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PowerFlex 6000 Medium Voltage Variable Frequency Drive

1. 4 Rated Frequency HMI Display Integer Part i Motor Voltage HMI Display Integer Part Actual Frequency HMI Display Integer Part Motor Current HMI Display Integer Part z a AE I l Deceleration Time s j Acceleration Time s Numpad Cancel Backspace Rockwell Automation Publication 6000 UM001B EN P October 2014 51 Chapter3 Setup and Operation Press Reet to restore all user parameters to the factory setting A ATTENTION Operations in this graphic can only operate while on local control Control Selection ls NOT Correct Please Switch To Local Control OK f ATTENTION This operation can only operate while drive is not running Drive Is Running CAN NOT Operate OK Press peor to return to the Parameter Access Level screen TIP User parameter access will logout when you exit User Settings 52 Rockwell Automation Publication 6000 UM001B EN P October 2014 Setup and Operation Chapter 3 Setup Settings View or modify P or T Parameters in the Setup Settings interface Reset Parameter Values Parameter Number oo a SO Parameter Field IRESE Select a Parameter number to see the description here View Change P or T Parameters IMPORTANT You must have Setup login access to view or modify P or T parameters 1 Press ne oer under Parameter Access Level The Setup Login dialog box appears Press ee System Settings re User
2. Rated Output Frequency so ORF fo 75 120 120 Power Cell Fault Auto Reset Delay s a ON 10 on CO owrimeenie O l emn e e Major Rev Of DSP Main Firmware Cannot Modify Minor Rev Of DSP Main Firmware 2 Cannot Modify Display Fault Masks Button o Jo fo 1 Display DSP Variables o Jo fo 1 1 100 1 1 1 2 Predefined Curve 1 3 Predefined Curve 2 ca Ca E 00 OFF 0 00 OFF OFF 10 199 99 199 99 163 84 MN Fault Reset Timeout s s Flying Start Low High Speed Regions Boundary Rockwell Automation Publication 6000 UM001B EN P October 2014 T Parameters Parameter Number 101 T02 T03 T04 T05 T06 T07 T08 T09 T10 T11 T12 T13 Parameters and Function Codes Chapter 4 Description Default Modify Upper Value Root Limit 1 Fault To Bypass 0 Disable 1 Enable Fault To Bypass Delay Bo JON fo 60 Fault To Bypass Delay When Starting 60 the Motor 0 60s Fault To Bypass Minimum Frequency 5 Rated 0 Rated Frequency Hz Frequency 1 Auto Restart After Input Supply Power Loss 0 Disable 1 Enable Input Supply Power Loss Time for 20 20 Auto Restart 0 20s Local Frequency Command Selection 1 0 Digital 1 Analog Remote Frequency Command Selection 1 Analog 2 4 Step Speed 4 Communication Port Frequency Step For Accel or Decel 1 1 Rated Frequency rimes 58 OF Automatic Bypass To Drive or Dri
3. HMI Communication Interface Fiber Optic Socket Interface Terminals Status Indicators Phase control board transceiver indicator light Output PWM and control signals to Power Modules Collect and process fault and state information from Power Modules to CPU board Each phase PWM board can control up to nine power cells Process analog input signals switch and fault information control DA and switch signal output realize V F algorithm set and change parameters in communication with HMI Collect and process analog input signals to CPU Board output analog signals processed by DT board Collect and output digital signals digital to analog conversion function Acts as a base board in the Control Unit and interfaces the digital and analog signal cables Connection between HMI and Control Unit Provides inputs from the HMI and PLC to the CPU Board Connection between Power Modules and Control Unit two per module Connects external inputs outputs and the CPU Board B board healthy indicator T transmit data to power module indicator R receive data from power module indicator CPU Board Indicator Lights 5V 3 3V FPGA DSP1 DSP2 5V power supply indicator 3 3V power supply indicator FPGA healthy indicator DSP1 healthy indicator DSP2 healthy indicator Rockwell Automation Publication 6000 UM001B EN P October 2014 31 Chapter 2 32 Drive System Layout EtherNet IP Port f es te bluo Odom i on aM A a i tam l
4. Power Cell 22 Failed To Bypass One Phase Lost In Power Cell 22 Two Phases Lost In Power Cell 22 IGBT Set 1 Over Current In Power Cell 23 IGBT Set 2 Over Current In Power Cell 23 Input Over Voltage In Power Cell 23 Communication Error In Power Cell 23 No PWM1 Pulse For IGBT Set 1 In Power Cell 23 No PWM2 Pulse For IGBT Set 2 In Power Cell 23 IGBT Set 1 Failed To Turn On In Power Cell 23 IGBT Set 2 Failed To Turn On In Power Cell 23 Power Cell 23 Bypassed Over Temperature In Power Cell 23 Power Cell 23 Failed To Bypass One Phase Lost In Power Cell 23 Two Phases Lost In Power Cell 23 IGBT Set 1 Over Current In Power Cell 24 IGBT Set 2 Over Current In Power Cell 24 Input Over Voltage In Power Cell 24 Communication Error In Power Cell 24 No PWM1 Pulse For IGBT Set 1 In Power Cell 24 No PWM2 Pulse For IGBT Set 2 In Power Cell 24 IGBT Set 1 Failed To Turn On In Power Cell 24 IGBT Set 2 Failed To Turn On In Power Cell 24 Power Cell 24 Bypassed Over Temperature In Power Cell 24 Power Cell 24 Failed To Bypass One Phase Lost In Power Cell 24 Two Phases Lost In Power Cell 24 IGBT Set 1 Over Current In Power Cell 25 IGBT Set 2 Over Current In Power Cell 25 Input Over Voltage In Power Cell 25 Communication Error In Power Cell 25 No PWM1 Pulse For IGBT Set 1 In Power Cell 25 No PWM2 Pulse For IGBT Set 2 In Power Cell 25 IGBT Set 1 Failed To Turn On In Power Cell 25 Rockwell Au
