Cleaner with Anti-static hose
Anti-static Cleaning Cloth
No. 30 Torx Driver
Documentation
PF7000 User’s Manual – Publication 7000-UM150_-EN-P
PF7000 Parameters Manual – Publication 7000-TD001_-EN-P
400A Vacuum Contactor Manual – Publication 1502-UM050_-EN-P
Drive-Specific Electrical and Mechanical Prints
Drive-Specific Spare Parts List
Materials
Torque Sealer (Yellow) Part number --- RU6048
Electrical Joint Compound ALCOA EJC No. 2 or approved equivalent
(For Power Devices)
Aeroshell no. 7 Part number 40025-198-01 (for Vacuum Contactors)
Troubleshooting
(Firmware 5.xxx)
FAULT MESSAGES
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
AC/DC#1 DC Fail 143 The output of the specified AC/DC Power – Measure the input voltage and verify it is
AC/DC#2 DC Fail 144 Supply has seen the 56VDC output voltage within limits
drop below the hardwired trip level. The trip – Measure the output voltage and confirm
AC/DC#3 DC Fail 145 whether the output level indeed falls below
level is fixed in hardware as 52VDC ±
AC/DC#4 DC Fail 146 1.7VDC, depending on hardware the trip level
AC/DC#5 DC Fail 147 tolerances.. All of the outputs of the optional – Verify fault detection wiring is per the
multiple AC/DC power supplies are drawings, and measure the voltage on the
AC/DC#6 DC Fail 148
individually monitored and displayed trip signals back to the CIB. The 5VDC is
supplied from the CIB to the fault circuit,
separately.
and is pulled low on the power supply
when healthy.
– Verify the internal cooling fan is
operational
– Replace the Power Supply if required
AC300 DC Fail 153 Optional for drives with an internal or – Measure the input voltage and verify it is
external UPS option – The 300W AC/DC within limits
converter specially fed by the UPS has seen – Measure the output voltage and confirm
the 56VDC output voltage drop below the whether the output level indeed falls below
hardwired trip level. The trip level is fixed in the trip level
hardware as 51.5VDC ± 1.4VDC, – Verify fault detection wiring is per the
depending on hardware tolerances. drawings, and measure the voltage on the
trip signals back to the CIB. The 5VDC is
supplied from the CIB to the fault circuit,
and is pulled low on the power supply
when healthy.
– Replace the Power Supply if required
Adapter 1 Loss 309 There has been a loss of communication – Ensure that the SCANport device is
Adapter 2 Loss 310 between the CIB and the identified powered
SCANport Adapter (Polled Communication). – Verify the SCANport light status and
Adapter 3 Loss 311
The drive will configure the specific Adapter ensure the device is operating properly
Adapter 4 Loss 312 Loss 1-6 as a fault when the associated bits – Verify the customer SCANport network is
Adapter 5 Loss 313 in Adapter Loss Mask (P175) is set to a 1. properly communicated with the device
Adapter 6 Loss 314 – Check CIB LED MOD A status
– Cycle control power to the drive
– Change the Adapter and/or CIB if all
attempts to restore communication fail
Adaptr1 ForceFlt 129 There has been a loss of communication – Verify the adapter LED status and ensure
Adaptr2 ForceFlt 130 between the identified DPI adapter and the the device is operating properly
customer’s communication network. The – Verify the customer network is properly
Adaptr3 ForceFlt 131
communication between the drive and the communicated with the device
Adaptr4 ForceFlt 132 DPI adapter may still be active. This is a – Check CIB LED status and compare to
Adaptr5 ForceFlt 133 requirement for DPI communications. If the the information in Chapter 6 of the User’s
Adaptr6 ForceFlt 134 loss of communication from the network to Manual
the adapter is required to be a warning, this – Change the Adapter if all attempts to
must be set in the adapter itself, not within restore communication fail
the drive.
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
Air Filter 73 The Pressure drop at the input to the – Verify fan rotation
converter section sensed by the pressure – Check for blocked airflow in the filters/
transducer (as a voltage) has dropped heatsinks/ ducting (if installed) – Clean as
below the value set in Pressure Value Trip required
(P319). This is dependent on the operation – Improper Trip settings – Verify Pressure
of the Main Cooling Fan. Value voltage level when running with
clear air flow, and compare to expected
values for that specific drive type
– Verify Alarm and Trip set-up procedure
was completed adequately and adjust as
necessary
– Verify for drives with external ducting that
there is sufficient air to the drive input
– Verify supply voltage to differential
pressure transducer, and confirm output is
stable
Auxiliary Prot’n 141 Standard External Fault/Warning Input – Check device responsible for the
included to allow the end-user to install a auxiliary contact to this input, and
protective relay/system status contact that investigate cause of the open contact
can activate a drive fault or warning, status
depending on configuration of Aux Prot – Check the 120V signal through the
Class (P445) external device
– Check the XIO board inputs and
parameter status bits
Bad Reference 246 The CIB verifies a 2.5VDC reference in the – Cycle control power to see if fault still
A-D converters during initial power up. If exists (Note: It can be reset, as it is only
this is missing, the A-D converters will not checked on initial power up: Resetting
respond as expected, and could cause the fault is NOT an indication the
problems with functions including reference problem is cleared
commands – Replace CIB if fault persists
Cab Temp High 229 The drive has a temperature switch in – Identify which switch has opened, and
(C-Frame Only) several cabinets, and all the N/C switches focus on that cabinet
are connected in series and fed back to the – Check for proper air flow within the
XIO input. The levels are set differently for identified section
different cabinets. – Verify muffin fans are operating correctly
– Verify ambient temperature is within
tolerances
CIB A/Ds 240 CIB Hardware Fault – CIB Hardware Problem
CIB Time Base 239 CIB Hardware Fault – Cycle control voltage to the drive, and if
the problem still exists the CIB board
should be replaced
CIB Heartbeat 197 The heartbeat link between the CIB and the – Possible Failed CIB or DCB-L
DCB-L has been lost. – Check LED status and compare with
table in the manual
– Cycle control voltage to the boards, and
if the problem still exists replace the
CIB/DCB-L boards as necessary
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
Conductivity Hi 227 The measured coolant conductivity is – Verify that no foreign debris has entered
(C-Frame Only) greater than 2 μS/cm3. the system (iron piping, non-deionized
water, etc.)
– Change the de-ionizing cartridge and run
the system, verifying that the conductivity
is decreasing
Coolant Level Lo 228 The measured coolant level within the – Verify that the drive cooling system does
(C-Frame Only) reservoir has dropped below the second not have any coolant leaks – repair if
(lowest) level sensor and the drive has found
faulted. This sensor is set for the minimum – Add the proper amount of de-ionized
level required to ensure there will be no air water to get the level above the warning
drawn into the system through the reservoir. sensor (de-ionized water will evaporate,
not the glycol)
Coolant Temp Hi 226 The measured coolant temperature has – Verify the heat exchanger fans are
(C-Frame Only) exceeded 54°C (129°F). operating
– Verify that the thermostatic valve is fully
opened
– Check that all valves are in the normal
operating position
– Verify that the drive is operating within
specified load and ambient conditions
Coolant Temp Lo 225 The measured coolant temperature has – Verify that the thermostatic bypass valve
(C-Frame Only) dropped below 4°C (40°F). It will not clear (V10) was not left open
until the coolant temperature reaches 10°C – Verify that the ambient temperature
(50°F). This fault will only occur if the drive within the drive control room is not below
is not running, to stop you from starting with specification
a low coolant temperature. If you are – Warm up the control room ambient to get
already running when the coolant level the drive to an operational level
drops, you will only get a warning.
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
Current Sens 178 Current Sensor fault – If you have the Line HECS/CT code, the
line current measurement is not what is
expected at this level of dc current.
Either of the CT DC HECS and there
burden resistors may be damaged or
programmed incorrectly. For example,
the DC HECS may actually be 2500:1,
the drawings and parameters indicate
4000:1. Another cause would be an
unplugged DC HECS.
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
DC Link Flow Low 231 The flow switch in the DC Link coolant path – Verify pressure values in the cooling
(C-Frame Only) has detected the flow is less than optimal, system are nominal
indicating a problem with the flow path. This – Verify the cooling path is not restricted
is not designed to specifically measure flow. because of tube crimping
This is a switch that differentiates between – Check flow switch for proper operation
flow and no flow. – It may be required to disconnect cooling
path and complete a check on the DC
Link for blockages
DC Link OC HW 170 The measured I DC Link Feedback (P322) – Verify that the parameters for drive and
has exceeded DC Overcurrent Trip (P169) device ratings, and installed current
or 75% of the device rating, whichever is sensing components are set accordingly
lower. The drive faults instantaneously. – Verify that the DC Link LEM is wired
properly and properly powered
– Verify the Burden Resistor value
– Complete a DC Current Test to verify the
feedback corresponds to the IDC
Command
– Setup trending to capture DC Link
DC Link OC SW 171 The Measured I DC Link Feedback (P322) Feedback and other related read-only
has exceeded DC Overcurrent Trip (P169) parameters (Contact factory if you
for the duration set in DC Overcurrent Delay require assistance)
(P170). This fault should never occur on it’s – Check Alpha Line, and verify that the
own, but only after a DC Link OC HW fault. value is not too low (15°) and the current
regulator is not in limit; Decrease Flux
Command Base Speed or increase
incoming Line Voltage
– Restart the drive to allow the start up
diagnostics to detect any shorted
thyristors, but only attempt this once if
shorted SCRs are detected
DC Link OT 137 The thermal switch in the drive DC Link – Verify operating conditions (ambient/
Reactor has detected an over-temperature altitude/ load levels/ ventilation and fans)
and has opened. There is a thermal switch in and verify that the DC Link Reactor is
each DC Link winding, and they are within ratings
connected in series. – Check the 120V signal through the
thermal switch
– Verify the drive cooling circuit is
operating correctly (Air Pressure value or
liquid-cooling path)
– Check the XIO board inputs and
parameter status bits
– Determine through elimination whether
there is a faulty switch and replace if
necessary
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
DC/DC Fail 155 The last of the 5VDC or the 15VDC supplies – Measure the input voltage to the DC/DC
from the DC/DC power supply to the drive power supply and verify it is at 56VDC
control logic has failed, or any of the other – Measure the output voltage and compare
voltages that are non-redundant have failed. to expected values listed in Chapter 4 of
This fault means that you will have no the User’s Manual
voltage on a required output. – Verify fault detection wiring is per the
drawings, and measure the voltage on the
trip signals back to the CIB. The 5VDC is
supplied from the CIB to the fault circuit,
and is pulled low on the power supply
when healthy.
– Verify the output from the alarm signal is
wired correctly. This signal is a
– Replace Power Supply
DPI Interface 243 This fault typically occurs when you have – Ensure Communication Type is set for
the Communication Type (P147) set for 125k for any drive with SCANPort
500k (DPI only), and you have a SCANPort connections
adapter connected to the CIB. SCANPort – Ensure you are not using a SCANPort
operates at 125k, and the DPI can operate splitter with Port 5 active as the drive
at both speeds. This can also occur if the internally has assigned Port 5 to DPI,
SCANPort network attempts to access Port and this conflict will create a fault
5, which is internally assigned to DPI. – Cycle power to ensure you
Communication Type change takes
Note: ‘MOD A’ LED on the CIB indicates a effect
healthy SCANPort Adapter when Green. – The final cause could be a CIB Hardware
‘MOD B’ LED on the CIB indicates a healthy problem, and the board should be
DPI Adapter when Green. replaced if the above actions are
unsuccessful
DI Contactor 18 The Drive Input Contactor has opened – The drive system needs to have
without command from the PF7000 drive. complete control over all contactors, so
DO Contactor 19 The Drive Output Contactor has opened investigation of the specific contactor
without command from the PF7000 drive. fault is required
– Verify contactor feedback
OP Contactor 34 The system output contactor has opened
without command from the PF7000 drive. – Verify the control power circuit for the
contactor
BP Contactor 20 The Bypass Contactor has opened without
– Check permissive string to the contactor
command from the PF7000 drive.
control relay (refer to drawing) -Check
contactor/breaker for physical
malfunction (auxiliaries)
– Check SCB inputs and outputs
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
DI Iso Switch 29 The Drive Input Isolation Switch is in the – Depending on the mode of operation
opposite state than expected, or the state (Normal, System Test, Open-Circuit
has changed during operation. Test, DC Current Test, or Open-Loop),
DO Iso Switch 30 The Drive Output Isolation Switch is in the there are specific states for all the
opposite state than expected, or the state possible system isolation switches (Refer
has changed during operation. to the description of the Parameter 192 –
IsolSw/Ctctr Cfg in the parameters
OP Iso Switch 32 The System Output Isolation Switch is in the
manual)
opposite state than expected, or the state
has changed during operation. – Ensure the isolation switches are in the
proper position
BP Iso Switch 31 The Bypass Isolation Switch is in the
– Verify wiring feedback
opposite state than expected, or the state
– Verify isolation switch mechanical
has changed during operation.
auxiliary setup
Drive OL 191 A Drive Overload condition has been – Transient Loading – Check torque limit
detected, where the overload condition is and overload settings and compare
calculated using DC Current Feedback loading to torque settings and trip
(P322) and an algorithm based on Drive settings
Overload Trip (P163) as the absolute trip – Open Burden Resistor – Check Current
level, Drive Overload Delay (P164) as the feedback and check the burden resistors
base trip delay, and Drive Overload Min
(P269) as initial detection level.
Dvc AK/Snubb 195 Device Anode-Cathode or Snubber fault – NOT USED IN 5.xxxx
External 1-16 1-16 These are the optional additional External – Review XIO Board Drawing:
Faults available when there is an additional – Identify source of Input from External
XIO board installed. This is configured with Fault XIO Board print and investigate the
XIO Ext Faults (P593), and this message cause of the fault
will appear if the specific input (1-16) is – Verify voltage signals from external
configured in Fault Config as a Class 1 or sources
Class 2 fault.
Ext Cooling Loss 224 The drive has detected the loss of the ability – Review the inputs to the drive Liquid
(C-Frame only) to provide cooling for the drive. This is Cooling XIO and determine the source of
detected through feedback from the Heat the missing signals
Exchanger Cooling fans contactors and – Investigate the Heat Exchanger fans and
overloads. control for a cause
Field Loss 35 This fault indicates that the field current is – Verify the field current from the exciter is
either missing or insufficient. This is done present
through an indirect method by checking if – Verify the analog output from the drive is
the drive is in Flux Regulator limit for the reaching the field exciter control circuit
delay set in Field Loss Delay (P559). This
means your exciter reference I Field
Command (P314) is at 100% for the time of
the delay.
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
Gate Test Pwr On 196 The temporary power supply harness used – Remove the test harness from the drive
for Gating Tests on the SCR rectifiers has immediately after Gate Test is finished
not been removed from the DC/DC Power – Verify fault detection wiring is per the
Supply, and you have attempted to start the drawings, and measure the voltage on the
drive. trip signals back to the CIB. The 5VDC is
supplied from the CIB to the fault circuit,
and is pulled low on the power supply
when healthy.
