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Rockwell Automation Allen-Bradley PowerFlex 6000 User Manual Download Page 6

6

Rockwell Automation Publication 6000-UM002G-EN-P - August 2022

Appendix D

Torque Requirements

Torque Requirements  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   135

Appendix E

Spare Parts Storage

Requirements and Recommendations  . . . . . . . . . . . . . . . . . . . . . . . . . . .   137

Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   137
Power Cells  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   137
Signal Conditioners. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .   137
Control Equipment and Boards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  138
EC Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  138

Spare Parts Maintenance Schedule  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  138
Spare Parts Connection Matrix . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  139
Power Supply Connection Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . . . .  139

1606 Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  139

Control Equipment and Boards Connection Guidelines. . . . . . . . . . . .  140

Control Unit  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  140

Power Components Connection Guidelines  . . . . . . . . . . . . . . . . . . . . . .  142

Power Cells  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  142

Cooling System Connection Guidelines . . . . . . . . . . . . . . . . . . . . . . . . . .  144

EC Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  144

Connection Wire Sizes  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  145
Guidelines for Extended Shutdown or Storage . . . . . . . . . . . . . . . . . . . .  146

Medium Voltage Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  146
Storage Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  146
Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  146
Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  146
Power Cells  . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  146

Guidelines for Inspection After Extended Shutdown or Storage . . . .  147

Visual Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  147
Cooling Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  147
Control Circuits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  147

Index

. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .  149

Summary of Contents for Allen-Bradley PowerFlex 6000

Page 1: ...User Manual Original Instructions PowerFlex 6000 Medium Voltage Variable Frequency Drive Bulletin Number 6000G ...

Page 2: ...ftware 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 These labels may also be on or inside the equipment to provide specific precautions The following icon may appear in the text of this document...

Page 3: ...opology 12 Simplified Electrical Diagrams 13 Standards Compliance 18 Chapter 2 Drive System Layout Elevation Drawings 19 Isolation Transformer Cabinet 20 Isolation Transformer 23 Isolation Transformer Temperature Monitor 24 Top mounted Cooling Fans 25 Incoming Line Power Cable Connections 25 Outgoing Motor Cable Connections 26 Door Position Limit Switch 26 Interlocking 27 Voltage Sensing Board 29 ...

Page 4: ...tings 60 System Settings 60 User Parameter Settings 61 Change User Parameters 62 Chapter 4 Parameters and Function Codes P Parameters 66 Chapter 5 Preventative Maintenance and Component Replacement Safety 83 Introduction 84 Daily Inspection 84 Clean the Air Filters 84 Regular Maintenance Intervals 84 Physical Checks No Medium Voltage or Control Power 85 Power Connection Inspection 85 Physical Insp...

Page 5: ...t Breakers 120 Inspect Coils 121 Inspect Contacts 121 Inspect Pilot Lights 121 Inspect Locking and Interlocking Devices 122 Connections 122 Inspect LV Component Terminal and Plug in Connections 122 Inspect Medium Voltage Cable Connections 122 Inspect Power Cable and Control Wire Terminals 122 Inspect Transformer Secondary Windings 122 Inspect Power Module Input and Output Power Connections 123 Gen...

Page 6: ...39 Power Supply Connection Guidelines 139 1606 Power Supply 139 Control Equipment and Boards Connection Guidelines 140 Control Unit 140 Power Components Connection Guidelines 142 Power Cells 142 Cooling System Connection Guidelines 144 EC Cooling Fans 144 Connection Wire Sizes 145 Guidelines for Extended Shutdown or Storage 146 Medium Voltage Supply 146 Storage Environment 146 Cooling Fans 146 Con...

Page 7: ...uch as Dimensional and electrical drawings that are generated for each customer s order Spare parts lists compiled for each customer s order See the following documents for additional product detail or instruction relating to PowerFlex 6000 drives PowerFlex 6000 Medium Voltage Variable Frequency Drive Installation Manual publication 6000 IN006 instructions for installing the drive dimensions requi...

Page 8: ...recautions 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 ...

Page 9: ...ference Manual publication SECURE RM001 Provides guidance on how to conduct security assessments implement Rockwell Automation products in a secure system harden the control system manage user access and dispose of equipment UL Standards Listing for Industrial Control Products publication CMPNTS SR002 Assists original equipment manufacturers OEMs with construction of panels to help ensure that the...

Page 10: ...10 Rockwell Automation Publication 6000 UM002G EN P August 2022 Preface Notes ...

Page 11: ... high voltage gloves Repeat the live line tool hot stick testing at the drive incoming line power cable connections to verify that medium voltage is not present Pay special attention to any capacitors connected to medium voltage that can retain a charge for a period of time Only after the drive equipment has been verified as isolated and de energized can subsequent work be performed Even though th...

Page 12: ...r also provides two other principal functions Mitigate common mode voltage stress so motors with standard insulation levels can be used Reduce Total Harmonic Distortion THD due to the phase shifting of its secondary windings so input side harmonics don t negatively impact the plant or utility power grid A number of identical low voltage power modules are series connected cascaded together to produ...

Page 13: ...ment in the unlikely event of a failure This minimizes power module replacement time so process uptime is maximized Figure 1 6 6 kV Example Power Structure Simplified Electrical Diagrams Figure 2 2300V 2400V 3300V 18 Pulse 9 Power Modules Figure 3 4000V 4160V 24 Pulse 12 Power Modules Input power 3 phase AC Power Modules Isolation Transformer M Isolation Transformer Secondary Windings U V W M Isol...

Page 14: ...igure 5 6300V 6600V 6900V 36 Pulse 18 Power Modules Figure 6 10000V 48 Pulse 24 Power Modules Figure 7 11000V 54 Pulse 27 Power Modules M Isolation Transformer Secondary Windings U V W M Isolation Transformer Secondary Windings U V W M Isolation Transformer Secondary Windings U V W M Isolation Transformer Secondary Windings U V W ...

Page 15: ...osed Permit Close MV Indicator MV Closed Indicator Warning Indicator Fault Indicator Running Indicator Stop Indicator Ready Indicator Remote Control Indicator Permit to Close Customer Breaker CB Emergency Fault Trip Emergency Stop status MV Pre Closed MV Closed Warning Fault Running Stop Ready Remote Control Permit Close CB Trip Three phase Induction Motor Emergency Fault Trip Reserved MV Close Em...

Page 16: ...16 Rockwell Automation Publication 6000 UM002G EN P August 2022 Chapter 1 Introduction Figure 9 PowerFlex 6000 Principal Components All in One Design A Frame Power Modules HMI Cooling Fan Door Filters ...

Page 17: ...All MV doors are interlocked with mechanical interlocking device optional Isolation Transformer Temperature Monitor All door filters can be changed while the drive is running All cooling fans are internally powered by a dedicated winding in the Isolation Transformer no separate fan power supply is needed from customer All MV doors are lockable Intuitive easy to use color touch screen HMI Many comm...

Page 18: ...uirements of HV equipment for voltages above 1000V AC or 1500V DC and not exceeding 36 kV IEC 60529 Degrees of Protection provided by enclosures IEC 61800 3 Adjustable speed electric power drive systems Part 3 EMC requirements and specific test methods IEC 61800 4 Adjustable speed electric power drive systems Part 4 Rating specification for AC power drive systems above 1000V AC and not exceeding 3...

