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PowerFlex® 6000 Medium Voltage Variable Frequency Drive

1. 1 In Windows ME press Terminal Settings F4 2 Press the Down Arrow to choose Time Date Regional Settings and press Enter 3 Choose Time zone and press Enter 4 Scroll up or down and select the desired time zone a Press Daylight Savings F1 b Select the Yes radio button and press Close F8 5 Press OK F7 6 Choose Date and press Enter a Press Year F1 Month F2 and Day F3 to set the correct date b Press OK F7 7 Choose Time and press Enter a Press Hour F1 Minute F2 and Seconds F3 to set the correct time b Press OK F7 8 Press Close F8 twice Reset F7 and Yes F7 to restart the HMI 9 Select language and bypass mode in the System Parameters Settings interface 10 Press to accept and proceed to the Main Interface Screen Verify the date and time is updated under Version Info Version Info 4 3 2014 3 52 36 PM Rockwell Automation Publication 6000 INO07A EN P October 2014 65 Chapter3 Commissioning Notes 66 Rockwell Automation Publication 6000 INO07A EN P October 2014 Chapter 4 No load Test Introduction medium voltage doors on the PowerFlex 6000 and Bypass Cabinet if supplied prior to removing Lockout and Tagout provisions and closing the input circuit breaker All safety related work practices outlined in Electrical Safety requirements for Employee Work places must be followed when removing the input circuit breaker from the locked out tagged out
2. Fault To Bypass Setup 0 Disable 1 Enable T02 Fault To Bypass Delay 3 Jo fo feo Setup Setup While T1 1 valid 103 Fault To Bypass Delay When Starting Setup While T1 1 valid the Motor 0 60s T04 Fault To Bypass Minimum Frequency Rated Setup While T1 1 valid 0 Rated Frequency Hz Frequency T05 Auto Restart After Input Supply Power Loss 1 Setup 0 Disable 1 Enable T06 Input Supply Power Loss Time for 20 20 Setup Auto Restart 0 205 T07 Local Frequency Command Selection ON 1 Setup If T7 0 enter the frequency on the HMI If T7 1 use a 0 Digital potentiometer to set the frequency on the LV Control 1 Analog Cabinet Confirm P262 1 70 Rockwell Automation Publication 6000 INO07A EN P October 2014 T Parameter TOS T09 T10 T11 T12 T13 No load Test Chapter 4 Description Modify Login Instruction Root Level Remote Frequency Command Selection Setup Confirm P262 1 1 Analog If T8 1 then the analog quantity 4 20 mA from Remote 2 4 Step Speed E dia to 0 Hz 20 mA corresponds to the rated a If T8 2 use T13 to set step speed If T8 4 communication mode with remote Frequency Step For Accel or Decel OMIT MM Changes the step frequency when Accel or Decel is pressed Frequency Exit Exit Config Environment Password Environment Password Exit Config Environment Password 555 oF Setup Setup This function will not work if the drive is running Aut
3. 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 Additional Resources 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 http www ab com Provides declarations of conformity certificates and other certification details Rockwell Automation Publication 6000 IN007A EN P October 2014 9 Preface Notes 10 Rockwell Automation Publication 6000 INO07A EN P October 2014 Overview Chapter 1 Introduction Information contained in this chapter will assist in commissioning a PowerFlex 6000 medium voltage AC drive Review the information contained in this chapt
4. Automation Publication 6000 IN007A EN P October 2014 77 Chapter 4 78 No load Test 5 From the Main Interface Screen press the Set Frequency input field Allowed MVClosd Ready Connect Running Warning Local Remote Monitoring Parameters Actual Frequenc 3049 50 Set Frequency Actual Frequency Motor Speed Version Info Motor Voltage 5 HMI 3001 Motor Current 6 In the Set Freq dialog box enter a value of 10 and press m Press eS to confirm o 020000 Allowed MVClosd Ready Connect Running Warning Local Remote Set Freq Rockwell Automation Publication 6000 INO07A EN P October 2014 No load Test Chapter 4 Y 7 Press EH and press es in the Start Drive dialog box to confirm operation Allowed MVClosd Ready Connect Running Warning Local Remote al Frequency Start Drive 8 Record the output voltage in the HMI screen The value must not by more than 10 of output voltage based on the drive configuration 9 Press the Set Frequency input field In the Set Freq dialog box enter a cc 55 Yes value of 20 and press m Press to confirm 10 Record the output voltage in the HMI screen Repeat this process for 30 40 and 50 Hz or 60 Hz 11 Run the drive for 30 minutes at 50 Hz or 60 Hz dependent on system frequency 12 Switch off customer supplied control power The Control Power Supply Loss warning appears in the HMI The K8 relay wi
5. Local status indicator is on Verify Operation of Input Output and Bypass Isolation Switches Manual Bypass Input Output Isolation Switches 1 Press Operation from the Main Interface screen Input Supply S Control Owner Selection 52 Rockwell Automation Publication 6000 INO07A EN P October 2014 Commissioning Chapter 3 2 Open the Bypass cabinet door and close QS2 and QS3 Verify the Input and Output contactors are closed on the HMI Input Supply 3 Close the customer supplied input circuit breaker by installing a temporary jumper wire X 117 X 119 Verify the input circuit breaker is closed Input Supply Control Owner Selection Rockwell Automation Publication 6000 INO07A EN P October 2014 53 Chapter3 Commissioning Bypass Isolation Switches 1 Press Operation from the Main Interface screen Input Supply Control Owner Selection 2 Open the Bypass cabinet door and close QS1 Verify the bypass isolation switch is closed on the HMI 54 Rockwell Automation Publication 6000 INO07A EN P October 2014 Commissioning Chapter 3 3 Close the customer supplied input circuit breaker by installing a temporary jumper wire X 117 X 119 Verify the input circuit breaker is closed Input Supply Control Owner Selection Verify Operation of Input Output and Bypass Contactors Automatic Bypass Input Output Drive Contactors IMPORTANT Turn the 3 position on the selector sw
6. P463 Flying Start Low High Speed Regions Boundary 96 IMPORTANT P416 enables Flying Start Selection If the Flying Start is not successful change the other parameters listed accordingly Otherwise these parameters do not normally need to be changed If the drive cannot search the speed in the field increase P417 to decrease the search step and improve the accuracy or increase P113 and decrease P115 to improve the accuracy If there was any noise during the restore stage increase P457 or P459 P463 does not need to be changed Search from Maximum Frequency to implement AC mode to VF mode Relevant parameter P461 P462 P465 Description these parameters use the auto restart feature after a system fault Instruction if P461 is enabled P461 1 the drive will restart at once when system fault occurs If there is something wrong with a Power Module it will wait for P465 before restarting If a fault happens twice during the Fault Reset Timeout P462 the drive will trip IMPORTANT __Ifrestart feature was enabled the second mode of flying start feature must be enabled Rockwell Automation Publication 6000 INO07A EN P October 2014 A Analog Input 93 C Cabinet Plates Pre Commissioning Sealing 29 Commissioning 31 Control System Check 35 Procedure List 31 Setup 32 Process Flowcharts 12 Set Date 64 Set Regional Settings 65 Set Time Zone 64 Commissioning Requirements Computer Requirements 15 Electri
7. Yellow L11 A Phase Line Cable Terminal U Phase e Power Module Bus e VSB Input Cable e Motor Cable Termination e Motor Cable Connection to Power Module Bus Green L12 B Phase Line Cable Terminal V Phase e Power Module Bus e VSB Input Cable e Motor Cable Termination e Motor Cable Connection to Power Module Bus Red L13 C Phase Line Cable Terminal W Phase e Power Module Bus e VSB Input Cable e Motor Cable Termination e Motor Cable Connection to Power Module Bus 22 Rockwell Automation Publication 6000 INO07A EN P October 2014 Drive Megger Check Preparation and Inspection Chapter 2 Incoming Line and Outgoing Motor cables must be routed separately to prevent cable insulation damage All cables must be terminated on each end and sufficiently torqued All customer power cables must be Hi Potted or Meggered and read a sufficient insulation value Review Hi Pot or megger test report from the customer Control Wiring Identify all customer required control wiring detailed on the Electrical Drawings and locate it within the terminal blocks Verify the cable insulation is not tightened in a terminal connection All connections must have proper continuity Inspect the control cable routing to ensure that DC control wiring and AC control wiring are separated from each other Routing them together in the same bundle or cabling product may result in unwanted noise being induced in the drive control In the overhead ca
8. equipment Hazardous voltages may exist in the cabinet even with the input 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 Servicing energized industrial control equipment can be Rockwell Automation Publication 6000 IN007A EN P October 2014 15 Chapter2 Preparation and Inspection Inspect Drive Components Lockout and tagout the input circuit breaker before opening the doors to the drive system cabinets After the cabinet doors are opened immediately test the incoming and outgoing power cables 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 local safety guidelines for detailed procedures on how to safely isolate the equipm
9. parameter field to enter the number of power cells per phase and press u E 6 Pressthe P224 parameterfield 7 Change the value from 120 to 80 Press EN and press NH 8 Press EN to exit P Parameter Settings to confirm Setup has logged out and EM to return to the Main Interface Screen WARNING Remove the temporary jumper X1 117 X1 119 in the LV Control Cabinet which was installed to enable the Control System Test Rockwell Automation Publication 6000 IN007A EN P October 2014 63 Chapter3 Commissioning Set Date and Time Zone To access the Date and Time Zone settings you must exit the PowerFlex 6000 HMI to Windows CE Access T Parameters 1 Press Seinos from the Main Interface Screen Setup Settings under Parameter Access Level 2 Press The Setup Login dialog box appears Press S l 3 Enter the User and Password details 4 Press to login 5 Once logged in press oe T Parameter Settings in the Setup Parameter Type 6 Press 7 Press the T10 parameter input field Enter 555 and press el TIP It will take 3 5 minutes to shutdown 64 Rockwell Automation Publication 6000 INO07A EN P October 2014 Commissioning Chapter 3 Change Time Date Regional Settings IMPORTANT Enter the Time Zone settings before changing the date and time
10. stop Trip fault Active Alarms QTY AccTime Message 1 00 00 28 E Stop Trip 3 00 07 00 System Locked 4 Twist to pull out the E stop button on the front of the LV Control cabinet 5 Press Home to return to the Main Interface Screen Rockwell Automation Publication 6000 INO07A EN P October 2014 Commissioning Chapter 3 to remove the fault Press ue to confirm 6 Press operation in the Reset Drive dialog Verify Switching from Local Control to Remote Control Depending on whether the drive has an automatic or manual Bypass or no Bypass configuration the Operation Interface screen will be different 1 Press from the Main Interface Screen 2 Press in the Control Owner Selection 3 Press i in the Select Remote Control dialog ipu EY Control Owner Selection 7 User CB Pe sw Select Remote Control i ED a 4 Press to return to the Main Interface Screen and confirm Remote status indicator light is on e 00000e e Allowed MVClosd Ready Connect Running Warning Local Remote 5 Press from the Main Interface Screen Rockwell Automation Publication 6000 INO07A EN P October 2014 51 Chapter3 Commissioning 6 Under Control Owner Selection press EA Control Owner Selection Select Local Control Yes 7 Select to confirm selection in the Select Local Control to return to the Main Interface Screen and dialog and press confirm the