– Replace the DC/DC Power Supply if the
harness is removed and the fault can not
be cleared
GND Offset 245 CIB Hardware Fault – CIB Hardware Problem
– Cycle control Power to the drive, and if
the problem still exists the board should
be replaced
Ground OC 173 The Ground Current measured on the – Verify the Burden resistor has not
Ground Fault CT has exceeded the value in opened
Ground Fault Overcurrent Trip (P171) for – Verify parameters are set properly
the duration set in Ground Fault Overcurrent – Megger the drive and motor and input
Delay (P172). The GFCT (Zero-Sequence transformer/AC line reactor to search for
CT) is not installed in all drives. a ground fault in the system
Input Prot’n #1 135 Standard External Fault/Warning Input – Check device responsible for the
included to allow the end-user to install a auxiliary contact to this input and
protective relay (IE Input Feed Protection investigate the fault indicated by the
Relay) auxiliary contact that can activate a device’s fault message
drive fault or warning, depending on – Investigate internal and external causes
configuration of InputProt1 Class (P440). for this fault code
– Check the 120V signal through the
external device
– Check the XIO board inputs and
parameter status bits
InputProt’n #2 140 Standard External Fault/Warning Input – Check device responsible for the
included to allow the end-user to install a auxiliary contact to this input and
protective relay (IE Input Feed Protection investigate the fault indicated by the
Relay) auxiliary contact that can activate a device’s fault message
drive fault or warning, depending on – Investigate internal and external causes
configuration of InputProt2 Class (P444). for this fault code
– Check the 120V signal through the
external device
– Check the XIO board inputs and
parameter status bits
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
Input Xfmr/LR OT 136 The temperature switch in the drive Input – Verify operating conditions (ambient/
Isolation Transformer or Line Reactor has altitude/ current levels/ ventilation and
detected an over-temperature and opened. fans/ cooling oil) and verify that the
There is a thermal switch in each phase Rectifier Transformer/Reactor is within
winding, and they are connected in series. ratings
– Check the 120V signal through the
thermal switch
– Verify that it is not a faulty switch
– Check the XIO board inputs and
parameter status bits
– Determine through elimination whether
there is a faulty switch and replace if
necessary
Inv HeatSink FO 76 While Not Running, the Fiber Optic signal – Check TFB and FOI board for power
from the TFB on the Inverter Heatsink, – Check the Fiber Optic cables are
connected to Channel A fiber optic receiver properly seated in the transmitters and
RX7 on FOI-M-A is not present. This is only receivers
a fault while not running. If this occurs while – Check the fiber optic cable for kinks,
running it will appear as a warning. bends, breaks that could be blocking the
Inv Temp Ch B FO 77 Not Normally Used: While Not Running, the signal
Fiber Optic signal from the optional TFB – This can occur if the sensor is not
connected to Channel B fiber optic receiver connected to the TFB
RX7 on FOI-M-B is not present. This is only
a fault while not running. If this occurs while
running it will appear as a warning.
Inv HS Low Temp 40 If the measured temperature IHeatsink – Verify that the ambient in the control
Temp C (P253) is less than 2°C, and the room is not below 2°C
drive is not running, the drive will display this – Verify power to the TFB
fault. – There could be a mechanical problem
Inv ChB Low Temp 41 If the measured temperature Temp I Ch B C with the temperature sensor or with the
(P552) is less than 2°C, and the drive is not cable feeding the signal back to the TFB
running, the drive will display this fault. This – Swap with the rectifier hardware to
is not enabled on most drives, and the identify the bad component
parameter is a high-level parameter.
Inv Heatsink OT 69 The temperature detection on the Inverter – Confirm actual temperature in
Heatsink, connected to Channel A fiber optic parameters is not higher than the trip
receiver RX7 on FOI-M-A, has exceeded value – If so, investigate the conditions of
Inverter Heatsink Temperature Trip (P315). the drive (ambient/ loading/ elevation /
ventilation/ filter status /heatsink
Inv ChannelB OT 70 Not Normally Used - The temperature clogging)
detection on an Inverter Heatsink,
– Check the sensor and temperature
connected to fiber optic receiver RX7 on
offline (ambient) for accuracy
FOI-M-B, has exceeded Inverter
Temperature Trip Channel B (P570)
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
Inv HS Sensor 38 While Not Running, The drive has detected – Verify sensor is completely seated
a missing temperature sensor connected to properly on TFB.
the TFB on the inverter heatsink. A missing – Measure sensor resistance.
sensor can result in either a Fiber Optic – Replace if necessary.
Loss fault or a Sensor fault because a
missing sensor can be interpreted as either
0°C or over 100°C, and both are unrealistic
values.
Inv ChB Sensor 39 While Not Running, Not normally used: The
drive has detected a missing temperature
sensor connected to the optional TFB
connected to the fiber optic receiver RX7 on
FOI-M-B. A missing sensor can result in
either a Fiber Optic Loss fault or a Sensor
fault because a missing sensor can be
interpreted as either 0°C or over 100°C, and
both are unrealistic values.
Inv HCS Power 28 The power supplied to the Motor Hall-Effect – Verify the DC voltage on the DC/DC
Current Sensors (±24VDC) is monitored on supply, at the SCB-M terminals, and at
the control board and will fault the drive if the Current Sensors
the voltage is out of tolerance. – Check the Current Sensor wiring and
ensure all connections are per the
Electrical Drawing
IsoTx Air Filter 71 The Pressure sensed by the pressure – Verify fan rotation
(A-Frame Only) transducer in the Integral Isolation – Check for blocked airflow in the filters /
Transformer section (as a voltage) has ducting (if installed) – Clean as required
dropped below the value set in Pressure – Improper Trip settings – Verify Pressure
Value Transformer Trip (P654). Value voltage level when running with
clear air flow
– Verify Alarm and Trip set-up procedure
was completed adequately and adjust as
necessary, and compare with expected
values for that specific drive type
– Verify for drives with external ducting that
there is sufficient air to the drive input
– Verify supply voltage to pressure
transducer, and confirm output is stable
Line DC Link OV 172 The DC Link Voltage measured on the Line – Verify that the parameters are set
side of the DC Link has exceeded Line DC properly
Overvoltage Trip (P173) for the duration set – Verify that there is no problems with
in Line DC Overvoltage Delay (P174). steady-state overvoltages on the input to
the drive
– Ensure all SGCTs are powered
– Verify VSB resistors, grounds,
connections, and tap settings
– Complete a Gating Test on the rectifier
and inverter to confirm devices are firing
– Verify that the waveforms measured on
the SCB-L are as expected
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
Line Fltr Cap OV 176 The measured line voltage Vline Bridge – Verify the parameters are set properly
(P696) has exceeded Line Overvoltage Trip – Verify VSB connections and tap settings,
(P165) for the duration set in Line resistor values, and grounds
Overvoltage Delay (P166). This is the only – This is less likely to be caused by a true
uncompensated voltage, representing the Line Overvoltage and more likely to be
voltage on the input to the bridge. All other due to the effects of capacitive leading
voltages in the line-side are compensated VARs on a high-impedance system
using L commutation. – Tap down the input if possible
Line Harmonic OV 200 The drive has detected a steady-state – Verify waveforms show excessive
resonance-induced overvoltage on the line. harmonics using oscilloscope on SCBL
This is defined at the level set in Harmonic unfiltered voltage testpoints
OV Trip (P675) for the delay Harmonic OV – Investigate sources for excessive
Delay (P676) (on top of normal line voltage) harmonics on customer power system
for 1 second. The drive only detects the 5th – Contact factory for possible re-tuning of
harmonic to eliminate nuisance faults from input filter
capacitor charging events.
Line HCS Power 175 The power supplied to the DC Link Hall- – Verify the DC voltage on the DC/DC
Effect Current Sensor (±24VDC) is supply, at the SCB-L terminals, and at
monitored on the control board and will fault the Current Sensor
the drive if the voltage is out of tolerance. – Check the Current Sensor wiring and
ensure all connections are per the
Electrical Drawing
Line Heartbeat 25 The DCB-M has detected the loss of the – Verify DC Control voltages to both DCBs
heartbeat signal from the DCB-L – Possible Failed DCB – Check LED status
of both boards and compare with table in
the manual – Recycle power and replace
board if necessary
Line Neutral OV 192 For SCR rectifiers, the Neutral-to-Ground – DESIGNED FOR PWM-Rectifier ONLY:
voltage calculated from the measured line – Insulation Failure – Megger the motor
voltages has exceeded Ground Fault insulation/motor cables/drive insulation to
Overvoltage Trip (P587) for the duration set ground
in Ground Fault Overvoltage Delay (P588). – Verify the integrity of the input grounding
For PWM rectifier, the Neutral-to-Ground network if applicable
voltage is measured directly from the Line – Megger the input Isolation Transformer
Filter Capacitor Neutral. In both cases, the Secondary/Input Cables to ground
actual value is displayed in V Neutral Line – Verify Parameter settings are appropriate
(P589) for AC Line Reactor or Isolation
Transformer drives
Line OC 166 The measured Line Current has exceeded – CHECK FOR SHORTED SCRs – DO
Line Overcurrent Trip (P161) for the duration NOT ATTEMPT TO RESET THIS
set in Line Overcurrent Delay (P162). FAULT UNTIL YOU HAVE VERIFIED
THE SCRS ARE NOT SHORTED
– Investigate Possible damage to the input
isolation transformer if there have been
several aborted starts with Line OC faults
– Verify that the drive sizing is not too
small for the Rated Motor Current
– Verify Parameters are set properly
– Verify the Burden resistors are not
opened and there are no loose grounds
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
Line OV 159 The calculated Line Voltage has exceeded – Verify the parameters are set properly
Line Overvoltage Trip (P165) for the – Verify VSB connections and tap settings,
duration set in Line Overvoltage Delay resistor values, and grounds
(P166). This is calculated by looking at the – Verify that the parameter L Commutation
compensated individual bridge voltages (P140) was tuned properly.
Master, Slave1 and Slave2 (P136-138), and – If voltage is too high, change tap settings
comparing them to 1/3 of Line Overvoltage on the input source to lower voltage to an
Trip. acceptable level
Line ADC_DAC 210 Line DCB Internal Hardware Fault – Board Malfunction – Cycle Control
Line DMA Overrun 217 Line DCB Internal Hardware Fault Power, to see if the Fault condition
Line Timer0 208 Line DCB Internal Hardware Fault remains and Replace DCB-L if
necessary
Line Timer1 209 Line DCB Internal Hardware Fault
Line FPGA 207 Line DCB Internal Hardware Fault
Line FOB ChA 211 This fault occurs if the Line Fiber Optic – Improper parameter settings for Rectifier
Interface Board A is not connected, but is Series Devices or Rectifier Type
required based on the number of devices – Verify parameters
specified (Drive Type and Line Voltage – Damaged FOI Board – Check the LED
Dependent). status on the FOI board – replace if
Line FOB ChB 212 This fault occurs if the Line Fiber Optic necessary
Interface Board B is not connected, but is – DCB-L pin damage – Inspect the pins on
required based on the number of devices the DCB-L and ensure there is no
specified (Drive Type and Line Voltage damage
Dependent). – Replace the DCB-L if necessary
Line FOB ChC 213 This fault occurs if the Line Fiber Optic
Interface Board C is not connected, but is
required based on the number of devices
specified (Drive Type and Line Voltage
Dependent).
Line FOB ChA PS 214 The 5VDC power supply to the Line Fiber – Bad 5VDC supply – Check the 5VDC
Optic Interface Board A from the Line DCB test point on the DCB-L
is not present. – Verify LED status on the FOI Board
Line FOB ChB PS 215 The 5VDC power supply to the Line Fiber – Check all the pins that mount the FOI
Optic Interface Board B from the Line DCB board to the DCB and ensure none are
is not present. bent/broken
Line FOB ChC PS 216 The 5VDC power supply to the Line Fiber
Optic Interface Board C from the Line DCB
is not present.
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
Master CurrentUB 163 The measured and calculated phase – Verify that all Current Transformer
currents in the Master Bridge have connections are connected properly and
exceeded the value set in Line Current that no wires are reversed – Ring-out
Unbalance Trip (P108) for the duration set in wires to verify connections
Line Current Unbalance Delay (P109). – Check grounding on CTs
– Ensure that all plugs are firmly
connected in the SCBL
– Check that all input voltages are
balanced
– Verify Parameter settings
– Check the burden resistors
– Verify the Input Capacitor values if
installed
– Verity that there are no open sharing
resistors.
– Verify all Line Thyristors are firing in
Gating Test Mode
Master VoltageUB 160 The measured phase voltages in the Master – CHECK TSN FUSING
Bridge have exceeded the value set in Line – Verify the VSB connections and tap
Voltage Unbalance Trip (P271) for the settings, and check resistance of VSB
duration set in Line Voltage Unbalance board – Megger board to confirm integrity
Delay (P272). – Check actual voltage values on the
Operator Interface terminal for each
bridge and the total line voltage
– Check for possible source voltage supply
problems
– Use Multimeter and Oscilloscope to
check voltages on the drive voltage test
points
Motor Current UB 33 The measured current unbalance on the – Verify the current sensor wiring and
drive output has exceeded Mtr I UB Trip Burden Resistors from the Motor current
(P208) for the duration set in Mtr I UB Delay sensors
(P214). – Verify the HCS power
– Check the Output Filter Capacitors for
balanced loading on all 3 phases
– Investigate the possibility of Motor
winding or cabling problems
Motor DC Link OV 17 DC Link Voltage on the motor side, – Verify the motor is connected and the
measured through the Voltage Sensing Output Contactor is not open
Board, has exceeded Motor DC Overvoltage – Verify there is no open SGCTs Complete
Trip (P193) for the duration set in Motor DC a Resistance and Firing check
Overvoltage Delay (P194). – Check VSB circuit (grounds) through to
SCB-M
– Check Burden resistor values
– Check the trip parameter setting
Motor Flux UB 24 The measured Motor Flux has exceeded – Verify the VSB resistors are not open
Motor Flux Unbalance Trip (P585) for the and that they are balanced
duration set in Motor Flux Unbalance Delay – Check for Shorted Motor Output Filter
(P586). Capacitors
– Check for a grounded phase on the drive
system using a megger test
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
Motor FOB ChA 53 This fault occurs if the Motor Fiber Optic – Improper parameter settings for Inverter
Interface Board A is not connected, but is Series Devices
required based on the number of devices – Verify parameters
specified (Motor Voltage Dependent). – Damaged FOI Board - Check the LED
Motor FOB ChB 54 This fault occurs if the Motor Fiber Optic status on the FOI board – replace if
Interface Board B is not connected, but is necessary
required based on the number of devices – DCB-M pin damage – Inspect the pins on
specified (Motor Voltage Dependent). the DCB-M and ensure there is no
Motor FOB ChC 55 This fault occurs if the Motor Fiber Optic damage – Replace the DCB-M if
Interface Board C is not connected, but is necessary
required based on the number of devices
specified (Motor Voltage Dependent).
Motor FOB ChA PS 56 The 5VDC power supply to the Motor Fiber
Optic Interface Board A from the Motor DCB
is not present.
Motor FOB ChB PS 57 The 5VDC power supply to the Motor Fiber
Optic Interface Board B from the Motor DCB
is not present.
Motor FOB ChC PS 58 The 5VDC power supply to the Motor Fiber
Optic Interface Board C from the Motor DCB
is not present.
Motor Heartbeat 167 The DCB-L has detected the loss of the – Verify DC Control voltages to both DCBs
heartbeat signal from the DCB-M. – Possible Failed DCB – Check LED status
of both boards and compare with table in
the manual – Recycle power and replace
board if necessary
Motor Load Loss 74 The drive has detected a loss of load – Verify the parameter settings
condition. This is activated as a fault using – Ensure that the load should not normally
the parameter Load Loss Detect (P199), be in an unloaded condition
and the necessary setpoints are Load Loss – This is designed for applications likely to
Level (P246), Load Loss Delay (P231), and lose the load (downhole pump – hollow-
Load Loss Speed (P259). shaft motor) and we do not want to run
with the loss of load
Motor Neutral OV 67 The Neutral-to-Ground voltage measured – Insulation Failure – Megger the motor
from the Output Filter Capacitor Neutral insulation/motor cables/drive insulation to
point has exceeded Ground Fault ground
Overvoltage Trip (P189) for the duration set – Verify the integrity of the output
in Ground Fault Overvoltage (P190). This grounding network if applicable
value is displayed in V Motor Neutral – Megger the input Isolation Transformer
(P347). Secondaries/Input Cables to ground
– Verify Parameter settings are appropriate
for AC Line Reactor or Isolation
Transformer drives
– Verify the integrity of the Output Filter
Capacitors, looking for shorts or signs of
physical damage
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
Motor OC 21 The measured motor current I Stator (P340) Possible Causes:
has exceeded Motor Overcurrent Trip – Real OC/Transients
(P177) for the duration set in Motor – Bad Burden resistor/Current Sensor
Overcurrent Delay (P178). Circuit Failure – Check components
– Parameter settings too low compared to
torque limit – Verify Parameter settings
– Current regulator in limit (check line
voltage and Alpha line while running)
Motor OL 65 A Motor Overload condition has been – Transient Loading - Check torque limit
detected, where the overload condition is and overload settings and Compare
calculated using I Stator(P340) and an loading to torque settings and trip
algorithm based on Motor Overload Trip settings
(P179) as the absolute trip level, Motor – Burden Resistor – Check LEM feedback
Overload Delay (P180) as the base trip delay, and Check the burden resistors
and Motor Overload Min (P351) as the point
where the overload calculation begins.