Page 19: ...able connection is needed In this case a lifting cart is supplied for power cell replacement The PowerFlex 6000 drive is shipped in two sections the Isolation Transformer cabinet and the Power Module LV Control cabinet unless it is an A Frame drive which is shipped in one single cabinet See the PowerFlex 6000 Medium Voltage Variable Frequency Drive Shipping and Handling Manual publication 6000 IN0...

Page 20: ...Power Module cabinet LV Control cabinet H Frame Isolation Transformer cabinet Power Module cabinet LV Control cabinet B Frame Isolation Transformer 23 Isolation Transformer Temperature Monitor 24 Top mounted Cooling Fans 25 Incoming Line Power Cable Connections 25 Outgoing Motor Cable Connections 26 Door Position Limit Switch 26 Voltage Sensing Board 29 ...

Page 21: ...Transformer Cabinet 140 215 A A Frame Isolation transformer Cable clamp Power cable connections to Power Modules Incoming line power cable connections for bottom entry Outgoing motor power cable connections for bottom entry Limit switch Isolation transformer Cable clamp Power cable connections to Power Modules Incoming line power cable connections for bottom entry Outgoing motor power cable connec...

Page 22: ...n cabinet not applied Isolation transformer Cable clamp Voltage Sensing Board L1 L2 L3 U V W Power cable connections to Power Modules Incoming line power cable connections Outgoing motor power cable connections Cable clamp Voltage Sensing Board Isolation Transformer Door position limit switches L3 L2 L1 W V U Incoming line power cable connections Outgoing motor power cable connections Power cable ...

Page 23: ...hree phase secondary side windings dependent on the motor voltage requirements from 2 3 11 kV The phase relationship between the secondary windings is optimized to provide the highest reduction of line side harmonics The isolation transformer s three phase primary coils are oriented A B and C from left to right as viewed from the front The secondary windings are also divided into three principal s...

Page 24: ...e at the isolation transformer secondary winding termination points because the isolation transformer cabinet and power module cabinet are shipped separately see publication 6000 IN008 For A frame drives the field power cable connections are already terminated when the drive arrives at the site Isolation Transformer Temperature Monitor A discrete transformer temperature monitor is mounted on the L...

Page 25: ...12 Figure 13 Figure 14 and Figure 15 When the Junction cabinet is not applied the incoming line cables connect to the line side terminals in the Isolation Transformer cabinet Incoming line cables can be routed inside through the top or bottom of the Isolation Transformer cabinet When the Junction cabinet is applied the incoming line cables connect to the terminals inside the Junction cabinet If it...

Page 26: ...tion Instructions publication 6000 IN006 for additional details Door Position Limit Switch Each cabinet door that allows access to medium voltage components is lockable and also has a Guardmaster safety limit switch If the cabinet door is opened when the input switching device feeding power to the drive is closed the input device is tripped off Figure 18 Door Position Limit Switch Location ATTENTI...

Page 27: ...oors of the power module cabinet Figure 19 Deadbolt Assembly Mounted to Door 1 Lock out and isolate the drive from medium voltage Verify with a hot stick that there is no medium voltage present 2 Determine that the key interlock is correctly aligned by securely bolting the medium voltage doors of the cabinet closed and removing from the lock The key should turn easily if any force is required to t...

Page 28: ...roperly align the assembly 6 Clean the torque seal grease from the key interlock once finished aligning the counterpart Once properly aligned the key should turn freely when the cabinet door is fully bolted shut If the key does not function when the door is tightly bolted closed adjustments have to be made to the depth of the counterpart This adjustment can be done by adding shims on the landing p...

Page 29: ...hich allows the drive to monitor the output input voltage Figure 21 Voltage Sensing Board Figure 22 Power Cabling Overview 3 3 kV L11 L12 L13 A1 B1 C1 A2 B2 C2 A3 B3 C3 A4 B4 C4 A5 B5 C5 A6 B6 C6 A7 B7 C7 A8 B8 C8 A9 B9 C9 U V W PC A1 PC A2 PC A3 PC B1 PC B2 PC B3 PC C1 PC C2 PC C3 U V W Input power 3 phase AC any voltage Isolation Transformer Motor VoltageSensing Board Isolation Transformer cabin...

Page 30: ...ircuit the drive can continue to run without shutting down when encountering a Power Module failure This helps ensure a higher level of process reliability Since the drive uses a solid state bypass the dimensions of the drive do not increase when adding the automatic bypass option Basic Principle of Power Module The Power Module combines a three phase rectifier and an H bridge inverter which is po...

Page 31: ...wer Module is transmitted through the electrical optical converter and sent to the main control unit When there is a fault the main control unit sends control signals to lockout or bypass the affected Power Module The Power Module cabinet consists of Power Modules current transformers and high voltage cable The Power Modules are divided evenly into three phases U V and W The units in each phase ar...

Page 32: ...odule A Frame Figure 26 Power Module H Frame and B Frame Line terminals Fuse Output terminal Optic fiber socket and status indicator Output terminal Optic fiber socket and status indicator Fuse Line terminals 70 A rating 140 215 A rating Line terminals Fuse Optic fiber socket and status indicator Output terminal ...

Page 33: ...l 40 A without Bypass 40 Powercell 75 A without Bypass 75 Powercell 100 A without Bypass 100 Powercell 120 A without Bypass 120 Powercell 150 A without Bypass 150 Powercell 180 A without Bypass 180 Powercell 200 A without Bypass 200 Module Bypass Powercell 40 A with Bypass 40 Powercell 75 A with Bypass 75 Powercell 100 A with Bypass 100 Powercell 120 A with Bypass 120 Powercell 150 A with Bypass 1...

Page 34: ...air through the top of the cabinet LV Control Cabinet The LV Control cabinet consists of the Control Unit the human machine interface HMI PLC AC DC power supplies contactors and relays The HMI is on the front door of the LV Control cabinet where an operator can set up monitor and control the drive Figure 27 LV Control Cabinet A Frame Control Unit all modules 35 PLC 38 HMI 38 UPS 38 Synchronous Tra...

Page 35: ...rol unit provides the core functionality of the variable frequency drive This includes controlling the power modules to produce the required output voltage and frequency monitoring the power modules motor voltage and motor current to provide alarm and trip signals based on the information DTB1 terminal block strip DTB2 terminal block strip Phoenix connectors for power wiring ...

Page 36: ...ards and Power Modules It uses these inputs in its motor control and protection algorithms to determine the necessary actions to be taken and outputs to be set In combination with the PWM Boards the CPU board sends the necessary optical PWM control signals to the Power Modules to allow the Power Modules to output the required voltage and frequency to the motor Transceiver indicators PWM board A PW...

Page 37: ...ollect and process analog input signals to CPU Board output analog signals processed by DT board Digital Signal Processor Board DT Collect and output digital signals digital to analog conversion function DB Board Acts as a base board in the Control Unit and interfaces the digital and analog signal cables Connector PLC Communication Interface Connection between PLC and Control Unit Fiber optic Sock...

Page 38: ...catalog number EHIM T10CED4G The HMI is connected to the Micro850 controller through a communication interface standard RJ45 EtherNet IP connection The HMI configures operating parameters and input operation commands and displays the operation status operation parameters parameter trends and fault messages UPS The UPS supplies power to the LV Control cabinet using internal batteries if the custome...