11. the activities and documentation needed to review the drive application 2 Review the start up activities and timelines 3 Review the Pre commissioning Checklist see 6000 IN006_ EN P Review the drive application Review Drive Application To ensure trouble free commissioning it is necessary for all personnel involved in the start up to familiarize themselves with the drive and actual application Service on the equipment should not be performed without a clear understanding of how the equipment has been designed to function and how the equipment has been applied Before commissioning the drive inspect the process that the drive is intended to control This identifies how the equipment is designed to suit the application and any potential hazards Determine what measures must be taken to ensure that commissioning the equipment does not expose anyone to hazardous situations or damage to the equipment Verify that the load is not turning due to the process as a freewheeling motor can generate voltage that will be back fed to the equipment being serviced Take all actions necessary to ensure that motor regeneration into the drive does not occur while the equipment is being started up or being serviced Review Electrical System One line Diagram Identify all relevant equipment Tag Identification names and numbers Study the system for sources of power and parallel paths of medium voltage power Retain a copy of the one line diagram
12. to accept Rockwell Automation Publication 6000 IN007A EN P October 2014 73 Chapter4 No load Test Change Parameter T13 1 Press the T13 Parameter input field 2 Enter desired speed values in the Enter Four Steps dialog box Press the input field to enter a value IMPORTANT Parameter T08 must be set to 2 3 Press BW to accept IMPORTANT Refer to publication 6012 UM001_ EN P PowerFlex 6000 Drive Bypass Units User Manual or detailed information about operating the switches in bypass cabinets 74 Rockwell Automation Publication 6000 INO07A EN P October 2014 No load Test Chapter 4 Close Isolation Switches in Bypass Cabinet 1 Manual bypass see Figure 21 a Open QS1 direct line operation isolation switch b Close QS2 and QS3 drive operation isolation switches 2 Automatic Bypass with isolating switches see Figure 20 a Close QS1 and QS2 drive operation isolation switches Close Input Circuit Breaker medium voltage doors on the PowerFlex 6000 and Bypass Cabinet if supplied prior to closing the input circuit breaker All safety related work practices outlined in Electrical Safety requirements for Employee Work places must be followed when removing the input circuit breaker from the locked out tagged out state ATTENTION Medium Voltage is required for this test Close and lock all 1 Remove tags and locks on the input circuit breaker 2 Close input circui
13. 07A EN P October 2014 Single Line Diagrams Figure 18 PowerFlex 6000 without Bypass OF Input Circuit Breaker by Customer PowerFlex 6000 Circuit Breaker Rockwell Automation Publication 6000 INO07A EN P October 2014 Appendix B 83 AppendixB Single Line Diagrams Figure 19 6012M Automatic Bypass Version 1 without Isolation Switches Input Circuit Breaker QF by Customer KM1 PowerFlex 6000 KM3 Circuit Vacuum Breaker Contactor X NG 84 Rockwell Automation Publication 6000 INO07A EN P October 2014 Single Line Diagrams Appendix B Figure 20 6012M Automatic Bypass Version 2 with Isolation Switches Qr Input Circuit Breaker by Customer Bypass Unit KM3 KM1 PowerFlex 6000 Circuit Vacuum Isolation Breaker Contactor Switch X A Laka Rockwell Automation Publication 6000 INO07A EN P October 2014 85 AppendixB Single Line Diagrams Figure 21 6012M Manual Bypass L OF Input Circuit Breaker by Customer Bypass Unit 051 052 PowerFlex 6000 53
14. 2 the output voltage will be improved per P451 Low Speed Voltage Compensation Set Maximum Modulation Index and Limit Output Voltage Amplitude Relevant parameters P455 P456 Description this function sets the maximum modulation index and limit the output voltage amplitude so the drive can run above rated frequency Instruction change the output voltage without changing the output frequency by adjusting P455 Adjust this value according to the field conditions to ensure the output voltage frequency is consistent with standard V F curve P456 is the output voltage amplitude limit the amplitude of output voltage cannot exceed this value Set Flux Time Relevant parameters P454 Description this function is designed to build a steady rotating magnetic field before the rotor operates Instruction P454 is the time to build the rotating magnetic field This value will not generally be changed Rockwell Automation Publication 6000 INO07A EN P October 2014 Analog Input Stop Mode Flying Start Function Special Function Parameter Settings Appendix C Relevant parameter P205 P206 3 3 3 kV and 6 6 6 kV drives use the same VSB board Set P205 and P206 according to the following table Voltage Level kV P205 P206 Relevant parameter P24 P252 P253 Description the drive has two ways to stop the drive ramp down or coast stop Instruction P24 1 to select coast stop P24 0 to select ramp down If P24 1 the o
15. 2014 No load Test Chapter 4 Table 12 Setup and R amp D Parameters Continued P Description Modify Login Instruction Parameter Root Level P091 Skip Frequency 1 Upper Limit o Jo oa 75 R amp D P092 Skip Frequency 2 Lower Limit o ON fo q75 RD P093 Skip Frequency 2 Upper Limit NT 75 RED P113 Flying Start Initial Output Voltage 100 La Percentage 96 P114 Flying Start Current Comparison Delay For 1000 5000 R amp D Motor Speed Search ms P115 Flying Start Current Threshold For Successful 5 100 R amp D Motor Speed Search P198 HECSRated umenti fo Jon fo 500 Setup Set value according to the Electrical Drawings P199 Motor Rated Current A fo JON fo 500 Setup Set value according to the customer motor nameplate data as erte okagesangfaar maen 1959 m i sos un rs Horace ws fon o memo P213 Output Short Circuit Fault Threshold Short Circuit Fault Threshold aseran nen m on fo 199 99 Setup P216 High Frequency Output Over Current 199 99 Threshold P224 Output Voltage Deviation Fault Threshold so fo Jo 199 99 Setup Set to 120 for Control System Check Set to 80 afterwards P252 Motor In Stopping Condition Threshol 1 1 R amp D P253 Motor Coast Stop Time w ON fo 10000 P259 Frequency Command Analog Offset 0 0 100 199 99 P260 Frequency Command Analog Scaling Factor 00 fo 0 199 99 P262 Frequency Command Source Selection OFF 1 Setup 0 Digital 1 Analog P335 Analo
16. 2014 87 Appendix C 88 Special Function Parameter Settings Switch Control Sources Relevant parameter P4 Description P4 selects the control source to start stop or reset the drive There are two Control Sources the HMI and the hard wired I O interface DCS They cannot be enabled at the same time Rated Maximum Output Frequency Relevant parameter P460 P466 Description sets the rated output frequency Instruction P460 is drive s rated output frequency which should be the same as the motor s rated frequency 0 75 Hz P466 is the drive s Maximum Output Frequency P460 cannot exceed P466 Motor Parameter Setting Relevant parameter P17 P199 Description set basic motor parameters such as rated current and the number of pole pairs Instruction P199 is motor rated current which is used to determine faults P17 sets the number of motor pole pairs Hall Effect Current Sensor Setting Relevant parameter P198 Instruction Set the HECS rated current A used for the drive current sampling Rockwell Automation Publication 6000 INO07A EN P October 2014 Special Function Parameter Settings Appendix C Analog Output Display Parameter Setting Relevant parameters Analog Output Display Parameter Set Frequency P351 P352 P353 P371 Motor Voltage P354 P355 P356 P372 Output Frequency P357 P358 P359 P373 Motor Current P360 P361 P362 P374 Description sets the display parameters for the follo
17. 384 Rockwell Automation Publication 6000 IN007A EN P October 2014 69 Chapter4 No load Test Table 12 Setup and R amp D Parameters Continued P Description Modify Login Instruction Parameter Root Level P416 Flying Start Mode 3 Setup 0 Disable 1 Set Frequency 2 Stop Frequency Plus 5 Hz 3 Rated Frequency P417 Flying Start Motor Speed Search Timeout s so ON Jo 1000 P438 Flying Start Current Compensation Threshold owo Jon Jo 199 99 P451 Low Speed Low Speed Voltage Compensation Compensation Low Speed Voltage Compensation 099 OFF fo 10 Setup P452 Low Speed Voltage Compensation Frequency 20 100 E Threshold P455 Modulation Index 87 99 199 99 Setup Improve the real output of inverter voltage value For example rated voltage of the inverter for 10 kV if the actual output is 9700V the need to improve the actual output voltage to 10 kV need to change this value P456 Motor Voltage Upper Limit 87 99 JN fo 199 99 P457 Flying Start Voltage Recovery Time s 5 163 84 R amp D Low Speed Region P459 Flying Start Voltage Recovery Time s 5 163 84 R amp D High Speed Region 1 ON Can be modified at any time OFF Drive must be off to modify 2 With Remote DCS only There are no specific T parameters to modify when commissioning a drive Verify the values and only modify per customer specifications Description Modify Login Instruction Root Level
18. Auxiliary Fan Input Cables b ies 3 Disconnect the Voltage Sensing Board Output Cable Keep the plug at least 100 mm away from the Voltage Sensing Board Figure 2 Voltage Sensing Board Output Connection Cable VSB Output Cable 4 Disconnect the Isolation Transformer Temperature Monitor Keep the P plug at least 100 mm away from the connection point on the Monitor Figure 3 Isolation Transformer Temperature Monitor ES cL EZ ter IB E ras T Jl AL zu 1 DOCU i a Car T M Lm ii Uo t Keep the plug at least a 100 mm away from Temperature Monitor plug 24 Rockwell Automation Publication 6000 INO07A EN P October 2014 Preparation and Inspection Chapter 2 5 Switch the miniature circuit breakers in the LV Cabinet off Figure 4 Control Switches Miniature Circuit Breakers Sy 6 Switch the miniature circuit breakers in the Isolation Transformer Cabinet LV Control panel off Switch the Top Main Cooling Fan circuit breakers off Figure 5 Control Switches Top Main Cooling Mini ircuit Break iniature Circuit Breakers Fan Circuit Breakers a ARA oe r E ES b es ry Poe ririn o iman i E E 7 Remove two star connection cables the cabling that goes through the HECS and connect them to the output connections of any two power modules within a phase Figure 6 Star Connection Cable Rockwell Auto
19. Circuit Vacuum Isolation Breaker Contactor Switch X d Y 86 Rockwell Automation Publication 6000 INO07A EN P October 2014 Overview System Setting Functions Appendix C Special Function Parameter Settings Table 12 on page 68 outlines specific parameters that must be checked and or modified when commissioning a drive Listed below are specific parameters a brief description and their function to execute optional special functions which while not essential to commissioning a drive and will not be done every time are frequently performed The system setting includes the amount of power modules in one phase the command source the drive rated parameter setting the motor parameter setting the sensor parameter setting the restoring of factory default parameter setting analog output parameter setting Number of Power Modules Per Phase Relevant parameter P7 Description sets the amount of power modules per phase IMPORTANT Thisnumber MUST match the actual amount of power cells in one phase P7 is equal to the amount of power modules in one phase for example if the amount of power cells in one phase is 6 P7 6 Power Module fault and warning information is based on P7 If P7 0 this is ignored and the user can run the drive using low voltage Use this parameter to check low voltage components and the control box See Set P Parameters on page 38 Rockwell Automation Publication 6000 IN007A EN P October
20. Commissioning Manual Allen Bradley PowerFlex 6000 Medium Voltage Variable Frequency Drive Commissioning Manual Publication 6000 IN007 A EN P vm g d p MEL i ae J vem vs ze t E LN J gh re H E 1 Allen Bradley Rockwell Software 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 t
21. LV Cabinet to the Bypass position l Press Operation from the Main Interface screen Input Supply Control Owner Selection Contactor Operation 58 Rockwell Automation Publication 6000 IN007A EN P October 2014 Commissioning Chapter 3 Yes 2 Press under Contactor Operation and press to confirm Input Supply Control Owner Selection Close Bypass Contactor Verify the bypass contactor is closed Input Supply Control Owner Selection Contactor Operation Rockwell Automation Publication 6000 IN007A EN P October 2014 59 Chapter3 Commissioning 60 Yes 3 Press under Contactor Operation and press to confirm Input Supply SSSSSSSSSS SSNS a ontr ol Owner Sel ecti on Open Bypass Contactor peas Operation Control Owner Selection Contactor Operation aM exe id Rockwell Automation Publication 6000 INO07A EN P October 2014 Commissioning Chapter 3 Verify Operation of DCS Input and Output Signals Figure 17 Status Indicators o 00000006 Allowed MVClosd Ready Connect Running Warning Local Remote Table 9 Drive to DCS Signal Name Terminal Number HMI Status Terminal Open Terminal Closed MVPRE Closed CB Red Grey Fault Red Grey Drive running Running Connect Grey Drive STOP Running Connect Grey READY 913 914 Red Grey DCS control 915 916 Red Grey Table 10 4 20 mA Output Current 925 026 0 Rated Current Output Frequency 927 928 A