Motor OV 22 The measured Motor AC Voltage has Possible Causes:
exceeded Motor Overvoltage Trip (P181) for – Parameter setting incorrect (flux
the duration set in Motor Overvoltage Delay command/trip values)
(P182). – VSB damage – Check VSB resistors,
grounds, and verify tap settings are
correct
– Self-Excitation – Check for flying
start/induced motor rotation
Motor Overspeed 66 The motor Speed Feedback (P289) has – Check for unbalance on the motor and
exceeded Motor Overspeed Trip (P185) for line feedback voltages
the duration set in Motor Overspeed Delay – Improper Settings – Check parameter
(P186). settings for Reference Command
Maximum and Ensure it is not too close
to Overspeed Trip increase
– Adjust Speed Regulator Bandwidth to
control overshoot, and ensure
acceleration rate near maximum speed is
not too great
– Check for load transients
– For Tachometers, ensure the ppr is set
properly and the feedback is valid
– Check tachometer pulse train with an
oscilloscope
Motor Protection 138 Standard External Fault/Warning Input – Check device responsible for the
included to allow the end-user to install a auxiliary contact to this input and
protective relay (IE Bulletin 825 Motor investigate the fault indicated by the
Protection Relay) auxiliary contact that can device’s fault message
activate a drive fault or warning, depending – Investigate internal and external causes
on configuration of Motor Prot Class (P443). for this fault code
– Check the 120V signal through the
external device
– Check the XIO board inputs and
parameter status bits
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
Motor Stall 23 The drive has detected a motor stall Possible Causes:
condition, with a delay set by Motor Stall – Insufficient torque on starting– Increase
Delay (P191). The different methods of Torque Command 0 and 1 to avoid motor
Motor Stall detection depend on whether a stalls when starting if Speed Feedback
tachometer/encoder is installed or not. Mode is Sensorless
Sensorless faults involve the motor not – Insufficient torque – Increase Torque
building up enough flux feedback to be Limit Motoring to avoid motor stalls while
detected by the drive, while tachometer running
feedback methods look at the difference – Reverse Load Rotation – Ensure the
between the tachometer/encoder feedback load is not rotating in the opposite
and the speed command. direction
– Increase motor stall delay
– Ensure Tachometer Feedback is
functional where applicable
– Ensure the motor is not spinning forward
at a speed greater than Reference
Command
Motor ADC_DAC 52 Motor DCB Internal Hardware Fault – Board Malfunction – Cycle Control Power
Motor DMA 59 Motor DCB Internal Hardware Fault to see if the Fault remains, and Replace
Overrun DCB-M if necessary
Motor FPGA 49 Motor DCB Internal Hardware Fault
Motor Timer0 50 Motor DCB Internal Hardware Fault
Motor Timer1 51 Motor DCB Internal Hardware Fault
Mstr Xfr Err 46 Master transfer Error – The master drive cannot find a slave
This is applicable to parallel drive only drive able to take over as master
– Possible causes are: slave drive not
ready, or slave drive masked off
Mtr Cap OV 44 Motor filter capacitor Over Voltage fault. – This is drive output Voltage [Surface
This is for ESP application voltage terminology used in ESP
application]. The drive gives this fault in
an ESP application only.
– The protection uses P#181 setting but
drive calculates the motor filter cap
voltage [Surface V] which is different
from motor voltage in ESP application.
– Check the voltage sensing board for any
resistor failure
– Check for any open circuit at the drive
output.
– Check the devices at the inverter.
MV in Gate Test 26 The drive has Medium Voltage applied and – Check input contactor control and Status
the user attempted to place the drive in – Ensure that the isolation switch is in the
Gating Test mode. open position and locked out – Confirm
with hot-stick and status parameters
MV in System Test 27 The drive has Medium Voltage applied and – Check input contactor control and Status
the user attempted to place the drive in – Ensure that the isolation switch is in the
System Test mode. open position and locked out – Confirm
with hot-stick and status parameters
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
No DO/OP Ctctr 37 This fault is specifically used for Open – If there truly is no Output Contactor in the
Circuit Test Mode, which demands that an system, then you can mask the fault.
Output Contactor be specified in IsoSw/Ctctr Then there will be a No DO/OP Ctctr
Cfg (P192). If the contactor is not specified, warning, and you can continue with the
you will get this fault in Open Circuit Test test.
Mode. This is to help avoid inexperienced
people putting the drive in open circuit test
mode without actually open circuiting the
output with either a contactor or by
disconnecting the cable.
Open Cct UV 36 Under Voltage during open circuit test – During open circuit test mode the drive
trips on this fault if difference between
flux command base speed value and
drive output voltage is more than 40%,
and speed ramped to 95% of the line
frequency.
– Check if any short circuit at the drive
output
– Make sure motor is not connected
OutPut Open 43 DO or OP open fault – Drive sees DO or OP contactor open.
– Check for open circuit at the drive output
PD Capcty Lo 47 Parallel Drive Capacity Low. – The available drive capacity is less than
This is applicable to parallel drive only 50% of the motor rated current. The
drive cannot run.
Pressure Loss 223 The measured system pressure has – Check that the pumps are operating
(C-Frame Only) dropped below a preset trip level. The – Verify that there are no leaks in the
standard operating pressure is around system
50psi. The pressure switch is not designed – Verify that there is no blockage in the
to be an accurate measure of pressure, but system
is designed as a Pressure/No Pressure
indication. Typically anything less than
20psi will activate this switch.
Printer USART 242 CIB Hardware Fault – CIB Hardware Problem
– Cycle control Power to the drive, and if
the problem still exists the board should
be replaced
Pump/Fan Pwr Off 230 The control power to the pumping system – Verify the disconnect switch is closed
(C-Frame Only) and the heat exchanger fans is not present. and that there are no blown fuses
– Measure the voltage at the pump and fan
inputs to ensure voltage is present
– Trace the feedback to the drive from the
circuit, looking for loose wiring or
incorrect auxiliaries
R Neutral OC 206 Neutral Resistor Over Current. – Check the neutral R for open
This is applicable to Direct to Drive only – Check devices on rectifier and inverter
for shorts
– Check the Line and Motor filter cap for
short between Phase to Neutral or Phase
to Phase.
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
Rect Heatsink FO 198 While Not Running, the Fiber Optic signal – Check TFB and FOI board for power
from the TFB on the Rectifier Heatsink, Check the Fiber Optic cables are
connected to Channel A fiber optic receiver properly seated in the transmitters and
RX7 on FOI-L-A is not present. This is only receivers
a fault while not running. If this occurs while – Check the fiber optic cable for
running it will appear as a warning. kinks/bends/breaks that could be
Rect Temp ChB FO 199 Not Normally Used: While Not Running, the blocking the signal
Fiber Optic signal from the optional TFB
connected to Channel B fiber optic receiver
RX7 on FOI-L-B is not present. This is only
a fault while not running. If this occurs while
running it will appear as a warning.
Rec HS Low Temp 204 If the measured temperature RHeatsink – Verify that the ambient in the control
Temp C (P254) is less than 2°C, and the room is not below 2°C
drive is not running, the drive will display this – Verify power to the TFB
fault. – There could be a mechanical problem
Rec ChB Low 205 If the measured temperature Temp R Ch B with the temperature sensor or with the
Temp C (P556) is less than 2°C, and the drive is cable feeding the signal back to the TFB
not running, the drive will display this fault. – Swap with the inverter hardware to
This is not enabled on most drives, and the identify the bad component
parameter is a high-level parameter.
Rect HeatSink OT 193 The temperature detection on the Rectifier – Confirm actual temperature in
Heatsink, connected to Channel A fiber optic parameters is not higher than the trip
receiver RX7 on FOI-L-A, has exceeded value – If so, investigate the conditions of
Rectifier Heatsink Temperature Trip (P315). the drive (ambient/ loading/ elevation /
Rect ChannelB OT 194 Not Normally Used - The temperature ventilation/ filter status /heatsink
detection on a Rectifier Heatsink, connected clogging)
to fiber optic receiver RX7 on FOI-L-B, has – Check TFB and FOI board for power and
exceeded Rectifier Temperature Trip fiber optic integrity
Channel B (P525). – Check the sensor and temperature
offline (ambient) for accuracy
Rec HS Sensor 201 The drive has detected a missing – Verify sensor is completely seated
temperature sensor connected to the TFB properly on TFB.
on the rectifier heatsink. A missing sensor – Measure sensor resistance.
can result in either a Fiber Optic Loss fault – Replace if necessary.
or a Sensor fault because a missing sensor
can be interpreted as either 0°C or over
100°C, and both are unrealistic values.
Rec ChB Sensor 202 Not normally used: The drive has detected
a missing temperature sensor connected to
the optional TFB connected to the fiber optic
receiver RX7 on FOI-L-B. A missing sensor
can result in either a Fiber Optic Loss fault
or a Sensor fault because a missing sensor
can be interpreted as either 0°C or over
100°C, and both are unrealistic values.
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
RNeutral OL 203 The neutral resistor required for Direct-to- – Verify the resistor ratings
Drive technology has reached an overload – Verify that the drive Voltage Feedback
condition. This is determined from Splitter board is operating properly
parameters R Neutral (P680), R Neutral – Investigate the possibility of voltage
Rating (P681). The current through the unbalances on the input or output of the
neutral resistor is calculated by measuring drive that would create a voltage
the voltage across the resistor and knowing differential across the resistor
the resistance. I Common Mode (P697) – Contact the factory for further
displays that current, and R Neutral OL instructions
(P682) shows the overload accumulator.
The resistor is allowed 500% for 10 seconds
every 5 minutes, and P682 is normalized to
fault whenever the value reaches 1.00.
SCB Incompat 177 Signal Conditioning Board Incompatible – This is for DTD drive only
– The SCB -280 and 380 are used in DTD
drive. The boards have different filter that
cause this fault.
– Use -380 board on SCBL and SCBM
Slave1 CurrentUB 164 The measured and calculated phase – Verify that all Current Transformer
currents in the Slave 1 Bridge have connections are connected properly and
exceeded the value set in Line Current that no wires are reversed – Ring-out
Unbalance Trip (P108) for the duration set in wires to verify connections
Line Current Unbalance Delay (P109). – Check grounding on CTs
– Ensure that all plugs are firmly
connected in the SCBL
– Check that all input voltages are
balanced
Slave2 CurrentUB 165 The measured and calculated phase – Verify Parameter settings
currents in the Slave2 Bridge have – Check the burden resistors
exceeded the value set in Line Current – Verify the Input Capacitor values if
Unbalance Trip (P108) for the duration set in installed
Line Current Unbalance Delay (P109). – Verify that there are no open sharing
resistors
– Verify all Line Thyristors are firing in
Gating Test Mode
Slave1 Phasing 168 The voltage phasing on the Slave1 bridge is – Verify cables are terminated correctly
not phased the same as the voltages on the – Verify the feedback wires from the
Master bridge. terminals to the VSB is terminated correctly
– The faults can be masked, and then the
voltages and phasing can be checked
Slave2 Phasing 169 The voltage phasing on the Slave 2 bridge is using the test points on the SCB-L, being
not phased the same as the voltages in the aware that there will be phase
Master Bridge. differences between the master and
secondary bridges depending on the
drive configuration. Refer to Manual.
FAULT FAULT
CODE DESCRIPTION RECOMMENDED ACTIONS
MESSAGE
Slave1 VoltageUB 161 The measured phase voltages in the Slave – CHECK TSN FUSING
1 Bridge have exceeded the value set in – Verify the VSB connections and tap
Line Voltage Unbalance Trip (P271) for the settings, and check resistance of VSB
duration set in Line Voltage Unbalance board – Megger board to confirm
Delay (P272). integrity
– Check actual voltage values on the
Slave2 VoltageUB 162 The measured phase voltages in the Slave2 Operator Interface terminal for each
Bridge have exceeded the value set in Line bridge and the total line voltage
Voltage Unbalance Trip (P271) for the – Check for possible source voltage supply
duration set in Line Voltage Unbalance problems
Delay (P272). – Use Multimeter and Oscilloscope to
check voltages on the drive voltage test
points
Spd Cmd Loss 317 The drive has lost communication with the – Ensure that the SCANport device is
device responsible for providing the speed powered
command to the drive. This has been set to – Verify the SCANport light status and
annunciate as a fault. The drive will ensure the device is operating properly
configure the Speed Command Loss as a – Verify the customer SCANport network is
fault when the associated bit in Adapter properly communicated with the device
Loss Mask (P175) is set to a 1. Setting the – Check CIB LED status
bit to 0 will cause the drive to indicate a – Cycle control power to the drive
warning and run at the last commanded
– Change the Adapter and/or CIB if all
speed.
attempts to restore communication fail
Sync Xfer Failed 75 A Synchronous Transfer was not completed – Instability at Synchronous Speed - Check
in the time specified in Synchronous for stability of the synchronous transfer
Transfer Time (P230) and the drive has process/ speed regulator
faulted. This fault will only occur if the – Load can not reach Synchronous Speed
parameter Sync Xfer Option (P419) is – Check load conditions for torque limit
configured as Enable Fault. If the or low alpha line (low line voltage)
parameter is set as Enable Warn, the drive – Consult factory for review of
will go back to last speed command and synchronous transfer parameters
issue a warning.
Tach Loss F 42 Tach Loss fault – Check the tach feedback
Temp Feedback Ls 232 This fault occurs only if the drive is not – Verify sensor is completely seated
(C-Frame only) running. The drive has detected missing properly on TFB.
temperature feedback from the cooling – Measure sensor resistance.
system. A missing sensor can be – Verify Fiber Optics are properly seated
interpreted as either 0°C or over 100°C, and on TFB
both are unrealistic values, so it is – Verify the TFB has power
considered a Feedback Loss. – Replace if necessary.
Terminal USART 241 CIB Hardware Fault – CIB Hardware Problem
– Cycle control Power to the drive, and if
the problem still exists the board should
be replaced
XIO Interface 244 CIB Hardware Fault – CIB Hardware Problem
– Cycle control Power to the drive, and if
the problem still exists the board should
be replaced
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
U1A Device Flt 117 INVERTER SGCT FAULT – Complete a resistance check per the
U1B Device Flt 123 instructions in the manual
U1C Device Flt 480 This fault will only occur during the initial – NOTE: SGCTs may not have completely
U4A Device Flt 120 contactor closure and the diagnostic shorted, and still could read in the kΩ
U4B Device Flt 126 sequence after a start command. The range – Any devices with low suspect
U4C Device Flt 483 inverter monitors the state of the feedback readings should be changed
V3A Device Flt 119 before a gate pulse is given, and monitors – Check the LED status of the SCGT gate
V3B Device Flt 125 the feedback after a gate pulse has been driver card for abnormal readings
V3C Device Flt 482 sent. The SGCT has smart diagnostics, so – Complete a Gating Test mode check on
V6A Device Flt 122 the feedback may indicate short before the devices
V6B Device Flt 128 firing, and if the pulse is received and the – Verify the associated 20V power supply
V6C Device Flt 485 device is really shorted, the diagnostic will is powered and active
118 toggle the feedback to let you know the
W2A Device Flt – Verify all the power connections to the
problem is with the device, or the power SCGT firing card are seated properly
W2B Device Flt 124
supply for that device.