5. Root Skip Frequency 1 Lower Limit oc Skip Frequency 1 Upper Limit Skip Frequency 2 Lower Limit Skip Frequency 2 Upper Limit Flying Start Initial Output Voltage Percentage 5 Flying Start Current Comparison Delay For Motor Speed 1000 Search ms Flying Start Current Threshold For Successful Motor 5 Speed Search HECS Rated Current A Motor Rated Current A ms earar orasan f rnrn 1 1 Motor Ib Scaling Correction Factor Motor Uab Voltage Address Motor Uab Voltage Scaling Factor Correction 199 99 Motor Uac Voltage Scaling Factor Correction 199 99 Filter Time For Abnormal Output Voltage ms 1000 5 Fieno OT even pO ms Filter Time For Motor Over Temperature 0 1 s i ms Motor Over Temperature Warning Cancellation 1 Temperature Output Voltage Abnormality Warning Cancellation 5 Threshold 1 1 1 1 1 3 4 0 2 3 Over Current Low High Speed Region Boundary 0 80 20 0 1 1 Ground Fault Detection Scaling Correction Factor 100 Filter Time For Ground Fault ms 1000 Ground Fault Warning Threshold 2 Ground Fault Trip Threshold Filter Time For Overspeed Fault Upper Limit 10 0 1 0 0 0 6000 1 0 0 0 0 0 0 0 0 0 0 0 58 Rockwell Automation Publication 6000 UM001B EN P October 2014 Upper Limit Ses ee 5000 5000 5000 500 199 99 500 199 99 500 199 99 199 99 32767 32767 199 99 100 32767 199 99 199 99 32767 199 99 199
6. f i te i 7 i kri r Im ae DEG ETE nu t a P M j a LEE Car aau EF CE B i 3 001 3 001 oF few oF 7 oF jee avs au le a PA i i f m 0 000 Pusz 0 000 PUCT 0 000 pups 0 000 pucs 0 000 0 000 puss 0 000 Pucs 0 000 _ 0 000 of i Rockwell Automation Publication 6000 UM001B EN P October 2014 Setup and Operation Chapter 3 Alarm If the drive encounters and alarm or warnings will blink indicating an active alarm Press the a button in the Top Menu Bar to see the active alarms Active Alarms QTY AccTime Message 2 00 23 35 E Stop Trip 2 System Locked 2 Auxiliary Power Off 2 Cabinet Door Open 2 2 List of Active Alarms Power Module Cabinet Fan Circuit Breaker Open Transformer Cabinet Fan Circuit Breaker Open Alarm Code Quantity Accumulated Time Alarm Code Alarm code Codes beginning with W indicates a warning codes beginning with F indicates a fault QTY How many times the alarm has occurred Acc Time Time which has elapsed since the alarm Message Description of the warning or fault Active Alarms Controls Reset Status Scroll to Top or Page Up Scroll Alarm Shows Alarm History Bottom of List Page Down by Entry Reset Status Reset Status will reset just the quantity and accumulated time of the alarms This function does not reset the drive Rockwell Automation Publication 6000 UM001B EN P Oct
7. 18 Bypassed Over Temperature In Power Cell 18 Power Cell 18 Failed To Bypass One Phase Lost In Power Cell 18 Two Phases Lost In Power Cell 18 IGBT Set 1 Over Current In Power Cell 19 IGBT Set 2 Over Current In Power Cell 19 Input Over Voltage In Power Cell 19 Communication Error In Power Cell 19 No PWM1 Pulse For IGBT Set 1 In Power Cell 19 Rockwell Automation Publication 6000 UM001B EN P October 2014 69 Chapter4 Parameters and Function Codes Code F1806 F1807 F1808 F1809 F1810 F1811 F1812 F1813 F1900 F1901 F1902 F1904 F1905 F1906 F1907 F1908 F1909 F1910 F1911 F1912 F1913 F2000 F2001 F2002 F2004 F2005 F2006 F2007 F2008 F2009 F2010 F2011 F2012 F2013 F2100 F2101 F2102 F2104 F2105 F2106 Alarm No PWM2 Pulse For IGBT Set 2 In Power Cell 19 IGBT Set 1 Failed To Turn On In Power Cell 19 IGBT Set 2 Failed To Turn On In Power Cell 19 Power Cell 19 Bypassed Over Temperature In Power Cell 19 Power Cell 19 Failed To Bypass One Phase Lost In Power Cell 19 Two Phases Lost In Power Cell 19 IGBT Set 1 Over Current In Power Cell 20 IGBT Set 2 Over Current In Power Cell 20 Input Over Voltage In Power Cell 20 Communication Error In Power Cell 20 No PWM1 Pulse For IGBT Set 1 In Power Cell 20 No PWM2 Pulse For IGBT Set 2 In Power Cell 20 IGBT Set 1 Failed To Turn On In Power Cell 20 IGBT Set 2 Failed To Turn On In Power Cell 20 Power Cell 20 Bypassed Over Temp
8. 27 Power Cell 27 Bypassed Over Temperature In Power Cell 27 Power Cell 27 Failed To Bypass One Phase Lost In Power Cell 27 Two Phases Lost In Power Cell 27 Output Short Circuit Output Over Current Motor Over Temperature Output Over Voltage Abnormal Output Voltage Ground Fault Over Speed Fault Motor Stalled 72 Rockwell Automation Publication 6000 UM001B EN P October 2014 Parameters and Function Codes Chapter 4 Code Alarm F2900 Cabinet Door Opened While Drive Energized F2901 E Stop Trip F2902 Input Circuit Breaker Opened Not Initiated By The Drive F2903 Non Zero Frequency Command Exists Upon Start F2904 Flying Start Failed F2905 Input Circuit Breaker Tripped F2909 System Locked F2910 CPU Board In Wrong Position F2911 AT Board In Wrong Position F2912 5V Power Supply Fault F2913 15V Power Supply Fault F2914 24V DCS Power Supply Fault F2915 24V PLC Power Supply Fault F3000 PWMA Board In Wrong Position F3001 PWMB Board In Wrong Position F3002 PWMC Board In Wrong Position F3003 DT Board In Wrong Position F3100 PWMA Board Not Compatible With PUA1 Board F3101 PWMA Board Not Compatible With PUA2 Board F3102 PWMA Board Not Compatible With PUA3 Board F3103 PWMA Board Not Compatible With PUA4 Board F3104 PWMA Board Not Compatible With PUA5 Board F3105 PWMA Board Not Compatible With PUA6 Board F3106 PWMA Board Not Compatible With PUA7 Board F3107 PWMA Board Not Compatible With PUA8 Board F3108 PWMA Board
