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6000-IN006_-EN-P - Rockwell Automation

1. msg c eel OE oe oo es eee Y md m 1e E L 12171121 LL Te Pm a 11 111 1 9 LJ ad mw Dry type Isolation REEL et Transformer eee Sdn s L L L L U L L LA IL IE E RR LLIT Secondary Winding Output Terminals JD nnnannnn FEE E HH TRIB S TT al T s P Ira LA HAA a T A ee o 11111 t DH a 11111 R v s INE o MIIL e e 9 JO EEEN DTD Connect Control Power Introduction Wiring Externally supplied control power is required to operate the drive The standard voltage supported is 220V AC 50 Hz The other typical phase voltages of 230V AC 110V AC and 120V AC are also supported 50 60 Hz but need to be specified at the time of order A minimum of 3 kVA is required to supply the control circuit Wiring Routing and Connection The control power wiring enters the drive through an opening in the bottom plate of the LV Control Cabinet Rockwell Automation Publication 6000 INOO6B EN P November 2015 89 Chapter6 Drive Electrical Installation For UL Figure 58 Control Power Wiring Opening Fixed mounted Power Module Configuration Cable entrance in top of LV Control Cabinet Front View The control power wiring terminates to the DTBI terminal block strip on the left side of the LV Contro
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6. I vl 1 1 Figure 49 Isolation Transformer Cabinet Drawout Power Module Configuration without Bypass Cabinet L11 225 7 D Door Position b Limit Switches i Voltage Sensing t Dry type Isolation Transformer M ERE mi hh M al Lr M p X __ M Cable Clamp Rockwell Automation Publication 6000 INOO6B EN P November 2015 75 Chapter5 Drive Electrical Installation For IEC Connect Control Power Introduction Wiring Externally supplied control power is required to operate the drive The standard voltage supported is 220V AC 50 Hz The other typical phase voltages of 230V AC 110V AC and 120V AC are also supported 50 60 Hz but need to be specified at the time of order A minimum of 3 kVA is required to supply the control circuit Wiring Routing and Connection The control power wiring enters the drive through an opening in the bottom plate of the LV Control Cabinet Figure 50 Control Power Wiring Opening Fixed mounted Power Module Configuration e E Cable entrance in bottom rear of LV Control Cabinet Cable entrance in bottom front of LV Control Cabinet 76 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Drive Electrical Installation For IEC Chapter 5 The control power wiring terminates to the X1 terminal block strip on the left side of the LV C
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10. ar S SS c ca WSS A AE Rockwell Automation Publication 6000 INOO6B EN P November 2015 79 Chapter 5 80 Drive Electrical Installation For IEC When the doors of the Power Module LV Control Cabinet or Isolation Transformer Cabinet are not closed when the drive is being maintained or when the control power switch is not closed the drive will not send a signal allowing the input circuit breaker to close this is wired as a permissive contact in the input circuit breaker s closing circuit so that the input circuit breaker cannot close Wire Routing and Connection The electrical safety interlock control signal wiring enters the drive through the same opening as the control power wiring in the bottom of the LV Control Cabinet Figure 50 or Figure 51 The wiring terminates to the X1 terminal block strip on the right side of the LV Control cabinet Figure 52 See Figure 83 or Figure 84 for general information Refer to Electrical Drawings for actual connection points Rockwell Automation Publication 6000 INOO6B EN P November 2015 Introduction Safety and Codes Chapter 6 Drive Electrical Installation For UL The installation of all external power cables and control signal wiring is covered in this chapter General electrical safety and installation guideline topics are also included The basic activities include connecting the system ground cable line and motor cables control power and all control sign
11. Inspect the interior of all cabinets carefully for hardware or tools that may Complete the Installation have been misplaced 2 Check and verify that no hardware or foreign material has fallen in the secondary windings in the Isolation Transformer cabinet 3 Check that all mechanical work has been completed properly All barriers and guards that may have been removed must be reinstalled 4 Check that all electrical connections have been made and torqued as specified S Verify the safety circuit is working properly see page 79 6 Reinstall all of the cabinet back plates Rockwell Automation Publication 6000 INOO6B EN P November 2015 105 Chapter7 Drive Electrical Interconnection For IEC Notes 106 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Chapter 8 Drive Electrical Interconnection For UL Introduction The drive is shipped in two sections the Isolation Transformer cabinet and the Power Module LV Control cabinet An optional bypass cabinet may also be supplied Chapter 2 describes mechanically joining these cabinets together This chapter describes the activities required to electrically connect these drive cabinets components together information about connecting the Bypass cabinet to the drive is included in publication 6000 UM002_ EN P 6012DB Medium Voltage Bypass Cabinet User Manual Electrical ntercon nection Connect Internal Cabling and Wiring Page Su m mary Connect Isolatio
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14. C4 o coa wN 9 V9 V VQ 9V f10009 m 6t vo V vdetv f10009 mE 1030W Jaquiny bojeze c Lo LO co c c MO c Lo aN SVHU C 6 cc LPC ZOLL ZOUL SpHu c 6 HIS OSL OOZL 007 629 OLr m CX9 X G 91 L6SXC81X0CV Mo p a 22 C4 o ae wN Ove ELZ 8l 091 EEL CL 0 9y wea 92 LPC ZOLL LOUL SyHd C CN N LA D eon apo d 31njonJ jg 112 49M0d c ce m c c O c c c up 1 ur uiui XMXH Mopary 16101 1 SUeJ Jo sqi 6y 6 II 49MOd cM CUI suoisueuim Aly 830 jueuieJinboy 5 N N h h 3 3 D D S119 10Mog 6 uorjeinfijuo 55 8L 3nding JY ADOHZ 00EZ S 3nduj AOOHZ 9 91081 Rockwell Automation Publication 6000 INOO6B EN P November 2015 132 Appendix E PowerFlex 6000 Dimensions and Weights For UL 8886 YEBI mm 89 YESI mH 89 PEBL EI sty 9 S rZ 55 06 Fr L 889 veg 6L c zoel z9 0091 oger 9 S prc 98115 LC6pL 8898 veg 6L c z9eL 79 0041 0674 985 rr S 8119 L761 888 9891 61 c zoel z9 OOEL 06 8 9 S rc BLES LZ6rL 288 veg 6L c zoel z9 O0tL 0678 S ES rc Br LS LZ6rL 888 v
15. Input circuit breaker closing indication 136 VFD provided normally closed active dry contact 121 voltage class lt 220V AC 5A spare Input circuit breaker opening indication VFD provided normally closed active dry contact 137 121 voltage class lt 220V AC 5A spare VFD alarm indication 138 121 VFD provided normally open active dry contact voltage class lt 220V AC 5A spare VFD fault indication 139 121 VFD provided normally open active dry contact voltage class lt 220V AC 5A spare VFD operation indication 140 121 VFD provided normally open active dry contact voltage class lt 220V AC 5A spare VFD stop indication 141 121 VFD provided normally open active dry contact voltage class lt 220V AC 5A spare VFD ready indication 142 121 VFD provided normally open active dry contact voltage class lt 220V AC 5A spare Spare 143 121 VFD provided normally open active dry contact voltage class lt 220V AC 5A spare Spare 120 121 LJ VFD provided 220V AC load lt 10 W spare All of the AI AO DI DO connection points are expandable based on user requirements 150 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Appendix H Power Cabling and Control Signal Wiring Details For UL Figure 87 Schematic Diagram of the Drive System without a Bypass Cabinet Diagrams Schematic Y 01553226 pue pasn 1nd1no 1ndur y 0 553726 3jes S 3194
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19. sjeuiqe ssed q gqzL09 xa 4jemog Idul JY AOOEE S 5 6 CMECEK HE CHN NE CHE EE HN MEER EE sey ater oe ufieM suoisueuiq 1y619M ww suoisueuiq 615 suoisueuq sduiy nding V V V ssed g jenuew 2 uosa ssed g ryeuio ny 015 3 ssed g ryeuioyny Bugu 1 M0d 1030W 6310A sjeuiqe ssed q gqzL09 xa 4jeMog dul JY A000 21421 Rockwell Automation Publication 6000 INOO6B EN P April 2014 144 Appendix G Power Cabling and Control Signal Wiring Details For IEC Figure 83 Schematic Diagram of the Drive System without a Bypass Cabinet Schematic Diagrams p p u s Dede 0128101 UNN upuelg uy jeubis j041u0 ZH 09 06 aseyd v Aorz Occ OCC OCL OLL JeubiS 0 07 01 u0 N aAup 1nd3no 1ndui ay 01 558226 ayes si ay Jey Puunsu 104 jq suods s 331 1ndur ay Jo jerjddns au sJayy0 q paljddns a i ep 3ndui ue sepnput upruM 815 5 siu ui jusuoduuo auo sr aAup 306 0 uinipau au JOLOW 0 Y 01559226 Jes pue pasn JI d35NVQ Ajddns Jo adoos jou1015n Jayea1g WNDU ureansd ZH 09 06 aseud c y LUE LLIT CHI L uoIp uuo0 3 Lal M AW punoly paljddns 1910151 1 Wiring locations are for design reference only actual wiring must comply with the drawings provided with the drive 145 Rockwell Automat
20. Chapter 6 The general grounding point must be reliably connected with the grounding network Attach an external ground cable to the main ground bus in compliance with applicable national and local electrical codes IMPORTANT The primary grounding cable must have a diameter of at least 50 mm and meet all applicable national and local electrical codes Run the system ground cable separately from power and signal wiring so that faults e do not damage the grounding circuit will not interfere with or damage the protection or metering systems or cause undue disturbance on power lines Incoming line power cable ratings are shown on the Electrical Drawings and reflect what would typically be supplied based on line voltage rating All voltage ratings for outgoing motor cables shown are line to ground rated power frequency voltages and line to line power frequency voltages Table 18 Cable Insulation Requirements for Outgoing Motor Cables Cable Insulation Rating kV Motor Side System Voltage Insulation Level Select cables of appropriate voltage classes when the incoming line grid side voltage class is different from the outgoing line motor side voltage class Standard power cable ratings commercially available can vary in different regions around the world Cable must meet the minimum line to ground and line to line requirements IMPORTANT Follow the recommended field power cabling insulation levels to help ensure t
21. DDs e Certifications All necessary hardware for mounting lifting angles and fan assemblies and securing the cabinets together e Keys for the lockable cabinet handles e The locking key for drawout power modules if supplied 2 Uptonine drawout Power Modules can be shipped in one crate 3 ThePower Module lift cart is wrapped in plastic for shipment within China and crated for shipment outside of China 4 Refer to Dimensional Drawings or PowerFlex 6000 Dimensions and Weights For IEC on page 123 to determine the number of fans crates 16 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Initial Inspection Checklist Table 2 Shipping Damage Assessment Isolation Transformer Cabinet Power Module Cabinet Low Voltage Control Cabinet Bypass Cabinet if supplied Low Voltage Door Pilot Lights Voltage Indicator Relay Cabinet Insulators Switch assemblies Vacuum contactors Mechanical linkages Storage Installation Site Requirements Low Voltage Door Shipping and Handling Procedures For IEC Chapter 1 Fixed mounted Low Voltage Door Transformer Temperature monitor relay Power module retaining tabs Pilot lights Cabinet Drawout Push buttons Voltage Sensing Board Power Module Support frame HMI Interface Incoming Line Power Cable Terminal Power modules shipped in separate Panel Insulators crate s DIN rail m
22. For IEC 6y 146 suey LS Dy 3491M suoisuawig sla 18Mog ZZ 7 35 pS 3ndyng induj JY A000 01 3 6 Appendix D Rockwell Automation Publication 6000 INOO6B EN P November 2015 128 Appendix D PowerFlex 6000 Dimensions and Weights For IEC vc8S 05 0 E Am EBBE PEBL ERN ANI 0909 09tL 00 v Ut LC I 00vc CIEL Eg 00 007 000 005 UR LC 00tc OCLI EN 08E 86 05 0 KARS 88t vt8l ere 0986 O9EL 0055 Ot C P 00vc CIEL KA 00 OOH 000c 005 0861 060 0951 P OSE vC8S 05 0 EXE EBBE PEBL Lep ee 0906 O9EL 00 OtZC I 00vc CIEL Ea 00 OOH 0000 005 OS L 0 8L O0rL a GLE 86 09 0 8 t C vc8S 09 0 east se EBBE PEBL AEA 0906 O9EL 006 DEL a 00vc CIEL EH 00 OOH O00C O0vC KLL 0891 O9CL EA 087 EBBE PERLU 61 O9ES O9EL 0007 c OELE OEE 0050 COEL CO OOEL OOH 0000 005 0591 09 OCEL 09 oE vc8S 05 0 ELSE EBBE PEBL lord 2 0906 09tL 00 t OtZC E 00vc CIEL EA 00 005 000c 005 00 OOSL OCLL we URC PCORK URLC 8 t EBBE PERLU 61 C 0987 O9EL O0St 0 46 OEE OOVC COEL C9 OOEL OOH 000 005 RRC L OSEL OLOL OLC SCC milan x iini lee tun ee ae oe uu Lek s aci o mele sise uui uw mel e Dux iue Ln NNI 7387303073173 miss x acid S
23. Table 12 Power Module Specifications Type Output Rating Amps Dimensions HxWxD approx Fixed mounted lt 150 A 420 x 180 x 615 mm 16 5 x 7 1 x 24 2 in 151 200 A 420 x 260 x 615 mm 16 5 x 10 2 x 24 2 in 201 380 A 575 x 342 x 691 mm 22 6 x 13 5 x 27 2 in 381 420 A 575 x 342 x 910 mm 22 6 x 13 5 x 35 8 in Drawout Weight approx 20 kg 44 1 Ib 25 kg 55 1 Ib 40 kg 88 2 Ib 50 kg 110 2 Ib ATTENTION Two people are required to handle the Power Modules Always handle the drawout Power Modules using the two recessed lifting handles on both mounting rails Figure 38 Figure 38 Drawout Power Module Lifting Handles ANS oS 7 4 W o7 A Mounting Rail Recessed Lifting Handles ATTENTION Do not use the front mounted positioning handles for lifting the Power Modules They are designed to position or withdraw the Power Module when on the tray assembly Rockwell Automation Publication 6000 INOO6B EN P November 2015 Drive Mechanical Installation For IEC Chapter 3 Install Power Modules 1 Place the Power Module module on the lift cart Ensure the Power Module is properly oriented the finger assemblies must face towards the drive 2 Position the lift cart in front of the cabinet and raise the Power Module to the proper height 3 Align the wheels on the Power Module with the tray assembly guides on each side of the Power Module tray a
24. The drive is intended to operate in conditions with no special precautions to minimize the presence of sand or dust but not in close proximity to sand or dust sources IEC 721 1 defines this as being less than 0 2 mg m of dust e If outside air does not meet this condition filter the air to EU EN779 Class F6 or ASHRAE Standard 52 2 MERV 11 These ratings address a high percentage of the 1 0 3 0 um particle size Clean or change filters regularly to ensure proper flow e The make up air must be between 0 40 C 32 104 F Relative humidity must be less than 9096 non condensing e If the ducting length is greater than 3 m an axial fan must be installed at the air outlet The exhaust flow of the axial fan must be greater than the total flow amount of all the centrifugal fans in this air duct e The ducting must not be shared by the two cabinets e The distance from each side of the hood to the corresponding side of the fan must not be less than 60 mm 2 4 in e Do not cover any medium voltage or control power wires which enter or exit from the top of the cabinet e The air duct outlet must slope downward to prevent water damage e Screens must be installed in the air duct outlet Rockwell Automation Publication 6000 INOO6B EN P November 2015 55 Chapter3 Drive Mechanical Installation For IEC e Anair inlet must be added to the drive room The cross sectional area of this inlet must meet the ventilation requireme
25. door is opened Connect the system ground cable to the drive ground bus Figure 46 Figure 46 Ground Cable Connection in the Isolation Transformer Cabinet M8 Nut Lock Washer oe Ground Bus M8 25 Bolt Flat Washer d IMPORTANT Ifan optional Bypass cabinet is supplied the system ground cable connection is in the Bypass cabinet Refer to publication 6000 UM002 EN P Before connecting the incoming line and outgoing motor power cables follow standard industry practice to verify the integrity of the power cable insulation from the input breaker to the drive and from the drive to the motor The installer must ensure that all power connections are in accordance with national and local electrical codes Each drive is equipped with provisions for bottom power cable entry as standard Provisions for top power cable entry can also be provided This must be specified at the time of order Rockwell Automation Publication 6000 INOO6B EN P November 2015 73 Chapter5 Drive Electrical Installation For IEC Cable access openings are located on the bottom plate of the connection cabinet identified by the customer specific Dimension Drawing Figure 47 Power Cable Entry Locations in the Isolation Transformer Cabinet Outgoing Motor Cables Incoming Line Cables The drive is supplied with the following provisions for power cable lugs Table 17 Power Terminals Incoming Line Cable Connections L11 L12 L13 Outgoing
26. http www ab com Provides declarations of conformity certificates and other certification details You can view or download publications at http www rockwellautomation com literature To order paper copies of technical documentation contact your local Allen Bradley distributor or Rockwell Automation sales representative Rockwell Automation Publication 6000 INOO6B EN P November 2015 Preface Contractor Scope of Work Typical scope of work by the freight company third party contractor and or customer based on ex works INCO terms e Load equipment on truck at a Rockwell Automation manufacturing facility and transport equipment to site e Offload equipment from truck on site e Perform initial inspection e Move equipment to the final installation location e Position the cabinet sections together as shown in Dimensional Drawing and level the cabinet lineup e Mechanically join cabinets together e Affix the cabinets to the floor e Install assemblies shipped loose fan assemblies For IEC only drawout power modules if applicable e Install external ductwork to exhaust heated air from control room if required e Install power and control cabling and terminate cable connections to drive system e Connect system ground cable e Megger test of incoming line and outgoing motor power cables C j ing line and i bles e Connect incoming line and outgoing motor power cables e Connect control power wiring e Conne
27. the terminals from the first winding set are 1U 1V and 1W the terminals from the next winding set are 2U 2V and 2W and so on As shown in Figure 76 the first winding set 1U 1V and 1W will connect to the three phase input power connection of the first power module in the U motor phase array PCA1 the second winding set will connect to the second power module in the U motor phase array PCA2 and the third winding set will connect to the third power module in the U motor phase array PCA3 The next three winding sets connect to the power modules in the V motor phase array The remaining three winding sets connect to the power modules in the W motor phase array Figure 76 shows 2 3 2 4 kV 4 0 4 16 kV 6 0 kV 6 3 kV and 6 6 kV configuration Larger configurations have more power modules and therefore have more corresponding isolation transformer secondary windings The concept is the same the top third of the winding sets feeds the power modules in the phase the middle third feeds the power modules in the V phase and the bottom third feeds the power modules in the W phase Each three phase secondary winding set of the isolation transformer has three individual single phase power cables connecting its output to the three phase power input of its corresponding power module For drives with fixed mounted power modules the U V and W phase interconnections to the isolation transformer secondary windings are on the front of th
28. 06 959 pp C 5 807041 co C 9 6 2229 3456 9 ESSE PERLU 61 C 88 v 8L EL C CLyv OCCO OC6L 0044 0192 OVE OOEZ CIEL C9 OOEL ocet 009 UCL L L6SXC8LX0CV OrHd V HIS OOL 00 OBLL 08 088 OZL OOL 19 0001 0009 pocLL rcc 0704 56 01 HEL S5 06 959 pp C BLLS 807041 co C 9 6 2229 34 6 9 ESSE PERLU 61 C C CLS 006 000 0192 OVE OOEZ CIEL C9 OOEL ocet 009 UCL L L6SXC8LX0CV OrHd V HIS OOL 00cc OOLL 00LL 028 LLL 6 J9 V 6V f10009 LL recv 0789 v6 0L EL 66 06 959 p CO 8L L9 9007 Z9 EZ C 9 C amp CX9L X 91 x ESSE PERLU EL C C COS 006 001 0192 OVE OOEZ CIEL C9 OOEL UC KD 009 UCL L L6SXCSLXOCY OrHd V HIS OOL 0017 OOOL OOOL OSZ COL RN Jo V f aS8V 0009 OL ccv 0099 v6 0L HEL 55 06 959 pc 8E L9 807041 Z9 EZ C 29 CX9 X 6 9L J 88 EBL EL C C 026 000 0v9c UPE OOEZ CIEL C9 OOEL ocet 009 UCL L L6SXC8LX0CV OVHY v MIS Ool 0002 0 9 L6 9 49 V q9 V f10009 OL Pelr 0999 56 01 VEL 65 06 959 p 8E L9 807041 CIE C 9 C CX0 X 6 9L ESSE PERLU EL C 026 0060 0192 OVE OOEZ CIEL C9 OOEL ocet 009 UCL L L6SXC8LX0CV OVHY E YIS bL 006 008
29. 102 286 783 384 1049 400 1100 4320 1362 2640 STR_1 97 135 116 162 891 1241 1194 1663 1250 1750 4520 1362 2640 STR 4 155 200 186 240 1432 1852 1919 2482 2000 2600 5200 1362 2640 STR 2 Table 51 6900V Input amp 6600V AC Output 36 Pulse Configuration 18 Power Cells Motor Amps Typical Motor Power Rating Transformer Rating Width Depth Height Structure Code Cont 31 85 37 102 300 820 400 1100 400 1100 4320 1362 2640 STR_1 97 135 116 162 933 1300 1250 1750 1250 1750 4520 1362 2640 STR 4 155 200 186 240 1500 1940 2000 2600 2000 2600 5200 1362 2640 STR 2 Rockwell Automation Publication 6000 INOO6B EN P November 2015 141 AppendixE PowerFlex 6000 Dimensions and Weights For UL Notes 142 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Appendix F PowerFlex 6000 Bypass Cabinet Dimensions and Weights For IEC only Rockwell Automation Publication 6000 INO06B EN P April 2014 143 PowerFlex 6000 Bypass Cabinet Dimensions and Weights For IEC only Appendix F os ocu o6 ow ou 06 oss omz ox 08 095402 0107 os os 06 ow os 06 os ox 08 0 6 f mH ded R eun Sie 1yb1aM 015 14619 05 1 05 ssed g enuew 2 015
30. 2 Minimum cable bend radius recommendations vary by national codes cable type and cable size Consult local codes for guidelines and requirements General relationship of cable diameter to bend radius is typically between 7x 12x e g if the cable diameter is 1 in 2 54 cm the minimum bend radius could range between 7 12 in 18 8 30 48 cm 3 Ascabling methods can vary widely maximum cable sizes shown do not account for the size of the conduit hub Verify size of conduit hub s against the Drive enclosure openings shown 156 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Additional Resources 10 Air Conditioning Index Control Power Wiring Checklist 117 Installation 76 89 Routing 76 89 Calculation 56 65 Torque Requirements 119 Sizing 56 65 Control Signal Wiring 71 85 Ambient Air Temperature 17 33 Routing 71 85 Anchor bolts 48 62 Shield Grounding 72 85 Angle Brackets 20 36 Shielded cables 71 85 ASHRAE Standard 52 2 MERV 11 55 Torque Requirements 119 er Control Signal Wiring Details Aviation Plug 50 64 Schematic No Bypass 145 151 Schematic With Bypass 146 B Cooling Air 17 33 KPI Cooling Fans Back Plates Dimensions 50 64 Remove 47 61 Hardware 50 64 Bypass Cabinet Installation 50 64 Dimensions and Weights 143 Model 50 64 Eye bolts 28 Orientation 50 64 Lifting 28 Weight 50 64 Lifting Hardware 28 Wiring Bundles 102 113 Shipping Damage Checklist 17 C D Design Considerati
31. C4 c Leo wN 87871 8c8 00011 56 0 LEV CXLEOLXES OL 8 8 0v 9 Ov L 0006 0590 6LOXC9CXOCY POR URLC 1 8 OVHU 9 00 Ove 000 19 100007 0009 ZZZEL 2662 08401 56 50 LE vCXLEOLXES OL YESS 06 0 8 9tiy8 0929 O9EL 0067 Ov9C 619Xc9cXQ0CT OrHd 9 C HIS OOZ 008E OSCE 0520 089 6ce LOL d9 V NQL6L V 10009 ZSS L 2662 09501 56 0 8l LE vCXLEOLXES OL POR 06 0 8 88 v 0919 09tL 0087 0590 00 00cc 619Xc9cX0CT OrHd 9 c HIS O8L 00 6 0000 000 00951 SOC LZL dO V 4QLZLV f10009 vELEL rccv 0168 v6 01 VEL se06 9 ES rr c 811S 80020 29 EZ 72 29 19798 62091 660 9 POR 06 0 8 6tvs 9 0 68 006 0507 099 OVE O0tC COtL CO 004 OED 009 OCZL 00040 L6SXC81X0CT OrHd 9 S HIS OSL 0008 OS L OS L OOEL ZZL d9 V NQ8vLV 10009 0 8 v6 0L e EU sc 06 9 55 rir c 807071 CEZ 119 19 98 442091 0465 9 JO V 4d6 1V f10009 c C4 ce c Mo c C4 c ce C4 C4 L6SXC81X0CV OVHU S e coa o ce wN Lo c a POR 06 0 8 T cc c Lo m c c co N Lo ea Mo Lr ca Mo c C4 Mo Mo oO CX9 X G 91 co Lra co 2
32. Cables 1 The number of Isolation Transformer secondary cables is dependent on motor voltage class e 9 cables per motor phase 27 total for 3 3 3 kV 18 cables per motor phase 54 total of 6 6 6 kV 27 cables per motor phase 81 total for 10 kV SIDE VIEW Rockwell Automation Publication 6000 INOO6B EN P November 2015 45 Chapter3 Drive Mechanical Installation For IEC Figure 32 Aligning Cabinets with Drawout Power Modules 6 6 6 kV shown Bypass Cabinet Optional Isolation Transformer Cabinet Power Module LV Control Cabinet Table 10 Sidesheet Openings Front Wireway Rear Wireway U Phase Motor Cable V Phase Motor Cable o o o o W phase Motor Cable O 2 Q Ground Bus Connection 38 Voltage Sensing alle 9 Board Cables Isolation Transformer Secondary Cables 1 Thenumber of Isolation Transformer secondary cables is dependent on motor voltage class 9 cables per motor phase 27 total for 3 3 3 kV 18 cables per motor phase 54 total of 6 6 6 kV 27 cables per motor phase 81 total for 10 kV OOOOOOOO OOOOOOOO 00000000 6 6 6 kV configurations only require 18 cable hole locations per phase Extra cable hole locations allow for added installation flexibility OOOOOOOO OOOOOOOO Ooooooooo SIDE VIEW 46 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Drive Mechanical Installation For IEC Chapter 3 3 Secure the
33. Details For UL Appendix H Standard Input Output Connection Points Table 59 0 Connections related to High Voltage Cabinet Serial Number Name of 1 0 Connection A fao DI DO Note 1 Input circuit breaker closing node is allowed 1 Serially connected into the input circuit breaker s closing circuit the VFD 917 918 provides passive normally open points valid when closed Input circuit breaker closing node is allowed Serially connected into the input circuit breaker s closing circuit the VFD 957 958 spare provides passive normally open points valid when closed 2 Trip connection points within the VFD Can be connected into input circuit breaker s closing circuit in parallel the VFD 919 920 provides passive normally open points valid when closed Trip connection points within the VFD Can be connected into input circuit breaker s closing circuit in parallel the VFD 959 960 spare provides passive normally open points valid when closed 3 Input circuit breaker already closed Circuit breaker s auxiliary normally open connection points valid when closed connection point 117 119 4 Input vacuum contactor closing Serially connected into the vacuum contactor closing the VFD provides passive 961 962 spare normally open points valid when closed Table 60 1 0 Connections related to Remote Distributed Control System seral Number garg 2 User provided 4 20 mA spare ft