W2C Device Flt 481
W5A Device Flt 121
W5B Device Flt 127 The firmware now completes a diagnostics
sequence immediately after any drive reset,
W5C Device Flt 484
with the goal of detecting faults before any
destructive action is taken from the next
action
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
U1A Fbk FO Loss 93 INVERTER SGCT FAULT – Check that the fiber optic cables are
U1B Fbk FO Loss 99 (Feedback Fiber-Optic Loss) seated properly in the Optical Interface
U1C Fbk FO Loss 468 Board and the SCGT firing card
U4A Fbk FO Loss 96 This fault will only occur during the initial – Check that the fiber optic cable is not
U4B Fbk FO Loss 102 contactor closure and the diagnostic pinched or damaged
U4C Fbk FO Loss 471 sequence after a start command. The – Complete a resistance check per the
V3A Fbk FO Loss 95 inverter monitors the state of the feedback instructions in the manual
V3B Fbk FO Loss 101 before a gate pulse is given, and monitors – NOTE: SGCTs may not have completely
V3C Fbk FO Loss 470 the feedback after a gate pulse has been shorted, and still could read in the kΩ
V6A Fbk FO Loss 98 sent. This fault occurs when the feedback range – Any devices with low suspect
V6B Fbk FO Loss 104 was low from the device before gating, and readings should be changed
V6C Fbk FO Loss 473 is still low from the device after gating. The – Check the LED status of the SCGT gate
W2A Fbk FO Loss 94 drive then assumes the feedback must be driver card for abnormal readings
W2B Fbk FO Loss 100 the problem. – Complete a Gating Test mode check on
W2C Fbk FO Loss 469 the devices
W5A Fbk FO Loss 97 The firmware now completes a diagnostics – Verify the associated 20V power supply
W5B Fbk FO Loss 103 sequence immediately after any drive reset, is powered and active
W5C Fbk FO Loss 472 with the goal of detecting faults before any – Verify all the power connections to the
destructive action is taken from the next SCGT firing card are seated properly
action
U1A Gat FO Loss 105 INVERTER SGCT FAULT – Check that the fiber optic cables are
U1B Gat FO Loss 111 (Gating Fiber-Optic Loss) seated properly in the Optical Interface
U1C Gat FO Loss 474 Board and the SCGT firing card
U4A Gat FO Loss 108 This fault will only occur during the initial – Check that the fiber optic cable is not
U4B Gat FO Loss 114 contactor closure and the diagnostic pinched or damaged
U4C Gat FO Loss 477 sequence after a start command. The – Complete a resistance check per the
V3A Gat FO Loss 107 inverter monitors the state of the feedback instructions in the manual
V3B Gat FO Loss 113 before a gate pulse is given, and monitors – NOTE: SGCTs may not have completely
V3C Gat FO Loss 476 the feedback after a gate pulse has been shorted, and still could read in the kΩ
V6A Gat FO Loss 110 sent. This fault occurs when the feedback range – Any devices with low suspect
V6B Gat FO Loss 116 was high from the device before gating, and readings should be changed
V6C Gat FO Loss 479 is still high from the device after gating. The – Check the LED status of the SCGT gate
W2A Gat FO Loss 106 drive then assumes the gating pulse must driver card for abnormal readings
W2B Gat FO Loss 112 not have reached the device. – Complete a Gating Test mode check on
W2C Gat FO Loss 475 the devices
W5A Gat FO Loss 109 The firmware now completes a diagnostics – Verify the associated 20V power supply
W5B Gat FO Loss 115 sequence immediately after any drive reset, is powered and active
W5C Gat FO Loss 478 with the goal of detecting faults before any – Verify all the power connections to the
destructive action is taken from the next SCGT firing card are seated properly
action
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
U1A Online Flt 81 INVERTER SGCT FAULT – Complete a resistance check per the
U1B Online Flt 87 instructions in the manual
U1C Online Flt 462 This fault will occur during operation of the – NOTE: SGCTs may not have completely
U4A Online Flt 84 drive. The drive has detected that the shorted, and still could read in the kΩ
U4B Online Flt 90 feedback from the device was not correct, range – Any devices with low suspect
U4C Online Flt 465 and does not wait to determine the exact readings should be changed
V3A Online Flt 83 problem. The drive polls the entire bridge 3 – Check the LED status of the SCGT gate
V3B Online Flt 89 times before and 3 times after each gating driver card for abnormal readings
V3C Online Flt 464 command. All 6 of these readings for each – Complete a Gating Test mode check on
V6A Online Flt 86 device must be consistent for the fault to the devices
V6B Online Flt 92 occur. There is also a parameter called – Verify the associated 20V power supply
V6C Online Flt 467 Inverter Device Diagnostic Delay (P268), is powered and active
82 which allows you to change the number of
W2A Online Flt – Verify all the power connections to the
consecutive firings to eliminate nuisance SCGT firing card are seated properly
W2B Online Flt 88
faults. It will still poll 3 times before and
W2C Online Flt 463 – For nuisance faults, contact the factory
after each firing, but will now require the
W5A Online Flt 85 about extending the Diagnostic Delay
condition to exist for the number of
W5B Online Flt 91 consecutive firings set in the Diagnostic
W5C Online Flt 466 Delay parameter for a fault to occur.
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
2U1A Fbk FO Loss 267 PWM RECTIFIER SGCT FAULT – Verify that the Feedback Fiber-Optic
2U1B Fbk FO Loss 273 (Feedback Fiber-Optic Loss) from the SCGT to the FOI board is not
2U1C Fbk FO Loss 324 damaged or disconnected
2U4A Fbk FO Loss 270 This fault will occur during the initial – Verify that the Gate Pulse has been
2U4B Fbk FO Loss 276 contactor closure, the diagnostic sequence received by the SGCT board using
2U4C Fbk FO Loss 327 after a start command, or the diagnostic Gating Test Mode
2V3A Fbk FO Loss 269 sequence after a stop command. The – Complete a resistance check described
2V3B Fbk FO Loss 275 rectifier monitors the state of the feedback in Chapter 4, checking the devices,
2V3C Fbk FO Loss 326 before a gate pulse is given, and monitors sharing resistors, and snubber circuitry
2V6A Fbk FO Loss 272 the feedback after a gate pulse has been – Replace all faulty components
2V6B Fbk FO Loss 278 sent. This fault occurs when the feedback
2V6C Fbk FO Loss 329 was low from the device before gating, and
2W2A Fbk FO Loss 268 is still low from the device after gating. The
2W2B Fbk FO Loss 274 drive then assumes the feedback must be
2W2C Fbk FO Loss 325 the problem.
2W5A Fbk FO Loss 271
2W5B Fbk FO Loss 277 The firmware now completes a diagnostics
2W5C Fbk FO Loss 328 sequence immediately after any drive reset,
with the goal of detecting faults before any
destructive action is taken from the next
action
2U1A Gat FO Loss 279 PWM RECTIFIER SGCT FAULT – Check that the fiber optic cables are
2U1B Gat FO Loss 285 (Gating Fiber-Optic Loss) seated properly in the Optical Interface
2U1C Gat FO Loss 330 Board and the SCGT firing card
2U4A Gat FO Loss 282 This fault will occur during the initial – Check that the fiber optic cable is not
2U4B Gat FO Loss 288 contactor closure, the diagnostic sequence pinched or damaged
2U4C Gat FO Loss 333 after a start command, or the diagnostic – Complete a resistance check per the
2V3A Gat FO Loss 281 sequence after a stop command. The instructions in the manual
2V3B Gat FO Loss 287 rectifier monitors the state of the feedback – NOTE: SGCTs may not have completely
2V3C Gat FO Loss 332 before a gate pulse is given, and monitors shorted, and still could read in the kΩ
2V6A Gat FO Loss 284 the feedback after a gate pulse has been range – Any devices with low suspect
2V6B Gat FO Loss 290 sent. This fault occurs when the feedback readings should be changed
2V6C Gat FO Loss 335 was high from the device before gating, and – Check the LED status of the SCGT gate
2W2A Gat FO Loss 280 is still high from the device after gating. The driver card for abnormal readings
2W2B Gat FO Loss 286 drive then assumes the gating pulse must – Complete a Gating Test mode check on
not have reached the device. the devices
2W2C Gat FO Loss 331
2W5A Gat FO Loss 283 – Verify all the power connections to the
2W5B Gat FO Loss 289 The firmware now completes a diagnostics SCGT firing card are seated properly
2W5C Gat FO Loss 334 sequence immediately after any drive reset,
with the goal of detecting faults before any
destructive action is taken from the next
action
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
2U1A Online Flt 255 PWM RECTIFIER SGCT FAULT – Complete a resistance check per the
2U1B Online Flt 261 instructions in the manual
2U1C Online Flt 318 This fault will occur during operation of the – NOTE: SGCTs may not have completely
2U4A Online Flt 258 drive. The drive has detected that the shorted, and still could read in the kΩ
2U4B Online Flt 264 feedback from the device was not correct, range – Any devices with low suspect
2U4C Online Flt 321 and does not wait to determine the exact readings should be changed
2V3A Online Flt 257 problem. The drive polls the entire bridge 3 – Check the LED status of the SCGT gate
2V3B Online Flt 263 times before and 3 times after each gating driver card for abnormal readings
2V3C Online Flt 320 command. All 6 of these readings for each – Complete a Gating Test mode check on
2V6A Online Flt 260 device must be consistent for the fault to the devices
2V6B Online Flt 266 occur. There is also a parameter called – Verify the associated 20V power supply
2V6C Online Flt 323 Rectifier Device Diagnostic Delay (P266), is powered and active
256 which allows you to change the number of
2W2A Online Flt – Verify all the power connections to the
consecutive firings to eliminate nuisance SCGT firing card are seated properly
2W2B Online Flt 262
faults. It will still poll 3 times before and
2W2C Online Flt 319 – Reset the drive and let the offline
after each firing, but will now require the
2W5A Online Flt 259 diagnostics further define the problem
condition to exist for the number of
2W5B Online Flt 265 consecutive firings set in the Diagnostic – For nuisance faults, contact the factory
2W5C Online Flt 322 Delay parameter for a fault to occur. about extending the Diagnostic Delay
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
2U1A Offline OC 366 6P or 18P SCR RECTIFIER FAULT – Complete a resistance check on the
2U1B Offline OC 372 (Offline Open-Circuit) rectifier, including the gate-cathode
2U1C Offline OC 402 resistance, the snubber and sharing
2U4A Offline OC 369 For SCR rectifiers, this fault will occur after resistors
2U4B Offline OC 375 the initial contact closure, or during the – Complete a firing check on the rectifier
2U4C Offline OC 405 diagnostic sequence after a start command. – Verify the snubber circuitry, and the
2V3A Offline OC 368 After the Short-Circuit test described below, sharing resistors
2V3B Offline OC 374 the drive fires each device, and verifies that – Verify fiber optic integrity from FOI board
2V3C Offline OC 404 the feedback from that device went low. If transmitter to SCRGD board receiver
2V6A Offline OC 371 the feedback does not go low, the drive – Replace all faulty components
2V6B Offline OC 377 assumes the SCR must be Open-Circuited.
2V6C Offline OC 407
2W2A Offline OC 367
2W2B Offline OC 373
2W2C Offline OC 403
2W5A Offline OC 370
2W5B Offline OC 376
2W5C Offline OC 406
3U1B Offline OC 438
3U4B Offline OC 441
3V3B Offline OC 440
3V6B Offline OC 443
3W2B Offline OC 439
3W5B Offline OC 442
4U1C Offline OC 444
4U4C Offline OC 447
4V3C Offline OC 446
4V6C Offline OC 449
4W2C Offline OC 445
4W5C Offline OC 448
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
2U1A Offline SC 378 6P or 18P SCR RECTIFIER FAULT – Complete a resistance check on the
2U1B Offline SC 384 (Offline Short-Circuit) rectifier, including the gate-cathode
2U1C Offline SC 408 resistance, the snubber and sharing
2U4A Offline SC 381 For SCR rectifiers, this fault will occur after resistors
2U4B Offline SC 387 the initial contact closure, or during the – Complete a firing check on the rectifier
2U4C Offline SC 411 diagnostic sequence after a start command. – Verify the snubber circuitry, and the
2V3A Offline SC 380 This is the first test on the rectifier. When all sharing resistors
2V3B Offline SC 386 devices blocking, the feedback from the – Verify fiber optic integrity from SCRGD
2V3C Offline SC 410 devices should toggle from open to short to board transmitter to FOI board receiver
2V6A Offline SC 383 open every time the line voltage sine wave – Replace all faulty components
2V6B Offline SC 389 passes through zero. If this is consistently
2V6C Offline SC 413 showing short (no feedback), then the drive
2W2A Offline SC 379 assumes that the device is Short-Circuited.
2W2B Offline SC 385
2W2C Offline SC 409
2W5A Offline SC 382
2W5B Offline SC 388
2W5C Offline SC 412
3U1B Offline SC 450
3U4B Offline SC 453
3V3B Offline SC 452
3V6B Offline SC 455
3W2B Offline SC 451
3W5B Offline SC 454
4U1C Offline SC 456
4U4C Offline SC 459
4V3C Offline SC 458
4V6C Offline SC 461
4W2C Offline SC 457
4W5C Offline SC 460
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
2U1A Online OC 342 6P or 18P SCR RECTIFIER FAULT – Complete a resistance check on the
2U1B Online OC 348 (Online Open-Circuit) rectifier, including the gate-cathode
2U1C Online OC 390 resistance, the snubber and sharing
2U4A Online OC 345 For SCR rectifiers, this fault will occur during resistors
2U4B Online OC 351 operation. After a firing signal is sent to a – Complete a firing check on the rectifier
2U4C Online OC 393 device, the drive monitors the feedback – Verify the snubber circuitry, and the
2V3A Online OC 344 status to ensure the voltage drops to zero sharing resistors
2V3B Online OC 350 across that device, indicating it has been – Verify fiber optic integrity from FOI board
2V3C Online OC 392 turned on. If the feedback does not drop to transmitter to SCRGD board receiver
2V6A Online OC 347 zero before approximately 30-50 µsec, the – Replace all faulty components
2V6B Online OC 353 drive will assume the device is open and a
2V6C Online OC 395 fault will occur. There is a 6 cycle fixed
2W2A Online OC 343 delay, which means that this has to occur for
2W2B Online OC 349 6 consecutive firings before the fault is
2W2C Online OC 391 instigated.
2W5A Online OC 346
2W5B Online OC 352
2W5C Online OC 394
3U1B Online OC 414
3U4B Online OC 417
3V3B Online OC 416
3V6B Online OC 419
3W2B Online OC 415
3W5B Online OC 418
4U1C Online OC 420
4U4C Online OC 423
4V3C Online OC 422
4V6C Online OC 425
4W2C Online OC 421
4W5C Online OC 424
FAULT FAULT
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
2U1A Online SC 354 6P or 18P SCR RECTIFIER FAULT – For multiple device faults, the risk of a
2U1B Online SC 360 (Online Short-Circuit) line to line short exists, so tests with MV
2U1C Online SC 396 isolated should be attempted
2U4A Online SC 357 For SCR rectifiers, this fault will occur during – Complete a resistance check on the
2U4B Online SC 363 operation. Before an individual leg is fired, rectifier, including the gate-cathode
2U4C Online SC 399 the drive takes 5 samples of the voltage resistance, the snubber and sharing
2V3A Online SC 356 across that device. This is because the resistors
2V3B Online SC 362 notching on the line could cause individual – Complete a firing check on the rectifier
2V3C Online SC 398 readings to be low. If they are all low, the – Verify the snubber circuitry, and the
2V6A Online SC 359 device is assumed to be short-circuited and sharing resistors
2V6B Online SC 365 a fault occurs. There is also a parameter – Verify fiber optic integrity from SCRGD
2V6C Online SC 401 called Rectifier Device Diagnostic Delay board transmitter to FOI board receiver
(P266), which allows you to change the – Replace all faulty components
2W2A Online SC 355
number of consecutive firings to eliminate – For nuisance faults, contact the factory
2W2B Online SC 361
nuisance faults. It will still check 5 times about extending the Diagnostic Delay
2W2C Online SC 397
2W5A Online SC 358 before each firing, but will now require the
2W5B Online SC 364 condition to exist for the number of
2W5C Online SC 400 consecutive firings set in the Diagnostic
3U1B Online SC 426 Delay parameter for a fault to occur.
3U4B Online SC 429
3V3B Online SC 428
3V6B Online SC 431
3W2B Online SC 427
3W5B Online SC 430
4U1C Online SC 432
4U4C Online SC 435
4V3C Online SC 434
4V6C Online SC 437
4W2C Online SC 433
4W5C Online SC 436
WARNING MESSAGES
WARNING WARNING
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
AC/DC#1 DC Fail 95 The output of the specified AC/DC Power – Measure the input voltage and verify it is
AC/DC#2 DC Fail 96 Supply has seen the 56VDC output voltage within limits
drop below the hardwired trip level. The trip – Measure the output voltage and confirm
AC/DC#3 DC Fail 97 whether the output level indeed falls below
level is fixed in hardware as 52VDC ±
AC/DC#4 DC Fail 98 1.7VDC, depending on hardware tolerances. the trip level
AC/DC#5 DC Fail 99 All of the outputs of the optional multiple – Verify fault detection wiring is per the
AC/DC power supplies are individually drawings, and measure the voltage on the
AC/DC#6 DC Fail 100
monitored and displayed separately. THIS trip signals back to the CIB. The 5VDC is
supplied from the CIB to the fault circuit,
WILL ONLY APPEAR IF YOU HAVE A
and is pulled low on the power supply
REDUNDANT POWER SUPPLY.
when healthy.
