Powerflex® 7000 Medium Voltage Ac Drive Air-Cooled ("A" Frame) - Forge Control

Bulletin 7000 User Manual
PowerFlex® 7000 Medium Voltage AC Drive Air-Cooled

(“A” Frame)—ForGe Control
(Using PanelView 550)
Publication 7000A-UM151D-EN-P
Important User Information
Solid-state equipment has operational characteristics differing from those of electromechanical 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://www.rockwellautomation.com/literature/) 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 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.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
IMPORTANT Identifies information that is critical for successful application and understanding of the product.
Allen-Bradley, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Table of Contents
Preface Overview Who should use this Manual ....................................................P-1

What is not in this Manual .......................................................P-1
Manual Conventions ................................................................P-2
General Precautions .................................................................P-3
Who to call for Commissioning ...............................................P-3
Chapter 1 Overview of Drive Introduction .............................................................................. 1-1

Drive Configurations ............................................................... 1-2
Topology .................................................................................. 1-3
Rectifier Designs
Active Front End (AFE) Rectifier .................................... 1-4
“Direct-to-Drive” Technology ................................................ 1-5
Motor Compatibility ................................................................ 1-6
Simplified Electrical Drawings
2400 volt – Active Front End (AFE) Rectifier .................. 1-7
3300/4160 volt – Active Front End (AFE) Rectifier ......... 1-8
6600 volt – Active Front End (AFE) Rectifier .................. 1-9
Operator Interface .................................................................. 1-10
Chapter 2 Drive Installation Safety and Codes ..................................................................... 2-1

General Handling Procedures .................................................. 2-1
Drive Storage ........................................................................... 2-1
Siting of the Drive ................................................................... 2-2
Site Considerations ............................................................ 2-2
Installation ............................................................................... 2-4
Installation of Exhaust Air Hood ...................................... 2-4
Installation of Integral Transformer Cooling Fan ............. 2-8
Neutral Resistor Assembly ............................................... 2-9
Installation of Neutral Resistor Assembly ...................... 2-10
Cabinet Layout and Dimensional Drawings of Drive ............ 2-11
PowerFlex 7000 “A” Frame Dimensional Drawing .............. 2-12
Drive Layout .......................................................................... 2-13
Direct-to-Drive AFE Rectifier Configuration #1 ............ 2-13
AFE Rectifier (Separate Isol. Transformer (Config. #2) ..... 2-14
AFE Rectifier (Integral Isol. Transformer (Config. #3) ....... 2-15
Cabling Cabinet #1 (with Input Starters) .............................. 2-16
Cabling Cabinet #1 (without Input Starters) ......................... 2-17
Cabling Cabinet #2 ............................................................... 2-18
Cabling Cabinet #3 ............................................................... 2-19
Converter Cabinet .................................................................. 2-20
Control/DC Link/Fan Cabinet ............................................... 2-21
Low Voltage Control Tub ...................................................... 2-22
IEC Component and Device Designations ............................ 2-24
Power Wiring Selection ......................................................... 2-24
Cable Insulation .............................................................. 2-25
Wire Group Numbers ...................................................... 2-26
7000 “A” Frame 7000A-UM151D-EN-P – March 2013

ii Table of Contents
Chapter 2 Drive Installation Power Cabling Access ........................................................... 2-27

(cont.) To access the customer power cable terminations .......... 2-27
Power Connections ................................................................ 2-28
Line/Motor Terminations ................................................ 2-28
Power Cabling Installation Requirements ....................... 2-28
Dimension Views:
Cabling Cabinet for Config. #1 with Input Starter ......... 2-29
Cabling Cabinet for Config. #1 without Input Starter ..... 2-30
Cabling Cabinet for Config. #2 ...................................... 2-31
Cabling Cabinet for Config. #3 ...................................... 2-32
Power and Control Wiring ..................................................... 2-33
Control Cables ................................................................ 2-33
Grounding Practices ............................................................... 2-34
Grounding Guidelines and Practices for Drive Signal
and Safety Grounds ................................................... 2-35
Grounding Requirements and Specifications for
Customer and Power Integrators .............................. 2-36
Identification of Types of Electrical Supplies
– Grounded and Ungrounded Systems ..................... 2-36
Ground Bus ..................................................................... 2-36
Interlocking ............................................................................ 2-37
Chapter 3 Operator Interface Chapter Objectives ................................................................... 3-1

Terminology ............................................................................ 3-1
Overview ................................................................................. 3-3
Keypad .............................................................................. 3-3
Function (Softkeys) Keys ........................................... 3-3
Cursor (Selection) Keys .............................................. 3-4
Data Entry Keys .......................................................... 3-4
What is a Screen? .............................................................. 3-5
Components ................................................................ 3-5
Information Windows ................................................. 3-6
Accessing/Writing to Drive .................................. 3-7
Communication Error ........................................... 3-7
Language Changing ............................................. 3-8
General Operation ....................................................... 3-8
Operator Interface Power-up Sequence ............................. 3-9
Top Level Menu .............................................................. 3-11
How to:
Obtain Help ..................................................................... 3-12
Related Topics .......................................................... 3-12
Help On Help ............................................................ 3-13
Modify Operator Interface Operation (Utility) ............... 3-14
Changing Backlight Delay ........................................ 3-14
Changing Contrast .................................................... 3-15
7000A-UM151D-EN-P – March 2013 7000 “A” Frame

Table of Contents iii
Chapter 3 Operator Interface Setting Time ............................................................. 3-16

(cont.) Setting Date .............................................................. 3-17
Selecting Meters ....................................................... 3-17
Viewing Revision Levels .......................................... 3-20
Transfer Data in Memory ......................................... 3-21
Picking an Access Level ........................................... 3-21
Select a Parameter ............................................................ 3-22
Via Groups ................................................................ 3-22
Via Name .................................................................. 3-23
Via Code ................................................................... 3-24
Edit Text .......................................................................... 3-26
Configure the Drive ......................................................... 3-28
Enter/Modify an Access Level ................................. 3-28
Drive Set-up .............................................................. 3-32
Language Selection ............................................ 3-33
Modify Parameters ............................................. 3-34
Numerical Value ................................................ 3-34
Enumerated Value .............................................. 3-36
Bit Encoded Value ............................................. 3-37
Analog Ports ....................................................... 3-38
Fault Masks ........................................................ 3-39
User Definable External Text ............................. 3-42
PLC .................................................................... 3-43
XIO ..................................................................... 3-45
Message Prompting .................................................. 3-45
Store/Retrieve Configuration (NVRAM) ................. 3-46
Initialize ............................................................. 3-46
Save .................................................................... 3-47
Load ................................................................... 3-47
Display Parameters .......................................................... 3-48
Custom Group ........................................................... 3-50
View Drive Status ........................................................... 3-51
View and Reset Alarms ................................................... 3-51
Help for Alarms ........................................................ 3-52
Request Printouts ............................................................ 3-53
Loading Programs (Firmware) ........................................ 3-54
Parameter Transfers ........................................................ 3-56
Upload to Operator Interface ............................. 3-57
Download from Operator Interface .................... 3-57
Upload to Memory Card .................................... 3-57
Download from Memory Card ........................... 3-58
Parameter File Format ........................................ 3-58
Loading Language Modules ............................................ 3-59
System Programming ...................................................... 3-60

iv Table of Contents
Chapter 3 Operator Interface Operator Interface Menu Hierarchy Chart

(cont.) What does it show? ......................................................... 3-61
How do you read it? ........................................................ 3-61
Example ........................................................................... 3-62
PowerFlex 7000 “A” Frame Terminal Menu Tree .......... 3-63
PCMCIA Memory Card Installation Data
Description ...................................................................... 3-65
Installing the Memory Card ............................................ 3-65
Chapter 4 Component Definition Cabling Cabinet for Config. #1 (Direct-to-Drive) ................. 4-1
and Maintenance Cabling Cabinet for Config. #1
(Direct-to-Drive, optional Input Starter) .......................... 4-2
Cabling Cabinet for Config. #2
(AFE Rectifier with Separate Isolation Transformer) ....... 4-3
Cabling Cabinet for Config. #3
(AFE Rectifier with Integral Isolation Transformer) ....... 4-4
Converter Cabinet Components ............................................... 4-5
Converter Cabinet .................................................................... 4-6
Surge Arresters ....................................................................... 4-6
Description ....................................................................... 4-6
Operation .......................................................................... 4-7
Field Test and Care .......................................................... 4-7
PowerCage™ ........................................................................... 4-8
SGCT and Snubber Circuit .................................................... 4-11
Uniform Clamping Pressure .................................................. 4-12
Checking Clamping Pressure ................................................. 4-13
Clamping Pressure Adjustment ....................................... 4-13
Temperature Sensing ............................................................. 4-14
Symmetrical Gate Commutated Thyristor Replacement ....... 4-15
Snubber Resistors .................................................................. 4-18
Testing Snubber Resistors ............................................... 4-18
Fiber Optic Cabling .............................................................. 4-19
Air Pressure Sensor ................................................................ 4-19
DC Link/Fan/Control Components ........................................ 4-20
Filter Capacitors .............................................................. 4-21
Filter Capacitor Replacement .......................................... 4-22
Testing Filter Capacitors ................................................ 4-23
First Method ............................................................ 4-23
Second Method ........................................................ 4-24
Recommended Digital Multimeters (DMM) .................. 4-27
Fan Replacement ................................................................... 4-28
DC Link Section .............................................................. 4-28
Safety Notes .................................................................... 4-28
Fan Installation ................................................................ 4-29
Top of Integral Isolation Transformer Section ................ 4-29
Top of Integral Line Reactor/Input Starter Section ......... 4-29

Table of Contents v
Impeller Maintenance (DC Link/Fan Section) ...................... 4-31

Chapter 4 Component Definition Impeller Removal from Motor Shaft ............................... 4-31
and Maintenance Safety Notes .................................................................... 4-31
(cont.) Installation of Impeller Assembly onto Motor Shaft ....... 4-32
Impeller Maintenance ........................................................... 4-34
Isolation Transformer Cooling Fan ................................. 4-34
Inlet Ring Removal and Replacement ................................... 4-34
Safety Notes .................................................................... 4-34
DC Link / Fan Section ..................................................... 4-34
Procedure ......................................................................... 4-34
Top on Integral Isolation Transformer Section ............... 4-35
Replacement of Air Filters ..................................................... 4-35
Procedure ......................................................................... 4-35
Control Power Components ................................................... 4-38
Ride-Through .................................................................. 4-38
AC/DC Power Supply ............................................................ 4-41
Description ...................................................................... 4-41
Location ........................................................................... 4-42
Low Voltage Control Section ................................................ 4-44
DC/DC Power Supply ............................................................ 4-46
Description ...................................................................... 4-46
IO Connectors on Control Boards ........................................ 4-47
Drive Processor Module ........................................................ 4-48
ACB Analog Control Board .................................................. 4-49
Interface Module (IFM) ................................................. 4-50
Analog Inputs and Outputs .............................................. 4-50
External Input/Output Boards ................................................ 4-51
Optical Interface Boards ........................................................ 4-53
Environmental Considerations ............................................... 4-55
Hazardous Materials ........................................................ 4-55
Disposal ........................................................................... 4-57
Appendix A Commissioning Start-up Commissioning Services ........................................... A-1

Drive Commissioning ...................................................... A-1
Appendix B Catalog Number Catalog Number Explanation................................................... B-1

Explanation Supply Voltage, Control Voltage, Frequency and
Control Power Transformer Selection ............................... B-2
PowerFlex 7000 Drive Selection Explanation ........................ B-3
When is a Tachometer Required? ........................................... B-4
PowerFlex 7000 Drive Performance ....................................... B-5
Glossary of Terms ................................................................... B-5
Typical Application Load Torque Profiles ............................. B-6

vi Table of Contents
Appendix C Torque Requirements Torque Requirements for Threaded Fasteners ........................ C-1
Appendix D Meggering Drive Meggering ..................................................................... D-1

Meggering the PowerFlex 7000A ........................................... D-1
Equipment Required ......................................................... D-2
Procedure .......................................................................... D-2
Appendix E Preventative Preventive Maintenance Check List ....................................... E-1

Maintenance Operational Maintenance ........................................................ E-1
Annual Maintenance ............................................................... E-2
Initial Information Gathering ........................................... E-2
Physical Checks (NO Medium Voltage and
NO Control Power) .................................................... E-2
Control Power Checks (NO Medium Voltage) ................ E-4
Final Power Checks before Restarting ............................. E-4
Additional Tasks During Preventive Maintenance .......... E-5
Final Reporting ................................................................. E-5
Time Estimations ............................................................. E-6
Tool / Parts / Information Requirements .......................... E-7
Maintenance Schedule ........................................................... E-8
Preventative Maintenance Service Schedule ......................... E-9
General Notes ...................................................................... E-11
Maintenance of MV Motor Control Equipment ............ E-11
Periodic Inspection ........................................................ E-11
Contamination ............................................................... E-12
High Voltage Testing .................................................... E-12
Maintenance after a Fault Condition ............................. E-12
Part-specific Notes ............................................................... E-13
Cooling Fans ................................................................. E-13
Operating Mechanisms .................................................. E-13
Contacts ......................................................................... E-13
Vacuum Contactors ....................................................... E-13
Power Cable and Control Wire Terminals ................... E-14
Coils ............................................................................. E-14
Batteries ......................................................................... E-14
Pilot Lights .................................................................... E-14
Solid-State Devices ....................................................... E-15
Locking and Interlocking Devices ................................ E-15
Appendix F Specifications Specifications ...........................................................................F-1

Dimensions/Weights ............................................................... F-4
Nominal Power Ratings .......................................................... F-4

Preface
Overview
Who Should Use This Manual This User 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 the drive
system.
What Is Not in this Manual This manual is designed to provide only information specific to the
PowerFlex 7000 “A” Frame drive. Therefore customer specific
topics are not presented. These customer specific topics include:
• Dimensional and Electrical Drawings generated for each
customer specific order. (This manual does provide generic
drawings for illustrative purposes only.)
• Spare Parts Lists compiled for each customer specific order.
(This manual does provide a generic list of possible components
and a description of their characteristics and functionality.)
The above information is provided to the customer during the

order process cycle.
Three User Manuals address this product line:
“A” Frame for lower power air-cooled configurations
(up to approximately 1250 hp/933 kW)
“B” Frame for higher power air-cooled configurations
“C” Frame for all liquid-cooled configurations
If you have multiple drive types or power ranges, ensure you have
the correct manual.
For detailed information on Troubleshooting, Parameters and

Functional Description for MV variable frequency drives, please
refer to Technical Data publication 7000-TD002_-EN-P.
For detailed information on receiving and handling for Medium

Voltage variable frequency drive and related equipment, please refer
to General Handling Procedures, publication 7000-IN002_-EN-P.
Reference Manuals (for “A”, “B” and “C” Frame drives) are also
available. These manuals provide additional technical information
about the drive components. Contact your local Rockwell
Automation Sales office to order copies of these publications.
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.

P-2 Preface
Manual Conventions Symbols are used throughout this manual to indicate specific types
of information.
WARNING Warnings tell readers where people may be

hurt if procedures are not followed properly.
ATTENTION Cautions tell readers where machinery may be

damaged or economic loss can occur if
procedures are not followed properly.
Both of the above could indicate:

• A possible trouble spot
• Tell what causes the trouble spot
• Give the result of an improper action
• Tell the reader how to avoid trouble
SHOCK HAZARD This symbol alerts the user to a potential

electrical shock hazard that exists on a
component or printed circuit board.

Preface P-3
General Precautions ATTENTION This drive contains ESD (Electrostatic

Discharge) sensitive parts and assemblies.
Static control precautions are required when
installing, testing, servicing or repairing this
assembly. Component damage may result if
ESD control procedures are not followed. If
you are not familiar with static control
procedures, reference Allen-Bradley
publication 8000-4.5.2, “Guarding Against
Electrostatic Damage” or any other
applicable ESD protection handbook.
ATTENTION An incorrectly applied or installed drive can

result in component damage or a reduction in
product life. Wiring or application errors,
such as, undersizing the motor, incorrect or
inadequate AC supply, or excessive ambient
temperatures may result in malfunction of the
system.
ATTENTION Only personnel familiar with the PowerFlex

7000 Adjustable Speed Drive (ASD) and
associated machinery should plan or
implement the installation, start-up and
subsequent maintenance of the system.
Failure to comply may result in personal
injury and/or equipment damage.
Who to Call for Commissioning Rockwell Automation Medium Voltage Support group is
responsible for Commissioning Support and activities in our product
line.
They may be contacted at 519-740-4100, request Medium Voltage

Support – Project Manager.
The support they offer includes, but is not limited to:
– Quoting and Managing Product On-site Start-ups.

– Quoting and Managing Field Modification projects.
– Quoting and Managing Customer in-house and on-site
product training.

P-4 Preface

Chapter 1
Overview of Drive
Introduction The PowerFlex® 7000 represents the third generation of medium

voltage drives from Rockwell Automation, and is part of the
PowerFlex family of AC drive products. The Allen-Bradley
PowerFlex® family of Drives incorporates leading-edge technology,
embedded communications, and significant commonality across
multiple platforms, networks, operator interface programming and
hardware.
The PowerFlex 7000 is a general purpose stand alone medium

voltage drive that controls speed, torque, direction, starting, and
stopping of standard induction or synchronous AC motors. It is
intended for use on a host of standard and specialty applications such
as fans, pumps, compressors, mixers, conveyors, kilns, and test
stands. Primary industries for these applications include petrochemical,
cement, mining and metals, forest products, power generation, and
water/waste water.
The PowerFlex 7000 is a global product that adheres to the most

common standards from NEC, IEC, NEMA, UL, and CSA. It is
available with the world’s most common supply voltages at medium
voltage, from 2400-6600 volts.
The design focus is on high reliability, ease of use, and lower total
cost of ownership.

1-2 Overview of Drive
Drive Configurations – PowerFlex 7000 “A” Frame

Configuration #1
Direct-to-Drive
(AFE with DTC DC Link)
Elimination of isolation transformer results in lower
losses and saved space Direct-
to-Drive
An integrated system solution for fewer connections (Optional
and reduced installation costs Input
New or existing motors Starter)
Small system footprint

3 cables in/3 cables out on entire system for easy
installation
Low line harmonics and high power factor (typical
current THD < 5%, PF > 0.98)
Fan control power and control circuit power
supplied internally
Input starter optional
Configuration #2
AFE Rectifier
(Separate isolation transformer)
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 AFE
Rectifier
Fan control power supplied internally (1-phase
control circuit power supplied by customer,
120V/60 Hz, 110V/50 Hz, 20 amp)
Configuration #3
AFE Rectifier
(Integral isolation transformer)
An integrated system solution for fewer connections
and reduced installation costs Integral
Small system footprint Isolation
Transformer
New or existing motors
3 cables in/3 cables out for easy installation
Integral cooling fans for VFD and transformer
Fan control power supplied internally (1-phase
control circuit power supplied by customer,
120V/60 Hz, 110V/50 Hz, 20 amp)

Overview of Drive 1-3
Topology The PowerFlex 7000 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.
The PowerFlex 7000 has the additional benefit of inherent

regenerative braking for applications where the load is overhauling
the motor, or where high inertia loads need to be slowed down
quickly. Symmetrical Gate Commutated Thyristors (SGCTs) are
used for machine converter switches and line converter switches.
LINE CONVERTER DC LINK MACHINE CONVERTER

L+ M+
SGCTs SGCTs
2U (X1) U (T1)
2V (X2) V (T2)
2W (X3) W (T3)
L- M-
Figure 1.1 – PWM-CSI AC Drive

Rectifier Designs Active Front-End (AFE) Rectifier
An Active Front-End rectifier is particularly attractive since it does

not require an isolation transformer to meet IEEE 519-1992.
Many competing technologies in today’s MV market require a multi-

winding transformer to mitigate the unwanted harmonics through
cancellation by phase shifting the transformer secondary windings.
Depending on the topology, the transformer can have up to 15 sets of
secondary windings.
Elimination of the isolation transformer reduces capital and

installation costs, saves on valuable floor space, reduces
operating costs and increases overall system efficiency.
The AFE rectifier requires a switching pattern that complies with

similar rules as the inverter. The pattern used for the example shown
in Figure 1.3 is a 42-pulse selective harmonic elimination (SHE)
pattern, which eliminates the 5th, 7th and 11th harmonics. The integral
input capacitors are designed to reduce the current harmonics of the
higher order.
The filter resonant frequency is placed below 300 Hz (for a 60 Hz

system) where no residual harmonics exist. This prevents the
excitation of system harmonic frequencies. Other factors that are
considered when designing the filter are the input power factor and
the requirement on Total Harmonic Distortion (THD) of input
current and voltage waveforms.
The small integral AC line reactor (see Fig. 1.2) provides additional
filtering and current limiting features to a line side short circuit fault.
The line current and voltage waveforms are also shown in Figure 1.2.
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 throughout a typical operating speed range for
variable torque loads.

a)
b)
a) Line current
b) Line-to-line voltage at PCC
Figure 1.2 – AFE rectifier and its input current/voltage waveforms
The AFE rectifier can be used in conjunction with a rectifier duty

isolation transformer or with an AC line reactor (as shown in Figure 1.2).
Isolation transformers are available:

1) Integral to the Drive
2) Remote indoor dry type, or
3) Outdoor oil-filled type
This allows for maximum flexibility in dealing with floor space,

installation cost and control room air conditioner loading.
“Direct-to-Drive” Technology Reduce the cost, size and weight of your medium voltage drive
system with the Allen-Bradley PowerFlex 7000 with Direct-to-Drive
technology. This is the first and only technology that allows you to
directly connect a medium voltage drive to utility power without the
requirement of an isolation transformer. Isolation transformers with
multiple secondary windings are required for traditional AC drives to
address line-side harmonic concerns and common mode voltage.
However, typical isolation transformers are large, heavy, costly,
complex and inefficient. Direct-to-Drive technology combines an
Active Front End (AFE) rectifier to dramatically lower line-side
harmonics and a patented DC link inductor to address common mode
voltage at its source. By addressing harmonics and common mode
voltage, the isolation transformer becomes redundant. This reduces
system complexity to maximize uptime and increases system
efficiency to lower operational costs. Exceptional output voltage and
current waveforms, true of our entire product line, make this ideal for
retrofit applications and allow the use of standard motors for new
applications.