34. Drawout Power Module Installation 51 Drawout Power Module Interconnection 99 Drawout Power Module Specifications 52 Electrical Safety Interlock Wire Entry 80 93 Fan Wiring Bundles 102 113 Fixed mounted Power Module Interconnections 99 111 Ground Bus 105 114 Keys 15 31 Lifting 21 36 LV Control Wiring Bundles 102 113 Motor cables 100 101 112 Overhead Lifting Angles 22 38 Power Module Lift Cart 51 Remove Back Plates 47 61 Shipping Damage Checklist 17 33 Terminal Block Strip location 77 90 Voltage Sensing Board cables 100 101 112 Power Terminals 74 88 PowerFlex 6000 Dimensions 123 131 Documentation box 16 32 Electrical Installation 67 81 External Ducting Specifications 55 Hardware Box 16 32 Installation Site 17 33 Isolation Transformer Cabinet Layout 75 89 Keys 15 31 Lift Power Module LV Control Cabinet 21 36 Line Cable Sizes 155 Load Cable Sizes 155 Mechanical Installation 43 59 Mounting Clearance 18 34 Overhead Lifting 21 36 Power Module Lift Cart 51 Pre Commissioning 115 Schematic No Bypass 145 151 Schematic With Bypass 146 Shipment List 16 32 Shipping and Handling 13 29 Storage 17 33 Unpacking and Inspection 15 31 Weights 123 131 Pre commissioning Checklist 116 Inspection 115 Verification 115 Pre commissioning Checklist 116 Control Wiring 117 Drive Line up Status 118 Installation and Mounting 116 Interconnection Wiring 117 Power Wiring 117 Receivin
35. LS8 079 78 H9 V fq69V f10009 0L vccv 0999 v6 oL EL 64 06 9 ES v c 8U 19 807041 952 CL 9 amp CX9L X 9L ESSE vE8L OL C 026 0062 01792 OVE OOEZ COEL C9 OOEL 0ctv 009 UCL L L6SXT SLXOCY OVHY E L YIS bL 0061 008 894 ELS vl 9 029 0009 0L yccv 09019 Y6 EOL EL 55 06 955 rZ 8U 19 807040 2952 CL 9 6 2229 3456 ESSE vVE8L OL C 026 0087 01792 OVE OOEZ COEL C9 OOEL 0ctv 009 UCL L L6SX78LX0CV OVHY E YIS GL 0081 004 899 86r Y H9 V fqvsV f10009 E 2g EZ Bugu samo i 1030y 6310A ES 030 aes ed ms sqn 6y aufiaM S Ey sduiy sojow Jaquiny bojeze 5 3 7M suoisuauiq S119 4aMog 9 L 7 3 9 3ndino JY ADDED 3 3nduj A0099 62 91061 135 Rockwell Automation Publication 6000 INOO6B EN P November 2015 PowerFlex 6000 Dimensions and Weights For UL Appendix E 82041 8c8 OOZEL v6 01 VEL se 06 9 ES HH Z 8U19 22702 L v CXLEOLXES 9L POR OSZ7 8 YESS 06 0 8 vedo OVLZ OvLL 0009 0990 OVE OOEC CIEL c9 OOEL 0005 6LOXCOCXOCY OVHY 9 C HIS 00 0067 0090 009c Ov6L Ove 000 00024 0009 828 878 0001 v6 01 rE U 5506 ES rc 9115 22 02
36. OOEC COtL c9 OOEL 06 4 619Xc9cX0CV co Mo 98 08 0009 c c O c 92 EBBE VE8L p L 86 961 ZZL9 56 0 EU 5406 9 ES rr C LS LC6vL co c se ov L v CXLE 0LXES 91 EBBE EBL OL tv OSvL 0067 OV9C OVE OOEC EL C9 EL 06 4 009 O6LL 619XcC9CXQCT OrHd v 0 YIS URL 008 008 Ot SvS 9 SSL 9 055 0009 68 8667 6566 15 60 SL 65 06 9 S rr C LS 9 661 2950 7 8 SECXOLLXES OL LLVC ZOLL LOUL Ly O9EL 008 0897 08 00 0 EL C2 EL OSSE 009 096 L6SXC8LXO0CY vel 0009 CX9 XEG 91 L6SXC81X0CV Mo p a 22 m C4 o cea wN LLL Vorv vaLLLV 0009 c Lo Lo M c c MO c Lo aN LPC ZOLL OUL SyHd C 6 YIS OCL OO9L 6 209 456 9 L6SXC81X0CV Mo a coa C4 o ae wN 9 000 0009 c Lo Lo M c c Me c Lo 92 LPC ZOLL ZOUL SyHd C 6 YIS 00 OOSL 00S 169p OSt 0 CX9 X 91 L6SXC81X0CV Mo b a M C4 o ae wN coa 9 69 0009 c Lo Lo c c Me c Lo nN LPC ZOLL LOUL SyHd C 6 YIS 6 209 456 9 16578 70 Mo p a 22
37. Procedures For IEC Chapter 1 Unpack and Inspect the Drive Before leaving the factory all drives have undergone both performance and quality tests However damage may occur during the shipping or handling process Immediately upon receiving the drive inspect the crates for signs of damage After the crates are offloaded disassemble the crating and check for possible shipping damage Use a crowbar or other suitable tool to carefully remove the packaging Do not insert the tool too far into the packaging or damage to the drive cabinet may occur Inspect the drive cabinets for physical damage according to the Rockwell Automation Conditions of Sale Open the doors and inspect the major components for signs of damage Table 2 Figure 1 Crated Cabinet E IMPORTANT Any daims for visible breakage or damage must be made to the freight company by the user as soon as possible after receipt of shipment Rockwell Automation will provide the user with reasonable assistance in the securing of adjustment for such damage claims Access to the medium voltage cabinets of the drive is restricted by the use of lockable handles The cabinet keys are located in the same document hardware box as the EDs and DDs see Required Supplemental Information on page 9 The box is accessible through the opening in the cabinet side sheet without opening a door Rockwell Automation Publication 6000 INOO6B EN P November 2015 15 Chapter 1 Shipping and
38. Should Use This Manual What Is Not in this Manual Required Supplemental Information Preface This document provides procedural information for physically unloading moving and installing PowerFlex 6000 medium voltage drives This manual is intended for use by professional riggers general contractors electrical contractors or plant operations personnel familiar with moving and siting heavy equipment Specific experience with solid state variable speed drive equipment is NOT required for this part of the installation process but is mandatory for subsequent processes This manual provides information specific for physically unloading and situating a PowerFlex 6000 drive It does not include project specific or drive specific topics such as e Dimensional Drawings and Electrical Drawings generated for each customer s order e Spare parts lists compiled for each customers order e Drive specific technical specifications Refer to the following documents for additional product detail or instruction relating to PowerFlex 6000 drives e PowerFlex 6000 Medium Voltage Variable Frequency Drive Commissioning Manual 6000 IN007_ EN P required procedures and checklists for Rockwell Automation Field Service Engineers e PowerFlex 6000 Medium Voltage Variable Frequency Drive User Manual 6000 UMO001 EN P instructions for daily recurring drive usage HMI interface and maintenance tasks for the product end user This manual i
39. Use fire retardant cables for the drive input output connections Shielded or unshielded cable can be used based on the criteria considered by the distribution system designer and national and local electrical codes If shielded power cables are used connect the shield of the main input output power cables with the general grounding point of the drive Ground the drive output protective grounding connection separately and only at the drive side Comply with the maximum tensile stress and the minimum curvature radius recommended by the cable manufacturer Do not bundle the input output cables of the drive together The power cable tray must not be less than 300 mm 12 in There must be no gaps where the conduit connects to the cabinet and the ground bond must be less than 0 1 ohms Spacing between wire groups is the recommended minimum for parallel runs of approximately 61 m 200 ft or less IMPORTANT The power cable distance from the drive to the motor must not be longer than 300 m If the power cable exceeds 300 m contact the factory Configurations can be provided for longer cable distances but must be specified at the time of order All input and output power wiring control wiring or conduit must be brought through the conduit entrance holes of the cabinet Use appropriate connectors to maintain the environmental rating of the cabinet Voltage drop in motor leads may adversely affect motor starting and running performance Inst
40. User provided 4 20 mA spare 2 VFD speed feedback signal 927 928 L WE VFD provided 4 20mA 3 VFD current feedback signal 925 926 H O VFD provided 4 20mA 4 Alternate start command signal User provided normally open passive dry contact 431 401 spare pulsed quantity valid with 3S Remote DCS start command signal User provided normally open passive dry contact 449 401 pulsed quantity valid with 3S Alternate command signal 432 401 spare User provided normally open passive dry contact pulsed quantity valid with 3S 5 Remote DCS stop command signal 450 401 User provided normally closed passive dry contact pulsed quantity valid with 3S 6 Spare 433 401 User provided normally open passive dry contact pulsed quantity valid with 3S 7 G G User provided normally open passive dry contact pulsed quantity valid with 3S 8 Spr 3540 User provided normally open passive dry contact switch quantity Spe B640 p User provided normally open passive dry contact switch quantity User provided normally open passive dry contact switch quantity pet ff User provided normally open passive dry contact switch quantity 9 Remote DCS alterate 448 40 User provided normally open passive dry contact switch quantity 10 Remote DCS fault reset command 412 401 oo User provided normally open passive dry contact IMEEM i r User provided normally op
41. applies only to the drive it does not include the UPS uninterruptible power supply If the storage temperature fluctuates significantly or if the relative humidity exceeds 90 use heating and moisture protection devices to prevent condensation Store the drive in a conditioned building with adequate air circulation Do not store the drive outdoors Environmental Conditions e Elevation above sea level must be less than 1000 m 3250 f e Ambient air temperature must be between 0 40 C 32 104 2 l Relative humidity must be less than 90 non condensing e The drive must be installed indoors there must be no dripping water or other fluids in the room e Cooling air must be clean without significant concentrations of sand corrosive or conductive dust or explosive gas e Free from significant vibration e The drive must be anchored on a level floor Please refer to the dimension drawing for the anchor point sizes and locations For the equipment to operate in conditions other than those specified consult the local Rockwell Automation Sales Office 1 Options are available for operation up to 3000 m a s l However these must be stated at the time of order and cannot be retrofitted in the field Options are available for ambient temperatures up to 50 C 122 F However these must be stated at the time of order and cannot be retrofitted in the field Rockwell Automation Publication 6000 INOO6B EN P Novembe
42. available for operation up to 3000 m a s l However these must be stated at the time of order and cannot be retrofitted in the field 2 Options are available for ambient temperatures up to 50 C However these must be stated at the time of order and cannot be retrofitted in the field Rockwell Automation Publication 6000 INOO6B EN P November 2015 17 Chapter1 Shipping and Handling Procedures For IEC 18 Mounting Clearance Distance Install the drive with appropriate clearance distances on all sides to ensure proper operation and allow maintenance of the drive Table 3 Minimum Mounting Clearance Distances Location Minimum Distance Required approx In Front 1500 mm 60 in Behind s 1000 mm 39 in Above e 400 mm 16 in without ducting requirements e 1000 mm 39 in with ducting requirements 1 Distance above is measured from the top plate of the drive cabinet excludes height of fan housing damage or reduction in product life Ambient conditions not within the ATTENTION An incorrectly applied or installed drive can result in component specified ranges may result in malfunction of the drive Mounting Requirements The base must be smooth flat and level If power cabling is entering from below and a cable trench system is used refer to Figure 3 The base structure of the drive cabinet may be constructed with 10 channel steel approximately 100 x 48 x 5 3 mm 3 9 x 1 9 x 0 2 in Dimension pairs r
43. be used for installation and wiring Table 27 Torque Requirements for IEC Thread Size Torque n E M10 M12 M14 M16 M20 m Table 28 Torque Requirements for UL Torque Thread Size Ww v v Rockwell Automation Publication 6000 INOO6B EN P November 2015 lb ft 1 0 2 1 3 4 8 1 16 2 28 8 45 7 70 1 135 7 lb ft 2 2 4 4 Td 19 2 37 6 65 104 1 158 7 310 0 119 AppendixB Torque Requirements Notes 120 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Appendix C General Wire Categories General Wire Categories Conductors Group Conductors Category Signal Examples Power Supplies 1 AC power supply 220V 10 TO 600V AC Control 2 220V AC or Relay Logic PLC 1 0 220V DC Logic 3 24V AC or PLCVO 24V DC logic DC supply 5 Digital circuit Pulse train input high speed tachometer PLC communication 1 18 AWG twisted pair shielded 2 18 AWG 3 conductor shielded 3 18 AWG twisted pair shielded 4 24 AWG twisted pair shielded Control To PLC mm in Power Supplies mm in Tray 228 6 9 00 152 4 6 00 Tray 228 6 9 00 152 4 6 00 Tray 228 6 9 00 152 4 6 00 All signal wiring must be run in separate steel conduit Conductors Group Recommended Cable Per IEC NEC Local codes and application requirements Per IEC NEC Local codes and application requirements Per IEC NEC Local
44. capacity of not more than 20W for indication backup and 11 passive dry contact outputs powered by the drive with a capacity of 220V AC 5A for DCS status fault indication For detailed information see Table 59 and Table 60 on page 153 These outputs are scalable depending on user requirements The drive is provided with dry contact outputs 1 N O with a capacity of 220V AC 5 A valid when closed which trigger the user provided medium voltage circuit breaker for interlock with the user provided medium voltage switch cabinet For detailed information see Table 59 and Table 60 on page 153 Ethernet interface is supplied as standard other communication interfaces including Modbus and Profibus are provided as options Wiring Routing and Connection The control signal wiring enters the drive through the same opening as the control power wiring in the LV Control Cabinet Figure 58 The wiring terminates either to the 181 or DTB2 terminal block strips on either side of the LV Control cabinet Figure 59 See Figure 87 or Figure 88 for general information Refer to Electrical Drawings for actual connection points Rockwell Automation Publication 6000 INOO6B EN P November 2015 91 Chapter6 Drive Electrical Installation For UL Connect Electrical Safety Introduction Interlock Circuit to Input Circuit Breaker The electrical safety interlock circuit is part of the overall control signal wiring activity However it is mentioned
45. ccv 0184 E EOL HEL 55 06 9 55 pO 8U 19 80021 YEZ CL 9 6 2229 3456 vc88 06 0 HC ESSE VE8L OL C C1987 O vVS OC6L OSSE 01792 OVE OOEZ COEL 29 OOEL 0ctv 009 UCL L L6SXC8LXOCV OVHY S v HIS 0401 0062 OOEL lvcL 926 OCl 000 0009 POLLL vct 0872 v6 o0L EL 65 06 9 ES pO 8U 19 66 YEZ CL 9 6 2229 3456 0 YESS 06 0 8 C EG 006 0024 01792 OVE OOEZ COEL C9 OOEL UCRT 009 UCL L L6SX78LX0CV OVHY S v HLS OOL OSEZ OSCL PELL L68 9IL L6 H9 V fq46V f10009 LL rccv 0704 v6 0L EL 55 06 9 ES p GU 19 607041 CEZ CL 19 CX0L X 69L E ESSE VESL 61 C C LS O 6L 0004 01792 OVE OOEZ COEL 29 OOEL 0ctv 009 UCL L L6SXC8LXOCV OrHd V HIS OOL 00cc OOLL 6v0L 8 COL b H9o V fqs8V f10009 LL PCC 0299 v6 01 EL 565 06 955 pr Z 8L 19 907041 79 EZ C 9 C CX0L X 69L ESSE VE8L EL C C 026 001 01792 OVE 00 COEL C9 OOEL UC KD 009 UCL L L6SXC8LX0CV OrHd V HIS OOL OOLZ 0001 6 H9o V fq8 V f10009 0L llr 0099 p6 0L EL 64 06 9 ES vc GU 19 807041 2952 CL 9 amp CX9L X 9L ESSE VE8L 61 C C 026 000 01792 OVE OOEZ COEL 29 OOEL OCEV 009 UCL L L6SX78LX0CV OVHY p YIS GL 0002
46. codes and application requirements All signal wiring must be run in separate steel conduit A wire tray is not suitable The minimum spacing between conduits containing different wire groups is 76 2 mm 3 in Belden 87601 Belden 3770 Belden 9460 A wire tray is not suitable Belden 87601 Belden 9460 Belden 9463 The minimum spacing between conduits containing different wire groups is 76 2 mm 3 in Rockwell Automation Publication 6000 INOO6B EN P November 2015 121 AppendixC General Wire Categories Notes 122 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Appendix D PowerFlex 6000 Dimensions and Weights For IEC Overview Dimensions mm W1 Width of Cabinet 1 Isolation Transformer section W2 Width of Cabinet 2 Power Module section and Low Voltage Control section W Total width D1 Depth of cabinet base footprint D2 Depth of doors beyond cabinet base D Total depth including door depth H1 Height of Cabinet H2 Height of Fan H Total height including fan Weight kg M1 Weight of Cabinet 1 Isolation Transformer section A 02 Jl p M2 Weight of Cabinet 2 Power Module section and Low Voltage Control section C N Total weight Tgl Rockwell Automation Publication 6000 INOO6B EN P November 2015 123 PowerFlex 6000 Dimensions and Weights For IEC Appendix D vC8S vC8S vC8S vC8S vC8S PCR PCR EBBE 88t EBBE 88t 88t
47. control equipment from power sources and confirm discharge of stored energy in capacitors If it is necessary to work in the vicinity of energized equipment the safety related work practices outlined in Electrical Safety requirements for Employee Work places must be followed Before attempting any work verify the system has been locked out and tested to have no potential SHOCK HAZARD Connecting to potentially energized industrial control Lockout and tagout the input circuit breaker before performing any electrical connection work After the input circuit breaker cabinet doors are opened immediately test the outgoing connections and any components connected to medium voltage with a live line tool hot stick while wearing high voltage gloves Pay special attention to any capacitors connected to medium voltage that can retain a charge for a period of time Only after the equipment has been verified as isolated and de energized can subsequent work be performed Even though the input to the drive may be open it is still possible for hazardous voltage to be present Refer to national and local safety guidelines for detailed procedures on how to safely isolate the equipment from hazards Rockwell Automation Publication 6000 INOO6B EN P November 2015 67 Chapter5 Drive Electrical Installation For IEC Electrical Drawings Grounding System Requirements 68 ATTENTION The national and local electrical codes outline provisions for saf
48. dimensions IMPORTANT See Mounting Clearance Distance on page 34 to verify that the fans have the appropriate clearance distance on top of the cabinet Table 14 Fan Housing Specifications Model Dimensions HxWxD approx Weight approx RH40M 340 x 440 x 500 mm 13 4 x 17 3 x 19 7 in 20 kg 44 1 Ib RH45M 380 x 490 x 550 mm 15 0 x 19 3 x 21 7 in 25 kg 55 1 Ib 1 Place the fan housing on the top plate of the drive making sure the socket is on the same side as the aviation plug 2 Secure the fan housing using M6 hardware 6 places See Torque Requirements on page 119 3 Connect the aviation plug located on top of the cabinet with the socket on the fan housing Figure 44 Main Cooling Fan Housing Main Cooling Fan Housing M6 Tapping Screw 4 places per fan M6 Bolt 6 places per fan Socket Aviation Plug Rear View s Table 15 Power Module Specifications Type Output Rating Amps Dimensions HxWxD approx Weight approx Fixed mounted lt 150 A 420 x 182 x 597 mm 16 5 x 7 2 x 23 5 in 30 kg 66 1 Ib 151 200 A 420 x 260 x 619 mm 16 5 x 10 3 x 24 4 in 50 kg 110 2 Ib 64 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Air Conditioning Sizing Drive Mechanical Installation For UL Chanter 4 If the drive is located in an enclosed space install air conditioners for each drive A general formula to calculate air conditioner power required DriveRatin
49. for longer cable distances but must be specified at the time of order All input and output power wiring control wiring or conduit must be brought through the conduit entrance holes of the cabinet Use appropriate connectors to maintain the environmental rating of the cabinet Voltage drop in motor leads may adversely affect motor starting and running performance Installation and application requirements may dictate that larger wire sizes than indicated in national and local electrical codes are used Wire sizes must be selected individually observing all applicable safety and national and local electrical codes The minimum permissible wire size does not necessarily result in the best operating economy The minimum recommended size for the wires between the drive and the motor is the same as that used if a main voltage source connection to the motor was used The distance between the drive and motor can affect the size of the conductors used Consult the Electrical Drawings and appropriate national and local electrical codes to determine correct power wiring If assistance is needed contact your local Rockwell Automation Sales Office Rockwell Automation Publication 6000 INOO6B EN P November 2015 Control Signal Wiring Design Considerations Drive Electrical Installation For UL Chapter 6 Use shielded cables for all the analog and digital control cables Steel conduit or a cable tray can be used for all PowerFlex 6000 drive powe
50. identified by the customer specific Dimension Drawing Rockwell Automation Publication 6000 INOO6B EN P November 2015 87 Chapter 6 88 Drive Electrical Installation For UL Figure 56 Power Cable Entry Locations in the Isolation Transformer Cabinet Incoming Line Cables Outgoing Motor Cables The drive is supplied with the following provisions for power cable lugs Table 19 Power Terminals Incoming Line Cable Connections L3 Outgoing Motor Cable Connections W IMPORTANT Ifan optional Bypass cabinet is supplied the incoming line and outgoing motor cable connections are in the Bypass cabinet Refer to publication 6000 UM002 EN P Figure 57 shows typical connection points for the primary entrance exit cable Connect the three phase medium voltage inputs L1 L2 and L3 to the user provided input three phase AC power Connect three phase medium voltage inputs U V and W to the user provided three phase asynchronous motor Cable clamps are provided in the cabinet to aid in routing and supporting the incoming line and outgoing motor power cables Rockwell Automation Publication 6000 INOO6B EN P November 2015 Drive Electrical Installation For UL Chapter 6 Figure 57 Isolation Transformer Cabinet Fixed mounted Power Module Configuration without Bypass Cabinet Door Position Limit Switches L3 L2 L1 STET tt e ble ble D Cable Clamp D
51. in this manual You can contact Customer Support for initial help in getting your product up and running United States or Canada 1 440 646 3434 Outside United States or Canada Use the Worldwide Locator at http www rockwellautomation com rockwellautomation support overview page or contact your local Rockwell Automation representative New Product Satisfaction Return Rockwell Automation tests all of its products to help ensure that they are fully operational when shipped from the manufacturing facility However if your product is not functioning and needs to be returned follow these procedures United States Contact your distributor You must provide a Customer Support case number call the phone number above to obtain one to your distributor to complete the return process Outside United States Please contact your local Rockwell Automation representative for the return procedure Documentation Feedback Your comments will help us serve your documentation needs better If you have any suggestions on how to improve this document complete this form publication RA DU002 available at http www rockwellautomation com literature Rockwell Automation maintains current product environmental information on its website at http www rockwellautomation com rockwellautomation about us sustainability ethics product environmental compliance page Medium Voltage Products 135 Dundas Street Cambridge ON N1R 5X1 Canada Tel 1 519 740 410
52. oee oo zo joi ooo oooz me e ose se u cone veel ot quer z6 ov osse on oec oove zoei zo ooer oooz onc ose os sr cone veo e z ever ne owc oxi ooz oez oc ever zo onc ooz os o ws i ss cove veel ot z quer a6 ov ove osi ose onc oee onc zo ooo oooz onc os oss om o os cone veel ot os ais ov oc oez oee oove eset zo ooer ooo oooz ooo oos oes oor vs sr ct He SL oor ee a oo ff om 0 oe cone veel z quer ais orf owe ox ooz oez oee onc esc zo oooz ooz oor ozv oze amp o cone veel oi os ais or fose oooe onz occ ooz zoei zo ooer ooo oooz ooz sse oe oc sc cone ot z os cis orf foree o osor oez orc ever zo over ooo oooe ooe oze oc amp g PowerFlex 6000 Dimensions and Weights For IEC 339 vesi ES t l L 09 0981 0061 oezz oee mez cori zo oer ooo 0002 oooz og ox wz o g wi sn ae WD s P uo MO JAly 630 mm 810 Om Bugu Bugu 15 0 sduiy oy L m Dy 4913M suoisuawig 1030W ed and
53. output 18 Pulse Configuration 9 Power Cells 124 3300V AC Input Bypass Cabinet 144 3300V AC Input Output 18 Pulse Configuration 9 Power Cells 125 4160V Input amp 4000 4160V AC Output 24 Pulse Configuration 12 Power Cells 133 140 6000V AC Input Bypass Cabinet 144 6000V AC Input Output 36 Pulse Configuration 18 Power Cells 126 6600V AC Input Bypass Cabinet 144 6600V AC Input Output 36 Pulse Configuration 18 Power Cells 127 6600V Input amp 6000V AC Output 36 Pulse Configuration 18 Power Cells 134 140 6600V Input amp 6300V AC Output 36 Pulse Configuration 18 Power Cells 135 140 6600V Input amp 6600V AC Output 36 Pulse Configuration 18 Power Cells 136 140 6900V Input amp 6000V AC Output 36 Pulse Configuration 18 Power Cells 137 140 6900V Input amp 6300V AC Output 36 Pulse Configuration 18 Power Cells 138 141 6900V Input amp 6600V AC Output 36 Pulse Configuration 18 Power Cells 139 141 Documentation box 16 32 Electrical Drawings 68 82 Drawout Power Modules Air Flow 56 Cable Routing and Connection 99 Dimensions 52 Fan Wiring Bundles 102 Installation 51 Lift cart 51 Motor Cable connection 101 Output Rating 52 Shipping Splits 46 Voltage Sensing Board connection 101 Weight 52 Drive Electrical Installation 67 81 Cable Connections 99 111 Cable Insulation Rating 69 83 Cable Routing 99 111 Control Power Wiring 76 89 Control Power Wiring In
54. to drive shall be of pulse type with a duration of 3 seconds Connection marked with dotted line shall be in the customer s scope of supply Rockwell Automation Publication 6000 INOO6B EN P November 2015 148 Power Cabling and Control Signal Wiring Details For IEC Appendix G Standard Input Output Connection Points Table 57 1 0 Connections related to High Voltage Cabinet Serial Number Name of I 0 Connection A AO foo Note 1 Input circuit breaker closing node is allowed 1 Serially connected into the input circuit breaker s closing circuit the VFD 917 918 provides passive normally open points valid when closed 2 Trip connection points within the VFD 1 Can be connected into input circuit breaker s closing circuit in parallel the VFD 919 920 provides passive normally open points valid when closed 3 Input circuit breaker already closed Circuit breaker s auxiliary normally open connection points valid when dosed connection point 117 119 Table 58 1 0 Connections related to Remote Distributed Control System garg Ws SpeQ240 ft User provided 4 20 mA spare tf User provided 4 20 mA spare spre User provided 4 20 mA spare 2 VFD speed feedback signal 927 928 VFD provided 4 20mA 3 VFD current feedback signal 925 926 VFD provided 4 20mA 4 Alternate start command signal 431 401 User provided normally open passiv
55. 0 Fax 1 519 623 8930 Online www ab com mvb Allen Bradley Rockwell Software Rockwell Automation and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies www rockwellautomation com Power Control and Information Solutions Headquarters Americas Rockwell Automation 1201 South Second Street Milwaukee WI 53204 2496 USA Tel 1 414 382 2000 Fax 1 414 382 4444 Europe Middle East Africa Rockwell Automation NV Pegasus Park De Kleetlaan 12a 1831 Diegem Belgium Tel 32 2 663 0600 Fax 32 2 663 0640 Asia Pacific Rockwell Automation Level 14 Core F Cyberport 3 100 Cyberport Road Hong Kong Tel 852 2887 4788 Fax 852 2508 1846 Publication 6000 INO06B EN P November 2015 Supersedes Publication 6000 INOO6A EN P April 2014 Copyright 2015 Rockwell Automation Inc All rights reserved Printed in Canada