9. Electric Power Transformer Classification of Environmental Conditions Part 3 Classification of Groups of Environmental Parameters and their Severities Section 1 Storage Classification of Environmental Conditions Part 3 Classification of Groups of Environmental Parameters and their Severities Classification of Environmental Conditions Part 3 Classification of Groups of Environmental Parameters and their Severities Stationary Use at Weather protected Locations Electromagnetic Compatibility EMC Part 2 Environment Chapter 4 Compatibility Levels in Industrial Plants for Low Frequency Conducted Disturbances Electromagnetic Compatibility EMC Part 4 Testing and Measurement Techniques Chapter 7 General Guide on Harmonics and Inter harmonics Measurements and Instrumentation for Power Supply Systems and Equipment Connected Thereto Adjustable Speed Electrical Power Drive Systems Part 3 EMC Requirements and Specific Test Methods Adjustable Speed Electrical Power Drive Systems Part 4 General Requirement Rating Specifications for AC Power Drive Systems above 1000V AC and not Exceeding 35 kV Code for Designation of Colors Environment Condition Guides for Specifying Performance Rating of Equipment Functional Safety of Electrical Electronic Programmable Electronic Safety related Systems Electrotechnical terminology Low Voltage Apparatus IEC60050 441 1984 Semiconductor Converters Specification of Basic Requirements IEC60146
10. F0713 F0800 F0801 F0802 F0804 F0805 F0806 F0807 F0808 F0809 F0810 F0811 F0812 F0813 F0900 F0901 Alarm IGBT Set 2 Over Current In Power Cell 7 Input Over Voltage In Power Cell 7 Communication Error In Power Cell 7 No PWM1 Pulse For IGBT Set 1 In Power Cell 7 No PWM2 Pulse For IGBT Set 2 In Power Cell 7 IGBT Set 1 Failed To Turn On In Power Cell 7 IGBT Set 2 Failed To Turn On In Power Cell 7 Power Cell 7 Bypassed Over Temperature In Power Cell 7 Power Cell 7 Failed To Bypass One Phase Lost In Power Cell 7 Two Phases Lost In Power Cell 7 IGBT Set 1 Over Current In Power Cell 8 IGBT Set 2 Over Current In Power Cell 8 Input Over Voltage In Power Cell 8 Communication Error In Power Cell 8 No PWM1 Pulse For IGBT Set 1 In Power Cell 8 No PWM2 Pulse For IGBT Set 2 In Power Cell 8 IGBT Set 1 Failed To Turn On In Power Cell 8 IGBT Set 2 Failed To Turn On In Power Cell 8 Power Cell 8 Bypassed Over Temperature In Power Cell 8 Power Cell 8 Failed To Bypass One Phase Lost In Power Cell 8 Two Phases Lost In Power Cell 8 IGBT Set 1 Over Current In Power Cell 9 IGBT Set 2 Over Current In Power Cell 9 Input Over Voltage In Power Cell 9 Communication Error In Power Cell 9 No PWM1 Pulse For IGBT Set 1 In Power Cell 9 No PWM2 Pulse For IGBT Set 2 In Power Cell 9 IGBT Set 1 Failed To Turn On In Power Cell 9 IGBT Set 2 Failed To Turn On In Power Cell 9 Power Cell 9 Bypassed O
11. F1607 F1608 F1609 F1610 F1611 F1612 F1613 F1700 F1701 F1702 F1704 F1705 F1706 F1707 F1708 F1709 F1710 F1711 F1712 F1713 F1800 F1801 F1802 F1804 F1805 Parameters and Function Codes Chapter 4 Alarm No PWM1 Pulse For IGBT Set 1 In Power Cell 16 No PWM2 Pulse For IGBT Set 2 In Power Cell 16 IGBT Set 1 Failed To Turn On In Power Cell 16 IGBT Set 2 Failed To Turn On In Power Cell 16 Power Cell 16 Bypassed Over Temperature In Power Cell 16 Power Cell 16 Failed To Bypass One Phase Lost In Power Cell 16 Two Phases Lost In Power Cell 16 IGBT Set 1 Over Current In Power Cell 17 IGBT Set 2 Over Current In Power Cell 17 Input Over Voltage In Power Cell 17 Communication Error In Power Cell 17 No PWM1 Pulse For IGBT Set 1 In Power Cell 17 No PWM2 Pulse For IGBT Set 2 In Power Cell 17 IGBT Set 1 Failed To Turn On In Power Cell 17 IGBT Set 2 Failed To Turn On In Power Cell 17 Power Cell 17 Bypassed Over Temperature In Power Cell 17 Power Cell 17 Failed To Bypass One Phase Lost In Power Cell 17 Two Phases Lost In Power Cell 17 IGBT Set 1 Over Current In Power Cell 18 IGBT Set 2 Over Current In Power Cell 18 Input Over Voltage In Power Cell 18 Communication Error In Power Cell 18 No PWM1 Pulse For IGBT Set 1 In Power Cell 18 No PWM2 Pulse For IGBT Set 2 In Power Cell 18 IGBT Set 1 Failed To Turn On In Power Cell 18 IGBT Set 2 Failed To Turn On In Power Cell 18 Power Cell