Motor Compatibility The PowerFlex 7000 achieves near sinusoidal current and voltage
waveforms to the motor, resulting in no significant additional heating
or insulation stress. Temperature rise in the motor connected to the
VFD is typically 3 °C (5.4 °F) higher compared to across-the-line
operation. Voltage waveform has dv/dt of less than 10 volts per
microsecond. Reflected wave and dv/dt issues often associated with
VSI (voltage source inverter) drives do not exist with the PowerFlex
7000. Typical motor waveforms are shown in Figure 1.3. 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.
Standard motors are compatible without de-rating, even on retrofit

applications.
Motor cable distance is virtually unlimited. This technology is capable

of controlling motors up to 15 km (9.3 miles) away from the drive.
Arms
300.00
200.00
100.00
Motor current 0.00
-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)
Figure 1.3 – Motor waveform @ full load, full speed

Simplified Electrical Drawings – 2400V with AFE Rectifier

L+ M+
SGCTs SGCTs
LR
U (T1)
L1
V (T2)
L2
W (T3)
L3
L- M-
2400 Volt – AFE Rectifier, Configuration #1 – Direct-to-Drive

(Configurations without Integral Input Starter are available)

REMOTE L+ M+
ISTX
SGCTs SGCTs
2U (X1) U (T1)
1U
2V (X2) V (T2)
1V
2W (X3) W (T3)
1W
L- M-
2400 Volt – AFE Rectifier, Configuration #2 – Separate Isolation Transformer

INTEGRAL L+ M+
ISTX
SGCTs SGCTs
2U (X1) U (T1)
1U
2V (X2) V (T2)
1V
2W (X3) W (T3)
1W
L- M-
2400 Volt – AFE Rectifier, Configuration #3 – Integral Isolation Transformer

Simplified Electrical Drawings – 3300/4160V with AFE Rectifier

L+ M+
SGCTs SGCTs
LR
U (T1)
L1
V (T2)
L2
W (T3)
L3
L- M-
3300/4160 Volt – AFE Rectifier, Configuration #1 – Direct-to-Drive


REMOTE L+ M+
ISTX
SGCTs SGCTs
2U (X1) U (T1)
1U
2V (X2) V (T2)
1V
2W (X3) W (T3)
1W
L- M-
3300/4160 Volt – AFE Rectifier, Configuration #2 – Separate Isolation Transformer

INTEGRAL L+ M+
ISTX
SGCTs SGCTs
2U (X1) U (T1)
1U
2V (X2) V (T2)
1V
2W (X3) W (T3)
1W
L- M-
3300/4160 Volt – AFE Rectifier, Configuration #3 – Integral Isolation Transformer

Simplified Electrical Drawings – 6600 V with AFE Rectifier

L+ M+
SGCTs SGCTs
LR
U (T1)
L1
V (T2)
L2
W (T3)
L3
L- M-
6600 Volt – AFE Rectifier, Configuration #1 – Direct-to-Drive


REMOTE L+ M+
ISTX
SGCTs SGCTs
2U (X1) U (T1)
1U
2V (X2) V (T2)
1V
2W (X3) W (T3)
1W
L- M-
6600 Volt – AFE Rectifier, Configuration #2 – Separate Isolation Transformer

INTEGRAL L+ M+
ISTX
SGCTs SGCTs
2U (X1) U (T1)
1U
2V (X2) V (T2)
1V
2W (X3) W (T3)
1W
L- M-
6600 Volt – AFE Rectifier, Configuration #3 – Integral Isolation Transformer

Operator Interface
Figure 1.4 – PowerFlex 7000 Operator interface terminal
The operator interface terminal features a 16-line, 40-character, pixel

based LCD display that makes text and graphics easy to read. Bar
chart meters are configurable for common process variables
including speed, voltage and load.
Everything is user friendly about the PowerFlex 7000 operator interface

terminal including the greeting on the opening screen. The terminal
is designed for the greatest ease of use for start-up, monitoring and
troubleshooting. The setup wizard helps the user to set the required
parameter menus by asking questions or prompting selections for
desired operation. Warnings and comments appear complete with
help text to keep the user on the right track. The setup wizard combined
with the auto-tuning feature allows the drive to be tuned to the motor
and load as quickly and accurately as possible, resulting in fast start-
ups, smooth operation, and less down time.

Chapter 2
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.
General Handling Procedures Refer to “General Handling Procedures for PowerFlex 7000 Medium
Voltage Drives”, publication no. 7000-IN002_-EN-P supplied in the
drive shipment (affixed to the drive). Additional copies can be
ordered through your local Rockwell Automation Sales office.
Drive Storage If it is necessary to store the drive, be certain to store in a clean dry
dust free area.
Storage temperature should be maintained between -40°C and 70°C

(-40°F and 185°F). If storage temperature fluctuates or if humidity
exceeds 95%, space heaters should be used to prevent condensation.
The drive should be stored in a heated building having adequate air
circulation. The drive must never be stored outdoors.

2-2 Drive Installation
Siting of the Drive Site Considerations
The standard environment in which the equipment is designed to

operate is:
• Elevation above sea level less than 1000 meters (3250 feet)
• Ambient air temperature between 0°C (32°F) and 40°C (104°F)
• Relative humidity of the air not to exceed 95% non-condensing
For the equipment to operate in conditions other than those specified

consult the local Rockwell Automation Sales office.
The equipment requires the following site conditions:

(A) Indoor installation only, no dripping water or other fluids
(B) Clean air for cooling requirements
(C) Level floor for anchoring the equipment. Refer to dimension
drawings for the location of the anchoring points.
(D) The room in which the equipment is located must allow for full
opening of the doors of the equipment, typically 1200 mm
(48 inches). Also, allowances have to be made for clearance
for fan removal. This fan allowance must be greater than 700
mm (27.5 inches) above the drive.
or
Dimension drawings can be obtained by contacting the local
Rockwell Automation Sales office. The equipment does not
require rear access for servicing.
(E) Allowance must be made for the stream of cooling air which
exits the drive at the top. The flow of cooling air into and out
the drive must be kept clear and uninhibited.
(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.

Drive Installation 2-3
(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 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.
ATTENTION An incorrectly applied or installed drive can

result in component damage or a reduction in
product life. Ambient conditions not within
the specified ranges may result in
malfunction of the drive.
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.
The location of the anchor points is provided with the dimension

drawing of the drive.
Install and tighten the anchor bolts. (M12 or ½” hardware required).

Engineering bolt systems are required for seismic requirements.
Consult factory.
Remove the top lifting angles, retain the hardware.
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.
Installation of Exhaust Air Hood
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. (For drives
with an acoustic hood, the components are shipped assembled. See
Figure 2.2)
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.
Secondly, loosely assemble the two L-shaped panel components

shipped with the drive as per Figure 2.1.

Flat plate
(Quantity = 1)
Exhaust hood panels

(Quantity = 2)
M6 thread forming screws

(Quantity = 20)
Figure 2.1 – Fan Hood Assembly
All the components are shipped assembled.
Figure 2.2 – Acoustic Fan Hood Assembly

Installation (cont.) Locate the exhaust hood on top of the cabinet per Figure 2.3 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.
For drives with an acoustic hood (shown in Figure 2.2), locate the
exhaust hood (refer to Figure 2.4).
ATTENTION Any screws that are accidentally dropped in

the equipment must be retrieved as damage
or injury may occur.
Assembled Exhaust Hood
M6 Screw
(Quantity = 12)
Ensure notch
orientation
to sides
Figure 2.3 – Fan Hood Installation

Assembled Acoustic
Exhaust Hood
Top Plate for Converter

and Common Mode Choke/
M6 Screw.
DC Link Cabinet
Remove Existing Screw
and reinsert with Hood.
(Quantity = 11)
Figure 2.4 – Acoustic Fan Hood Installation

Installation (cont.) Installation of Integral Transformer Cooling Fan
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.
4. Connect the fan wire harness to fan.
Assembled Exhaust Hood
M6 Screw
(Qty = 12)
Figure 2.5 – Fan Installation for Integral Isolation Transformer

Neutral Resistor Assembly
Top Plate for Neutral

Resistor Housing
Ground Resistor
Hood here
900 mm Converter –
800 mm Common Mode Choke Cabinet
and Common Mode
Choke Cabinet
Attach ground Neutral Resistor Assembly

to top plate
Refer to Electrical Drawings

to verify cable rating
to connect neutral
Line Filter resistor assembly. Motor Filter
Capacitors Capacitors
Figure 2.6 – Hood Assembly for Neutral Resistor

Assembled Acoustic
Exhaust Hood
Hood Ground Stud
M6 Screw.
Remove existing screw
and reinsert with Hood.
(Quantity = 11)
M6 Screw
(Quantity = 6)
Ground Exhaust Hood here.

(Use Green M6 Screw)
and Common Mode
Neutral Resistor Assembly Choke/DC Link Cabinet
Figure 2.7 – Acoustic Hood Assembly for Neutral Resistor
Installation of Neutral Resistor Assembly

(Drives with Common Mode Chokes)
On top of the converter cabinet, a sheet metal enclosure containing

power resistors is to be installed.
1. Locate the resistor assembly on top of the cabinet as shown in

Figure 2.6. (For acoustic hood assembly, refer to Figure 2.7.)
2. Affix the assembly to the top plate using M6 thread forming
screws provided.
3. Remove the top plate of the resistor assembly to permit access to
the wiring connection points.
4. Connect the resistor wiring and per the electrical diagram
provided with the drive, a typical connection diagram is shown
in Figure 2.6. Ensure that the resistor wiring is routed through
the hole having a plastic bushing to protect the wire insulation.
The neutral resistor assembly housing has a ground connection
that is to be connected to the top plate of the drive.
5. Re-install the top plate of the neutral resistor housing.

Cabinet Layout and The following dimension drawing is a sample and may not accurately
Dimensional Drawings detail your drive. It is 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.
The dimension drawing provides important information for the

installation of the equipment.
The FLOOR PLAN shows:

• the locations for anchoring the equipment to the floor (balloon D)
• size and location of openings for bottom power cable entry
(balloons A and B)
• size and location of openings for bottom control wiring entry
(balloon C)
The ROOF PLAN shows:

• size and location of openings for top power cable entry (balloons
A and B)
• size and location of openings for top control wiring entry
(balloon C)
• minimum aisle clearance in front of equipment (balloon M)
The Front View shows:

• minimum clearance required at top of drive for fan maintenance
(balloon K)

PowerFlex 7000 “A” Frame Dimensional Drawing
SAMPLE
Note: Contact Factory for Seismic Mounting Information.

Drive Layout The following diagrams are presented to show the typical layout of
the three main configurations of the PowerFlex 7000 “A” Frame Drive.
Configuration #1
Direct-to-Drive
(AFE with DTC DC Link)
Line Reactor/Starter Converter Cabinet Control/DC Link/Fan Cabinet

Cabling Catinet
Figure 2.8 – Direct-to-Drive (AFE with DTD DC Link)

Configuration #2
AFE Rectifier
(Separate Isolation Transformer)
Cabling Cabinet Converter Cabinet Control/DC Link/Fan Cabinet
Figure 2.9 – AFE Rectifier (Separate Isolation Transformer)

Configuration #3
AFE Rectifier
(Integral Isolation Transformer)
Isolation Transformer Converter Cabinet Control/DC Link/Fan Cabinet

and Cabling Catinet
Figure 2.10 – AFE Rectifier (Integral Isolation Transformer)

Cabling Cabinet #1 The cabling cabinet of the drive with integral line reactor and input
starter is located in the left-hand section. The mounting and location
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: This cabinet is also available without integral starter (see
Figure 2.13). The width of the cabinet changes as a function of the
drive voltage ratings.
Line Cable Terminations

(behind Disconnect Switch)
Fused Disconnect Switch
Disconnect Switch Operating Handle
Vacuum Contactor Assembly
Control Power Transformer
Control Power Transformer Fuses
Motor Cable Terminations

(Hall Effect Sensors behind)
AC Line Reactor
Figure 2.11 – Cabling Cabinet for Configuration #1 with Input Starters

Cabling Cabinet #1
Low Voltage
Compartment
Line Cable
Terminations
Hall Effect Sensors
Current
Transformers
Control Power
Transformer Fuses
Motor Cable
Terminations
AC Line Reactor
Figure 2.12 – Cabling Cabinet for Configuration #1 without Input Starters

Cabling Cabinet #2 Cabling cabinet #2 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.
Low Voltage Wireway
Current Transformer
Hall Effect Sensor
Line Terminals Motor Cable Terminations
Hall Effect Sensor
Current Transformer
Fan Control Power Transformer
Control Power
Transformer Fuses
Figure 2.13 – Cabling Cabinet for Configuration #2

Cabling Cabinet #3 The cabling cabinet of the drive with integral isolation transformer is
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.
Fan Housing
Top Cable Entry
and Exit locations
Ground Bus
Hall Effect Sensors
Line Terminals
Load Terminals
Current Transformers
(CT)
Integral Isolation
Transformer
(Front)
(Back)
Bottom Cable Entry

Side View and Exit locations Front View

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 width of the inverter / rectifier modules changes as a

function of the drive voltage ratings (2400-6600V).
Inverter Modules
Isolated Gate Drive

Power Supplies
(IGDPS)
Rectifier Modules
Voltage Sensing Boards
Figure 2.15 – Major Components of the Converter Cabinet

(3300/4160V version shown)

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
Line Filter Capacitor
Figure 2.16 – Major Components of Control / DC Link / Fan Cabinet

(with low voltage control tub removed)

Low Voltage Control Tub The low voltage control tub is mounted in front of the DC link
(Located in Control / DC Link / inductor in DC link / fan cabinet of the drive. Refer to Chapter 6,
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.
AC to DC
Pioneer
Power Supply
Analog Fiber Optic

Control Interface
Board Boards
Drive
Processor
Module
Board
DC to DC
Power Supply
Hinged
Panel
(Closed)
Hinged Panel (Open)
Figure 2.17 – Location of Low Voltage Control Tub (Pioneer Power Supply)

AC to DC
Cosel
Power Supply
Analog Fiber Optic

Control Interface
Board Boards
Drive
Processor
Module
Board
DC to DC
Power Supply
Hinged
Panel
(Closed)
Hinged Panel (Open)
Figure 2.18 – Location of Low Voltage Control Tub (Cosel Power Supply)

IEC Component and PowerFlex 7000 electrical drawings use conventions that are based
Device Designations 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
electrical drawing (ED) set. The device designations used on the
drawings and labeling are also listed with explanations on each
drawing set.
Wiring identification uses a source/destination wire number

convention on point to point multi-conductor wiring and in situations
where the system is warranted. The wire-numbering system of
unique, single numbers for multi-drop and point to point wiring
continues to be used for general control and power wiring. Wiring
that connects between the sheets or that ends at one point and starts
at another point on a drawing has an arrow and drawing reference to
indicate the ongoing connection. The drawing reference indicates
the sheet and the X/Y coordinates of the continuation point. The
reference system is explained on a sheet in each drawing set. The
unique wire numbering system serves as confirmation that the
correct wire is being traced from sheet to sheet or across a drawing.
Wires in multi-conductor cables are typically identified by color
rather than by number. The abbreviations used to identify the colors
on the drawings are fully identified on a sheet in the 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:
Adherence to the following recommended field power cabling

insulation levels for medium voltage drives will help to ensure
trouble-free start-up and operation. The cable insulation level must
be increased over that which would be supplied for an Across-the-
line application with the same rated line to line voltage.
Either shielded or unshielded cable may be used based on the criteria

considered by the distribution system designer. However, NEC
requires shielded cables for installations above 2 kV.

Cable Insulation
The cable insulation requirements for the PowerFlex 7000 “A”
Frame drive are given in the tables below.
ATTENTION Voltage ratings shown in the following

tables are peak line-to-ground. Some cable
manufacturers rate voltage line-to-line RMS.
Ensure the cable meets the rating specified
in the following tables.
Cable Insulation Requirements for AFE Drives with Separate Isolation Transformer
Cable Insulation Rating (kV)
System Voltage (V, RMS) (Maximum Peak Line-to-Ground)
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
Cabling from secondary side of Isolation Transformer to input of VFD
Cable Insulation Requirements for “Direct-to-Drive” Technology or Integral

Isolation Transformer
Cable Insulation Rating (kV)
System Voltage (V, RMS) (Maximum Peak Line-to-Ground)
Line Side Machine Side
2400 ≥ 2.2 ≥ 2.2
3000 ≥ 2.75 ≥ 2.75
3300 ≥ 3.0 ≥ 3.0
4160 ≥ 3.8 ≥ 3.8
6000 ≥ 5.5 ≥ 5.5
6300 ≥ 5.8 ≥ 5.8
6600 ≥ 6.0 ≥ 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)
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)
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).
Belden 8760 - 18 AWG, twisted pair, shielded

Belden 8770 - 18 AWG, 3-conductor, shielded
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.
Table 2.A – Wire Group Numbers

The wire sizes must be selected individually, observing all applicable

safety and CEC, IEC or NEC regulations. The minimum permissible
wire size does not necessarily result in the best operating economy.
The minimum recommended size for the wires between the drive and
the motor is the same as that used with an across-the-line starter.
The distance between the drive and motor may affect the size of the
conductors used.
Consult the wiring diagrams and appropriate CEC, IEC or NEC

regulations to determine correct power wiring. If assistance is
needed, contact your local Rockwell Automation Sales Office.
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).
To access the customer power cable terminations
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 2.21, 2.19
and 2.22.
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.
The installer is responsible for modifying the power cable access

plates to suit their requirements.
Note that appropriate connectors must be used to maintain the

environmental rating of the enclosure.

Power Connections The installer must ensure that interlocking with the upstream power
source has been installed and is functioning.
The installer is responsible for ensuring that power connections are

made to the equipment in accordance with local electrical codes.
The drive is supplied with provision for cable lugs. The power
terminals are identified as follows:
Line/Motor Terminations
• Drives with Connection to remote transformers: 2U, 2V, 2W

• Drives with integral transformers: 1U, 1V, 1W
• Drives with integral line reactor and input starter: L1, L2, L3
• Motor Connections: U, V, W
• Drives with integral line reactor, no input starter: 1U, 1V, 1W
Power Cabling Installation Requirements
To determine cable distance from top or bottom of input cabinet to

termination points, refer to Figures 2.21, 2.19 and 2.22.
The installer is responsible for ensuring that power connections are

made with appropriate torque. (Refer to Appendix B "Torque
Requirements" in back of manual.)
The drive is supplied with provision for grounding of cable shields

and stress cones near the power 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.
700.0 Line Cables

[27.56] L1, L2, L3
190.6
[7.50]
Top Cable Entry
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]
Bottom Cable Entry
RH Side Sheet removed for clarity
Figure 2.19 – Dimension Views of Cabling Cabinet for Configuration #1 with Input Starter

Power Connections (cont.)
Cable Entry Location

(Top) 1000 [39.4]
700.00
[27.56]
A B
209.6
[8.25]
480.5 [18.92]
366.2 [14.42] 480.5

[18.92]
1133.0
[44.61] 251.9 [9.92]
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
SECTION B-B SECTION A-A
A B
Figure 2.20 – Dimension Views of Cabling Cabinet for Configuration #1 without Input Starter

400.0 [15.75]
1000.3 [39.38]
112.8 112.8 [4.44]

[4.44]
2314.6
[91.12]
1409.4
[55.49]
1180.8
[46.49]
952.2
[37.49]
412.9 [16.26]
SECTION A-A
Figure 2.21 – Dimension Views of 400 mm Cabling Cabinet for Confiuguration #2 Line and Load Motor Terminals

Power Connections (cont.)
1000.4 [39.39]
700.0 [27.56]
157.9 [6.22] 157.9 [6.22]

731.4 [28.79]
328.3
[12.92]
1U U
1V V
1W W
1998.0
[78.66]
2314.6
1890.0 [91.12]
[74.41]
1782.0
[70.16]
Figure 2.22 – Dimension Views of Cabling Cabinet for Configuration #3

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
Control cable entry/exit should be located near the terminal block

'TBC' – the customer's connections are to be routed along the
empty side of the TBC terminals. These terminals are sized to
accept a maximum #14 AWG. The low voltage signals (includes
4-20mA) are to be connected using twisted shielded cable, with a
minimum #18 AWG.
Of special concern is the tachometer signal. Two tachometer inputs

are provided to accommodate a quadrature tachometer (senses motor
direction). The tachometer power supply is isolated and provides
+15 Volts and a ground reference. Many tachometer outputs have an
open collector output, in which case a pull-up resistor must be added
to ensure that proper signals are fed to the system logic. (Refer to
Appendix A "When is a Tachometer Required?" to see if one
needs to be supplied.)
IMPORTANT Low voltage signals are to be connected using

twisted shielded cable with the shield connected
at the signal source end only. The shield at the
other end is to be wrapped with electrical tape
and isolated. Connections are to be made as
shown on the electrical drawings (ED) provided.

