Drive Maintenance

PowerFlex 7000
CSM Training School

2014
PF7000 A & B Frames Preventive

Maintenance
(Confidential – For Internal Use Only)
Copyright © 2008 Rockwell Automation, Inc. All rights reserved.
1
Maintenance and Troubleshooting
1. Operational Maintenance
2. Annual Maintenance
3. Components Replacement
4. Common Faults & Recommended Actions
(Confidential – For Internal Use Only) Copyright © 2008 Rockwell Automation, Inc. All rights reserved. 2
PF7000 A & B Frames Preventive
Maintenance
• The preventive maintenance activities on the PF7000 Air-Cooled Drive (A-Frame or B-
Frame) can be broken down into two categories:
Operational Maintenance: can be completed while drive is running.
Annual Maintenance: should be completed during scheduled downtime.
Operational Maintenance
This process really involves only one task: Changing or Cleaning the Air Filters.
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 pressure differential across the
devices drops to a drive-specific level which can be anywhere from 7% to 17%
blocked, depending on the type of heatsink and device configuration.
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.
This can be done while the drive is running.
Annual Maintenance
These maintenance tasks should be performed on an annual basis.
These are recommended tasks that you may find 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.
The maintenance tasks are:

Initial Information Gathering
Physical Checks (NO Medium Voltage and NO Control Power)
Control Power Checks (No Medium Voltage)
Final Power Checks before Restarting
Additional tasks during preventive maintenance
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
Physical Checks
Insert warning for locking out MV (NO Medium Voltage and NO Control Power)
1) 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 / discolouration
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
Physical Checks (cont.)
2) 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
3) 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
Clean all contaminated components using a vacuum cleaner 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
4) Carry out the physical inspection and verification for the proper operation of the
contactor/isolator interlocks, and door key interlocks.
5) Physical verification of the additional cooling fans mounted in the AC Line Reactor
cabinet, Harmonic Filter cabinet for mounting and connections.
6) 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.
7) Carry out the insulation meggering of the drive, motor, isolation transformer/line
reactor, and the associated cabling (Refer to User’s Manual, Chapter 6).
8) Check clamp head indicator washers for proper clamp pressure, and adjust as
necessary (Refer to User’s Manual, Chapter 6).
Control Power Checks
Control power checks done with no medium voltage applied
1) Apply 3 Phase Control power to the PF7000 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 all contactor maintenance).
2) Verify all single-phase cooling fans for operation This includes the cooling fans in
the AC/DC Power supplies and the DC/DC converter.
3) Verify the proper voltage levels at the CPT (if installed), AC/DC Power Supplies,
DC/DC converter, isolated gate power supply boards (Refer to User’s Manual,
Chapter 4).
4) Verify the proper gate pulse patterns using Gate Test Operating Mode.
5) 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
1) Ensure all cabinets are cleared of tools, and all component connections are back
in place and in the running state.
2) Put all equipment in the normal operating mode, and apply medium voltage.
3) If there were any input or output cables removed, verify the input phasing, and
bump the motor for rotation.
4) 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.
5) Save all parameter changes (if any) to NVRAM.
6) Run the application up to full speed/full load, or to customer satisfaction.
Additional Tasks During Preventive Maintenance
1) Investigation of customer’s concerns relating to drive performance (Relate any

problems found during above procedures to customer issues).
2) Reminder of safety practices and interlocks on MV equipment, specific operating

concerns, and the need to properly identify operating conditions.
3) Recommendation for critical spare parts which should be stocked in-plant to

reduce production downtime.
4) Vacuum Bottle Integrity Testing using a Vacuum Checker or AC Hipot (Refer to a

detailed description of contactor maintenance manual).
Tools & Materials Required
1) 100 MHz Oscilloscope with minimum 2 Channels and memory

