Product Update Number:

Medium Voltage Support Technical Services Update

Title:

PF7000_4th Gen_GEN-15

Product Service Advisory PSA 2010-02-001 ForGe Control Users

Original Issued By: Manzoor Memon Revised By: Robert Carriere Reviewed By: Najeeb Bohio Carlos Siri Fred Jason Date: February 02, 2010 December 08, 2010 Date: December 20, 2010 Products Affected

PowerFlex 7000 VFD (7000A, 7000, 7000L) ForGe Control

Only personnel who have been trained and understand the PowerFlex 7000 MV Variable Frequency Drive (VFD) and Bulletin 1500 product line can work on this equipment. Appropriate PPE and applicable safety procedures must be followed at all times. Please refer to the attached sheet. Please submit any questions you have about this document to: Rockwell Automation Canada Inc. 135 Dundas Street Cambridge, Ont. N1R 5X1 Attn: Medium Voltage Support Phone: Fax: Email : 1.519.740.4790 (Option 1 for MV Technical Support) 1.519.740.4756 mvsupport_technical@ra.rockwell.com

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NOTE: The original Customer Letter mailed/posted refers to firmware version 7.003. In a few instances, the revised fault detection scheme created nuisance alarms. This detection scheme has been further modified in 8.003 to avoid nuisance alarms. Please download and install firmware version 8.003 or greater. QUESTIONS: (problem/issue/product change/etc) What are the requirements for upgrading the VFD firmware? What steps need to be taken in the event of a VFD fault where there is the potential for capacitor failure? SUMMARY: This Tech Note explains the firmware upgrade requirements for a PowerFlex 7000 VFD on the ForGe Control platform (must be updated to Firmware Release Number 8.003 or greater), and provides instructions for upgrading the firmware. This Tech Note also provides the necessary guidelines that must be followed in the event of tripping of the VFD on a fault where there is the potential for capacitor failure. ANSWER: (details) IMPORTANT: This document is valid for PowerFlex 7000 VFD firmware revision 8.003 or higher, for ForGe Control platform for Active Front End [AFE] rectifiers only. Per the Product Service Advisory (PSA 2010-02-001) it is mandatory to upgrade the firmware in all PowerFlex 7000 VFDs on the ForGe Control platform to the latest revision level (must be firmware Revision Number 8.003 or greater). The firmware enhancements and firmware upgrade/download instructions are explained below. NOTE: To upgrade/download firmware, the VFD needs to be stopped and isolated from Medium Voltage. Make sure you have all the necessary hardware and firmware before proceeding to download the firmware. If any help or guidance is required, after reading this Tech Note, please call your local RA office for clarification. In firmware versions 7.003 up to 8.001, changes were made in the processing of the Master (Line) Current Unbalance fault (set to a 3% trip level, 0.1 sec delay). In a few cases, these new requirements generated nuisance alarms, requiring a revision to the detection scheme. In firmware version 8.002 and greater, a new alarm and detection scheme has been implemented to determine when the potential for capacitor failure exists. This new alarm Line Cap Failure fault (Fault Code 136) provides alternating flashing messages of "Line Cap Failure" and DoNotApplyMV and does not allow a reset of the fault unless a specific code is entered. This alarm indicates that there exists a potential for capacitor failure, requiring all necessary checks and troubleshooting steps to be carried out before re-energizing the VFD, as described in the ForGe User Manual - Component Definition and Maintenance chapter (chapter 5). Some of the important steps are duplicated here for a quick reference. Note that in firmware version 8.002 and above, Line Current Unbalance setting will be reverted back to the original requirements (5% trip, 1 sec delay).

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The detection strategy for this new alarm in firmware versions 8.002 and greater will be as follows: The "Line Cap Failure" (Fault Code 136) will be detected when a Line Current unbalance condition is detected AND a Line Neutral Over-Voltage condition is detected.

In the event of the VFD tripping on Master Current Unbalance fault (in the case of firmware revision 7.XXX) or in the event of the VFD tripping on Line Cap Failure (in the case of firmware revision 8.XXX), the flashing messages as described above would appear on the Main screen as well as on the Alarm screen across the STATUS line. The VFD will prevent resetting the fault and clearing the Fault Queue. You must verify the integrity of Line Filter Capacitors (AFE rectifier VFDs only), looking for short circuits or signs of physical damage before attempting to reenergize the VFD. For testing the filter capacitors, follow the instructions outlined later in this document. Only after testing and confirming the filter capacitors are in good condition, can you take the following steps to reset the Master Current Unbalance fault and clear the Fault Queue. 1. From the Main screen, press F10 to get to the Access screen (screen shots for reference only actual data/detail shown may be slightly different). At the Access screen, scroll down to Rockwell by pressing the down arrow key and enter passcode 42426 and then press the Enter key. The Current Access will now change to Rockwell.