22. 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 IN007A EN P October 2014 Copyright O 2014 Rockwell Automation Inc All rights reserved Printed in Canada
23. P MOUE ECL 93 Flying Start FUNCTION a naar ia ak Ea AA E rk ba 93 Restart the Divenne a n wus A N 94 Table of Contents Notes 6 Rockwell Automation Publication 6000 INO07A EN P October 2014 Introduction Who Should Use This Manual What Is Not in This Manual Required Supplemental Information Preface This document provides procedural information for commissioning PowerFlex 6000 medium voltage drives This manual is intended for Rockwell Automation Field Service Engineers with Medium Voltage Drive factory training and field experience commissioning medium voltage solid state variable speed drive equipment This manual is generic and does not include project specific or drive specific information Contact the Start up Project Manager for required project specific or drive specific information such as e Dimensional Drawings and Electrical Drawings generated for the customer s order e Spare parts lists compiled for the customers order e Drive specific technical specifications e Pre commissioning Checklist e PLC program for standard integral PLC Dimensional Drawings and Electrical Drawings Thoroughly review the project specific Dimensional Drawings DDs and Electrical Drawings EDs to understand the specific drive system being commissioned before performing any mechanical or electrical work Within these drawings is detailed information which is important to understand for the commissioning and installation o
24. age 1 00 04 11 Abnormal Output Voltage Warning 1 00 04 11 Power Module Cabinet Fan Fault 4 Turn the 013 circuit breaker to the ON position to remove the fault 5 Press Home to return to the Main Interface Screen Simulate Cabinet Door Open Warning 1 Open the left Isolation Transformer Cabinet door 2 Press EM to confirm the Cabinet Door Open Warning The drive will shut off Active Alarms QTY AccTime Message 1 00 00 24 Cabinet Door Opened While Drive Energized 1 00 00 24 System Locked 3 Close the left Isolation Transformer Cabinet to remove the warning 4 Repeat this procedure using the e Right Isolation Transformer Cabinet door e Left Power Module LV Cabinet door e Right Power Module LV Cabinet door e Bypass Cabinet door if applicable Rockwell Automation Publication 6000 INO07A EN P October 2014 49 Chapter 3 50 Commissioning to return to the Main Interface Screen Yes 6 Press to remove the fault Press to confirm operation in the Reset Drive dialog 9 oo Allowed MVClosd Ready Connect Running Warning Local Remote n Monitc jal Frequenc po 40 50 Set Frequenc Reset Drive Actual Frequenc Motor Spee Motor Voltag Motor Currer 4 35 Z2U14 4 16 18 PM Verify E Stop Functionality 1 Press ETE on the Main Interface Screen to start the drive 2 Push the E stop button on the front of the LV Control cabinet 3 Press EM and confirm the E
25. age cables have attached nameplates 5 Verify the diameter of control power cables comply with the drawings Electrical Drawings 6 Verify that the electrical safety circuit wiring between the input circuit breaker and the drive is shielded and only the end at the drive side is grounded 7 Verify the wiring between the DCS and the drive is shielded and only the end the drive side is grounded 8 Verify that the user provided ground cable is gt 50 mm 9 Verify the isolation transformer s primary input voltage matches the system primary voltage 10 Verify that the customer motor specifications match the drive voltage and current capabilities 11 Verify that the isolation transformer s input side wiring is correct Electrical Drawings 12 Verify that the motor output side wiring is correct Electrical Drawings 13 Verify all external control wiring is terminated correctly and to the proper terminal blocks Electrical Drawings 14 Verify torque on incoming line power cable and outgoing motor power cable terminations Electrical Drawings Power Cabling Trace the power cabling from termination point to termination point while examining the cable and its routing for mechanical damage sharp bend radiuses and sources of induced noise and heat The power cabling must be is sufficiently braced to contain the cabling in the event of a ground fault Color coding is used to indicate the phase orientation of the drive Table 6 Color Coding Color Outgoing Motor Side
26. and output not shorted 2 and 4 Control power is fed from the isolation transformer tertiary winding for the 05 circuit breaker therefore not present for this test Verify open status 1 and 2 and output not shorted 2 and 4 Verify that UPS operates normally and that the UPS output is AC220V The output of the UPS is connected to the input of Q2 and Q3 The UPS output voltage can be checked at the input of Q2 or Q3 1is L 3 is N Verify that the input voltage of power supplies is AC220V L N Refer to Figure 16 Verify that the PLC HMI and Control Unit power up Verify that the output voltage is AC220V 2 is L 4 is N Verify CLOSED state 5 and 6 Verify that the PLC I O status lights and control relay red indicating lights illuminate Verify closed status 1 and 2 Verify closed status 1 and 2 Verify that the input voltage at the Q6 circuit breaker is Verify that the input voltage at the Q7 circuit breaker is A Figure 16 AC DC Power Supplies Rockwell Automation Publication 6000 IN007A EN P October 2014 Comments 01 connects customer supplied control power to the control circuit UPS UPS feeds control power to the circuits supplied by the Q2 and Q3 circuit breakers Q2 connects control power directly to AC DC power supplies G1 G2 and G3 PLC HMI and Control Unit Q3 connects control power to PLC 1 0 and control relays Q4 connects control power from isolation transformer ter
27. at the Q1 circuit breaker is Item Close Breaker Q1 Start UPS Press ON button Close Breaker Q2 Close Breaker Q3 Close Breaker Q4 Close Breaker Q5 Close Breaker Q6 Close Breaker Q7 Verify that the output voltage is AC220V 2 is L 4 is N Verify CLOSED state 5 and 6 AC220V 1 is L 3 is N Verify output is not shorted 2 and 4 Verify OPEN state 5 and 6 Before pressing the ON button withdraw the Type UPS power plug from the power receptacle XS2 Verify that the input voltage of the XS2 receptacle is AC220V Verify that the PE connection of the XS2 receptacle is properly grounded Plug the UPS into the receptacle Press and hold the ON button for 3 seconds to turn on the UPS all status lights on the UPS will be green Verify that the input voltage at the Q2 circuit breaker is AC220V 1 is L 3 is N Ignore if done in Start UPS step Verify output is not shorted 2 and 4 Verify that the input voltage at the Q3 circuit breaker is AC220V 1 is L 3 is N Ignore if done in Start UPS step Verify output is not shorted 2 and 4 Verify OPEN state 5 and 6 Control power is fed from the isolation transformer tertiary winding for the Q4 circuit breaker therefore not present for this test A two pole breaker is supplied for lower power drives 220V powered auxiliary fans A three pole breaker is supplied for higher power drives 380V power auxiliary fans Verify open status 1and 2
28. ble tray provided at the front of the drive the AC control DC control and fiber optic cables must be separate These cables may also be from the bottom Control wiring must be routed separately from power cabling Inspect for additional control not shown on the Electrical Drawings Determine its purpose mark the changes on the electrical diagram and send the prints to the Start up Project Manager for future reference Perform a tug test on all control cables to ensure that they are securely fastened and check each plug and connector to ensure it is properly seated in its socket Isolate the Power and Control Circuits ATTENTION Verify the grounding cable connection is secure N Disconnect the low voltage power before the megger test Short circuit the 3 input cables and 3 output cables on one point 1 Isolate and lock out the drive system from any high voltage source Disconnect any incoming power sources medium voltage sources should be isolated and locked out and all control power sources should be turned off at their respective circuit breaker s Verify with a potential indicator that power sources have been disconnected and that the control power in the drive is de energized Rockwell Automation Publication 6000 IN007A EN P October 2014 23 Chapter2 Preparation and Inspection 2 Disconnect four 380V AC cables a b c and o cables from the bottom of the Isolation Transformer Figure 1 380V AC Bottom mounted
29. cabinets for foreign material that might have been Equipment IS Ready for wiring debris remain in the drive system cabinets Clear any metal shavings Energization that may result from any drilling activities left behind during the installation process Ensure no tools hardware or 2 Ifany internal barriers were removed during the commissioning process ensure they are reinstalled Seal the Cabinet Plates Once the back plates have been reattached the seams along the plates must be sealed with silicone Where the silicone is applied is dependent on the cabinet configuration Fixed mounted or Drawout Power Module IMPORTANT Usethe approved silicone that is shipped with the drive Figure 11 Silicone Locations on Fixed mounted Power Module Configuration Apply silicone as shown by bold lines Apply silicone as shown by bold lines Rockwell Automation Publication 6000 IN007A EN P October 2014 29 Chapter2 Preparation and Inspection Notes 30 Rockwell Automation Publication 6000 INO07A EN P October 2014 Chapter 3 Commissioning Introduction ATTENTION The Control System Check requires LV Control power only The Input Circuit Breaker must remain locked out and tagged out for this procedure A number of activities are required before the Control System Check can be performed Procedure Page Simulate Closed Input Circuit Breaker 32 Energize Control Circuit 32 The complete Control System Check reguires the f
30. cal Equipment 15 Hand Tools 15 Software 15 Test Equipment 15 Control System Check 35 P Parameters Restore Settings 62 Set to Enable Testing 37 Procedure List 31 Setup 32 Energize Control Circuit 32 Simulate Closed Input Circuit Breaker 32 Simulate Warnings and Faults 45 Verify E Stop Functionality 50 Factory Default Settings 35 Operation to Set Frequency 43 Switching Local to Remote Control 51 Verify Operation of Bypass Contactors 55 Bypass Isolation Switches 52 DCS Input 61 Frequency Steps 41 Input Output 52 55 Output Signals 61 Control Wiring 23 D Diagrams 6012M Automatic Bypass Version 1 84 6012M Automatic Bypass Version 2 85 6012M Manual Bypass 86 PowerFlex 6000 without Bypass 83 Documentation and Application Review Process Flowcharts 12 Documentation Rockwell Automation 12 Drive Application Review 13 Drive Components Inspection 16 Checklist 18 Drive Megger Check 23 Rockwell Automation Publication 6000 INO07A EN P October 2014 Index Electrical Installation Inspection 22 F Flying Start Function 93 Functional Assessment 17 Checklist 19 Installation Review 21 Electrical Inspection 22 Mechanical Inspection 21 Interconnection Review 20 Checklist 20 L Lockout 15 Safety Test 16 M Mechanical Installation Inspection 21 No Load Test Check Cooling Fan Operation 75 Close Input Circuit Breaker 75 Close Isolation Switches in Bypass Cabinet 75 Configure P and T Parameters 68 Energ