56. 0072 6192429024007 OVHY 9 C MIS O8L 008 0620 OSIC v09L 802 VL H9fv favzLV n0009 Z7SSEL T667 O9SOL v6 0L HEL 65 06 9 9 pO 8L L9 CC v00 IEZ 19 99 vOl 0Lxec oL E YSS 0SZ7 8 YESS 0SZ7 8 8 vV 0919 09 009p 01792 OVE 0080 COEL C9 OOEL 00622 009 0072 6192429024007 OVHY 9 C MIS O8L 00 000 6L6L CtVL 981 SSL HO V fQSsL V f 10009 VELEL PZZ 0169 v6 oL HEL 65 06 9 55 r GU 19 800040 29 20 CL 9 CX0 X 69L E YESS 06 0 HC YESS 0SZ7 8 6 v 9 0 68 OC6L OSOL 01792 OVE OOEZ COEL 29 OOEL 0ctv 009 0cLL L6SXC81X0CV OVHY 9 S HIS OSL 000 OSZL 699 LVCL C91 GEL HOFV fGSELV N0009 t6971 ccv 0 9 v6 oL HEL 65 06 9 ES p GU 19 80021 2952 CL 9 S E7XOLZXES 9L YESS 06 0 8 ESSE VE8L OL C 6 119 0 4 85 OC6L 069 0v9c OVE OOEZ COEL C9 OOEL 0ctv 009 UCL L L6SXC81X0CV OVHY S v HIS OSL 0087 SE9L LOSL SOLL 9CL H9fV q9cLV f10009 pSZZL vccv 0509 56 0 HEL 55 06 9 55 rT GU 19 600040 290 CL 9 S E7XOLZXES 9L ves 06 0 HC ESSE VE8L OL C 1609S 0 66 026 OSOE 01792 OVE OOEZ COEL C9 OOEL 0ctv 009 0cLL L6SXC81X0CV OVHY S v HIS 001 0092 OOSL EEVL 690L 6EL OLL H9fV fd9LLV N0009 PEUZ LU
57. 009 LV f10009 H9 V 4dSS 1 V f10009 H9 V 4dSt LV f10009 H9 V 4d9c LV f10009 H9 V 4091 LV f10009 H9 V 40001V f10009 H9 V 40 6V 10009 H9 V 4dS8V 10009 H9 V 408 V f10009 H9 V 4069V 10009 H9f VQ c9V 10009 H9 V dvSV f10009 H9 V 4Q0Zv V f10009 H9 V 4d6 V 10009 H9 V 4dStV 10009 H9 V 4d1 V f10009 jequiny 60 6 6 Rockwell Automation Publication 6000 INOO6B EN P November 2015 138 Appendix E PowerFlex 6000 Dimensions and Weights For UL 87041 8088 OOZEL v6 0L r 5506 ES rec 819 CC v0C 29 50 1998 L vCXLE OLXES OL E POR 06 0 8 vcu6 OPLA Ov L 0009 0996 OVE 00 0 CIEL C9 00 OOCS 009 0044 619Xc9cXQCy OrHd 9 c HIS 00c 006v 0090 009c Ov6L Orc 000 f9fV 4000cV f0009 828 8089 0001L v6 0L r 55 06 9 85 rec 8L 19 CC v0C 29 50 1998 LE vCXLE OLXES OL 2 YESS 09 0 8C 8 8 0v 9 Ov L 0006 0 96 OVE OO0tC CIEL c9 OOEL OOCS 009 0024 619Xc9cXQcCy OrHd 9 c diS 00c 006 OSEC jOStC tS L 810 fof V 40c8LV f0009 CLLEL 2662 0801 v6 0L rE U S706 9 85 rec 819 CC v0C 09 50 1998 LE vCXLE OLXES OL YESS 09 0 8C 9tiy8 0979 09 0065 099 OVE ODE CIEL C9 00 OOCS 009 0024 6LOXCOCXOCY OrHd 9 c HIS 08L 008 OSCE 0520 089 80
58. 01 902 VFD provided normally open passive dry contact voltage class lt 220V AC 5 A used for Remote DCS Circuit breaker closing indication 903 904 VFD provided normally open passive dry contact voltage class lt 220V AC 5A used for Remote DCS Rockwell Automation Publication 6000 INOO6B EN P November 2015 149 AppendixG Power Cabling and Control Signal Wiring Details For IEC Table 58 1 0 Connections related to Remote Distributed Control System Continued Serial Number Name of 1 0 Connection EA RM Note VFD alarm indication 905 906 VFD provided normally open passive dry contact voltage class lt 220V AC 5A used for Remote DCS VFD fault indication 907 908 VFD provided normally open passive dry contact voltage class lt 220V AC 5A used for Remote DCS VFD operation indication 909 910 VFD provided normally open passive dry contact voltage class lt 220V AC 5A used for Remote DCS VFD stop indication 911 912 VFD provided normally closed passive dry contact voltage dass lt 220V AC 5A used for Remote DCS VFD ready indication 913 914 VFD provided normally closed passive dry contact voltage class lt 220V AC 5A used for Remote DCS Remote DCS control indication 915 916 VFD provided normally closed passive dry contact voltage class lt 220V AC 5A used for Remote DCS 13 VFD allow closing indication 135 121 VFD provided normally closed active dry contact voltage class lt 220V AC 5A spare
59. 015 Drive Electrical Installation For UL Chapter 6 When the doors of the Power Module LV Control Cabinet or Isolation Transformer Cabinet are not closed when the drive is being maintained or when the control power switch is not closed the drive will not send a signal allowing the input circuit breaker to close this is wired as a permissive contact in the input circuit breaker s closing circuit so that the input circuit breaker cannot close Wire Routing and Connection The electrical safety interlock control signal wiring enters the drive through the same opening as the control power wiring in the bottom of the LV Control Cabinet Figure 58 The wiring terminates to the DTBI terminal block strip on the right side of the LV Control cabinet Figure 59 See Figure 87 or Figure 88 for general information Refer to Electrical Drawings for actual connection points Rockwell Automation Publication 6000 INOO6B EN P November 2015 93 Chapter6 Drive Electrical Installation For UL Notes 94 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Chapter Drive Electrical Interconnection For IEC Introduction The drive is shipped in two sections the Isolation Transformer cabinet and the Power Module LV Control cabinet An optional bypass cabinet may also be supplied Chapter 2 describes mechanically joining these cabinets together This chapter describes the activities required to electrically connect these drive c
60. 061 Rockwell Automation Publication 6000 INOO6B EN P November 2015 134 Appendix E PowerFlex 6000 Dimensions and Weights For UL c m Cc C4 C4 c c Lo EBBE EBL 6 L OrHd t H9 V fqQZtV f10009 v6 0L SECXOL LXEG 9L 00 2 0590 L6SXC81X0CV v6 0L SECXOL LXEG 9L 0097 0590 L6SXC81X0CV ccv 0055 56 0 620 9 4656 9 0c6L 0066 0590 L6SXC81X0CV v6 0L 620 9 456 9 0v9c L6SXC81X0CV 00vc pw fiw cu x c N N c LLY 9S A o a mM s en en en N EBBE EBL 6L OrHd t H9 V fq6t V f10009 EBBE EBL 6 L 605 OCE H9 V fqStv f10009 EBBE EBL 6 L 98 H9 V fqLeV f10009 up s s w Aly 830 yuawasinbay 8ZOZL 878 OOZEL 76 E0L E vOXLEOLXES 9L rcs 06 0 8 YESS 06 0 8 VCCL6 OYLA OVZL 0009 0192 619XcocXQCy OVHY 9 C MIS 002 0067 0090 890 58 ObC 002 Ho V fq00cV f10009 87871 9285 000LL F6 0L E vOXLEOLXES OL YESS 06 0 8C YSS 0SZ7 8 9 8 8 OvZ9 Or L 000S 0192 6192429024007 OVHY 9 C HS 000 006 OSET 920 91 8lC Ho9 V fQC81V f 10009 ZZLEL 7662 08401 76 0L 9L E vOXLEOLXES OL YESS 06 0 8 YESS 0SZ7 RC OELV8 0979 09 006b 01792 00
61. 25 009 ooz 61992025 OPHU 9 C WIS TSSEL 2662 09501 v6 01 5 65 06 o rz 8115 22 02 9 0 19 99 LE VZXLEOLXES 9L g8 pL 0919 0981 0085 oroz OPE 0080 zosi C9 OOEL 0025 009 ooz 619202 OHY 9 Z WIS VELEL ZZY 0168 r6 01 EL 65 06 985 prz 8119 80070 IEZ CL 19 S EZXOL LXES 9L 66759 0165 0 61 osor oroz ore ooez ZIEL zo 0041 oze 009 ozz 60902 ObHY 9 WIS 56961 YZZY 0158 v6 01 EL 65 06 9 rc 98119 80070 CEZ CL 9 S EZX9L LXES 9L 65119 01 5 0 61 058 oroz OPE 008 zosi zo OOEL ozer 009 ozz L6SXZBIXOZY OvHW S 55041 ZER 0508 v6 01 EL 65 06 9 rZ 98115 80070 c9 O CL 9 S EZX9L LXES 9L 6095 0155 ozel 059 ovoz ove 008 cC9EL z9 OOEL Ozer 009 ozzl L69Xtglx0cp OVHY S v WIS 5041 ZER 0187 r6 01 EL 65 06 9 ES rc 8119 80070 CIE CL 19 S EZX9L LXES 9L 98 OLS ozel osse ovoz ove 0086 COEL C9 OOEL ozer 009 OcLL L6SXZBIXOZY ObHY S r WIS POLLL rcv 0851 v6 01 EL 65 06 ES rc 98119 66 71 9 50 CL 9 S EZX9L LXES 9L ploy 0285 ozel oore ovoz ove 008 COEL C9 OOEL 0255 009 ozzl L6SXZBIXOZY OvHW S v
62. 3 x 7 9 240 mm 500 AWG 8 kV or 185 mm 350 AWG 15 kV phase 6300 V 50 60 Hz 1150 x 200 45 3 x 7 9 240 mm 500 AWG 8 kV or 185 mm 350 AWG 15 kV phase 6600 V 50 60 Hz 1150 x 200 45 3 x 7 9 240 mm 500 AWG 8 kV or 185 mm 350 AWG 15 kV phase Maximum Load 2300 2400 V 50 60 Hz 1150x200 45 3x 7 9 300 mm 600 AWG 5 kV or Cable Sizes 240 mm 500 AWG 8 kV phase 4000 4160 V 50 60 Hz 1150x 200 45 3 x 7 9 300 mm 600 AWG 5 kV or 240 mm 500 AWG 8 kV phase 6000 V 50 60 Hz 1150 x 200 45 3 x 7 9 240 mm 500 AWG 8 kV or 185 mm 350 AWG 15 kV phase 6300 V 50 60 Hz 1150 x 200 45 3 x 7 9 240 mm 500 AWG 8 kV or 185 mm 350 AWG 15 kV phase 6600 V 50 60 Hz 1150 x 200 45 3 x 7 9 240 mm 500 AWG 8 kV or 185 mm 350 AWG 15 kV phase 1 Cable sizes are based on overall dimensions of compact stranded three conductor shielded cable common for industrial cable tray installations Maximum sizing stated accounts for minimum rated cable insulation requirements and the next higher rated cable i e 8 kV is not commercially available in many areas of the world therefore Rockwell Automation provides an 8 kV minimum rating as well as a 15 kV rating when applicable Enclosure openings will accommodate the thicker insulation on the higher rated cable IEC ratings show the equivalent to the NEMA sizes The exact cable mm size shown is not commercially available in many cases use the next smaller standard size
63. 6 L N 660 0087 026 006 0596 OVE 00 60 COtL C9 OOEL Octv 009 OCI L6SXTSLXOCY OrHd L diS SZ 006 008 008 0297 0009 Y8EOL rccv 0919 56501 EL 55 06 9 85 HH Z 8L 19 807021 290 C 9 SECXOLLXES 9L E EBBE EBL 6 L ILLIC 007 006 0086 099 OVE O0tC CIEL C9 OOEL Octv 009 OC L6SXC81XO0Ct OrHd YIS SZ 008L 00 7 00 4 CCS v9 vS fOf V NQvSV f10009 99101 rccv 0 65 v6 01 EL 55 06 985 HH Z 8L 19 807021 2940 C 9 SEZXOLLXES9L E EBBE v 8L 6 L 9tvcc 009 006 0010 0996 OVE O0tC CIEL C9 OOEL Octv 009 OCA L6SXC81XO0Ct OrHd diS SZ OOZL UR 70 0009 7 6 ccv 0615 96 01 EL 6506 985 rec 8L L9 807021 2940 C 9 SECXOLLXES OL EBBE v 8L 6 L L 698L OcSy OC6L 009 099 OVE OOEC EL C9 OOEL Ocet 009 OCA LOSXC8LX0CV OrHd diS Ov 009 005 00S E 9 6t f9 V 406EV f10009 9216 vccv 0055 v6 0L EL 55 06 9 S rec 8L L9 807041 CSE C 9 S CX9 IES 91 EBBE v 8L 6 L L C89L Drp 0c6L 0056 OV9C OVE OOEC C9EL c9 OOEL Ocet 009 OCA L6SXT8LXOCY OrHd t URP SEE CY S 9f V 40S V 10009 6 209 745 9 L6SXC81X0CY C4 MS Mo 2
64. 62 3 6 Rockwell Automation Publication 6000 INOO6B EN P November 2015 124 Appendix D PowerFlex 6000 Dimensions and Weights For IEC 86 0S C EBBE HESI Fee OM 0986 O9EL 006 OELZ oge 0090 CIEL EB 00tL 0077 0002 0054 UR LC 006 OCLI EN 08 vC88 0S C EBBE HESI AES 0966 O9EL 002 OtZC ose 00vc 29 r3 00tL 0077 0002 0054 0861 0602 095 OSE vC8S 04 0 FIRT EBBE PEBL EX MO 09 6 0981 0007 OtZC og 00vc CIEL ES 00tL 0077 0002 0054 OS L 0 81 00 a GLE vC8S 06 6 8 EBBE HESL 61 09246 O9EL 0066 04 6 OEE OOK COEL c9 OOEL 00 0002 005 0591 09 OCEL 09t 00 C C vc8S8 0S C sel xw EBBE HESI el m 0906 O9EL 00 t OtZC oge 0090 CIEL ES 00tL 0077 0002 00542 KLL 0891 09 r3 087 vc88 04 0 EAE EBBE PEBL a e 0987 O9EL OOSE OELZ oge 0090 CIEL EB 00tL 0077 0002 0054 00 0051 Ocll OSC PCBS 06 6 8 C EBBE HESL OL C 0 9 O9EL OSCE 04 6 OEE OOFZ COtL c9 OOEL 0057 0002 005 RRC L OSEL OLOL OLC SCC suey 10 12 EBBE HESL 61 aT MOUUIV 16101 TM MOjjJAly E30 sue 007 6y 34519M na na l Guneysonog ww 015 6 1030W jOid 3ndingovy Y Y SIJ9 1 Mog 6 uonean yuo es ng 8L ndyng n
65. 8 L G GE Gr E D G GET OOGO Locking Key Eu N L SIDEVIEW pin The cam mechanism will catch the pin on the tray assembly 6 Continue rotating the locking key until the Power Module is fully seated This ensures the finger assemblies at the back of the Power Module are fully connected to the stab assemblies at the back of the Power Module compartment Cam Mechanism Actuator Locking Key 6 4 TOP VIEW Cam Mechanism Pin ATTENTION The Power Module finger assemblies must be fully seated on the cabinet stab assemblies 54 Rockwell Automation Publication 6000 INOO6B EN P November 2015 External Ducting Drive Mechanical Installation For IEC Chapter 3 The PowerFlex 6000 design can accommodate ducting exhaust air outside of the control room ATTENTION The Isolation Transformer Cabinet and the Power Module LV Control Cabinet must be ducted separately The following requirements are mandatory design requirements for systems that will externally duct the exhaust air and draw cleansed outside air e External ducting including an external filtering system must not add more than 50 Pa 0 2 in of water pressure drop to the PowerFlex 6000 drive air flow system Ensure a minimum top clearance of 1000 mm 39 4 in above the drive top plate e The control room must provide slightly more make up air creating a pressurized room This slight pressurization prevents unfiltered air drawing into the room
66. 913 914 1 VFD provided normally open passive dry contact voltage class lt 220V AC 5A used for Remote DCS Remote control indication 915 916 1 VFD provided normally open passive dry contact voltage class lt 220V AC 5A used for Remote DCS 13 VFD allow closing indication 941 941A 1 VFD provided normally closed passive dry contact voltage class lt 220V AC 5A used for Remote DCS Circuit breaker closing indication 942 942A 1 VFD provided normally closed passive dry contact voltage class lt 220V AC 5A used for Remote DCS VFD alarm indication 943 943A 1 VFD provided normally closed passive dry contact voltage class lt 220V AC 5A used for Remote DCS VFD fault indication 944 944A 1 VFD provided normally closed passive dry contact voltage class lt 220V AC 5A used for Remote DCS VFD operation indication 945 945A 1 VFD provided normally closed passive dry contact voltage class lt 220V AC 5A used for Remote DCS VFD stop indication 946 946A 1 VFD provided normally open passive dry contact voltage dass lt 220V AC 5A used for Remote DCS VFD ready indication 947 947A 1 VFD provided normally closed passive dry contact voltage class lt 220V AC 5A used for Remote DCS Remote control indication 948 948A 1 VFD provided normally closed passive dry contact voltage class lt 220V AC 5A used for Remote DCS 154 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Appendix Line
67. CB MV Closed MV Opening Warning Fault Drive Running Drive Stop Ready Control MV Closed Warning Fault Drive Running Drive Stop Ready DCS Control Bypass Choice Drive Choice Pre closed CB CB Open Emergency Stop 3 VIS SISISIS o N sO p 4e 3v Ss L____1 m p o mw Q 1 Oo Ci O Gi ca Gu 1 SSSSSSSSS S Cd 1 T EERTE LIIE Mitt dl 11111 OO Olio 5 eI G VVS SIS O 00 SISISIS ce o wo S N S Ci S S o CA o C o S S o o a G U L U L Y o I YYY lal YYY 2 920 DO 24V DC DCS Fault reset Spare Spare Spare Spare Spare Spare Spare Spare From Remote DCS Spare Spare DCS Start DCS Stop Spare Drive to Bypass Bypass to Drive Drive Choice Bypass Choice Output Current To Remote DCS 4 20 mA Output Frequency 4 20 mA Speed Input 4 20 mA From Remote DCS Anlg Input 4 20 mA lt spare Anlg Input 4 20 mA spare KM1NO KM2NO KM3NO KM1NC KM2NC KM3NC QS1NO QS2NO QS1NC QS2NC NOTE 1 4 20 mA shielded cable from customer input shall be grounded at the inverter side Remote DCS DI input
68. Control Cabinet Shipping and Handling Procedures For IEC Chapter 1 The preferred method of lifting the cabinets is an overhead crane If overhead lifting with a crane is not available use a fork lift with a capacity greater than the cabinet weight Lift the cabinet using the overhead lifting angles or isolation transformer lifting provisions and suitable spreader bars and rigging attached to the fork lift IMPORTANT Close and lock the cabinet doors before moving any cabinets Two lifting angles are used for the Power Module LV Control Cabinet and are affixed to either side of the shipping skid The length of the lifting angles depends on the length of the Power Module LV Control Cabinet Table 4 Lifting Angles Length approx Weight per Angle approx 1 2m 3 9 ft 13 1 kg 29 Ib 2 0m 6 6 ft 21 9 kg 48 Ib 2 4m 7 9 ft 26 3 kg 58 Ib 3 5 m 11 6 ft 54 6 kg 120 Ib 42 m 13 6 ft 64 1 kg 141 Ib 49 m 16 1 ft 125 x 80 x 10 mm 4 9x3 1x0 39in 75 8 kg 167 Ib Install the Lifting Angles IMPORTANT Labeland retain all lifting related hardware if the drive system may be moved in the future ATTENTION Failure to install the pair of lifting angles prior to moving the drive may result in personal injury and or equipment damage The lifting angles hold the Power Module LV Control cabinets together to prevent separation and damage while riggers move the drive to the final installation area The lifting angles
69. Dimensions and Weights For IEC 19 cy cees Ly ave 0066 sc 006 sc TAE ANTE oose se 006 sc m osc ez ws osz 8z wes osz 8z ress ose ez wes osz 8z wes osz ez vees osa ez 8 veal L 8 veal Gl mr vest ou cone veal 61 8 veal 61 eens cv v oot se e osor osve 0 ozz oze oove zosi zo oces oese Oc oger ocre vos Or v caw oose se e ooee ooo ove oor casi zo oses oese oz 04 osr ose v se e ove o ove oove casi zo oses oese over ooze ozr ose ever vec ve z os ove oove coer zo over oses oese oz osce ooge sze sie ever vec ve z coe osos ove oove coer zo over oses oese oz 09 ose oc ose ooe ever vece vz y onc oss ove oove coer zo over oses oese osie 08 ozsz ose onc even vec vz z ove oove coer zo over oses oese oz oooe onze ove ose ever vec vz z oez occ oove voc zo over oses oes owz osse oor or scc save veo or z onc oov oez oee oove caer zo over
70. EBBE 88t 88t ERNE ERNE Wd 04 6 FAN EBBE vt8l Lap 09 56 O9EL 0007 DEL oc 00vc C9EL o DUEL O0vv 000 O0vC 0004 OrLc 0091 och 08E 04 6 t EBBE vt8l 0925 O9EL 006 Ot C r 006 C9EL o DUEL O0vv 000 O0vC 0081 0 6 Ovrl v OSE 04 6 t EBBE vt8l Per oz 0906 O9EL 00 t OtZC EA 005 C9EL o DUEL 0057 0007 O0vC 0091 OLZL 0821 ae SLE 09 6 8 EBBE PEBL pL 098 09tL OOST OELZ Ott 0020 COEL CO 00tL 00 0004 0056 0081 0091 OOZL 09 00 C C 09 6 esl EBBE vt8l alt 0018 09tL OSPE OtZC E 006 COEL o DUEL O0vv 0002 O0vC 00v 005 OCLL 9x 084 04 6 t EBBE vt8l alt 09 6 09tL 0050 OtZC E 00vc COEL o DUEL O0vv 000 O0vC 0Scl OrtL 0001 wx 044 06 6 8 EBBE PEBL pL OLLE O9EL OSEC OtZC OEE 00520 COEL CO 00tL 00 000 0050 OSLL OECL 026 0 4 SCC Za x ia P R E C E P P C 2 XX MN a laas les om ote we w owe ser s wm onee ous owe os ww om ot v88l 6l MOJ E30 cM sueJ Jo suey 6 MOjJAly 30 puey y sduiy 6y 3 615 ow o O J9ulJ0JsueJ jndinoy vy uioo 9 uu C E ue we mel w Li suey Jo u0 Jaquinyy suoisuawig S119 4aMog 6 UOLJeANBIJUO 55 8L JY A000
71. Handling Procedures For IEC Figure 2 Lockable Cabinet Handles Drive Configurations There are two basic power cell configurations offered in the PowerFlex 6000 product line For a drive amperage rating 200 A a fixed mounted power module design is supplied Fixed mounted modules are shipped installed in the drive For a drive amperage rating of 200 A a drawout power module design is supplied The drawout power modules are removed from the drive before shipment and shipped in separate crates The cabinets may appear slightly different than shown in the illustrations based on voltage class and whether the drive configuration has fixed mounted or drawout power modules see Figure 31 and Figure 32 Shipment List The complete shipment will consist of a number of crates as shown below Table 1 Shipment Configurations VFD Motor Voltage Class Bypass Cabinet Isolation Transformer Power Module Power Modules Power Module Main Cooling Fans and Amp Rating optional Cabinet LV Control Cabinet Lift Cart 3 3 3 kV 6 6 6 kV 10 kV 1 The document hardware box contains e PowerFlex 6000 Medium Voltage Variable Frequency Drive User Manual 6000 UM001_ EN P e PowerFlex 6000 Medium Voltage Variable Frequency Drive Commissioning Manual 6000 IN007 EN P e PowerFlex 6000 Medium Voltage Bypass Cabinet User Manual if supplied 6000 UMO002 EN P e Testing Reports Electrical Drawings EDs and Dimensional Drawings
72. Installation Instructions Allen Bradley PowerFlex 6000 Medium Voltage Variable Frequency Drive Shipping Handling and Installation Manual Publication 6000 INOO6B EN P Allen Bradley RockwellSoftwae Automation Important User Information Read this document and the documents listed in the additional resources section about installation configuration and operation of this equipment before you install configure operate or maintain this product Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes laws and standards Activities including installation adjustments putting into service use assembly disassembly and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice If this equipment is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is ass
73. Jey 104 jq suods si a p 1ndur y Jo JaI ddns au 10 q parjddns Ja p 1ndui ue sapnpur yd yM w S s siu ur zuauoduo auo SI aAup 306 0 aul d35NV 1 Wiring locations are for design reference only actual wiring must comply with the drawings provided with the drive VN3W paljddns sawo sn i jeubls 0 07 1010 OL E gt gt papaau 9 Dede c unu 0173101 JNA upueJg uy eubis 0 07 30025 sawioysn zy 09 aseyd v AOZL JeyeaJg mr ureansd ZH 09 aseud M g l 151 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Power Cabling and Control Signal Wiring Details For UL Appendix H Figure 88 Terminal Strip Wiring Diagram for Drive System without a Bypass Cabinet iddns jo 30025 5 3 y ui aq eus aui 091100 YM payJeW uonsuuo E 0235 3314 Jo uoneinp e YIM ad M asind Jo aq Jeys ap o1 3ndur jg a10U9 7 3 531 3 I4 Je papunojf aq 3ndui Woy 5 papjerus vul OZ 1 ALON 8605 Qc y 0 bojeuy eds yw ozy y bojeuy yu UE E a yndu paadg A yw UC T SR jnding Aauanbe 4 P Vu QC M jnding 1uaum 71 weds ee emm dois 5 0 B 616 a 0Way s
74. L v CXLEOLXES 9L YESS 09 0 8C vC8S URLC 8C 8 8 0v 9 Ov L 0008 0996 OVE ODE CIEL C9 OOEL 0005 619Xc9cXQ0Cy OrHd 9 c HIS OOC 006 054 OStC tS L SLC CL fofV fQcaL V n0009 ZZLEL 2662 0801 v6 01 r SU 6506 9 ES rc 8U19 22702 L v CXLEOLXEG OL YESS 09 0 8C YESS 06 0 8C 9tlv8 0929 09 0065 0990 OVE OO0tC CIEL c9 OOEL 0005 00cc 619Xc9cX0Ct OrHd 9 c lS 08L 008 OSCE 0ScC OS9L 800 PLL fofV fQv LV 0009 L v CXLEOLXEG 9L UU LN p C4 D c o co o co N cc c co ce cona ce c c C4 c c Leo ZSS L 2662 O9SOL v6 01 VEL 6506 ES rc BLL 88 v 0919 09 008v 059 OVE 0040 COtL C9 ODE c C4 coo c c c up on si m D SA 9 ez sl 22 ul qxMxH juo 2 23 Eg 3 Moug iat 2S as xd P 2 Pee 2 88 sqi 6y 1ubieM 48Mog j S gt z Sdwysojow saquiny fojeze Jaquinn A 3 S cM Ww suoisueuinq 81 245 81 7 3 9 0 JY A0099 9 Indul A0099 OF 91061 Rockwell Automation Publication 6000 INOO6B EN P November 2015 136 Appendix E PowerFlex 6000 Dimensions and Weights For UL N cc c c a coa c we coa
75. MV Closed MV Opening Warning Fault Drive Running Drive Stop Ready Control MV Pre closed CB MV Closed Warning Fault Drive Running Drive Stop Ready DCS Control Pre closed CB CB Open A 24V DC R DCS Fault reset Spare Spare Spare Spare Spare From Remote DCS Spare Spare Spare Spare NW Spare DCS Start DCS Stop Spare M Spare Modbus RS485 Output Current To Remote DCS 2 4 20 mA lt Output Frequency 4 20 mA NOTE grounded at the inverter side Speed Input 4 20 mA Anlg Input 4 20 mA From Remote DCS spare Anlg Input 4 20 mA spare duration of 3 seconds customer s scope of supply 2080 SERIALISUI 1 2 3 4 8 DCD RXD TXD 485 A 485 CND RTS CTS 121212 21212 1 4 20 mA shielded cable from customer input shall be 2 Remote DCS DI input to drive shall be of pulse type with a 3 Connection marked with dotted line shall be in the 147 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Power Cabling and Control Signal Wiring Details For IEC Appendix G Typical Terminal Strip Wiring Diagram Drive System with a Bypass Cabinet Figure 86 From Customer From CB Spare To DCS To Remote DCS From Remote DCS 1 220V AC N OV AC MV Closed 220V AC N OV AC MV Pre closed
76. Motor Cable Connections W IMPORTANT Ifan optional Bypass cabinet is supplied the incoming line and outgoing motor cable connections are in the Bypass cabinet Refer to publication 6000 UM002 EN P Figure 48 shows typical connection points for the primary entrance exit cable Connect the three phase medium voltage inputs L11 L12 and L13 to the user provided input three phase AC power Connect three phase medium voltage inputs U V and W to the user provided three phase asynchronous motor Cable clamps are provided in the cabinet to aid in routing and supporting the incoming line and outgoing motor power cables 74 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Drive Electrical Installation For IEC Chapter 5 Figure 48 Isolation Transformer Cabinet Fixed mounted Power Module Configuration without Bypass Cabinet C rz V NP L11 4 W um S HH E SS fa L12 P et Door Position Z Limit Switches g L13 S 2 Voltage Sensing Board Dry type Isolation Transformer j I I i E r y a HH Uu Secondary Winding Output Terminals Iam IAN ITI U LI TRITT QT Hl ULL i Cable Clamp E m e L i a i i A ILL NNN WT bron TI TUR M AI f
77. S OC6L OSSE 0996 OVE OOEC EL C9 OOEL Ocet 009 OCA LOSXC8LX0CV OrHd S v IS OcL OOSC 00 OOEL 026 00L f9fV 40001V f10009 VOLL rcv 087 v6 oL eE U 55 06 95 HH Z 8L 19 S6 21 290 72 29 S EZX9L ZXES 9L E YESS 09 0 8C CLIP OCES OC6L OOVE 0990 OVE OOEC EL c9 OOEL OCS 009 OCL L6SXC8LXQCY OrHd S v HIS OOL OSEC OSCI 6 L6 f9f NdZ6 N0009 Pg LU rccv 0501 v6 01 HEL 55 06 9 85 HH Z 8L 19 807041 290 CL 9 SEZXOLLXES 9L EBBE v 8L 6 L tliv OCLS OC6L OOCE 0596 OVE 00 0 COtL C9 OOEL Octv 009 OCI L6SXTSLXOCY OrHd t OOLL 028 S 70587 0009 6420 9 456 9 L6SXC81X0CY co 2 ce boc N m MS URL Lp 9f V 408 V f10009 c C4 c c Mo c C4 m OrHd Y YIS OOL 0014 0Scl OOLL 0001 EBBE v 8L 6 L c c ce rc801 rccv 0099 v6 01 rE U 55 06 9 85 rec 8L 19 807021 290 C 9 S EZX9L ZXES 9L EBBE v 8L 6L VS9EE 0265 OC6L 000 0990 OVE 0080 CIEL C9 00 Octv 009 OCI L6SXC8LXQCY 0 9 9f V 4069V 10009 t0901 rccv 0889 v6 01 rE U 55 06 9 85 rec 8L 19 807041 290 C 9 ISK X 91 EBBE EBL
78. TE x 5 03 oo re e t RU paste cte s at a aa f 114 Complete the Installation us esed rere tU rona SESS 114 Appendix A Pre Commissioning Responsibilities see 115 Inspection and Verification 0 115 Pre Cominissioning Checklist 2e tdeo orco prie idea 116 Appendix B Torque Requirements onseeredioe d pisa ex 119 Appendix C General Wife C WETTE wkend ies Ped ved dis dd ben CR Void 121 Appendix D M adis RETI NES NERO 123 Appendix E CCIW suum ELLE LEM E a AU 131 Rockwell Automation Publication 6000 INOOGB EN P November 2015 PowerFlex 6000 Bypass Cabinet Dimensions and Weights For IEC only Power Cabling and Control Signal Wiring Details For IEC Power Cabling and Control Signal Wiring Details For UL Line and Load Cable Sizes Index Table of Contents Appendix F 143 Appendix G Schematic Deran Lebe deste Cac e o UNS EEEE 145 Standard Input Output Connection Points 149 Appendix H Schemat DIAGEAHIS o eed aua qutaua den qued aped a ebd IS 151 Standard Input Output Connection 153 Appendix TT 155 Rockwell Automation Publication 6000 INOO6B EN P November 2015 7 Table of Contents Notes 8 Rockwell Automation Publication 6000 INOOGB EN P November 2015 Introduction Who
79. TENTION Do not pass cables through the support holes in the lifting angles Use slings with safety hooks or shackles 2 Adjust the rigging lengths to compensate for any unequal weight distribution of load TIP There are pairs of holes to attach lifting cables on either end of the lifting angle Generally use the outside holes on either end for the greatest stability The inner holes could be used to adjust for the cabinet s center of gravity The cabinet must remain in an upright position To reduce the tension on the rigging and the compressive load on the lifting device do not allow the angle between the lifting cables and vertical to exceed 45 Figure 24 N ATTENTION Do not tilt the drive 38 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Shipping and Handling Procedures For UL Chapter 2 Figure 24 Overhead Lifting Power Module LV Control Cabinet Two Pairs of Holes for Overhead Lifting Attachments 3 Remove the steel angle brackets bolting the cabinet to the skid 4 Lift the cabinet using overhead lifting angles and remove the wooden shipping skid from under the equipment this point Do not place any parts of the body underneath the cabinet Remove ATTENTION Only lift the cabinet high enough to remove the shipping skid at the shipping skid from the work area before continuing Remove Overhead Lifting Cables and Lifting Angles When the cabinet is in the desired position remove