12. M5 x 12 Nut gt i tq Washer M5 x 12 Nut 5 Install the HECS on the Mounting Bracket using the existing hardware ATTENTION Verify that the current sampling direction is correct This is indicated by an arrow symbol on the top of the HECS 6 Install the Mounting Bracket to the cabinet using existing hardware 7 Reroute the power cable through the HECS and reattach to the Power Module Inspect or Replace Door Position Limit Switch See Replace Door Position Limit Switch on page 89 100 Rockwell Automation Publication 6000 UM001B EN P October 2014 Preventative Maintenance and Component Replacement Chapter 5 LV Control Cabinet Inspect AC DC Power Supplies 101 Replace AC DC Power Supplies 102 Inspect UPS 104 Replace UPS 105 Replace UPS Batteries 106 Inspect PLC 108 Inspect Replace Control Unit or Control Boards 108 Inspect the HMI 111 Replace the HMI 111 Replace LV Control Relays 113 Replace LV Control Circuit Breakers 114 Inspect Coils 116 Inspect Contacts 116 Inspect Pilot Lights 116 Inspect Locking and Interlocking Devices 116 Inspect AC DC Power Supplies Ensure the input and output terminal connections are tight Use a voltmeter to check the output voltage A green LED indicates normal operation Figure 37 AC DC Power Supplies G1 Cocos Pc x8 e oe G2 nat Rockwell Automation Publication 6000 UM001B EN P October 2014 101 Chapter5 Preventative Maint
13. Replace AC DC Power Supplies 102 Replace Control Boards 108 Replace Control Unit 108 Replace G1 AC DC Power Supply 102 Replace G2 AC DC Power Supply 102 Replace G3 AC DC Power Supply 103 Replace LV Control Circuit Breakers 114 Replace LV Control Relay 113 Replace the HMI HMI Replace 111 Replace UPS Batteries 106 Test UPS Battery Voltage 107 LV Control Circuit Breakers Hardware 115 Location 114 Replace 114 LV Control Relay Hardware 113 Location 113 Replace 113 LV Control Relays Maintenance Schedule 124 LV Control Unit 30 M Main Interface Screen Layout 33 Maintenance 77 Inspect Power Connection 79 Inspect Power Module Input Connections 118 Inspect Power Module Output Power Connections 118 Isolation Transformer Secondary Windings 117 LV Component Terminals 117 MV Connections 117 Physical Checks 79 Regular 78 Report 80 Schedule 123 Manual Bypass 49 Medium Voltage Cable Connections Maintenance Schedule 124 Monitoring Parameters Display 35 Motor Current 35 Motor Speed 35 Motor Voltage 35 Mounting Bracket HECS 100 MV Door Safety Interlock 23 Location 23 MVCisd 34 Nominal Line Voltage 122 Nominal Load Motor Voltage 122 0 Open Bypass Contactor 47 Open Drive Input Contactors 46 Open Drive Output Contactors 46 Operation Layout 43 Operation Bar Accel 35 Decel 35 Reset 35 Start 35 Stop 35 Outgoing Motor Power Cable Connections Location 19 Output Voltage AC DC Power Suppli
14. Set Freq 0 00 Hz Numpad Yes Cancel Cancel Backspace 3 Enter desired frequency and press el Yes Cancel 4 Press to accept or to cancel f 00200000 Allowed MVClosd Ready Connect Running Warning Local Remote Monite al Frequency Set Frequenc Set Freq Actual Frequenc sion Info 36 Rockwell Automation Publication 6000 UM001B EN P October 2014 Setup and Operation Chapter 3 Drive Operation Controls Yes Press the desired Drive Operation Control button and to accept or Cancel to cancel Start Drive Yes Cancel Accel Speed By Step Decel Speed By Step Stop Drive Yes Cancel Reset Drive Yes Cancel ATTENTION Drive Operation Controls will only function if using Local Control otherwise the following dialog appears gt Control Selection Ils NOT Correct Please Switch To Local Control OK Rockwell Automation Publication 6000 UM001B EN P October 2014 37 Chapter3 Setup and Operation Will always appear blue The number of Power Modules in the drive will appear as blue the rest appear as grey Fields show the firmware version where applicable 38 View Version Information Press View under Version Info to view the currently installed Firmware The Version Information screen shows the most current firmware installed for the applicable devices l z 3 001 3 001 hai
15. 1 1 1991 Semiconductor Converters Application Guide IEC60146 1 2 1991 Semiconductor Converters Transformers and Reactors IEC 60146 1 3 1991 Semiconductor Self commutated Converters Electric driving Control Gear Part 2 Electric driving Control Gear Incorporating Electronic Devices Quality of Electric Energy Supply Harmonics in Public Supply Network Degrees of Protection Provided by Enclosures IP Code IEC 60529 1989 Insulation Coordination for Equipment within Low Voltage Systems Part 1 Principles Requirements and Tests IEC 60664 1 1992 Standard Voltages Standard Frequencies Electric and Electronic Products Basic Environmental Test Regulations for Electricians Guidelines for Vibration sine Colors of Insulated Conductors Used in Electrical Assembly Devices Colors of Indicator Lights and Push Buttons Used in Electrical Assembly Devices Specification for Single and Double sided Printed Boards with Plain Holes Sectional Specification Single and Double sided Printed Boards with Plated through Holes Rockwell Automation Publication 6000 UM001B EN P October 2014 15 Chapter 1 16 Introduction Standard Number GB 10233 2005 GB 12668 4 2006 GB 12668 3 2006 GB 12668 701 2013 GB T 15139 94 GB 13422 2013 IEEE 519 1992 GB T 12668 4 2006 GB1094 11 2007 Standard Description Basic Test Method for Low Voltage Switchgear and Controlgear Adjustable Speed Drive Electrical System Part 4 General Requirem