Page 39: ...pared to a non synchronous transfer in which power to the motor is interrupted for a significant length of time the transient drop in motor speed is much less with synchronous transfer The PowerFlex 6000 drive can start up to 10 motors on one drive utilizing a bumpless transfer that is available with and without an output reactor See Figure 32 for configuration details Figure 32 Typical Synchronou...

Page 40: ...ts to the VFD via a hardwired Ethernet cable There is no significant functional distance limitation This is ideal for non PLC users wanting to control and monitor remotely for example at the driven machine or control room This is also ideal if you for example have policies in place to control access to medium voltage equipment and the associated requirements of PPE when using the operator interfac...

Page 41: ...Drive Setup and Configuration Controls There are five buttons in the Top Menu Bar A description of the functionality is described in Table 4 1 Screen Layout 1 Top Menu Bar 2 Status Bar 3 Set and Monitor Box 4 Actual Frequency Display Box 5 Version Information Box 6 Actual Date and Time 7 Operation Bar 2 3 4 5 6 7 Table 4 Setup and Configuration Controls Return to Main Interface screen Check warnin...

Page 42: ... CloAllowed The drive is in a state that will allow MV to be applied MVClosd Indicates that the input switching device feeding MV power to the drive is closed Ready Drive is ready to start Running The drive is running Warning Fault If there are only warnings in the system the Warning indicator will turn red Once there is a fault in the system the Warning indicator will turn to a Fault indicator as...

Page 43: ...g self test at startup otherwise this button is invalid Accel Increases the frequency by the set step Decel Decreases the frequency by the set step Stop Stop output of the drive Reset 1 1 The drive must not be running to complete this operation Resets the drive under fault conditions once Table 7 Monitoring Parameters Set Frequency Frequency set for the drive Hz Actual Frequency Actual frequency o...

Page 44: ...0 UM002G EN P August 2022 Chapter 3 Setup and Operation Set Frequency Hz 1 Press the Set Frequency input field 2 Press the Set Freq input field 3 Enter desired frequency and press 4 Press to accept or to cancel Numpad Cancel Backspace Enter ...

Page 45: ...ve Operation Controls Press the desired Drive Operation Control button and to accept or to cancel ATTENTION Drive Operation Controls will only function if using Local Control otherwise the following dialog appears ATTENTION The Stop command will function regardless of which control method is active ...

Page 46: ...nder Version Info to view the currently installed Firmware The Version Information screen shows the most current firmware that is installed for the applicable devices Will always appear black The number of Power Modules in the drive will appear as blue the rest appears as grey Fields show the firmware revision where applicable ...

Page 47: ...e alarms Active Alarms Controls Reset Status will reset just the quantity and accumulated time of the alarms This function does not reset the drive List of Active Alarms Quantity Accumulated Time Alarm QTY How many times the alarm has occurred Acc Time Time that has elapsed since the alarm Message Description of the warning or fault Reset Status Scroll to Top or Bottom of List Scroll Alarm by Entr...

Page 48: ...peration Alarm History Press to see a detailed listed of all warnings and faults on the drive The controls to scroll through the alarms are the same Sort Alarms Press once to sort once to sort by time Press again to sort by message Current alarms appear as red past alarms appear as grey ...

Page 49: ...e four different trending options Voltage Current Frequency and Customized Press any button to view the trends You can view Voltage Current and Frequency trends or create up to five of your own customized trends Voltage is measured in volts Current in amps and Frequency in Hz Back Y axis X axis Trend controls ...

Page 50: ...50 Rockwell Automation Publication 6000 UM002G EN P August 2022 Chapter 3 Setup and Operation Back Y axis X axis Trend controls Back Y axis X axis Trend controls ...

Page 51: ...6000 UM002G EN P August 2022 51 Chapter 3 Setup and Operation The trend controls are the same for all four screens Back Y axis X axis Trend controls Zoom Y axis in Zoom Y axis out Scroll X axis left Scroll X axis right Pause trending ...

Page 52: ...e Main Interface screen press 2 Press or in the Trends Selection screen 3 Use the and buttons to zoom in or out Press the and buttons to scroll 4 Press to pause the trend capture 5 Press to return to the Trends Selection screen The time that is shown in the X axis captures 20 minutes Scrolling left or right will scroll in 10 minute increments ...

Page 53: ...ust 2022 53 Chapter 3 Setup and Operation Customize a Trend 1 Fromthe Main Interface screen press 2 Press in the Trends Selection screen 3 Press in the Customized screen IMPORTANT You can customize up to five trends however these trends will not be saved ...

Page 54: ...ion 4 Select the parameter that you want to display from the list You can also select a K parameter to display 5 Press to return to the Customized screen IMPORTANT If a parameter is selected the trend is displayed in percentage If a K parameter is selected the trend displays the actual value ...

Page 55: ...s to scroll 7 Press to pause the trend capture 8 Press to return to the Trends Selection screen Operation The Operation interface displays the bypass mode control owner selection and contactor operation The time that is shown in the X axis captures 20 minutes Scrolling left or right will scroll in 10 minute increments Bypass Configuration Select Local Remote Control Open Close Drive Bypass Contact...

Page 56: ...he Bypass Configuration matches one of the three Input Supply graphics 3 To change the Bypass Mode set parameter P484 Confirm Bypass Mode 56 Choose Local Remote Operation 57 Open Close Drive Input and Output Contactors 58 Open Close Bypass Contactors 59 No Bypass Cabinet Manual Bypass Cabinet Automatic Bypass Cabinet The Contactor Operation selection appears when Automatic Bypass is selected ...

Page 57: ...on 1 Press from the Main Interface screen 2 Under Control Owner Selection press either or 3 Select to confirm in the Select Local Control Select DCS Control or Select Remote Box Control dialog box ATTENTION Changing the Control Owner Selection while the drive is running may lead to personal injury and or equipment damage ...

Page 58: ...s either or 2 Select to confirm in the Close Drive Input Output Contactors or Open Drive Input Output Contactors dialog box IMPORTANT Turn the 2 position on the selector switch on the front of the LV cabinet to the DCS position ATTENTION Operations in this graphic can only operate while on local control ATTENTION This operation can only operate while drive is not running ...

Page 59: ...ess either or 2 Select to confirm in the Close Bypass Contactors or Open Bypass Contactors dialog box IMPORTANT Turn the 3 position on the selector switch on the front of the LV cabinet to the Bypass position ATTENTION Operations in this graphic can only operate while on local control ATTENTION This operation can only operate while drive is not running ...

Page 60: ... Settings Change the HMI language and view the bypass status under System Settings 1 Press 2 Press to select other language from the Languages screen Current Access Level User Account System Settings Select Language User Settings View or modify User level parameter settings Setup Settings View or modify Setup level parameters settings R D Settings For use by authorized Rockwell Automation personne...

Page 61: ...n press to return 4 The Bypass Status windows shows the current bypass mode setting 5 To change the bypass mode setting modify parameter P484 6 Press to accept User Parameter Settings You can access view or change the user parameters in the User Parameter Settings screen User parameter list User parameter value Parameter description ...

Page 62: ...following 1 In the Settings screen press The Login dialog box appears 2 Enter the User Name and Password details Press to enter the user name Press when finished Press to enter the password Press when finished 3 Press to login 4 If the login was successful the Current User will show as User and the User Parameter Settings screen is displayed automatically If the login failed the Login dialog is sh...

Page 63: ...up and Operation In the User Parameters Settings screen the user parameters automatically refresh After you have logged in to the User Access level you can change the parameter value by doing the following 1 Press the parameter number that you want to change A dialog box appears ...

