Allen-Bradley PF7000A User manual

PowerFlex 7000 Medium Voltage AC Drives

Publication 7000-TG002J-EN-P

Troubleshooting Guide

Important User Information

Read this document and the documents listed in the additional resources section about installation, configuration, and

operation of this equipment before you install, configure, operate, or maintain this product. Users are required to

familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes, laws,

and standards.

Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required

to be carried out by suitably trained personnel in accordance with applicable code of practice.

If this equipment is used in a manner not specified by the manufacturer, the protection provided by the equipment may be

impaired.

In no event will Rockwell Automation, Inc. be responsible or liable for indirect or consequential damages resulting from the

use or application of this equipment.

The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and

requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or

liability for actual use based on the examples and diagrams.

No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or

software described in this manual.

Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,

Inc., is prohibited.

Throughout this manual, when necessary, we use notes to make you aware of safety considerations.

Labels may also be on or inside the equipment to provide specific precautions.

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.

WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,

which may lead to personal injury or death, property damage, or economic loss.

ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property

damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.

IMPORTANT

Identifies information that is critical for successful application and understanding of the product.

SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous

voltage may be present.

BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may

reach dangerous temperatures.

ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to

potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL

Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).

Rockwell Automation Publication 7000-TG002J-EN-P - March 2015 3

Summary of Changes

This manual contains new and updated information.

New and Updated

Information

This table contains the changes made to this revision.

Topic Page

Added Fault 159 21

Updated STO Gating Flt description 40

4Rockwell Automation Publication 7000-TG002J-EN-P - March 2015

Summary of Changes

Notes:

Rockwell Automation Publication 7000-TG002J-EN-P - March 2015 5

Table of Contents

Preface

About this Publication . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

Acronyms and Abbreviations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

Chapter 1

Fault Messages

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

Fault Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12

Chapter 2

Warning Messages

Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55

Warning Messages . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56

Appendix A

Spare Parts

Components and Related Part Numbers . . . . . . . . . . . . . . . . . . . . . . . . . . . 87

Appendix B

Fault Codes

Listed Numerically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 89

Appendix C

Warning Codes

Listed Numerically . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 107

6Rockwell Automation Publication 7000-TG002J-EN-P - March 2015

Table of Contents

Notes:

Rockwell Automation Publication 7000-TG002J-EN-P - March 2015 7

Preface

About this Publication This manual contains troubleshooting information for medium voltage

PowerFlex® 7000 drives only.

Who Should Use This Manual This manual is intended for qualified service personnel responsible for

troubleshooting and repairing medium voltage PowerFlex 7000 drives. You

should have previous experience with, and basic understanding of, electrical

terminology, procedures, required troubleshooting equipment, equipment

protection procedures and methods, and safety precautions.

Additional Resources These documents contain additional information concerning related products

from Rockwell Automation.

You can view or download publications at

http:/www.rockwellautomation.com/literature/. To order paper copies of

technical documentation, contact your local Allen-Bradley distributor or

Rockwell Automation sales representative.

Resource Description

Publication 7000-IN006 PowerFlex 7000 Medium Voltage AC Drive (B Frame) Commissioning - ForGe Control

Publication 7000-IN007 PowerFlex 7000 Medium Voltage AC Drive (B Frame) Installation - ForGe Control

Publication 7000-IN008 PowerFlex 7000 Medium Voltage AC Drive (B Frame) Trans. & Handling - ForGe Control

Publication 7000-IN010 Handling, Inspection, and Storage of Medium Voltage Line Filter Capacitors

Publication 7000-PP002 PowerFlex 7000 Air-Cooled Drives

Publication 7000-QS002 HMI Interface Board Software Updater and Firmware Download Procedure

Publication 7000-TD001 PowerFlex 7000 Medium Voltage AC Drive (Firmware Version 6.xxx) - Classic Control

Publication 7000-TD002 PowerFlex 7000 Medium Voltage AC Drive (Firmware Version 9.xxx) - ForGe Control

Publication 7000-UM150 PowerFlex 7000 Medium Voltage AC Drive (B Frame) - Classic Control