Grounding Practices The purpose of grounding is to:
• provide for the safety of personnel

• limit dangerous voltages on exposed parts with respect to ground
• facilitate proper over current device operation under ground fault
conditions, and
• provide for electrical interference suppression
IMPORTANT Generally, the means used for external grounding

of equipment should be in accordance with the
Canadian Electrical Code (CEC), C22.1 or the
National Electrical Code (NEC), NFPA 70 and
applicable local codes.
Refer to the grounding diagrams that follow for ground connections.

The drive’s main ground bus must be connected to the system
ground. This ground bus is the common ground point for all grounds
internal to the drive.
Connected to the neutral point

of the output capacitor
ISOLATION
TRANSFORMER AC
U (T1)
2U MOTOR
OUTPUT V (T2)
2V GROUND
NETWORK
W (T3)
2W
GROUND BUS
Figure 2.23 – Ground Connection Diagram with Isolation Transformer
Connected to the neutral point

AC LINE of the output capacitor
REACTOR
TRANSFORMER U (T1) AC
2U MOTOR
GROUND V (T2)
2V
FILTER
W (T3)
2W
GROUND BUS
Figure 2.24 – Ground Connection Diagram with Line Reactor

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.
Note that if a drive isolation transformer is used, the WYE secondary

neutral point should not be grounded.
Each AC motor frame must be bonded to grounded building steel

within 6 m (20 feet) of its location and tied to the drive's ground
bus via ground wires within the power cables and/or conduit. The
conduit or cable armor should be bonded to ground at both ends.
Grounding Guidelines and Practices for Drive Signal and Safety

Grounds
When interface cables carrying signals where the frequency does not
exceed 1 MHz are attached for communications with the drive, the
following general guidelines should be followed:
• It is good practice for the mesh of a screen to be grounded
around its whole circumference, rather than forming a pigtail that
is grounded at one point.
• Coaxial cables with a single conductor surrounded by a mesh
screen should have the screen grounded at both ends.
• Where a multi-layer screened cable is used (that is, a cable with
both a mesh screen and a metal sheath or some form of foil), there
are two alternative methods:
– The mesh screen may be grounded at both ends to the metal
sheath. The metal sheath or foil (known as the drain) should,
unless otherwise specified, be grounded at one end only,
again, as specified above, at the receiver end or the end which
is physically closest to the main equipment ground bus.
or
– The metal sheath or foil may be left insulated from ground
and the other conductors and the mesh cable screen
grounded at one end only as stated above

Grounding Practices (cont.) Grounding Requirements and Grounding Specification for

Customers and Power Integrators
An external ground must be attached to the main ground bus. The
grounding means must comply with applicable local codes and
standards. As general guidelines, for information only, the ground
path must be of sufficiently low impedance and capacity that:
• the rise in potential of the drive ground point when subjected to a
current of twice the rating of the supply should be no higher than
4 volts over ground potential.
• the current flowing into a ground fault will be of sufficient
magnitude to cause the protection to operate.
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.
Identification of Types of Electrical Supplies – Grounded and

Ungrounded Systems
When dealing with an ungrounded, three-phase electrical supply

system, the cable insulation must be capable of handling not only the
phase to phase voltage, but also the voltage to ground if one of the
other phases develops a ground fault. In practice, the cable
insulation of an ungrounded, three-phase system must be good for at
least a continuous voltage of root three (1.732) times (1.1) times the
rated voltage of the supply. (1.732 x 1.1 = 1.9 times the rated line-
to-line voltage)
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.


Chapter 3
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 and 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 PowerFlex 7000 Medium Voltage AC Drive •
Technical Data (Publication 7000-TD002_-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).
Read-only Parameter – A memory location which can only be read.

A read-only parameter contains real-time data and is used to read the
current conditions within the drive, such as running speed.
Tag – A generic reference to either a parameter or a read-only

parameter.
PanelView 550 – The PanelView 550 is a product marketed by

Rockwell Automation consisting of a hardware terminal and a
software package, integrated into a single product. The Medium
Voltage Drive only uses the hardware portion of the product and has
replaced the software package.

3-2 Operator Interface
PowerFlex Operator interface – References to the operator

interface refer to the product consisting of the PanelView 550
interface hardware and the unique software contained within it,
which allows it to function with the Medium Voltage Drive.
Editing Field – An area of a screen that is displayed in reverse

video. When the field is in this state, data may be entered into it via
the keypad.
XIO – the eXternal Inputs and Output adapters used by the drive to
interface hardwired signals to the drive.
Operation – A task which is to be performed. In order to complete

the task, a number of screens may be involved; i.e. selecting a
parameter is an operation that requires at minimum two screens.
This operation itself is an operation of modifying a parameter.
NVRAM – Non-Volatile Random Access Memory. This is memory

that is not affected by loss of power. It is used for long term storage
of data such as parameters and alarm queues.
Flash – A type of memory technology which will indefinitely store

information and is unaffected by power loss. It is used for storage of
firmware, parameters and data files.
PCMCIA – A standard for flash memory cards. Personal Computer

Memory Card International Association.

Operator Interface 3-3
Overview The operator interface used on the PowerFlex 7000 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
Figure 3.1– PowerFlex 7000 Drive Operator Interface Terminal
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.
Function (Softkeys) Keys
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.
Cursor (Selection) Keys
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 which contain an Enumeration string, pressing either

the up or down key will provide a list of options to pick from. Using
the cursor keys, make a selection and press enter. If more options
exist than can be displayed on the screen, a triangle symbol or
inverted triangle to the right of the list will show that there are more
selections available in the indicated direction. Continue to use the
up/down cursor keys to move to these additional selections.
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.
Data Entry Keys
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.

While entering a value, the value may be edited using the

[backspace] key. This key will remove the right most digit (or
decimal point or negative). The help screen uses the backspace key
to return to the previous level of help.
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
Figure 3.2 – Screen Components

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.
Figure 3.3 – Screen Name & Item
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
Numerous screens require communications with the drive in order to

function. At times, the duration of this activity will be noticeable to
you. During this activity, a special 'window' is used within the
current screen to inform you of this activity. The time required for
the activity will vary.

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.
You can selectively choose to download the complete database to the

operator interface on command, thus eliminating the initial access
delays. If uninterrupted, the operator interface will automatically
download the database on power-up, or during periods of inactivity.
Refer to the section on "Advanced Screen Operations - Database
Download".
Some screens require that information be written to the drive.

During this task, a window is used to display the message "Writing
to Drive...” During this time, the operator interface will not respond
to any user input, until the task at hand is completed.
Communication Error
While the operator interface is reading or writing to the drive, it is

possible for communications to be disrupted for a number of reasons.
If this were to occur, a special window is used to inform you of this.
During this time, the operator interface will not respond to any user
input, until the task at hand is completed.
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.
In both cases, once communications has been re-established, the

information window will be removed and the operator interface will
return to normal operation.

Figure 3.4 – Communications Error
Figure 3.5 – Communications Error
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 that can be performed on a screen vary depending on

the actual screen being displayed. The majority of the operations are
activated by the function keys located along the bottom of the screen.
Although the meaning of these keys does change from one screen to
the next, there are some functions which are available on most
screens and always have the same assignment.
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
This operation is active on every screen, even if the 'Softkey' is not

displayed. Help is context sensitive and will display help that relates
to the screen that you are currently viewing.
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
When a screen is capable of displaying data that requires more than

one page, this 'Softkey' will be active. The 'Softkey' will increment
the page number being viewed.
F9 - Previous Page
When a screen is capable of displaying data that requires more then

one page, this 'Softkey' will be active. The 'Softkey' will decrement
the page number being viewed.
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:
a) Linking to Drive - During this phase the operator interface is

establishing communications with the drive communications
board. The screen will also show information about the software
product contained in the PowerFlex operator interface, such as:
- software part number and revision level

- date and time stamp of program creation

b) Obtaining Drive Database - During this phase, the database of

information about the drive is obtained from the drive.
Obtaining the database at this point in time is optional and may
be aborted by pressing any key on the operator interface.
Obtaining the entire database does however speed up subsequent
operations since relevant portions of the database do not have to
be obtained. (Without obtaining the entire database, the operator
interface will access portions of the drive database as required.
This slows down the first access to the operation that requires the
data. Subsequent operations requiring the same data are not
affected). Aborting the download will not affect portions of the
database already obtained.
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:
a) On an unconfigured drive, the operator interface will enter the

'Setup Wizard' mode. Until the user has gone through the entire
'Setup Wizard', this will be the default mode to power up in. The
'Setup Wizard' can be cancelled at any time by pressing the
appropriate softkey.
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.
The screen identifies the drive product to which the operator

interface is attached and its overall state of operation. Four digital
meters show four selected parameters located in the drive. A Hobbs
meter displays the number of hours that the drive has been running.
The status of the drive will show one of the following:
NOT READY – drive is not ready to start

READY – drive will start when commanded
FORWARD RN – drive is running in the forward direction
REVERSE RN – drive is running in the reverse direction
WARNING – drive has a warning
FAULTED – the drive is faulted
DISCHARGING – waiting for the input filter capacitor to
discharge on an Active Front End drive
before re-start
Figure 3.6 – Top Level Menu

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.
Throughout the section, you want to focus on how the operation is

performed. The operator interface will take care of what screens are
needed to perform the operation.
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.
Figure 3.7 – Typical Help Screen
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.
Figure 3.8 – Help on Related Topic (Softkey)
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.
To return to a previous screen of help information, press the

[backspace] key. To return to the screen from which help was
originally accessed, press the [F10] key.
Figure 3.9 – Help on Help

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.
Figure 3.10 – Utility Operation Screen
Changing Backlight Delay
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.
The setting may also be aborted by pressing any of the assigned

function keys (other than F1). The function associated with that key
will be executed.
Figure 3.11 – Utility Light
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.

function keys (other than F1). The function associated with that key
will be executed.

Figure 3.12 – Utility Contrast
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.

function keys (other than F1 and F5). The function associated with
that key will be executed.
Figure 3.13 – Utility Time

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.

function keys (other than F1 and F4). The function associated with
that key will be executed.
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.
Figure 3.14 – Utility Date
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.

Figure 3.15 – Utility Meter
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 .
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 meter
(i.e. V Line). The name of the meter will have been changed to a
default string as shown in Figure 3.16 for meter 2.
Figure 3.16 – Utility Meter V Line
The text consists of 8 characters. This text is displayed on the Top

Level Menu along with the value and units of the tag. Select the
meter that you wish to modify via the [cursor up] and [cursor down]
keys. To modify the text, press the [cursor right] 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 first character position of the string will be in reverse video as

shown in Figure 3.17. Refer to the section entitled "Edit Text".

Figure 3.17 – Edit the Text
When editing is complete, the screen will appear as in Figure 3.18.
Figure 3.18 – Editing Completed
The operator interface contains a default set of meters. This default

set is selected by pressing the [F2] key any time the 'Meters' screen is
displayed. This results in the default text and tags as shown in
Figure 3.15.
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.
Figure 3.19 – Top Level Meter Modified

Viewing Revision Levels
For the purpose of maintenance or upgrading of software, the

revision levels of all the software contained in the terminal and the
drive may be viewed. To access this screen, press the [F9] key.
A screen typical of Figure 3.20 shows:

– the type of drive
– a 16-character, user definable string to uniquely identify a drive
– revision level of the terminal software and its part number
– revision level of the bootcode contained in the terminal
– revision level of various boards contained in the drive
These are identified by name.
Figure 3.20 – Utility Rev Level
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 .)
A screen typical of Figure 3.21 will be displayed. To modify the text

refer to the section entitled "Edit Text", noting the following
exception. When the text has been entered (as in Figure 3.22) the
enter key has no effect. Simply press the exit key [F10] to accept the
edited string.
Prior to exiting the screen, the string can be returned to its state upon
entry to the screen by pressing the [F7] key.

Figure 3.21 – Edit the Drive Name
Figure 3.22 – Editing Completed
Transfer Data in Memory
The operator interface contains long term storage in two forms.

Flash memory contained in the operator interface is used to store the
firmware and optionally language modules and parameters used in
the drive. This information can also be stored on a removable flash
card that can be taken to another drive.
In order to transfer information from the two forms of memory, press

the [F7] key. This displays a new screen (Figure Error! Reference
source not found.) from which all flash memory operations are
performed. Refer to the section entitled “Flash Memory Transfers”
for instructions on these features.
Picking an Access Level
Access Levels are used in the drive to protect parameters from

unauthorized changes and to filter out the amount of information
viewed. Each access level takes on the parameters and permissions
of the lower access levels.
The default access level is 'Monitor'. In this level, only a small

subset of the parameter database is viewable. No changes are
allowed to any configuration information.

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.
Select a Parameter Various operations require that a parameter be selected. All

selection operations are done via one of three methods described in
this section. All parameters are organized into groups. Selecting via
groups is the default method.
The screens associated with the selection process are called

automatically as part of the operation from other screens.
Via Groups
This is the default screen (Figure 3.23) used in the selection of a

parameter. It shows all the groups that are accessible for the operation
currently being performed. For example: if you are selecting a
parameter, any groups that are showing read-only parameters only will
not be shown. The current access level will also affect the number of
groups that are currently viewable, and can be selected from. If more
than one page of groups exist, press the [F8] and [F9] keys to view the
other pages.
Press the [cursor up] or [cursor down] keys to select the desired
group, (i.e. reverse video the group name). Press the [enter] key.
The SELECT screen (Figure 3.24) is displayed showing the members
of the selected group. The name of the selected group currently
being displayed is shown after the screen name, i.e. Motor Ratings.
Again 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.

Figure 3.23 – Selecting a Group
Figure 3.24 – Selecting a Member of a Group
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.
Selecting via a name is initiated from the SELECT GROUP screen

(Figure 3.23) by pressing the [F7] key. This displays the SELECT
LETTER screen shown in Figure 3.25.
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 either of these two screens (SELECT LETTER or SELECT

LIST) you can return directly to the default selection method via
groups by pressing the [F7] key.
Figure 3.25 – Selecting via a Letter (Step 1)
Figure 3.26 – Selecting Name via List (Step 2)
From the SELECT LETTER screen (Figure 3.25) the tag may also
be selected via a code by pressing the [F5] key.
Via Code
This method of selecting a tag is initiated from the SELECT

LETTER screen (Figure 3.25) by pressing the [F5] key. It allows
you to select the tag, given that you know the tag code associated
with the desired tag. Every parameter (i.e. tag) has a unique code
associated to identify it to devices incapable of making decisions
based on a name, such as a PLC for example.

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.
Figure 3.27 – Select via Code (Step 1)
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.
Figure 3.28 – Valid Tag Code
Figure 3.29 – Invalid Tag Code

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.
Figure 3.30 – Selected Tag Inappropriate
Edit Text Various operations require a text string to be entered. Operations

requiring this are:
- setting external faults
- adding text to selected Top Level Menu meters
- identifying the drive with a text string
- entering a filename
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.
Figure 3.31 – Typical Text Edit Screen

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 _ ( ) [ ] { } < > | @ # $ % & * ! ^ + = ; : ?
Note: these character set may vary depending on the language

selected.
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.
The editing operation is completed by pressing the [enter] key.

Changes are not permanently made until the screen is exited via the
[F10] key.
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].
Regardless of the method used for configuration, the default factory

parameters will be obtained from the Drive Identity Module (DIM).
The use of the DIM allows each drive to be customized at the factory
to the intended application, using all known information at the time
of building the drive.
Enter/Modify an Access Level
The drive is protected from unauthorized changes via passwords

consisting of a number between 0 and 65535. These passwords are
associated with Access Levels. Each Access Level, (except for the
first one 'Monitor') has its own password number (PIN). These
values can be unique or all can be set to the same value.
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 screen shown in Figure 3.32 is accessible from within a number

of screens where the Access Level affects the operation of
subsequent operations, such as:
1) [F10] key on the Top Level Menu,
2) [F8] key on the Modify Parameter screen,
3) [F8] key on the Setup Screen,
4) [F8] key on the Transfer Screen,
5) [F8] key on the Diagnostic Setup screen.
Figure 3.32 – Access Screen
The Current Access level is shown. To select a different access

level, use the up/down cursor keys to select the desired the level.
Then enter the password value (PIN) for that level using the data
entry keys. The value can be any number between 0 and 65535. As
the number is entered via the keys [0]-[9], the value will be shown
by a placeholder (i.e. * in the editing field), as shown in Figure 3.33.
Figure 3.33 – Pin Entry
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.

Figure 3.34 – Access Level Changed
When the desired operations have been completed, the operator

interface should be placed back to the 'Monitor' level in order to
protect against unauthorized modifications. From this screen press
the [F8] key. The level will change back to 'Monitor' as shown in
Figure 3.32.
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.
Figure 3.35 – PIN Change
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.

Figure 3.36 – PIN Change Completed
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.
Figure 3.37 – Invalid PIN
Figure 3.38 – Invalid PIN Verification
If you were not successful in changing the password, simply start

over again by typing in the current password value.

Drive Setup This section describes how to:

• select an alternate language
• enter data to a drive parameter
• assign a tag to an analog port
• enable and disable a fault via a mask
• assign text to be associated with optional external fault inputs
• re-enter Setup Wizard
• configure the XIO link
• define the tags to be accessible by a PLC.
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.
At power-up, the operator interface access level is 'Monitor'. If this

is the current mode and you wish to change any of the setup data,
press the [F8] key now in order to change the access level before
proceeding into any of the other setup operations available from this
screen (Figure 3.40). Refer to the section Enter/Modify an Access
Level .
Figure 3.39 – Setup Screen

Figure 3.40 – Basic Access Level
Language Selection
The drive is capable of supporting multiple languages. The operator

interface supports these languages via language modules which must
initially be loaded via the flash card (refer to the section Flash
Memory Transfers).
To select an alternate language, press the [F9] key on the SETUP

screen. The screen will show all language modules currently loaded
as in Figure 3.41. Associated with each language is a module
revision level. Use the [cursor up] and [cursor down] keys to select
the desired language and press the [enter] key.
The operator interface will switch to the new language selected. It is

possible for other devices attached to the drive to request a language
change. If this occurs, the operator interface will switch to the new
language, if the required language module is loaded.
Figure 3.41 – Language Selection

Modify Parameters
To change a parameter, Use the up/down arrow keys on the SETUP

screen to select the 'Parameters' option and press the [enter] key.
This will begin the selection process of a parameter as described in
the section entitled "Select a Parameter". The selection process to
change a parameter can also be initiated while displaying the
members of a parameter group on the DISPLAY screen (Figure 3.68)
by pressing the [F7] key.
When you have successfully selected a parameter, one of three

possible screens will be displayed depending on the type of
parameter.
Numerical Value
When the parameter is a numerical value, the MODIFY

PARAMETER screen typical of Figure 3.42 will be displayed. This
screen shows:
– 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.
Figure 3.42 – Parameter Data Entry

Figure 3.43 – Modify Numerical Value
To be allowed to make changes to the parameter, the operator

interface must be set to an Access Level other than 'Monitor'. (You
will be able to view the screen; however, pressing the data entry keys
will have no effect). If you are not in the correct level, press the [F8]
key in order to gain access to the parameter. Refer to the section
entitled Enter/Modify an Access Level for further information on
the operation to change the level.
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.
Some data must be entered in HEX. To accomplish this, use the

cursor up/down keys to scroll through the values 0-F for the right
most digit. To accept the digit and enter to the right of the current
digit, press the right cursor key. Press the [Enter] key to accept the
value.
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
When the parameter is an enumerated value, the MODIFY

screen shows:
• the name of the parameter for which you are make the changes
(i.e. Operating Mode)
• the tag code for the parameter (i.e. 4)
• the actual value of the parameter contained in the drive.
Figure 3.44 – Modify Enumerated Value
Figure 3.45 – Option List Viewed on Single Page

Having gained access, press the up or down cursor keys to obtain a

list of possible options to select from. Use the up/down arrow keys
to move the highlighting to the desired option (Figure 3.45). If more
options exist then what can be displayed on a single screen, a triangle
or inverted triangle symbol will indicate in which direction the list
can be expanded (Figure 3.46).