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81. a source destination wire number convention on point to point multi conductor wiring and in situations where the system is warranted The wire numbering system of unique single numbers for multi drop and point to point wiring continues to be used for general control and power wiring Wiring that connects between the sheets or that ends at one point and starts at another point on a drawing has an arrow and drawing reference to indicate the ongoing connection The drawing reference indicates the sheet and the X Y coordinates of the continuation point The reference system is explained on a sheet in each drawing set The unique wire numbering system serves as confirmation that the correct wire is being traced from sheet to sheet or across a drawing Wires in multi conductor cables are typically identified by color rather than by number Abbreviations used to identify the colors on the drawings are fully identified on a sheet in the drawing set As a general guideline the ground path must be of sufficiently low impedance and capacity that e the rise in potential of the drive ground point when subjected to a current of twice the rating of the supply should be no higher than 4 V over ground potential e the current flowing into a ground fault is of sufficient magnitude to cause the protection to operate Rockwell Automation Publication 6000 INOO6B EN P November 2015 Power Cable Insulation Requirements Drive Electrical Installation For UL
82. abinets components together information about connecting the Bypass cabinet to the drive is included in publication 6000 UM002_ EN P 6012DB Medium Voltage Bypass Cabinet User Manual Electrical ntercon nection Connect Internal Cabling and Wiring Page Su m mary Connect Isolation Transformer Secondary Power Cables 97 Connect Motor and Voltage Sensing Board Cables 100 Connect LV Control and Fan Wiring Bundles 102 Connect Ground Bus 105 Rockwell Automation Publication 6000 INOO6B EN P November 2015 95 Chapter7 Drive Electrical Interconnection For IEC Power Cable Interconnection Overview 96 Input power 3 phase AC any voltage Figure 61 provides a three line drawing overview of the power cable interconnections between the power modules PC XX in the Power Module LV Control cabinet and the secondary windings of the isolation transformer in the Isolation Transformer cabinet The number of power modules is dependent solely on output motor voltage e 9 power modules for 3 3 3 kV e 18 power modules for 6 6 6 kV e 27 power modules for 10 kV It also shows the connection point from the U V and W motor output phases from the power module array to the voltage sensing board cables and the motor cables The isolation transformer secondary windings as shown do reflect the actual orientation on the isolation transformer The Power Module LV Cabinet orientation is optimized for drawing clarity To better understand the physica
83. ae ov 09 oser os oez occ owc zoer z over me oc ooz oo os oos iS ss cone ve ot Jae ne ov es ooer ooze oerz oee ooz zoer z ovor oc ooz 5 os om o os cone ve ou aver ne ov 09 ser osi oez oee ow zoer z ooo ooz ooz s es oo ss s cane ek Ll fs of at fo oe e e o o foe or m e T cone ve ov Jae ane ov 08 oset occ ooz zoer z oni ovor oc ooz oo ow oze e o cone ve or Jae ane ov out os oez occ ore z oni ovor oc ooo sse oe ox ec z cone ve ot os ae ov osre ser oo occ ove zoer z over oov oc ooz oze oee ose cc s TT s WD sA MOUUIV 16101 Ps WD s TAN ERES m RE 6301 T EN Ps Tt 6y 3ubiaM juo mda wpm Guneysomog jeunojsue1 1030W ed Ind no YYY SII Jemog 8L uoneinfijuo sjnd 9 JY A0099 ZE 3 6 127 Rockwell Automation Publication 6000 IN006B EN P November 2015 vei 00111 9 tech ves es s ooz 08 0104 oze oozz toL zo ooz 0681 oser 000 00 oos 095 vos gt ves rl 0000 oz 9 eses 9v rv v 0 ooru 010 oze o
84. al safety interlock circuit is part of the overall control signal wiring activity However it is mentioned separately in this document due to its critical importance related to the safe operation of the drive and personnel safety The circuits connected between the drive and the input circuit breaker e allow the drive to trip the input circuit breaker if a drive cabinet door is opened This applies to the cabinet doors where medium voltage is present The LV Control cabinet door can be opened while the drive is energized allow the drive to prevent the input circuit breaker from closing when required e indicate to the drive when the input circuit breaker is closed MV Door Safety Interlock If the MV cabinet door is opened the Allen Bradley Guardmaster Limit Switch 440P CRPS11D4B on the cabinet door will actuate The drive will send a trip signal to the input circuit breaker to disconnect the medium voltage power supply to the drive ATTENTION The door position interlock is a safety feature It must not be used solely as a part of the plant operation process to ensure the drive has been disconnected from input medium voltage Keep the medium voltage doors locked as standard practice Always go to the input circuit breaker feeding the drive to verify if it is open Lock out and tagout the input circuit breaker before performing any work on the drive or bypass units Figure 53 Interlock for Cabinet Doors 0
85. al wiring from the sources to the drive See Figure 87 and Figure 88 for an overview of these connections Electrical interconnections are also required between cabinets that have shipped separately These are described in Drive Electrical Interconnection For UL on page 107 equipment can be dangerous Severe injury or death can result from electrical shock burn or unintended actuation of control equipment Hazardous voltages may exist in the cabinet even with the circuit breaker in the off position Required practice is to disconnect and lock out control equipment from power sources and confirm discharge of stored energy in capacitors If it is necessary to work in the vicinity of energized equipment the safety related work practices outlined in Electrical Safety requirements for Employee Work places must be followed Before attempting any work verify the system has been locked out and tested to have no potential SHOCK HAZARD Connecting to potentially energized industrial control Lockout and tagout the input circuit breaker before performing any electrical connection work After the input circuit breaker cabinet doors are opened immediately test the outgoing connections and any components connected to medium voltage with a live line tool hot stick while wearing high voltage gloves Pay special attention to any capacitors connected to medium voltage that can retain a charge for a period of time Only after the equipment has been
86. allation and application requirements may dictate that larger wire sizes than indicated in national and local electrical codes are used Wire sizes must be selected individually observing all applicable safety and national and local electrical codes The minimum permissible wire size does not necessarily result in the best operating economy The minimum recommended size for the wires between the drive and the motor is the same as that used if a main voltage source connection to the motor was used The distance between the drive and motor can affect the size of the conductors used Consult the Electrical Drawings and appropriate national and local electrical codes to determine correct power wiring If assistance is needed contact your local Rockwell Automation Sales Office Rockwell Automation Publication 6000 INOO6B EN P November 2015 Control Signal Wiring Design Considerations Drive Electrical Installation For IEC Chapter 5 Use shielded cables for all the analog and digital control cables Steel conduit or a cable tray can be used for all PowerFlex 6000 drive power or control wiring however use only steel conduit for all signal wiring ATTENTION Steel conduit is required for all control and signal circuits when the drive is installed in European Union countries Wires for digital and analog signals must be routed separately Control cables and power cables must be routed separately the distance between the control cable t
87. and Load Cable Sizes The data in the following tables are informative only do not base final design criteria solely on this data Follow national and local installation codes industry best practices and cable manufacturer recommendations As cabling methods can very widely maximum cables sizes do not account for the size of the conduit hub Table 61 Line and Load Cable Sizes for IEC Description Drive Enclosure Max Size amp No Incoming Motor V Freq Opening mm in Cables IEC 2 8 Maximum Line 3000 V 50 60 Hz 110 4 33 300 mm 5 kV or 240 mm 8 kV phase 3300 V 50 60 Hz 110 4 33 300 mm 5 kV or 240 mm 8 kV phase 6000 V 50 60 Hz 110 4 33 240 mm 8 kV or 185mm 15 kV phase Cable Sizes 6600 V 50 60 Hz 110 4 33 240 mm 8 kV or 185mm 15 kV phase 10 000 V 50 60 Hz 110 4 33 185 mm 15 kV phase Maximum Load 3000 V 50 60 Hz 110 4 33 300 mm 5 kV or 240 mm 8 kV phase Cable Sizes l 3300 V 50 60 Hz 110 4 33 300 mm 5 kV or 240 mm 8 kV phase 6000 V 50 60 Hz 110 4 33 240 mm 8 kV or 185mm 15 kV phase 6600 V 50 60 Hz 110 4 33 240 mm 8 kV or 185mm 15 kV phase 10 000 V 50 60 Hz 110 4 33 185 mm 15 kV phase 1 Cable sizes are based on overall dimensions of compact stranded three conductor shielded cable common for industrial cable tray installations Maximum sizing stated accounts for minimum rated cable insulation requirements and the next higher rated cable i e 8 kV is not commercia
88. are shipped with the Power Module LV Control Cabinet and must be secured before lifting the cabinet 1 Remove the lifting angles from the skid 2 Remove the attachment hardware that is pre installed in the mounting holes in the cabinet top plate before shipment Rockwell Automation Publication 6000 INOO6B EN P November 2015 21 Chapter1 Shipping and Handling Procedures For IEC 3 Align and secure the lifting angles in six places as shown in Figure 7 using the hardware removed in step 2 Figure 7 Install Fasteners from the Lifting Angles to the Drive in six places Lifting Angle Pair Washer Install the supplied hardware M12 bolt and nut two flat washers to join the lifting angles together in three places Figure 8 Figure 8 Bolt vertical slots on the Lifting Angles in three places M12 Nut wee M12 Bolt re Attach the Overhead Lifting Cables 1 Attach rigging assembly firmly to the lifting angles on the top of the Power Module LV Control Cabinet Figure 9 be sufficient to safely raise the cabinet Check the shipping weights by referring ATTENTION The load carrying capacity of the lifting device and rigging must to the container s commercial invoice 22 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Shipping and Handling Procedures For IEC Chapter 1 ATTENTION Do not pass cables through the support holes in the lifting angles Use slings with safet
89. awing reference indicates the sheet and the X Y coordinates of the continuation point The reference system is explained on a sheet in each drawing set The unique wire numbering system serves as confirmation that the correct wire is being traced from sheet to sheet or across a drawing Wires in multi conductor cables are typically identified by color rather than by number Abbreviations used to identify the colors on the drawings are fully identified on a sheet in the drawing set As a general guideline the ground path must be of sufficiently low impedance and capacity that e the rise in potential of the drive ground point when subjected to a current of twice the rating of the supply should be no higher than 4 V over ground potential Rockwell Automation Publication 6000 INOO6B EN P November 2015 Power Cable Insulation Requirements Drive Electrical Installation For IEC Chapter 5 e the current flowing into a ground fault is of sufficient magnitude to cause the protection to operate The general grounding point must be reliably connected with the grounding network Attach an external ground cable to the main ground bus in compliance with applicable national and local electrical codes IMPORTANT The primary grounding cable must have a diameter of at least 50 mm and meet all applicable national and local electrical codes Run the system ground cable separately from power and signal wiring so that faults e do not damag
90. base and the cabinet The steel base profile shall be reliably grounded Moving with Rod or Pipe Rollers This method is only suitable when there are no inclines and the drive is moved on the same floor Boards with cross section of about 50 x150 mm 2 x 6 in and length of at least 300 mm 12 in longer than the drive must be placed under the wooden skid Lift the cabinet and carefully and slowly lower the drive cabinet onto the roller pipes until the drive weight is borne on the roller pipes Do not remove the shipping skid the skid is required for this process Refer to Attach the Overhead Lifting Cables on page 22 Roll the drive to its destination location Steady the cabinet to prevent tipping Rockwell Automation Publication 6000 INOO6B EN P November 2015 19 Chapter 1 20 Shipping and Handling Procedures For IEC Minimum 51 x 152 mm 2x 6 in Remove the Wooden Skids Remove the wooden shipping skids when the drive is in its final installation location Steel angle brackets bolt the cabinet to the wooden shipping skid Remove this hardware lift the cabinets off the skids and remove the skids from underneath Refer to Lift the Power Module LV Control Cabinet on page 21 and Lift the Isolation Transformer Cabinet on page 25 Figure 6 Angle Brackets Steel Angle Brackets Rockwell Automation Publication 6000 INOO6B EN P November 2015 Overhead Lifting Methods Lift the Power Module LV
91. ble M8x25 Hex Bolt Flat Washer Lock Washer M8 Hex Nut Front View 112 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Connect LV Control and Fan Wiring Bundles Drive Electrical Interconnection For UL Chapter8 Introduction There are control wiring bundles that must be reconnected after the drive cabinets are connected together These control wiring bundles are connected for the factory test and then disconnected and bundled at the shipping splits before shipment The configuration Fixed mounted Power Module without Bypass is shown below The configuration is shown in the as shipped state This shows where the wire bundles are coiled up where they originate where they terminate and whether they are ran in the front or rear wireway The connected state is also shown for each configuration For exact wire numbers and terminal block designations refer to the Electrical Drawings DTB1 to DTB4 refer to terminal block strips in the various cabinets Fixed mounted Power Module Configuration without Bypass Figure 80 Interconnection Configuration As shipped PJ1 A Isolation Transformer Cabinet Power Module LV Control Cabinet Top View Front Figure 81 Interconnection Configuration Connected Isolation Transformer Cabinet Power Module LV Control Cabinet Top View Front Rockwell Automation Publication 6000 INOO6B EN P November 2015 113 Chapter8 Drive Electr
92. bles iu eid 87 Connect Incoming Line and Outgoing Motor Power Cables 87 Connect Control Power Wiring asi e dude ovid pep diua 89 nttodHctiolit fave te sete itenim deh E Eee e e DU dra EI 89 Wiring Routing and Connection 89 Connect External Control Signal Wiring 0 0c eee ee 91 IntroductlOlis oe Gases need ri DS Dada E ded e 91 Analog and Digital I O Overview ses 91 Wiring Routing and Connection eee eee eee 91 Connect Electrical Safety Interlock Circuit to Input Circuit Breaker 92 Introductions te E LAU E tdi dert ELE 92 MV Door Safety Interlock 52i esee er pere RU FREE E RES 92 Chapter 7 ISS Se T Ea dud E E ROEA EE 95 Electrical Interconnection Summary 95 Power Cable Interconnection Overview cece cece ee eee 96 Connect Isolation Transformer Secondary Power Cables 97 IAEPOCUCHIO NE eso o Ee EE ende aes Pura ice tte 97 Cable Routing and Connection us i rever tp RE EPEE REPE RS 99 Connect Motor and Voltage Sensing Board Cables 100 Inftrodcbiofheseemc LIE CELL AERE 100 Connect LV Control and Fan Wiring Bundles 102 Libo CLIO Dea 3 ors eur d uten Sein eee aa ee eae a 102 Rockw
93. bles pass freely though the center section of the cabinet and that they do not contact the middle top plate support brackets 26 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Shipping and Handling Procedures For IEC Chapter 1 3 Attach the U ring attachments to the lifting provisions on the isolation transformer Figure 14 Overhead Lifting Isolation Transformer Cabinet Support Brackets Steel Cable U rings Lifting Provision Power cable connection openings to adjacent bypass cabinet if supplied Not applicable without a bypass cabinet ATTENTION The cabinet is attached to the base of the isolation transformer The cabinet is designed to be lifted only by the isolation transformer lifting A provisions Do not attach cables to the Isolation Transformer cabinet ATTENTION Keep the weight of the isolation transformer centered when lifting It is recommended to use the four lifting provisions at all corners of the isolation transformer Alternatively the two lifting provisions diagonally opposed could be used Rockwell Automation Publication 6000 IN006B EN P November 2015 27 Chapter1 Shipping and Handling Procedures For IEC Lift the Bypass Cabinet If the optional Bypass Cabinet is supplied lift the Bypass Cabinet using four M12 eye bolts The back plate does not have to be removed to install the M12 nuts as they are welded to the inside of the top plate Refer to Tor
94. cabinets together using M8 hardware See Torque Requirements on page 119 for proper torque requirements Open the doors to access front edge joining holes 5 places Secure with M8 hardware 10 places rT det 1 T rrr T fal TTT Te eta TIT M8x25 Hex Bolt Lock Washer Flat Washer x2 M8 Hex Nut ex Nu 4 Remove all back plates to access rear edge joining holes 5 places TIP Each back plate will have two keyhole screw holes on either side Remove all of the other screws first Loosen the two screws in the keyhole screw holes last and lift the back plate to remove Do not remove these screws Do not replace the back plates until the Drive Electrical Interconnection Process is complete See Drive Electrical Interconnection For IEC on page 95 To replace the back plates the two remaining screws orient and hold the back plate in place while fastening the other screws holding the back plates to the frame of the cabinet Tighten these screws last to complete the process 51 3333 H 1 IST 19T Hr REHE Rockwell Automation Publication 6000 IN006B EN P November 2015 47 Chapter 3 Drive Mechanical Installation For IEC Affix Cabinets to Floor 48 110 110 Bypass Cabinet optional Typical floor drawings show minimum clearance distance conduit openings and mounting holes for anchor bolts as shown in Figure 33 Refer to project specific Dimensional Drawings
95. ct all external customer required control signal wiring e Connect electrical safety interlock control signal wiring circuit to input circuit breaker e Connecting the power cables and control wiring between cabinets that are shipped separately 4 5 e Complete Pre commissioning Checklist All or part of these activities could be provided by Rockwell Automation or its representatives based on contract INCO terms and negotiated scope of supply services agreement Contact the local Rockwell Automation office for further information Customer should lead the initial inspection process If an optional bypass cabinet is supplied the system ground cable incoming line power cables and outgoing motor power cables are connected to the bypass cabinet Refer to 6012DB Medium Voltage Bypass Cabinet User Manual 6000 UM002_ EN P Additional information about interconnecting the power cables and control wiring for a system including a bypass cabinet is included in the 601208 Medium Voltage Bypass Cabinet User Manual 6000 UM002_ EN P Interconnection of power cables and low voltage control wiring bundles between separately shipped cabinets can be done by the contractor or Rockwell Automation The commissioning quote from Rockwell Automation reflects this and will contain two options a the base quote reflecting the power cable and control wiring interconnection work being done by the contractor b the optional quote adder reflecting the additiona
96. duy JY AOOEE OF A1GEL 125 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Cv 9t SE ooze ooe 009 our oze oove casi zo oost oes oese oove ov oosv oot vos oos ozo our oze oove zoei zo ooet oces oese oove 08 ozon oc 99 oss ozo ons oze oove zoei zo oor oes oese oove 64 ose ozr os ozoe osos our oze oove zoer zo ooet oces cse oove oste ovee orse sze sis 069 ozoe ooss orc oze oove zoer zo ooet oces cst oove onze ose oo os ozoe oors out oze oove zoei zo 08 oes cse oove 004 ovez oee os oos ozoe ooos oez oee oove zoer zo ooet oces cst oove ossz oooz ooe osz ves osz ez e eave veer ei z oos oez oee ooz zoer zo ooet oes oese ooz osez owe oe oe sc ves osz ez e eee vee ei z oo om oe oee oove zoi ox oor oove ooze oriz wo ove ox eons co co v sef e Wu Lm NN CE zu LUI EN ves ez e case veer ei z ous ori ow oe oee oove cor zo ooer oos oc ooze oz on EEG am NM MN MM EN Eu NM eens cv v uL oose se oose se 6 veee vz s oose
97. e dry contact pulsed quantity valid with 3S Remote DCS start command signal 449 User provided normally open passive dry contact 401 pulsed quantity valid with 3S 5 Alternate stop command signal 432 401 User provided normally open passive dry contact pulsed quantity valid with 3S Remote DCS stop command signal 450 401 User provided normally open passive dry contact pulsed quantity valid with 3S 6 Spare 433 401 User provided normally open passive dry contact pulsed quantity valid with 3S 7 w User provided normally open passive dry contact pulsed quantity valid with 35 8 Spare 885 400 p User provided normally open passive dry contact switch quantity marea 0 User provided normally open passive dry contact switch quantity User provided normally open passive dry contact switch quantity Spe 8840 p User provided normally open passive dry contact switch quantity 9 Lec acies WIN REN User provided normally open passive dry contact switch quantity 10 Remote DCS fault reset command 412 401 User provided normally open passive dry contact pulsed quantity valid with 3S Alternate reset command 412 401 User provided normally open passive dry contact pulsed quantity valid with 3S 11 Emergency stop button command User provided normally closed passive dry contact 1101 1102 voltage dass higher than 220V AC 5 A switch quantity 12 VFD allow closing indication 9
98. e isolation transformer The power cable connections to the power modules are made at the factory Therefore the field power cable connections need to be made at the isolation transformer secondary winding termination points Figure 78 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Drive Electrical Interconnection For UL Chapter 8 Cable Routing and Connection Figure 78 6 0 6 3 6 6 kV Fixed mounted Power Module Configuration 1 n U 1 n V 1 n W Secondary Winding Connections Secondary Winding Connections Secondary Winding Connections Power Cable to Power Module flf UU k LIT TIT T TRITT IT IT FI I TT I 6 E 2 Trt TTS HELLE fA ees aT a 1 49 49 1 M8 Hex Nut M8 Flange Nut LL IHHL ALAM Ca s I 1 T s H L P o e s 9 Ti Front View Rockwell Automation Publication 6000 INOO6B EN P November 2015 111 Chapter8 Drive Electrical Interconnection For UL Connect Motor and Voltage Introduction Sensing Board Cables The Voltage Sensing Board cables and the motor cables both connect to the same output point of each motor phase array Figure 76 The voltage sensing board cables and motor cables are always bundled in the isolation transformer cabinet for shipment Figure 79 6 0 6 3 6 6 kV Fixed mounted Power Module Configuration VSB Ca
99. e the grounding circuit e will not interfere with or damage the protection or metering systems or cause undue disturbance on power lines Incoming line power cable ratings are shown on the Electrical Drawings and reflect what would typically be supplied based on line voltage rating All voltage ratings for outgoing motor cables shown are line to ground rated power frequency voltages and line to line power frequency voltages Table 16 Cable Insulation Requirements for Outgoing Motor Cables Cable Insulation Rating kV Motor Side System Voltage V RMS Line to Ground Rated Line to Line Rated Power Frequency Voltage U Power Frequency Voltage U Select cables of appropriate voltage classes when the incoming line grid side voltage class is different from the outgoing line motor side voltage class Standard power cable ratings commercially available can vary in different regions around the world Cable must meet the minimum line to ground and line to line requirements IMPORTANT Follow the recommended field power cabling insulation levels to help ensure trouble free start up and operation The cable insulation level must be increased over that which would be supplied for an across the line application with the same rated line to line voltage Rockwell Automation Publication 6000 IN006B EN P November 2015 69 Chapter5 Drive Electrical Installation For IEC Power Cable Design Considerations Motor Cable Sizing 70
100. eath Wear proper Personal Protective Equipment PPE Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment PPE gt gt gt Allen Bradley Rockwell Software Rockwell Automation PowerFlex and TechConnect are trademarks of Rockwell Automation Inc Trademarks not belonging to Rockwell Automation are property of their respective companies Preface Shipping and Handling Procedures For IEC Shipping and Handling Procedures For UL Table of Contents Introductio s 25 s oa ote o PEN ERE bes RA eee 9 Who Should Use This Manual eene 9 AW bhar Ts Notin this Manualzs RRR R AW EXEUEERCE RR ERE 9 Required Supplemental Information icistcccscavictedseriuieiineens 9 General Precautions sasGebe eohve bee dus 10 COMMISSIONING SUPPO i s poser dere pH oe oee easy EEES 10 Additional Resources 0 10 Contractor Scope Of WOBE ub estes teen ces ques 11 Chapter 1 Oe Bd oh ee eai A eee er 12 General Handling Information n veo reed 14 Orleddine and Moving 71406082 a Rr jou utere 14 Fork 14 Unpack and Inspect the 2 oon or Pone ESAE RP RAS 15 Dive Contiparat OD 4 eoe eet d Ro OH Qu lene 16 Shipmelit Lisbon A
101. een operated manually to verify free movement The back plates to the cabinets have been reinstalled Table 22 Safety Initials The grounding of the drive should be in accordance with national and local electrical codes 116 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Pre Commissioning Appendix A Table 23 Control Wiring Alllow voltage wiring entering the drive is labeled appropriate wiring diagrams are available and all customer interconnections are complete EE All AC and DC circuits are run in separate conduits All wire sizes used are selected by observing all applicable safety and national and local electrical codes Pf Remote 1 0 is correctly installed and configured if applicable All 3 phase control wiring is within specified levels and has been verified for proper rotation UVW All single phase control wiring is within specified levels and has grounded neutrals Control lines must be shielded and grounded Control and Power lines must run in separate conduits The electrical safety interlock wiring to input circuit breaker is correctly installed Table 24 Power Wiring The power cable connections to the drive motor and isolation transformer adhere to national and local electrical codes The cable terminations if stress cones are used adhere to the appropriate standards Appropriate cable insulation levels are adhered to as per Rockwell Automation specifications All