31. ctual Frequency 0 Rated Frequency e O 6 ap D lt Z2 D e e 00020202026 e Rockwell Automation Publication 6000 IN007A EN P October 2014 61 Chapter 3 62 Commissioning When the two terminals specified are shorted verify the result shown in the third column occurs Table 11 DCS to Drive Signal Name Terminal Number Function Fault Reset 412 401 Reset System DCS Start 449 401 Start Drive DCS Stop 450 401 Stop Drive E stop 1101 1101 E stop Drive Frequency Set 931 402 Set Drive Frequency Restore P Parameter Settings Setup Settings 1 Press sees and press diga under Parameter Access Level The Setup Login dialog box appears Press e A Ti Pa ye arameis p A EE P 4 cw Es i M Current User System Settings DEFAULT User Settings L a c lt a p Setup Settings R amp D Settings 2 Enter the User and Password details F3 Password User H Press to enter user details Press when finished Rockwell Automation Publication 6000 IN007A EN P October 2014 Commissioning Chapter 3 ya when finished to enter password details Press 3 Press to login Setup Settings 4 Press P J Press P Parameter Settings and press N WARNING Do NOT press Reset This will reset all factory set parameters 5 Press the P007
32. cursor for the higher voltage rating This may limit the damage if there is a problem If the reading is very high apply the test voltage per Figure 10 4 Perform a Megger test with the insulation meter voltage set according to the voltages shown in Table 7 for 1 minute and record the result The test should produce a reading greater than the minimum values listed below If the test results produced a value lower than these values start segmenting the drive system down into smaller components and repeat the test on each segment to identify the source of the ground fault ATTENTION Discharge the Megger prior to disconnecting it from the equipment Rockwell Automation Publication 6000 IN007A EN P October 2014 27 Chapter2 Preparation and Inspection 5 Disconnect the Insulation Meter and jumpers installed in steps 1 and 2 6 Reconnect all wires cables and connections in reverse order of removal Figure 10 Connected Insulation Meter Outgoing Motor Power Insulation Meter Ground Bus Bar Table 7 Insulation Test Voltage Values Drive Rated Voltage U1 1000 lt U1 lt 5000 5000 lt U1 Typical of Drive Entire Drive Incoming Line Power PA Cable Connections Insulation Resistance Test Direct Voltage V 2500 5000 Minimum Megger Value 1kM Ohm 28 Rockwell Automation Publication 6000 IN007A EN P October 2014 Preparation and Inspection Chapter 2 Final Steps before 1 Review interior of all
33. cy between P413 and P415 P415 gt P413 gt 0 Frequency Skip Relevant parameter P89 P90 P91 P92 P93 Description this function is designed to avoid a trip at certain output frequencies Instruction this function is enabled by P89 There are two bands one is between P90 and P91 the other is between P92 and P93 The Set Frequency can skip out from these two bands if it is within them The Set Frequency will be changed automatically into the upper limit of the bands while the speed increases or changed into the lower limit of the band while the speed decreases Figure 22 The recommended width of these intervals is 1 Hz Figure 22 Principle diagram of Frequency Skip Function Drive Recognize Frequency l l I l I I l P90 P91 Po P93 gt User Set Frequency Rockwell Automation Publication 6000 INO07A EN P October 2014 91 AppendixC Special Function Parameter Settings Speed Reference Functions 92 V F Curve Setting Relevant parameters P451 P452 P453 Description calculates the drive s output voltage according to set frequency There are four available V F curves linear curve straight curve and parabolic curve Set the compensation voltage to improve the lower frequency start torque Instruction P451 is low speed voltage compensation P452 is low speed voltage compensation frequency threshold If the output frequency is lower than P45
34. ed Version Info Motor Voltage 7 HMI Motor Current 4 3 2014 3 52 36 PM 2 In the Set Freq dialog box enter a value of 5 and press m Yes Press to confirm TIP The Set Frequency and Actual Frequency occasionally will not show the exact integral value selected due to internal data conversion in the HMI program 000000060606 Allowed MVClosd Ready Connect Running Warning Local Remote Monit ial Frequency Set Frequenc Actual Frequenc Zu14 10 57 10 AM TERT 76 Rockwell Automation Publication 6000 INO07A EN P October 2014 No load Test Chapter 4 Y 3 Press EH and press es in the Start Drive dialog box to confirm operation 00000 Allowed MVClosd Ready Connect Running Warning Local Remote Start Drive IMPORTANT When the drive is lt 0 5 Hz the Connect light will be illuminated When the speed of the drive surpasses 0 5 Hz the Connect and Running lights will be red 4 Observe the direction of motor rotation If motor rotating direction is incorrect Open the Input Circuit Breaker ME Perform the Lockout and Tagout procedures ta mm Verify that medium voltage is not present in the drive and in the motors cable connection box by using a hot stick e Swap any two cables in the motor s cable connection box f Repeat Close Input Circuit Breaker on page 75 If the motor rotating direction is correct continue to step 5 Rockwell
35. ed L Review all isolation transformer secondary wiring from Power Module cabinet 2 sets CA Verify that the shields of all of the system s connecting wires are properly grounded L Verify all control wires per Electrical Drawing Cables are run in LV cable sections along front and back of cabinet Fixed Mounted Power Module CA Verify all isolation transformer secondary windings from Power Module Cabinet are properly connected 1 set Drawout Power Module L Verify all isolation transformer secondary windings from Power Module Cabinet are properly connected 3 sets L Verify all power supply cables for main cooling fans for Isolation Transformer Cabinet are properly connected 3 sets CA Verify the braided ground connection to adjacent cabinet s is properly installed CA Verify that the shields of all of the system s connecting wires are properly grounded L Review load power cable connection from Isolation Transformer Cabinet L Verify Voltage Sensing Board power cables from Isolation Transformer Cabinet are properly installed Rockwell Automation Publication 6000 INO07A EN P October 2014 Check torque on all power and ground cable connections per specifications Bypass Cabinet if supplied Isolation Transformer Cabinet Power Module Cabinet Low Voltage Control Cabinet L Verify control signal wiring bundles from LV Control cabinet to LV panel in Isolation Transformer cabinet and LV pa
36. eed Command Functions 90 Set Frequency Command Source Relevant parameter P262 Description this function selects the frequency command source analog or digital Instruction If P262 0 digital setting is selected if P212 1 analog setting is selected Digital mode is setting the frequency from HMI analog mode is setting the frequency from hard wired analog I O These two modes cannot be enabled at the same time Set Frequency Correction Relevant parameters P259 P260 Description this improves the sampling accuracy IMPORTANT ltcanonly be enabled when the setting frequency source is set to analog Instruction Set Frequency P260 Original Set Frequency P259 Frequency Command Deadband Upper Limit Relevant parameter P414 Description this function limits the low frequency starting range reduce the low frequency output error for analog input mode This parameter avoids the drive s output fluctuation when the frequency is around 0 Hz Instruction if the original set frequency is lower than P414 the set frequency will be changed to P414 Rockwell Automation Publication 6000 INO07A EN P October 2014 Special Function Parameter Settings Appendix C Frequency Amplitude Limit Relevant parameter P413 P415 Description this function limits the amplitude of the Set Frequency The Set Frequency must not exceed the maximum output frequency of the drive Instruction this function can limit the Set Frequen
37. ent from hazards Safety Test Complete every point included in this section prior to continuing with the drive commissioning to ensure that the commissioning continues in an environment safe to all those involved in servicing the drive Ensure that commissioning of this drive is performed in accordance with local safety standards After performing the lockout and tagout procedure see page 15 open all of the cabinet doors Inspect each component for signs of shipping damage see Table on page 18 An initial inspection would have been done by the customer when the equipment was received However this would have been done from the front only and was just looking for obvious signs of damage see publication 6000 IN006_ EN P Record the part number and description of any damaged components and immediately contact the Start up Project Manager to order replacement components if required damaged drive A ATTENTION Verify the equipment against any damage Do not install a Verify that all components are securely affixed to the cabinet Most components will be easily visible on the doors or from the front of the cabinets after the doors are opened Some components are best viewed from the rear of the cabinet For rear inspection remove top and bottom rear access plates from the drive and bypass cabinet if supplied See publication 6000 IN006_ EN P IMPORTANT Thelnspect Drive Components Checklist see page 18 mentions the principa
38. ential Arc Flash Arc Flash will cause severe injury or death Wear proper Personal Protective Equipment PPE Follow ALL Regulatory requirements for safe work practices and for Personal Protective Equipment PPE gt gt gt 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 Preface Introduction Preparation and Inspection Commissioning Table of Contents Introductio s 2545 ss th de e OPER ERE biis dues eres ee 7 Who Should Use This Manual rennes y What ls Netin This Manual 2 iW NK Ga eee aa a ERES 7 Required Supplemental Information see eee 7 Dimensional Drawings and Electrical Drawings 7 Shipping Handling and Installation Manual 8 General Precautions cece ccc cece ehh hn 9 Additional ResoOurCes use e ite eo teo t a ERREUR Le added a ee eek 9 Chapter 1 KA TE NE ar Te ee TOT RR 11 Documentation and Application Review eee 12 Review all Rockwell Automation Supplied Documentation 12 Pre commissioning Customer Meeting eee 13 Review Drive ADDIICAtIOH a pa sebo ani E da aaa ga bag ag pa a 13 Chapter 2 Gather Required Tools and Test Equipment 15 Lockoutand TAsOutucaddshocedstacatyd a E Sida ood e keane 15 Inspect Drive Comp
39. equency and Actual Frequency occasionally will not show the exact integral value selected due to internal data conversion in the HMI program ee 1 Allowed MVClosd Ready Connect Running Warning Local Remote Monit Set Frequenc Set Freq Rockwell Automation Publication 6000 IN007A EN P October 2014 41 Chapter3 Commissioning Ye 3 Press EE and press S lin the Start Drive dialog box to confirm operation M D 0002050 Allowed MVClosd Ready Connect Running Warning Local Remote Start Drive IMPORTANT When the drive is 0 5 Hz the Connect light will be illuminated When the speed of the drive surpasses 0 5 Hz the Connect and Running lights will be red The Warning light will illuminate when the Actual Frequency increases above 10 00 Hz This is an internal function for testing purposes only 4 When the Actual Frequency reaches 10 Hz press ES Press ESSE in the Accel Speed by Step dialog box TIP T Parameter T09 determines the value of the frequency step change The default is 1 Refer to Access T Parameters on page 64 0090000 Allowed MVClosd Ready Connect Running Warning Local Remote Monite Set Frequenc Accel Speed By Step The Set Frequency and Actual Frequency are now 11 Hz 42 Rockwell Automation Publication 6000 IN007A EN P October 2014 Commissioning Chapter 3 5 Press Decet and press EN in the Decel Speed by Step dialog box T
40. er prior to commissioning the drive and use it as a reference while the drive commissioning is performed WARNING Perform the commissioning checks illustrated in the sequence that they have been presented Failure to do so may result in equipment failure personal injury or death Prior to commissioning the following work will have been performed by the customer or the customer electrical contractor Connect External Cabling and Wiring Connect System Ground Cable Megger Test of Power Cables Connect Incoming Line and Outgoing Motor Power Cables Connect Control Power Wiring Connect External Control Signal Wiring Connect Electrical Safety Interlock Control Signal Wiring Circuit to Input Circuit Breaker Connect Internal Cabling and Wiring Connect Isolation Transformer Secondary Power Cables to Power Modules Connect Motor Cables and Voltage Sensing Board Cables to U V and W Output Phase Buses Connect LV Control and Fan Wiring Bundles Connect Ground Bus Splices 1 Ifan optional bypass unit is supplied the system ground cable incoming line power cables and outgoing motor power cables are connected to the bypass unit 2 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 c