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.
Figure 3.46 – Option List Viewed on Multiple Pages
Figure 3.47 – Modification Completed
Bit Encoded Value
When the parameter is a bit encoded value, the MODIFY

screen shows:
• the name of the parameter for which you are make the changes
(i.e. Logic Mask)
• the tag code for the parameter (i.e. 241)
• the name of the bit currently selected (Adapter 0)
• the actual value of the parameter bits contained in the drive.

Figure 3.48 – Modify Bit Encoded 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.
Analog Ports
The drive contains a number of external analog ports to which you

can assign any parameter. To setup an analog port, use the up/down
arrow keys on the SETUP screen to select the 'Analog' option and
press the [enter] key.
This will display a series of screens as shown in Figure 3.49 . The

screen shows the current tags and their tag code, which are associated
with each of the analog ports. To change the tag attached to a port,
use the [cursor up] and [cursor down] keys to highlight the desired
port 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).

Figure 3.49 – Analog Setup

the selection process, the selected tag will be assigned to the port.
To remove an assignment to the highlighted port, press the [delete]
(Backspace) key.

Fault Masks
A number of the faults within the drive may be selectively enabled or

disabled by you. To view or modify the current fault mask settings,
use the up/down arrow keys on the SETUP screen to select the 'Fault
Masks' option and press the [enter] key.
A typical screen as shown in Figure 3.50 shows all of the user

maskable faults. Associated with each fault is the state of the mask.
If OFF, it means the fault is disabled and will not occur. The normal
state is ON or enabled.
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).
Figure 3.50 – Fault Screen
Figure 3.51 – Fault Mask OFF
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.

Figure 3.52 – AC O/V, Disabled
Figure 3.53 – Fault Overview, Enabled
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.
To change the state of a mask on the FAULTS OVERVIEW screen,

use the [cursor up] and [cursor down] keys to select the desired mask
and press the [enter] key. In the example of Figure 3.52, the “AC
O/V” is currently disabled and is selected. When [enter] is pressed
its mask is enabled, thus removing the fault from this screen as
shown in Figure 3.54. Pressing [F7] toggles the screen to show the
enabled faults, which the AC O/V is one of (Figure 3.55). (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).

Figure 3.54 – AC O/V Removed From List
Figure 3.55 – AC O/V Now Enabled
The changes to the fault masks do not take effect 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).
Figure 3.56 – AC O/V Mask is ON

User Definable External Text

The drive contains a number of external fault inputs. You can
custom define the text associated with these inputs, which will be
used on the alarm screen and the fault mask screens. To define the
text, use the up/down arrow keys on the SETUP screen to select the
'External Text' option and press the [enter] key. A screen typical of
Figure 3.57 will be seen.
Figure 3.57 – External Setup Text
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.
Figure 3.58 – Modify Text

Figure 3.59 – Modification Completed
PLC
The drive can be optionally connected to a PLC via a RIO (Remote
Input/Output) adapter. The drive appears to the PLC as a rack of
information. The tags that are associated with each of the words
within a rack can be defined. To setup the PLC link, use the
up/down arrow keys on the SETUP screen to select the 'PLC' option
and press the [enter] key.
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).

Figure 3.60 – PLC Input Links
Figure 3.61 – PLC Output Links

section entitled "Select a Parameter". When selecting a tag for the
output words, only parameters will be allowed. Both parameters and
read-only parameters are allowed for the selection of input words.
When you have completed the selection process, the selected tag will
be assigned to the link. To remove an assignment to the highlighted
link, press the [delete] (Backspace) key.
XIO
The drive uses XIO adapters to hardwire to discrete inputs and
outputs. Each drive contains one or more of these modules. Each
module contains a unique address that is assigned automatically
according to where it is attached on the link. This address value can
be seen on the LED display of the module. The drive must be
configured with these address values to link them to a parameter in the
drive. To setup the XIO configuration, use the up/down arrow keys on
the SETUP screen to select the 'XIO' option and press the enter key
Note: This feature is currently inactive and is reserved for future
enhancements.

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.
Figure 3.62 – Message Prompt Screen
Figure 3.63 – NVRAM Screen

Store/Retrieve Configuration (NVRAM)
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 drive contains a default set of parameters and setup information.

This can form a basis for configuring the drive. To initialize the drive
with the default set of data, press the [F3] key. The screen will appear
as in Figure 3.64, indicating the operation you are about to perform.
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.
Figure 3.64 – Initialize Operation
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).
Figure 3.65 – Save Operation

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).
Figure 3.66 – Load Operation
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).
Figure 3.67 – Display Screen

Figure 3.68 – Feature Select Group Chosen
Figure 3.69 – Bit Encoded Parameter
Figure 3.70 – Bit Description for Local Outputs
The DISPLAY screen, typical of Figure 3.68, is displayed. The

screen shows the name of the group being displayed to the right of
the screen name (“FEATURE SELECT”). One or more pages of the
members in the group are displayed along with the value for this tag
in the drive and its unit of measurement. Values that are bit encoded
will show a hex value for the parameter value. Use the up/down
cursor keys to select the parameter which is bit encoded and then
press the [enter] key (Figures 3.69 and 3.70). The VIEW
PARAMETER screen will then show that parameter as it is decoded
per bit as shown in Figure 3.70.

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.
From the DISPLAY screen, it is possible to modify a parameter. If
the group you are currently viewing contains parameters, press the
[F7] key. The operator interface then allows you to select the
parameter you wish to modify. Refer to the section entitled "Modify
Parameters" for further details.
If you have modified any parameters in the drive, you will be
prompted to make the changes permanent. This prompt will occur
upon exiting the DISPLAY GROUP screen. Refer to "Message
Prompting" for further details.
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.
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.
Figure 3.71 – Display Custom Screen

Figure 3.72 – V Line Assigned
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.
Figure 3.73 – Status Screen
View and 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.
Figure 3.74 – Alarm Summary Screen

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 aid in troubleshooting, a time and date stamp is also provided,

indicating the last time the drive was started and stopped for any
reason.
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.
Figure 3.75 – Fault Queue

Help for Alarms
When viewing the fault or warning queue, help text may be

associated with the alarm entry. Use the up/down cursor keys to
highlight the alarm in question and press the [enter] key. An
ALARM HELP screen, typical of that shown in Figure 3.76 will be
shown for that alarm. Not all alarms will have this additional help
text. For those alarms the screen shown in Figure 3.77 is displayed.
Figure 3.76 – Alarm Help
Figure 3.77 – No Alarm Help
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 screen typical of Figure 3.78 is displayed. It shows the current

status of the printer (A-B part #80025-290-01) and the type of
reports that are available. (Refer to the “Syntest SP401 Thermal
Printer User Manual” for information regarding the use of the printer
hardware and a description of the various reports available.) Using
the [cursor up] and [cursor down] keys, select the desired report and
press the [enter] key. The report will be sent to the printer.

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.
Figure 3.78 – Typical Printer Screen
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.
a) If an operator interface has a memory card inserted when it is
powered up or rebooted, and that card has a valid firmware file
with the extension of .FMW, the operator interface will
automatically load the first .FMW file it encounters on the card.
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).
When the filename has been obtained, the TRANSFER: PROGRAM

screen such as that in Figure 3.79 will be displayed, showing the
filename, indicating the operation you are about to perform and
showing the current status of the operation.

Figure 3.79 – Load New Firmware
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.
Due to the nature of this operation, all other operator interface

functions will cease during a download. Once the download begins,
the operator interface’s screen will be unable to show any status
information. For this reason the two LEDs on the back of the
operator interface are used as such:
• Flashing Green - indicates that all is healthy and the transfer is
proceeding.
• 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.
When the transfer completes successfully, the new firmware will

automatically begin operation. Refer to the section Operator
Interface Power-up Sequence.
WARNING: Any time the operator interface is powered up

with a flash card inserted which contains a valid firmware *.FMW
file, the operator interface will attempt to load new firmware (note
item ‘a’ above). For this reason, it is not advisable to leave a
memory card containing a firmware file in the operator interface,
after the firmware has been downloaded.

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.
To transfer parameters, press the [F4] key from the TRANSFER

screen. The screen shown in Figure 3.80 will be displayed. (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). Within this screen it is possible to perform four different
parameter transfers.
Figure 3.80 – Transfer Parameters Menu

Upload to Operator Interface
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 3.81, 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.
Figure 3.81 – Transfer Stored Parameters
Download from Operator Interface
The parameters stored in the operator interface are downloaded to

the drive by pressing the [F3] key. A screen similar to that shown in
Figure 3.81 will be shown (except the operation will show
“MEMORY TO DRIVE”). To confirm the operation, press the [F8]
key to proceed, or the [F9] key to abort. Performing a “MEMORY
TO DRIVE” transfer will overwrite the active parameters in the drive.
It will not affect the parameters stored within the drive’s NVRAM.
After parameters have been downloaded you will be prompted to

make the new parameters downloaded to the drive permanent. Refer
to section “Message Prompting” for further details.
Upload to Memory Card
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 3.82 will be displayed, showing the filename,
indicating the operation you are about to perform and showing the
current status of the operation.

Figure 3.82 – Transfer File Parameters
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.
Download from Memory Card
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 3.82 (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.
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.
Parameter File Format
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.
Information is this section is not needed to operate the operator

interface. It is required knowledge if you wish to create a parameter
file off-line and then download into a drive. The filename must have
the extension of *.PAR in order to be recognized as a parameter file.
The format of the file is as follows:

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 3.83.
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).
When the filename has been obtained, the TRANSFER:

LANGUAGE screen such as that in Figure 3.84 will be displayed,
showing the filename, indicating the operation you are about to
perform and showing the current status of the operation.
Figure 3.83 – Language Directory

Figure 3.84 – Transfer Language Module
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.
In order to download a newer version of a language, all languages

in the operator interface must first be cleared (this is a
characteristic of flash memory) by pressing the [F2] key on the
TRANSFER:LANGUAGE screen. The screen as in Figure 3.85
will then ask you to confirm the operation. Press the [F8] key to
proceed, or the [F9] key to abort.
Figure 3.85 – Clear Languages
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.

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 3.86 and 3.87.
What does it show?
The chart shows the relationship between screens and a particular

operation. It also shows the path to reach a particular screen. This
chart does not introduce you to the use of the operator interface,
however is useful as a reference to the preceding material.
How do you read it?
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.
Some of the operations have screens in common. These are shown

only once on the diagram. Their use is indicated by symbols inserted
into a circle. For example: The ACCESS screen is displayed from
the MAINMENU by pressing the [F10] key. In this location
(marked by an *), the operation of the screens ACCESS and
PASSWORD CHANGE are shown in their entirety. These
operations are also available from the MODIFY PARAMETER
screen and SETUP screens by pressing the [F8] key. At these
locations, the operation of screens is represented by the symbol 'P',
which represents the same flow as previously defined.
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
As an example of using the chart, we will modify a parameter while

displaying it, starting from the Top Level Menu referred to in the
chart as the MAINMENU screen. This example assumes you have
read the previous sections of this manual. The example will
concentrate more on the flow of screens and how it relates to the
chart, rather then the actual operations being performed by each
screen. The symbols refer to those of the chart. Descriptions of
movement, i.e. lateral, refer to flow depicted on the chart.
Displaying the MAINMENU, press the [F4] key. The DISPLAY

GROUP screen is now shown. Cursor to a parameter group and
press the [enter] key. This laterally moves us to the DISPLAY
screen. Since you selected a parameter group, pressing the [F7] key
takes us into a selection operation (symbol 'D') in which the
SELECT screen is displayed. This allows us to use the cursor keys
to select the desired parameter.
Pressing the [enter] key laterally moves us to the symbol T which

ends the selection process. For this example, the symbol T laterally
moves to the symbol M that defines a new process in which the
selected parameter can be modified. The MODIFY PARAMETER
screen is now displayed.
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.

MainMenu :
Forts. på sid 2
7000 “A” Frame

E H
F3 -Print F2 -Utility F7 -Status F5 -NVRAM F1 -Help
Printer : Utility : Status : NVRAM : Help :
F8 -Meters F7 -Transfer F9 -Rev Lvl F6- Alarms F1 -Help

T S Meters : Transfer : Revision Levels : A Help :Help :
F8 -Access F8 -Text
P Q
Drive Text :
R
F5 -Lang 'ge F2 -Format F3 -Program F4 -Paramtr F8 -Access F7 -Dir

:Language :Format :Program :Parameters P F
F3 -Lang 'ge F2 -Format F3 -Program
F7 -Dir F7 -Dir
F G F G
Figure 3.86 – Menu Hierarchy

Directory :
S D
F7 -Group
F2 -Crd > Drv F2 -Drv > Crd F7 -Dir

Select Group : Select : F F F
F7 -List G
Select Letter : Select List :
Note: All screens have access to the F1-Help and F6-Alarm key.
F5 -Code They are not shown on the diagram in order to improve clarity.
Select Code : T
Operator Interface
PowerFlex 7000 Terminal Menu Tree Page 1 of 2

3-63
7000A-UM151D-EN-P – March 2013

3-64
MainMenu :
Forts. från sid 1
Q F8- Yes F 9 -No

A E Q P
R
F 8 -Setup F 6 -Alarms Message : F 10 - Access
Setup : Alarm Summary : F 10 - Exit Access :
7000A-UM151D-EN-P – March 2013

Operator Interface
R
F 8 -Access F 9 -Lang 'ge F 9 -Faults F 8 -Warning
F 9 -Diags F 9 -Change
P Language : Faults : Warnings :
Diagnostics : Password Change
External Text Q Fault Help :
F 9 -View
R F 8 -D Setup
External Setup : T S Diag Setup : Diag View :
F 4 -Display
Display Group : Display : View Parameter : F 8 -Access
P
F 7 -Custom F 7 -Modify
T S Display Custom : D T M F 10 & < Memory
Fault Masks
F 10 & ^ Obtain Database
PLC
Figure 3.87 – Menu Hierarchy

Faults Setup : ^
F 10 & Communications
Analog
F 7 -Overvw
F 7 -Analyze
XIO Faults Overview :
Protocol Analyzer
Analog Setup : S T F 7 -Toggle
XIO Setup :
Parameters
T S M PLC Setup : S T
Modify Parameter F 8 -Toggle Note: All screens have access to the F1-Help and F6-Alarm key.
Setup Wizard They are not shown on the diagram in order to improve clarity
F 8 -Access
P
Page 2 of 2
7000 “A” Frame

PowerFlex 7000 Terminal Menu Tree
PCMCIA Memory Card Description

Installation Data
The memory card slides into the card slot located on the backside of
the PowerFlex 7000 drive operator interface. These instructions show
how to insert the card in the Operator interface.
WARNING The memory card should be kept free from

moisture, extreme temperatures, and direct
sunlight. Failure to observe this caution could
result in damage to the card.
WARNING Do not subject memory card to flexing or

extreme shock. Failure to observe this caution
could result in damage to the card.
Installing the Memory Card
1. Locate the vertical card slot on the back of the operator interface.
See Figure 3.88.
CARD SLOT
COMMUNICATION CABLE
Figure 3.88 – Rear View of Operator Interface

2. Position the card vertically so the key slot is facing the right side
of the operator interface.
KEY SLOT
Figure 3.89 – Key Slot Orientation
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.

Chapter 4
Component Definition and Maintenance
Cabling Cabinet Components
Low Voltage
Compartment
Line Cable
Terminations
Hall Effect Sensors
Current
Transformers
Control Power
Transformer Fuses
Motor Cable
Terminations
AC Line Reactor

(Direct-to-Drive)

4-2 Component Definition and Maintenance
Line Cable Terminations

(behind Disconnect Switch)
Fused Disconnect Switch
Disconnect Switch Operating Handle
Vacuum Contactor Assembly
Control Power Transformer
Control Power Transformer Fuses
Motor Cable Terminations

(Hall Effect Sensors behind)
AC Line Reactor

(Direct-to-Drive, optional input starter shown)

Component Definition and Maintenance 4-3
Low Voltage Wireway
Current Transformer
Hall Effect Sensor
Line Terminals Motor Cable Terminations
Hall Effect Sensor
Current Transformer
Fan Control Power Transformer
Control Power
Transformer Fuses

(AFE Rectifier with Separate Isolation Transformer)

Fan Housing
Top Cable Entry
and Exit locations
Ground Bus
Hall Effect Sensors
Line Terminals
Load Terminals
Current Transformers
(CT)
Integral Isolation
Transformer
(Front)
(Back)
Bottom Cable Entry

Side View and Exit locations Front View
Figure 4.4 –Cabling Cabinet for Configuration #3

(AFE Rectifier with Integral Isolation Transformer)

Converter Cabinet Components
Inverter Modules
Isolated Gate Drive

Power Supplies
(IGDPS)
Rectifier Modules
Figure 4.5 – Converter Cabinet Components (3300/4160 V version)

Converter Cabinet The converter cabinet contains three rectifier modules and three inverter
modules. Figure 4.5 shows a 3300/4160 V converter with a PWM
Rectifier.
Isolated Gate Driver Power Supplies (IGDPS) are mounted on the

cabinet’s right side sheet (6600 V, 2400 V Drives) and on the cabinet’s
left side sheet (3300 V, 4160 V Drives).
Thermal sensors are installed on the top module of the inverter and
rectifier. The exact location depends on the drive configuration.
Surge Arresters Description

Heavy duty distribution class surge arresters are used for transient
overvoltage protection in the drives with AFE rectifiers. The arresters are
certified as per ANSI/IEEE Std C62.11-1993.
The surge arresters are basically MOVs, with or without an air gap in
series, packed in sealed housing. They provide overvoltage protection
similar to what the TSN module does. They differ from the TSN in that
fusing is not required for the operation of surge arresters.
There are 3 types of surge arresters depending on the voltage class of the
drive as shown in the table below:
Drive voltage 2.4 kV 3.3 kV 4.16kV, 4.8 kV 6.0-6.9 kV

Arrester rating (RMS) 3 kV 6 kV 9 kV
Arrester MCOV (RMS) 2.55 5.10 7.65
The most severe temporary overvoltage occurs when one phase is

grounded in an ungrounded system. The full line-to-line voltage is applied
to the arrester in this case. The arresters are designed to operate under this
condition continuously without any problems as shown by their Maximum
Continuous Operating Voltage (MCOV) rating.
There are three Y-connected surge arresters attached to the incoming MV

lines. The neutral point of the arresters is connected to the ground bus.

Drive input power from

line terminals
U V W
Heavy duty
distribution
class surge
arrester
Figure 4.6 – Surge Arresters
Operation
The operation of arresters without a gap is the same as that of MOVs.

Depending on design, the arrester may also be gapped. Both gapped and un-
gapped arresters provide adequate overvoltage protection.
The arresters are able to withstand or ride through most commonly seen bus
transients within their capability. However, caution should be taken if there is
a harmonic filter on the MV bus to which PF7000 is connected. The filter
should satisfy relevant international or local standards, such as IEEE Std
1531— Clause 6.4, to avoid high inrush currents.
The surge arrester is certified as per ANSI/IEEE Std C62.11-1993.

Certification tests include high current short duration tests, low current long
duration tests and fault current withstand tests. The fault current withstand
tests consist of different combinations of kA and number of cycles, including
a 20kA 10-cycle test, under which the arresters are non-fragmenting and
without expelling any internal components.
When the incoming energy exceeds the handling capability of the arrester and
causes arrester failure, the housing is designed to split open to vent without
causing damage to any adjacent components.
Field Test and Care
No field testing is necessary. The arresters do not require special care.

However at very dusty sites, it is suggested to clean the arrester when the
whole drive is cleaned.

PowerCage™ A PowerCage is a converter module, consisting of the following elements:

• epoxy resin housing
• power semi-conductors with gate driver circuit boards
• heatsinks
• clamp
• snubber resistors
• snubber capacitors
• sharing resistors
Each drive consists of three PowerCage rectifier modules and three

PowerCage inverter modules.
AFE type rectifiers use SGCTs as semi-conductors.
All inverter modules use SGCTs as semi-conductors.

The size of the PowerCage will vary depending on the system voltage.
The power semi-conductor usage in the converter section is as follows:
Configuration Inverter SGCTs Rectifier SGCTs Rectifier SCRs

2400V, AFE 6 6 0
3300/4160V, AFE 12 12 0
6600V, AFE 18 18 0
ATTENTION To prevent electrical shock, ensure the main

power has been disconnected before working on
the converter cabinet. Verify that all circuits are
voltage free using a hot stick or appropriate
voltage-measuring device. Failure to do so may
result in injury or death.