102. eflect the 1300 mm or 1500 mm deep cabinet configurations and the corresponding Drive Cable Trench depth See PowerFlex 6000 Dimensions and Weights For IEC on page 123 Figure 3 A typical cross sectional view of the trench system Back e Front 1300 mm 51 in or 1500 mm 59 in 150 mm Cabinet body is 6 in bolted to the 950 mm 37 in or i channel steel base 1150 mm 45 in Channel Steel Base 4 4 AE B 1 P MR 4 b 4 b 5 jos q 4 l E EE aca Pu F 4 A k 4 4 4 ni a 7 lt ics 4 44 4 cl a d E E T a 4 4 4 4 4 SNP L 4 x 4 yw Z v rut pe a Aa a 4 E xin Ae 85 ua c 5 i 4 lt A we T Ta BS oo 7 i ES 4 9 pea Main Cable Trench Cable Passage Drive Cable Trench Rockwell Automation Publication 6000 INOO6B EN P November 2015 Shipping and Handling Procedures For IEC Chapter 1 Embed the channel steel base profile in the base with its top surface flush with ground level or protruding slightly above ground level Figure 4 Channel Steel Base Location Channel Steel Base Bolt or weld the drive cabinet on the profile steel base Refer to Affix Cabinets to Floor on page 48 A reliable connection must be made between the steel
103. ell Automation Publication 6000 INOO6B EN P November 2015 5 Table of Contents Drive Electrical Interconnection For UL Pre Commissioning Torque Requirements General Wire Categories PowerFlex 6000 Dimensions and Weights For IEC PowerFlex 6000 Dimensions and Weights For UL Fixed mounted Power Module Configuration without Bypass 102 Fixed mounted Power Module Configuration with Bypass 103 Drawout Power Module Configuration without Bypass 103 Drawout Power Module Configuration with Bypass 104 Connect Ground Bus eese has 105 Introd cese reo voee a bad bete ei AVE T 105 Complete the Installation voces seo E e ERREUR RENS eds Ed es 105 Chapter 8 InttodiictiOhi 2v eet e obe hd cu d eurer a dai eas 107 Electrical Interconnection Summary eee eee ences 107 Power Cable Interconnection Overview eene 108 Connect Isolation Transformer Secondary Power Cables 109 l attOducllObi ees orte datar bmi den etate d Pet A 109 Cable Routing and Connection des E UPERER OUS 111 Connect Motor and Voltage Sensing Board Cables 112 InttOQUuctIOT sois o o etd eerte iibris vd T 112 Connect LV Control and Fan Wiring Bundles 113 InttoducbtOE xe taeda E etie ese E ea a idee 113 Fixed mounted Power Module Configuration without Bypass 113 Connect Ground Buss c eese ERE Ce Fes Xe bn bea ees 114 It EOQUCEIO
104. ely installing electrical equipment Installation must comply with specifications regarding wire type conductor sizes branch circuit protection and disconnect devices Failure to do so may result in personal injury and or equipment damage Before connecting any power cables or control signal wiring review and understand the information contained in the project specific Electrical Drawings They contain critical information such as e Minimum power cable insulation ratings and sizes e Power terminal locations and designations e Terminal block designations for all connections to external customer control signal wiring and control power supply cables The practice used within the PowerFlex 6000 electrical drawing is based on the IEC International Electrotechnical Commission standard The symbols used to identify components on the drawings are international Device designations used on the drawings and labeling are explained on each drawing set Wiring identification uses a source destination wire number convention on point to point multi conductor wiring and in situations where the system is warranted The wire numbering system of unique single numbers for multi drop and point to point wiring continues to be used for general control and power wiring Wiring that connects between the sheets or that ends at one point and starts at another point on a drawing has an arrow and drawing reference to indicate the ongoing connection The dr
105. en passive dry contact 11 Emergency stop button command User provided normally closed passive dry contact 1101 1102 voltage class higher than 220V AC 5 A switch quantity Rockwell Automation Publication 6000 INOO6B EN P November 2015 153 AppendixH Power Cabling and Control Signal Wiring Details For UL Table 60 1 0 Connections related to Remote Distributed Control System Continued Serial Number Name of 1 0 Connection N fao DO Note Emergency stop button command 1 User provided normally closed passive dry contact 1103 1104 voltage class higher than 220V AC 5 A switch quantity 12 VFD allow closing indication 901 902 1 VFD provided normally open passive dry contact voltage class lt 220V AC 5 A used for Remote DCS Circuit breaker closing indication 903 904 1 VFD provided normally open passive dry contact voltage class lt 220V AC 5A used for Remote DCS VFD alarm indication 905 906 1 VFD provided normally open passive dry contact voltage class lt 220V AC 5A used for Remote DCS VFD fault indication 907 908 1 VFD provided normally open passive dry contact voltage dass lt 220V AC 5A used for Remote DCS VFD operation indication 909 910 1 VFD provided normally open passive dry contact voltage class lt 220V AC 5A used for Remote DCS VFD stop indication 911 912 1 VFD provided normally closed passive dry contact voltage class lt 220V AC 5A used for Remote DCS VFD ready indication
106. enea ete concede dedit 16 Initial Inspection T T oe onus see tox LU ERU EVE sedan 17 a rE A des 17 Installation Site Requirements sau ope due dede mb e boe E Dude 17 Environmental Conditions sees eee 17 Mounting Clearance Distance dores eee 18 MOUNTING Bequiieflehtsssus au dno RR tama E eras db decus 18 Moving with Rod or Pipe Rollers sss 19 Remove the Wooden Skids eee 20 Overhead Lifting Methods ated 46e bns boe MORAN Eb bus 21 Lift the Power Module LV Control Cabinet 21 Install the Lifting codes aues oa TE Tae ER SEU OE a 21 Attach the Overhead Lifting Cables 22 Remove Overhead Lifting Cables and Lifting Angles 24 Lift the Isolation Transformer Cabinet 00 c cece ee eee 25 Lift the Bypass C abIDeb ci bedienen due aded 28 Chapter 2 reat he hake oak ee ene E LEE art One omnes ED s 29 General Handling nfotmatlo D ausos btt npe bui ne Db x en Stati 30 Offloading and Moving Crates sss n Fa reta real dedo eu 30 Fore ee D CL 30 Unpack and Inspect the Drive c i i tsk er RR Re XE 31 Drive COBDIPUEALIOTIS od cu dada os es etd gens Pelea os rubei 32 SDipiueht List adu enorm tee eras Rae PEE 32 Initial I speeuom Checklist soda awe ope de ed esas 33 n P V m 33 Installation Site Requirements eoo erp EE ox
107. er 2015 Drive Electrical Installation For UL Drive Electrical Interconnection For IEC Table of Contents nrod ctiO dps in INS da Pedes puit Mae 76 Wiring Routing and Connection erre hembras 76 Connect External Control Signal Wiring s 78 Init oc ctio ldoeconcdudieonekiste at uet E LER LE Le Liu ete 78 Analog and Digital I O Overview 78 Wiring Routing and Connection 78 Connect Electrical Safety Interlock Circuit to Input Circuit Breaker 79 Introd T e A aAa e 79 MV Door Saloy Interlock 79 Chapter 6 IntfOd ctiOlksscsac edes aA edi aO pde Mes 81 SALCEU OUI ERE do snper seti eed d Sp Me 81 Electrical DraWIliBSess Om AA butt ue 82 Grounding System Requirements e e PER ER Lain 82 Power Cable Insulation Requirements 0 eee sence eee 83 Power Cable Design Considerations e eee eee eee 84 Motor Capi SIZING sia soca qu FEAT Saudi pits 84 Control Signal Wiring Design Considerations 85 Control Signal Wire Shield Grounding 85 Electrical Installation Summary isa derer er PU ERR 87 Connhectthe System Ground Cable 4 ede RR 87 Megger Test of Power Ca
108. er Cabinet Power Module LV Control Cabinet Top View Front Rockwell Automation Publication 6000 INOO6B EN P November 2015 103 Chapter7 Drive Electrical Interconnection For IEC Figure 72 Interconnection Configuration Connected X1 to X4 e Fan to X4 Isolation Transformer Cabinet Power Module LV Control Cabinet Top View Front Drawout Power Module Configuration with Bypass Figure 73 Interconnection Configuration As shipped Fan to X4 Bypass Cabinet Isolation Transformer Cabinet Power Module LV Control Cabinet Top View Front Figure 74 Interconnection Configuration Connected Fan to X4 Bypass Cabinet Isolation Transformer Cabinet Power Module LV Control Cabinet Top View Front 104 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Drive Electrical Interconnection For IEC Chapter 7 Connect Ground Bus Introduction A solid ground bus is located at the bottom front of each cabinet When a shipping split is required two braided ground bus connectors are supplied One is attached above the solid ground bus and one below Figure 75 Ground bus connection openings are provided in the cabinet sidesheets for this connection See Table 9 on page 45 and Table 10 on page 46 Figure 75 Interconnection Ground D m e M8 Hex Nut Braided Ground Bus Connector Grounding Bus Braided Ground Bus Connector M8x30 Hex Bolt pi
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110. es ouz ore ooz zo oces ose oove oo oose se e evar verc osis Ott ooz toti zo oces 064 oove oss nes ose sz e Jer ver ot z oo uc osos ovt oee oot zoer zo ooer oo9 ooz ooze ost owe nes ez eme veo ot z oni osv oer oe oove ox zo oni ov oove ooz oriz veas osz vz e esc ven et z oss oni ost oer oe oov zoer zo oni oo oovz ooze oser nes ose sz e eave veo ot z oss osee oec oee ooz evet zo ooi oo omc oxc ves osz oz eme ve ot c oos over soe occ oo zoer zo ori onc ooze wes osee vz e eme ve et z os over osve oec oov zo oni onc ooze oos nes ose sc e ease veo ot z oo over osce oer oee ooz xr zo ooet omc oxc over cone oi z mel ais ov over Ori Ont oez oee oove zo ooer ooo oooz oooz cone veel oi z os Z6 orf oser oesz oez oee oove Cot zo ooer ooo oooz oooz ozor cone veo ov z mei ais oz osez oz oee ever e ooz ooz 6 cone veel RL ais ov olv over osoz oez
111. es only opening the doors Access for the rear connections requires removing the back plates of the cabinet IMPORTANT Rear access to all cabinets is required for subsequent processes Do not reinstall back plates until after the conclusion of the Drive Electrical Interconnection process Rockwell Automation Publication 6000 INOO6B EN P November 2015 43 Chapter3 Drive Mechanical Installation For IEC 1 Arrange the sections as directed in the Dimensional Drawings and move the sections together 44 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Drive Mechanical Installation For IEC Chapter 3 2 Align the cabinet side sheets together at the holes for the hardware see step 3 Figure 31 Aligning Cabinets with Fixed mounted Power Modules 6 6 6 kV shown Bypass Cabinet Optional Isolation Transformer Cabinet Power Module LV Control Cabinet ieee mua FETE Hu FH HERENEN jy Sie ie aie ae E E F EEEIEE r Re b EREE y ie ihi eR tw ew ek en i rere rrr rete FIEL HIE ERE ES e eee et 1 1 iiri erate eee tte ses EET LEE EEEE PEE EERI ZTS E sewer firn LK Table 9 Sidesheet Openings Front Wireway Rear Wireway U Phase Motor Cable V Phase Motor Cable W Phase Motor Cable oO Ground Bus Connection Voltage Sensing Board Cables o oe00000 0 Isolation Transformer Secondary
112. es removing the back plates of the cabinet IMPORTANT Rear access to all cabinets is required for subsequent processes Do not reinstall back plates until after the conclusion of the Drive Electrical Interconnection process 1 Arrange the sections as directed in the Dimensional Drawings and move the sections together Rockwell Automation Publication 6000 INOO6B EN P November 2015 59 Chapter4 Drive Mechanical Installation For UL 2 Align the cabinet side sheets together at the holes for the hardware see step 3 Figure 40 Aligning Cabinets with Fixed mounted Power Modules 6 0 6 3 6 6 kV shown Isolation Transformer Cabinet Power Module LV Control Cabinet Side View Table 13 Sidesheet Openings UPhase Motor Cable Ground Bus Connection VPhase Motor Cable Isolation Transformer Secondary Cables 1 The number of Isolation Transformer secondary cables is dependent on motor voltage class 9 cables per motor phase 27 total for 2 3 2 4 kV 12 cables per motor phase 36 total of 4 0 4 16 kV 18 cables per motor phase 54 total for 6 0 6 3 6 6 kV 60 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Drive Mechanical Installation For UL Chapter 4 3 Secure the cabinets together using M8 hardware See Torque Requirements on page 119 for proper torque requirements Open the doors to access front edge joining holes 5 places Flat Washer x2 Secure with M10 hardware 10 place
113. ese veal ov z jaa ae or co 9 MO JAly 30 mam amu das 6 0 esse ver ot z we ze or osse over ooze oz 08 oer zo onc ooz oss 05 Ow 9 96 g esse vest ot z wer ne ov oe over osiz orc oee cer ooet oor oz oz oss ow o os esse vest ot z al ze ov osoz oez oee ooz zo over ono oooz ooz os om oe vs sh esse ver ot z we ze or ove over ost oz orc owz coer zo ooer oov onc ooz oor ozr oze 9 o esse vest ot z wer cis or oue over ose osz oee oovz zoe co ooet mir oz oz sse oe ow amp 9 2 esse vest ot z wer cis or 1 one over osz oee mt zo ooet oor oz oz sie oee ost s z E esse ver ot z we ue or over our RR oee owz oer zo oor oooz ooz ose oz oc amp g 8 pe a la erac m i jc ng n a sz WD s ES wi sf ps wpm Suneysomog B 34619 Jeuuojsuei 1030W ed andingoy vv suey E suoisuawig SII 4aMog 8L uoneinfijuo asjng 92 JY A0009 LE 3 61 Appendix D Rockwell Automation Publication 6000 INOO6B EN P November 2015 126 Appendix D PowerFlex 6000
114. ex dus 33 Environmental Conditions eese 33 Rockwell Automation Publication 6000 INOO6B EN P November 2015 3 Table of Contents Drive Mechanical Installation For IEC Drive Mechanical Installation For UL Drive Electrical Installation For IEC Mounting Clearance DIEGO eodein Gadd reported 34 Mounting Requirements rse itetisi TEE EEE E ERSAT 34 Moving with Rod or Pipe Rollers 35 Remove the Wooden Sides 35 Overhead Liltine Methods soie pb oh oh A e o tiet ute 36 Lift the Power Module LV Control Cabinet 36 Iiscalluhe Ltng ANNEES aa ae atento EE Ed 37 Attach the Overhead Lifting Cables 38 Remove Overhead Lifting Cables and Lifting Angles 39 Lift the Isolation Transformer Cabinet 00 cess eee eens 40 Chapter 3 1811 ose sta Pocuine semi a men iet ends 43 Mechanical Installation Summary ss 43 Connect Shipping RTT Erst aint n i entries oU edd 43 Affix Cabinets to Floor 48 Install Main Coolins Patisues issu beUo Rte RV E 50 Install Drawout Power Modules 1 51 Power Module Lift Cart eene 51 Install Power Modules eeeees rne 53 E R eerste atacand oe be ethene d 55 Dip GOonditlonitig SIZING
115. for actual locations Figure 33 Typical Floor Drawing Fixed mounted Power Module Configuration Outgoing Motor Cable opening Control Signal Wiring and Incoming Line Cable opening Control Power Cable openings 1210 550 4000 Isolation Transformer Cabinet Power Module LV Control Cabinet Secure the cabinet to the channel steel base using M16 bolt lock washer two flat washers and a nut Figure 34 Bolt Cabinet to Steel Base Lock Washer M16 Bolt 1 Mounting holes are represented as in Figure 33 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Drive Mechanical Installation For IEC Chapter 3 Optional The cabinet can also be welded to the steel base once it is securely bolted if desired Each weld location should be 100 mm 3 9 in for every 1000 mm 39 4 in See Mounting Requirements on page 18 for further information on the steel base and desired trench and mounting specifications Figure 35 Welding locations H BH PN MIR Recommended Weld Locations ATTENTION Failure to correctly anchor the cabinet may result in damage to the equipment or injury to personnel Channel Steel Base Rockwell Automation Publication 6000 INOO6B EN P November 2015 49 Chapter3 Drive Mechanical Installation For IEC Install Main Cooling Fans Main cooling fans are shipped in separate crates Table 1 The fans are shipped assembled in the fan housing but must be installed after siting
116. g and Connection 99 111 Fan Wiring Bundles 102 113 Motor Cable connection 100 112 Shipping Splits 45 60 Voltage Sensing Board connection 100 112 Fork Lifts 14 30 Lifting Capacity 14 30 G General Precautions 10 Safety and Codes 67 81 General Wire Categories 121 Ground Bus LV Cabinet 72 86 System Ground Cable Installation 73 87 Grounding System Requirements 68 82 Hardware Back Plates 47 61 Fan Housing 50 64 Ground Bus 105 114 Lifting Angles 22 37 Power Module Power Cables 99 111 Secondary Winding Connections 99 111 Shipping Splits 47 61 System Ground Cable 73 87 Torque Requirements 119 Hardware box 16 32 IEC721 1 55 Input Connection Points 149 153 Inspection Checklist 17 33 Installation Site Requirements 17 33 Isolation Transformer Cabinet Cabinet Keys 15 31 Fan Wiring Bundles 102 113 Ground Bus 105 114 Incoming Line Cable Location 74 88 Layout 75 89 Lifting 25 40 Lifting Precautions 27 42 LV Control Wiring Bundles 102 113 Outgoing Motor Cable Location 74 88 Remove Back Plates 47 61 Secondary Power Cables 97 109 Secondary Winding Connections 99 111 Shipping Damage Checklist 17 33 K Keys 15 31 Index L Lift Cart 51 Lifting capacity 51 Operation 51 Lifting Angles Dimensions 21 36 Hardware 22 37 Install Overhead Lifting Cables 22 38 Installation 21 37 Length 21 36 Location 21 36 Remove 21 24 37 39 Torque Requirements 119 Weight 21 36 Line Cable S
117. g and Unpacking 116 Safety 116 Relative Humidity 17 33 Required Supplemental Information 9 Rod Rollers 19 35 5 Safety and Codes 67 81 ASHRAE Standard 52 2 MERV 11 55 Checklist 116 EU EN779 Class F6 55 IEC 721 1 17 IEC 21 1 55 Lockout and tagout 67 81 Shielded Cables 70 84 Shipment List 16 32 Shipping and Handling 13 29 Cabinet keys 15 31 Checklist 116 Damage claims 15 31 Fork Lifts 14 30 Inspection Checklist 17 33 Isolation Transformer Cabinet 25 40 Lifting Angles 21 36 Mounting Clearance 18 34 Overhead Lifting Cables 22 38 Overview 13 29 Shipment configuration 16 32 Unpacking and Inspection 15 31 Shipping Damage Checklist 17 33 Shipping Splits 43 59 Connection 43 59 Fixed mounted Power Modules 45 60 Hardware 47 61 Sidesheet Openings Drawout Power Modules 46 Sidesheet Openings Fixed Mounted Power Modules 45 60 Specifications Cabinet Dimensions 123 131 Cabinet Weight 123 131 Cable Insulation Rating 69 83 Drawout Power Modules 52 External Ducting 55 Fan Housing 50 64 Fixed mounted Power Modules 52 64 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Index Standard Input Output Connection Points 149 153 High Voltage Cabinet 149 153 Remote Distributed Control System 149 153 Storage 17 33 Storage Temperature 17 33 System Ground Cable Installation 73 87 Location 73 87 Torque Requirements 119 T Tagout 67 81 Terminal Block Strip Fan Wiring bundle
118. g kW x 1 DriveEfficiency E Air Conditioning Size tons EXAMPLE For a 1000 kW drive with 96 596 efficiency E 10 tons of AC required This is for a general estimate Refer to the actual heat loss data to calculate air conditioning sizing Contact the local Rockwell Automation office for actual data Rockwell Automation Publication 6000 INOO6B EN P November 2015 65 Chapter4 Drive Mechanical Installation For UL Notes 66 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Introduction Safety and Codes Chapter 5 Drive Electrical Installation For IEC The installation of all external power cables and control signal wiring is covered in this chapter General electrical safety and installation guideline topics are also included The basic activities include connecting the system ground cable line and motor cables control power and all control signal wiring from the sources to the drive See Figure 83 and Figure 84 for an overview of these connections Electrical interconnections are also required between cabinets that have shipped separately These are described in Drive Electrical Interconnection For IEC on page 95 equipment can be dangerous Severe injury or death can result from electrical shock burn or unintended actuation of control equipment Hazardous voltages may exist in the cabinet even with the circuit breaker in the off position Required practice is to disconnect and lock out
119. ge The lifting angles hold the Power Module LV Control cabinets together to prevent separation and damage while riggers move the drive to the final installation area The lifting angles are shipped with the Power Module LV Control Cabinet and must be secured before lifting the cabinet 1 Remove the lifting angles from the skid 2 Remove the attachment hardware that is pre installed in the mounting holes in the cabinet top plate before shipment 3 Align and secure the lifting angles in six places as shown in Figure 22 using the hardware removed in step 2 Figure 22 Install Fasteners from the Lifting Angles to the Drive in six places Lifting Angle Pair Lockwasher Washer 4 Install the supplied hardware M12 bolt and nut two flat washers to join the lifting angles together in three places Figure 23 Rockwell Automation Publication 6000 INOO6B EN P November 2015 37 Chapter2 Shipping and Handling Procedures For UL Figure 23 Bolt vertical slots on the Lifting Angles in three places M12 Nut P Washer M12 Bolt Mian Attach the Overhead Lifting Cables 1 Attach rigging assembly firmly to the lifting angles on the top of the Power Module LV Control Cabinet Figure 24 ATTENTION The load carrying capacity of the lifting device and rigging must be sufficient to safely raise the cabinet Check the shipping weights by referring to the container s commercial invoice AT
120. h a single conductor surrounded by a mesh screen ground the screen at both ends e When using a multi layer screened cable that is a cable with both a mesh screen and a metal sheath or some form of foil there are two alternative methods Ground the mesh screen at both ends to the metal sheath The metal sheath or foil known as the drain should unless otherwise specified be grounded at one end only again as specified above at the receiver end or the end that is physically closest to the main equipment ground bus Leave the metal sheath or foil insulated from ground and ground the other conductors and the mesh cable screen at one end only as stated above Rockwell Automation Publication 6000 INOO6B EN P November 2015 85 Chapter6 Drive Electrical Installation For UL Grounding provisions for control signal wiring is shown in Figure 54 Figure 54 Vertical Ground Bus in LV Cabinet EL NIS 4 a A T A p p p p a pm ad a 2d A z Eez a M z Vertical Ground Bus Provisions for Grounding Control Signal Wiring Shields and so on Ground Bus 86 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Electrical Installation Summary Connect the System Ground Cable Megger Test of Power Cables Connect Incoming Line and Outgoing Motor Power Cables Drive Electrical Installation For UL Chapter 6 Connect External Cabl
121. he lifting angles together retain or recycle hardware 2 Remove and retain the hardware from the base of the lifting angles and retain or recycle the lifting angles 3 Reinstall the hardware M20 x 60 removed in step 2 to seal the holes on the top of the drive Figure 10 Figure 10 Insert bolts M20 Bolt Lockwasher Washer P 24 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Shipping and Handling Procedures For IEC Chapter 1 Lift the Isolation 1 Unfasten and remove the middle top plate on top of the cabinet and retain Transformer Cabinet middle top plate and hardware Figure 11 Remove Top Middle Plate M6 x 12 Bolt Middle Top Plate T L Washer M16 x 50 Bolt Lock Washer Washer The cabinet version with a single main cooling fan will have two support brackets The cabinet version with two fans will have three support brackets Rockwell Automation Publication 6000 INOO6B EN P November 2015 25 Chapter1 Shipping and Handling Procedures For IEC Most configurations have one or two top mounted main cooling fans in the isolation transformer cabinet However high power configurations can have more Figure 12 Isolation Transformer with one Fan Assembly Overhead view Fan Opening Middle Top Plate Support Brackets Fan Openings Middle Top Plate Support Brackets 2 Attach the steel cable to the U ring attachments Figure 14 ensuring the ca
122. he fork lift has sufficient lifting capacity Cabinets exceeding 4 m should be offloaded and moved with two fork lifts operating in tandem e Insert the forks into the openings of the wooden shipping skid e Balance the crates on the forks The crates can be heavier on one side Use safety straps when handling to steady the crate while moving 30 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Shipping and Handling Procedures For UL Chapter 2 Unpack and Inspect the Drive Before leaving the factory all drives have undergone both performance and quality tests However damage may occur during the shipping or handling process Immediately upon receiving the drive inspect the crates for signs of damage After the crates are offloaded disassemble the crating and check for possible shipping damage Use a crowbar or other suitable tool to carefully remove the packaging Do not insert the tool too far into the packaging or damage to the drive cabinet may occur Inspect the drive cabinets for physical damage according to the Rockwell Automation Conditions of Sale Open the doors and inspect the major components for signs of damage Table G Figure 17 Crated Cabinet IMPORTANT Any daims for visible breakage or damage must be made to the freight company by the user as soon as possible after receipt of shipment Rockwell Automation will provide the user with reasonable assistance in the securing of adjustment fo
123. hipped state This shows where the wire bundles are coiled up where they originate where they terminate and whether they are ran in the front or rear wireway The connected state is also shown for each configuration For exact wire numbers and terminal block designations refer to the Electrical Drawings X1 to X5 refer to terminal block strips in the various cabinets Fixed mounted Power Module Configuration without Bypass Figure 67 Interconnection Configuration As shipped Fan to X4 Isolation Transformer Cabinet Power Module LV Control Cabinet Top View Front Figure 68 Interconnection Configuration Connected Fan to X4 Isolation Transformer Cabinet Power Module LV Control Cabinet 102 Top View Front Rockwell Automation Publication 6000 INOO6B EN P November 2015 Drive Electrical Interconnection For IEC Chapter 7 Fixed mounted Power Module Configuration with Bypass Figure 69 Interconnection Configuration As shipped L Fan to X4 Bypass Cabinet Isolation Transformer Cabinet Power Module lV Control Cabinet Top View Front Figure 70 Interconnection Configuration Connected bum Fan to X4 Bypass Cabinet Isolation Transformer Cabinet Power Module LV Control Cabinet Top View Front Drawout Power Module Configuration without Bypass Figure 71 Interconnection Configuration As shipped Fan to X4 Isolation Transform