16. 11 Power Cell 11 Failed To Bypass One Phase Lost In Power Cell 11 Two Phases Lost In Power Cell 11 IGBT Set 1 Over Current In Power Cell 12 IGBT Set 2 Over Current In Power Cell 12 Input Over Voltage In Power Cell 12 Communication Error In Power Cell 12 No PWM1 Pulse For IGBT Set 1 In Power Cell 12 No PWM2 Pulse For IGBT Set 2 In Power Cell 12 IGBT Set 1 Failed To Turn On In Power Cell 12 IGBT Set 2 Failed To Turn On In Power Cell 12 Power Cell 12 Bypassed Over Temperature In Power Cell 12 Power Cell 12 Failed To Bypass One Phase Lost In Power Cell 12 Two Phases Lost In Power Cell 12 IGBT Set 1 Over Current In Power Cell 13 IGBT Set 2 Over Current In Power Cell 13 Input Over Voltage In Power Cell 13 Rockwell Automation Publication 6000 UM001B EN P October 2014 67 Chapter4 Parameters and Function Codes Code F1204 F1205 F1206 F1207 F1208 F1209 F1210 F1211 F1212 F1213 F1300 F1301 F1302 F1304 F1305 F1306 F1307 F1308 F1309 F1310 F1311 F1312 F1313 F1400 F1401 F1402 F1404 F1405 F1406 F1407 F1408 F1409 F1410 F1411 F1412 F1413 F1500 F1501 F1502 F1504 Alarm Communication Error In Power Cell 13 No PWM1 Pulse For IGBT Set 1 In Power Cell 13 No PWM2 Pulse For IGBT Set 2 In Power Cell 13 IGBT Set 1 Failed To Turn On In Power Cell 13 IGBT Set 2 Failed To Turn On In Power Cell 13 Power Cell 13 Bypassed Over Temperature In Power Cell 13 Power Cell 13 Faile
17. 99 32767 199 99 199 99 199 99 199 99 199 99 199 99 32767 199 99 199 99 32767 Parameters and Function Codes Chapter 4 Parameter Description Default Modify Upper Number Value Root Limit part FucDelay ms o on fo Soo P300 Digital Output 0 Memory Address 9 Jo fo 500 a A MA Analog ion 0 15 ms ein cee P309 Digital Output 2 Logic a 1 1 Inverting 0 Non Inverting Rockwell Automation Publication 6000 UM001B EN P October 2014 59 Chapter 4 60 Parameters and Function Codes Parameter Number P313 P314 P315 P316 P317 P318 P319 P320 P321 P322 P323 P324 P325 P326 P327 P328 P329 P330 P331 P332 P333 P334 P335 P336 P337 P338 P339 P340 P341 P342 P343 P344 P345 Description Default Modify Upper Value Root Limit Digital Output 3 Logic 1 1 Inverting 0 Non Inverting Digital Output 3 Bit Selection 0 15 3 Jo fo 15 Digital Output 3 Delay ms o Jo fo 32767 Digital Output 4 Memory Address 9 Jo po 500 Digital Output 4 Logic 1 1 Inverting 0 Non Inverting Digital Output 4 Bit Selection 0 15 4 FON Jo 15 Digital Output 4 Delay ms o Jo Jo 32767 Digital Output 5 Memory Address 9 JN fo 500 Digital Output 5 Logic 1 1 Inverting 0 Non Inverting Digital Output 5 Bit Selection 0 15 5 Jo Jo 15 Digital Output 5 Delay ms o Jo fo 32767 Digital Output 6 Memory Address 9 Jo fo 500 Digital Output 6 Logic 1 1 Inv
18. R 5 AL R 1 ete d e f g h i g Control Voltage Descnipuon Code Description IP31 AG 110V IP42 AJ 120V AL 220V AP 240V Decciption 5 The only control voltage frequency combinations available as a standard supported option p are 110V 50 Hz 220V 50 Hz 120V 60 Hz and 240V 60 Hz 3 0 kV h 3 3 kV 6 6 0 kV Nominal Load Motor Voltage 6 6 kV Code Description 10 kV B 3 0 kV 1W1kV C 3 3 kV F 6 0 kV J 6 6 kV R 10 kV Description 6 Nominal line voltage equals nominal load voltage except for 11 kV line voltage where 11 kV is NOT available as a load voltage For 11 kV line voltage the only valid load voltage options 50 Hz are 3 3 kV and 6 6 kV 60 Hz i Options Refer to PowerFlex 6000 Medium Voltage Drives Options List Rockwell Automation Publication 6000 UM001B EN P October 2014 PowerFlex 6000 Maintenance Schedule Appendix C Preventative Maintenance Schedule This Annual Preventative Maintenance Program includes a visual inspection of all drive components visible from the front of the unit power supply voltage level checks general cleaning and maintenance checking of all accessible power connections for tightness and other tasks Inspection This indicates that the component should be inspected for signs of excessive accumulation of dust dirt etc or external damage M Maintenance This indicates a maintenance task that is outside the normal preventative maintenance tasks R Replacement This
19. Settings Setup Settings 2 Enter the User and Password details Rockwell Automation Publication 6000 UM001B EN P October 2014 53 Chapter3 Setup and Operation User Press WALKE to enter user details Press when finished Press to enter password details Press when finished 3 Press to login The Current User will now display Setup indicating appropriate access has been granted T Current User mri Setup 4 Once logged in press sue sere to proceed IMPORTANT Ifthe login information was incorrect you will be prompted to login again P Parameter Settings T Parameter Settings 5 Press or in the Setup Parameter Type 6 Press the Parameter Field and enter desired value on the keypad dialog and pres RE 7 Press 2 or to Page Up or Page Down through the parameters 54 Rockwell Automation Publication 6000 UM001B EN P October 2014 Setup and Operation Chapter 3 Restore P or T Parameters Press Reset to restore the parameters to factory settings to cancel to accept or Press Restore Setup P Parameter Default Settings Please Click the P Parameter Number to View the Description f ATTENTION Operations in this graphic can only operate while on local control Control Selection Ils NOT Correct Please Switch To Local Control ATTENTION This operation can only opera