ATTENTION The SGCT circuit board is sensitive to static

charges. It is important that these boards should
not be handled without proper grounding.
ATTENTION Some circuit boards can be destroyed by static

charges. Use of damaged circuit boards may
also damage related components. A grounding
wrist strap is recommended for handling
sensitive circuit boards.
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.
SGCT SGCT Heatsink
Clamp Base
Module housing Temperature Clamp head

Feedback Board
Figure 4.7 – 2-Device PowerCage

PowerCage™ (cont.)
Clamp Base Matched set Matched set

2 SGCTs 2 SGCTs Heatsink
Temperature Clamp head

Module housing
Feedback Board
Matched set Matched set

Clamp Base 3 SGCTs 3 SGCTs Heatsink
Clamp head
Module housing Temperature
Feedback 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
Figure 4.10 – SGCT and snubber circuit
In addition to the snubber circuit, a sharing resistor is connected in

parallel with the SGCT. The function of the sharing resistor is to ensure
the voltage is shared equally among the SGCTs when connected in series.
SGCTs are connected in series to increase the total reverse voltage
blocking (PIV) capacity as seen by the electrical circuit. A single SGCT
has a PIV rating of 6500 V. This single device will provide sufficient
design margin for electrical systems with 2400 V medium voltage supply.
At 4160 V, 2 SGCTs must be connected in series to provide a net PIV of
13000 V to achieve the necessary design margin. Similarly, three SGCTs
must be connected in series at 6600 V, providing a net PIV of 19500 V to
achieve the necessary design margin.
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.

SGCT Device Diameter Clamp Force

400 A SGCT 38 mm 8.6 kN
800 A SGCT 47 mm 13.5 kN
1500 A SGCT 63 mm 20 kN
Pressure on the SGCTs must be uniform to prevent damage and to ensure

low thermal resistance. Uniform pressure can be achieved by loosening
the heatsink mounting bolts, tightening the clamp and then tightening the
heatsink bolts. See section “Uniform Clamping Pressure” for instructions.
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 with dust
particles.
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.
1. Apply a thin layer of Electrical Joint Compound (Alcoa EJC No. 2 or

approved equivalent) to the clamp head pressure pad face.
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.
5. Check clamp indicating washer.

Checking Clamping Pressure Periodically, the clamping force in the PowerCage should be inspected.
Ensure there is no power to the equipment.

the drive. Verify that all circuits are voltage free
using a hot stick or appropriate voltage-
measuring device. Failure to do so may result in
injury or death.
Calibration Nut - DO NOT ADJUST Indicating Washer
Clamp Bar Adjusting Nut
Disc Springs
Pressure Pad
Figure 4.11 – Clamp Head Illustration
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.
Clamping Pressure Adjustment
1. Ensure that all power to the drive is off.

2. Do not loosen the adjustment nut. If the clamping pressure is let off,
the assembly procedure must be carried out to ensure uniform
pressure on the thyristors.
3. Tighten with a 21-mm wrench on the adjustment nut (upward motion)
until the indicating washer can be turned by fingers with some
resistance. IT SHOULD NOT SPIN FREELY.

IMPORTANT Never rotate the calibration nut located outside

the indicating washer at the end of the threaded
rod. The rotation of the outer nut will affect the
torque calibration, which is factory set. Only
adjust the inside nut. (See Figures 4.11 and 4.12.)
Clamp head block
DO NOT ADJUST outside nut.

SGCT captive screws
Inside nut used for loosening
Disc springs
and applying load to assembly
Figure 4.12 – Detail of the clamping assembly
Temperature Sensing Thermal sensors are located on heatsinks in the converter. The thermal
sensor is mounted on the heatsink with the temperature feedback board.

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:
• 3300V and 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:
Solid Green indicates that the Power Supply to the Card is

LED 4 Green
OK
Solid Green indicates that the Gate-Cathode resistance is
LED 3 Green
OK
LED ON indicates the gate is ON, and Flashes alternately
LED 2 Yellow
with LED 1 while gating
LED ON indicates the gate is OFF, and Flashes alternately
LED 1 Red
with LED 2 while gating
SGCT captive screws
Inside nut used for loosening Do not adjust outside nut.

and applying load to assembly
Figure 4.13 – Replacing the SGCT

Symmetrical Gate 1. Ensure there is no power to the equipment.

Commutated Thyristor
Replacement (cont.) ATTENTION To prevent electrical shock, ensure the main
using a hot stick or appropriate voltage-
injury or death.
2. Note the position of the fiber optic cables for assembly.

3. To remove the SGCT, it is necessary to remove the gate driver power cable
and fiber optic cables. Exceeding the minimum bend radius (50 mm
[2 in.] ) of the fiber optic cables may result in damage.
ATTENTION The fiber optic cables can be damaged if struck

or bent sharply. The minimum bend radius is 50
mm (2 inches). The connector has a locking
feature that requires pinching the tab and gently
pulling straight out. The component on the
printed circuit board should be held to prevent
damage.
4. Remove the load on the clamp head assembly as described on page

6-19.
5. Two brackets secure the board to the heatsink. Loosen the captive
screws until the circuit board is free. It may be necessary to adjust the
position of the heatsinks to allow free movement of the SGCT.
6. Slide the circuit board straight out.
ATTENTION The SGCT can be destroyed or damaged by static

charges. Personnel must be properly grounded
before removing the replacement SGCT from the
protective anti-static bag that it is supplied in.
Use of damaged circuit boards may also damage
related components. A grounding wrist strap is
recommended for handling sensitive circuit boards.
IMPORTANT Replacement SGCTs will be supplied, grouped in

matched sets. This means that all of the SGCTs
in a leg have been grouped together based on
their electrical performance. Grouping similarly
matched devices ensures balanced load sharing of
a leg of devices. When replacing the device, it is
necessary to replace all the SGCTs in a matched
set, even if only one has failed.

7. Clean the heatsink with a soft cloth and rubbing alcohol.
8. While grounded, remove the SGCT from the anti-static bag it is

supplied in.
9. Apply a thin layer of Electrical Joint Compound (Alcoa EJC No. 2 or

approved equivalent) to the contact faces of the new SGCTs to be
installed. The recommended procedure is to apply the compound to
the pole faces using a small brush, and then gently wipe 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.
IMPORTANT Too much joint compound may result in

contamination of other surfaces leading to system
damage.
10. Slide the SGCT into place until the mounting brackets contact the
surface of the heatsink.
11. Tighten the captive screws located in the brackets.
12. Follow procedure “Uniform Clamping Pressure” to ensure the

heatsinks are clamped to a uniform pressure.
13. Connect the power cable and fiber optic cables (ensure the bend
radius is not exceeded).

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 (SGCT). The purpose of the snubber circuit is to reduce the
voltage stress (dv/dt and peak) 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.
Testing Snubber Resistors
Access to the snubber resistor is not required to test its resistance.

Located within the PowerCage under the heatsink is a snubber circuit test
point. For each device, there is one test point.
Measure resistance between

heatsink and test point.
Snubber resistor test point
Figure 4.14 – Testing the Snubber Resistor

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.
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.
Flexible tube for

low pressure port
High pressure port
Mounting screw
Wire terminals
Figure 4.15 – Air Pressure Sensor
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.
If, as a result of blockage or fan failure, flow becomes so reduced that

there is a risk of thermal damage for either the converter or transformer, a
fault signal will cause drive shutdown.

D.C. Link / Fan / Control Components

Low voltage
Control Tub
Retaining
Hardware
Fan
AC/DC
Power
Supply Inlet Ring
DC Link
M+ L+ L- M- Inductor
Analog Drive
Control Board
Grounding
Network/
Filter
Motor Filter
Capacitor
Medium Voltage
Barrier (for
access to
Line/Motor
Capacitors) Line Filter
Capacitor
Figure 4.16 – DC Link and Fan cabinet Figure 4.17 – 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.
There is a current sensor on the M+ conductor.
Above the D.C. link is the fan.
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 from entering the drive.

Filter Capacitors
Filter capacitors are used on the motor side for all drives. The AFE
rectifier option also includes filter capacitors on the line side. Refer to
Figure 4.17 (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.
The capacitors are equipped with internal “bleeding resistors” to discharge

the capacitor and reduce its voltage below 50V in 5 minutes when left
disconnected. A typical three-phase capacitor is shown below:
Motor Filter
Capacitor
Line Filter Capacitor

(with AFE Rectifier only)
Figure 4.18 – Motor Filter Capacitor
WARNING Allow 5-10 minutes for motor capacitors to

safely discharge voltage prior to opening cabinet
doors.

D.C. Link / Fan / Control Generator Note:

Components (cont.) 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.
Filter Capacitor Replacement
1. Ensure there is no power to the equipment.

the capacitor. Verify that all circuits are voltage
free using a hot stick or appropriate voltage-
injury or death.
ATTENTION Verify 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.
2. Remove medium voltage barrier below the low voltage panel to

access capacitor. (See Figure 4.16).
3. Short all four bushings together and to ground on both capacitors
before handling the connections.
4. Note the location of all the cables and mark them accordingly.
5. Remove the 4 power connections to the terminals, and the single

ground connector from the drive to the capacitor frame.
6. Remove the grounding network and top bracket that holds the
capacitor in place. At the bottom of the capacitor, there is no
hardware securing the capacitor; it fits into a slot in the assembly.
7. Remove the capacitor from the drive. THESE CAPACITORS CAN
WEIGH AS MUCH AS 100 kg (220 lbs), SO YOU WILL REQUIRE
TWO PEOPLE TO REMOVE A CAPACITOR.
IMPORTANT Do not lift capacitor by bushings. Doing so

may damage bushings and result in oil leakage.

8. Install the new capacitor, sliding it back until it fits into the slot.
Fasten the top bracket and grounding network.
9. Reconnect all the power cables and the ground connection. These use
M14 hardware, but should only be tightened to 30 Nm (22 ft-lbs.) due
to capacitor mechanical constraints.
10. Remove any shorting/grounding conductors.
11. Reinstall the sheet metal that was removed, and complete one final
check to ensure connections are secure and correct.
Testing Filter Capacitors
Two methods of testing/checking the capacitors are explained below. The

first method is simple, easy, and takes least amount of time to check the
capacitors. In this method, you would need a digital multimeter (DMM)
to measure the capacitance in micro-Farad (µF) across each phase-to-
neutral of the capacitors. It is recommended that you should use this
method since it avoids the chance of creating re-torque issues because you
don’t have to disconnect the capacitors unless the readings are off by 15%
or more. For accurate measurements, Rockwell recommends that you
should use one of the DMMs given in Figure 4.19.
The second method involves disconnecting all capacitors from the circuit,
and testing each capacitor individually by applying 120V across each
phase-to-neutral and measuring the current in each phase. This method is
most accurate and can be used to confirm the integrity of the capacitor
when the readings from the first method appear to be unsatisfactory.
First Method
1. Ensure there is no power to the equipment before testing the

capacitor.
ATTENTION To prevent electrical shock ensure the main

injury or death.
ATTENTION Verify the load is not running due to process. A

freewheeling motor can generate voltage that
on.

D.C. Link / Fan / Control 2. Follow appropriate safety steps to isolate the equipment from medium
Components (cont.) voltage.
3. Verify that there is no voltage present on the capacitor by using a hot

stick or any other appropriate voltage-measuring device.
4. Perform visual inspection to ensure there is no oil leak or bulge in any

of the capacitors.
5. Using a DMM measure the capacitance across each phase-to-neutral

of capacitors without removing any connections. If the difference
between the highest and the lowest readings is below 15% then all
capacitors are in good condition.
6. If the difference between the highest and the lowest readings is off by
15% or more, then you might have a bad capacitor.
7. Before disconnecting the capacitors, note the location of all the cables
and mark them accordingly.
8. Disconnect power cables/bus bars from the capacitor terminals on all

four bushings and isolate them from the capacitor. (Refer to “Filter
Capacitor Replacement” guidelines in the Classic User Manual -
Component Definition and Maintenance chapter (chapter 6) for using
proper torque when reconnecting the capacitors)
Second Method
1. Ensure there is no power to the equipment before testing the

capacitor.
ATTENTION To prevent electrical shock ensure the main

injury or death.

ATTENTION Verify the load is not running due to process. A

freewheeling motor can generate voltage that
on.
2. Follow appropriate safety steps to isolate the equipment from medium

voltage.
3. Verify that there is no voltage present on the capacitor by using a hot

stick or any other appropriate voltage-measuring device.
4. Perform visual inspection to ensure there is no oil leak or bulge in any

of the capacitors.
5. Note the location of all the cables and mark them accordingly.
6. Disconnect power cables from the capacitor terminals on all four

bushings and isolate them from the capacitor. (Refer to “Filter
Capacitor Replacement” guidelines in the Classic User Manual -
Component Definition and Maintenance chapter (chapter 6) for using
proper torque when reconnecting the capacitors)
7. Connect a low voltage single-phase test power, for instance 110V or

220V, across a phase and the neutral of the capacitor. Switch on the
test power and measure the test voltage and current drawn by the
capacitor. Repeat the test for all three phases and note down the test
voltage and current.
ATTENTION The capacitor will charge during this test so care

must be taken to prevent a shock or injury.
When moving the test connections from one
phase to the next, wait for at least five minutes
until the capacitor is discharged. Using a hot
stock or other voltage-measuring device, verify
that the capacitor is fully discharged before
touching it.
8. Now, calculate the capacitance from the measured values of test

voltage and current. For a good capacitor, the calculated capacitance
value for each of the three readings should be within +15% of the
capacitor nameplate micro-Farad. If it is outside this range then the
capacitor must be replaced.
Example: An example is given below to illustrate how the capacitance

value is calculated.

D.C. Link / Fan / Control e.g. - the capacitor under test is rated at 400 kVAR, 6600V, 50Hz, 29.2 µF.
Components (cont.) You are using 200V, 50Hz test power and have recorded the values of
voltage and current for each test as given in the table below.
Phase - Neutral L1-N L2-N L3-N

Test Voltage 200V 200V 200V
Measured Current 1.87A 1.866A 1.861A
Let us calculate the capacitance using the first reading. In this case:
V = 200V, I = 1.87 for L1-N
Xc = V/I = 200/1.87 = 106.95

C= 1
2π f Xc
C=1
2 × 3.14 × 50 × 106.95
C = 29.7 μF
Where, f = frequency of the applied voltage.
Similarly, you can calculate the capacitance for the remaining two
measurements for L2-N and L3-N.

Recommended Digital Multimeters (DMM)

to be used for checking filter capacitors
BK Precision LCR/ESR Meter, Model 885
Fluke 179 Fluke 12 Fluke 29 Fluke 87V
Figure 4.19 – Recommended Digital Multimeters (DMM)

Fan Replacement There are several models of cooling fans used in PowerFlex drives.
Differing fan types may be used in the various locations throughout the
drive.
DC Link Section
The fan consists of a motor impeller assembly. To replace the fan, it is
necessary to remove the fan exhaust hood. See Figure 4.20.

the current transformer. Verify that all circuits
are voltage free using a hot stick or appropriate
voltage-measuring device. Failure to do so may
result in injury or death.
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 side sheets 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
Mounting bracket
Inlet ring
Figure 4.20 – Fan Removal

Fan Installation
Care must be taken in handling of the fan as its balance could be affected
by poor handling.
Fan installation is performed in the reverse order of its removal. Upon

completion of installation, rotate the impeller by hand to ensure that there
is no contact with the inlet ring.
Top of Integral Isolation Transformer Section
Cross Channel
Mounting Holes Terminal Blocks
Fan
Inlet Ring
Figure 4.21 – Isolation Transformer Fan Removal
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.
3. Disassemble and replace the fan.
4. Reassemble in the reverse order of removal.

Fan Replacement (cont.) Top of Integral Line Reactor and Input Starter Section
Ventilator Cover
Terminal Blocks
Fan Mounting Bracket
Fans
Figure 4.22 – Starter/Line Reactor Cabinet Fan Removal
1. Remove the top ventilation cover from the exterior of the cabinet.
2. Remove mounting screws and invert fan mounting bracket to expose

fan mounting hardware.
3. Unplug or disconnect fan leads from terminal blocks and replace fan.
4. Reassemble in the reverse order of removal.

Impeller Maintenance Impeller Removal from Motor Shaft

(DC Link / Fan Section)
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. Two cap screws, when tightened to 10.2 N-m (7.5 ft-lbs.), lock
the bushing onto the motor shaft and the impeller to the bushing.
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 cap screws.
Physical injury or component damage may result.
D E C
DO NOT LUBRICATE
CAPSCREWS, BORE,
OR BUSHING BARREL
A – Taper surfaces
B – Capscrews
C – Split in Taper Bushing A
D – Key
E – Threaded Hole for Separating Tapers
Figure 4.23 – Cutaway View of Fan Impeller and Bushing

Impeller Maintenance 1. Record the distance from the end of the motor shaft to the bushing.
(DC Link / Fan Section) The new impeller must be installed in the same location. Failure to do
(cont.) 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.
2. Remove both cap screws from the bushing. The impeller or bushing
may fall as screws are loosened.
3. Thread the cap screws 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 cap screws 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.
NOTE: DO NOT LUBRICATE CAPSCREWS, BORE, OR

BUSHING BARREL, AS THIS WILL HINDER CLAMPING
FORCE OF THE BUSHING ON THE SHAFT AND THE
IMPELLER BORE
Installation of Impeller Assembly onto Motor Shaft
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. Cap screws, 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 cap screws, 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 cap screws
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 cap screws 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 cap screws 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.
6. Tighten the cap screws progressively with a wrench. Do this evenly

as though mounting an automobile wheel. Turn one a quarter turn,
then the next a quarter turn, then go back and turn the other a quarter
turn and so on. Torque to 10.2 N-m (7.5 ft-lbs.)
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
Fan impellers are statically and dynamically balanced within acceptable

tolerances at the factory. Damage in shipping or from poor handling or
installation may upset the unit’s balance. An impeller that is not properly
balanced can lead to excessive vibration causing undue wear on the entire
unit.
If vibration is excessive, shut down the fan and determine the cause.
Common causes of excessive vibration:
Support structure not sufficiently rigid or level. Vibration amplified

by resonance in duct work or support structure.
Bearing locking collar or mounting bolts loose. Impeller or bushing
loose.
Material accumulation on impeller.
Wheel rubbing on inlet ring.

Impeller Maintenance Isolation Transformer Cooling Fan
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 4.23).
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.

power has been disconnected before working
within the DC Link and Fan Area. Verify that all
circuits are voltage free using a hot stick or
appropriate high voltage-measuring device.
Failure to do so may result in injury or death.
DC Link / Fan Section
NOTE: If rear panel access is possible, remove rear middle panel of

the DC link / fan portion of the cabinet and remove the inlet ring
from the back.
Procedure
If rear panel access is not possible, follow this procedure:
1. Remove bolts and swingout low voltage panel (see Fig. 4.16).
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.
Top of Integral Isolation Transformer Section

1. Remove fan as described in “Fan Replacement”.
2. Disassemble bolts and remove inlet ring.
3. To install 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.
4. 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.
It is necessary to periodically remove and clean, or remove and replace
the filter material. The frequency with which the filters are renewed
depends on the cleanliness of the supplied cooling air.
It is possible to renew the filters while the drive is running, but the
procedure is easier to perform while the drive is shut down.
Procedure (see Figure 4.24):

Using an 8 mm (5/16”) Hex key, loosen the ¼ turn fasteners and
swing open the hinged grill assembly.
Remove filter material.
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.