124. ical Interconnection For UL Connect Ground Bus Introduction A solid ground bus is located at the bottom front of each cabinet When a shipping split is required two braided ground bus connectors are supplied One is attached above the solid ground bus and one below Figure 82 Ground bus connection openings are provided in the cabinet sidesheets for this connection See Table 13 on page 60 Figure 82 Interconnection Ground ith aS t and 227 VIR 4 f TURNEE Fitili 11 11111 hdi N Bt 8 JEJE U H A M8 Hex Nut Lock Washer Grounding Bus Connector Flat Washer Grounding Bus M8x30 Hex Bolt Complete the Installation 1 Inspect the interior of all cabinets carefully for hardware or tools that may have been misplaced 2 Check and verify that no hardware or foreign material has fallen in the secondary windings in the Isolation Transformer cabinet 3 Check that all mechanical work has been completed properly All barriers and guards that may have been removed must be reinstalled 4 Check that all electrical connections have been made and torqued as specified S Verify the safety circuit is working properly see page 92 6 Reinstall all of the cabinet back plates 114 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Pre Commissioning Responsibilities Appendix Pre Commissioning Roc
125. id on either side of the cabinetry where applicable The cabinets must remain in an upright position during handling be sufficient to safely raise the drive Check the shipping weights by referring to ATTENTION The load carrying capacity of the lifting device and rigging must the container s commercial invoice Round rollers can be used to assist in moving the cabinets to the installation site Once at the final site the pipe rolling technique can be used to place the cabinet in the desired location equipment is not scratched dented or damaged in any manner Stabilize the WARNING Exercise extreme caution when moving the drive to ensure the drive during handling to prevent tipping and injury to personnel Any error in transporting or installing the drive will delay the drive commissioning progress Rockwell Automation Publication 6000 INOO6B EN P November 2015 13 Chapter1 Shipping and Handling Procedures For IEC General Handling Information Offloading and Moving Crates Rockwell Automation strongly recommends using professional riggers with suitable rated lifting equipment to move the drive to the final installation site Qualified professionals must inspect all lifting equipment prior to moving the cabinets Keep the cabinets in an upright position Some units are top heavy and may fall over if tilted The cabinets are not rigid structures Do not torque or twist the cabinets while siting the drives or joining
126. inet User Manual if supplied 6000 UMO002 EN P e Testing Reports Hectrical Drawings EDs and Dimensional Drawings DDs e Certifications e All necessary hardware for mounting lifting angles and fan assemblies and securing the cabinets together e Keys for the lockable cabinet handles 2 ThePower Module lift cart is wrapped in plastic for shipment within China and crated for shipment outside of China 32 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Initial Inspection Checklist Storage Installation Site Requirements Shipping and Handling Procedures For UL Chapter2 Table 6 Shipping Damage Assessment Isolation Transformer Cabinet Power Module Cabinet Low Voltage Control Cabinet Low Voltage Door Fixed mounted Low Voltage Door Transformer Temperature monitor Power module retaining tabs Pilot lights relay Push buttons Cabinet HMI Interface Voltage Sensing Board Panel Incoming Line Power Cable Terminal Insulators Outgoing Load Power Cable Terminal Insulators Transformer Secondary Windings Inspect nomex wrap Verify windings from core are undamaged Check for debris in top of core DIN rail mounted components UPS Fiber optic cables PLC Control Unit Store the drive in a dry clean and cool area The storage temperature must be maintained between 25 55 C 13 131 F This temperature rating
127. ing and Wiring Page Connect the System Ground Cable 87 Megger Test of Power Cables 87 Connect Incoming Line and Outgoing Motor Power Cables 87 Connect Control Power Wiring 89 Connect External Control Signal Wiring JI Connect Electrical Safety Interlock Circuit to Input Circuit Breaker 92 The drive ground bus runs along the bottom of the drive at the front The ground bus is accessible at the bottom of the front of each drive cabinet when the cabinet door is opened Connect the system ground cable to the drive ground bus Figure 55 Figure 55 Ground Cable Connection in the Isolation Transformer Cabinet wr 2 Customer Contractor supplied System Ground Cable Terminal Box Ground Bus IMPORTANT Ifan optional Bypass cabinet is supplied the system ground cable connection is in the Bypass cabinet Refer to publication 6000 UM002 EN P Before connecting the incoming line and outgoing motor power cables follow standard industry practice to verify the integrity of the power cable insulation from the input breaker to the drive and from the drive to the motor The installer must ensure that all power connections are in accordance with national and local electrical codes Each drive is equipped with provisions for bottom power cable entry as standard Provisions for top power cable entry can also be provided This must be specified at the time of order Cable access openings are located on the bottom plate of the connection cabinet
128. ingy yv S119 1 M0d 81 7 35 9c 3ndino A0099 Indul JY A000 LL SE FIGEL Appendix D Rockwell Automation Publication 6000 INOO6B EN P November 2015 130 Appendix E PowerFlex 6000 Dimensions and Weights For UL Overview Dimensions mm W1 Width of Cabinet 1 Isolation Transformer section Width of Cabinet 2 Power Module section and Low Voltage Control section W Total width D1 Depth of cabinet base footprint D2 Depth of doors beyond cabinet base D Total depth including door depth H1 Height of Cabinet H2 Height of Fan H Total height including fan Weight kg M1 Weight of Cabinet 1 Isolation Transformer section M2 Weight of Cabinet 2 Power Module section and Low Voltage Control section M Total weight Rockwell Automation Publication 6000 INOO6B EN P November 2015 131 PowerFlex 6000 Dimensions and Weights For UL Appendix E c c co EBBE VE8L p L C Vo V Vd00cv 0009 OrHW p OL HIS O0c 0000 000 Lre LOZ OvHU by OL Y1S O8L 006L m 9c9 961 199 56501 OSvL OOLE 0592 OVE 606 9 S pt c 8L 19 LC 9L 290 sg ov L v CXLEOLXEG 9L OOEC c9tL c9 OOEL 06 009 O6LL 619Xc9cX0CV 961 6 9 v6 0L VEL S5 06 9 ES vir c 9L 19 LC 691 c9 c sg ov L v CXLEOLXES 91 OSvL 000 059 OVE
129. ion Publication 6000 INOO6B EN P November 2015 Power Cabling and Control Signal Wiring Details For IEC Appendix G Figure 84 Schematic Diagram of the Drive System with a Bypass Cabinet p p u s Dede VA 0179 02 nai ui jeubis 0 07 ZH 09 05 eseud v Aorc 0 C 0CC OCL OLL T eubis J013u0 Y 0 07 N 3t 01559226 ajes pue pasn 3nd3no 1ndui ay 01 559226 ayes S 3194 Jey buunsue 104 e qisuodsaJ s 32 3 Indu y Jo 19 aul S190 Aq pai ddns adiaap 1ndui ue sepnpul upiuw 15 5 siu ur JUBUODWOD auo si Ap abe oA au u35NVQ Ajddns jo 3 025 jau10 sn 1342319 ureansdi ZH 09 06 aseyd e AALL E JOLOW 0 Y k puno 3 eubis Jawoysn jonuo Y uorpeuuo 3 N 0 23 07 AW ssed g LN3W 1 Wiring locations are for design reference only actual wiring must comply with the drawings provided with the drive Rockwell Automation Publication 6000 INOO6B EN P November 2015 146 Appendix G Power Cabling and Control Signal Wiring Details For IEC inet Diagram for Drive System without a Bypass Cabi iring Terminal Strip Wi Figure 85 From Customer From CB Spare To Remote DCS LL To CB From Remote pcs Emergency Stop 220V AC N OV AC w Closed 220V AC N OV AC MV Pre closed CB
130. izes 155 Drive Enclosure Opening 155 Maximum Size 155 Motor Voltage Frequency 155 Line to Ground Rated Power Frequency Voltage 69 Line to Line Power Frequency Maximum Voltage 69 Load Cable Sizes 155 Drive Enclosure Opening 155 Maximum Size 155 Motor Voltage Frequency 155 Lockout 67 81 M Megger Test Power Cables 73 87 Motor Cables Sizing 70 84 Torque Requirements 119 U Phase Sidesheet opening Drawout 46 U Phase Sidesheet opening Fixed mounted 45 60 Phase Sidesheet opening Drawout 46 V Phase Sidesheet opening Fixed mounted 45 60 W Phase Sidesheet opening Drawout 46 W Phase Sidesheet opening Fixed mounted 45 60 Mounting Clearance 18 34 Mounting Distance Minimum Clearance 18 34 Mounting Requirements 18 34 Trench System 18 34 0 Outgoing Motor Cables Location 74 88 Output Connection Points 149 153 Overhead Lifting 21 36 Overhead Lifting Cables Installation 22 38 Remove 24 39 Rockwell Automation Publication 6000 INOO6B EN P November 2015 159 Index 160 P Pipe Rollers 19 35 Power Cables Checklist 117 Desing Considerations 70 84 Ground bond 70 84 Insulation Requirements 69 83 Interconnection Overview 96 108 Maximum Distance 70 84 Schematic No Bypass 145 151 Schematic With Bypass 146 Torque Requirements 119 Power Module Lift Cart 51 Lifting Capacity 51 Operating Procedure 51 Precautions 51 Power Module LV Control Cabinet Control Power Wiring Location 76 89
131. kwell Automation manages the start up service for each installed drive at the customers site but there are a number of tasks the customer or its representatives must complete before scheduling Rockwell Automation personnel for drive commissioning Review this information prior to commissioning the drive as a reference for drive line up commissioning Record the information in the data sheets provided these are useful during future maintenance and troubleshooting exercises ATTENTION Perform the pre commissioning tasks in the order listed in this chapter Failure to do so may result in equipment failure or personal injury IMPORTANT Rockwell Automation requests a minimum of four weeks notice to schedule each start up Inspection and Verification Before the drive commissioning occurs Rockwell Automation recommends that the customer arranges a pre installation meeting to review a the start up plan b the start up schedule c the drive s installation requirements d the pre commissioning checklist Customer personnel must be on site to participate in the system start up procedures See Safety and Codes on page 81 susceptible to damage or destruction by static charges Personnel working near ATTENTION The CMOS devices used on the control circuit boards are static sensitive devices must be appropriately grounded Rockwell Automation Publication 6000 INOO6B EN P November 2015 115 AppendixA Pre Commissioning Pre C
132. l Automation strongly recommends using professional riggers with suitable rated lifting equipment to move the drive to the final installation site Qualified professionals must inspect all lifting equipment prior to moving the cabinets Keep the cabinets in an upright position Some units are top heavy and may fall over if tilted The cabinets are not rigid structures Do not torque or twist the cabinets while siting the drives or joining the shipping splits Use fasteners with a minimum metric Grade 10 9 SAE Grade 8 strength Rockwell Automation recommends using Crosby bolt type shackles All lifting cables must meet lifting capacity requirements Close and secure all drive doors before moving the equipment Keep the cabinets bolted to the wooden shipping skids to minimize the possibility of it tipping Do not remove the wooden skid until the cabinets are at the final installation area Depending on the type of drive cabinet the crate may include a pair of lifting angles Install both lifting angles on top of the cabinet ATTENTION Do not stand near or underneath equipment being lifted overhead to prevent access from unauthorized personnel ATTENTION Restrict access to areas where equipment will be lifted overhead Fork Lifts The terms fork lift lift truck and fork lift truck are all commonly used and refer to the same thing A single fork lift may be used for offloading and moving cabinets up to 4 m 157 in wide if t
133. l cabinet Figure 59 See Figure 87 or Figure 88 for general overview Refer to Electrical Drawings for actual connection points Figure 59 Terminal Block Strip locations DTB1 Terminal E DTB2 Terminal Ium GEL GEL NE GERE AE INE EGRE GNE GNO m m m Block Strip TLLA Block Strip 90 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Connect External Control Signal Wiring Drive Electrical Installation For UL Chapter 6 Introduction This section summarizes the control signal wiring from the remote DCS PLC or discrete control to the drive General connections are detailed in Power Cabling and Control Signal Wiring Details For UL on page 151 Refer to the Electrical Drawings for connection information specific to the drive being installed Analog and Digital 1 0 Overview Four 4 20 mA analog input signals One may be used for DCS with rotating speed setting and three for backup For detailed information see Table 59 and Table 60 on page 153 Two 4 20 mA analog output signals for indication signals such as output motor current and frequency see Table 59 and Table 60 on page 153 Sixteen passive dry contact inputs internal 24V DC power supply start stop and reset controls For detailed information see Table 59 and Table 60 on page 153 These inputs are scalable depending on user requirements Twenty dry contact outputs including nine active dry contact outputs with a
134. l orientation the components and connections shown in the Power Module LV Control Cabinet would be rotated 905 counter clockwise The phase is the top horizontal row the V phase is the middle horizontal row and the W phase is the bottom horizontal row Refer to the Electrical Drawing for actual wire number designations Figure 61 Power Cabling Overview 3 3 kV Fixed mounted Power Module Configuration Voltage Sensing Board aaa U C C C C NO EN i EN 4 L ES EM UJ PCC Isolation Transformer Cabinet Power Module LV Control Cabinet Rockwell Automation Publication 6000 IN006B EN P November 2015 Drive Electrical Interconnection For IEC Chapter 7 Connect Isolation Introduction Transformer Secondary Power Cables The isolation transformer s three phase primary coils are oriented C B and A from left to right as viewed from the front The secondary windings are also divided into three principal sections from top to bottom The upper third are to feed the power modules in the U output phase The middle third are to feed the power modules in the V output phase The bottom third are to feed the power modules in the W output phase Figure 62 Figure 62 Isolation Transformer Primary and Secondary Winding Orientation PRIMARY WINDING INPUT SECONDARY WINDING OUTPUT The secondary windings are brought out to corresponding
135. l time and cost for Rockwell Automation to perform the power cable and control wiring interconnection work immediately prior to the commissioning process Rockwell Automation Publication 6000 INOO6B EN P November 2015 11 Preface Notes 12 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Overview Chapter 1 Shipping and Handling Procedures For IEC This document pertains to PowerFlex 6000 medium voltage drives and also mentions the optional bypass cabinets Additional procedures may apply for specific equipment Refer to other documentation provided with the equipment IMPORTANT Chapter 1 contains important information about offloading the drive crates and handling the drive cabinets Review this chapter before attempting to offload the crates from the delivery truck and move the drive cabinets The instructions help you safely offload and transport your Rockwell Automation Medium Voltage product to the installation site WARNING Never attempt to lift or move the drive by any means other than the handling methods listed in this publication Failure to do so may result in personal injury or death damage to the drive and potential economic loss The PowerFlex 6000 drive cabinets are bolted to wooden skids and placed into wooden shipping crates After the crating is removed the cabinets must remain bolted to the wooden skids until moved to its final installation area Lifting angles are affixed to the shipping sk
136. ley publication 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook ATTENTION An incorrectly applied or installed drive can result in component damage or a reduction in product life Wiring or application errors such as undersizing the motor incorrect or inadequate AC supply or excessive ambient temperatures may result in malfunction of the system ATTENTION Only personnel familiar with the PowerFlex 6000 Adjustable Speed Drive ASD and associated machinery should plan or implement the installation start up and subsequent maintenance of the system Failure to comply may result in personal injury and or equipment damage After installation Rockwell Automation is responsible for commissioning activities for the PowerFlex 6000 product line Contact your local Rockwell Automation sales representative to arrange commissioning Rockwell Automation support includes but is not limited to e quoting and managing product on site start ups e quoting and managing field modification projects e quoting and managing product training at Rockwell Automation facilities and on site These documents contain additional information concerning related products from Rockwell Automation Resource Description Industrial Automation Wiring and Grounding Guidelines Provides general guidelines for installing a Rockwell publication 1770 4 1 Automation industrial system Product Certifications website
137. lly available in many areas of the world therefore Rockwell Automation provides an 8 kV minimum rating as well as a 15 kV rating when applicable Enclosure openings will accommodate the thicker insulation on the higher rated cable IEC ratings show the equivalent to the NEMA sizes The exact cable mm size shown is not commercially available in many cases use the next smaller standard size 2 Minimum cable bend radius recommendations vary by national codes cable type and cable size Consult local codes for guidelines and requirements General relationship of cable diameter to bend radius is typically between 7x 12x e g if the cable diameter is 1 in 2 54 cm the minimum bend radius could range between 7 12 in 18 8 30 48 cm 3 Ascabling methods can vary widely maximum cable sizes shown do not account for the size of the conduit hub Verify size of conduit hub s against the Drive enclosure openings shown Rockwell Automation Publication 6000 INOO6B EN P November 2015 155 Appendix Line and Load Cable Sizes Table 62 Line and Load Cable Sizes for UL Description Drive Enclosure Max Size amp No Incoming Motor V Freq Opening mm in Cables uL 2 8 Maximum Line 2300 2400 V 50 60 Hz 1150 x 200 45 3x 7 9 300 mm 600 AWG 5 kV or Cable Sizes 240 mm 500 AWG 8 kV phase 4000 4160 V 50 60 Hz 1150 x 200 45 3 x 7 9 300 mm 600 AWG 5 kV or 240 mm 500 AWG 8 kV phase 6000 V 50 60 Hz 1150 x 200 45
138. mber 2015 Shipping and Handling Procedures For UL Chapter 2 Moving with Rod or Pipe Rollers This method is only suitable when there are no inclines and the drive is moved on the same floor Boards with cross section of about 50 x150 mm 2 x 6 in and length of at least 300 mm 12 in longer than the drive must be placed under the wooden skid Lift the cabinet and carefully and slowly lower the drive cabinet onto the roller pipes until the drive weight is borne on the roller pipes Do not remove the shipping skid the skid is required for this process See Attach the Overhead Lifting Cables on page 38 Roll the drive to its destination location Steady the cabinet to prevent tipping Figure 20 Rod or Pipe Rollers Minimum 51 x 152 mm 2 x 6 in Remove the Wooden Skids Remove the wooden shipping skids when the drive is in its final installation location Steel angle brackets bolt the cabinet to the wooden shipping skid Remove this hardware lift the cabinets off the skids and remove the skids from underneath Refer to Lift the Power Module LV Control Cabinet on page 36 and Lift the Isolation Transformer Cabinet on page 40 Rockwell Automation Publication 6000 INOO6B EN P November 2015 35 Chapter2 X Shipping and Handling Procedures For UL Overhead Lifting Methods Lift the Power Module LV Control Cabinet Figure 21 Angle Brackets Steel Angle Brackets The preferred method of lifting the cabi
139. mechanical installation process described in this chapter the electrical installation process described in Drive Electrical Installation For IEC on page 67 and the electrical interconnection process described in Drive Electrical Interconnection For IEC on page 95 The cabinets must be arranged as shown in the Dimensional Drawing Connect Shipping Splits 43 Affix Cabinets to Floor 48 Install Main Cooling Fans 50 Install Drawout Power Modules if applicable 51 External Ducting 55 Follow all applicable guidelines for siting the components before continuing with these installation instructions There may be some variation in the process depending on the type and number of drive components in your particular installation ATTENTION Install the drive on a level surface 1 mm per meter N 0 036 in per 36 in of drive length in all directions If necessary use metal shims to level the cabinets before joining them attempting to level after joining may twist or misalign the cabinets The PowerFlex 6000 drive is shipped in two sections the Isolation Transformer Cabinet and Power Module LV Control Cabinet These two cabinets must be connected after located in its final position The cabinets are connected together in 10 places five along the front edge of the cabinet and five along the rear edge of the cabinet Access to the interior of the cabinet is required to make these connections Access for the front connections requir
140. modules in the W phase Each three phase secondary winding set of the isolation transformer has three individual single phase power cables connecting its output to the three phase power input of its corresponding power module For drives with fixed mounted power modules the U and W phase interconnections to the isolation transformer secondary windings are on the front of the isolation transformer and the connections to the V phase are on the rear of the isolation transformer The power cable connections to the power modules are made at the factory Therefore the field power cable connections need to be made at the isolation transformer secondary winding termination points Figure 63 For drives with drawout power modules all of the interconnections between the isolation transformer secondary windings and the power modules are made in the rear of the isolation transformer and the connection to the power modules are also in the rear The power cable connections to the isolation transformer secondary winding termination point are made at the factory Therefore the field power cable connections must be made at the power module input points Figure 64 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Drive Electrical Interconnection For IEC Chapter 7 Cable Routing and Connection Figure 63 6 6 6 kV Fixed mounted Power Module Configuration Secondary Winding from Isolation Transformer A Phase Secondar
141. n Transformer Secondary Power Cables 109 Connect Motor and Voltage Sensing Board Cables 112 Connect LV Control and Fan Wiring Bundles 113 Connect Ground Bus 114 Rockwell Automation Publication 6000 INOO6B EN P November 2015 107 Chapter8 Drive Electrical Interconnection For UL Power Cable Interconnection Overview Input power 3 phase AC any voltage Figure 76 provides a three line drawing overview of the power cable interconnections between the power modules PC XX in the Power Module LV Control cabinet and the secondary windings of the isolation transformer in the Isolation Transformer cabinet The number of power modules is dependent solely on output motor voltage e 9 power modules for 2 3 2 4 kV e 12 power modules for 4 0 4 16 kV e 18 power modules for 6 0 6 3 6 6 kV It also shows the connection point from the U V and W motor output phases from the power module array to the voltage sensing board cables and the motor cables The isolation transformer secondary windings as shown do reflect the actual orientation on the isolation transformer The Power Module LV Cabinet orientation is optimized for drawing clarity To better understand the physical orientation the components and connections shown in the Power Module LV Control Cabinet would be rotated 905 counter clockwise The phase is the top horizontal row the V phase is the middle horizontal row and the W phase is the bottom horizontal row Refer to the Elec
142. ncludes generic information about the drive cabinet layout orientation and generic electrical connection information Review the project specific Dimensional Drawings DDs and Electrical Drawings EDs to better understand the specific drive system cabinet orientation and wiring requirements before performing any mechanical or electrical work Paper copies of the DDs and EDs are placed in the document hardware box in the Isolation Transformer Cabinet before shipment Contact the local Rockwell Automation office to obtain digital copies if required If the drive system is supplied with a bypass cabinet important information is included in the user manual Bulletin 6012DB Medium Voltage Bypass Cabinet User Manual 6000 UM002_ EN P instructions to connect incoming line and outgoing motor power cables interconnection of power cables and control wiring between bypass cabinet and drive and instructions for daily recurring usage and maintenance tasks Rockwell Automation Publication 6000 INOO6B EN P November 2015 9 Preface General Precautions Commissioning Support Additional Resources A A ATTENTION This drive contains ESD Electrostatic Discharge sensitive parts and assemblies Static control precautions are required when installing testing servicing or repairing this assembly Component damage may result if ESD control procedures are not followed If you are not familiar with static control procedures reference Allen Brad
143. nets is an overhead crane If overhead lifting with a crane is not available use a fork lift with a capacity greater than the cabinet weight Lift the cabinet using the overhead lifting angles or isolation transformer lifting provisions and suitable spreader bars and rigging attached to the fork lift IMPORTANT Close and lock the cabinet doors before moving any cabinets Two lifting angles are used for the Power Module LV Control Cabinet and are affixed to either side of the shipping skid The length of the lifting angles depends on the length of the Power Module LV Control Cabinet Table 8 Lifting Angles Length approx Dimensions approx Weight per Angle approx 1 55 m 5 08 ft 100 x 80 x 8 mm 3 9 x 3 1x0 32in 17 0 kg 37 Ib 1 79 m 5 87 ft 100 x 80 x 8 mm 3 9 x 3 1x0 32 in 19 6 kg 43 Ib 37 Ib 43 Ib 23 9 kg 53 Ib 56 Ib 67 Ib 2 18 m 7 15 ft 100 x 80x 8 mm 3 9 x 3 1 x 0 32 in 232m 7 61 ft 100 x 80 x 8mm 3 9x3 1x0 32in 25 4 kg 56 Ib 2 80 m 9 19 ft 100 x 80 x 8 mm 3 9 x 3 1 x 0 32 in 30 6 kg 67 Ib 36 Rockwell Automation Publication 6000 IN006B EN P November 2015 Shipping and Handling Procedures For UL Chapter 2 Install the Lifting Angles IMPORTANT Labeland retain all lifting related hardware if the drive system may be moved in the future ATTENTION Failure to install the pair of lifting angles prior to moving the drive may result in personal injury and or equipment dama