Page 64: ... parameter value Use the keypad to enter a new value for the parameter 3 Press to confirm the new value Press to return to the ParameterAccess Level screen User parameter access will logout when you exit User Settings P parameter number Press here to input a new value for the parameter P parameter number This range applies to all parameters ...

Page 65: ...riptions on the parameters and alarms that are described in this chapter see the PowerFlex 6000 Medium Voltage Variable Frequency Drive Firmware Parameters and Troubleshooting Manual publication 6000 TD004 ATTENTION If you enter a value that is greater than the allowed range for the parameter the input field will turn red ...

Page 66: ...line Y Y P017 Number of Motor Pole Pairs 0 100 2 2 2 2 2 2 2 2 2 2 2 2 Offline Y P019 Encoder Resolution 0 4096 1024 1024 1024 1024 1024 1024 1024 1024 1024 1024 1024 1024 Offline Y P024 Stop Method 0 Ramp Down 1 Coast Stop 0 1 0 0 0 0 0 0 0 0 0 0 0 0 On Off Y Y P025 Flux Reduction Enable 0 Disable 1 Enable 0 1 0 0 0 0 0 0 0 0 0 0 0 0 On Off Y P030 Powercell Fault Trip Signal Mask 32768 32767 1 1 ...

Page 67: ...100 10 10 10 10 10 10 10 10 10 10 10 10 On Off Y P053 Load Loss Control Exit Delay 0 16000 5000 5000 5000 5000 5000 5000 5000 5000 5000 5000 5000 5000 ms On Off Y P057 Power Cell Bypass Upper Limit Time For Over Temperature 0 32767 10 10 10 10 10 10 10 10 10 10 10 10 s On Off Y P058 Power Cell Bypass Phase A Cell Number For Simulation 0 9 0 0 0 0 0 0 0 0 0 0 0 0 On Off Y Y P059 Power Cell Bypass P...

Page 68: ... Setting Enable Code 0 Disable 1 Enable 0 1 0 0 0 0 0 0 0 0 0 0 0 0 Offline Y P088 Switch Frequency Setting 0 600 Hz 1 1200 Hz 0 1 0 0 0 0 0 0 0 0 0 0 0 0 Offline Y P089 Skip Frequency Enable 0 Disable 1 Enable 0 1 0 0 0 0 0 0 0 0 0 0 0 0 On Off Y Y P090 Skip Frequency 1 Lower Limit 0 75 0 0 0 0 0 0 0 0 0 0 0 0 On Off Y Y P091 Skip Frequency 1 Upper Limit 0 75 0 0 0 0 0 0 0 0 0 0 0 0 On Off Y Y P0...

Page 69: ...net Fan Fault Trip Delay 1 60 30 30 30 30 30 30 30 30 30 30 30 30 m On Off Y Y P117 Fan Control Filter Cabinet Fan Fault Trip Delay 1 60 30 30 30 30 30 30 30 30 30 30 30 30 m On Off Y Y P118 Pre charge Max Time 2 20 6 6 6 6 6 6 6 6 6 6 6 6 s On Off Y Y P119 Pre charge Min Repeat Interval 5 60 5 5 5 5 5 5 5 5 5 5 5 5 m On Off Y Y P120 Pre charge Primary Voltage Threshold 0 100 80 80 80 80 80 80 80 ...

Page 70: ... 50 167 40 159 80 152 80 158 10 143 70 On Off Y Y P152 Line Voltage Ubc Scaling Factor 0 00 199 99 153 00 146 70 175 90 159 90 175 80 169 00 146 50 167 40 159 80 152 80 158 10 143 70 On Off Y Y P153 Line Voltage Ung Scaling Factor 0 00 199 99 100 00 100 00 100 00 100 00 100 00 100 00 100 00 100 00 100 00 100 00 100 00 100 00 On Off Y Y P154 Line Over Voltage Fault Threshold 0 00 199 99 115 00 115 ...

Page 71: ...lt Delay 0 32767 10 10 10 10 10 10 10 10 10 10 10 10 ms On Off Y Y P178 Motor Autotune Rs Upper Limit 0 100 50 50 50 50 50 50 50 50 50 50 50 50 On Off Y P179 Motor Autotune Maximum Iq For No Load 0 00 399 99 30 00 30 00 30 00 30 00 30 00 30 00 30 00 30 00 30 00 30 00 30 00 30 00 On Off Y P180 Pre charge Resistor Short Circuit Fault Threshold 0 10 2 2 2 2 2 2 2 2 2 2 2 2 On Off Y P181 Pre charge Re...

Page 72: ...rload Current 0 00 399 99 104 99 104 99 104 99 104 99 104 99 104 99 104 99 104 99 104 99 104 99 104 99 104 99 On Off Y Y P215 Motor Overload Cycle Time 0 32767 600 600 600 600 600 600 600 600 600 600 600 600 s On Off Y Y P216 Motor Overload Trip Threshold 0 00 399 99 120 00 120 00 120 00 120 00 120 00 120 00 120 00 120 00 120 00 120 00 120 00 120 00 On Off Y Y P217 Motor Overload Time 0 32767 60 6...

Page 73: ...00 1 1 1 1 1 1 1 1 1 1 1 1 On Off Y Y P253 Motor Coast Stop Time 0 10000 10 10 10 10 10 10 10 10 10 10 10 10 On Off Y Y P254 DC Bus Under Voltage Fault Threshold 0 100 63 63 63 63 63 63 63 63 63 63 63 63 On Off Y P256 Ground Fault Warning Cancellation Threshold 0 00 199 99 5 00 5 00 5 00 5 00 5 00 5 00 5 00 5 00 5 00 5 00 5 00 5 00 On Off Y P257 Motor Stall Warning Cancellation Threshold 0 00 199 ...

Page 74: ...Y Y P283 Low Voltage Ride Through Enable 0 Disable 1 Enable 0 1 1 1 1 1 1 1 1 1 1 1 1 1 On Off Y Y P284 Low Voltage Ride Through Min Time Limit 10 16383 40 40 40 40 40 40 40 40 40 40 40 40 ms Offline Y P285 Low Voltage Ride Through Max Time Limit 10 16383 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 ms Offline Y P286 Low Voltage Ride Through Recovery Frequency Compensation Factor 20...

Page 75: ...n Off Y P306 Digital Output 1 Bit Selection 0 15 1 1 1 1 1 1 1 1 1 1 1 1 On Off Y P307 Digital Output 1 Delay 0 32767 0 0 0 0 0 0 0 0 0 0 0 0 ms On Off Y P308 Digital Output 2 Memory Address 0 500 99 99 99 99 99 99 99 99 99 99 99 99 On Off Y P309 Digital Output 2 Logic 0 Non Inverting 1 Inverting 0 1 0 0 0 0 0 0 0 0 0 0 0 0 On Off Y P310 Digital Output 2 Bit Selection 0 15 2 2 2 2 2 2 2 2 0 2 2 2 ...

Page 76: ...Address 0 500 206 206 206 206 206 206 206 206 206 206 206 206 On Off Y P337 Analog Output 2 Filter Time 0 32767 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 1000 ms On Off Y P338 Analog Output 2 Offset 100 100 0 0 0 00 0 0 0 0 0 0 0 0 On Off Y P339 Analog Output 2 Scaling Factor 0 00 199 99 100 00 100 00 100 00 100 00 100 00 100 00 100 00 100 00 100 00 100 00 100 00 100 00 On Off Y Y P34...