Replacement of Air Filters Recommended cleaning method of filters:

(cont.)
1. Vacuum Clean – A few passes of a vacuum cleaner on the inlet side
of the filter will remove accumulated dust and dirt in seconds.
2. Blow with Compressed Air – point compressed air nozzle in
opposite direction of operating air flow (Blow from exhaust side
toward intake side)
3. Cold Water Rinse – Under normal conditions the foam media used
in the filters, require no oily adhesives. Collected dirt is washed away
quickly and easily using just a standard hose nozzle with plain water.
(Ensure filter is completely dry before reinstalling)
4. Immersion in Warm Soapy Water – Where stubborn air-borne dirt
is present, the filter may be dipped in a solution of warm water and
mild detergent. Then simply rinse in clear clean water, let stand until
completely dry and free of moisture, and return to service.
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
Figure 4.24 – Filter Replacement

Figure 4.25 – Air Flow Pattern for Drive Cooling
Figure 4.26 – Air flow through PowerCage

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. AFE Rectifier with DTD DC Link – Conf. #1 (refer to Figure 4.27)
2. AFE Rectifier with Separate Isolation Transformer – Config. #2
(refer to Figure 4.28)
3. AFE Rectifier with Integral Isolation Transformer – Config. #3
(refer to Figure 4.29)
Ride-Through
Standard controls with 5 cycle ride-through – The drive main control

boards will remain energized for a total of 5 cycles after control power is
interrupted. If control power is not restored during the 5 cycles, a
controlled shutdown will occur.
Figure 4.27 illustrates the control power distribution for AFE drives with
integral starter/line reactor.
Printer
Operator Interface
Relays
Fuse
C Hold-up +5V-LOGIC
+/-15V-LOGIC
AC/DC Converter
56V DC DC/DC CONVERTER +/-24V-HECS
120V 1000W/1500W
+24V-ISOLATORS
1-ph
+24-XIO
DC Fail
SENSE CABLE
380V 50Hz
or
Line 460V 60Hz
Reactance 3-ph
20V Isolated
Gate Driver
Fan
Power Supply 20V
VFD
Figure 4.27 – AFE Rectifier with DTD DC Link (Configuration #1)

Figure 4.28 illustrates the control power distribution for AFE drives with
remote transformer/starter (A) or integrated line reactor with remote
starter (B).
-Printer
-Operator Interface
-Relays
Customer
Supplied
C Hold-up +5V-LOGIC
120V
1-ph +/-15V-LOGIC
AC/DC Converter
56V DC DC/DC CONVERTER +/-24V-HECS
1000W/1500W
+24V-ISOLATORS
+24-XIO
DC Fail
SENSE CABLE
20V Isolated
Gate Driver
Power Supply 20V
Tx Fan
380V 50Hz
or
Line 460V 60Hz
Reactor
OR 3-ph
Fan
VFD
VFD
Fan
A B
Figure 4.28 – AFE Rectifier with Separate Isolation Transformer (Configuration #2)

Control Power Components Figure 4.29 illustrates the control power distribution for AFE drives with
(cont.) integral transformer and remote starter.
Printer Operator
Interface Relays
Customer
C Hold-up +5V-LOGIC
Supplier
120V +/-15V-LOGIC
1-ph AC/DC Converter
Line 56V DC DC/DC CONVERTER +/-24V-HECS
Filter 1000W/1500W +24V-ISOLATORS
+24-XIO
DC Fail
SENSE CABLE
Tx Fan
380V 50Hz
or
460V 60Hz 20V Isolated
3-ph Gate Driver
Power Supply 20V
VFD Fan
Figure 4.29 – AFE Rectifier with Integral Isolation Transformer (Configuration #3)

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 56V DC output for the DC/DC power supply and the HV
IGDPS modules that power 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
Power
Single phase Supply
95-265V ac AC/DC
47-63 Hz Power Supply
0.98PF @1000W or 56V,1000W or 1500W
0.98PF@1500W HV IGDPS
Power
Supply
DC Fail
Figure 4.30 – AC/DC Converter Power Supply
DC FAIL: Upon loss of DC output (V outputs ≤ 49 VDC) this output goes

from low to high.

AC/DC Power Supply Location

(cont.)
The AC/DC power supply is located in the low voltage panel at the top
right-hand section of the drive. A typical low voltage compartment is
shown in Figure 4.31.
AC/DC Power Supply

(Pioneer)
Figure 4.31 – Location of AC/DC Pioneer Power Supply on Low Voltage Panel

AC/DC Power Supply

(Cosel)
Figure 4.32 – Location of AC/DC Cosel Power Supply on Low Voltage Panel

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 4.33 for a generic
representation of a low voltage tub arrangement.
AC to DC
Pioneer
Power Supply
Analog Fiber Optic

Control Interface
Board Boards
Drive
Processor
Module
DC to DC
Power Supply
Hinged
Panel
(Closed)
Hinged Panel (Open)
Figure 4.33 – Low Voltage Tub Compartment (Pioneer Power Supply)

AC to DC
Cosel
Power Supply
Analog Fiber Optic

Control Interface
Board Boards
Drive
Processor
Module
DC to DC
Power Supply
Hinged
Panel
(Closed)
Hinged Panel (Open)
Figure 4.34 – Low Voltage Tub Compartment (Cosel Power Supply)

DC/DC Power Supply Description
The DC/DC power supply is used as a source of regulated DC voltages for

various logic control boards and circuits. The input to this power supply
is from a regulated 56V DC source.
+5V - LOGIC
+/-15V - LOGIC
+ DC/DC
+/- 24V - HECS
56VDC Power Supply
C hold-up
- +24V - ISOLATOR
+24 - XIO
Sense Cable
Figure 4.35 – DC/DC converter power supply
The capacitor at the input terminals is for power dip ride-through purposes.
Upon loss of the 56V input, the capacitors (C hold-up) will maintain the
voltage level. This component is not required in all configurations.
Due to the critical nature of the ACB/DPM Logic power source, the
DC/DC power supply has been designed to provide redundancy for the
+5V rail. There are two separate +5V outputs, each capable of powering
the logic boards. In the event of one failing, the other power supply will
be automatically switched in to provide the output power.

IO Connectors on Control Boards
MOTOR & LINE COMM S COMM S

MOTOR &LINE UPS FAIL
AC VOLTAGE CONN ECTION CONN ECTION
DC LINK AND LINE VOLTAGE SIGNAL COMM S
PA RALLEL XIO BOARD DC FAIL SIGNAL
FEE DBA CK INPUTS NEUTRAL POINT SY NC . TRANSFER MONITORING CONN ECTIONS
FEE DBA CK INPUTS DR IVE MONITORING
VOLTAGE INTPUTS DPI/SCANPORT
J21
J25 J24 J23 J22 DPI
J27 J26 J17
INTERFACE
J20
J16
CONN ECT TO OIBB ,
J19
GET GATING SIGNALS
J18
DPM-J10 DPM-J13
ENC ODER DC -AB US +56V
INTERFACE J28 DPM-J11 DPM-J12 OUTPUT MONITORING
(IN UPS OPTION)
J34 J33
J15
DPM
POWER SUPP LY XIO-PWR(+24V),+/-15V,+/-24V
+5V DIG, DC POWER SUPP LIES
DPM-ENC ODER DPM - FAS ULTS &
OTHER I/O
J32
DC POWER SUPP LY
DPM J13
J14 MONITORING
5V1 , 5V2, 56V DC BUS
DOWNLOAD DPM
ACB Analog Control Board
& +24V ISOLATED

FIRMWARE J4
DPM - A/D SUB DPM - DAC’S SE RIAL COMM S CONN ECTIONS

SYS TEM DATA PRINTER OUTPUTS
J11 J12
COMM S CONN ECTIONS
TERMINAL (PA NEL VIEW)
J30 J31
CONTROL I/O METER
STATUS & OUTPUTS &
CONTROL J1 J10
SPEE D POT
POWER INPUT
MONITORING
AIR PRESS UR E
J9 INPUTS
J8
J2 J3 J4 J5 J6 J7
MOTOR DC LINK GROUND FAULT & ISOLATED & NON-ISOLATED

LINE CURR ENT INPUTS CURR ENT CURR ENT CMC NEUTRAL ANALOG INPUTS AND
INPUTS INPUTS CURR ENT INPUTS NON-ISOLATED OUTPUTS
Figure 4.36 – IO Connectors on Control Boards

Drive Processor Module This board contains the control processors. It is responsible for all the
drive control processing and stores all of the parameters used for the drive
control.
Figure 4.37 – Drive Processor Module (DPM)

ACB Analog Control Board The Analog Control Board (ACB) 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, and other external communication devices are
routed through this board.
Figure 4.38 – ACB Analog Control Board

ACB Analog Control

Board (cont.) Interface Module (IFM)
The Interface Module is used to make all customer useable connections to

the ACB. The pin numbers listed on the following pages refer to IFM pin
numbers.
Even pin numbers
Odd pin numbers

Connection to ACB (J8)
Figure 4.39 – Interface Module
Analog Inputs and Outputs

The PowerFlex 7000 offers one isolated process current loop transmitter
and three isolated process current loop receivers, embedded into the
control. These are accessible on the ACB.
The isolated Process Output is configured as 4-20 mA. The three isolated
process inputs are individually configurable for either a range of -10/0/+10V
or 4-20 mA (Refer to Programming Manual).
The following information will show the connections for each input and
output.

External Input/Output Boards The External Input/Output (XIO) Boards are connected through a network
cable (CAN Link) to the Analog Control Board (ACB). 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 ACB 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
Figure 4.40 – XIO Board
The standard drive comes with one XIO board; additional boards (up to 5)
can be daisy chained together from XIO Link B (J5) on the first board to
XIO Link A (J4) on the second board, for a total of 6 XIO cards. However,
at this time the drive only supports the use of addresses 1 to 3, depending on
the drive’s features and application. U6 on the XIO board displays the
board’s address which is automatically calculated from the XIO board’s
position in the network.
XIO Link A and B ports are interchangeable but it may make wiring easier
to follow if Link A is used for “upstream”, that is, closest to the ACB, and
Link B is used for “downstream” or farthest from the ACB.

LED D1 and display U6 indicate the status of the board. The following
table illustrates the possible states for D1.
LED Status Description

Solid Green Normal Operation
Solid Red Board Failure
Alternate Flashing of Red and No Communication Available to ACB board
Green (Normal during boot-up or unprogrammed)
Status of U6 Display
Display Description Explanation
— No valid address found – More than 6 XIO cards on network
– XIO cable failure
– XIO card failure
– ACB failure
0 Card in “Master” mode – Rockwell Use Only
– Remove connection to J3 and recycle power
1–6 Valid address – Normal
Decimal point ON Indicates network activity – Normal
Decimal point OFF No activity on the network – Normal at Power on, during firmware
download and with unprogrammed drive

Optical Interface Boards The Optical Interface (OIB) Boards are the interface between the DPM
and the Gate Driver circuitry. The drive control decides which device to
fire, and sends an electrical signal to the OIB boards. The OIB 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
Grey 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. Each OIB contains one extra
fiber optic receiver (RX7), which is used for temperature measurement.
Figure 4.41 – Optical Interface Board
The OIB boards are mounted directly on the Optical Interface Base Board
(OIBB) using two parallel 14-pin connectors for the electrical connection,
and plastic clips to provide the mechanical strength. There is one OIBB
for the inverter, and one OIBB for the rectifier device. The OIBBs are
interfaced to the DPM using two ribbon cables to connect to J11 and J12.
Each OIB board can handle the Firing and Diagnostic duplex fiber optic
connector for 6 devices, whether they are SCRs or SGCTs. Physically, on
the OIBBs, 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 OIB board on the OIBB is for the ‘A’ devices,
the middle OIB board on the OIBB is for the ‘B’ devices, and the bottom
OIB board on the OIBB is for the ‘C’ devices.

Optical Interface Boards

(cont.)
Figure 4.42 – Optical Interface Base Board (OIBB)

Each OIB also has input RX7 for a signal from a Temperature Feedback
Board. The quantity and location of thermistor connections is dependant
on the drive configuration. Typically there is one temperature sensor
from the Line Converter and one temperature sensor from the Machine
Converter, each going into the respective OIB in the ‘A’ position.
However some drive configurations only require one thermistor feedback
connection. The temperature feedback connection on OIBC is not
implemented on the OIBB and is never used. 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 OIB, and the following table illustrates the status
and description for the LED states:
LED Status Description

D1 Red – On Run – The OIB has received an Enable
signal. The drive control software is in
control of all gating.
D2 Yellow – On Ready –The OIB power supply is sufficient
for proper operation.
D3 Green – On Power – The OIB has received a voltage
signal greater than 2V.
Environmental Hazardous materials

Considerations
Environmental protection is a top priority for Rockwell Automation. The
facility that manufactured this medium voltage drive operates an
environmental management system that is certified to the requirements of
ISO 14001. As part of this system, this product was reviewed in detail
throughout the development process to ensure that environmentally inert
materials were used wherever feasible. A final review has found this
product to be substantially free of hazardous material.
Please be assured that Rockwell Automation is actively seeking

alternatives to potentially hazardous materials for which no feasible
alternatives exist today in the industry. In the interim, the following
precautionary information is provided for your protection and for the
protection of the environment. Please contact the factory for any
environmental information on any material in the drive or with any
general questions regarding environmental impact.

Environmental • Capacitor Dielectric Fluid

Consideration The fluids used in the filter capacitors and the snubber capacitors are
(cont.) 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.
To clean up, soak into an absorbent material and discard into an

emergency container, or, if significant leakage occurs, pump fluid
directly into the container. Do not dispose into any drain or into the
environment in general or into general landfill refuse. Dispose of
according to local regulations. If disposing of an entire capacitor, the
same disposal precautions should be taken.
• Printed Circuit Boards

Most of the printed circuit boards utilize lead-based solder. Shipping
and handling of these boards is not restricted under any regulations,
however, lead is considered a hazardous substance. Circuit boards
must be disposed of according to local regulations and must not be
disposed of with general landfill refuse.
• Lithium Batteries
This drive contains one small 3V lithium battery on the DPM board.
The battery part # 346567-Q01 or BR2335 contains approximately
0.09 g of lithium metal. These batteries meet shipping regulations at
the time of publication, however there are specific marking and
packaging requirements. Properly packaged single, spare or expired
batteries may be shipped consigned as UN3090 PI 968 Part 1. A
maximum of two spare cells may be packaged with the DPM,
provided they are mechanically separated from each other during
shipment. Shipping cartons shall bear the warning: “Primary Lithium
Batteries – Forbidden for transport aboard passenger aircraft.”
Lithium batteries must be disposed of according to local regulations
and must not be disposed of with general landfill refuse.
• Chromate Plating
Some sheet steel and fasteners are plated with zinc and sealed with a
chromate-based dip (gold-colored 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
This drive is highly protected against arcing faults and therefore it is
very unlikely the drive would be the cause of a fire. In addition, the
materials in the drive are self-extinguishing (i.e. they will not burn
without a sustained external flame). If, however, the drive is
subjected to a sustained fire from some other source, some of the
polymer materials in the drive will produce toxic gases. As with any
fire, individuals involved in extinguishing the fire or anyone in close
proximity should wear a self-contained breathing apparatus to protect
against any inhalation of toxic gases.
Disposal
When disposing of the drive, it should be disassembled and separated into

groups of recyclable material as much as possible (i.e. steel, copper,
plastic, wire, etc.). These materials should then be sent to local recycling
facilities. In addition, all disposal precautions mentioned above must also
be taken for those particular materials.


Appendix A
Commissioning
Start-up Commissioning Start-up will be performed at the customer's site. Rockwell

Services Automation requests a minimum of four- (4) weeks notice to
schedule each start-up.
The standard Rockwell Automation work hours are between 9:00

AM to 5:00 PM EST, (8 hr/day) Monday through Friday, not
including observed holidays. Additional working hours are available
on a time and material basis.
Rockwell Automation recommends the following:
Drive Commissioning
1. A pre-installation meeting/conference call with the customer to

review:
– The Rockwell Automation Start-up Plan
– The Start-up Schedule
– The Drive(s) installation requirements
2. Inspect the drive’s mechanical and electrical devices.
3. Perform a tug test on all internal connections within the drive
and verify wiring.
4. Verify critical mechanical connections for proper torque
requirements.
5. Verify and adjust mechanical interlocks for permanent
location.
6. Confirm all inter-sectional wiring is connected properly.
7. Re-verify control wiring from any external control devices
such as PLCs, etc.
8. Confirm cooling system is operational.
9. Verification of proper phasing from isolation transformer to
drive.
10. Confirm cabling of drive to motor, isolation transformer and
line feed.
11. Collect test reports indicating megger / hipot test has been
performed on line and motor cables.
12. Control power checks to verify all system inputs such as
starts/stops, faults, and other remote inputs.

A-2 Commissioning
Start-up Commissioning 13. Apply medium voltage to the drive and perform operational
Services (cont.) checks.
14. Bump motor and tune drive to the system attributes. (If the
load is unable to handle any movement in the reverse direction
the load should be uncoupled prior to bumping the motor for
directional testing).
15. Run the drive motor system throughout the operational range
to verify proper performance.
Please Note: Customer personnel will be required on-site to

participate in the start-up of the system.

Appendix B
Catalog Number Explanation
for PowerFlex 7000 Variable Frequency Drives
First Position Second Position Third Position Fourth Position Fifth Position Sixth Position Seventh Position
7000 – A 40 D A – RPDTD – 1 - … etc.

Bulletin Service Duty/ Current Enclosure Line and Rectifier Options
Number Altitude Code Rating Type Control Configuration/ (Refer to
Voltages Line Impedance PowerFlex 7000
Medium Voltage Drives
Type
Global Price List)
Code Description Code Description Code Description

D Type 1 w/gasket (IP21) AFE Rectifier with Integral Line
7000A “A” Frame (Air Cooled)
RPDTD Reactor and Direct-to-Drive DC
Type 1 w/gasket (IP21)
7000 “B” Frame (Air Cooled) T Link
– Seismic rated
7000L “C” Frame (Liquid Cooled) AFE Rectifier with provision for
Type 12 w/vents and RPTX connection to separate Isolation
K
filters (IP42) Transformer (standard DC Link)
Type 12 w/vents and AFE Rectifier with integral Isolation
U filters (IP42) – Seismic RPTXI
Transformer (standard DC Link)
rated AFE Rectifier with Integral Line
RPLR Reactor and Standard DC Link
(No longer offered for sale)
Code Description 6-pulse Rectifier with provision for
Normal Duty, 0-1000 m Altitude connection to separate Isolation
A R6TX
Maximum 40°C Ambient transformer (standard DC Link)
Normal Duty, 1001-5000 m Altitude Code Description (No longer offered for sale)
Reduced Ambient (from 40°C offering) 40 40 Amp 18-pulse Rectifier with provision for
1001 – 2000 m = 37.5°C 46 46 Amp R18TX connection to separate Isolation
B 53 53 Amp Transformer (standard DC Link)
2001 – 3000 m = 35°C
3001 – 4000 m = 32.5°C 61 61 Amp
4001 – 5000 m = 30°C 70 70 Amp
Heavy Duty, 0-1000 m Altitude 81 81 Amp
C
Maximum 40°C Ambient 93 93 Amp See Table B-1
D Reduced Ambient (from 40°C offering) 120 120 Amp
– Same as ‘B’ above 140 140 Amp
Normal Duty, 0-1000 m Altitude 160 160 Amp
E
Maximum 35°C Ambient 185 185 Amp
Normal Duty, 1001-5000 m Altitude 215 215 Amp
Reduced Ambient (from 35°C offering) 250 250 Amp
1001 – 2000 m = 32.5°C 285 285 Amp
F
2001 – 3000 m = 30°C 325 325 Amp
3001 – 4000 m = 27.5°C 375 375 Amp
4001 – 5000 m = 25°C 430 430 Amp
G
Maximum 35°C Ambient 575 575 Amp
Normal Duty, 0-1000 m Altitude
J 625 625 Amp
Maximum 50°C Ambient
657 657 Amp
Heavy Duty, 0-1000 m Altitude
L 720 720 Amp
Normal Duty, 0-1000 m Altitude Not all amperages are
N available at all ambient/
Custom Configuration altitude configurations.
Z Refer to Price Lists for
(Contact Factory)
exact offering.

B-2 Catalog Number Explanation – Drive Selection
Table B-1 – Supply Voltage, Control Voltage, Frequency and Control Power Transformer Selection
Voltage Frequency Modification Number
Nominal With a Without a
Control (Hz)
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.

Catalog Number Explanation – Drive Selection B-3
PowerFlex 7000 Drive The PowerFlex 7000 medium voltage AC drive selection tables are
Selection Explanation based on two (2) types of drive service duty ratings:
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.
Service Duty Rating, Continuous Current Rating & Altitude Rating

Code
There are different codes that define service duty and altitude in the
drive catalog number (see page B-1).
For example,
Catalog number 7000A – A105DED-R6TXI, has a continuous current

rating of 105 amps, with a “normal duty” service rating up to 1000
meters altitude.
Catalog number 7000A – B105DED-R6TXI has a continuous rating of

105 amps with a “normal duty” service rating up to 5000 meters altitude.
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.

When
When is
is aa tachometer
tachometer A tachometer is required under the following conditions:
required?
required? 1. When speed regulation accuracy must be between 0.01 – 0.02%
of nominal speed.
2. When the zero speed breakaway torque needed is greater than
90% of continuous running torque.
3. When continuous running speed is greater than or equal to 0.1
Hz, but less than 6 Hz.
4. For minimizing restart times using the flying start capability in
forward or reverse direction.
Table B-2 –Power Flex Speed Regulation

Frequency Output
Tachometer
< 6 Hertz 6 – 15 Hertz Above 15 Hertz
Without Tachometer Not applicable 0.1 % 0.1 %
With Tachometer 0.02 % 0.01% 0.01%
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.
Table B-3 – 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

Catalog Number Explanation – Drive Selection B-5
PowerFlex 7000 The PowerFlex 7000 drives have been tested on a dynamometer to
Performance verify performance under locked rotor, accelerating, and low speed-
(Torque Capabilities) high torque conditions. Table B-4 below shows the PowerFlex 7000
drive torque capabilities as a percent of motor rated torque, independent
of the drive’s momentary overload conditions.
Table B-4 – 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
Breakaway Torque: Torque required to start a machine from standstill.
Accelerating Torque: Torque required to accelerate a load to a given speed, in a certain

period of time. The following formula may be used to calculate the
average torque to accelerate a known inertia (WK2):
T = ( WK2 × change in RPM) / 308t
where, T = acceleration torque in (lb-ft).