Figure 1 - Changing Access level (F10)

Figure 2 - Entering the Passcode

Figure 3 - Current Access Rockwell

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2. Press F10 to exit the Access screen, and then press F8 to gain access to the Setup screen. With the cursor on Parameters, press the Enter key. This will take you to the Select Group screen.

Figure 4 - Exiting Access screen (F10)

Figure 5 - Selecting Parameters

Figure 6 - Entering Setup screen (F8)

Figure 7 - At the Select Group screen

3. At the Select Group screen, press F7 (List) and then F5 (Code).

Figure 8 select LIST (F7)

Figure 9 select CODE (F5)

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4. For firmware major revision 7, starting at minor revision 003 (7.003 and greater 7.XXX): At the Select Code screen, enter 704 and press the Enter key. The parameter description Debug Int 3 will appear on the screen. Press the Enter key again. The screen will change to the Modify Parameter screen. Now enter 12345 and then press the Enter key. The cursor will disappear and the new value would be 12345.

Figure 10 - Entering the parameter#704 Debug Int 3

Figure 11 - Entering the password 12345

For firmware major revision 8.001 and greater (8.XXX):

At the Select Code screen, enter 921 and press the Enter key. The parameter description Fault Lock Clear will appear on the screen. Press the Enter key again. The screen will change to the Modify Parameter screen. Now enter 12345 and then press the Enter key. The cursor will disappear and the new value would be 12345.

Figure 10 - Entering the parameter#921 Fault Lock Clear

Figure 11 - Entering the password 12345

5. At this point, press F10 a few times to exit back to the Main screen. If you are prompted to save changes, just ignore the message by pressing the F10 key.

Figure 12 - Ignore Save prompt message (F10)

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6. Now, you have 5 minutes to reset the fault and clear the Fault Queue. Note: If you dont clear the Fault Queue, the next time you cycle the control power the VFD will fault again on power up.

Figure 13 - Accessing Alarm screen (F6)

Figure 14 - Accessing Fault Queue (F9)

Figure 15 - Clearing Fault Queue (F7)

For detailed instructions on accessing the Terminal screens and resetting the faults or warnings and clearing the Alarm or Fault queues, refer to ForGe User Manual Operator Interface chapter (Chapter 3).

Downloading the VFD Firmware

Introduction
With the introduction of the PowerFlex 7000 Medium Voltage VFD, all VFD control functions are loaded on the Drive Processor Module (DPM) with firmware via a serial connection on the Drive Processor Module at data port J4. The firmware is packaged into a single executable file (with the extension .exe). The following describes how to download new or updated firmware to the VFD using the DPM data port. All firmware downloaded via this means is stored in non-volatile Flash memory. The latest firmware files and the associated Tech Notes are available on

http://www.ab.com/support/abdrives/webupdate/powerflex7000.html and the Medium Voltage intranet site, or

can be obtained from Medium Voltage Product Support. When upgrading firmware it is imperative that you review all of the associated firmware release notes as they contain critical information that must be followed (please review applicable release notes in addition to any intermediary release notes). Failure to do so may result in equipment damage or render the drive temporarily inoperable.

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Overview
When the system is powered up, the VFD executes the Application Code contained in the on-board flash memory. If it does not have valid firmware, then the entire system will drop into a download mode. In the download mode the system is waiting to receive a firmware download via the serial data port J4 on the DPM. The system may also be placed into download mode from the VFD Terminal. This can only be accomplished if you have obtained a minimum of ADVANCED level access. Once that has been obtained, from the main screen selecting UTILITY-TRANSFER-SYSTEM will place the VFD into download mode.

Preparation for Downloading Firmware

Required
Laptop running on Windows operating system A null-modem cable with a 9-pin female connector for the laptop serial port, and a 9- pin male connector for Drive Processor Module (Data Port-J4). (A serial cable with pins 2-3 swapped at one end will also work) Latest copy of the VFD firmware file (filename.exe) VFD Access level must be at least Advanced or higher (Service or Rockwell).

Here is a typical pin out of a complete null-modem cable.

Although the above cable will work, essentially a cable with pins 2, 3 and 5 is all that is required.

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Saving Original Settings

Ensure the parameters are saved to NVRAM, and saved to the Operator Interface Terminal, and saved to any other external source such as the Flash Card, DriveTools, or printed to a hardcopy. Press F10 (Access), and highlight Advanced. Press Enter, or enter the password value (if password required) and you should have Advanced level access.

Press F10 to Exit, and then F5 for NVRAM. Press F5 for SAVE, and F8 for YES. The parameters should now be saved to NVRAM. Press F10 again to EXIT.