Page 77: ... 0 99 0 99 0 99 0 99 0 99 0 99 0 99 Offline Y Y P376 Amplitude At First Point for 5 Point VF 0 00 3 00 0 99 0 99 0 99 0 99 0 99 0 99 0 99 0 99 0 99 0 99 0 99 0 99 Offline Y Y P377 Frequency At Second Point for 5 Point VF 10 100 20 20 20 20 20 20 20 20 20 20 20 20 Offline Y Y Y P378 Amplitude At Second Point for 5 Point VF 0 100 10 10 10 10 10 10 10 10 10 10 10 10 Offline Y Y Y P379 Frequency At Th...

Page 78: ... 10000 0 1 s 0 0 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 On Off Y P405 Deceleration Ramp Transition Time 0 00 100 00 0 99 0 99 0 99 0 99 0 99 0 99 0 99 0 99 0 99 0 99 0 99 0 99 On Off Y P406 Deceleration Time Unit 1000 0 01 s 10000 0 1 s 0 0 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 0 1 On Off Y P408 Flying Start Compensation Defer Restore Voltage Speed Current Threshold 20 00 39...

Page 79: ...urrent Limitation Threshold 0 00 399 99 100 00 100 00 100 00 100 00 100 00 100 00 100 00 100 00 100 00 100 00 100 00 100 00 On Off Y Y P442 Current Limitation Heating Time 0 16384 60 60 60 60 60 60 60 60 60 60 60 60 s On Off Y Y P443 Current Limitation Cooling Time 0 16384 540 540 540 540 540 540 540 540 540 540 540 540 s On Off Y Y P444 Current Limitation Decel Ramp Slope Change 0 00 399 99 A Fra...

Page 80: ...2 Fault Reset Timeout 0 04 120 00 120 00 120 00 120 00 120 00 120 00 120 00 120 00 120 00 120 00 120 00 120 00 120 00 s On Off Y P463 Flying Start Low High Speed Regions Boundary 0 100 16 16 16 16 16 16 16 16 16 16 16 16 On Off Y Y P465 Power Cell Fault Auto Reset Delay 0 10 4 4 4 4 4 4 4 4 4 4 4 4 s On Off Y P466 Maximum Output Frequency 0 75 50 50 50 50 50 50 50 50 50 50 50 50 Offline Y Y P467 O...

Page 81: ...urrent Frequency 2 Keep P480 Speed 1 3 Keep P481 Speed 2 4 Keep P482 Speed 3 5 Keep P483 Speed 4 0 5 1 1 1 1 1 1 1 1 1 1 1 1 On Off Y Y P486 PID Control Enable 0 Disable 1 Enable 0 1 0 0 0 0 0 0 0 0 0 0 0 0 Offline Y Y P487 PID Control Proportional Gain 0 000 32 767 0 001 0 001 0 001 0 001 0 001 0 001 0 001 0 001 0 001 0 001 0 001 0 001 On Off Y Y P488 PID Control Integral Time 0 000 32 767 0 001 ...

Page 82: ...82 Rockwell Automation Publication 6000 UM002G EN P August 2022 Chapter 4 Parameters and Function Codes Notes ...

Page 83: ...codes and regulations ATTENTION Use suitable personal protective equipment PPE per local codes or regulations Failure to do so may result in severe burns injury or death ATTENTION Always perform Power Lockout procedure before servicing equipment Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or d...

Page 84: ...ent cooling airflow which may cause some parts of the drive to send an overtemperature alarm or even trip 1 Transformer overtemperature alarm trip Power unit overtemperature trip Immediately after receiving the overtemperature warning you should plan to replace or clean the air filters At this point there should be a few days or weeks before the air filters fail but this depends on the amount of d...

Page 85: ...ld 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 Replace dirty wet or contaminated control devices unless they can be cleaned effectively by vacuuming or wiping Physical Checks No Medium Voltage or Control Power Power Connection Inspection Inspect PowerF...

Page 86: ...ance IR or dielectric withstanding voltage tests should not be used to check solid state control equipment When performing IR tests on 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 an IR test the solid state devices are degraded and repeated application of high voltage can lead...

Page 87: ...with Compressed Air Point compressed air nozzle in opposite direction of operating airflow Blow from exhaust side toward intake side 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 Immersion in Warm Soapy Water Where stubborn air borne dirt is pr...

Page 88: ...ter frame and tighten thumbscrews Figure 35 Replace the Filter A Frame Replace Filter for H Frame and B Frame Drives 1 Unlatch and open the cabinet filter door more than 90 Figure 36 Replace the Filter H Frame IMPORTANT When removing the filter prevent accumulated dirt on the inlet side of the filter from being sucked into the drive It may be difficult to remove the filter material without tearing...

Page 89: ...mer The control voltage is 220V The voltage of the fan can be measured through a small door on the Isolation Transformer 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 Verify that the aviation plug has a proper hand tight connection Verify that the ventilati...

Page 90: ...are secured on the terminal block in the fan housing as shown 2 Install the new wires of the resistor in reverse order of removal 3 After you have changed the wiring see Replace Fan for B Frame Fan Housing on page 93 for instructions on how to replace the fan ATTENTION Fan replacement requires working at a significant height from the floor Complete this procedure on a safe stable platform ATTENTIO...

Page 91: ...al louver and remove the louver 6 Disconnect the fan cables from the terminal block 7 Turn the fan assembly housing upside down and remove and retain the eight M8 x 20 hexagon combination screws that secure the fan support bracket and remove the bracket 8 Turn back the assembly and remove and retain the six M10 x 25 and M6 x 16 hexagon combination screws that secure the fan and remove the fan 9 In...

Page 92: ... hexagon screws from the top of the fan support bracket and remove the bracket from the fan assembly 4 Remove the wiring cover and disconnect the wiring 5 Install the fan in the reverse order of its removal Rotate the impeller by hand to verify that there is no contact with the fan housing assembly M6 x 20 integration hexagon bolt 4 M6 x 12 hexagon screw 8 Fan housing lid Fan support bracket Fan a...

Page 93: ...s that secure the fan support bracket and remove the bracket 6 Remove and retain five M6 x 16 and four M4 x 12 hexagon combination screws that secure the fan and remove the fan 7 Install the fan in the reverse order of its removal Rotate the impeller by hand to verify that there is no contact with the fan housing assembly M6 x 16 hexagon combination screw 5 M6 x 16 hexagon socket screw 18 Fan hous...

Page 94: ...proper direction 2 Verify the incoming and outgoing power cable connections are torqued to specifications See Torque Requirements on page 135 3 Check the cabinet interior and Isolation Transformer windings and remove any foreign material Vacuum dust or debris from the Isolation Transformer cabinet 4 Check for any physical evidence of damage or degradation of components Inspect Voltage Sensing Boar...

Page 95: ...move and retain the six nylon M8 x 30 bolts nuts and washers that secure the insulation barrier and remove the barrier 5 Remove and retain the six nylon M10 x 30 bolts nuts and washers that secure the VSB and remove the VSB 6 Install the new VSB in the reverse order of removal Junction cabinet front door VSB signal wires M6 nuts washers and lock washers 9 VSB PC cover VSB cables Signal wire termin...