– Verify the internal cooling fan is
operational
– Replace the Power Supply if required
AC300 AC Fail 103 The AC Fail signal from the 300W AC/DC – Investigate possibility of loss of input
power supplies has been activated. This is voltage to the AC/DC Power Supply
treated as a warning since a real loss of this – Verify output voltage
input voltage will result in a subsequent DC – Check alarm signal connections
fail signal. This happens at 85VAC. – Replace Power Supply if necessary.
AC/DC PS AC Fail 102 The AC Fail signal from the 1500W AC/DC – Investigate possibility of loss of input
power supplies has been activated. We voltage to the AC/DC Power Supply
treat this as a warning since a real loss of – Verify output voltage
this input voltage will result in a subsequent – Check alarm signal connections
DC fail signal. This will occur at 127VAC L- – Replace Power Supply if necessary.
L for 3-phase supplies, and 90VAC for
single-phase supplies.
Adapter 1 Loss 175 There has been a loss of communication – Ensure that the SCANport device is
Adapter 2 Loss 176 between the CIB and the identified powered
Adapter 3 Loss 177 SCANport Adapter (Polled Communication). – Verify the SCANport light status and
This will appear as a warning in the drive ensure the device is operating properly
Adapter 4 Loss 178 when the associated bits in Adapter Loss – Verify the customer SCANport network
Adapter 5 Loss 179 Mask (P175) are set to a 0. is properly communicated with the device
Adapter 6 Loss 180 – Check CIB LED status
– Cycle control power to the drive
– Change the adapter if all attempts to
restore communication fail
WARNING WARNING
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
Air Filter 29 The Pressure drop at the input to the – Verify fan rotation
converter section sensed by the pressure – Check for blocked airflow in the filters/
transducer (as a voltage) has dropped heatsinks/ ducting (if installed) – Clean as
below the value set in Pressure Value Alarm required
(P320). This is dependent on the operation – Improper Alarm settings – Verify Pressure
of the Main Cooling Fan. Value voltage level when running with
clear air flow, and compare to expected
values for that specific drive type
– Verify Alarm and Trip set-up procedure
was completed adequately and adjust as
necessary
– Verify for drives with external ducting that
there is sufficient air to the drive input
– Verify supply voltage to differential
pressure transducer, and confirm output
is stable
Autotune TimeLmt 53 Indicates that the autotune test could not – REFER TO THE POWERFLEX 7000
measure the parameter in the allotted time. SERIES B MANUAL (CHAPTER 4 –
COMMISSIONING) ON AUTOTUNE
PROCEDURES, RESULTS, AND
ACTIONS
Auxiliary Prot’n 71 Standard External Fault/Warning Input – See associated Fault Description
included to allow the end-user to install a
protective relay/system status contact that
can activate a drive fault or warning,
depending on configuration of Aux Prot
Class (P445)
Bus Transient 123 The drive has detected a transient of rapid – Check system for capacitive switching
loss of line, and has placed both bridges in events
freewheel mode until event clears. – Contact factory for detailed actions
Buss Fault Line 200 DEVELOPMENT ERROR – NOT ACTIVE –
Buss Fault Motor 194 DEVELOPMENT ERROR – NOT ACTIVE –
Buss Flt Ext Mem 162 DEVELOPMENT ERROR – NOT ACTIVE –
Buss Flt FPGA 161 DEVELOPMENT ERROR – NOT ACTIVE –
Bypass OV 184 The measured Line-Side Bypass Voltage – Verify the parameters are set properly
has exceeded Line Overvoltage Trip (P165) – Check for possible line voltage
for the duration set in Line Overvoltage transients
Delay (P166). – Verify VSB connections and tap settings,
resistor values, and grounds
– If voltage is too high, change tap
settings on the input source to lower
voltage to an acceptable level
Bypass Rvs Rotn 187 The phase sequence on the voltage – The drive will not allow a synchronous
measured on the primary side of the Bypass transfer unless the phasing is the same
Contactor is not the same as the phase – Confirm the phase sequences and swap
sequence on the output of the drive. cables if necessary
WARNING WARNING
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
Bypass UV 185 The measured Line-Side Bypass Voltage is – Verify the VSB connections and tap
less than Line Undervoltage Trip (P167) for settings, and check resistance of VSB
the period set by Line Undervoltage Delay board – Megger board to confirm integrity
(P166). – Check for possible source voltage
supply problems
– Use Multimeter and Oscilloscope to
check voltages on the drive test points
Bypass Volt UB 186 The measured Line-Side Bypass Voltage – Verify the VSB connections and tap
has exceeded the value set in Line Voltage settings, and check resistance of VSB
Unbalance Trip (P271) for the duration set in board – Megger board to confirm integrity
Line Voltage Unbalance Delay (P272). – Check for possible source voltage
supply problems
– Use Multimeter and Oscilloscope to
check voltages on the drive voltage test
points
CIB Battery Low 159 The battery on the CIB that powers the – Replace the PowerCap on the CIB
NVRAM has reached a preset low level of board
2.6VDC.
Conductivity Hi 147 The measured conductivity is greater than – Verify that no foreign debris has entered
(C-FRAME ONLY) 1 μS/cm3. the system (iron piping, non-deionized
water, etc.)
– There is no immediate need for action,
but be prepared to change the de-ionizing
cartridge and run the system, verifying
that the conductivity is decreasing
Coolant Level Lo 148 The level of the coolant in the reservoir has – You will lose coolant over time through
(C-FRAME ONLY) dropped below the low level warning evaporation, but you should still verify
indicator, activating the warning. that there are no slow leaks in the
system
– Add de-ionized water to the system
since this is what normally evaporates,
and check the coolant mixture with a
glycol tester
Coolant Temp Low 145 The measured coolant temperature has – Verify that the thermostatic bypass valve
(C-FRAME ONLY) dropped below 10°C (50°F). The warning (V10) was not left open
will not clear until the temperature rises – Warm up the control room ambient to
above 15°C (58°F). get the drive to an operational level
Coolant Temp Hi 146 The measured coolant temperature has – Verify the heat exchanger fans are
(C-FRAME ONLY) exceeded 48°C (120°F). The warning can operating
not be cleared until the temperature has – Verify that the thermostatic valve is fully
dropped below 44°C (110°F). opened
– Check that all valves are in the normal
operating position
Ctrl Power Loss 191 This warning tells the drive that the control – Investigate reliability of the control power
power has dipped, and this is used in the – Ensure the drive operates as expected
Autorestart feature algorithm as an indicator when there is a control power outage
to tell the drive to stop gating and wait for (UPS must be installed)
control power to return
WARNING WARNING
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
DI Contctr Fdbk 118 This warning indicates that the drive has – Verify the contactor is closed
sensed MV on the front end, but there is no – Confirm the feedback path from the
input contactor status coming back to the contactor to the XIO
drive – Replace XIO if required
DI Contctr Open 18 The input contactor has been commanded – Ensure the associated starter unit is set
to close and the contactor closed feedback to Normal mode
has not been detected. – Verify the feedback from the contactor
DI Contctr Clsd 19 The input contactor has been commanded status (normally control relay auxiliary
to open and the contactor open feedback and contactor mechanical auxiliary) is
has not been detected. wired properly and powered
DO Contctr Open 20 The output contactor has been commanded – Verify that there is control power to the
to close and the contactor closed feedback contactor
has not been detected. – Verify the associated SCB I/O
DO Contctr Clsd 21 The output contactor has been commanded – Verify that the Holding Coil or Closing
to open and the contactor open feedback Coil is not shorted
has not been detected. – Review Contactor control wiring
OP Contctr Open 46 The system output contactor has been – These warnings may also occur during
commanded to close and the contactor the autorestart feature, as the loss of
closed feedback has not been detected. power may also result in the inability to
hold in the contactor during the outage
OP Contctr Clsd 47 The system output contactor has been
commanded to open and the contactor open
feedback has not been detected.
BP Contctr Open 37 The bypass contactor has been commanded
to close and the contactor closed feedback
has not been detected.
BP Contctr Clsd 38 The bypass contactor has been commanded
to open and the contactor open feedback
has not been detected.
WARNING WARNING
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
DI IsoSw Open 42 The Drive Input Isolation Switch is Open – In DC Current test modes, the isolation
when it is expected to be closed, which is in switches are expected to be closed for
Normal mode, DC Current test mode, Open DC Current test; although only the input
Loop test mode, and Open Circuit test contactor is required the test will run with
mode, warnings if the switches are open
DI IsoSw Clsd 324 The Drive Input Isolation Switch is Closed – Ensure the isolation switches are in the
when it is expected to be open, which is in proper position for the specific operating
System Test mode and Gating Test mode. mode (Refer to the description of the
DO IsoSw Open 43 The Drive Output Isolation Switch is Open Parameter 192 – IsolSw /Ctctr Cfg in the
when it is expected to be closed, which is in parameters manual)
Normal mode, DC Current test mode, and – Verify wiring feedback
Open Loop test mode. – Verify isolation switch mechanical
DO IsoSw Clsd 325 The Drive Output Isolation Switch is Closed auxiliary setup
when it is expected to be open, which is in
Open Circuit mode, System Test mode and
Gating Test mode
OP IsoSw Open 45 The System Output Isolation Switch is Open
when it is expected to be closed, which is in
Normal mode, DC Current test mode, and
Open Loop test mode.
OP IsoSw Clsd 326 The System Output Isolation Switch is
Closed when it is expected to be open,
which is in Open Circuit mode, System Test
mode and Gating Test mode
BP IsoSw Open 44 The Bypass Isolation Switch is Open when it
is expected to be closed, which is in Normal
mode, DC Current test mode, and Open
Loop test mode.
BP IsoSw Clsd 327 The Bypass Isolation Switch is Closed when
it is expected to be open, which is in Open
Circuit mode, System Test mode and Gating
Test mode
DC/DC Redundant 101 The main outputs of the DC/DC power – Redundant Supply is paralleled, so there
supply (+5VDC, ±15VDC) have failed, but is no way to confirm output voltage level
the redundant outputs are still active. This – Verify the output from the alarm signal is
is set at 95% of rated value for 15VDC wired correctly
outputs, and 5.00VDC for 5.3VDC output. – Replace Power Supply when possible
DC Link OT 67 The thermal switch in the drive DC Link – See associated Fault Description
Reactor has detected an over-temperature
and has opened, but was set up as a
warning.. There is a thermal switch in each
DC Link winding, and they are connected in
series.
DC Link OC 115 The measured IDC Link Feedback (P322) – See associated Fault Description
has exceeded DC Overcurrent Trip (P169),
and instantaneously causes a warning.
WARNING WARNING
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
DC Link Range 126 The value entered for the parameter Link – Review DC Link nameplate data
Inductance (P27) is below a minimum value – Review Motor and Drive nameplate data
for the programmed Drive/Motor ratings. and verify that all parameters were
6P Rectifier – 0.85 pu entered properly
18P Rectifier – 0.42 pu – Contact factory if the above seems OK
PWM Rectifier – 0.55 pu
DcLnd Mstr 342 Slave Declined Master-slave only – Slave has lost communication with hub
PLC, or slave is masked off in parameter
Master Mask
DCBL Battery Low 125 The PowerCap on the DCB-L that powers – Replace the PowerCap after recording
the NVRAM where the parameters are all the parameters to the terminal,
stored is below 2.6 V DC. through Hyperterminal, with a printer or
with DriveTools
– Reinstall the parameters
DCBM Battery Low 188 The PowerCap on the DCB-M is below 2.6 – This is not critical unless you ever put
V DC.. this board in the rectifier position
– Replace the PowerCap
Desync Delay On 48 A transfer from the Line back to Drive – Wait for 1 minute and attempt the
(desync) has been commanded, but it has desync transfer again.
been less than 1 minute since the transfer
from Drive to Line (sync) was completed.
As a result, the Output Motor Filter Capacitors
have not had time to adequately discharge.
DPI Power Loss 109 The 12VDC used for SCANport/DPI – Verify DC/DC power supply output
communications has dropped below the set – Confirm wiring to the CIB from the
trip level. DC/DC Power Supply
DPI Ram Overflow 163 DEVELOPMENT ERROR – There is an – Noise/Grounding Issues
internal communication error in the drive – Confirm grounding is per the RA
control drawings
– Contact the Factory
Drive OL 111 A Line Overload warning has been detected, – Transient Loading – Check torque limit
where the overload condition is calculated and overload settings and Compare
using DC Current Feedback (P322) and loading to torque settings and trip
Line Overload Warning (P270) as the point settings
where the overload warning occurs. (P270)
is programmed as a percentage of the
difference between Line Overload Minimum
(P269)and Line Overload Trip (P163).
Drv in Test Mode 50 The drive Operating Mode (P4) is set to DC – Place drive back in Normal Mode before
Current Test Mode when an Autotune Test attempting Autotune
that turns the motor is initiated
Duplcte Mstr 341 Duplicate Master-master only – The Powerup Config parameter is set to
Master in more than one drive. The first
drive to power up will become the
master
WARNING WARNING
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
External 1-16 1-16 These are the optional additional External – See associated Fault Description
Faults available when there is an additional
XIO board installed. This is configured with
XIO Ext Faults (P593), and this message
will appear if the specific input (1-16) is
configured in Fault Config as a Warning.
Fan On 30 The drive control is receiving a hardwired – Check Fan feedback wiring and confirm
fan feedback even though the fan has not with ED
been commanded to run.
Fan 1 Loss 31 Drives with a Redundant Fan (P141) will – Investigate the cause of the Fan 1 loss
give this warning if Fan 1 is running, there (OL / damaged relay)
were no problems with Fan 2, and Fan 1 is – Verify Fan 2 is operating with the proper
lost. Fan 2 will start and the drive will current levels
continue running. – At the next possible shutdown, reset the
warnings and Fan 1 can be run again
Fan 2 Loss 32 Drives with a Redundant Fan (P141) will – Investigate the cause of the Fan 2 loss
give this warning if Fan 2 is running, there (OL / damaged relay)
were no problems with Fan 1, and Fan 2 is – Verify Fan 1 is operating with the proper
lost. Fan 1 will start and the drive will current levels
continue running. – At the next possible shutdown, reset the
warnings and Fan 2 can be run again
Fan1 ContctrOpen 22 When the drive is running, the feedback – If the drive faults, investigate problems
from the Fan 1 Contactor auxiliary and with the fan contactors or the fan
Isolation Switch is lost, but the drive will not overloads
trip and wait for Power Supply faults or Air
– If the drive is still running with this
Pressure faults to fault the drive.
warning, there is a problem with the
Fan2 ContctrOpen 199 When the drive is running, the feedback Fan Isolation Switch auxiliary
from the Fan 2 Contactor auxiliary and
Isolation Switch is lost, but the drive will not
trip and wait for Power Supply faults or Air
Pressure faults to fault the drive.
Gate Test Pwr On 119 The gating harness is plugged into the – This will occur whenever attempting a
DC/DC power supply, and the drive has gating test
detected some current flow – If there is no gating harness installed,
replace the DC/DC power supply
Gnrl IO Config 127 The XIO card which was being assigned to – Select the proper slot containing the XIO
the General I/O is not a card which can be card which is compatible for General I/O
used for this purpose. usage using XIO General Input/Output
(P592)
Gnrl IO Conflict 128 The XIO card previously being used for – Check the configuration of all XIO slots
General I/O has been reassigned for using XIO General Input/Output (P592)
another purpose. and XIO External Faults (P593), and
reassign if necessary.
Ground Differ 160 This represents an excessive difference – This could be a problem with the
between the Analog and the Digital grounds, grounding in the drive system
measured on the CIB Board – Verify grounds are per the drawings
– Replace CIB to eliminate board as a
problem
– Contact Factory if problem persists
WARNING WARNING
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
HeatExchnger Fan 144 The drive has detected a problem from the – Verify the Fan O/L settings and conditions
(C-FRAME ONLY) Liquid-to-Air heat exchanger fans. – Verify the Fan Control Relay status and
auxiliary contact signals.