2) 5kV DC Megger
3) Digital Multimeter
4) Torque Wrench
5) Laptop Computer with Relevant Software and Cables
6) Assorted Hand Tools (Screwdrivers, Open Ended Metric Wrenches, Metric Sockets, etc.)
7) 5/16 Allen Keys
8) Speed Wrench
9) Feeler Gauge
10) Vacuum Bottle Checker or AC-Hipot
11) Minimum of 15kV Hotstick / Potential Indicator
12) Minimum of 10kV Safety Gloves
13) Vacuum Cleaner with Anti-static hose
14) Anti-static Cleaning Cloth
15) No. 30 Torx Driver
16) Torque Sealer (Yellow) Part number --- RU6048
17) Electrical Joint Compound ALCOA EJC No 2 or approved equivalent (For Power Devices)
18) Aeroshell no. 7 Part number 40025-198-01 (For Vacuum Contactors)
Components Replacement (B-Classic)
Replacement of Air Filters (Page 349 or 6-61)
Voltage-Sensing Assembly Replacement (Page 293 or 6-5)
Transient Suppression Network Fuse Replacement (Page 296 or 6-8)
Metal-Oxide Varistor Replacement (Page 298 or 6-10)
Output Grounding Network Capacitor Replacement (Page 298 or 6-10)
Hall Effect Current Sensor Replacement (Page 301 or 6-13)
Current Transformer Replacement (Page 302 or 6-14)
Filter Capacitor Replacement (Page 304 or 6-16)
Symmetrical Gate Commutated Thyristor Replacement (Page 314 or 6-26)
Silicon Controlled Rectifier & SCR Self-Powered Gate Driver Board Replacement
(Page 317 or 6-29)
Components Replacement (B-Classic) (cont.)
Snubber and Sharing Resistor Replacement (Page 326 or 6-38)
Replacing Sharing Resistor (Page 330 or 6-42)
Air Pressure Sensor Replacement (Page 340 or 6-52)
Fan Removal and Replacement (Page 344 or 6-56)
Drive Control Board Replacement (Page 368 or 6-80)
Customer Interface Board Replacement (Page 375 or 6-87)
Signal Conditioning Board Replacement (Page 378 or 6-90)
External Input/Output Board Replacement (Page 380 or 6-92)
Fiber Optic Interface Board Replacement (Page 382 or 6-94)
Common Faults and Recommended Actions
Common Faults & Recommended Actions
(cont.)
(cont.)
(cont.)
(cont.)
(cont.)
(cont.)
(cont.)
(cont.)
(cont.)
(cont.)
(cont.)
(cont.)
QA Session
(Confidential – For Internal Use Only)
Copyright © 2008 Rockwell Automation, Inc. All rights reserved.
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PowerFlex 7000

CSM Training School

PF7000 A & B Frames Preventive

(Confidential – For Internal Use Only)

Copyright © 2008 Rockwell Automation, Inc. All rights reserved.

4. Common Faults & Recommended Actions

Operational Maintenance: can be completed while drive is running.

Annual Maintenance: should be completed during scheduled downtime.

The percentage is a measure of voltage drop, and should not be viewed as a

This can be done while the drive is running.

These maintenance tasks should be performed on an annual basis.

The maintenance tasks are:

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

1) Power Connection Inspection:

Inspect PF7000 drive, input/output/bypass contactor sections, and all

Use torque sealer on all connections

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

This includes Relays, Contactors, Timers, Terminal connectors, Circuit

Clean all contaminated components using a vacuum cleaner (DO NOT

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

Clean all contaminated components using a vacuum cleaner and wipe

NOTE: An important component to check for contamination is the heatsink.

Control power checks done with no medium voltage applied

5) Save all parameter changes (if any) to NVRAM.

6) Run the application up to full speed/full load, or to customer satisfaction.

1) Investigation of customer’s concerns relating to drive performance (Relate any

2) Reminder of safety practices and interlocks on MV equipment, specific operating

3) Recommendation for critical spare parts which should be stocked in-plant to

4) Vacuum Bottle Integrity Testing using a Vacuum Checker or AC Hipot (Refer to a

1) 100 MHz Oscilloscope with minimum 2 Channels and memory

Replacement of Air Filters (Page 349 or 6-61)

Voltage-Sensing Assembly Replacement (Page 293 or 6-5)

Transient Suppression Network Fuse Replacement (Page 296 or 6-8)

Metal-Oxide Varistor Replacement (Page 298 or 6-10)

Output Grounding Network Capacitor Replacement (Page 298 or 6-10)

Hall Effect Current Sensor Replacement (Page 301 or 6-13)

Current Transformer Replacement (Page 302 or 6-14)

Filter Capacitor Replacement (Page 304 or 6-16)

Symmetrical Gate Commutated Thyristor Replacement (Page 314 or 6-26)

Snubber and Sharing Resistor Replacement (Page 326 or 6-38)

Replacing Sharing Resistor (Page 330 or 6-42)

Air Pressure Sensor Replacement (Page 340 or 6-52)

Fan Removal and Replacement (Page 344 or 6-56)

Drive Control Board Replacement (Page 368 or 6-80)

Customer Interface Board Replacement (Page 375 or 6-87)

Signal Conditioning Board Replacement (Page 378 or 6-90)

External Input/Output Board Replacement (Page 380 or 6-92)

Fiber Optic Interface Board Replacement (Page 382 or 6-94)

(Confidential – For Internal Use Only)

Copyright © 2008 Rockwell Automation, Inc. All rights reserved.

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