41. eration of all operator interface devices AC DC Power Supplies Check connections Door Grounding Straps UPS Check connection uonpedsu pue uonejedald c Aa dey Chapter 2 Interconnection Review Preparation and Inspection The interconnection checklist summarizes the required items to review to validate the reconnection of power ground and control cables between cabinets within the drive system that were disconnected for shipment Power and control cables that pass from one cabinet to another are bundled in the appropriate cabinet These cables are connected for system test at the factory but disconnected and coiled up for shipment If this interconnection work was done by the contractor use this checklist to review and ensure the work was done correctly If the interconnection work was not done by the contractor the scope of work required to be performed is described in 6000 IN006_ EN P IMPORTANT Table 5 Interconnection Review Checklist Front Inspection Rear Inspection 20 CA Verify the braided ground connection to adjacent cabinet s is properly installed L Review the braided ground connection to adjacent cabinet L Verify line and load power cables from Isolation Transformer Cabinet are properly connected L Verify all control wires per Electrical Drawing listed in Torque Requirements on page 81 CA Verify the braided ground connection to adjacent cabinet s is properly install
42. erence for proper drive power cable termination locations Any discrepancy between the physical installation and the Electrical Drawings of the following items should be reviewed prior to commissioning the drive e Medium voltage power cabling in from the input circuit breaker to drive e Medium voltage power cabling out from drive to motor e Low Voltage control power cables from LV MCC or circuit breaker to drive e Ground connection from system ground to drive e Control signal wires and communication cables from remote DCS PLC or other remote device to drive e Electrical safety interlock control wiring from the drive to the input circuit breaker N ATTENTION Do not change wiring or remove terminal wiring Rockwell Automation Publication 6000 INO07A EN P October 2014 Gather Required Tools and Test Equipment Lockout and Tagout Chapter 2 Preparation and Inspection Hand Tools e Metric wrenches and sockets e Torque wrench e Assortment of screw drivers e Wire stripper cutter Flectrical Equipment e High voltage gloves 17 kV insulation rating minimum e Anti static strap e Live line tool Hot stick e 5 kV Insulation Tester lest Equipment e 600V 1000V rating digital multimeter with assorted clip leads Computer Requirements and Software e Laptop computer e USB cable e PLC program e CCW software dangerous Severe injury or death can result from electrical shock burn or unintended actuation of control
43. et 2 Usinga jumper wire connect terminal blocks 401 and 418 on the transformer protection relay 3 Press EM to view the alarm record Active Alarms QTY AccTime Message 1 00 00 13 System Locked 1 00 00 15 Transformer Over Temperature Trip 4 Remove the jumper wires to remove the Trip message 5 Press Home to return to the Main Interface Screen 46 Rockwell Automation Publication 6000 INO07A EN P October 2014 Commissioning Chapter 3 and press Yes to confirm the operation in the 6 Press Reset Drive dialog box M NG oO o Allowed MVClosd Ready Connect Running Warning Local Remote Monite jal Frequenc po 40 50 60 Set Frequenc k Reset Drive Actual Frequenc Motor Spee Motor Voltag 4731214 4 16 18 PM Wait until the Ready status indicator is red before starting another Motor Currer simulation a amara aana o Q 200022 Allowed MVClosd Ready Connect Running Warning Local Remote Simulate a Transformer Cabinet Main Cooling Fan Fault 1 Open the LV door of the Isolation Transformer cabinet TIP The circuit breakers for the main cooling fans for the entire drive are located here 2 Turn the first motor control circuit breaker Q10 controlling the Isolation Transformer Cabinet Main Cooling Fans one per fan to the OFF position Rockwell Automation Publication 6000 IN007A EN P October 2014 47 Chapter3 Commissioning 3 Press EE to c
44. f the equipment Table 1 Electrical Drawings Contactor Locations electrically Drive Topology General Notes Minimum Power Cable Insulation Ratings Component Designations Customer Power and Control Wiring Locations electrically Control and Medium Voltage Power Ratings Fuse Locations electrically Table 2 Dimensional Drawings Control and Medium Voltage Power Ratings Drive Options Motor Ratings Drive Power Component Selection Ratings Rockwell Automation Publication 6000 INO07A EN P October 2014 7 Preface If the drawings require changes to suit the installation and application of the system fax or e mail the marked up drawings to the Start up Project Manager Shipping Handling and Installation Manual Review publication 6000 IN006_ EN P PowerFlex 6000 Medium Voltage Variable Frequency Drive Shipping Handling and Installation manual The customer contractor has the option to perform the electrical interconnection work between cabinet shipping splits as shown in this manual or contract Rockwell Automation to perform this work This will be reflected in the Services Purchase Order and the pre commissioning checklist Verify that the documentation matches the actual scope of work done by the customer contractor You will be required to either perform this interconnection work immediately prior to the commissioning process or to verify the work was done correctly by the contractor It is very important to conf
45. for commissioning the drive If applicable send a copy of the one line diagram to the Start up Project Manager to be archived and used for future customer assistance Rockwell Automation Publication 6000 IN007A EN P October 2014 13 Chapter 1 Introduction On site Verification of Electrical System One line Diagram drive is locked out and tagged out Make sure the LV circuit breaker feeding control power to the drive is locked out and tagged out Make sure the drive is de energized before conducting the drive inspection process ATTENTION Make sure the medium voltage input circuit breaker feeding the Once all documentation has been reviewed an on site inspection of the drive is required Identity the physical locations of the connections to the drive using Tag Identification names or numbers from the one line diagram and Rockwell Automation Electrical Drawings All customer power and control wiring required for the drive line up installation has been identified on the Rockwell Automation Electrical Drawings by a dashed line Installation of all external power cabling and control wiring interfacing with the drive is completed by the customer or their electrical contractor Verify that this wiring is installed correctly and meets electrical voltage and current capacity requirements Trace the power cables point to point from the input circuit breaker to the drive and from the drive to the motor using the Electrical Drawings as a ref
46. g Output 1 Scaling Factor 100 199 99 Setup DCS display the output voltage proportion coefficient and can be changed as the customer operation request from 0 200 P339 Analog Output 2 Scaling Factor 199 99 Setup DCS display the output current proportion coefficient and can be changed as the customer operation request from 0 200 P352 Rated Frequency HMI Rated Frequency HMI Display Integer Part Integer Part Rated Frequency HMI Display Integer Part 50 ON 0 75 Setup P355 Motor Voltage HMI Display Integer Part 10000 16384 Setup Local display voltage correction coefficient the value must be done according to the rating of the inverter output voltage setting For example if the output is 3 kV then set P355 3000 P358 Actual Frequency HMI Display Integer Part 50 ON fo 75 Setup P361 Motor Current HMI Le ci ME eiii eius BENIN RON 5000 Setup Normally P361 P199 P399 Deceleration Time s 3276 Setup Default value is 300 s Set according to customer specification The time from 50 0 Hz after stopping the motor P401 Acceleration Time s 3276 Setup Default value is 200 s Set according to customer specification The time from 0 50 Hz after starting the motor P413 Frequency Command Lower Limit Command Lower Limit Frequency Command Lower Limit 0 J ON 16384 16384 P414 Frequency Command Deadband Upper Limit 049 fon fo jawa RAD P415 Frequency Command Upper Limit 16384 N 16384 16
47. gs and faults and how to clear or reset the alarm Warning codes begin with a W prefix and fault codes begin with a F prefix Alarm Requires Reset Transformer Overtemperature Warning YES Transformer Overtemperature Trip LL YES Transformer Cabinet Main Cooling Fan Fault YES Power Module Cabinet Main Cooling Fan Fault YES Cabinet Door Open Warning YES Left Isolation Transformer Cabinet Door Right Isolation Transformer Cabinet Door Left Power Module LV Cabinet Door Right Power Module LV Cabinet Door Bypass Cabinet Door if applicable The Set Frequency field will already have 50 Hz shown from the previous exercise in the Set Freq dialog box Yi 1 Press sen and press 7 lintheStart Drive dialog box 4 000000070 Allowed MVClosd Ready Connect Running Warning Local Remote Start Drive Simulate the Transformer Overtemperature Warning 1 Open the LV door of the Isolation Transformer cabinet 2 Using a jumper wire connect terminal blocks 401 and 419 on the transformer protection relay Rockwell Automation Publication 6000 INO07A EN P October 2014 45 Chapter3 Commissioning 3 Press Aam to view alarm record Active Alarms QTY AccTime Message 00 00 04 Abnormal Output Voltage Warning 00 00 04 Transformer Over Temperature Warning 4 Removethe jumper wires to remove the warning Simulate Transformer Overtemperature Trip Open the LV door of the Isolation Transformer cabin
48. he actual frequency will decrease by 1 Hz 20002300200 Allowed MVClosd Ready Connect Running Warning Local Remote Decel Speed By Step Verify Operation to Set Frequency 1 Press the Set Frequency input field and enter 50 in the Set Freq dialog box and press m O O Allowed MVClosd Ready Connect Running Warning Local Remote al Frequency Set Frequenc 60 Set Freq gt Actual Frequenc im RS 4 35 2U14 4 12 51 PM Rockwell Automation Publication 6000 IN007A EN P October 2014 43 Chapter 3 44 Commissioning Yes l 2 Press to accept and begin the simulation Actual Frequency will show the frequency increasing to 50 Hz 000000 Allowed MVClosd Ready Connect Running Warning Local Remote Monitoring Parameters Actual Frequenc Set Frequency Actual Frequency Motor Speed Motor Voltage Motor Current 3 Once the actual frequency has reached the set frequency press EN and press Eon in the Stop Drive dialog to confirm action o 9 o OQ O Allowed MVClosd Ready Connect Running Warning Local Remote Monit al Freguenc Set Frequenc Stop Drive Actual Frequenc Motor Spee Motor Voltag Motor Currer The actual frequency will decrease to 0 Hz Rockwell Automation Publication 6000 INO07A EN P October 2014 Commissioning Chapter 3 Simulate Warnings and Faults This section describes how to simulate warnin
49. he examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respect to use of information circuits equipment or software described in this manual Reproduction of the contents of this manual in whole or in part without written permission of Rockwell Automation Inc is prohibited Throughout this manual when necessary we use notes to make you aware of safety considerations 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 gt gt 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 pot
50. irm the alignment of the paperwork with the actual scope of work It is also extremely important to understand the contractors basic scope of work preceding the commissioning process Part of the overall commissioning process is to ensure this work has been done correctly If this work has not been done properly this must be brought to the attention of the customer immediately Do not proceed with commissioning until this issue is resolved Additional required information about the PowerFlex 6000 can be downloaded from http www rockwellautomation com literature e 6000 IN006_ EN P PowerFlex 6000 Medium Voltage Variable Frequency Drive Shipping Handling and Installation Instructions e 6000 UM001_ EN P PowerFlex 6000 Medium Voltage Variable Frequency Drive User Manual operating the HMI full parameter listing You must review these publications thoroughly before beginning the commissioning process They contain supplemental information that will aid in the commissioning process Rockwell Automation Publication 6000 INO07A EN P October 2014 General Precautions A A Preface 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 Bradley publication