20. Support After installation Rockwell Automation is responsible for commissioning activities for the PowerFlex 6000 product line Contact your local Rockwell Automation sales representative to arrange commissioning Rockwell Automation support includes but is not limited to e quoting and managing product on site start ups e quoting and managing field modification projects e quoting and managing customer in house and on site product training The user or its representatives are responsible for pre commissioning activities to prepare the drive for commissioning Failure to complete these activities prior to the commissioning process will delay the start up of the drive Please refer to the Pre commissioning Checklist in the PowerFlex 6000 Medium Voltage Variable Frequency Drive Shipping Handling and Installation Instructions 6000 IN006_ EN P Rockwell Automation Publication 6000 UM001B EN P October 2014 Safety Considerations Rockwell Automation Publication 6000 UM001B EN P October 2014 Chapter 1 Introduction Around the world Allen Bradley PowerFlex medium voltage drives from Rockwell Automation have built a reputation for providing efficient and reliable motor control for industry s most demanding applications From the hardware designed to help optimize production to the power of networked control platforms users can quickly and easily gain access to valuable information from their systems Better information leads to
21. Warning Local Remote 4 Actual Frequency Display Box 3 p J5 Monitoring Parameters 5 Version Information Box Set Frequency Hz 6 Actual Date and Time i Actual Frequency 0 00 Hz 7 Operation Bar Motor Speed gt Motor Voltage 6 Motor Current 7 Rockwell Automation Publication 6000 UM001B EN P October 2014 33 Chapter3 Setup and Operation Drive Setup and Configuration Controls There are five buttons in the Top Menu Bar A description of the functionality is described in Table 3 Table 3 Setup and Configuration Controls e Return to Main Interface screen Check warnings Check faults Reset alarm status Show alarm history Check voltage trends Check current trends Check frequency trends Pause trending Confirm change bypass configuration Change from local to remote control Close open drive contactors auto bypass Access System Settings Change Language Change Bypass Mode Access P and T Parameters Status Indicators O 0 O O O O Allowed MVClosd Ready Connect Running Warning Local Remote There are eight status indicators on Status Bar Table 4 Status Indicators Allowed The drive is in a state that will allow MV to be applied MVClosd Indicates that the input switching device feeding MV power to the drive is closed Ready Drive is ready to start Connect Being connected with medium voltage Running The drive is running Warning The system has faults or warnings Local The system is u
22. an AC motor Figure 18 Low Voltage Power Module DC Bus Single Phase IGBT Capacitor Network Inverter Network Output A Output B IGBT 1 IGBT 2 Control signals to the Power Module and the feedback signals from the Power Module are transmitted by fiber optic cables which provide electrical isolation between the medium voltage and low voltage sections of the drive and protects against electromagnetic interference Although the voltage produced by each power unit is typically less than 690V the voltage to ground can reach the VFD rated output voltage if operating at rated frequency The control signals from the main control unit through the optical electrical converter are sent to the Power Module control board for further processing and to the corresponding gate drive circuits to turn the IGBTs on or off Rockwell Automation Publication 6000 UM001B EN P October 2014 Chapter 2 Drive System Layout fault the main control unit sends control signals to lockout or bypass the affected Power Module The Power Module cabinet consists of Power Modules current transformers and The status information of the Power Module is transmitted through the electrical optical converter and sent to the main control unit When there is a The Power Modules are divided evenly into three phases U V and W The units in each phase are connected end to end at the output terminals Then high voltage cable using a star connection Current
23. fuse and replace cables and hardware in reverse order of removal 4 Torque all hardware to specifications see Torque Requirements on page 129 Figure 34 Exploded View of Fixed mounted Power Module Fuse Copper Washer Lock washer M8 Nut Fuse Rockwell Automation Publication 6000 UM001B EN P October 2014 97 Chapter5 Preventative Maintenance and Component Replacement Drawout Power Module ATTENTION Ensure the input circuit breaker feeding the drive is open Lock out and tagout the input circuit breaker before performing any work on the drive or bypass units 1 Remove and retain the M12 bolt washer lock washer and nut from the top and bottom of the fuse 2 Remove the fuse from between the fixed bracket and the power cable and bus bar 3 Install the new fuse and the hardware in reverse order of removal 4 Torque all hardware to specifications see Torque Requirements on page 129 reinstalled facing up as shown in Figure 35 Failure to install the hardware in A ATTENTION The hardware connecting the Drawout Power Modules MUST be this manner will affect clearance distance between bolts and can cause an arc Figure 35 Exploded View of Fixed mounted Power Module Fuse Nut Lock washer Washer Bus bar Fuse Washer M12 x30 Bolt Power Cable 98 Rockwell Automation Publication 6000 UM001B EN P October 2014 Preventative Maintenance and Component Replacement Chapter 5 Ins