To save to the Operator Interface Terminal and Flash Card, Press F2 (UTILITY), F7 (TRANSFER), and F4 (PARAMETERS). You should now be on the following screen:

In order to save parameters to the Operator Interface Terminal, press F5 (DRV>MEM). To save to the Flash Card, you must first insert the card in the terminal. Remove the back cover and insert the card in the slot on the terminal. It can only go in one way. Then press F4 (DRV>CRD). Saving to the card means that you will have to choose a file name. Use the Up and Down arrows to select the character, and then use the Right arrow to go to the next character. Press the Enter key when finished.

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Press F8 for YES, and the parameters will be transferred to the card. Press F10 to EXIT.

Download Mode
To place the VFD in download mode, you should be in the UTILITY TRANSFER screen. You will not be able to do this if the VFD is running. Ensure the VFD is stopped, and the E-Stop is pressed. This is just a precaution, as all versions of firmware 7.xxx and later will not allow you to attempt a download while running.

This time press F9 for SYSTEM, and a screen will appear telling you that you are in download mode. There are two status LEDs (D9 and D11) on the DPM, which provides indication of the programming process. The following illustrates the states of the LED: Solid Green when both LEDs are solid green, the application firmware is running. Flashing Green when either D9 or both LEDs are flashing the board is in download mode. After putting the VFD in download mode, the following is displayed on the VFD terminal:

If you press any Key after this message the Terminal will show:

COMMUNICATION ERROR
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Method to Download Firmware

The following illustrates how to download firmware on the PowerFlex 7000 VFD. The method involves two steps, which are explained below: 1. Connect your laptop to the DPM data port J4. Locate the PowerFlex 7000 Medium Voltage VFD firmware (example of an executable file: PF7KSupport7004A.exe) 2. Double click on the file to download the firmware. The executable program will open the following screen:

3. The DPM are preloaded with Bootcode. Therefore, just select the checkbox across firmware and click OK. This will start the process of the downloading of firmware, attempting connection to the VFD. The following screen will be displayed:

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The progress of the download is continuously displayed on the screen as shown.

The completion of the download is displayed on the screen as shown.

After downloading new firmware, the Drive boots automatically.

Reloading the Parameters

IT IS IMPORTANT TO REFER TO THE PRODUCT SAFETY ADVISORY BEFORE UPGRADING FIRMWARE. IT IS ALSO IMPORTANT TO REVIEW ALL FIRMWARE RELEASE NOTES FOR CRITICAL CHANGES. To reload the parameters from the Operator Interface, once again obtain ADVANCED level access. Then follow the same steps to get to the UTILITIES (F2) -> TRANSFER (F7) -> PARAMETERS (F4). Then choose F3 (MEM>DRV). This will prompt you for confirmation, and you can press F8 for YES. The parameters will then be transferred. You can also transfer from the Card to the VFD using F2 (CRD>DRV), and the difference is that you will first get a screen asking you to choose from all the available parameter listings on the card. Page 11 of 17 Product Service Advisory PN2010-01-010 PF7000_4th Gen_GEN-15

Select the one you want using the arrow keys, and press Enter. Then you can press F8 for Yes and transfer the parameters. Once the parameters are transferred, press the F10 (EXIT) key to get back to the main screen. It is important to go through the parameters and ensure the settings are proper for the VFD. New parameters may need to be changed for the specific VFD application, and this should be understood from reviewing the release notes beforehand. You should then press F5 (NVRAM) from Main Menu Screen, and save the parameters to NVRAM. Then cycle control power, and the VFD should come up with no faults or warnings, and the VFD will be ready to run. At this point you may also want to save the parameters to the Terminal, the Flash Card, via software or as a hardcopy. This will provide a record of the new settings. IMPORTANT: 1. For firmware revisions 7.003 to 8.001 you need to ensure that the Line Current Unbalance Trip and Delay are set as shown in the following table: Parameter Group Drive Protection Drive Protection Linear Number 108 109 Parameter Description Line CurUnbalTrp Line CurUnbalDly Default Setting 0.05 pu 1.00 sec Recommended Setting 0.03 pu 0.100 sec

2. For firmware revisions 8.002 and higher, the Line Current Unbalance Trip and Delay can be left at their default values: Parameter Group Drive Protection Drive Protection Drive Protection Drive Protection Drive Protection Linear Number 108 109 868 869 871 Parameter Description Line CurUnbalTrp Line CurUnbalDly LineCurUnbal Lvl Cap Trip Dly CapNeutVolt Lvl Default Setting 0.05 pu 1.00 sec 0.03 pu 200 msec 0.10 pu Recommended Setting 0.05 pu 1.00 sec 0.03 pu 200 msec 0.10 pu

NOTE: For 7000 A-Frame (Bulletin Number: 7000A) drives, the parameter P868 LineCurUnbal Lvl can be increased to 5% if there are nuisance trips. 3. Make sure you save all above changes to NVRAM. This can be verified after cycling the control power.