51. itch on the front of the LV Cabinet to the Drive position 1 Press omen from the Main Interface screen Input Supply S Control Owner Selection Contactor Operation Rockwell Automation Publication 6000 IN007A EN P October 2014 55 Chapter 3 56 Commissioning 2 Close the customer supplied input circuit breaker by installing a temporary jumper wire X 117 X 119 Verify the input circuit breaker is closed Control Owner Selection Contactor Operation under Contactor Operation and press Yes 3 Press to confirm Input Supply Ne e P ANAKAN C ontrol Owner Selecti on Close Drive Input 4 Output Contactors Rockwell Automation Publication 6000 INO07A EN P October 2014 Commissioning Chapter 3 Verify the input and output drive contactors are closed Input Supply Control Owner Selection Contactor Operation under Contactor Operation and press Yes 4 Press to confirm Input Supply XXXXXXXXX j NANA C ontr ol Owner Selecti on Open Drive Input amp Output Contactors Rockwell Automation Publication 6000 IN007A EN P October 2014 57 Chapter3 Commissioning 5 Verify the input and output drive contactors are closed Input Supply Control Owner Selection ee mama Contactor Operation bypass Contactors IMPORTANT Turn the 3 position on the selector switch on the front of the
52. ize Drive Control Circuit 68 Operate Motor by HMI 76 0 Overviews Commissioning 31 Documentation and Application Review 12 Load Test 80 No load Test 67 Special Function Parameter Settings 87 P Power Cabling 22 Color Coding 22 Pre Commissioning Cabinet Plates 29 Computer Requirements 15 Drive Megger Check 23 Electrical Equipment 15 Final Steps 29 Functional Assessment 17 Checklist 19 Installation Review 21 Electrical Inspection 22 95 Index 96 Mechanical Inspection 21 Interconnection Review 20 Checklist 20 Software 15 Test Equipment 15 Tools Hand Tools 15 Preparation and Inspection Process Flowcharts 12 Commissioning 12 Documentation and Application Review 12 Process Flowcharts Commissioning 12 Documentation and Application Review 12 Preparation and Inspection 12 Restart the Drive 94 S Safety Test Lockout 16 Special Function Parameter Settings 87 Analog Input 93 Flying Start Function 93 Restart the Drive 94 Speed Command Function Frequency Amplitude Limit 91 Frequency Command Deadband Upper Limit 90 Frequency Skip 91 Set Frequency Command Source 90 Set Frequency Correction 90 Speed Command Functions 90 Speed Reference Functions 92 Limit Output Voltage Amplitude 92 Set Flux Time 92 Set Maximum Modulation Index 92 V F Curve Setting 92 Stop Mode 93 System Setting Functions 87 Analog Output Display Parameter Set ting 89 Hall Effect Current Sensor Setting 88 Motor Para
53. l base components supplied in the drive and bypass units It is not comprehensive as customer required options may be supplied and three different bypass configurations are available Perform the shipping damage inspection for all components mounted in the drive cabinets and specific bypass unit cabinet if supplied Rockwell Automation Publication 6000 INO07A EN P October 2014 Preparation and Inspection Chapter 2 Functional Assessment After the components are visually inspected to identify any shipping damage a thorough functional assessment should be performed see Table 4 on page 19 The main purpose of this assessment is to ensure that all movable parts and assemblies operate properly connect properly and components are wired properly and securely The Functional Assessment procedure can be combined with the Inspect Drive Components checklist on page 18 Descriptions of the Power Cable Connections to be inspected and torqued to specifications are in the Interconnection Review and Installation Review sections Rockwell Automation Publication 6000 IN007A EN P October 2014 17 8l Y LOZ 19000 d N3 V 00NI 0009 uon e ijqng UOHeWOINY 9M0 Table 3 Inspect Drive Components Checklist Front Rear Bypass Cabinet if supplied Isolation Transformer Cabinet Power Module Cabinet Low Voltage Control Cabinet Door L Pilot Lights LJ Voltage Indicator Relay Cabinet LJ Insulators Ll Switch a
54. ll automatically switch off and the K9 relay will switch on to supply control power from the isolation transformer tertiary winding Rockwell Automation Publication 6000 INO07A EN P October 2014 79 Chapter4 No load Test 13 Switch on the customer supplied control power and push the Power Reset button in control cabinet panel This clears the Control Power Supply Loss warning 14 Press EM ATTENTION The following should be opened successively when the control power is switched off Q5 Q4 03 Q2 and UPS opening Q1 is not necessary when the control power is not disconnected Load Test of Drive System This process is essentially a repeat of the No Load test procedure The Input Circuit Breaker should be off and locked out and tagged out to prevent any possibility of energization of the motor circuit while the application is reconfigured to apply load Repeat steps 1 4 and 6 listed in the Table on page 67 80 Rockwell Automation Publication 6000 INO07A EN P October 2014 Torque Requirements Appendix A Torque Requirements Proper tightening torque must be used for installation and wiring Table 13 Torque Requirements Thread Size Torque o Mm ik d i is M10 M12 M14 M16 M20 184 Rockwell Automation Publication 6000 INO07A EN P October 2014 lb ft 1 0 2 1 3 4 8 1 16 2 28 8 45 7 70 1 135 7 81 AppendixA Torque Requirements Notes 82 Rockwell Automation Publication 6000 INO
55. lso If 110V or 120V is the control power voltage supplied by the customer a control power transformer is supplied in the LV control cabinet to step up the customer supplied control power to 220V Figure 13 This must be specified at time of order QI Q2 Q3 Q5 and Q6 miniature circuit breaker designations are located in the LV Control Cabinet Figure 14 The Q4 and Q7 miniature circuit breaker designations are located in the LV Control panel of the Isolation Transformer Cabinet Figure 15 Refer to the Electrical Drawings Test points indicated in the instructions are at the circuit breaker terminals not at the terminal blocks Circuit breaker device designation labels Q1 Q2 etc are affixed to the device mounting surfaces Figure 13 UPS and CPT Mounting Plate Top View XS2 Receptacle Optional Control Power Transformer UPS 32 Rockwell Automation Publication 6000 INO07A EN P October 2014 Figure 14 LV Control Cabinet 1 3 5 eee TT S TC EYS Se 2 4 6 arrg Commissioning ATE UE LAA aa Ty Ter ae s ole eelo ole o Rockwell Automation Publication 6000 IN007A EN P October 2014 Chapter 3 33 Chapter 3 Commissioning Table 8 Energize Control Circuit Sequence Before Closing Breaker After Closing Breaker Verify that the input voltage
56. mation Publication 6000 INO07A EN P October 2014 25 Chapter2 Preparation and Inspection 8 Disconnect the control cable of HECS Figure 7 Hall Effect Current Sensor b HECS Control Cable 9 Disconnect the HMI and Control Board power cables Figure 8 Back of HMI CE Tee Hiinat DOAA paf m TUTTI TIT al AR Bir Ppt a nen op Control Board Power Cables HMI Power Cable 26 Rockwell Automation Publication 6000 IN007A EN P October 2014 Preparation and Inspection Chapter 2 10 Remove the Analog Interface board and disconnect all of the terminals from the Control Unit Analog Interface Board location on Control Unit Control Unit terminals T m IL D Do e i a EL 1 Connect the Insulation Meter 1 Connect the red wire from the insulation meter to the U Phase and the black wire to the grounding bus personnel and tools prior to commencing the Megger test Barricade off any open or exposed conductors Conduct a walk around inspection before commencing the test ATTENTION Verify the drive and any connected equipment is clear of 2 Use jumper wires to make the connections as shown in Figure 10 The jumper wires must be rated for greater than 5 kV or must maintain sufficient clearance to any metal surface 3 Ifthe Megger has a lower voltage setting normally 500V or 1000V apply that voltage for 5 seconds as a pre
57. meter Setting 88 Number of Power Modules Per Phase 87 Rated Maximum Output Frequency 88 Restore Factory Setting 89 Switch Control Sources 88 Speed Command Functions 90 Speed Reference Functions 92 Stop Mode 93 T Tagout 15 Torque Requirements 81 Rockwell Automation Publication 6000 IN007A EN P October 2014 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 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 suppor
58. nel in the Bypass Cabinet if supplied are routed correctly Preparation and Inspection Chapter 2 Installation Review Prior to commencing the commissioning of the drive verify the equipment was properly installed Identifying errors in the drive installation prior to commencing the commissioning as opposed to mid way through the commissioning process will greatly reduce the amount of time required to commission the drive Verify the drive and all associated equipment have the system power grounding cable installed Refer to 6000 IN006_ EN P to review the contractors drive installation responsibilities and understand the scope of the work you will be reviewing Mechanical Installation Inspection Sequence Reference Document 1 Dimensional Drawings 3 Dimensional Drawings 6 Review duct installation if applicable 6000 INO06_ EN P mounte Refer to project specific EDs to review all electrical connections to external input and output devices Rockwell Automation Publication 6000 INO07A EN P October 2014 21 Chapter2 Preparation and Inspection Electrical Installation Inspection Sequence Task Reference Document 1 Verify that medium voltage cables are separated at least 30 cm from the control cables 2 Verify that all secondary control wiring use shielded cables 3 Verify that input and output medium voltage cables specifications meet the stated Electrical insulation requirements Drawings 4 Verify that input and output medium volt
59. ntrol System Check to proceed This section is password protected and the setup login process must be completed before making any changes Access Setup Settings 1 Press m from the Main Interface Screen 2 Press ra on under Parameter Access Level Rockwell Automation Publication 6000 IN007A EN P October 2014 37 Chapter3 Commissioning Login E The Setup Login dialog box appears Press User Settings 3 Enter the User and Password details Uset Press and enter setup Press when finished ya when finished Press to enter the password Press TIP The password will be sent by the Project Start up Manager 4 Press to login The Current User will now display Setup indicating appropriate access has been granted Setup Settings oe to proceed 5 Once logged in press IMPORTANT Ifthe login information was incorrect you will be prompted to login again Set P Parameters Once the appropriate access has been granted you can now select and change parameters 38 Rockwell Automation Publication 6000 INO07A EN P October 2014 Commissioning Chapter 3 For the simulation tests you only need to change two parameters P007 and P224 P Parameter Settings 1 Press in the Setup Parameter Type 2 Press the P007 parameter input field N WARNING Do NOT press EH This will reset all factory set parameters TIP When the P Parameter number is pressed e g P007 the de
60. of these documents from the Start up Project Manager However you will have received e copies of this information prior to commissioning by the Start up Project Manager Before commissioning the drive ensure you have the following resources e Project specific Electrical Drawings and Dimensional Drawings e PowerFlex 6000 Medium Voltage Variable Frequency Drive Shipping Handling and Installation Manual 6000 IN006_ EN P provides procedural information for physically unloading moving and installing equipment 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 UM001_ EN P instructions for daily recurring drive usage HMI interface and maintenance tasks Rockwell Automation Publication 6000 INO07A EN P October 2014 Introduction Chapter 1 e PLC Program The PLC I O processes control signals within the drive and I O signals to and from the customers control system and input circuit breaker The PLC program is standardized However it may be customized to address specific customer requirements by Rockwell Automation during the Application Engineering phase of order execution Pre commissioning Customer Meeting Before commissioning the drive it is recommended to schedule a meeting with the customer 1 Discuss