Page 96: ...on Board 3 Remove the nylon nuts that connect the Voltage Sensing Board to the Insulation Board Figure 39 Remove the Voltage Sensing Board from the Insulation Board 4 Install the new Voltage Sensing Board to the Insulation Board in reverse order of removal 5 Reinstall the Insulation Board to the cabinet side sheet in reverse order of removal 6 Reconnect the input and output cables according to the...

Page 97: ...lug from the back of the Limit Switch 3 For A Frame drives remove two M4 x 30 bolts from the mounting bracket For H Frame and B Frame drives remove two M4 x 35 bolts and hardware from the mounting bracket 4 Install the new Limit Switch in reverse order of removal Figure 40 Replace Door Position Limit Switch A Frame Figure 41 Replace Door Position Limit Switch H Frame and B Frame ATTENTION Verify t...

Page 98: ...Mounted Air Filters 98 Inspect or Replace Top Mounted Cooling Fans 98 Inspect Power Modules 98 Replace Power Module 98 Replace Power Module Fuses 104 Inspect or Replace HECS 104 Inspect or Replace Door Position Limit Switch 107 Table 8 Power Module Specifications Frame Output Rating Amps Dimensions HxWxD approx Weight approx A Frame 36 70 A 210 x 110 x 569 mm 8 3 x 4 3 x 22 4 in 13 kg 28 6 lb 71 1...

Page 99: ...or cable instead of an output copper bus 4 Disconnect the fiber optic cables Fuse Output copper bar connection location Fiber optic cables connection point Three phase input cables from isolation transformer M6 x 16 hexagon combination screws 2 Fuse Output copper bar not shown connection location Fiber optic cables connection point Three phase input cables from isolation transformer M6 x 20 mounti...

Page 100: ...TION Minimum bend radius that is permitted for the fiber optic cables is 50 mm 2 0 in Any bends with a shorter inside radius can permanently damage the fiber optic cable Motor cable to Junction cabinet VSB cable Output copper bar Fiber optic cables Motor cable VSB cable Output copper bar Fiber optic cables ATTENTION Do not use the front mounted positioning handles for lifting the Power Modules The...

Page 101: ...sm Do not stand under the lift tray when in use Store the lift cart with the tray fully lowered Hand Crank Foot Crank Pressure Release Knob 1 Check the lift tray before use to verify that the tray can be raised and lowered smoothly 2 Rotate the Pressure Release Knob counterclockwise to verify that the tray is in the lowest position 3 Move the Power Module on the tray and lift the module to the app...

Page 102: ...e input power cables 2 Remove the M6 x 16 mounting bolts from both sides of the Power Module 3 Remove the output copper bars that connect adjacent Power Modules 4 If the Power Module is at the end of a row remove the VSB and Motor cable instead of an output copper bar 5 Disconnect the fiber optic cables 6 Carefully withdraw the Power Module Mounting brackets Power Module Guide rail Mounting bracke...

Page 103: ... P August 2022 103 Chapter 5 Preventative Maintenance and Component Replacement 7 Install the new Power Module in reverse order of removal Mounting brackets Power Module Guide rail 140 215 A rating Secure points Power Module Guide rail 70 A rating ...

Page 104: ...three current sensors For H Frame drives they are located inside the Power Module cabinet For A Frame and B Frame drives they are located inside the Transformer cabinet Verify that the current sensor wire connector is properly seated Check for obvious signs of damage 1 Unplug the Current Sensor Connector from the HECS ATTENTION Verify that the input circuit breaker feeding the drive is open Lock o...

Page 105: ...G EN P August 2022 105 Chapter 5 Preventative Maintenance and Component Replacement Figure 48 HECS for A Frame Figure 49 HECS for H Frame Mounting insulation bracket Current Sensor connection HECS Current Sensor connection HECS Mounting bracket ...

Page 106: ...ng Bracket with the HECS still attached 4 Remove and retain hardware connecting the HECS to the Mounting Bracket Figure 51 Exploded view of the HECS and Mounting Bracket for A Frame Current Sensor connection HECS Mounting bracket IMPORTANT Note the orientation of the HECS on the bracket The new HECS must be installed facing the same direction M4 x 16 cross pan head combination screw 4 Ø6 lock wash...

Page 107: ...ardware 6 Install the Mounting Bracket to the cabinet using existing hardware 7 Reroute the power cable through the HECS and reattach to the Power Module Inspect or Replace Door Position Limit Switch See Replace Door Position Limit Switch on page 97 M5 x 16 cross pan head screw M6 nut Ø5 lock washer M5 nut Ø5 washer Ø6 lock washer Ø6 washer M5 x 16 cross pan head screw M6 nut Ø5 washer M5 nut Ø6 w...

Page 108: ...tage A green LED indicates normal operation Figure 54 AC DC Power Supplies Inspect AC DC Power Supplies 108 Replace AC DC Power Supplies 109 Inspect UPS 111 Replace UPS 112 Inspect PLC 114 Inspect Replace Control Unit or Control Boards 114 Inspect the HMI 117 Replace the HMI 117 Replace LV Control Relays 118 Replace LV Control Circuit Breakers 120 Inspect Coils 121 Inspect Contacts 121 Inspect Pil...

Page 109: ...er Supply not shown for clarity 3 Release the spring loaded latches at the bottom of the power supply and lift the control relay off the DIN rail Figure 56 Release the latches on the Power Supplies PS3 Power Supply not shown for clarity 4 Install the new power supply in reverse order of removal ATTENTION Always perform Power Lockout procedure before servicing equipment Verify with a hot stick or a...

Page 110: ...ot remove the screws on the top of the PS3 Power Supply 2 Remove the wires Figure 57 Remove PS3 Power Supply wires PS1 and PS2 Power Supply not shown for clarity 3 Remove three M3 tapping screws to remove the unit Figure 58 Remove AC DC Power Supply 4 Install the new power supply in reverse order of removal Loosen screws and remove all wires M3 tapping screws ...

Page 111: ...Check UPS Output Voltage 1 Open the LV Control cabinet door 2 Turn off the back up control power circuit breaker CB5 and the customer supplied power supply circuit breaker CB1 Figure 59 Circuit Breaker Location in LV Control Cabinet for A Frame IMPORTANT If the drive has not been turned on for more than 3 months the UPS batteries must be charged for at least 10 hours Apply either MV to the drive o...

Page 112: ... line side of the CB2 circuit breaker equivalent electrical point The input voltage must be 110 120 220 240V AC optional Replace UPS 1 Turn off the CB2 CB3 and CB6 circuit breakers in the LV Control cabinet Figure 60 2 Press and hold OFF on the front of the UPS PLC LV control relays Circuit breakers ATTENTION Always perform Power Lockout procedure before servicing equipment Verify with a hot stick...

Page 113: ...the UPS input and output power cables and disconnect the ground wire 5 For A Frame drives remove and retain four M6 screws and one UPS mounting bolt from the mounting base Figure 62 For H Frame and B Frame drives remove and retain four screws from the mounting bracket Figure 63 Figure 62 Replace UPS for A Frame Drives Press and hold for three seconds to turn off the UPS M6 x 16 bolt 4 Mounting bra...

Page 114: ...UM002 for further information for the PLC or publication 2080 WD002 for further information regarding the Isolated Serial Port Plug in Modules Inspect Replace Control Unit or Control Boards Verify that the terminal connections on the bottom of the Control Unit are secure and are free of dirt dust or foreign material Clean with an anti static cloth Verify that the fiber optic cables are properly co...