Publication 7000-UM151 PowerFlex 7000 Medium Voltage AC Drive (B Frame) - ForGe Control (Using

PanelView 500)

Publication 7000-UM201 PowerFlex 7000 HMI Offering with Enhanced Functionality

Publication 7000-UM202 PowerFlex 7000 Medium Voltage AC Drive (B Frame) - ForGe Control

Publication 7000-UM203 PowerFlex 7000 Series Safe Torque Off

Publication 7000A-UM150 PowerFlex 7000 Medium Voltage AC Drive (A Frame) - Classic Control

Publication 7000A-UM151 PowerFlex 7000 Medium Voltage AC Drive (A Frame) - ForGe Control (Using

PanelView 550)

Publication 7000L-UM301 PowerFlex 7000 Medium Voltage AC Drive (C Frame) - ForGe Control

Publication 7000L-UM302 PowerFlex 7000 Medium Voltage AC Drive (C Frame) - ForGe Control (Marine)

8Rockwell Automation Publication 7000-TG002J-EN-P - March 2015

Preface

Acronyms and Abbreviations Acronym/ Abbreviation Description

A/D Analog/Digital

A2D Analog to Digital

AC Alternating Current

ACB Analog Control Board

Accel Acceleration

ADC Analog to Digital Converter

Anlg Analog

BW Bandwidth

Cap Capacitor

Ch Channel

Chn Channel

CIB Customer Interface Board

CMC Common Mode Choke

Cmd Command

Conv Converter

CT Current Transformer

Ctctr Contactor

Cur Current

DAC Digital to Analog Converter

DB Dynamic Braking

DC Direct Current

DCB Drive Control Board

DCSL Drive Control and Synchronization Link

DD Dimensional Drawings

Decel Deceleration

DIM Drive Identity Module

Dly Delay

DO Drive Output

DPI Drive Peripheral Interface

DPM Drive Processor Module

DrvIn Drive Input

ED Electrical Drawings

ESP Electric Submersible Pump

Fbk Feedback

Flt Fault

Fltr Filter

FO Fiber-Optic

FOB Fiber-Optic Interface Board

FOI Fiber-Optic Interface

FPGA Field-Programmable Gate Array

Rockwell Automation Publication 7000-TG002J-EN-P - March 2015 9

Preface

Freq Frequency

GND Ground

Gnrl General

HECS Hall Effect Current Sensor

Hi High

HP Horse Power

HW Hardware

ICurrent

IGDPS Isolated Gate Driver Power Supply

Init Initialize

Inv Inverter

IO Input/Output

Isoltn Sw Isolation Switch

LInductance

LLine

LED Light-emitting diode

Liq Liquid

Lo Low

LR Line Reactor

LV Low Voltage

MMachine

Magntz Magnetizing

Max Maximum

Min Minimum

Mstr Master

MTR Motor

NVRAM Non-Volatile Random Access Memory

OC Overcurrent

OL Overload

OP Output

OT Overtemperature

OV Overvoltage

PD Parallel Drive

PF Power Factor

PFC Power Factor Correction

PID Proportional, Integral, Derivative (process control)

PLC Programmable Logic Control

PSD Power Structure Diagnostic

PWM Pulse-Width Modulation

Rect Rectifier

Acronym/ Abbreviation Description

10 Rockwell Automation Publication 7000-TG002J-EN-P - March 2015

Preface

Rot’n Rotation

SCB Signal Conditioning Board

SCR Silicon-Controlled Rectifier

SGCT Symmetrical-Gate Commutated Thyristor

Slv Slave

Spd Speed

SPGD Self-Powered Gate Driver

STO Safe Torque Off

SW Software

Sync Synchronous

Tach Tachometer

TFB Temperature Feedback Board

TFB3 Temperature Feedback Board, 3rd generation

Trp Trip

Trq Torque

TSN Transient Suppression Network

UB Unbalance

UPS Uninterrupted Power Supply

USART Universal Synchronous/Asynchronous Transmitter/Receiver

VVolt

VSB Volt Sensing Board

Wrn Warning

Xfer Transfer

XIO External Input/Output

Acronym/ Abbreviation Description

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