Hub Comm Wrn 340 Hub (PLC) Communication Loss – Check ControlNet adapter and cable
Inertia High 54 Indicates that the Autotune Inertia (P223) – REFER TO THE POWERFLEX 7000
was measured higher than 5.0 seconds. SERIES B MANUAL (CHAPTER 4 –
COMMISSIONING) ON AUTOTUNE
PROCEDURES, RESULTS, AND
ACTIONS
Input Close Dly 39 For PWM drives, this warning indicates that – Wait for the drive Ready status to
a start command has been given, but the appear, allowing you to start the drive
drive is still waiting for the DC voltage to – Verify the time in Parameter 583 is not
discharge from the line filter capacitors. too long
This can be observed by the status
‘Discharging’, on the main screen. This time
can be based on the capacitor properties, or
Parameter 583 – Input Contactor Close
Delay (whichever is longer)
Input Prot’n #1 65 Standard External Fault/Warning Input – See associated Fault Description
included to allow the end-user to install a
protective relay (IE Input Feed Protection
Relay) auxiliary contact that can activate a
drive fault or warning, depending on
configuration of InputProt1 Class (P440).
Input Prot’n #2 70 Standard External Fault/Warning Input – See associated Fault Description
included to allow the end-user to install a
second protective relay (IE Input Feed
Protection Relay) auxiliary contact that can
activate a drive fault or warning, depending
on configuration of InputProt2 Class (P445).
Input Xfmr/LR OT 66 The temperature switch in the drive Input – See associated Fault Description
Isolation Transformer or Line Reactor has
detected an over-temperature and opened.
There is a thermal switch in each phase
winding, and they are connected in series.
Inv Heatsink FO 197 While Running, the Fiber Optic signal from – Check TFB and FOI board for power
the TFB on the Inverter Heatsink, connected – Check the Fiber Optic cables are
to Channel A fiber optic receiver RX7 on properly seated in the transmitters and
FOI-M-A is not present. This is only a fault receivers
while not running. If this occurs while – Check the fiber optic cable for kinks,
running it will appear as a warning. bends, breaks that could be blocking the
Inv ChannelB FO 198 Not Normally Used: While Running, the signal
Fiber Optic signal from the optional TFB – This can occur if the sensor is not
connected to Channel B fiber optic receiver connected to the TFB
RX7 on FOI-M-B is not present. This is only
a fault while not running. If this occurs while – NOTE: This is a warning because the
running it will appear as a warning. drive should not fault on the loss of the
signal while running. There is no
imminent danger to the drive, but the
user needs to be aware that there is a
temperature feedback signal missing.
WARNING WARNING
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
Inv Heatsink OT 24 The temperature detection on the Inverter – Confirm actual temperature in
Heatsink, connected to Channel A fiber optic parameters is not higher than the
receiver RX7 on FOI-M-A, has exceeded warning value – If so, investigate the
Inverter Heatsink Temperature Warning conditions of the drive (ambient /
(P316). loading/ elevation / ventilation/ filter
status / heatsink clogging)
– Check the sensor and temperature
offline (ambient) for accuracy
Inv ChannelB OT 25 Not Normally Used – The temperature –
detection on an Inverter Heatsink,
connected to fiber optic receiver RX7 on
FOI-M-B, has exceeded Inverter
Temperature Warning Channel B (P571).
Inv HS Sensor 195 While Running, the drive has detected a – Verify sensor is completely seated
missing temperature sensor connected to properly on TFB.
the TFB on the inverter heatsink. A missing – Measure sensor resistance.
sensor can result in either a Fiber Optic – Replace if necessary.
Loss fault or a Sensor fault because a
missing sensor can be interpreted as either – NOTE: This is a warning because the
0°C or over 100°C, and both are unrealistic drive should not fault on the loss of the
values. signal while running. There is no
Inv ChB Sensor 196 Not normally used: While Running, the imminent danger to the drive, but the
drive has detected a missing temperature user needs to be aware that there is a
sensor connected to the optional TFB temperature feedback signal missing.
connected to the fiber optic receiver RX7 on
FOI-M-B. A missing sensor can result in
either a Fiber Optic Loss fault or a Sensor
fault because a missing sensor can be
interpreted as either 0°C or over 100°C, and
both are unrealistic values.
Inv Gate pwr 333 Inverter Gate driver power supply warning – The device feedback was not correct due
to power loss to the gate driver board.
– This can be from the 20V DC output of the
IGDPS or on the gate driver board itself.
– This warning can also appear as a result
of another device fault such as an
Online Fault.
Invalid Alrm Bit 89 DEVELOPMENT ERROR - An unused bit in – Contact the factory
the first 16 bits in either a fault or warning
word has been set and detected by the
Alarm Queue server. Either a used bit has
been overlooked in the Faults/Warnings
database, or the control is incorrectly setting
an alarm word.
Invalid DIM 90 The drive tried to access the DIM, but either – This fault may occur on drives upgrading
encountered a problem with the checksum major revisions of firmware (i.e. 2.xxx to
on the DIM, or the DIM was not installed 3.xxx), with the older DIM installed, or if
the DIM has a failure
– Remove the DIM
WARNING WARNING
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
Invld Mstr R 344 Invalid Master request-slave only – Drive tried to become master when
another master was already active
Iso Fn1 Cntr 329 Isolation Transformer Fan 1 contactor – Isolation transformer Fan 1 status is
NOT HIGH while the drive asked the
contactor to be closed.
Iso Fn2 Cntr 330 Isolation Transformer Fan 2 contactor – This warning occurs when the drive
commands the Isolation Transformer
Fan 2 contactor to close, and does not
detect the status feedback from the
contactor.
Iso Fn1 Loss 331 Isolation Transformer Fan 1 Loss – This warning occurs when the drive
detects a loss of pressure or a loss of
Fan 1 contactor feedback when running
on Fan 1.
Iso Fn2 Loss 332 Isolation Transformer Fan 2 Loss – This warning occurs when the drive
detects a loss of pressure or a loss of
Fan 2 contactor feedback when running
on Fan 2.
IsoTx Air Filter 26 The Pressure sensed by the pressure – Verify fan rotation
(A-Frame Only) transducer in the integral Isolation – Blocked airflow in the filters / ducting (if
Transformer section (as a voltage) has installed) – Clean as required
dropped below the value set in Pressure – Improper Warning settings – Verify
Value Transformer Warning (P655). Pressure Value voltage level when
running with clear air flow
– Verify Alarm and Trip set-up procedure
was completed adequately and adjust as
necessary
– Verify for drives with external ducting that
there is sufficient air to the drive input
– Verify supply voltage to pressure
transducer, and confirm output is stable
IxoTx Fan On 328 Isolation Transformer Fan ON warning – Isolation transformer Fan status is high
while it should be low.
L Comm Low 55 Indicates that the Autotune Lc (P217) – REFER TO THE POWERFLEX 7000
measured was less than 0.02 pu and the L SERIES B MANUAL (CHAPTER 4 –
Commutation (P140) will have to be tuned COMMISSIONING) ON AUTOTUNE
manually. PROCEDURES, RESULTS, AND
L Comm High 56 Indicates that the Autotune Lc (P217) ACTIONS
measured was greater than 0.15 pu and the
L Commutation (P140) will have to be tuned
manually.
WARNING WARNING
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
L Leakage Low 59 Indicates that the Autotune Ls (P220) – REFER TO THE POWERFLEX 7000
measured was less than 0.15 pu. SERIES B MANUAL (CHAPTER 4 –
L Leakage High 60 Indicates that the Autotune Ls (P220) COMMISSIONING) ON AUTOTUNE
measured was greater than 0.30 pu. PROCEDURES, RESULTS, AND
ACTIONS
L Magnetize Low 61 Indicates that the Autotune L mag (P221)
measured was less than 2.00 pu, and L
magnetizing (P131) will have to be tuned
manually.
L Magnetize High 62 Indicates that the Autotune L mag (P221)
measured was greater than 10.00 pu, and L
magnetizing (P131) will have to be tuned
manually.
Line Cap Range 124 In PWM rectifier drives, the calculated per – Verify capacitor nameplate data and
unit value of the Line Filter Capacitor compare with information entered in
(P133), based on the values entered for drive
Line Capacitor kVAR (P15), Line Capacitor
Volts (P16), and Line Capacitor Frequency
(P32) is outside of the normal range of 0.35-
0.55pu.
Line DC Link OV 116 The measured Line DC voltage has – See associated Fault Description
exceeded Line DC Overvoltage Trip (P173),
and instantaneously causes a warning.
Line Loss 120 The drive has detected a loss of input – Verify the VSB connections and tap
voltage from losing the frequency (PLL) lock settings, and check resistance of VSB
on the input voltage. This is designed to be board – Megger board to confirm
a faster method of detecting an integrity
undervoltage. The drive responds to this – Check TSN fusing
warning as it does to a Master UV warning. – Check actual voltage values on the
Terminal for each bridge and the total
line voltage
– Check for possible source voltage
supply problems
Liq IO Config 131 The XIO card which was being assigned to – Select the proper slot containing the XIO
(C-Frame Only) the Liquid Cooling System Faults Input is card which is compatible for Liquid
not a card which can be used for this Cooling System Faults usage.
purpose
Liq IO Conflict 132 The XIO card previously being used for – Check the configuration of all XIO slots
(C-Frame Only) Liquid Cooling System Faults has been and reassign if necessary.
reassigned for another purpose.
Logx IO Config 133 The XIO card which was being assigned to – Select the proper slot containing the XIO
Logix IO (basic PLC functionality) is not a card which is compatible for Logix IO
card which can be used for this purpose usage.
Logx IO Conflict 134 The XIO card previously being used for – Check the configuration of all XIO slots
Logix IO (basic PLC functionality) has been and reassign if necessary.
reassigned for another purpose.
WARNING WARNING
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
Master UV 112 The measured value V Master Average – Verify the VSB connections and tap
(P136) is less than Line Undervoltage Trip settings, and check resistance of VSB
(P167) with respect to 1/3 Rated Line board – Megger board to confirm integrity
Voltage (P18) [for 18-pulse drives], and – Check TSN fusing
Rated Line Voltage (P18) [for 6-pulse and – Check actual voltage values on the
PWM drives] for the period set by Line Terminal for each bridge and the total
Undervoltage Delay (P168). line voltage
– Check for possible source voltage
supply problems
– Use Multimeter and Oscilloscope to
check voltages on the drive test points
Motor Cap Range 23 The calculated per unit value of the Motor – Verify capacitor nameplate data and
Filter Capacitor (P128), based on the values compare with information entered in
entered for Motor Capacitor kVAR (P20), drive
Motor Capacitor Volts (P21), and Motor – Contact factory
Capacitor Frequency (P28) is outside of the
normal range of 0.26-0.55 pu.
Motor DC Link OV 192 DC Link Voltage on the motor side, – Verify the motor is connected and the
measured through the Voltage Sensing Output Contactor is not open
Board, has exceeded Motor DC Overvoltage – Verify there is no open SGCTs Complete
Trip (P193), and instantaneously causes a a Resistance and Firing check
warning. – Check VSB circuit (grounds) through to
SCB-M
– Check Burden resistor values
– Check the trip parameter setting
Motor Load Loss 41 The drive has detected a loss of load – Verify the parameter settings
condition. This is activated as a warning – Ensure that the load should not normally
using the parameter Load Loss Detect be in an unloaded condition
(P199), and the necessary setpoints are
Load Loss Level (P246), Load Loss Delay
(P231), and Load Loss Speed (P259).
Motor OL 17 A Motor Overload warning has been – Transient Loading - Check torque limit
detected, where the overload condition is and overload settings and Compare
calculated using I Stator (P340) and Motor loading to torque settings and trip
Overload Warning (P351) as the point settings
where the overload warning occurs. P351 is
programmed as a percentage of the
difference between Motor Overload Min
(P350) and Motor Overload Trip (P179).
Motor OV 193 The measured Motor AC Voltage has Possible Causes:
exceeded Motor Overvoltage Trip (P181) for Noise from contactor closure
the duration set in Motor Overvoltage Delay Self-Excitation – Check for flying
(P182), but this has occurred with the drive start/induced motor rotation
NOT gating (as in a Sync Transfer event)
Motor Protection 68 Standard External Fault/Warning Input – See associated Fault Description
included to allow the end-user to install a
protective relay (IE Bulletin 825 Motor
Protection Relay) auxiliary contact that can
activate a drive fault or warning, depending
on configuration of Motor Prot Class (P443).
WARNING WARNING
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
Mtr Cap OV W 334 Motor Filter Capacitor Over Voltage – This warning occurs when drive is not
gating. It may be when motor is
coasting.
– This is drive output V [Surface voltage
terminology used in ESP application].
The drive gives this warning in an ESP
application only.
– The protection uses P#181 setting but
drive calculates the motor filter cap
voltage [Surface V] which is different
from motor voltage in ESP application.
No DO/OP Ctctr 190 This warning is specifically used for Open – If there truly is no Output Contactor in the
Circuit Test Mode, which demands that an system, then you can mask the fault.
Output Contactor be specified in IsoSw/Ctctr Then there will be a No OP Ctctr
Cfg (P192). You will get this warning if the warning, and you can continue with the
No DO/OP Ctctr fault is masked, and you test.
are attempting Open-Circuit Test. – ENSURE THE OUTPUT OF THE DRIVE
IS TRULY OPEN-CIRCUITED
No PLL Lock 117 The drive has lost synchronization with the – Capture the voltage waveforms from the
incoming line voltage, and has announced a SCB-L test points and examine for
Phase Lock Loop warning. inconsistency
– Verify that the drive power system is
properly grounded
– Check for noise on the control power in
the drive
– Check the grounding for all signal and
control wiring
– Verify the Commutation Inductance
parameter is valid and retune if required
No Tach Installd 36 The drive has sensed that there is no – Verify whether there is a tachometer
tachometer/encoder connected, but the required for the system, and set the
Speed Feedback Mode (P89) has been set parameter Speed Feedback Mode
to Pulse Tach. accordingly
– Investigate the tachometer for damage
– Verify the wiring from the drive to the
tachometer is per the Electrical Drawing
– Verify the +15VDC supplying the
tachometer is not low/missing
NVRAM Cleared 87 The parameters stored in the NVRAM of the – Reload parameters from Terminal
DCB are corrupt and have been set to Memory. DriveTools, Flashcard, or from
default values. This can occur if new a hardcopy
firmware has been loaded into the DCB or – Replace PowerCap on DCB-L
Power Capacitors are low. – If parameters still can not be saved,
replace the DCBs
Opt Flt Config 129 The XIO card which was being assigned to – Select the proper slot containing the XIO
the Optional Faults Input is not a card which card which is compatible for Optional
can be used for this purpose. Faults usage.
Opt Flt Conflict 130 The XIO card previously being used for – Check the configuration of all XIO slots
Optional Faults has been reassigned for and reassign if necessary.
another purpose.
WARNING WARNING
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
Parameter Range 88 A parameter was read from NVRAM or the – If this was a result of an INIT operation,
DIM, which was outside the valid range. contact the factory
The parameter has been set to a default – If this was a result of a LOAD operation,
value. The Linear # of this parameter has correct the parameter value and perform
been stored in "Parameter Error", under the a SAVE operation
Feedback grouping. – Check the settings on the DIM to
determine whether it is limiting the
paramter’s max or min values.
Phantom Alarm 93 DEVELOPMENT ERROR - An unused bit in – Noise/Grounding Issue
the last 16 bits in either a fault or warning – Contact the factory
word has been set and detected by the
Alarm Queue server. These bits are never
used in firmware. Either a used bit has
been overlooked in the Faults/Warnings
database, or the control is incorrectly setting
an alarm word.
Pump Failure The drive has detected a fault from one of – Verify the Pump O/L settings and
(C-FRAME ONLY) the pumps in the cooling circuit. conditions
143
– Verify the Pump Control Relay status
and auxiliary contact signals.
Queues Cleared 91 This means that the drive had to clear the – This was an issue because the memory
fault and warning queues after an upgrade structure changed in 3.xxx firmware
of the firmware – No action is required
R Stator High 52 Autotune Rs (P219) measured during the – REFER TO THE POWERFLEX 7000
autotune test was higher than 0.20 pu, SERIES B MANUAL (CHAPTER 4 –
indicating the presence of extremely long COMMISSIONING) ON AUTOTUNE
motor leads. PROCEDURES, RESULTS, AND
ACTIONS
– Ensure motor windings are connected
properly.