24. indicates that the component has reached its mean operational life and should be replaced to decrease the chance of component failure It is very likely that components will exceed the design life in the drive and that is dependent on many factors such as usage heating etc C Cleaning This indicates the cleaning of a part that can be reused and refers specifically to the door mounted air filters Rv Review This refers to a discussion with Rockwell Automation to determine whether any of the enhancements changes made to the Drive Hardware and Control would be valuable to the application RFB R Refurbishment Replacement The parts can be refurbished at lower cost OR the parts can be replaced with new ones Rockwell Automation Publication 6000 UM001B EN P October 2014 123 AppendixC Preventative Maintenance Schedule Table 8 Preventative Maintenance Schedule 0 10 yrs Interval Period in years from commissioning date Component Component Component Item Location Category Isolation Air cooling system Door Mounted Air Filters Door Door Mounted Air Filters Air Filters ER UR CIR CIR CR Kg SER CR R Kg C R Transformer Cabinet Top Mounted Main kg RFB R eae Fans A ATTERRA Integral Magnetics Magnetics en Transformer LV Eria Transformer Temperature Monitor Se Sartrit eter Power Air cooling system Door Mounted Air Filters Door Door Mounted Air Filters Air Filters CR CIR UR UR UR UR UR U
25. on page 105 for instruction on safely removing the UPS Remove the UPS Batteries 1 Remove and retain seven screws from the outside of the UPS enclosure two screws on either side and three screws on the back 2 Remove the outer UPS cover and set aside Figure 44 Remove the UPS enclosure hardware UPS Enclosure 106 Rockwell Automation Publication 6000 UM001B EN P October 2014 Preventative Maintenance and Component Replacement Chapter 5 3 Remove the cables from the top battery one at a time and immediately wrap insulating tape around end of each cable Indicate on the tape the positive or negative terminal as appropriate ATTENTION Do not touch the positive and negative battery wires to each other or the UPS enclosure 4 Repeat step 2 for the two remaining batteries 5 Remove and retain two screws on either side of the mounting bracket and remove the bracket Figure 45 Remove the mounting bracket 6 Remove the batteries from the UPS Do NOT throw batteries in the garbage Dispose of the batteries according to local regulations 7 Place the new batteries in the enclosure and reinstall the mounting bracket using the hardware removed in step 5 8 Reconnect the cables to the correct terminals on each battery 9 Use avoltmeter to check the output of the batteries The total voltage must be 37 40V DC 10 Install the UPS enclosure using the hardware removed in step 1 See step 6 9 of Rep
26. power cable connections and grounding cables are torqued to specification Apply torque sealer where necessary Check for corrosion excessive temperature or contamination Inspect Power Cable and Control Wire Terminals Loose connections in power circuits can cause overheating that can lead to equipment malfunction or failure Loose connections in control circuits can cause control malfunctions Loose bonding or grounding connections can increase hazards of electrical shock and contribute to electromagnetic interference EMI Check the tightness of all terminals and bus bar connections and tighten securely any loose connections Replace any parts or wiring damaged by overheating and any broken wires or bonding straps Refer to the User Manual for torque values required for power cable and bus hardware connections Inspect Transformer Secondary Windings Check the Incoming Line Power Cable connections L1 L2 and L3 the Outgoing Motor Power Cable connections U V W and the Isolation Transformer Power Cable Connections are torqued to specifications See Figure 9 on page 19 and Figure 10 on page 19 Rockwell Automation Publication 6000 UM001B EN P October 2014 117 Chapter 5 General 118 Preventative Maintenance and Component Replacement Inspect the bus bars and cable connections Check for any signs of overheating discoloration and tighten the bus connections to the required torque specifications Clean all cables and