61. ollowing procedures to be performed Procedure Page Verify Factory Default Settings 35 Set P Parameters to Enable Testing 37 Verify Operation of Frequency Steps 41 Verify Operation to Set Frequenc 43 Simulate Warnings and Faults 43 Verify E Stop Functionality 50 Verify Switching from Local Control to Remote Control 51 Verify Operation of Input Output and Bypass Isolation Switches Manual Bypass 52 Verify Operation of Input Output and Bypass Contactors Automatic Bypass 1 55 Verify Operation of DCS Input and Output Signals 61 Restore P Parameter Settings 62 1 Only required if a bypass configuration is supplied Rockwell Automation Publication 6000 IN007A EN P October 2014 31 Chapter3 Commissioning Control System Check Setup Simulate Closed Input Circuit Breaker IMPORTANT _ The normal operating mode is for the input circuit breaker to be closed Install a temporary jumper X1 117 X1 119 in the LV Control Cabinet to simulate operating the system in normal mode input circuit breaker closed to allow the Control System Check process to proceed Refer to Electrical Drawings Energize Control Circuit Before beginning this process ensure that the customer s control power supply breaker is closed and control power is available Control power voltage used in the control circuit is nominally 220V and referred to in the example The control circuit can directly accommodate other widely used voltages of 230V and 240V a
62. omatic Bypass To Drive or qm Drive To Bypass Selection mew 0 er Ro o qmm p mel pF qm jm p qme T 3 3 1 Bm jaja qr pe 4 Step Variable Speed available only when T8 2 Speed 1 Rated Frequency Speed 2 Rated Frequency Speed 3 Rated Frequency Speed 4 2 ul Rated Frequency 1 ON Can be modified at any time OFF Drive must be off to modify Parameters T11 113 To change Parameter T 11 1 Press the T11 Parameter input field Rockwell Automation Publication 6000 IN007A EN P October 2014 71 Chapter 4 72 No load Test 2 In the Switch Method Selection dialog press E Or E Switch Method Selection 3 If you select E the e drive must be set to Local Control e position switch must be set to Drive e bypass contactor must be ON e drive must not be running 4 If you select EN the e drive must be set to Local Control e position switch must be set to Drive e drive must be running 5 Press Yes to confirm selection ATTENTION If the conditions are incorrect the following dialog appears Conditions Are Not Met CAN NOT Operate Rockwell Automation Publication 6000 INO07A EN P October 2014 No load Test Chapter 4 Change Parameter T12 1 Press the T12 Parameter input field 2 Enter desired PID values in the PID Parameter Settings dialog box Press the input field to enter a value 3 Press e
63. onfirm the Transformer Cabinet Main Cooling Fan Fault Active Alarms Code QTY AccTime Message 00 01 27 Abnormal Output Voltage Warning 1 00 01 27 Transformer Cabinet Fan Fault 4 Turn the first Q10 circuit breaker to the ON position to remove the fault 5 Press Home to return to the Main Interface Screen Simulate a Power Module Cabinet Main Cooling Fan Fault 1 Open the LV door of the Isolation Transformer cabinet TIP From left to right on the DIN rail in the LV cabinet the main cooling fan circuit breakers are located first for the Isolation Transformer cabinet then the Power Module cabinet Almost all drive configurations will have a maximum of three main cooling fans for the Isolation Transformer Cabinet Therefore the main cooling fan circuit breaker designations of 010 Q11 and Q12 are reserved for the Isolation Transformer Main Cooling Fans Power Module Cabinet Main Cooling Fan circuit breaker designations begin at Q13 Refer to the appendix in 6000 IN006_ EN P to determine the number of main cooling fans in each cabinet location or look at the fans on the top plate of the drive 2 Turn the applicable motor control circuit breaker Q13 controlling the Power Module Main Cooling Fans one per fan to the OFF position 48 Rockwell Automation Publication 6000 INO07A EN P October 2014 Commissioning Chapter 3 3 Press EHE and confirm the Power Module Cabinet Fan Fault Active Alarms QTY AccTime Mess
64. ontrol wiring interconnection work being done by the contractor b the optional quote adder reflecting the additional time and cost for Rockwell Automation to perform the power cable and control wiring interconnection work immediately prior to the commissioning process This work will be reviewed during the pre commissioning customer meeting and validated during the commissioning process see Installation Review on page 21 Rockwell Automation Publication 6000 IN007A EN P October 2014 11 Chapter 1 Introduction i Process Flowcharts Documentation and Application Review Review Roewe Pre commissioning Review Drive puomanon Customer Meeting Application Supplied Documentation Preparation and Inspection Gather Required Tools Lockout Inspect Drive Functional Interconnection and Test and Tagout Components Assessment Review Equipment Commissioning Control eoa Load Test of System Check gt Drive System LV Only E MV MV Documentation and Application Review Installation Review Hn Meggering o Final Review and Preparation Review all Rockwell Automation Supplied Documentation Each drive is shipped with the technical publications required to assist in commissioning and troubleshooting the drive Request copies or revisions
65. ower In Power Out connections Door L Pilot lights L Push buttons L Selector switches Q HMI L Interface board on the back of the LV door DIN rail mounted components UPS Fiber optic cables PLC Control Unit UPS connections c Aa dey uonpedsu pue uonejedaJd Y LOZ 1940120 d N3 V 00NI 0009 uon e ijqng UOHeWOINY 9M0 61 Table 4 Functional Assessment Checklist Bypass Cabinet if supplied Isolation Transformer Cabinet Power Module Cabinet Low Voltage Control Cabinet C HECS 2 L Electrical Door Interlock Verify proper operation of auxiliary contacts with an ohmmeter LJ Isolation switch auxiliary contacts Verify proper operation with an ohmmeter LJ Isolation switches Verify proper operation Outer jaws must securely contact the center stab in the closed position Front L Secondary Wiring and Low Voltage Fuses Check all connections per Electrical Drawings L Door Grounding Straps L Surge Arrestors Check braided copper connections L Voltage Sensing Relay Cables Perform tug test LJ Line and Load side power cables Verify phasing and torque L Top Ground Bus Verify braided connections Rear L Transformer Secondary Cables Verify cables are properly fed through the glanding plate and are undamaged L Voltage Sensing Board cables Verify the primary and secondary connections to the board are secure LY Door Interlock Limit Switches Test auxilia
66. pone ME eane ero ep mtt ARDENTES 16 Functional Assessment ccc cece cence ccc eeeeneeseeeseees 17 Interconnection Review ccc cece cece hn 20 ustall tton Reviews lt socktenc tu titi ete eyed ee eo a KAE 21 Mechanical Installation Inspection eee e eee eee 21 Electrical Installation Inspection 0c cece eee ee eee 22 Power Cabling anc aa NG pp ag Ba uis Sa A DN Ed eds oer E 22 Comical WITING starre diit aieo hasan cena TUN PIERDE 23 Drive Megger Check saa a pn a diae PUE Pu EPISC COE Eod Eb 23 Isolate the Power and Control Circuits ssse sees 23 Connect the Insulation Meter 0 ccc cece cece eene 27 Final Steps before Equipment is Ready for Energization 29 Seal the Cabinet Plates 0 ccc cece cece ence nene 29 Chapter 3 nttodUct Ol vere gk a a a a E a e fons A AN te hee ea bes actu wat 31 Control System Check Sepe asco aa aaa ana Aa gana NA a a a ag Bah 32 Simulate Closed Input Circuit Breaker eee 32 Enereize Control CITCUIC qas gang ES Rr a a A dto Ba a dad Ka a pa 32 Control System Check au anaa a ag Ue aol a a AE A ER RRA 35 Verify Factory Default Settings aaa ud aga a eu ha Partes aba a 35 Set P Parameters to Enable Testing eee ese D Verify Operation of Frequency Steps eee aee eee 41 Verify Operation to Set Freguency optet etre Presta 43 Simulate Warnings and Faults iic verre pta 45 Rockwell Automation P
67. ppendix B T 83 Appendix C OVODVIE WS udi enum MA AL See aa pr pd M E 87 System SELI PUNCTONG nines Disce Ka BB BNN Oeo etes a BANG 87 Number of Power Modules Per Phase eee eee eee 87 Switch Control Sources eed oue deu PE Eee ee eaaa eaaa eaaa d Me id 88 Rated Maximum Output Frequency eee eee eee eee 88 Motor Parameter Set Ulo sssrin Enea de ttideeas Ba gaga Ra aed 88 Hall Effect Current Sensor Sete i vast osa aa E Ag gg ieee 88 Analog Output Display Parameter Setting eee 89 Restore Factory Sct 050535 sna aka ga a nein ease yen ecu 89 Speed Command Functions eo resem ERE eea eee 90 Set Frequency Command Source eea eee 90 Seb Frequency Corre CHON ears quibos ene GN NA a PUR ET Eure 90 Frequency Command Deadband Upper Limit 90 Frequency Amplitude LIM aaa kaga ag ang Ka ah cane Rei a a BEN PES 91 Prequctey SET Dagang aa aa AB di bd ct alvo DERE de ag 91 4 Rockwell Automation Publication 6000 INO07A EN P October 2014 Index Rockwell Automation Publication 6000 INO07A EN P October 2014 Table of Contents Speed Reference PUlDCHODSCees er epa a NAN renr UE V EE E Medus 92 WIT Curve SETU D AM ana a na ba a a ka a E A aa ak saa a a a 92 Set Maximum Modulation Index and Limit Output Voltage PMD Mesa saa hg aa ad bed ue a b IN EEE 92 Set Phx DIG saa ee aa KE D KG EE aa eb KN aka Ka d KK meto a a a aa 92 y dini Seakan settee FEDERE 93 STO
68. reakers Q4 and Q7 in the Isolation Transformer Cabinet LV Panel Configure P and T Parameters TIP See Set P Parameters to Enable Testing on page 37 for information on how to access and change parameters Set the P parameters and T parameters as shown in Table 12 This table outlines the specific parameters that must be checked and or modified Parameters that must be modified are outlined in the Instruction column All other parameters listed must be verified For special functions or actions which are not listed here but are commonly performed while commissioning a drive see Special Function Parameter Settings on page 87 Table 12 Setup and R amp D Parameters P Description Modify Login Instruction Parameter Root Level P004 Command Source OFF 1 Setup 0 Communication Port 1 Other Sources P007 Number Of Power Cells Per Phase Setup Set to 0 for Control System Check Afterwards set to actual value according to Electrical Drawings P008 Motor Rotation Direction Under Local Control OFF Setup 1 Forward 0 Reverse P009 Motor Rotation Direction Command Setup Selection 0 Local 1 DCS P024 Stop Method 1 R amp D 0 Ramp Down 1 Coast Stop P040 Safe Start Condition 1 Setup 0 Zero Frequency Command Required 1 Frequency Command Allowed P089 Skip Frequency Enable 1 R amp D 0 Disable 1 Enable P090 Skip Frequency 1 Lower Limit o ON fo 75 RD 68 Rockwell Automation Publication 6000 IN007A EN P October
69. ry switch contacts wired back to terminal blocks in LV panel with ohmmeter L Temperature Sensing Wires 3 places Verify wires are intact and properly inserted C Bottom mounted Auxiliary Fan power from Isolation Transformer Auxiliary Winding Check connections C Door Grounding Straps C Transformer Temperature Protection Relay Tug test on all cable connections LY Auxiliary Cooling Fans 3 Check electrical connection Transformer Secondary Cables Verify cables are properly fed through the glanding plate are undamaged L Tap Changer Verify connection L Top Mounted Cooling Fans Check electrical connection L Fan Housings Assembly must be affixed properly to structure L Auxiliary Cooling Fans 3 Check electrical connection Check plug connectors L Door Interlock Limit Switches 2 Test switch contacts wired back to terminal blocks in LV panel with ohmmeter L Power Modules fiber optic cables Check all connections L Power Modules Fuses Test each fuse with multimeter L Door Grounding Straps LJ Top Mounted Cooling Fans Check electrical connection L Control Unit Check connection of all fiber optic cables Check connection of HMI interface board HMI Low Voltage wires Tug test all wires on door panel and relays and terminal blocks Circuit Breakers and Contactors Verify operation Vertical Ground Bus Check connections from all attached components Low Voltage Door Verify op