Rec Gate Pwr 205 Rectifier Gate driver power supply warning – The device feedback was not correct due
to power loss to the gate driver board.
– This can be from the 20V DC output of the
IGDPS or on the gate driver board itself.
– This warning can also appear as a result of
another device fault such as an Online
Fault.
Rec Heatsink FO 203 While Not Running, the Fiber Optic signal – Check TFB and FOI board for power
from the TFB on the Rectifier Heatsink, – Check the Fiber Optic cables are properly
connected to Channel A fiber optic receiver seated in the transmitters and receivers
RX7 on FOI-L-A is not present. This is only – Check the fiber optic cable for kinks, bends,
a fault while not running. If this occurs while breaks that could be blocking the signal
running it will appear as a warning. – This can occur if the sensor is not
Rec ChannelB FO 204 Not Normally Used: While Not Running, the connected to the TFB
Fiber Optic signal from the optional TFB NOTE: This is a warning because the
connected to Channel B fiber optic receiver drive should not fault on the loss of the
RX7 on FOI-L-B is not present. This is only signal while running. There is no
a fault while not running. If this occurs while imminent danger to the drive, but the
running it will appear as a warning. user needs to be aware that there is a
temperature feedback signal missing.
WARNING WARNING
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
Rec Heatsink OT 121 The temperature detection on the Rectifier – Confirm actual temperature in
Heatsink, connected to Channel A fiber optic parameters is not higher than the
receiver RX7 on FOI-L-A, has exceeded warning value – If so, investigate the
Rectifier Heatsink Temperature Warning conditions of the drive (ambient / loading
(P112). / elevation / ventilation/ filter status /
Rec ChannelB OT 122 Not Normally Used – The temperature heatsink clogging)
detection on a Rectifier Heatsink, connected – Check TFB and FOI board for power
to fiber optic receiver RX7 on FOI-L-B, has and fiber optic integrity
exceeded Rectifier Temperature Warning – Check the sensor and temperature
Channel B (P526). offline (ambient) for accuracy
Rec HS Sensor 201 While Running, the drive has detected a – Verify sensor is completely seated
missing temperature sensor connected to properly on TFB.
the TFB on the rectifier heatsink. A missing – Measure sensor resistance.
sensor can result in either a Fiber Optic – Replace if necessary.
Loss fault or a Sensor fault because a
missing sensor can be interpreted as either – NOTE: This is a warning because the
0°C or over 100°C, and both are unrealistic drive should not fault on the loss of the
values. signal while running. There is no
Rec ChB Sensor 202 Not normally used: While Running, the imminent danger to the drive, but the
drive has detected a missing temperature user needs to be aware that there is a
sensor connected to the optional TFB temperature feedback signal missing.
connected to the fiber optic receiver RX7 on
FOI-L-B. A missing sensor can result in
either a Fiber Optic Loss fault or a Sensor
fault because a missing sensor can be
interpreted as either 0°C or over 100°C, and
both are unrealistic values.
Reg in Limit 51 Either the Speed Regulator or the Flux – REFER TO THE POWERFLEX 7000
Regulator autotune test hit the regulator limit SERIES B MANUAL (CHAPTER 4 –
and the results of the test are not valid. COMMISSIONING) ON AUTOTUNE
PROCEDURES, RESULTS, AND
ACTIONS
Slip Range 189 This warning appears when unusual values – Verify Motor Nameplate Data
for slip appear, indicating there is either an – Contact the factory with the motor data
error in data or an unusual motor. The rated and the application information
slip for this warning has to be > 10%, or <
0.01%
Slave 0-7 OffL 348-355 Slave (0-7) DAN Communication Loss- – Slave is Off line.
Master only
Slave1 UV 113 The measured value V Slave1 Average – Verify the VSB connections and tap
(P137) is less than Line Undervoltage Trip settings, and check resistance of VSB
(P167) as a percentage of 1/3 Rated Line board – Megger board to confirm integrity
Voltage (P18), for the period set by Line – Check TSN fusing
Undervoltage Delay (P168). – Check actual voltage values on the
Slave2 UV 114 The measured value V Slave2 Average Terminal for each bridge and the total
(P138) is less than Line Undervoltage Trip line voltage
(P167) as a percentage of 1/3 Rated Line – Check for possible source voltage
Voltage (P18), for the period set by Line supply problems
Undervoltage Delay (P168). – Use Multimeter and Oscilloscope to
check voltages on the drive test points
WARNING WARNING
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
Slv RfsdMstr 343 Slave refused Master-master only – Slave has lost communication with hub
PLC, or slave is masked off in parameter
Master Mask
Speed Cmd Loss 183 The drive has lost communication with the – Ensure that the SCANport device is
device responsible for providing the speed powered
command to the drive. This has been set to – Verify the SCANport light status and
annunciate as a warning. ensure the device is operating properly
– Verify the customer SCANport network
is properly communicated with the device
– Check CIB LED status
– Cycle control power to the drive
SpdProfile Limit 92 The sum of the individual ramp times has – Review Ramp settings and adjust
exceeded the maximum value for Total accordingly to ensure they do not
Acceleration Time exceed the Total Acceleration Time
Sync Xfer Failed 40 A Synchronous Transfer was not completed – Verify that the setup for Synchronous
in the time specified in Synchronous Transfer has been completed
Transfer Time (P230). This warning will – Verify that the drive can reach
occur if the Sync Transfer fault is masked, synchronous speed
and the drive will continue to run at the last – Once stability has been verified, the
Reference Command before a parameters can be altered to reduce
synchronization command was initiated. restrictions on synchronous transfer
T DC Link High 58 Indicates that the Autotune Tdc (P218) – REFER TO THE POWERFLEX 7000
measured was greater than 0.100 pu, and SERIES B MANUAL (CHAPTER 4 –
the T DC Link (P115) will have to be tuned COMMISSIONING) ON AUTOTUNE
manually. PROCEDURES, RESULTS, AND
T DC Link Low 57 Indicates that the Autotune Tdc (P218) ACTIONS
measured was less than 0.020 pu, and the T
DC Link (P115) will have to be tuned
manually.
T Rotor Low 63 Indicates that the Autotune T rotor (P222)
measured was less than 0.2 sec, and T rotor
(P132) will have to be tuned manually.
T Rotor High 64 Indicates that the Autotune T rotor (P222)
measured was greater than 5.0 sec, and T
rotor (P132) will have to be tuned manually.
Tach Loss W 33 The tachometer feedback has varied from – The drive should annunciate the warning
the reference command by the value set in and continue to run on Stator feedback
Tach Loss Trip(P235) for the duration set in – Verify that the parameter Tachometer
Tach Loss Delay (P236). Feedback (Line or Motor) is/ is not giving
the correct feedback while running
– Investigate the tachometer for damage
– Scope the tachometer pulses on SCB
and verify they are not corrupted by for
example dust in the Optic disc of the tach.
– Verify the wiring from the drive to the
tachometer is per the Electrical Drawing
– Verify the +15VDC supplying the
tachometer is not low/missing
WARNING WARNING
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
Tach Power 35 +15VDC from the DC/DC power supply, – Check the output of the DC/DC power
sensed on the CIB, is less than the 95% supply
alarm level. – Check the wiring from the power supply
to the CIB
– Verify the tachometer/encoder wiring
Tach Reversed 34 The drive has sensed that the 2 channels – Set the parameter Tachometer Select to
(generally A and B) are reversed. ‘None’ and verify the parameter
Tachometer Feedback (Line or
Motor)shows the reverse speed
– Reverse the tachometer channels
Temp Feedback Ls 152 While Running, the drive has detected a – Verify sensor is completely seated
(C-Frame Only) missing temperature feedback. A missing properly on TFB.
sensor can be interpreted as either 0°C or – Measure sensor resistance.
over 100°C, and both are unrealistic values. – Replace if necessary.
Tuning Abort 49 Autotuning was unable to complete the – Investigate why the Autotune Test
commanded autotune test in a preset time aborted, and Retry Autotune Test
limit of 2 minutes. – Verify Autotune default parameters are
sufficient to complete test
– Attempt Manual Tuning
UPS Battery Low 106 Warning that the UPS Battery is low. – This is not very useful as the UPS
battery low occurs at the point where the
UPS can no longer run and a fault is
initiated.
UPS Failed 107 The UPS has had an internal failure. This is – Investigate the cause for the UPS failure
a warning because we do not want a – Check batteries
signal/wiring error to fault the drive. We are – Verify input voltage/UPS wiring
relying on the subsequent power supply – Refer to UPS manual
faults to protect the drive. – Replace UPS if required
UPS on Battery 105 Warning that the UPS is now on battery – Check for the reason that the UPS was
power required, and rectify the situation before
the battery power expires
UPS on Bypass 104 Warning that the UPS is now on Bypass. – Investigate cause for initial transfer to
This occurs when the drive has switched to UPS, and correct.
UPS, but a UPS fault has forced the system – Then investigate why the UPS failed and
to switch to Bypass, if available. was forced to go to bypass
USART Power 110 Warning that USART voltage detected on – Check all DC/DC voltages test points on
Loss the CIB is low. CIB (+5V, +15V, +3.3V)
– Replace DC/DC PS or CIB as required.
WARNING WARNING
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
Xfer Disable 345 Transfer Disabled-master only – Transfer of master not allowed while
drive is stopping
XIO Card #1-6 Loss 81-86 An XIO card has dropped off the – Reset the board in an attempt to re-
communications link between the XIO cards establish communications.
and the CIB. – Check all connections between the
Customer Interface Board and the
jumpers between individual adapters
– Verify the status of all XIO adapters by
comparing the LED status to the table in
the manual.
XIO Power Loss 108 The 24V to the XIO boards has dropped – Verify DC/DC power supply output
below the set trip level, which is 95% of – Confirm wiring to the CIB from the
rated voltage. DC/DC Power Supply
– Check XIO LED status and compare to
values in the manual
Zero Slip 28 The value for Rated Motor RPM (P26) is the – Verify Rated Motor RPM is less than
same as speed calculated from Motor Poles synchronous speed
(P99) and Rated Motor Frequency (P29).
WARNING WARNING
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
U1A Device Wrn 228 INVERTER SGCT WARNING – Complete a resistance check per the
U1B Device Wrn 234 FOR REDUNDANT DEVICES or N-1 instructions in the manual
U1C Device Wrn 246 CAPABILITY ONLY – NOTE: SGCTs may not have completely
shorted, and still could read in the kΩ
U4A Device Wrn 231
This warning will only occur during the initial range – Any devices with low suspect
U4B Device Wrn 237 contactor closure and the diagnostic readings should be changed in matched
U4C Device Wrn 249 sequence after a start command. The sets during the next outage
V3A Device Wrn 230 inverter monitors the state of the feedback – Check the LED status of the SCGT gate
before a gate pulse is given, and monitors driver card for abnormal readings
V3B Device Wrn 236
the feedback after a gate pulse has been – Complete a Gating Test mode check on
V3C Device Wrn 242 sent. The SGCT has smart diagnostics, so the devices
V6A Device Wrn 233 the feedback may indicate short before – Verify the associated 20V power supply
V6B Device Wrn 239 firing, and if the pulse is received and the is powered and active
V6C Device Wrn 251 device is really shorted, the diagnostic will – Verify all the power connections to the
toggle the feedback to let you know the SCGT firing card are seated properly
W2A Device Wrn 229
problem is with the device, or the power
W2B Device Wrn 235 supply for that device.
– NOTE: For Redundant devices, there
W2C Device Wrn 247
will be no change in the drive operation.
W5A Device Wrn 232 The firmware now completes a diagnostics For N-1 drives, the drive will attempt to
W5B Device Wrn 238 sequence immediately after any drive reset, run at a load/speed combination that
with the goal of detecting problems before does not exceed the voltage rating of the
W5C Device Wrn 250
any destructive action is taken from the next remaining devices.
action
U1A Online Wrn 216 INVERTER SGCT WARNING – Complete a resistance check per the
U1B Online Wrn 222 FOR REDUNDANT DEVICES or N-1 instructions in the manual
U1C Online Wrn 240 CAPABILITY ONLY – NOTE: SGCTs may not have completely
shorted, and still could read in the kΩ
U4A Online Wrn 219
This warning will occur during operation of range – Any devices with low suspect
U4B Online Wrn 225 the drive. The drive has detected that the readings should be changed
U4C Online Wrn 243 feedback from the device was not correct, – Check the LED status of the SCGT gate
V3A Online Wrn 218 and does not wait to determine the exact driver card for abnormal readings
problem. The drive polls the entire bridge 3 – Complete a Gating Test mode check on
V3B Online Wrn 224
times before and 3 times after each gating the devices
V3C Online Wrn 242 command. All 6 of these readings for each – Verify the associated 20V power supply
V6A Online Wrn 221 device must be consistent for the warning to is powered and active
V6B Online Wrn 227 occur. There is also a parameter called – Verify all the power connections to the
V6C Online Wrn 245 Inverter Device Diagnostic Delay (P268), SCGT firing card are seated properly
which allows you to change the number of – For nuisance faults, contact the factory
W2A Online Wrn 217
consecutive firings to eliminate nuisance about extending the Diagnostic Delay
W2B Online Wrn 223 faults. It will still poll 3 times before and
W2C Online Wrn 241 after each firing, but will now require the
– NOTE: For Redundant devices, there
W5A Online Wrn 220 condition to exist for the number of
will be no change in the drive operation.
226 consecutive firings set in the Diagnostic
W5B Online Wrn For N-1 drives, the drive will attempt to
Delay parameter for a warning to occur.
W5C Online Wrn 244 run at a load/speed combination that
does not exceed the voltage rating of the
The firmware now completes a diagnostics remaining devices.
sequence immediately after any drive reset,
with the goal of detecting faults before any
destructive action is taken from the next
action
WARNING WARNING
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
2U1A Device Wrn 264 PWM RECTIFIER SGCT WARNING – Complete a resistance check per the
2U1B Device Wrn 270 FOR REDUNDANT DEVICE CAPABILITY instructions in the manual
2U1C Device Wrn 282 ONLY – NOTE: SGCTs may not have completely
shorted, and still could read in the kΩ
2U4A Device Wrn 267
This warning will occur during the initial range – Any devices with low suspect
2U4B Device Wrn 273 contactor closure, the diagnostic sequence readings should be changed
2U4C Device Wrn 285 after a start command, or the diagnostic – Check the LED status of the SCGT gate
2V3A Device Wrn 266 sequence after a stop command. The driver card for abnormal readings
rectifier monitors the state of the feedback – Complete a Gating Test mode check on
2V3B Device Wrn 272
before a gate pulse is given, and monitors the devices
2V3C Device Wrn 284 the feedback after a gate pulse has been – Verify the associated 20V power supply
2V6A Device Wrn 269 sent. The SGCT has smart diagnostics, so is powered and active
2V6B Device Wrn 275 the feedback may indicate short before – Verify all the power connections to the
2V6C Device Wrn 287 firing, and if the pulse is received and the SCGT firing card are seated properly
device is really shorted, the diagnostic will
2W2A Device Wrn 265
toggle the feedback to let you know the – NOTE: There is only the Redundant
2W2B Device Wrn 271 problem is with the device, or the power option available on the Rectifier, and
2W2C Device Wrn 283 supply for that device. only on 6P drives (SCR orPWM). You
2W5A Device Wrn 268 can not have N-1 operation on the
2W5B Device Wrn 274 The firmware now completes a diagnostics rectifier since we can not control the line
sequence immediately after any drive reset, voltage.
2W5C Device Wrn 286
with the goal of detecting warnings before
any destructive action is taken from the next
action. The main example of this is closing
the input contactor on a shorted bridge.