144. nfiguration M10x30 Hex Bolt VSB Cable t am x eee EELT EROS ERO eee Bl LI a2 amp 2 Motor Cable ir M10 Hex Nut z a B al LEIM H RKR RKR c Petree et 1 4 s 89e Lock Washer Flat Washer fi c J saa ES m LELI un ut T a i amp 74 V Phase W Phase Front View 100 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Drive Electrical Interconnection For IEC Chapter 7 Figure 66 6 6 6 kV Drawout Power Module Configuration M10 Hex Nut Lock Washer Motor Cable a VSB Cable U Phase iH V Phase W Phase Rear View Rockwell Automation Publication 6000 INOO6B EN P November 2015 101 Chapter7 Drive Electrical Interconnection For IEC Connect LV Control and Fan Wiring Bundles Introduction There are control wiring bundles that must be reconnected after the drive cabinets are connected together These control wiring bundles are connected for the factory test and then disconnected and bundled at the shipping splits before shipment Each of the four drive configurations are shown e Fixed mounted Power Module without Bypass e Fixed mounted Power Module with Bypass e Drawout Power Module without Bypass e Drawout Power Module with Bypass Each configuration shows the as s
145. ng attachments Figure 30 ensuring the cables pass freely though the center section of the cabinet and that they do not contact the middle top plate support brackets Figure 29 Isolation Transformer with three Fan Assemblies Overhead view Fan Openings Middle Top Plate Support Brackets Rockwell Automation Publication 6000 INOO6B EN P November 2015 41 Chapter2 Shipping and Handling Procedures For UL 3 Attach the U ring attachments to the lifting provisions on the isolation transformer Figure 30 Overhead Lifting Isolation Transformer Cabinet Support Brackets U rings Steel Cable gym T MAA Bx ld P D Lifting Provision The cabinet is designed to be lifted only by the isolation transformer lifting ATTENTION The cabinet is attached to the base of the isolation transformer provisions Do not attach cables to the Isolation Transformer cabinet lifting It is recommended to use the four lifting provisions at all corners of the isolation transformer Alternatively the two lifting provisions diagonally opposed could be used ATTENTION Keep the weight of the isolation transformer centered when 42 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Introduction Mechanical Installation Summary Connect Shipping Splits Chapter 3 Drive Mechanical Installation For IEC The installation process is divided into three principal activities The
146. nsformer Cabinet Power Module LV Control Cabinet Secure the cabinet to the channel steel base using M16 bolt lock washer two flat washers and a nut Figure 42 Bolt Cabinet to Steel Base Lock Washer Fat Washer 1 Mounting holes are represented as in Figure 41 62 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Drive Mechanical Installation For UL Chanter 4 Optional The cabinet can also be welded to the steel base once it is securely bolted if desired Each weld location should be 100 mm 3 9 in for every 1000 mm 39 4 in See Mounting Requirements on page 34 for further information on the steel base and desired trench and mounting specifications Figure 43 Welding locations j E 2 ANN LJ Li Recommended Weld Locations Channel Steel Base ATTENTION Failure to correctly anchor the cabinet may result in damage to the equipment or injury to personnel Rockwell Automation Publication 6000 INOO6B EN P November 2015 63 Chapter4 Drive Mechanical Installation For UL Install Main Cooling Fans Main cooling fans are shipped in separate crates Table 5 The fans are shipped assembled in the fan housing but must be installed after siting the drive Most drive configurations will have two to five fans Higher power configurations will have a higher number of fans See PowerFlex 6000 Dimensions and Weights For UL on page 131 for fan quantities and
147. nts of all drives Screens must be installed in the air inlet e Theair inlet must be at least 1000 mm 39 4 in above the floor e Theair inlet and outlet must not be at the same side of the drive room Air Conditioning Sizing If the drive is located in an enclosed space install air conditioners for each drive A general formula to calculate air conditioner power required DriveRating kW x 1 DriveEfficiency 3 5 Air Conditioning Size tons EXAMPLE For a 1000 kW drive with 96 5 efficiency we T 10 tons of AC required This is for a general estimate Refer to the actual heat loss data to calculate air conditioning sizing Contact the local Rockwell Automation office for actual data Figure 39 Airflow for Fixed mounted and Drawout Cabinet Configurations Fixed mounted Power Module Configuration Drawout Power Module Configuration 1 Top ducting shown by contractor 56 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Notes Rockwell Automation Publication 6000 INOO6B EN P November 2015 Drive Mechanical Installation For IEC Chapter 3 57 Chapter3 Drive Mechanical Installation For IEC 58 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Introduction Mechanical Installation Summary Connect Shipping Splits Chapter 4 Drive Mechanical Installation For UL The installation process is divided into three principal activities The mechanical installati
148. o eed 56 Chapter 4 SPEO E A 59 Mechanical Installation Summary 1 cece eee eee eee 59 Conne cbsShIpDIHE DIR cactus Sesser ba TE EREE Ra RE Tta 59 Affix Cabinets to Floor 0 ccc ccc cece 62 Install Main Coole Fansivctxatsoiesusscaaltheiants Cae dd tia 64 Air ConditiGning SINE oeste ates eva cos dde eafb fade oat 65 Chapter 5 Introd ctlOfbe socios Eua Ed eadcm CM NT dei 67 and C depo pao e ur pU uua scere dee 67 Electrical DrawIH9 Soon setate de EDU dti deibo Mai vinnm 68 Grounding System Requirements cece cece eee eee eens 68 Power Cable Insulation Requirements cece eee eee 69 Power Cable Design Considerations cece e eee eee es 70 Motor Cable S IZIHE ciis o sep otro attsst ine detre pale quo iud oto bu 70 Control Signal Wiring Design Considerations 71 Control Signal Wire Shield Grounding sssuuue 72 Electrical Installation Summary on bres eR E PERPE E M ERR 73 Connect the System Ground Cable 73 Messer l est ob Power Sables soos serari oe tbi Ebepeie Mot 73 Connect Incoming Line and Outgoing Motor Power Cables 73 Connect Control Power Wiring 5 discuss babu M re eL dors ds 76 Rockwell Automation Publication 6000 INOOGB EN P Novemb
149. oei zo oor oov ovt ooze 002 osz ova sci wes sc c cave ves 6 z ocv oee 00 voci zo 0081 ov oov ooze 0902 oriz oo wi ozi wes sv e eme vem ot z ovs over ooo oce oovz zoet z9 008 oov oovz ooze 08 oesi ovr Gc soi vees gv e eme veo ot z ows ove ooze Ot C oee oove zoei v9 00 oor 0090 ooze oor ogzi sis 96 wees gv e save 38 ot z oos ove 00 O Z oee oovz zoei v9 oos ovr 005 ooz oori oosi ozni oo we wees sv e eme ven ot z over over oore 04 0 zoet zo 008 p mr ooz orsi oor 06 sv wees gt e save vesi ot z ove osez OE Z oee oovz zoei z9 oosi Ov 009 0000 Oc ott s 6 99 88 vest ot z zor Z6 OL osz oese ose oove zoet z9 008 oov oove ooo ooo oro os zr o esse veal ot z cor A16 OL Or over ooz 0 ose Ov eL ooi 00 a 0000 oos oss ozz 59 55 esse laL ot z cor n6 OL oos 08 04 oovz oer zo 008 oov oore 0000 oog ose ov us esse veal ot z cor 6 OL ooz 08 ose oovz oer zo 008 oov oore 0000 om osz oss 88 veal ot z
150. ommissioning Checklist Once all points of the checklist are complete initial each check box and provide the date Photocopy the checklist and fax the copy to the Rockwell Automation Start up Manager along with the planned start up date Upon receiving this checklist the Project Manager will contact the site to finalize arrangements for a start up engineer to travel to the site at your convenience Please print the following information Name Date Company Phone Pages Fax Drive Serial Number Rockwell Automation Service Engineer Requested YES NO Scheduled Commissioning Date Table 20 Receiving and Unpacking Initials Date Check 1 1 The drives have been checked for shipping damage upon receiving After unpacking the item s received are verified against the bill of materials pf Any claims for breakage or damage whether concealed or obvious are made to the carrier by the customer as soon as possible after receipt of shipment All packing material wedges or braces are removed from the drive Table 21 Installation and Mounting LX The drive is securely fastened in an upright position on a level surface The Isolation Transformer Cabinet Power Module Cabinet and Bypass Cabinet if applicable are correctly installed EE EN Lifting Angles have been removed Bolts are inserted into original location on top of drive prevent leakage of cooling air X 4 All contactors and relays have b
151. on process described in this chapter the electrical installation process described in Drive Electrical Installation For UL on page 81 and the electrical interconnection process described in Drive Electrical Interconnection For UL on page 107 The cabinets must be arranged as shown in the Dimensional Drawing Connect Shipping Splits An Affix Cabinets to Floor 62 Install Main Cooling Fans 64 Air Conditioning Sizing 65 Follow all applicable guidelines for siting the components before continuing with these installation instructions There may be some variation in the process depending on the type and number of drive components in your particular installation ATTENTION Install the drive on a level surface 1 mm per meter N 0 036 in per 36 in of drive length in all directions If necessary use metal shims to level the cabinets before joining them attempting to level after joining may twist or misalign the cabinets The PowerFlex 6000 drive is shipped in two sections the Isolation Transformer Cabinet and Power Module LV Control Cabinet These two cabinets must be connected after located in its final position The cabinets are connected together in 10 places five along the front edge of the cabinet and five along the rear edge of the cabinet Access to the interior of the cabinet is required to make these connections Access for the front connections requires only opening the doors Access for the rear connections requir
152. ons 71 85 Cable Insulation Insulation Level 83 Voltage Rating 83 Cables Control Power Wiring Location Drawout configuration 76 Control Power Wiring Location Fixed mounted configuration 76 89 Electrical Safety Interlock Wire routing 80 93 Fan Wiring Bundles 102 113 General Wire Categories 121 Ground Bus 105 114 Incoming Line Cable Location 74 88 Incoming Line Cables 73 87 Isolation Transformer Secondary Power Cables 97 109 Isolation Transformer Secondary Winding 99 111 Line Cable Sizes 155 Load Cable Sizes 155 Megger Test of Power Cables 73 87 Motor Cables 100 112 Outgoing Motor Power Cables 73 87 Overhead Lifting Cables 22 38 Power Cable Interconnection Overview 96 108 Shielded cables 70 84 System Ground Cable 73 87 Torque Requirements 119 Trench 18 34 Voltage Sensing Board 100 112 Channel Steel Base 19 34 Commissioning Support 10 Conduit Openings 48 62 Contractor Scope of Work 11 Rockwell Automation Publication 6000 INOO6B EN P November 2015 157 Dimensions and Weights 10 000V AC Input Bypass Cabinet 144 10 000V AC Input Output 54 Pulse Configuration 27 Power Cells 128 11 000V AC Input 3300V Output 18 Pulse Configuration 9 Power Cells 129 11 000V AC Input 6600V Output 36 Pulse Configuration 18 Power Cells 130 2400V Input amp 2300 2400V AC Output 18 Pulse Configuration 9 Power Cells 132 140 3000V AC Input Bypass Cabinet 144 3000V AC Input
153. ontrol cabinet Figure 52 See Figure 83 or Figure 84 for general overview Refer to Electrical Drawings for actual connection points Figure 52 Terminal Block Strip locations X1 Terminal Block Strip X2 Terminal Block Strip LA A IILI zz mmmummmumummmmumu T DS SB 6 6 S SB 6 Sooo decod Rockwell Automation Publication 6000 INOO6B EN P November 2015 77 Chapter5 Drive Electrical Installation For IEC Connect External Control Signal Wiring 78 Introduction This section summarizes the control signal wiring from the remote DCS PLC or discrete control to the drive General connections are detailed in Power Cabling and Control Signal Wiring Details For IEC on page 145 Refer to the Electrical Drawings for connection information specific to the drive being installed Analog and Digital 1 0 Overview Four 4 20 mA analog input signals One may be used for DCS with rotating speed setting and three for backup For detailed information see Table 57 and Table 58 on page 149 Two 4 20 mA analog output signals for indication signals such as output motor current and frequency See Table 57 and Table 58 on page 149 Sixteen passive dry contact inputs internal 24V DC power supply start stop and reset controls For detailed information see Table 57 and Table 58 on page 149 These inputs are scalable depending on user requirements Twenty dry contact outputs including nine active dry contact outputs
154. oove ooze osez oost ove ox cove veo or z over over oe oove coer zo over oot oxz oot siz on cove vest ou z oms over oez oe oove coer zo over oovz ooze zer ov save veo ou z 5 over oe occ oove coer zo over oooz ooze oze ooer om os cove veo eL z over over oose oez occ oove coer zo over oooz oxz oL OL sor on cove vest eL z over oor oez occ oove coer zo over onc oooz oost ost ser save vest ot z ow over ope onc 0 oove coer zo over onc oooz over ooot ver zu i ever ue ov over over ossz oe occ oove coer zo over oooz oooz osu oe oct oor aver as ov over osz oez occ owz zoer zo over ooo oooz or oog 0 ever ais or o over occ ove zo over ooo oc oooz 06 oss ozz 96 o ever as or over oez oee oove zor zo over ooo onc oooz oos ose oo se w ever as ov ome over oez oc zo over o oooz ooo ow ose os sx ss cone ve ot Jae
155. ound the mesh screen at both ends to the metal sheath The metal sheath or foil known as the drain should unless otherwise specified be grounded at one end only again as specified above at the receiver end or the end that is physically closest to the main equipment ground bus Leave the metal sheath or foil insulated from ground and ground the other conductors and the mesh cable screen at one end only as stated above Grounding provisions for control signal wiring is shown in Figure 45 Figure 45 Vertical Ground Bus in LV Cabinet Vertical Ground Bus Provisions for Grounding Control Signal Wiring Shields etc Ground Bus 72 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Electrical Installation Summary Connect the System Ground Cable Customer Contractor supplied System Ground Cable Megger Test of Power Cables Connect Incoming Line and Outgoing Motor Power Cables Drive Electrical Installation For IEC Chapter 5 Connect External Cabling and Wiring Page Connect the System Ground Cable 73 Megger Test of Power Cables 73 Connect Incoming Line and Outgoing Motor Power Cables LE Connect Control Power Wiring 76 Connect External Control Signal Wiring 78 Connect Electrical Safety Interlock Circuit to Input Circuit Breaker 79 The drive ground bus runs along the bottom of the drive at the front The ground bus is accessible at the bottom of the front of each drive cabinet when the cabinet
156. ounted components Outgoing Load Power Cable Terminal UPS Insulators Fiber optic cables Transformer Secondary Windings Q PLC Inspect nomex wrap G Control Unit Verify windings from core are undamaged Check for debris in top of core Store the drive in a dry clean and cool area The storage temperature must be maintained between 25 55 C If the storage temperature fluctuates significantly or if the relative humidity exceeds 90 use heating and moisture protection devices to prevent condensation Store the drive in a conditioned building with adequate air circulation Do not store the drive outdoors Environmental Conditions Elevation above sea level must be less than 1000 m 3250 Ambient air temperature must be between 0 40 32 104 F 2 Relative humidity must be less than 90 non condensing The drive must be installed indoors there must be no dripping water or other fluids in the room Cooling air must be clean without significant concentrations of sand corrosive or conductive dust defined by IEC 721 1 as being less than 0 2 mg m of dust or explosive gas Free from significant vibration The drive must be anchored on a level floor Please refer to the dimension drawing for the anchor point sizes and locations For the equipment to operate in conditions other than those specified consult the local Rockwell Automation Sales Office 1 Options are
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158. pAly 610 3 S S S sqi 6y 3419M Aamo Baan 3 Ey sdwiy 1030 Jaquiny 60 6167 E eo cM ur ww suoisueuiq D S119 1 M0d 9 L 7 3 9 3ndino JY A0009 2 3nduj A0069 Lt 91061 137 Rockwell Automation Publication 6000 INOO6B EN P November 2015 POR 06 0 8C 85 URLC 8 POR 0640 8C POR 06 0 8C vC8S 06 0 8C POR 0640 8C vC8S 06 0 8C POR 06 0 8C POR 06 0 8C EBBE 881 6 L EBBE 881 6 L EBBE 881 6 L EBBE 881 6 L EBBE 881 6 L EBBE 681 6 L EBBE EBL OL EBBE 881 6 L EBBE 881 6 L Joquiny up 9 1 S W Mojaly E30 PowerFlex 6000 Dimensions and Weights For UL cM Appendix E 82011 8289 00281 r6 0L 5 65 06 os riz BLES CL v00 50 19 99 LEYZXLEOLXES 9L VCU6 Ord obzi 0009 opoz ope 005 C9EL zo 004 0065 009 ooz 61990025 OPHY 9 C WIS 87871 8288 00011 56 01 EL 65 06 9 85 rz BLES 21500 2950 19 99 LE VZXLEOLXES 9L 9 8 0519 obzi 0005 oboz ove 0080 COEL zo ooet 0025 009 ooz 61992022 OPHY 9 C WIS TLLEL 2662 08 01 v6 01 5 65 06 rz 8119 22 02 29 EZ 19 99 LE VZXLEOLXES 9L ELER 0979 0981 0005 oroz OPE 0080 COL C9 OOEL 00
159. que Requirements on page 119 for appropriate torque requirements 1 Install four M12 eye bolts and washers in each corner of the top plate on the cabinet Figure 15 Install Bypass Cabinet hardware M12 Eye Bolt Washer c Welded Nut ILE 2 Attach a steel cable or other suitable lifting rigging to the eye bolts The lifting rigging must meet lifting capacity requirements Figure 16 Lift Bypass Cabinet Steel Cable aximum 456 a 3 When the cabinet is in the desired position remove the steel cable and hardware 4 Replace the eye bolts with four M12 bolts and washers provided in the document hardware box 28 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Overview Chapter 2 Shipping and Handling Procedures For UL This document pertains to PowerFlex 6000 medium voltage drives and also mentions the optional bypass cabinets Additional procedures may apply for specific equipment Refer to other documentation provided with the equipment IMPORTANT Chapter 1 contains important information about offloading the drive crates and handling the drive cabinets Review this chapter before attempting to offload the crates from the delivery truck and move the drive cabinets The instructions help you safely offload and transport your Rockwell Automation Medium Voltage product to the installation site WARNING Never attempt to lift or move the drive by an
160. r 2015 33 Chapter 2 34 Shipping and Handling Procedures For UL Mounting Clearance Distance Install the drive with appropriate clearance distances on all sides to ensure proper operation and allow maintenance of the drive Table 7 Minimum Mounting Clearance Distances Location Minimum Distance Required approx In Front e 1500 mm 60 in Behind e 1000 mm 39 in Above e 1000 mm 39 in 1 Distance above is measured from the top plate of the drive cabinet excludes height of fan housing damage or reduction in product life Ambient conditions not within the ATTENTION An incorrectly applied or installed drive can result in component specified ranges may result in malfunction of the drive Mounting Requirements The base must be smooth flat and level The base structure of the drive cabinet may be constructed with 10 channel steel approximately 100 x 48 x 5 3 mm 3 9 x 1 9 x 0 2 in Dimension pairs reflect the 1300 mm deep cabinet configuration and the corresponding Drive Cable Trench depth See PowerFlex 6000 Dimensions and Weights For UL on page 131 Figure 19 Channel Steel Base Location Channel Steel Base Bolt or weld the drive cabinet on the profile steel base See Affix Cabinets to Floor on page 62 A reliable connection must be made between the steel base and the cabinet The steel base profile shall be reliably grounded Rockwell Automation Publication 6000 INOO6B EN P Nove
161. r or control wiring however use only steel conduit for all signal wiring ATTENTION Steel conduit is required for all control and signal circuits when the drive is installed in European Union countries Wires for digital and analog signals must be routed separately Control cables and power cables must be routed separately the distance between the control cable tray and the power cable tray must not be less than 300 mm If the control cable must pass through the power cable tray the angle between the cable trays must be as close to 90 as possible Do not mix AC and DC wires in the same cable bundle General Wire Categories on page 121 identifies general wire categories for installing the PowerFlex 6000 drive Each category has an associated wire group number that is used to identify the required wire Application and signal examples along with the recommended type of cable for each group are provided A matrix providing the recommended minimum spacing between different wire groups which run in the same tray or in a separate conduit is also provided Control Signal Wire Shield Grounding Guidelines for Drive Signal and Safety Grounds when using interface cables carrying signals where the frequency does not exceed 1 MHz for communications with the drive follow these general guidelines e Ground screen mesh around the entire circumference rather than forming a pigtail grounded only at one point For coaxial cables wit
162. r such damage claims Access to the medium voltage cabinets of the drive is restricted by the use of lockable handles The cabinet keys are located in the same document hardware box as the EDs and DDs see Required Supplemental Information on page 9 The box is accessible through the opening in the cabinet side sheet without opening a door Rockwell Automation Publication 6000 INOO6B EN P November 2015 31 Chapter2 Shipping and Handling Procedures For UL Figure 18 Lockable Cabinet Handles v e B Drive Configurations There are two basic power cell configurations offered in the PowerFlex 6000 product line For a drive amperage rating 200 A a fixed mounted power module design is supplied Fixed mounted modules are shipped installed in the drive The cabinets may appear slightly different than shown in the illustrations based on voltage class see Figure 40 Shipment List The complete shipment will consist of a number of crates as shown below Table 5 Shipment Configurations VFD Motor Voltage Class and Power Module Amp Rating Cabinet Control Cabinet Lift Cart 2 3 2 4 kV 1mte crate Fixed mounted mounted 1 The document hardware box contains e PowerFlex 6000 Medium Voltage Variable Frequency Drive User Manual 6000 UM001_ EN P e PowerFlex 6000 Medium Voltage Variable Frequency Drive Commissioning Manual 6000 IN007 EN P e PowerFlex 6000 Medium Voltage Bypass Cab
163. ray and the power cable tray must not be less than 300 mm If the control cable must pass through the power cable tray the angle between the cable trays must be as close to 90 as possible Do not mix AC and DC wires in the same cable bundle General Wire Categories on page 121 identifies general wire categories for installing the PowerFlex 6000 drive Each category has an associated wire group number that is used to identify the required wire Application and signal examples along with the recommended type of cable for each group are provided A matrix providing the recommended minimum spacing between different wire groups which run in the same tray or in a separate conduit is also provided Rockwell Automation Publication 6000 INOO6B EN P November 2015 71 Chapter5 Drive Electrical Installation For IEC Control Signal Wire Shield Grounding Guidelines for Drive Signal and Safety Grounds when using interface cables carrying signals where the frequency does not exceed 1 MEZ for communications with the drive follow these general guidelines e Ground screen mesh around the entire circumference rather than forming a pigtail grounded only at one point For coaxial cables with a single conductor surrounded by a mesh screen ground the screen at both ends e When using a multi layer screened cable that is a cable with both a mesh screen and a metal sheath or some form of foil there are two alternative methods Gr
164. ready installed Drawout power modules are supplied for a drive current rating of gt 200 A The power modules are shipped separately and must be installed in the cabinet A Power Module lift cart is included and shipped together with the other components Power Module Lift Cart and feet away from the lifting mechanism Do not stand under the lift tray ATTENTION Only authorized personnel should operate the lift cart Keep hands when in use Store the lift cart with the tray fully lowered Lift Carts are supplied and shipped separately with drawout power module configurations The unit s hydraulic cylinder can be operated by either a hand or foot crank The lifting capacity is 1000 kg 2206 Ib Figure 37 Lift 1 Visually inspect the lift cart to ensure it is fully operational 2 Turn the Pressure Release Knob clockwise until tight Hand Crank 3 Raise the lift tray using the Hand Crank or the Foot Crank Pressure Release Knob TIP The Foot Crank raises the lift tray faster than the Hand Crank Use this to raise the Power Module to just below the tray assembly in the drive Use the Hand Crank for final precise positioning Lower the lift tray by turning the Pressure Pressure in Release Knob counter clockwise Cylinder Pressure in Cylinder Lift Tray Foot Crank Rockwell Automation Publication 6000 INOO6B EN P November 2015 51 Chapter 3 52 Drive Mechanical Installation For IEC
165. rouble free start up and operation The cable insulation level must be increased over that which would be supplied for an across the line application with the same rated line to line voltage Rockwell Automation Publication 6000 INOO6B EN P November 2015 83 Chapter6 Drive Electrical Installation For UL Power Cable Design Considerations Motor Cable Sizing 84 Use fire retardant cables for the drive input output connections Shielded or unshielded cable can be used based on the criteria considered by the distribution system designer and national and local electrical codes If shielded power cables are used connect the shield of the main input output power cables with the general grounding point of the drive Ground the drive output protective grounding connection separately and only at the drive side Comply with the maximum tensile stress and the minimum curvature radius recommended by the cable manufacturer Do not bundle the input output cables of the drive together The power cable tray must not be less than 300 mm 12 in There must be no gaps where the conduit connects to the cabinet and the ground bond must be less than 0 1 ohms Spacing between wire groups is the recommended minimum for parallel runs of approximately 61 m 200 ft or less IMPORTANT The power cable distance from the drive to the motor must not be longer than 300 m If the power cable exceeds 300 m contact the factory Configurations can be provided