WK2 = total system inertia (lb-ft2) that the motor
must accelerate, including motor, gear box, and load.
t = time (seconds) to accelerate total system load.
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 B-5 – 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.

Appendix C
Torque Requirements
for threaded fasteners
Unless otherwise specified the following values of torque are to be

used in maintaining the equipment.
DIAMETER PITCH MATERIAL Torque (N-m) Torque (lb.-ft.)

M2.5 0.45 Steel 0,43 0.32
M4 0.70 Steel 1,8 1.3
M5 0.80 Steel 3,4 2.5
M6 1.00 Steel 6,0 4.4
M8 1.25 Steel 14 11
M10 1.50 Steel 29 21
M12 1.75 Steel 50 37
M14 2.00 Steel 81 60
¼“ 20 Steel S.A.E. 5 12 9.0

3/8” 16 Steel S.A.E. 2 27 20

C-2 Torque Requirements

Appendix D
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. The ground fault condition 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.
With these two factors, it is recommended to first megger the input

and output zones when encountering a ground fault. If the location
of the ground fault can not be located outside the drive, the drive will
need to be meggered. This procedure must be performed with due
care as the hazards to drive exist if the safety precautions in the
procedure are not followed. This is due to the fact the megger
procedure applies high voltage to ground: all the control boards in
the drive have been grounded and if not isolated, they will have high
potential applied to them causing immediate damage.
Meggering the ATTENTION Use caution when performing a Megger test.

PowerFlex 7000A High voltage testing is potentially hazardous and
may cause severe burns, injury or death. Where
appropriate, the cause of the test equipment
should be connected to ground.
It is recommended that the insulation levels be checked before

energizing power equipment. Performing a Megger test will provide
a resistance measurement from the phase to phase and phase to
ground by applying a high voltage to the power circuitry. This test is
performed to detect ground faults without damaging any equipment.
This test is performed by floating the drive and all connected

equipment to a high potential while measuring the leakage current to
ground. Floating the drive implies temporary removal of any
existing paths to ground necessary for normal operation of the drive.
7000 “A“ Frame 7000A-UM151D-EN-P – March 2013

D-2 Meggering
ATTENTION There exists the possibility of serious or fatal

injury to personnel if safety guidelines are not
followed.
The following procedure details how the Megger test on the

PowerFlex 7000A is to be performed. Failure to comply with this
procedure may result in poor Megger reading and damage to drive
control boards.
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
Disconnect any incoming power sources, medium voltage

sources should be isolated and locked out and all control power
sources should be turned off at their respective circuit breaker(s).
Verify with a potential indicator that power sources have been

disconnected, and that the control power in the drive is de-
energized.
2. Isolate the Power Circuit from System Ground (Float the

drive)
It is necessary to remove the grounds on the following

components within the drive (Refer to the electrical diagrams
provided with the equipment to assist in determining the points
which need to be disconnected):
Voltage Sensing Boards (VSB)

Output Grounding Network (OGN)
Remove all ground connections from all of the VSBs in the

drive. This has to be done at the screw terminals on the VSB
rather than the ground bus. There are two grounds on each
board marked “GND 1”, and “GND 2”.

Meggering D-3
Note: It is important to disconnect the terminals on the

boards rather than from the ground bus as the grounding
cable is only rated for 600 V. Injecting a high voltage on the
ground cable will degrade the cable insulation. Do not
disconnect the white medium voltage wires from the VSBs.
They must be included in the test.
The number of VSBs installed in each drive varies depending on

the drive configuration.
Output Grounding Network
Remove the ground connection on the OGN (if installed).

This connection should be lifted at the OGN capacitor rather
than the grounding bus as the grounding cable is only rated
for 600 V.
Note: Injecting a high voltage on the ground cable during a

Megger test will degrade the cable insulation.
3. Disconnect Connections between Power Circuit and Low

Voltage Control
The connections between the low voltage control and the

power circuit are made through ribbon cable connectors.
The cables will be plugged into connectors on the Voltage
Sensing Board marked “J1”, “J2”, and “J3”, and terminate
on the Signal Conditioning Boards. Every ribbon cable
connection made on the VSBs should be marked for
identification from the factory. Confirm the marking
matches the connections, and disconnect the ribbon cables
and move them clear of the VSB. If these ribbon cables are
not removed from the VSB, then high potential will be
applied directly to the low voltage control through the SCBs,
and cause immediate damage to those boards.
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.

D-4 Meggering
Potential Transformer Fuses
A Megger test may exceed the rating of potential transformer

fusing. Removing the primary fuses from all potential and
control power transformers in the system will not only
protect them from damage but remove a path from the power
circuit back to the drive control.
Transient Suppression Network
A path to ground exists through the TSN network as it has a

ground connection to dissipate high energy surges in normal
operation. If this ground connection is not isolated the
Megger test will indicate a high leakage current reading
through this path, falsely indicating a problem in the drive.
To isolate this ground path, all fuses on the TSN must be
removed before proceeding with the Megger test.
4. Meggering the Drive
Note: Verify the drive and any connected equipment is clear

of personnel and tools prior to commencing the Megger test.
Barricade off any open or exposed conductors. Conduct a
walk-around inspection before commencing the test.
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.
Note: Be sure the Megger is discharged prior to

disconnecting it from the equipment.
Connect the Megger to the drive following the specific

instructions for that model. If the Megger has a lower
voltage setting (normally 500V or 1000V), apply that
voltage for 5 seconds as a precursor for the higher voltage
rating. This may limit the damage if you forgot to remove
any grounds. If the reading is very high, apply 5kV from
any drive input or output terminal to ground. Perform a
Megger test at 5 kV for 1 minute and record the result.

Meggering D-5
The test should produce a reading greater than the minimum

values listed below. If the test results produced a value lower
than these values start segmenting the drive system down
into smaller components and repeat the test on each segment
to identify the source of the ground fault. This implies
isolating the line side of the drive from the machine side by
removing the appropriate cables on the DC Link reactor.
The DC Link reactor may have to be completely isolated

from the drive, at which point all four of its power cables
must disconnected. It is imperative to ensure the electrical
components to be meggered are electrically isolated from
ground. Items that may produce lower than expected
readings are surge capacitors at the motor terminals, motor
filter capacitors at the output of the drive. The meggering
procedure must follow a systematic segmentation of
electrical components to isolate and locate a ground fault.
Type of Drive Minimum Megger Value

Liquid Cooled Drive 200 M Ohms
Air Cooled Drive 1k M Ohm
Drive with input/output
5k M Ohm
Caps Disconnected
Isolation Transformer 5k M Ohm
Motor 5k M Ohm
Note: The motor filter capacitors and line filter capacitors

(if applicable) may result in the Megger test result being
lower than expected. These capacitors have internal
discharge resistors designed to discharge the capacitors to
ground. If you are uncertain of the Megger test results
disconnect the output capacitors.
Note: Humidity and dirty standoff insulators may also cause

leakage to ground because of tracking. You may have to
clean a 'dirty' drive prior to commencing the Megger test.
5. Reconnecting Connections between Power Circuit and

Low Voltage Control
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.

D-6 Meggering
6. Reconnect the Power Circuit to the System Ground
Securely reconnect the two ground conductors on the VSBs.
The two ground connections on the VSB provide a reference

point for the VSB and enable the low voltage signal to be fed
to the SCBs. If the ground conductor was not connected, the
monitored low voltage signal could then rise up to medium
voltage potential which is a serious hazard that must be
avoided at all times. You must always ensure the ground
conductors on the VSB are securely connected before
applying medium voltage to the drive.
ATTENTION Failure to connect both ground connections on

the voltage sensing board will result in high
potential in the Low Voltage cabinet within the
drive which will result in damage to the drive
control and possible injury or death to
personnel.
Output Grounding Network
Reconnect the ground connection on the OGN capacitor. The

bolt connection should be torque down to 3.4 Nm (30 lb-in).
Exceeding the torque rating of this connection may result in
damage to the capacitor.
ATTENTION Failure to reconnect the OGN ground may result

in the neutral voltage offset being impressed on
the motor cables and stator, which may result in
equipment damage. For drives that did not
originally have the OGN connected (or even
installed), this is not a concern.

Appendix E
Preventative Maintenance Schedule
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.
Refer to the Tools/Parts/Information Requirements at the end of this

section for a list of documentation and materials needed to properly
complete the preventive maintenance documents.
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.
Once you receive an Air Filter Warning, you should immediately

make plans to change or clean the filter. You should still have days
or weeks until the drive reaches an Air Filter Fault, but this is
dependent on site-specific particle conditions.
This can be done while the drive is running. Refer to User Manual,
Chapter 4 – Component Definition and Maintenance for a detailed
description of the process.

E-2 Preventative Maintenance Schedule
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.
Initial Information Gathering

Some of the important information to be recorded includes:
Print Drive Setup

Print Fault/Warning Queues
Save Parameters to NVRAM
Save Parameters to Operator Interface
Circuit Board Part Numbers / Serial Numbers / Revision Letters*
(* This only needs to be recorded if parts have been modified or
changed since the last Preventive Maintenance activities)
WARNING To prevent electrical shock, ensure the main

using a hot stick or appropriate voltage-measuring
device. Failure to do so may result in injury or
death.
Physical Checks (NO Medium Voltage and NO Control Power)
Power Connection Inspection

Inspect PF7000 drive, input/output/bypass contactor sections,
and all associated drive components for loose power cable
connections and ground cable connections: torque them to the
required torque specifications.
Inspect the bus bars and check for any signs of overheating /
discoloration and tighten the bus connections to the required
torque specifications.
Clean all cables and bus bars that exhibit dust build-up.
Use torque sealer on all connections.
Carry out the integrity checks on the signal ground and safety
grounds.

Preventative Maintenance Schedule E-3
Check for any visual/physical evidence of damage and/or

degradation 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.
Check for any visual/physical evidence of damage and/or degradation

of components in the medium voltage compartments (inverter/rectifier,
cabling, DC Link, contactor, load break, harmonic filter, etc).
This includes main cooling fan, power devices, heatsinks, circuit
boards, insulators, cables, capacitors, resistors, current transformers,
potential transformers, fuses, wiring, etc.; Causes could be
corrosion, excessive temperature, or contamination.
Verify torque on heatsink bolts (electrical connections to bullet
assemblies) is within specifications (13.5 N-m).
Clean all contaminated components using a vacuum cleaner (DO
NOT use a blower), and wipe clean components where appropriate.
NOTE: An important component to check for contamination is the
heatsink. The fine grooves in the aluminum heatsinks can capture
dust and debris.
Carry out the physical inspection and verification for the proper
operation of the contactor/isolator interlocks, and door interlocks.
Carry out the physical inspection and verification for the proper
operation of the key interlocks.
Physical verification of the additional cooling fans mounted in the
AC Line Reactor cabinet, Harmonic Filter cabinet for mounting and
connections.
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.
Carry out the insulation meggering of the drive, motor, isolation
transformer/line reactor, and the associated cabling.
Refer to User’s Manual, Appendix D for meggering procedure.
Check clamp head indicator washers for proper clamp pressure, and
adjust as necessary.
Refer to page 5-17, “Uniform Clamping Pressure” and
“Checking Clamping Pressure” for details on proper clamp
pressure.

Annual Maintenance Control Power Checks (No Medium Voltage)

(cont.)
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.
Verify all single-phase cooling fans for operation.
This includes the cooling fans in the AC/DC Power supplies and
the DC/DC converter.
Verify the proper voltage levels at the CPT (if installed), AC/DC
Power Supplies, DC/DC converter, isolated gate power supply
boards.
Refer to Chapter 4 – Commissioning in Reference Manual
(Publication 7000A-RM001_-EN-P) for appropriate
procedures/voltage levels for the above checks.
Verify the proper gate pulse patterns using Gate Test Operating
Mode.
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 Power Checks before Restarting
Ensure all cabinets are cleared of tools, and all component

connections are back in place and in the running state.
Put all equipment in the normal operating mode, and apply medium
voltage.
If there were any input or output cables removed, verify the input
phasing, and bump the motor for rotation.
If there were any changes to the motor, input transformer, or
associated cabling, you will have to retune the drive to the new
configuration using Autotuning.
Save all parameter changes (if any) to NVRAM.
Run the application up to full speed/full load, or to customer
satisfaction.
Capture the drive variables while running, in the highest access
level if possible.

Additional Tasks During Preventive Maintenance
Investigation of customer’s concerns relating to drive performance

Relate any problems found during above procedures to
customer issues.
Informal instruction on drive operation and maintenance for plant
maintenance personnel
Reminder of safety practices and interlocks on MV equipment,
and on specific operating concerns
Reminder of the need to properly identify operating conditions
Recommendation for critical spare parts which should be stocked
in-plant to reduce production downtime
Gather information on all spare parts on site, and compare that
with factory-recommended critical spares to evaluate whether
levels are sufficient.
Contact MV Spare Parts group for more information.
Vacuum Bottle Integrity Testing using a Vacuum Checker or AC
Hipot
Refer to Publication 1502-UM050_-EN-P for a detailed
description of all contactor maintenance.
Final Reporting
A complete, detailed report on all steps in the Preventive

Maintenance procedures should be recorded to identify changes.
A completed copy of this checklist should be included.
A detailed description of ALL ADJUSTMENTS AND
MEASUREMENTS that were taken during the process should
be included in an addendum (Interlock Adjustments, Loose
Connections, Voltage Readings, Megger Results, Parameters,
etc.)
THIS INFORMATION SHOULD BE COMMUNICATED TO MV
PRODUCT SUPPORT SO THAT FUTURE SUPPORT
ACTIVITIES WILL HAVE THE LATEST SITE INFORMATION
AVAILABLE.
This can be faxed to (519) 740-4756, or
E-mailed to: MVSupport_Technical@ra.rockwell.com

Annual Maintenance Time Estimations

(cont.)
Operational Maintenance 0.5 hours per filter
Annual Maintenance
Initial Information Gathering 0.5 hours
Physical Checks
– Torque Checks 2.0 hours
– Inspection 2.0 hours
– Cleaning ** 2.5 hours **
– Meggering 1.5 hours
Control Power Checks
– Contactor Adjustments ** 2.0 hours **
– Voltage Level Checks 1.0 hours
– Firing Check 0.5 hours
– System Test ** 2.0 hours **
Medium Voltage Checks
– Final Inspection 0.5 hours
– Phasing Check ** 1.5 hours **
– Autotuning** 2.0 hours **
– Operation to Maximum Load Site Dependent
Additional Tasks
– Investigation ** Depends on Nature of the Problem **
– Informal Training/Refresher ** 2.0 hours **
– Spare Parts Analysis ** 1.0 hours **
– Vacuum Bottle Integrity Check ** 3.0 hours **
Final Report 3.0 hours
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.

Tool / Parts / Information Requirements
The following is a list of the tools recommended for proper maintenance

of the PF7000 drives. Not all of the tools may be required for a specific
drive preventive procedure, but if we were to complete all of the tasks
listed above the following tools would be required.
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-UM151_-EN-P
PF7000 Parameters Manual – Publication 7000-TD002_-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)

PowerFlex 7000 Rockwell recognizes that following a defined maintenance schedule will
Maintenance Schedule deliver the maximum product availability. By rigorously following this
maintenance schedule, the Customer can expect the highest possible uptime.
This Annual Preventative Maintenance Program includes a visual inspection
of all drive components visible from the front of the unit, resistance checks
on the power components, power supply voltage level checks, general
cleaning and maintenance, checking of all accessible power connections for
tightness, and other tasks. For more details, please refer to Chapter 5
(Component Definition and Maintenance) of this User Manual.
I – Inspection
This indicates that the component should be inspected for signs of excessive
accumulation of dust/dirt/etc. or external damage (e.g. looking at Filter
Capacitors for bulges in the case, inspecting the heatsinks for debris
clogging the air flow path, etc.).
M – Maintenance
This indicates a maintenance task that is outside the normal preventative
maintenance tasks, and can include the inductance testing of Line
Reactors/DC Links, or the full testing of an isolation transformer.
R – Replacement
This indicates that the component has reached its mean operational life, and
should be replaced to decrease the chance of component failure. It is very
likely that components will exceed the design life in the drive, and that is
dependent on many factors such as usage, heating, etc.
C – Cleaning
This indicates the cleaning of a part that can be reused, and refers
specifically to the door-mounted air filters in the liquid-cooled drives and
some air-cooled drives.
Rv – Review
This refers to a discussion with Rockwell Automation to determine whether
any of the enhancements/changes made to the Drive Hardware and Control
would be valuable to the application.
RFB/R – Refurbishment/Replacement
The parts can be refurbished at lower cost OR the parts can be replaced with
new ones.

Rockwell Automation PowerFlex 7000 Preventative Maintenance Service Schedule
Interval Period (in years) 0 1 2 3 4 5 6 7 8 9 10

Commissioning Activities S
Door Mounted Air Filters C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R
Air-Cooling Main Cooling Fan Motor I I I I I I RFB/R I I I
System
Redundant Cooling Fan Motor (if supplied) I I I I I I RFB/R I I I
Small Aux. Cooling Fans “Caravel” I I I I R I I I I R
Mesh Filters C C C C C C C C C C C
De-ionizing Filter Cartridge R R R R R R R R R R R
Liquid-Cooling All Fittings/Connections/Hose Clamps I I I I I I I I I I
System
Redundant Cooling Pump Motors/Pumps I I I I I I I I I I
Redundant Cooling Pump Motor Seals I I I I I I I I I R
Thermostatic Valve Element I I I I I I R I I I
Power Devices (SGCTs/SCRs) I I I I I I I I I I
Snubber Resistors/Sharing Resistors/HECS I I I I I I I I I I
Power Switching
Rectifier Snubber Capacitors I I I I I I I I I Rv/R
Components
Inverter Snubber Capacitors I I I I I I I I I R
Integrated Gate Driver Power Supply I I I I RFB/R I I I I RFB/R
Integral Isolation Transformer/Line Reactor I I I I M I I I I M
Magnetics/Power DC Link/Common Mode Choke I I I I M I I I I M
Filters Line/Motor Filter Capacitors I I I I M I I I I M
AC/DC and DC/DC Power Supplies I I I I RFB/R I I I I RFB/R
Control Cabinet Control Boards I I I I I I I I I I
Components Batteries (DCBs and CIB) I I R I I R I I R I
Batteries (UPS) I I I I R I I I I R
Low Voltage Terminal Connections/
I I I I I I I I I I
Plug-in Connections
Medium Voltage Connections I I I I I I I I I I
Connections
Heatsink Bolted Connections I I I I I I I I I I
Medium Voltage Connections (Rectifier) – – – I – – – I – I
Medium Voltage Connections (Inverter) – – – – – – – – – I
Firmware – – Rv – – Rv – – Rv –
Enhancements
Hardware – – Rv – – Rv – – Rv –
Parameters I I Rv I I Rv I I Rv I
Operational
Variables I I Rv I I Rv I I Rv I
Conditions
Application Concerns I I Rv I I Rv I I Rv I
Spare Parts Inventory/Needs I I Rv I I Rv I I Rv I
Only applies to air-cooled VFDs (i.e. ‘A’ Frame and ‘B’ Frame)
If filter supplied is not a washable type, replace filter. If filter supplied is a washable type, wash or replace (depending on state of filter).
Only applies to liquid-cooled VFDs (i.e. ‘C’ Frame)
A 4-year replacement interval applies to 6-pulse or 18-pulse versions. Active Front End rectifiers have a 10-year rectifier snubber capacitor replacement interval.
Replace UPS batteries yearly for 50°C rated VFDs.
When rectifier snubber capacitors are replaced, the MV connections for rectifier need to be inspected.
When inverter snubber capacitors are replaced, the MV connections for inverter need to be inspected.
These components may be serviced while the VFD is running.