2U1A Online Wrn 252 PWM RECTIFIER SGCT WARNING – Complete a resistance check per the
2U1B Online Wrn 258 FOR REDUNDANT DEVICES CAPABILITY instructions in the manual
2U1C Online Wrn 276 ONLY – NOTE: SGCTs may not have completely
shorted, and still could read in the kΩ
2U4A Online Wrn 255
This warning will occur during operation of range – Any devices with low suspect
2U4B Online Wrn 261 the drive. The drive has detected that the readings should be changed
2U4C Online Wrn 279 feedback from the device was not correct, – Check the LED status of the SCGT gate
2V3A Online Wrn 254 and does not wait to determine the exact driver card for abnormal readings
problem. The drive polls the entire bridge 3 – Complete a Gating Test mode check on
2V3B Online Wrn 260
times before and 3 times after each gating the devices
2V3C Online Wrn 278 command. All 6 of these readings for each – Verify the associated 20V power supply
2V6A Online Wrn 257 device must be consistent for the warning to is powered and active
2V6B Online Wrn 263 occur. There is also a parameter called – Verify all the power connections to the
2V6C Online Wrn 281 Rectifier Device Diagnostic Delay (P266), SCGT firing card are seated properly
which allows you to change the number of
2W2A Online Wrn 253 – Reset the drive and let the offline
consecutive firings to eliminate nuisance diagnostics further define the problem
2W2B Online Wrn 259 warnings. It will still poll 3 times before and
– For nuisance faults, contact the factory
2W2C Online Wrn 277 after each firing, but will now require the
about extending the Diagnostic Delay
2W5A Online Wrn 256 condition to exist for the number of
2W5B Online Wrn 262 consecutive firings set in the Diagnostic
Delay parameter for a warning to occur. – NOTE: There is only the Redundant
2W5C Online Wrn 280 option available on the Rectifier, and
only on 6P drives (SCR orPWM). You
The firmware now completes a diagnostics
can not have N-1 operation on the
sequence immediately after any drive reset,
rectifier since we can not control the line
with the goal of detecting warnings before
voltage.
any destructive action is taken from the next
action
WARNING WARNING
DESCRIPTION RECOMMENDED ACTIONS
MESSAGE CODE
2U1A Offline SC 300 6P SCR RECTIFIER WARNING – Complete a resistance check on the
2U1B Offline SC 306 (Offline Short-Circuit) rectifier, including the gate-cathode
FOR REDUNDANT DEVICE CAPABILITY resistance, the snubber and sharing
2U1C Offline SC 318
ONLY resistors
2U4A Offline SC 303 – Complete a firing check on the rectifier
2U4B Offline SC 309 – Verify the snubber circuitry, and the
For SCR rectifiers, this warning will occur
2U4C Offline SC 321 after the initial contact closure, or during the sharing resistors
2V3A Offline SC 302 diagnostic sequence after a start command. – Verify fiber optic integrity from SCRGD
2V3B Offline SC 308 This is the first test on the rectifier. When all board transmitter to FOI board receiver
2V3C Offline SC 320 devices blocking, the feedback from the – Replace all faulty components
devices should toggle from open to short to
2V6A Offline SC 305 open every time the line voltage sine wave – NOTE: There is only the Redundant
2V6B Offline SC 311 passes through zero. If this is consistently option available on the Rectifier, and only
2V6C Offline SC 323 showing short (no feedback), then the drive on 6P drives (SCR orPWM). You can
2W2A Offline SC 301 assumes that the device is Short-Circuited. not have N-1 operation on the rectifier
2W2B Offline SC 307 since we can not control the line voltage.
2W2C Offline SC 319
2W5A Offline SC 304
2W5B Offline SC 310
2W5C Offline SC 322
2U1A Online SC 288 6P SCR RECTIFIER WARNING – For multiple device faults, the risk of a
2U1B Online SC 294 (Online Short-Circuit) line to line short exists, so tests with MV
FOR REDUNDANT DEVICE CAPABILITY isolated should be attempted
2U1C Online SC 312
ONLY – Complete a resistance check on the
2U4A Online SC 291 rectifier, including the gate-cathode
2U4B Online SC 297 resistance, the snubber and sharing
For SCR rectifiers, this warning will occur
2U4C Online SC 315 during operation. Before an individual leg is resistors
2V3A Online SC 290 fired, the drive takes 5 samples of the – Complete a firing check on the rectifier
voltage across that device. This is because – Verify the snubber circuitry, and the
2V3B Online SC 296 sharing resistors
2V3C Online SC 314 the notching on the line could cause
individual readings to be low. If they are all – Verify fiber optic integrity from SCRGD
2V6A Online SC 293 low, the device is assumed to be short- board transmitter to FOI board receiver
2V6B Online SC 299 circuited and a warning occurs. There is – Replace all faulty components
2V6C Online SC 317 also a parameter called Rectifier Device – For nuisance faults, contact the factory
Diagnostic Delay (P266), which allows you about extending the Diagnostic Delay
2W2A Online SC 289
to change the number of consecutive firings
2W2B Online SC 295 – NOTE: There is only the Redundant
to eliminate nuisance warnings. It will still
2W2C Online SC 313 check 5 times before each firing, but will option available on the Rectifier, and
2W5A Online SC 292 now require the condition to exist for the only on 6P drives (SCR orPWM). You
2W5B Online SC 298 number of consecutive firings set in the can not have N-1 operation on the
Diagnostic Delay parameter for a warning to rectifier since we can not control the line
2W5C Online SC 316 voltage.
occur.
X R6LR – 6-pulse rectifier with integral line reactor and input starter
R6TX – 6-pulse rectifier for connection to remote transformer
R6TXI – 6-pulse rectifier with integral transformer
RPLR – PWM rectifier with integral transformer
RPTX – PWM rectifier for connection to remote transformer
RPTXI – PWM rectifier with integral transformer
RPDTD – Direct-to-Drive Technology
Table A-1
Catalog Number Descriptions
Catalog Number Description
7000A PowerFlex 7000 “A” Frame, Variable Frequency AC Drive, Air-cooled
Table A-2
Service Duty Rating, Continuous Current Rating and Altitude Rating Code
Continuous Current Capability
Service Duty Rating and Altitude Rating Code
Code Rating
A = Normal Duty 40 40 Amp.
0-1000 m Altitude (@ 40°C ambient) 46 46 Amp.
53 53 Amp.
B = Normal Duty 61 61 Amp.
1001-5000 m Altitude 70 70 Amp.
(2000 m Altitude @ 37.5°C ambient) 81 81 Amp.
(3000 m Altitude @ 35.0°C ambient) 93 93 Amp.
(4000 m Altitude @ 32.5°C ambient) 105 105 Amp.
(5000 m Altitude @ 30.0°C ambient) 120 120 Amp.
C = Heavy Duty, 0-1000 m Altitude 140 140 Amp.
(maximum 40°C ambient) 160 160 Amp.
D= Heavy Duty
1001-5000 m Altitude
(2000 m Altitude @ 37.5°C ambient)
(3000 m Altitude @ 35.0°C ambient)
(4000 m Altitude @ 32.5°C ambient)
(5000 m Altitude @ 30.0°C ambient)
Table A-3
Supply Voltage, Control Voltage, Frequency and Control Power Transformer Selection
Voltage Frequency Modification Number
Nominal (Hz) With a Without a
Control
Line C.P.T. C.P.T.
120 A AD
2400 60
120-240 AA —
110 CY CDY
3300 50
220 CP CDP
110 EY EDY
50
220 EP EDP
4160
120 E ED
60
120-240 EA —
110 JY JDY
6600 220 50 JP JDP
110-220 JAY —
A Control Power Transformer modification must be selected (6, 6B ...etc.) to size the transformer.
Control Circuit Power is supplied from a separate/external source. Terminal blocks shall be provided to accommodate.
PowerFlex 7000 The PowerFlex 7000 “A” Frame medium voltage AC drive selection
“A” Frame Drive tables are based on two (2) types of drive service duty ratings:
Selection Explanation
1) Normal Duty (110% overload for one (1) Minute, once every
10 minutes) – used for Variable Torque (VT) applications only.
Drives with this rating are designed for 100% continuous operation,
with 110% overload for one (1) minute, once every 10 minutes.
2) Heavy Duty (150% overload for one (1) Minute, once every 10
minutes) – used for Constant Torque (CT) applications only.
Drives with this rating are designed for 100% continuous operation
with 150% overload for one (1) minute, once every 10 minutes.
There are different codes that define service duty and altitude in the
drive catalog number per Table A-2.
For example,
Please note that the ambient temperature rating of the drive is reduced
at higher altitudes. If 40°C ambient is required at 1001-5000 meters
altitude, then a rating code of Z is required.
Notes:
Speed Regulation is based on % of motor synchronous speed.
Tachometer to be mounted on the AC machine
Operational 15 V DC Power Supply mounted in drive to power
the tachometer as a standard option with the tachometer feed
back card.
Customer is responsible for providing and mounting of
tachometer
Sleeve bearing motors require the tachometer to have an axial
movement tolerance.
Recommended tachometers are the shaft mounting type,
examples are the Avtron 585 and 685 models or the Northstar
(Lakeshore) RIM Tach HS85, 12 to 15V models or equivalent.
Magneto resistive models are more adaptable to harsh
environments.
When installing, the tachometer body and electronics must be
isolated from ground (options available from the tachometer
manufacturer to accomplish this).
When cable lengths exceed 305 m (1000 ft.) for the Northstar or
610 m (2000 ft.) for the Avtron, consult the factory.
Tachometer Selection
Recommended Tach PPR
Motor RPM Tach ppr
3600 600
3000 600
1800 1024
1500 1024
1200 2048
1000 2048
900 2048
720 2048
600 2048
PowerFlex 7000 The PowerFlex 7000 “A” Frame drives have been tested on a
“A” Frame Drive dynamometer to verify performance under locked rotor, accelerating,
Performance and low speed-high torque conditions. Table A-5 below shows the
PowerFlex 7000 “A” Frame drive torque capabilities as a percent of
(Torque Capabilities)
motor rated torque, independent of the drive’s momentary overload
conditions.
Table A-5
PowerFlex 7000 Drive Torque Capabilities
7000 Torque Capability 7000 Torque Capability
Parameter Without Tachometer With Tachometer
(% of Motor Rated Torque) (% of Motor Rated Torque)
Breakaway Torque 90% 150%
90% ( 0-8 Hertz ) 140% ( 0-8 Hertz )
Accelerating Torque
125% ( 9-75 Hertz ) 140% ( 9-75 Hertz )
100% ( 1-2 Hertz )
Steady State Torque 125% ( 9-75 Hertz ) **
140% ( 3-60 Hertz ) **
Maximum Torque Limit 150% 150%
** Drive will require over sizing to achieve greater than 100% continuous torque.
Glossary of Terms
Steady State Torque: Continuous operating torque required to control the load, without
instability.
Torque Limit: An electronic method of limiting the maximum torque available from
the motor.
The software in a drive typically sets the torque limit to 150% of motor
rated torque.
Table A-6
Typical Application Load Torque Profiles *
Load Load Torque as Percent Required Drive Tachometer
Application Torque of Full-Load Drive Torque Service Required for Extra
Profile Break-away Accelerating Peak Running Duty Rating Starting Torque?
Agitators
Liquid CT 100 100 100 Heavy Yes
Slurry CT 150 100 100 Heavy Yes
Blowers ( Centrifugal)
Damper Closed VT 30 50 40 Normal No
Damper Open VT 40 110 100 Normal No
Chipper ( Wood) Starting Empty CT 50 40 200 Contact Factory No
Compressors
Axial-vane, Loaded VT 40 100 100 Normal No
Reciprocating, start unloaded CT 100 50 100 Normal Yes
Conveyors
Belt type, loaded CT 150 130 100 Heavy Yes
Drag type CT 175 150 100 Contact Factory Yes
Screw type, loaded CT 200 100 100 Contact Factory Yes
Extruders (Rubber or Plastic) CT 150 150 100 Contact Factory Yes
Fans ( Centrifugal, ambient)
Damper closed VT 25 60 50 Normal No
Damper open VT 25 110 100 Normal No
Fans ( Centrifugal, hot gases)
Damper closed VT 25 60 100 Normal No
Damper open VT 25 200 175 Contact Factory No
Fans ( Propeller, axial flow) VT 40 110 100 Normal No
Kilns ( Rotary, loaded) CT 250 125 125 Contact Factory Yes
Mixers
Chemical CT 175 75 100 Contact Factory Yes
Liquid CT 100 100 100 Heavy Yes
Slurry CT 150 125 100 Heavy Yes
Solids CT 175 125 175 Contact Factory Yes
Pulper VT 40 100 150 Contact Factory No
Pumps
Centrifugal, Discharge open VT 40 100 100 Normal No
Oil field Flywheel CT 150 200 200 Contact Factory Yes
Propeller VT 40 100 100 Normal No
Fan Pump VT 40 100 100 Normal No
Reciprocating / Positive Displacement CT 175 30 175 Contact Factory Yes
Screw type, started dry VT 75 30 100 Normal No
Screw type, primed, discharge open CT 150 100 100 Heavy Yes
Slurry handling, discharge open CT 150 100 100 Heavy Yes
Turbine, Centrifugal, deep-well VT 50 100 100 Normal No
Vane-type, positive displacement CT 150 150 175 Contact Factory Yes
Separators, air ( fan type ) VT 40 100 100 Normal No
* NOTE: PowerFlex 7000 “A” Frame suitable only for normal duty service rating.
Table A-7
Normal Duty and Heavy Duty Ratings / Dimensions Table
VFD Total Width Approx.
Nominal Drive Type Structure
Maximum
Line and Weight
Current Code
Voltage Rectifier Type (mm) (inches) lb (kg)
(A)
Base Drive, 6 Pulse or PWM rectifier 160 2100 82.67 4300 (1955) 71.7
Integral Transformer, 6 Pulse
2400V 60 Hz 160 2400 94.49 4750 (2160) 71.3
or PWM rectifier
3300V 50 Hz Integral Line Reactor & Starter,
160 2400 94.49 9800 (4455) 71.4
4160V 50/60 Hz X 6 Pulse or PWM rectifier
Integral Line Reactor,
160 2400 94.49 4600 (2100) 71.11
6 Pulse or PWM rectifier
Base Drive, 6 Pulse or PWM rectifier 105 2400 94.49 6500 (2955) 71.8
Integral Transformer, 6 Pulse
105 2800 110 10000 (4545) 71.6
or PWM rectifier
6600V 50 Hz Integral Line Reactor & Starter,
105 2800 110 7500 (3410) 71.5
6 Pulse or PWM rectifier
Integral Line Reactor,
105 2800 110 6350 (2880) 71.12
6 Pulse or PWM rectifier
X 106 Amp rating is not available for drives rated at 4160V, 50 Hz.
Torque Requirements
for threaded fasteners
000 No Command
001 External Ref0 ( Front Panel Pot)
010 Preset 1
011 Preset 2
15,13 Speed Command Select
100 Preset 3
101 External Ref1 (Programmed Reference)
110 Manual Reference (Local DPI Adapter)
111 Not Used
000 No Command
001 External Ref0 ( Front Panel Pot)
010 Preset 1
011 Preset 2
15-13 Speed Command Select
100 Preset 3
101 External Ref1 (Programmed Reference)
110 Manual Reference (Local DPI Adapter)
111 Not Used
000 No Command
001 External Ref0 ( Front Panel Pot)
010 Preset 1
011 Preset 2
15-13 Speed Command Select
100 Preset 3
101 External Ref1 (Programmed Reference)
110 Manual Reference (Local DPI Adapter)
111 Not Used
Meggering
Drive Meggering When a ground fault occurs, there are three zones in which the
problem may appear: input to the drive, the drive, output to the
motor. When a ground fault occurs, it indicates a phase conductor
has found a path to ground. Depending on the resistance of the path
to ground, a current with magnitude ranging from leakage to fault
level exists. Based on our experiences in drive systems, the highest
probability for the source of the fault exists in either the input or
output zones. The drive itself rarely has been a source of a ground
fault when it is properly installed. This is not to say there will never
be any ground fault problems associated with the drive, but the
chances are the fault is outside of the drive. Also, the procedure for
meggering the drive is more complex than meggering outside the
drive.
Equipment Required
Torque Wrench and 7/16 inch socket
Phillips Screwdriver
2500/5000 Volt Megger
Procedure
1. Isolate and Lock Out the Drive System from High Voltage
Note: The VSB ribbon cable insulation is not rated for the
potential applied during a Megger test. It is important to
disconnect the ribbon cables at the VSB rather than the SCB
to avoid exposing the ribbon cables to high potential.
All three phases on the line and machine sides of the drive
are connected together through the DC Link and Snubber
Network. Therefore a test from any one of the input or
output terminals to ground will provide all the sufficient
testing required for the drive.
Reconnect the ribbon cables “J1”, J2” and “J3” in all the
VSBs. Do not cross the cable connections. Mixing the
feedback cables may result in serious damage to the drive.