70. scription appears in the information box at the bottom of the screen Rockwell Automation Publication 6000 IN007A EN P October 2014 39 Chapter3 Commissioning 3 Press 0 on the keypad dialog and press m Parameter 007 will now show a value of 0 4 Repeat steps 2 and 3 to change Parameter 224 to 120 S Press EM to exit P Parameter Settings and EN Press to confirm Setup has logged out 6 Press EM to return to the Main Interface Screen 40 Rockwell Automation Publication 6000 INO07A EN P October 2014 Commissioning Chapter 3 Verify Operation of Frequency Steps There are two parts to this procedure increasing the frequency in set increments and increasing the frequency to a specific rated frequency TIP During the Control System Check procedure an Abnormal Output Voltage Warning will appear as the procedure is done without MV and the Control System is expecting an output voltage Ignore this warning for this procedure Increase Frequency by Step 1 From the Main Interface Screen press the Set Frequency input field 2000000070 Allowed MVClosd Ready Connect Running Warning Local Remote Monitoring Parameters Actual Frequency 30 40 50 Actual Frequency Motor Speed Version Info Motor Voltage l V HMI Motor Current A 41312014 3 52 36 PM 2 In the Set Freq dialog box enter a value of 10 and press m Yes Press to confirm TIP The Set Fr
71. ssemblies L Vacuum contactors L Mechanical linkages Door L Transformer Temperature monitor L IV Cabinet components Fan control circuit breakers Cabinet L Transformer Plastic Baffle L Outgoing Motor Power Cable standoffs on Cabinet Sidesheet L Outgoing Motor Power Cable Terminal Insulators on transformer L Voltage Sensing Board L Incoming Line Power Cable Terminal Insulators on transformer L Motor Cable Braces Fixed Mounted Power Module Configuration LJ Transformer Secondary Windings 2 sets nspect nomex wrap Verify windings from core are undamaged Check for debris in top of core Fixed Mounted Power Module Configuration L Transformer Secondary Windings 1 nspect nomex wrap Verify windings from core are undamaged Check for debris in top of core Drawout Power Module Configuration C Transformer Secondary Windings 3 nspect nomex wrap Verify windings from core are undamaged Check for debris in top of core 1 Motor Cable terminations could be on the transformer structure or cabinet sidesheet depending on the power rating Fixed Mounted Power Module Configuration L Power Module retaining tabs L check for debris LJ Output Bus Supports LJ Fuse Mounting Supports Drawout Power Module Configuration LJ Support frame LJ Power Modules Fixed Mounted Power Module L Heat sink Verify orientation relative to barrier plates Drawout Power Module Ll P
72. state ATTENTION Medium Voltage is required for parts of this test Close and lock all No load Test The No load Test consists of the following procedures and must be performed in the sequence shown Sequence Procedure Page 1 Energize Drive Control Circuit 68 LV Only Confiqure P and T Parameters 68 Close Isolation Switches in Bypass Cabinet 75 Close Input Circuit Breaker 75 Operate Motor by HMI 76 1 This procedure is performed only if an optional bypass configuration is supplied here Failure to do so may result in personal injury or death property damage A WARNING These procedures must be performed in the order they are listed or economic loss when the Input Circuit Breaker is in the open position Isolation Switches must ATTENTION Isolation switches in bypass cabinets can only be opened or closed not be operated when the Input Circuit Breaker is closed Rockwell Automation Publication 6000 INO07A EN P October 2014 67 Chapter4 No load Test Energize Drive Control Circuit The Energize Control Circuit process is already described on page 32 For the Energize Drive Control Circuit procedure repeat the process in the same sequence without the requirements of taking voltage measurements Close circuit breaker Q1 Start UPS Press and hold the ON button for approximately 3 seconds 1 2 3 Close circuit breakers Q2 Q3 Q5 and Q6 in the LV Control Panel 4 Close circuit b
73. t breaker 3 Verify that there are no faults or warnings on the HMI screen Check Cooling Fan Operation 1 Open the Low Voltage panel door on the Isolation Transformer Cabinet door 2 Close all of the Drive Main Cooling Fan circuit breakers Q10 in the Isolation Transformer Cabinet LV Panel 3 Verify that all cooling fans are operating 4 Turn off the first Main Cooling Fan Circuit Breaker Q10 and record the direction of the fan Viewed from the rear the blades will rotate left to right counter clockwise when viewed from the top If the fan is rotating in the wrong direction turn off the specific Main Cooling Fan breaker Verify the output voltage is 0 Switch two wires on the output of the circuit breaker 5 Turn the circuit breaker back on and repeat for the remaining Main Cooling Fan circuit breakers 6 Verify that there are no faults or warnings on the HMI screen IMPORTANT Allfans must turn in the same direction Rockwell Automation Publication 6000 INO07A EN P October 2014 75 Chapter4 No load Test Operate Motor by HMI IMPORTANT Before completing this procedure verify there are no warnings or failure messages on the HMI The Ready status indicator must be red 1 From the Main Interface Screen press the Set Frequency input field 9090020929 Allowed MVClosd Ready Connect Running Warning Local Remote Monitoring Parameters Actual Frequency 30 40 m Actual Frequency Motor Spe
74. t 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 Medium Voltage Products 135 Dundas Street Cambridge ON N1R 5X1 Canada Tel 1 519 740 4100 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
75. tiary winding to bottom mounted auxiliary fans 6 Q5 connects back up control power from isolation transformer tertiary winding to switch to the control circuit UPS if the main customer supplied control power is lost isL 4 Q6connects control power to door mounted pilot Verify that the output voltage is AC220V 2 AC220V 1 is L 3 is N Verify output is not shorted 2 and 4 is N Verify that the LV Door pilot lights illuminate isL 4 Q7 connects control power to isolation Verify that the output voltage is AC220V 2 AC220V 1 is L 3 is N Verify output is not shorted 2 and 4 is N Verify that the Isolation Transformer temperature monitor powers up lights and spare relays for DCS transformer temperature monitor ATTENTION The following should be opened successively when the control power is switched off Q5 04 Q3 Q2 and UPS opening Q1 is not necessary when the control power is not disconnected Commissioning Chapter 3 Control System Check Verify Factory Default Settings Confirm Language Bypass Mode and Local Operation The default Language setting and bypass mode are set before shipment IMPORTANT You can change the language but cannot change the bypass mode as this is set at the factory to match the shipped drive configuration 1 Select language in the System Parameter Settings interface screen Select Bypass Mode Select Language No Bypass Manual Bypass Au
76. to Bypass 2 Press to accept and proceed to the Main Interface Screen TIP Detailed information about the HMI screens is included in publication 6000 UMO001 EN P PowerFlex 6000 Medium Voltage Variable Frequency Drive User Manual Allowed MVClosd Ready Connect Running Warning Local Remote Monitoring Parameters Actual Freque 30 40 50 1 70 80 Hz Actual Frequency Motor Speed Version Info Motor Voltage V HMI Motor Current 4 3 2014 3 52 36 PM Rockwell Automation Publication 6000 IN007A EN P October 2014 35 Chapter 3 36 Commissioning 3 Press pang and confirm the Bypass Configuration matches one of the three Input Supply graphics No Bypass Cabinet upply Control Owner Selection Manual Bypass Cabinet Control Owner Selection Automatic Bypass Cabinet Control Owner Selection oC M Contactor Operation Note the Contactor Operation selection appears when Automatic Bypass is selected 4 Under Control Owner Selection press Rockwell Automation Publication 6000 IN007A EN P October 2014 Commissioning Chapter 3 The Select Local Control dialog box appears Input Supply Control Owner Selection Select Local Control S Select 5 to confirm Local Control and press oe to return to the Main Interface Screen Set P Parameters to Enable Testing There are two specific P parameters that must be changed to allow the Co
77. ublication 6000 INO07A EN P October 2014 3 Table of Contents No load Test Torque Requirements Single Line Diagrams Special Function Parameter Settings Verify E Stop Functionality lt a csu cccmmeagednediwnesesscernteaas 50 Verify Switching from Local Control to Remote Control 51 Verify Operation of Input Output and Bypass Isolation Switches Manual DU DASS sa aa nis aa ns sees debet Saa esu nU UEM t 52 Verify Operation of Input Output and Bypass Contactors DO DAK Bypass seta mten ism ebd a dida esce IPFE A 55 Verify Operation of DCS Input and Output Signals 61 Restore P Parameter Settings saa ap aa do bei RA qud 62 Set Date and Time Zone 222a sows eb ua ree eee eee 64 Access T Paramete ses 495i E ERR Ee eI QUIC Je RE 64 Change Time Date Regional Settings eee 65 hapter 4 TINERO I NGE ON aa saa ad sa Na a a a r Guten tetas ae ee a Eu 67 Nododd WeSC sr anna denen Ga tan NG EA DEA T E LE E 67 Energize Drive Control Circuit eee eaaa 68 Conttoure Pand T Parameter sae aga a ga a E 68 Close Isolation Switches in Bypass Cabinet 79 Close Input Circuit Breakers eese cree ERE ex a a aan deberes 75 Check Cooling Fan Operation anana brake Aa pa pa a Ka 75 Operate Motor by AM Lois aa ka ti a ana temas She Rene oM 76 Load Testof Drive Sy stein tes od edt ra e Ag Bg ba Bag a teas 80 Appendix A JTORQue IKE GUIEEM ENS a sesa sak aaa bed ah KA Gela a e a Ban bak aana KG 81 A
78. utput will stop immediately so the motor will stop by inertance If P24 0 the output will stop the from the set frequency to 0 Hz When the frequency P252 rated frequency P252 is a percentage value the system will be locked To restart the drive if coast stop was selected wait until it stops before restarting The time needed is FrequencyBeforeStop P253 x MaximumFrequency Relevant parameter P113 P114 P115 P416 P417 P438 P457 P459 P463 K5 Description The PowerFlex 6000 has three flying start modes e search the frequency from set frequency e search the frequency from the last stop frequency added 5 Hz e search from the maximum frequency Instruction the flying start feature identifies the motor speed based on the output current Rockwell Automation Publication 6000 INO07A EN P October 2014 93 AppendixC Special Function Parameter Settings Restart the Drive 94 Some parameters must be changed based on the field application e P113 Flying Start Initial Output Voltage Percentage 96 e P114 Flying Start Current Comparison Delay For Motor Speed Search e P115 Flying Start Current Threshold For Successful Motor Speed Search e P416 Enable Flying Start mode e P417 Flying Start Motor Speed Search Timeout s e P438 Flying Start Current Compensation Threshold e P457 Flying Start Voltage Recovery Time s Low Speed Region e P459 Flying Start Voltage Recovery Time s High Speed Region e
79. wing analog output signals Set Frequency Actual Frequency Motor Voltage and Motor Current Instruction each signal has four display parameters memory address filter parameter HMI display integer part and HMI display decimal part EXAMPLE To output the given frequency when the memory address is 221 the filter time is 100 ms the maximum integer part is 60 the maximum decimal part is 0 set P351 100 P352 60 P353 0 P371 221 The value of P371 P372 P373 P374 are default values and do not generally need to be changed Field Support Engineers can change them according to the specific configuration Restore Factory Setting Relevant parameter P5 Description restore factory setting parameters Instruction this function includes the three different access levels User Level Setup Level and R amp D Level The amount of parameters restored is dependent on the access level Press Reset to restore parameters The following table shows the parameters which can be restored in the different access levels User P5 40 P4 P262 P198 P199 P352 P355 P358 P361 P399 P401 Setup P5 30 P4 P262 P198 P199 P352 P355 P358 P361 P399 P401 P7 P8 P9 P40 P260 P213 P216 P220 P222 P224 P230 P238 P335 P339 P343 P347 P451 P416 P442 P455 P461 R amp D P5 50 All P parameters Rockwell Automation Publication 6000 INO07A EN P October 2014 89 AppendixC Special Function Parameter Settings Sp

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