Page 115: ...nd connections Replace a Control Board 1 Turn off all the control power turn off the UPS and confirm that the LV Control cabinet is unenergized before operation If applicable remove the fiber optic wires IMPORTANT The Control Unit does not have to be removed to replace Control Boards ATTENTION When removing the fiber optic cables be careful to prevent the cables from straining or crimping as a res...

Page 116: ...nt Replacement 2 Remove the fastening screws on both sides of the board 3 Use both hands and carefully remove the board by using the handles on either side on the front of the board 4 Install the new boards in the reverse order of removal Fastening screws Only remove the board using the two handles on the front ...

Page 117: ...tion cables are hand tight 2 Power up the HMI 3 Verify that the HMI display is operating normally Replace the HMI Connect fiber optic wires here Refer to electrical drawings Reconnect the PLC cable Reconnect the bottom terminal ATTENTION Always perform Power Lockout procedure before servicing equipment Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage fr...

Page 118: ...ated touch screen display inside the LV Control cabinet door 4 Reinstall all hardware and reconnect all cables in reverse order of removal Replace LV Control Relays 1 Open the LV Control cabinet door Figure 65 LV Control Relay Location Ground cable 24V power supply HMI EtherNet IP cable from PLC 3 pin power connector Mounting lever 8 IMPORTANT Support the device from the outside of the door to pre...

Page 119: ...wires on the control relay Figure 66 Loosen screws on the LV Control Relay 3 Release the spring loaded latches at the bottom of the control relay and lift the control relay off the DIN rail Figure 67 Release the spring loaded latch on the LV Control Relay 4 Install the new control relay in reverse order of removal Loosen screws and remove wires Loosen screws and remove wires ...

Page 120: ...ove the wires on the circuit breaker Figure 69 Screw location on Circuit Breaker 4 Release the spring loaded latches at the bottom of the circuit breaker and lift the circuit breaker off the DIN rail ATTENTION Always perform Power Lockout procedure before servicing equipment Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may resu...

Page 121: ... magnet pole faces or in operating mechanisms can cause sticking and can interfere with electrical continuity Replace contacts only after the contact face material is badly worn Replace contacts in complete sets to avoid misalignment and uneven contact pressure Inspect Pilot Lights Replace any burned out lamps or damaged lenses Do not use solvents or cleaning agents on the lenses Do not use test e...

Page 122: ... 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 that is damaged b...

Page 123: ...onal Maintenance Service Rockwell Automation also offers professional maintenance service that is provided by the Rockwell Automation field support engineer contact your local Rockwell Automation sales person for more information Miscellaneous Preventive Maintenance Work Communicate with the customer regarding problems found during the preventive maintenance process Raise the problems found during...

Page 124: ...ound protection line greater than 25 square feet Safety gloves that can withstand at least 17 kV Vacuum cleaner with anti static hose provided by customers Anti static cleaning cloth Power Module lift cart required for pull out Power Modules Table 9 Estimated Time Required for Maintenance Work Activity Time Required Daily maintenance 0 5 hours for each air filter Annual maintenance Initial collect...

Page 125: ...uld be recorded to identify changes A detailed description of all adjustments and measurements that were taken during the process must be recorded interlock adjustments loose connections voltage readings insulation resistance IR test results parameters and so on Prepare Final Report The Rockwell Automation Service Engineer will provide a maintenance report to the customer based on the outcome of t...

Page 126: ...126 Rockwell Automation Publication 6000 UM002G EN P August 2022 Chapter 5 Preventative Maintenance and Component Replacement Notes ...

Page 127: ...V 6 9 kV 7 2 kV 10 0 kV 11 0 kV For other input voltage ratings contact your local sales representative or factory Input Voltage Tolerance 10 of Nominal Input Voltage Sag minimum 30 of Nominal Input Frequency 50 60 Hz 5 Input Impedance Device Multiphase Isolation Transformer Input Current THD 1st 49th Complies with IEEE519 1992 standard Output Voltage 0 2300 2400V 0 3000 3300V 0 4000 4160V 0 6000 ...

Page 128: ...s RTU RS 485 Modbus TCP RJ45 Modbus PLUS RS 465 PROFIBUS RS 485 EtherNet IP RJ45 Enclosure Standard NEMA Type 1 IP31 Optional IP42 Structure Finish Epoxy Powder Paint Exterior Sandtex Light Grey RAL 7038 Black RAL 8022 Internal Control Sub Plates High Gloss White RAL 9003 Corrosion Protection Unpainted Parts Zinc Plated Bronze Chromate Ambient Temperature Operating 0 40 C standard 0 50 C optional ...

Page 129: ...inutes C Heavy Duty 0 1000 m Altitude Maximum 40 C Ambient 150 overload for 1 minute every 10 minutes 4 Drive Current Rating Code Description Code Description 15 15 Amp 680 680 Amp 5 Enclosure Type Code Description M Type 1 IP31 with door gaskets K Type 1 IP42 with door gaskets 6 Nominal System Voltage 1 Code Description Code Description A 2 400V L 7 200V B 3 000V P 8 320V C 3 300V R 10 000V E 4 1...

Page 130: ... 2400V 2300V 2400V 3000V 3000V 3300V 3300V 4160V 4000V 4160V 6000V 6000V 6600V 6300V or 6600V 7200V 6900V Other Nominal Line Motor Voltage Configurations can be supplied contact factory 9 Normal Load Motor Voltage 1 2 Code Description Code Description A 2300V 2400V F 6000V B 3000V H 6300V C 3300V J 6600V E 4000V 4160V K 6900V D 5500V R 10000V S 11000V 10 Transformer Efficiency Code Description HE ...

Page 131: ...tenance task that is outside the normal preventative maintenance tasks 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 cleanin...

Page 132: ...g Fans I I I I RFB R I I I I RFB R Power Module Electrolytic Capacitors 1 I I I I I I I I I I Misc HECS I I I I I I I I I I LV Control Cabinet Misc AC DC Power Supplies I I I I I I I I I I UPS UPS 2 I I I I I I I I I I LV Control PLC I I I I I I I I I I Control Unit I I I I I I I I I I HMI I I I I I I I I I I LV Control Relays I I I I I I I I I I LV Control Circuit Breakers I I I I I I I I I I All...

Page 133: ...r cooling System Door mounted Air Filters C R C R C R C R C R C R C R C R C R C R Top mounted Cooling Fans I I I I RFB R I I I I I Power Module Electrolytic Capacitors I I R I I I I I I I Misc HECS I I I I I I I I I I LV Control Cabinet Misc AC DC Power Supplies I I I I I I I I I I UPS UPS 1 I I I I I I I I I I LV Control PLC I I I I I I I I I I Control Unit I I I I I I I I I I HMI I I I I I I I I...

Page 134: ...134 Rockwell Automation Publication 6000 UM002G EN P August 2022 Appendix C Preventative Maintenance Schedule Notes ...

Page 135: ...quirements Torque Requirements Proper tightening torque must be used for installation and wiring Table 13 Torque Requirements Thread Size Torque Class 8 8 N m lb ft M4 3 0 2 2 M5 5 9 4 4 M6 10 5 7 7 M8 26 0 19 2 M10 51 0 37 6 M12 89 0 65 7 M14 141 0 104 1 M16 215 0 158 7 M20 420 0 310 0 ...