Rockwell Automation PowerFlex 7000 Preventative Maintenance Service Schedule (cont.)
Interval Period (in years) 11 12 13 14 15 16 17 18 19 20

Commissioning Activities
Door Mounted Air Filters C/R C/R C/R C/R C/R C/R C/R C/R C/R C/R
Air-Cooling Main Cooling Fan Motor I I I RFB/R I I I I I I
System
Redundant Cooling Fan Motor (if supplied) I I I RFB/R I I I I I I
Small Aux. Cooling Fans “Caravel” I I I I R I I I I R
Mesh Filters C C C C C C C C C C
De-ionizing Filter Cartridge R R R R R R R R R R
Liquid-Cooling All Fittings/Connections/Hose Clamps I I I I I I I I I I
System
Redundant Cooling Pump Motors/Pumps I I I I I I I I I I
Redundant Cooling Pump Motor Seals I I I I I I I I I R
Thermostatic Valve Element I I I R I I I I I I
Power Devices (SGCTs/SCRs) I R I I I I I I I I
Snubber Resistors/Sharing Resistors/HECS I I I I I I I I I I
Power Switching
Rectifier Snubber Capacitors I I I I I I I I I Rv/R
Components
Inverter Snubber Capacitors I I I I I I I I I R
Integrated Gate Driver Power Supply I I I I RFB/R I I I I RFB/R
Integral Isolation Transformer/Line Reactor I I I I M I I I I M
Magnetics/Power DC Link/Common Mode Choke I I I I M I I I I M
Filters Line/Motor Filter Capacitors I I I I M I I I I M
AC/DC and DC/DC Power Supplies I I I I RFB/R I I I I RFB/R
Control Cabinet Control Boards I I I I I I I I I I
Components Batteries (DCBs and CIB) I R I I R I I R I I
Batteries (UPS) I I I I R I I I I R
Low Voltage Terminal Connections/
I I I I I I I I I I
Plug-in Connections
Medium Voltage Connections I I I I I I I I I I
Connections
Heatsink Bolted Connections I I I I I I I I I I
Medium Voltage Connections (Rectifier) – I – – – I – – – I
Medium Voltage Connections (Inverter) – – – – – – – – – I
Firmware – Rv – – Rv – – Rv – –
Enhancements
Hardware – Rv – – Rv – – Rv – –
Parameters I Rv I I Rv I I Rv I I
Operational
Variables I Rv I I Rv I I Rv I I
Conditions
Application Concerns I Rv I I Rv I I Rv I I
Spare Parts Inventory/Needs I Rv i I Rv I I Rv I I
Only applies to air-cooled VFDs (i.e. ‘A’ Frame and ‘B’ Frame)
If filter supplied is not a washable type, replace filter. If filter supplied is a washable type, wash or replace (depending on state of filter).
Only applies to liquid-cooled VFDs (i.e. ‘C’ Frame)
A 4-year replacement interval applies to 6-pulse or 18-pulse versions. Active Front End rectifiers have a 10-year rectifier snubber capacitor replacement interval.
Replace UPS batteries yearly for 50°C rated VFDs.
When rectifier snubber capacitors are replaced, the MV connections for rectifier need to be inspected.
When inverter snubber capacitors are replaced, the MV connections for inverter need to be inspected.
These components may be serviced while the VFD is running.

General Notes Maintenance of Medium Voltage Motor Control Equipment
ATTENTION Servicing energized Medium Voltage Motor

Control Equipment can be hazardous. Severe
injury or death can result from electrical shock,
bump, or unintended actuation of controlled
equipment. Recommended practice is to
disconnect and lockout control equipment from
power sources, and release stored energy, if
present.
For countries following NEMA standards, refer to National Fire Protection

Association Standard No. NFPA70E, Part II and (as applicable) OSHA rules
for Control of Hazardous Energy Sources (Lockout/Tagout) and OSHA
Electrical Safety Related Work Practices safety related work practices,
including procedural requirements for lockout-tagout, and appropriate work
practices, personnel qualifications and training requirements, where it is not
feasible to de-energize and lockout or tagout electric circuits and equipment
before working on or near exposed circuit parts.
For countries following IEC standards, refer to local codes and regulations.
Periodic Inspection
Medium Voltage Motor control equipment should be inspected periodically.

Inspection intervals should be based on environmental and operating
conditions and adjusted as indicated by experience. An initial inspection
within 3 to 4 months after installation is suggested. Refer to the following
standards for general guidelines for setting-up a periodic maintenance
program.
For countries following NEMA standards, refer to National Electrical

Manufacturers Association (NEMA) Standard No. ICS 1.1 (Safety
Guidelines for the Application, Installation, and Maintenance of Solid-Sate
Control) for MV Drives and ICS 1.3 (Preventive Maintenance of Industrial
Control and Systems Equipment) for MV Controllers.
For countries following IEC standards, refer to IEC 61800-5-1 Sec. 6.5 for
MV Drives and IEC 60470 Sec. 10, IEC 62271-1 Sec. 10.4 for MV
Controllers.

General Notes (cont.) Contamination
If inspection reveals that dust, dirt, moisture or other contamination has

reached the control equipment, the cause must be eliminated. This could
indicate unsealed enclosure openings (conduit or other) or incorrect
operating procedures. Replace any damaged or embrittled seals and repair
or replace any other damaged or malfunctioning parts (e.g., hinges,
fasteners, etc.). Dirty, wet or contaminated control devices must be replaced
unless they can be cleaned effectively by vacuuming or wiping. Compressed
air is not recommended for cleaning because it may displace dirt, dust, or
debris into other parts or equipment, or damage delicate parts.
High Voltage Testing
High voltage insulation resistance (IR) or dielectric withstanding voltage

(megger) tests should not be used to check solid-state control equipment.
When meggering electrical equipment, such as transformers or motors,
solid-state devices must be bypassed before performing the test. Even
though no damage may be readily apparent after a megger test, the solid-
state devices are degraded and repeated application of high voltage can lead
to failure.
Maintenance after a Fault Condition
Opening of the short circuit protective device (such as fuses or circuit

breakers) in a properly coordinated motor branch circuit is an indication of a
fault condition in excess of operating overload. Such conditions can cause
damage to medium voltage motor control equipment. Before restoring
power, the fault condition must be corrected and any necessary repairs or
replacements must be made to restore the medium voltage motor control
equipment to good working order. Refer to NEMA Standards Publication
No. ICS-2, Part ICS2-302 for procedures. Use only replacement parts and
devices recommended by Allen-Bradley to maintain the integrity of the
equipment. Ensure the parts are properly matched to the model, series and
revision level of the equipment. After maintenance or repair of the
equipment, always test the control system for proper functioning under
controlled conditions (that avoid hazards in the event of a control
malfunction). For additional information, refer to NEMA ICS 1.3,
PREVENTIVE MAINTENANCE OF INDUSTRIAL CONTROL AND
SYSTEMS EQUIPMENT, published by the National Electrical
Manufacturers Association, and NFPA70B, ELECTRICAL EQUIPMENT
MAINTENANCE, published by the National Fire Protection Association.

Part-specific Notes Cooling Fans

Inspect fans used for forced air cooling. Replace any that have bent,
chipped, or missing blades, or if the shaft does not turn freely. Apply power
momentarily to check operation. If unit does not operate, check and replace
wiring, fuse, or fan motor as appropriate. Clean or change air filters as
recommended in the Users Manual.
Operating Mechanisms
Check for proper functioning and freedom from sticking or binding. Replace
any broken, deformed or badly worn parts or assemblies according to
individual product User Manuals. Check for and securely retighten any
loose fasteners. Lubricate, if specified in individual product instructions.
Many devices are factory lubricated. If lubrication during use or
maintenance of these devices is needed, it will be specified in their
individual product instructions and/or User Manual. Note: Allen-Bradley
magnetic starters, contactors and relays are designed to operate without
lubrication. Do not lubricate these devices, because oil or grease on the pole
faces (mating surfaces) of the operating magnet may cause the device to
stick in the "ON" mode.
Contacts
Check contacts for excessive wear and dirt accumulations. Vacuum or wipe
contacts with a soft cloth if necessary to remove dirt. Contacts are not
harmed by discoloration and slight pitting. Contacts should never be filed, as
dressing only shortens contact life. Contact spray cleaners should not be
used as their residues on magnet pole faces or in operating mechanisms may
cause sticking and can interfere with electrical continuity. Contacts should
only be replaced after contact face material has become badly worn. Always
replace contacts in complete sets to avoid misalignment and uneven contact
pressure.
Vacuum Contactors
Contacts of vacuum contactors are not visible, so contact wear must be

checked indirectly. Vacuum bottles should be replaced when:
1. The contactor wear indicator line shows need for replacement, or
2. The vacuum bottle integrity tests show need for replacement.
Replace all vacuum bottles in the contactor at the same time to avoid
misalignment and uneven contact wear. If the vacuum battles do not require
replacement, check and adjust overtravel to the value listed in the product
User Manual.

Part-specific Notes Power Cable and Control Wire Terminals

(cont.)
Loose connections in power circuits can cause overheating that can lead to
equipment malfunction or failure. Loose connections in control circuits can
cause control malfunctions. Loose bonding or grounding connections can
increase hazards of electrical shock and contribute to electromagnetic
interference (EMI). Check the tightness of all terminals and bus bar
connections and tighten securely any loose connections. Replace any parts
or wiring damaged by overheating, and any broken wires or bonding straps.
Refer to the User Manual for torque values required for power cable and bus
hardware connections.
Coils
If a coil exhibits evidence of overheating (cracked, melted or burned

insulation), it must be replaced. In that event, check for and correct
overvoltage or undervoltage conditions, which can cause coil failure. Be
sure to clean any residue of melted coil insulation from other parts of the
device or replace such parts.
Batteries
Replace batteries periodically as specified in product manual or if a battery

shows signs of electrolyte leakage. Use tools to handle batteries that have
leaked electrolyte; most electrolytes are corrosive and can cause burns.
Dispose of the old battery in accordance with instructions supplied with the
new battery or as specified in the product manual.
Pilot Lights
Replace any burned out lamps or damaged lenses. Do not use solvents or
cleaning agents on the lenses.

Solid-State Devices
ATTENTION Use of other than factory recommended test

equipment for solid-state controls may result in
damage to the control or test equipment or
unintended actuation of the controlled
equipment. Refer to paragraph titled HIGH
VOLTAGE TESTING.
Solid-state devices require little more than a periodic visual inspection.

Discolored, charred or burned components may indicate the need to replace
the component or circuit board. Necessary replacements should be made
only at the PC board or plug-in component level. Printed circuit boards
should be inspected to determine whether they are properly seated in the
edge board connectors. Board locking tabs should also be in place. Solid-state
devices must also be protected from contamination, and cooling provisions
must be maintained – refer to paragraphs titled CONTAMINATION and
COOLING DEVICES. Solvents should not be used on printed circuit boards.
Locking and Interlocking Devices
Check these devices for proper working condition and capability of

performing their intended functions. Make any necessary replacements only
with Allen-Bradley renewal parts or kits. Adjust or repair only in
accordance with Allen-Bradley instructions found in the product User
Manuals.


Appendix F
Specifications
Specifications Description Specifications

Power Rating (Air Cooled) 200 to 1250 hp (150 to 933 kW)
Motor Type Induction or Synchronous
Input Voltage Rating 2400V, 3300V, 4160V, 6600V
Input Voltage Tolerance ± 10% of Nominal
Voltage Sag -30%
Control Power Loss Ride-Through 5 Cycles (Std)
Input Protection Surge Arrestors
Input Frequency 50/60 Hz, +/- 5%
Power Bus Short-circuit Current Withstand 5 Cycle
3300 V – 6000 V 25 kA RMS SYM
Basic Impulse Level 50 kV (0 – 1000 m)
Power Bus Design Copper – Tin plated
Ground Bus Copper – Tin plated 6 x 51 mm (¼ x 2 in.)
Customer Control Wire Way Separate and Isolated
Vacuum Contactor with Fused Isolating Switch
Input Power Circuit Protection
(optional)
Input Impedance Device Isolation Transformer or AC Line Reactor
0 – 2300 V
0 – 3300 V
Output Voltage
0 – 4000 V
0 – 6000 or 6300 V
Inverter Design PWM
Inverter Switch Symmetrical Gate Commutated Thyristor (SGCT)
Inverter Switch Failure Mode Non-rupture, Non-arc
Inverter Switch Failure Rate (FIT) 100 per 1 Billion Hours Operation
Inverter Switch Cooling Double Sided, Low Thermal Stress
Inverter Switching Frequency 420-540 Hz
Voltage SGCTs (per phase)
2400 V 2
Number of Inverter SGCTs 3300 V 4
4160 V 4
6600 V 6
Voltage PIV
2400 V 6500 V
SGCT PIV Rating
3300 V 6500 V
(Peak Inverse Voltage)
4160 V 6500 V
6600 V 6500 V
Rectifier Designs AFE (Active Front End)
Rectifier Switch SGCT
Rectifier Switch Failure Mode Non-rupture, Non-arc
Rectifier Switch Failure Rate (FIT) 100 (SGCT) per 1 Billion Hours Operation
Rectifier Switch Cooling Double Sided, Low Thermal Stress
Voltage Sag tolerance is reduced to -25% when control power is supplied from medium voltage via CPT.
Short-circuit fault rating based on input protection device (contactor or circuit breaker).
BIL rating based on altitudes < 1000 m (3,300 ft.) Refer to factory for derating on altitudes >1000 m).

F-2 Specifications
Specifications Description Specifications

(cont.) Voltage AFE
2400 V 2
Number of Rectifier Devices
3300 V 4
per phase
4160 V 4
6600 V 6
Output Waveform to Motor Sinusoidal Current / Voltage
Medium Voltage Isolation Fiber Optic
SHE (Selective Harmonic Elimination)
Synchronous Trapezoidal PWM
Modulation Techniques
Asynchronous and Synchronous SVM
(Space Vector Modulation)
Digital Sensorless Direct Vector
Control Method
Full Vector Control with Tach Feedback (Optional)
Tuning Method Auto Tuning via Setup Wizard
Speed Regulator Bandwidth 5-25 Radians / Second
Torque Regulator Bandwidth 15-50 Radians / Second
0.1% without Tachometer Feedback
Speed Regulation
0.01-0.02% with Tachometer Feedback
Acceleration/Deceleration Range Independent Accel/Decel – 4 x 1200 sec.
Acceleration/Deceleration Ramp Rates 4 x Independent Accel/Decel
S Ramp Rate Independent Accel/Decel – 2 x 1200 sec.
Critical Speed Avoidance 3 x Independent with Adjustable Bandwidth
Stall Protection Delay / Speed
Load Loss Detection Adjustable level, delay, speed set points
Control Mode Speed or Torque
Current Limit Adjustable in Motoring and Regenerative
Output Frequency Range 0.2-75 Hz
Normal Duty Heavy Duty
Service Duty Rating 150% Overload for
110% Overload for
Overload Rating 1 minute every 10 minutes
1 minute every 10 minutes
(Constant or Variable Torque
(Variable Torque Load)
Load)
> 97.5%
Typical VFD Efficiency Contact Factory for Guaranteed Efficiency
of Specific Drive Rating
Input Power Factor 0.98 minimum, 30 – 100% Load
IEEE 519 Harmonic Guidelines IEEE 519 Compliant
VFD Noise Level < 85 dB(A) per OSHA standard 3074
Regenerative Braking Capability Inherent – No Additional Hardware or Software Required
Yes – Able to Start into and Control a Spinning Load in
Flying Start Capability
Forward or Reverse Direction
Operator Interface 40-character, 16-line formatted text
English German
Languages French Chinese
Spanish
Under certain conditions, power system analysis will be required.

Specifications F-3
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 (3) Isolated, 4-20mA or 0-10 V
• Analog input 12 Bit (4-20 mA)
Analog Resolution
• Analog input 13 Bit (0-10V)
• (1) Isolated, 4-20 mA
Analog Outputs
• (8) Non-isolated, 0-10 V
Communication Interface DPI
Scan Time Internal DPI – 2 ms min., 4 ms max.
R I/O Lon Works
DeviceNet CAN open
Ethernet RS485 HVAC
Communications Protocols
Profibus RS485 DF1
(Optional)
Modbus RS232 DF1
Interbus USB
ControlNet
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
0° to 40°C (32°F to 104°F)
Ambient Temperature
0° to 50°C (32°F to 122°F) Optional
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

F-4 Specifications
Dimensions / Weights
VFD Total Width
Nominal Line Approx. Weight
Drive Type Maximum
Voltage Millimeters Inches lb (kg)
Current
Configuration #1 – Direct-to-Drive 140 2100 82.67 4300 (1955)
2400V 60 Hz or Configuration #2 – AFE Rectifier with separate isolation
160 2400 94.49 8300 (3765)
3300V 50 Hz or transformer
4160V 50/60 Hz Configuration #3 – AFE Rectifier with Integral isolation
160 2400 94.49 9800 (4455)
transformer
Configuration #1 – Direct-to-Drive 93 2400 94.49 6500 (2955)
Configuration #2 – AFE Rectifier with separate isolation
105 2800 110.24 10000 (4545)
6600V 50/60 Hz transformer
Configuration #3 – AFE Rectifier with integral isolation
105 2800 110.24 7500 (3410)
transformer
Note: Total Depth = 1000 mm (39.37 in.)
Total Height without fan shroud = 2318 mm (91.25 in.)
Total Height with fan shroud = 2643 mm (104.05 in.)
Nominal Power Ratings

VFD Current Range
Nominal Line Voltage Nominal HP Range Nominal kW Range
(Amps)
2400V 60 Hz 46 – 160 200 – 700 150 – 522
3300V 50 Hz 46 – 160 250 – 1000 187 – 750
4160V 50/60 Hz 46 – 160 350 – 1250 260 – 933
6600V 50/60 Hz 40 – 105 500 - 1250 400 – 933

Medium Voltage Products, 135 Dundas Street, Cambridge, ON, N1R 5X1 Canada, Tel: (1) 519.740.4100, Fax: (1) 519.623.8930, www.ab.com/mvb
Publication 7000A-UM151D-EN-P – March 2013 Copyright © 2010 Rockwell Automation, Inc. All rights reserved. Printed in Canada.
Supersedes 7000A-UM151C-EN-P – October 2010

Powerflex® 7000 Medium Voltage Ac Drive Air-Cooled ("A" Frame) - Forge Control

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Bulletin 7000 User Manual

PowerFlex® 7000 Medium Voltage AC Drive Air-Cooled

Preface Overview Who should use this Manual ....................................................P-1

Chapter 1 Overview of Drive Introduction .............................................................................. 1-1

Chapter 2 Drive Installation Safety and Codes ..................................................................... 2-1

7000 “A” Frame 7000A-UM151D-EN-P – March 2013

Chapter 2 Drive Installation Power Cabling Access ........................................................... 2-27

Chapter 3 Operator Interface Chapter Objectives ................................................................... 3-1

7000A-UM151D-EN-P – March 2013 7000 “A” Frame

Chapter 3 Operator Interface Setting Time ............................................................. 3-16

7000 “A” Frame 7000A-UM151D-EN-P – March 2013

Chapter 3 Operator Interface Operator Interface Menu Hierarchy Chart

7000A-UM151D-EN-P – March 2013 7000 “A” Frame

Impeller Maintenance (DC Link/Fan Section) ...................... 4-31

Appendix A Commissioning Start-up Commissioning Services ........................................... A-1

Appendix B Catalog Number Catalog Number Explanation................................................... B-1

7000 “A” Frame 7000A-UM151D-EN-P – March 2013

Appendix D Meggering Drive Meggering ..................................................................... D-1

Appendix E Preventative Preventive Maintenance Check List ....................................... E-1

Appendix F Specifications Specifications ...........................................................................F-1

7000A-UM151D-EN-P – March 2013 7000 “A” Frame

The above information is provided to the customer during the

For detailed information on Troubleshooting, Parameters and

For detailed information on receiving and handling for Medium

7000 “A” Frame 7000A-UM151D-EN-P – March 2013

WARNING Warnings tell readers where people may be

ATTENTION Cautions tell readers where machinery may be

Both of the above could indicate:

SHOCK HAZARD This symbol alerts the user to a potential

7000A-UM151D-EN-P – March 2013 7000 “A” Frame

General Precautions ATTENTION This drive contains ESD (Electrostatic

ATTENTION An incorrectly applied or installed drive can

ATTENTION Only personnel familiar with the PowerFlex

They may be contacted at 519-740-4100, request Medium Voltage

The support they offer includes, but is not limited to:

– Quoting and Managing Product On-site Start-ups.

7000 “A” Frame 7000A-UM151D-EN-P – March 2013

7000A-UM151D-EN-P – March 2013 7000 “A” Frame

Introduction The PowerFlex® 7000 represents the third generation of medium

The PowerFlex 7000 is a general purpose stand alone medium

The PowerFlex 7000 is a global product that adheres to the most

7000 “A” Frame 7000A-UM151D-EN-P – March 2013

Drive Configurations – PowerFlex 7000 “A” Frame

Small system footprint

7000A-UM151D-EN-P – March 2013 7000 “A” Frame

Topology The PowerFlex 7000 utilizes a Pulse Width Modulated (PWM) –

The PowerFlex 7000 has the additional benefit of inherent

LINE CONVERTER DC LINK MACHINE CONVERTER

Figure 1.1 – PWM-CSI AC Drive

7000 “A” Frame 7000A-UM151D-EN-P – March 2013

Rectifier Designs Active Front-End (AFE) Rectifier

An Active Front-End rectifier is particularly attractive since it does

Many competing technologies in today’s MV market require a multi-

Elimination of the isolation transformer reduces capital and

The AFE rectifier requires a switching pattern that complies with

The filter resonant frequency is placed below 300 Hz (for a 60 Hz

7000A-UM151D-EN-P – March 2013 7000 “A” Frame

Figure 1.2 – AFE rectifier and its input current/voltage waveforms

The AFE rectifier can be used in conjunction with a rectifier duty