166. s 4 Remove all back plates to access rear edge joining holes 5 places TIP Each back plate will have two keyhole screw holes on either side Remove all of the other screws first Loosen the two screws in the keyhole screw holes last and lift the back plate to remove Do not remove these screws Do not replace the back plates until the Drive Electrical Interconnection Process is complete See Drive Electrical Interconnection For UL on page 107 To replace the back plates the two remaining screws orient and hold the back plate in place while fastening the other screws holding the back plates to the frame of the cabinet Tighten these screws last to complete the process 1 IIT U D m FEE NU MEE EHHA ODE il ee P m SS HL Rockwell Automation Publication 6000 INOO6B EN P November 2015 61 Chapter4 Drive Mechanical Installation For UL Affix Cabinets to Floor Typical floor drawings show minimum clearance distance conduit openings and mounting holes for anchor bolts as shown in Figure 41 Refer to project specific Dimensional Drawings for actual locations Figure 41 Typical Floor Drawing Fixed mounted Power Module Configuration Bottom View Isolation Transformer Cabinet Power Module LV Control Cabinet Control Signal Wiring and Incoming Line Cable opening Outgoing Motor Cable opening Control Power Cable openings Top View Isolation Tra
167. s 102 113 Location 77 90 Schematic No Bypass 147 152 Schematic With Bypass 148 Torque Requirements 119 Trench System 18 34 U U ring attachments 26 41 V Voltage Sensing Board Cable Installation 100 112 Sidesheet opening 45 W Weights 566 Dimensions and Weights Weld locations 49 63 Wiring External Control Signal Wiring 78 91 LV Control Bundles 102 113 Wooden Skids 20 35 Removal 20 35 Rockwell Automation Publication 6000 INOO6B EN P November 2015 161 Index Notes 162 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Rockwell Automation Support Rockwell Automation provides technical information on the Web to assist you in using its products At http www rockwellautomation com support you can find technical and application notes sample code and links to software service packs You can also visit our Support Center at https rockwellautomation custhelp com for software updates support chats and forums technical information FAQs and to sign up for product notification updates In addition we offer multiple support programs for installation configuration and troubleshooting For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com services online phone Installation Assistance If you experience a problem within the first 24 hours of installation review the information that is contained
168. separately in this document due to its critical importance related to the safe operation of the drive and personnel safety The circuits connected between the drive and the input circuit breaker allow the drive to trip the input circuit breaker if a drive cabinet door is opened This applies to the cabinet doors where medium voltage is present The LV Control cabinet door can be opened while the drive is energized allow the drive to prevent the input circuit breaker from closing when required e indicate to the drive when the input circuit breaker is closed MV Door Safety Interlock If the MV cabinet door is opened the Allen Bradley Guardmaster Limit Switch 440P CRPS11D4B on the cabinet door will actuate The drive will send a trip signal to the input circuit breaker to disconnect the medium voltage power supply to the drive solely as a part of the plant operation process to ensure the drive has been disconnected from input medium voltage Keep the medium voltage doors locked as standard practice Always go to the input circuit breaker feeding the drive to verify if it is open Lock out and tagout the input circuit breaker before performing any work on the drive or bypass units ATTENTION The door position interlock is a safety feature It must not be used Figure 60 Interlock for Cabinet Doors Door Position Limit Switch VA MEX amp Rockwell Automation Publication 6000 INOO6B EN P November 2
169. shields for shielded cables must be grounded at the source end only If shielded cables are spliced the shield must remain continuous and insulated from ground All wire sizes used are selected by observing all applicable safety and national and local electrical codes All power connections are torqued as per Rockwell Automation specifications Refer to Torque Requirements on page 119 All customer power cabling has been meggered or hi pot tested before connecting to drive system Power wiring phase rotation has been verified per the specific electrical diagrams supplied by Rockwell Automation Table 25 Interconnection Wiring Initials Date Check Pf The power cable connection between the Isolation Transformer and Power Modules EBENE The motor cable connection to the three output buses EE The Voltage Sensing Board connections to the three output buses Pf All low voltage connections to the Isolation Transformer Low Voltage panel Rockwell Automation Publication 6000 INOO6B EN P November 2015 117 AppendixA Pre Commissioning Table 26 Drive Line up Status Initials Date Check MENU The medium voltage and low voltage power is available for startup activities The motor is uncoupled from the driven load ZEE EE The load is available for full load testing 118 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Torque Requirements Appendix B Torque Requirements Proper tightening torque must
170. ssembly Power Module Positioning Handles o oo COCO 0000 00000 CO000 00000 00000 00000 Oo ooo COCO OO000 oooooo ooooooQO0 cooooooooooo00 ooooooooooooo oooooooooooo0 OOoooooooooooo 0000000000000 0000000000000 000000000000 00000000000 0000000000 000000000 00000000 0000000 000000 90000 COCO O ooooo ooooo0 COCO O ooooo oooooO COCO COCO oo Cam Mechanism Actuator Tray Assembly Guides Wheels 4 Push the Power Module slowly backwards into the cabinet until the cam mechanism contacts the pin mounted on the tray assembly Rockwell Automation Publication 6000 INOO6B EN P November 2015 53 Chapter3 Drive Mechanical Installation For IEC 5 Insert the locking key into the cam mechanism actuator and rotate clockwise while gently pushing on the face of the Power Module Cabinet Stab Finger Assemblies Assemblies 08000 _ 00000 OOO OOOO0 Connection to 5 H CO CO 3 C CX E3 CO XSEL Motor Phase Bus OC O00 QOO S 0 B L gt OOOOOOOOOOOOO OOOOO0 N O OOOOOOOO000000 0 OO OOOOOOO0000000 0 BOT OOOO0O000000000 OO OOOO OOOOO0O00000000 0 NUM EDD GB D BOBDE Wara C0000 0000000000000 Cam Mechanism nd M C0000 OOOOOOO000000 from Isolation E 00000 60000000000 Transformer
171. stallation 76 89 Control Signal Wiring Design 71 85 Control Signal Wiring Shield Grounding 72 85 Electrical Drawings 68 82 External Control Signal Wiring 78 91 Grounding System Requirements 68 82 Incoming Line Cables 73 87 Isolation Transformer Secondary Power Cables 97 109 Motor Cables 70 84 Outgoing Motor Power Cables 73 87 Power Terminals 74 88 Summary 73 87 Torque Requirements 119 Drive Electrical Interconnection Checklist 117 Fan Wiring Bundles 102 113 Ground Bus 105 114 Isolation Transformer Secondary Power Cables 97 109 Motor cables 100 112 Power Cable Interconnection 96 108 Summary 95 107 Torque Requirements 119 Voltage Sensing Board 100 112 Drive Mechanical Installation 43 59 Affix Cabinet to Floor 48 62 Air Conditioning Sizing 56 65 Connect Shipping Splits 43 59 External Ducting 55 Install Cooling Fans 50 64 Install Drawout Power Modules 51 Power Module Lift Cart 51 Summary 43 59 Electrial Safety Interlock 79 92 Electrical Drawings 68 82 Contents 68 82 Electrical Safety Interlock Location 79 92 Wire Routing 80 93 Elevation above sea level 17 33 EU EN779 Class F6 55 External Control Signal Wiring 78 91 Analog 0 78 91 Digital 0 78 91 Torque Requirements 119 Wiring Routing 78 91 External Ducting Specifications 55 Eye bolts 28 Rockwell Automation Publication 6000 INOO6B EN P November 2015 F Fixed mounted Power Modules Air Flow 56 65 Cable Routin
172. the drive Most drive configurations will have two to five fans Higher power configurations will have a higher number of fans See PowerFlex 6000 Dimensions and Weights For IEC on page 123 for fan quantities and dimensions IMPORTANT See Mounting Clearance Distance on page 18 to verify that the fans have the appropriate clearance distance on top of the cabinet Table 11 Fan Housing Specifications Model Dimensions HxWxD approx Weight approx RH40M 330 x 440 x 500 mm 13 0 x 17 3 x 19 7 in 20 kg 44 1 Ib RH45M 370 x 490 x 550 mm 14 6 x 19 3 x 21 7 in 25 kg 55 1 Ib 1 Place the fan housing on the top plate of the drive making sure the socket is on the same side as the aviation plug 2 Secure the fan housing using M6 hardware 6 places See Torque Requirements on page 119 3 Connect the aviation plug located on top of the cabinet with the socket on the fan housing Figure 36 Main Cooling Fan Housing Main Cooling Fan Housing M6 Hardware 6 places per fan DDDDDDED Rear View Socket Aviation Plug 50 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Drive Mechanical Installation For IEC Chapter 3 Install Drawout Power Power Modules are available in a wide variety of amperage ratings relating to the Modules if applicable required motor current Power Modules rated up to and including 200 A are fixed mounted in the drive and ship al
173. the lifting angles 1 Remove rigging from the lifting angles and remove the bolts holding the lifting angles together retain or recycle hardware 2 Remove and retain the hardware from the base of the lifting angles and retain or recycle the lifting angles 3 Reinstall the hardware M20 x 60 removed in step 2 to seal the holes on the top of the drive Figure 25 Rockwell Automation Publication 6000 INOO6B EN P November 2015 39 Chapter2 Shipping and Handling Procedures For UL Figure 25 Insert bolts E M20 Bolt d Lockwasher N Washer Lift the Isolation 1 Unfasten and remove the middle top plate on top of the cabinet and retain Transformer Cabinet middle top plate and hardware Figure 26 Remove Top Middle Plate s Middle Top Plate M6 x 12 Bolt Lock Washer a z Washer Lock Washer The cabinet version with a single main cooling fan will have two support brackets The cabinet version with two fans will have three support brackets 40 Rockwell Automation Publication 6000 IN006B EN P November 2015 Shipping and Handling Procedures For UL Chapter 2 Most configurations have one or two top mounted main cooling fans in the isolation transformer cabinet However high power configurations can have more Figure 27 Isolation Transformer with one Fan Assembly Overhead view Fan Opening Middle Top Plate Support Brackets 2 Attach the steel cable to the U ri
174. the shipping splits Use fasteners with a minimum metric Grade 10 9 SAE Grade 8 strength Rockwell Automation recommends using Crosby bolt type shackles All lifting cables must meet lifting capacity requirements Close and secure all drive doors before moving the equipment Keep the cabinets bolted to the wooden shipping skids to minimize the possibility of it tipping Do not remove the wooden skid until the cabinets are at the final installation area Depending on the type of drive cabinet the crate may include a pair of lifting angles Install both lifting angles on top of the cabinet ATTENTION Do not stand near or underneath equipment being lifted overhead to prevent access from unauthorized personnel ATTENTION Restrict access to areas where equipment will be lifted overhead Fork Lifts The terms fork lift lift truck and fork lift truck are all commonly used and refer to the same thing A single fork lift may be used for offloading and moving cabinets up to 4 m 157 in wide if the fork lift has sufficient lifting capacity Cabinets exceeding 4 m should be offloaded and moved with two fork lifts operating in tandem e Insert the forks into the openings of the wooden shipping skid e Balance the crates on the forks The crates can be heavier on one side Use safety straps when handling to steady the crate while moving 14 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Shipping and Handling
175. tor Power Rating Transformer Rating Width Depth Height Cont w Table 47 6600V Input amp 6300V AC Output 36 Pulse Configuration 18 Power Cells Motor Amps Typical Motor Power Rating Transformer Rating Width Depth Height Cont LOU T Ww 9 Table 48 6600V Input amp 6600V AC Output 36 Pulse Configuration 18 Power Cells Motor Amps lt L Motor Power 2 Height Cont CUM ei 31 135 37 162 300 1300 400 1750 400 1750 4320 1362 2640 155 200 186 240 1500 1940 2000 2600 2000 2600 5200 1362 2640 Table 49 6900V Input 8 6000V AC Output 36 Pulse Configuration 18 Power Cells Motor Amps aoir owe tang Ta Dew Weg 148 1300 1750 1750 4520 1362 2640 171 200 205 240 1500 1753 2000 2350 2000 2350 5200 1362 2640 140 Rockwell Automation Publication 6000 IN006B EN P November 2015 Structure Code STR 9 STR 10 Structure Code STR 6 STR 7 STR 8 Structure Code STR 1 STR 2 Structure Code STR 1 STR 2 Structure Code STR 1 STR 2 Structure Code STR 1 STR 2 STR 2 PowerFlex 6000 Dimensions and Weights For UL AppendixE Table 50 6900V Input amp 6300V AC Output 36 Pulse Configuration 18 Power Cells Motor Amps Typical Motor Power Rating Transformer Rating Width Depth Height Structure Code Cont 31 85 37
176. trical Drawing for actual wire number designations Figure 76 Power Cabling Overview 2 3 2 4 kV Fixed mounted Power Module Configuration Voltage Sensing Board Isolation Transformer Cabinet Power Module LV Control Cabinet 108 Rockwell Automation Publication 6000 INOO6B EN P November 2015 Drive Electrical Interconnection For UL Chapter 8 Connect Isolation Introduction Transformer Secondary Power Cables The isolation transformers three phase primary coils are oriented L1 L2 and L3 from left to right as viewed from the front The secondary windings are also divided into three principal sections from top to bottom The upper third are to feed the power modules in the U output phase The middle third are to feed the power modules in the V output phase The bottom third are to feed the power modules in the W output phase Figure 77 Figure 77 Isolation Transformer Primary and Secondary Winding Orientation PRIMARY WINDING INPUT SECONDARY WINDING OUTPUT The secondary windings are brought out to corresponding vertical isolated stand offs on the body of the transformer orientated L1 L2 and L3 from left to right as viewed from the front See Figure 78 Rockwell Automation Publication 6000 INOO6B EN P November 2015 109 Chapter 8 110 Drive Electrical Interconnection For UL Each secondary winding set will have a designated W V and U terminal connection For example from top to bottom and left to right
177. u 9 YIS L 006 008 008 sl OrHd 9 HIS 00 008 007 007 ccs OrHW E 9 WIS m 00ZL mm OSV 00S 009 EZE 620 9 446 9 L6SXC81X0CV 39 V 3098V 10009 CX9 X G 91 L6SXC81X0CV co N Mo Jo V 30v V 10009 4420 9 446 9 L6SXC81X0CV OVHU E J9fV ICL9V N0009 a cc p L c c Mo 4420 9 456 9 165468 LNU Cp 065 URp SEE OVHU E J9fV IdSS N0009 cc L c c Lo 6420 9 456 9 L6SXC81X0CV EM 191 106 0009 e cc 6 209 456 9 L6SXC81X0CV a OrHd t 39 V 30 V f10009 juo kad ur ww QXMXH s co e D wea wea l cc Sue Jo es 5 ao R 2 sdwy 4030 60 616 9 25 04 jequnN S 2 A S lt V 1010W 00 6 67 5 3 eco 5 ar S119 1 M0d ZL uorje1nfijuo asjng pz 3nding JY A09 Lv 000t 8 Indul AODLY LE 1921 133 Rockwell Automation Publication 6000 INOO6B EN P November 2015 PowerFlex 6000 Dimensions and Weights For UL Appendix E 5 06 4 OrHd 9 C HIS 000 0066 0580 0580 tS L OVC 000 9 00027 0009 eo C4 co Leo c we wN N eo C4 87871 8c8 00011 r6 0L FEL 66 06 985 rc SU L9 72702 2950 1998 L VCXLE OLXES 9L 8 8 0v 9 OVZL 0006 099 O
178. ueJ Jo U0 Jaquiny ve MoJJIly 16101 Gin MOJ E30 sue buijoo 64 uba lwan 015 10 andingoy yy sIJ9 15 6 7 55 9L 0 AOOEE Indul JY A000 LL pE ILL 129 Rockwell Automation Publication 6000 INOO6B EN P November 2015 oze vos ozr 09 985 09 ooze Ot ose Oz eve sie 099 09 00 ozsz 94 og w z ooe og ooo oz S osl oz oo 0091 91 091 Or ze 091 09 ost ost ogzi 991 ori 0411 ost Sa 0L vet zu 068 041 w 008 soL 06 zL 96 09 cous o 9 se e fosco ooce oseo ozz oze ooz zost zo oost oces oese oorz oger cons o co v se e oses ooce osso ozz oze ooz zost zo oost oces oese oorz oos cous mr 9 cine ose St 096 osio ozz oze ooz zost zo oost oces oese onze ave oose se nlm oee oses ouz ore ooz zosi zo oces ose oc oost oose se e evar veee we z ose ozoe ore ooz tori zo ooer oces 064 ose osse oose St e evr vz z orc oovs oze owe zoei zo ooet oces oese oose se nlm oo os
179. umed by Rockwell Automation Inc with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations WARNING Identifies information about practices or circumstances that can cause an explosion in a hazardous environment which may lead to personal injury or death property damage or economic loss ATTENTION Identifies information about practices or circumstances that can lead to personal injury or death property damage or economic loss Attentions help you identify a hazard avoid a hazard and recognize the consequence IMPORTANT Identifies information that is critical for successful application and understanding of the product Labels may also be on or inside the equipment to provide specific precautions SHOCK HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that dangerous voltage may be present BURN HAZARD Labels may be on or inside the equipment for example a drive or motor to alert people that surfaces may reach dangerous temperatures ARC FLASH HAZARD Labels may be on or inside the equipment for example a motor control center to alert people to potential Arc Flash Arc Flash will cause severe injury or d
180. verified as isolated and de energized can subsequent work be performed Even though the input to the drive may be open it is still possible for hazardous voltage to be present Refer to national and local safety guidelines for detailed procedures on how to safely isolate the equipment from hazards Rockwell Automation Publication 6000 INOO6B EN P November 2015 81 Chapter6 Drive Electrical Installation For UL Electrical Drawings Grounding System Requirements 82 ATTENTION The national and local electrical codes outline provisions for safely installing electrical equipment Installation must comply with specifications regarding wire type conductor sizes branch circuit protection and disconnect devices Failure to do so may result in personal injury and or equipment damage Before connecting any power cables or control signal wiring review and understand the information contained in the project specific Electrical Drawings They contain critical information such as e Minimum power cable insulation ratings and sizes e Power terminal locations and designations e Terminal block designations for all connections to external customer control signal wiring and control power supply cables The practice used within the PowerFlex 6000 electrical drawing is based on the UL Underwriters Laboratories standard Device designations used on the drawings and labeling are explained on each drawing set Wiring identification uses
181. vertical isolated stand offs on the body of the transformer orientated C B and A from left to right as viewed from the front See Figure 63 Rockwell Automation Publication 6000 IN006B EN P November 2015 97 Chapter 7 98 Drive Electrical Interconnection For IEC Each secondary winding set will have a designated C B and A terminal connection For example from top to bottom and left to right the terminals from the first winding set are C1 B1 and A1 the terminals from the next winding set are C2 B2 and A2 and so on As shown in Figure 61 the first winding set C1 81 and A1 will connect to the three phase input power connection of the first power module in the U motor phase array PCA1 the second winding set will connect to the second power module in the U motor phase array PCA2 and the third winding set will connect to the third power module in the U motor phase array PCA3 The next three winding sets connect to the power modules in the V motor phase array The remaining three winding sets connect to the power modules in the W motor phase array Figure 61 shows 3 3 3 kV configuration The 6 6 6 kV and 10 kV configuration have more power modules and therefore have more corresponding isolation transformer secondary windings The concept is the same the top third of the winding sets feeds the power modules in the U phase the middle third feeds the power modules in the V phase and the bottom third feeds the power
182. with a capacity of not more than 20W for indication backup and 11 passive dry contact outputs powered by the drive with a capacity of 220V AC 5A for DCS status fault indication For detailed information see Table 57 and Table 58 on page 149 These outputs are scalable depending on user requirements The drive is provided with dry contact outputs 1 N O with a capacity of 220V AC 5 A valid when closed which trigger the user provided medium voltage circuit breaker for interlock with the user provided medium voltage switch cabinet For detailed information see Table 57 and Table 58 on page 149 Ethernet interface is supplied as standard other communication interfaces including Modbus and Profibus are provided as options For detailed information see Figure 86 on page 148 Wiring Routing and Connection The control signal wiring enters the drive through the same opening as the control power wiring in the LV Control Cabinet Figure 50 or Figure 51 The wiring terminates either to the X1 or X2 terminal block strips on either side of the LV Control cabinet Figure 52 See Figure 83 or Figure 84 for general information Refer to Electrical Drawings for actual connection points Rockwell Automation Publication 6000 INOO6B EN P November 2015 Connect Electrical Safety Interlock Circuit to Input Circuit Breaker Door Position Limit Switch Drive Electrical Installation For IEC Chapter 5 Introduction The electric
183. y Secondary Secondary Winding Winding Winding Connections Connections Connections I em E Power Cable KL Shi to Power Module EC ILI Wil T Wail LH eat TRUEST i T a M8 Hex Nut M8 Flange Nut Front View Figure 64 6 6 6 kV Drawout Power Module Configuration Bus Bar Flat Washer M12 Hex Nut Lock Washer Secondary Connection Winding from toPower c Isolation a ENT E e d Module ES 45 ey SL Transformer e p LL A i U Phase vl yos x M12x35 Hex Bolt 9 s 9 4T 9 gt 39 ry Li DA A H K d e GEN V Phase WPhae J K Rear View Rockwell Automation Publication 6000 INOO6B EN P November 2015 99 Chapter7 Drive Electrical Interconnection For IEC Connect Motor and Voltage Introduction Sensing Board Cables The Voltage Sensing Board cables and the motor cables both connect to the same output point of each motor phase array Figure 61 However because the fixed mount and drawout power module mechanical designs are different the physical connection point differs between these two configurations The voltage sensing board cables and motor cables are always bundled in the isolation transformer cabinet for shipment Figure 65 6 6 6 kV Fixed mounted Power Module Co
184. y hooks or shackles 2 Adjust the rigging lengths to compensate for any unequal weight distribution of load TIP There are pairs of holes to attach lifting cables on either end of the lifting angle Generally use the outside holes on either end for the greatest stability The inner holes could be used to adjust for the cabinet s center of gravity The cabinet must remain in an upright position To reduce the tension on the rigging and the compressive load on the lifting device do not allow the angle between the lifting cables and vertical to exceed 45 Figure 9 N ATTENTION Do not tilt the drive Figure 9 Overhead Lifting Power Module LV Control Cabinet Two Pairs of Holes for Overhead Lifting Attachments 450 3 Remove the steel angle brackets bolting the cabinet to the skid Rockwell Automation Publication 6000 INOO6B EN P November 2015 23 Chapter1 Shipping and Handling Procedures For IEC 4 Lift the cabinet using overhead lifting angles and remove the wooden shipping skid from under the equipment this point Do not place any parts of the body underneath the cabinet Remove ATTENTION Only lift the cabinet high enough to remove the shipping skid at the shipping skid from the work area before continuing Remove Overhead Lifting Cables and Lifting Angles When the cabinet is in the desired position remove the lifting angles 1 Remove rigging from the lifting angles and remove the bolts holding t
185. y means other than the handling methods listed in this publication Failure to do so may result in personal injury or death damage to the drive and potential economic loss The PowerFlex 6000 drive cabinets are bolted to wooden skids and placed into wooden shipping crates After the crating is removed the cabinets must remain bolted to the wooden skids until moved to its final installation area Lifting angles are affixed to the shipping skid on either side of the cabinetry where applicable The cabinets must remain in an upright position during handling be sufficient to safely raise the drive Check the shipping weights by referring to ATTENTION The load carrying capacity of the lifting device and rigging must the container s commercial invoice Round rollers can be used to assist in moving the cabinets to the installation site Once at the final site the pipe rolling technique can be used to place the cabinet in the desired location equipment is not scratched dented or damaged in any manner Stabilize the WARNING Exercise extreme caution when moving the drive to ensure the drive during handling to prevent tipping and injury to personnel Any error in transporting or installing the drive will delay the drive commissioning progress Rockwell Automation Publication 6000 INOO6B EN P November 2015 29 Chapter2 Shipping and Handling Procedures For UL General Handling Information Offloading and Moving Crates Rockwel
186. z a S ia We a 18 1e w eo e e e e wN 007 9 Y MALEY N0009 c C4 EBBE v 8L 6 L OrHd t C4 on cc c ce c c m N co coa 22 Mo ce C4 co C4 S co Mo N ce c e N Jequiny 00 4 up s lt ww qxMxH m U0 e S Wwe D Wn a lt 2 2301 zz sueyjo 62 1 Be 2 58 9 1 M0d jequiny a R e 2r sdwiy 1030W saquiny 60Je3e 7M ui ww suoisueuiq R R as S119 4aMog 81 7 3 9 3nd3no JY A0099 9 Indul A0069 t 91061 139 Rockwell Automation Publication 6000 INOO6B EN P November 2015 AppendixE PowerFlex 6000 Dimensions and Weights For UL Table 44 2400V Input amp 2300 2400V AC Output 18 Pulse Configuration 9 Power Cells Motor Amps Typical Motor Power Rating Transformer Rating Width Depth Height Cont NEN e Ww gt TW Table 45 4160V Input amp 4000 4160V AC Output 24 Pulse Configuration 12 Power Cells Motor Amps Typical Motor Power Rating Transformer Rating Width Depth Height om o o Ww 9 110 145 132 174 670 880 900 1180 900 1180 3790 1362 2640 153 200 183 240 933 1220 1250 1635 1250 1635 4380 1362 2640 Table 46 6600V Input amp 6000V AC Output 36 Pulse Configuration 18 Power Cells Motor Amps Typical Mo

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