Page 136: ...136 Rockwell Automation Publication 6000 UM002G EN P August 2022 Appendix D Torque Requirements Notes ...

Page 137: ... with nominal input voltage At adequate storage temperatures this procedure should be performed at least every five years At higher temperatures this procedure should be performed every three years UPS Batteries It is not recommended to purchase spare batteries and keep them in local storage Batteries must be stored under special conditions refrigerated environment to slow down the rate of self di...

Page 138: ... 9 12 15 18 21 24 27 30 33 36 39 42 45 48 51 54 57 60 Power Supplies 1606 Power Supply E 1 E 1 UPS Batteries Ch Ch Ch Ch Ch Ch Ch Ch Ch Ch Ch Ch Ch Ch Ch Ch Ch Ch Ch Ch Control Equipment and Boards DB Board E E E E E DTBoard E E E E E AT Board E E E E E PWM Board E E E E E Power Components Power Cells E 2 E 2 E 2 E 2 E 2 Air cooling System EC Cooling Fans Ro Ro E Ro Ro E Ro Ro E Ro Ro E Ro Ro E Ro...

Page 139: ...nnection Matrix Component Category Component Item Supporting Device 1 Variable AC Source 120V or 240V Multichannel Variable DC Source with Current Limiting Function Variable AC Source 380 480V AC 3 phaseVoltage Regulator 0 750V AC Circuit breaker 380V AC 20 A DB Board DT Board AC Autotransformer 120V or 240V 2 Power Supplies 1606 Power Supply Control Equipment and Boards DB Board DT Board AT Board...

Page 140: ...onnect the devices DC input terminals Phase A PWM slot Phase B PWM slot Phase C PWM slot CPU Board slot AT Board slot DT Board slot P1 terminal 6 pins P2 terminal 6 pins P3 terminal 4 pins Table 16 Power Interface and Distribution for Control Unit Terminal Pin Symbol Description Power Tolerance Current Requirements A Power W CPU PWM 3 DT AT P1 1 5V Digital power 5 2 48 3 6 9 2 5 2 M1 Digital groun...

Page 141: ...DC source with current limiting functionality to DC input terminals P1 and P2 of the DB Board according to Table 16 3 Use 1 3 mm2 16 AWG wire to connect the devices Energize the PWM Board 1 Plug the DT and PWM boards into their respective slots as shown in Figure 72 2 Connect the multichannel variable DC source with current limiting functionality to DC input terminals P1 and P2 of the DB Board acc...

Page 142: ...fter the power cell has fully discharged Reform the power cells 1 Connect the wires as shown in Figure 73 Add a circuit breaker MCB between the power supply and the voltage regulator Connect the secondary winding of the voltage regulator to the three phase input of the power cell 2 Close the MCB and turn on the voltage regulator Bring up the input voltage slowly to 30 of the power cell s voltage r...

Page 143: ...he VFD and the power supply Return wire connections to its original configuration after the power cell has fully discharged WARNING During this step monitor and check for any abnormalities If any abnormalities occur turn off the MCB immediately WARNING During this step monitor and check for any abnormalities If any abnormalities occur turn off the MCB immediately WARNING During this step monitor a...

Page 144: ...age Cooling System Connection Guidelines EC Cooling Fans 1 Connect the variable AC source 380 480V AC to the AC input terminals of the EC cooling fan 2 Use 1 3 mm2 16 AWG wire to connect the devices Figure 75 EC Cooling Fans Delta fan Ziehl Abegg fan Power input terminals Power input terminals ...

Page 145: ...7 348 300 0 5480 13 91 152 012 250 0 5000 12 70 126 677 0000 4 0 0 4600 11 68 107 160 000 3 0 0 4096 10 40 84 970 00 2 0 0 3648 9 27 67 400 0 1 0 0 3249 8 25 53 460 1 0 2893 7 35 42 390 2 0 2576 6 54 33 610 3 0 2294 5 83 26 650 4 0 2043 5 19 21 140 5 0 1819 4 62 16 760 6 0 1620 4 11 13 290 7 0 1443 3 67 10 550 8 0 1285 3 26 8360 9 0 1144 2 91 6630 10 0 1019 2 59 5260 11 0 0907 2 30 4170 12 0 0808 ...

Page 146: ...t or below 70 Place rodent barriers on the drive to keep small rodents from nesting in the drive Cooling Fans Rotate cooling fans by hand or power once every three months This helps to maintain circulation of lubricant in the bearings and to help prevent brinelling of the bearings Control Circuits Apply control power to all control circuits once per year for one hour to help maintain the integrity...

Page 147: ...ks No Medium Voltage or Control Power on page 85 Reset the real time clock If you observe any damage follow the recommendations that are described in Preventative Maintenance and Component Replacement on page 83 Cooling Fans Verify that the cooling fans can rotate freely before starting up the drive Control Circuits Control Power Apply control power in stages to detect and isolate any potential da...

Page 148: ...148 Rockwell Automation Publication 6000 UM002G EN P August 2022 Appendix E Spare Parts Storage Notes ...

Page 149: ...l Board Hardware 116 Inspect Replace 114 115 Control Owner Selection Local Remote 57 Control Unit Analog Signal Processor Board AT 36 Component Description 37 Component Layout 35 CPU Board 36 DB Board 36 Digital Signal Processor Board DT 36 Fiber Optic Socket 36 Function Summary 36 Hardware 115 Inspect Replace 114 115 Interface Terminals 36 Maintenance Schedule 132 133 Overview 35 PLC Communicatio...

Page 150: ...e Connections 25 Inspect 94 Inspect Secondary Windings 122 Location 21 22 23 Maintenance Schedule 132 133 Outgoing Motor Power Cable Connections 26 Power Cabling Overview 29 Primary and Secondary Winding Orientation 24 Primary Winding Voltage Rating 23 Replace HECS 104 Replace Voltage Sensing Board 94 Secondary Winding Voltage 23 Temperature Monitor 24 Top mounted Cooling Fans 89 Voltage Sensing B...

Page 151: ... Connections 85 Physical Inspection 85 Pilot Lights Maintenance 121 PLC Additional Information 114 Communication Interface 36 Inspect 114 Location 34 Maintenance Schedule 132 133 Overview 38 Power Cable Connections Location 21 22 Power Cabling Overview 29 Power Module Basic Principles 30 Components 32 99 Current Ratings 19 33 HECS 105 106 Inspect 98 Inspect Input and Output Connections 123 Install...

Page 152: ...3 Inspect 89 Maintenance Schedule 132 133 Replace 90 Topology Connectivity Overview 15 Overview 12 Pulse Width Modulation 12 Typical Power Structure 13 Torque Requirements 135 Transformer Efficiency 130 Trends Current 49 Customize 53 Customized 49 Frequency 49 Screen Layout 49 Scroll Controls 51 Selection 52 Voltage 49 Typical Power Structure 13 U UPS Front Display 113 Inspect 85 111 LV Circuit Br...

Page 153: ...Rockwell Automation Publication 6000 UM002G EN P August 2022 153 PowerFlex 6000 Medium Voltage Variable Frequency Drive User Manual ...

Page 154: ...s rok auto knowledgebase Local Technical Support Phone Numbers Locate the telephone number for your country rok auto phonesupport Literature Library Find installation instructions manuals brochures and technical data publications rok auto literature Product Compatibility and Download Center PCDC Download firmware associated files such as AOP EDS and DTM and access product release notes rok auto pc...

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