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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 (F) 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 dont 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 Appendix A. 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. To prevent electrical shock, ensure the main power has been disconnected before working on the capacitor. 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.

Verify the load is not running due to process. A freewheeling motor can generate voltage that will be back-fed to the equipment being worked on.

2. 3. 4. 5.

Follow appropriate safety steps to isolate the equipment from medium voltage. Verify that there is no voltage present on the capacitor by using a hot stick or any other appropriate voltage-measuring device. Perform visual inspection to ensure there is no oil leak or bulge in any of the capacitors. 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. Product Service Advisory PN2010-01-010 PF7000_4th Gen_GEN-15

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6.

If the difference between the highest and the lowest readings is off by 15% or more, then you might have a bad capacitor. If more than one capacitor is used in the circuit, then you would need to isolate each of them and check them separately to identify which one is defective. Before disconnecting the capacitors, note the location of all the cables and mark them accordingly. Disconnect power cables from the capacitor terminals on all four bushings and isolate them from the capacitor. (Refer to Filter Capacitor Replacement guidelines in ForGe User Manual - Component Definition and Maintenance chapter (chapter 5) for using proper torque when reconnecting the capacitors) Repeat step 5 to check each capacitor separately to confirm which one is defective.

7.

8.

9.

Second Method:
1. Ensure there is no power to the equipment before testing the capacitor. To prevent electrical shock, ensure the main power has been disconnected before working on the capacitor. 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.

Verify the load is not running due to process. A freewheeling motor can generate voltage that will be back-fed to the equipment being worked on.

1.

Verify that there is no voltage present on the capacitor by using a hot stick or any other appropriate voltage-measuring device. Perform visual inspection to ensure there is no oil leak or bulge in any of the capacitors. Note the location of all the cables and mark them accordingly. Disconnect power cables from the capacitor terminals on all four bushings and isolate them from the capacitor. (Refer to Filter Capacitor Replacement guidelines in ForGe User Manual - Component Definition and Maintenance chapter (chapter 5) for using proper torque when reconnecting the capacitors).

2. 3. 4.

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5.

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.

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 stick or other voltage-measuring device verify that the capacitor is fully discharged before touching it.

6.

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. e.g. - the capacitor under test is rated at 400kVAR, 6600V, 50Hz, 29.2OF. 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 Test Voltage Measured Current L1-N 200V 1.87A L2-N 200V 1.866A L3-N 200V 1.861A

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 C=1

2 f Xc

2 3.14 50 106.95 C = 29.7 F

Where, f = frequency of the applied voltage. Similarly, you can calculate the capacitance for the remaining two measurements for L2-N and L3-N.

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Appendix A
Recommended Digital Multimeters (DMM) to be used for checking filter capacitors 1. 2. 3. 4. 5. BK Precision LCR/ESR Meter, Model 885 (Figure 16) [www.bkprecision.com] Fluke 179 (Figure 17) [www.fluke.com] Fluke 12 (Figure 18) Fluke 29 (Figure 19) Fluke 87V (Figure 20)

Figure 16

Figure 17

Figure 18

Figure 19 Page 16 of 17

Figure 20 PF7000_4th Gen_GEN-15

Product Service Advisory PN2010-01-010

Component affected: None Product affected: PF7000 ForGe VFDs (7000A, 7000, 7000L) with AFE rectifier. Factory Corrective Action: Not required Required Field Action: It is mandatory that the firmware in all medium voltage PowerFlex 7000 VFDs with ForGe Control platform be upgraded to the latest version (8.003 or greater). After upgrading the firmware, the copy of latest VFD settings must be sent to MV Tech Support by e-mail at MVSupport_Technical@ra.rockwell.com for record and future reference. Document Revision History: Date Revision February 02, 2010 February 19, 2010 March 25, 2010 1.0 2.0 3.0

Author Manzoor Memon Manzoor Memon Manzoor Memon/ Fred Jason

1. 2. 3. 1. 2.

Description Original document

Corrected null modem pin assignment Corrected LED status under Download Mode Deleted Setting Elapsed Time Added a method for testing filter capacitors Edited a few paragraphs in the Tech Note

April 27, 2010 May 3, 2010 October 15, 2010

4.0 5.0 6.0

Carlos Siri Fred Jason Robert Carriere

December 08, 2010

7.0

Robert Carriere

December 20, 2010

8.0

Fred Jason

Reviewed Downloading Firmware, Reloading Parameters and Testing Filter Capacitors Corrected PSA and documentation references. Edited for clarity and consistency. 1. Added information pertaining to new firmware release (major rev 8, minor revs 001 and 002). 2. Edited a few paragraphs in the Tech Note. 1. Added information pertaining to new firmware release (major rev 8, minor rev 003). 2. Edited a few paragraphs in the Tech Note. 3. Revised parameter settings table. Edited for clarity and consistency.

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