27. switch is closed System Closed CAN NOT Operate OK Rockwell Automation Publication 6000 UM001B EN P October 2014 49 Chapter3 Setup and Operation User Settings You can access view or change the user parameters in User Settings Reset all Parameters to Factory Values g IMotor Rated Current A Je E V HOBBEEBEEE Freq Command Source Selection 0 Digital 1 Analog User Parameter List Rated Frequency HMI Display Integer Part Motor Voltage HMI Display Integer Part Actual Frequency HMI Display Integer Part Motor Current HMI Display Integer Part HECHE Deceleration Time s Acceleration Time s User Parameter Value Parameter Description Change User Parameters i Pes User Settings 2 The User Login dialog box appears Press iai i 3 Enter the User and Password details User qt Press Ea to enter user details Press when finished Press to enter password details Press when finished 50 Rockwell Automation Publication 6000 UM001B EN P October 2014 Setup and Operation Chapter 3 4 Press to login 5 Ifthe login was successful the Current User will show as User User Settings 6 Press j IMPORTANT Ifthe login information was incorrect you will be prompted to login again In the User Parameters Settings screen the user parameters automatically refresh User amet TSE tings ToM Freq Command Source Selection 0 Digital 1 Analog a
28. the following standards for general guidelines for setting up a periodic maintenance program For countries following NEMA standards refer to National Electrical Manufacturers Association NEMA Standard No ICS 1 1 Safety Guidelines for the Application Installation and Maintenance of Solid Sate Control for MV Drives and ICS 1 3 Preventive Maintenance of Industrial Control and Systems Equipment for MV Controllers For countries following IEC standards refer to IEC 61800 5 1 Sec 6 5 for MV Drives and IEC 60470 Sec 10 IEC 62271 1 Sec 10 4 for MV Controllers If inspection reveals that dust dirt moisture or other contamination has reached the control equipment the cause must be eliminated This could indicate unsealed enclosure openings conduit or other or incorrect operating procedures Replace any damaged or embrittled seals and repair or replace any other damaged or malfunctioning parts Replace dirty wet or contaminated control devices unless they can be cleaned effectively by vacuuming or wiping IMPORTANT Compressed air is not recommended for cleaning because it may displace dirt dust or debris into other parts or equipment or damage delicate parts 78 Rockwell Automation Publication 6000 UM001B EN P October 2014 Preventative Maintenance and Component Replacement Chapter 5 Physical Checks No Medium Power Connection Inspection Voltage or Control Power Inspect PowerFlex 6000 drive input output bypass sections an
29. transformers are 3 individual phases are formed Different models of Power Modules are used for VFDs of different power ratings installed into the U phase and W phase Figure 19 mounted Power Module Typical Fixed Figure 19 Output Terminal Optic Fiber Socket and Status Indicator Fuse Line Terminals 27 Rockwell Automation Publication 6000 UM001B EN P October 2014 Chapter2 Drive System Layout Table 1 Power Module Ratings Catalog Number Current Rating Amps TPUxx 030 AC3 30 TPUxx 040 AC3 40 TPUxx 050 AC3 50 TPUxx 060 AC3 60 TPUxx 075 AG3 75 TPUxx 080 AC3 80 TPUxx 100 AC3 100 TPUxx 120 AC3 120 TPUxx 150 AC3 150 TPUxx 180 AC3 180 TPUxx 200 AC3 200 TPUxx 300 AC3 300 TPUxx 380 AC3 380 TPUxx 420 AC3 420 Hall Effect Current Sensors HECs The Hall Effect Current Sensors are current transformers capable of measuring current throughout the output frequency range of the drive They monitor the current waveform in each of the phases going to the motor and provide feedback to the control system Top mounted Main Cooling Fan s The Top mounted Cooling Fans ensure reliable cooling of the Power Modules They draw cool air in through the vents in the Power Module Cabinet doors through the Power Modules and exhaust the heated air out through the top of the cabinet 28 Rockwell Automation Publication 6000 UM001B EN P October 2014 Drive System Layout Chapter 2 LV Control Cabinet Control U
30. voltage Power Rating Range 6 kV motor voltage Power Rating Range 6 6 kV motor voltage Power Rating Range 10 kV motor voltage Motor Type Input Voltage Rating Input Voltage Tolerance Input Voltage Sag Input Frequency Input Impedance Device Output Voltage Rectifier Configurations Inverter Configuration Power Semiconductors Output Current THD 1st 49th Output Waveform to Motor Medium Voltage Isolation Control Method Output Frequency Range Acceleration Deceleration time Flying Start Capability Service Duty Rating Input Power Factor VFD Efficiency VFD Noise Level Operator Interface Languages Control Power External Input Ratings External Output Ratings Analog Inputs Optional Analog Outputs Optional Communications Protocols Optional Enclosure Structure Finish Corrosion Protection Ambient Temperature Operating Ambient Temperature Storage Relative Humidity Altitude 1 Average for Product Portfolio Technical Specifications 320 1600 kW 360 1720 kW 200 3360 kW 220 3720 kW 200 5600 kW Induction asynchronous motors 3 KV 3 3 kV 6 KV 6 6 kV 10 kV 11 kV 10 of Nominal 20 of Nominal duration 60 seconds 50 60 Hz 5 Multiphase Isolation Transformer 0 3000V 0 3300V 0 6000V 0 6600V 0 10 000V 18 pulse 3 kV 3 3 kV 36 pulse 6 kV 6 6 kV 54 pulse 10 kV 11 kV Pulse Width Modulated PWM power modules Diodes rectifier IGB
31. 00 0009000000 0000000000 0000000000 0000000000 00090000000 0000000000 0009000009 0000000000 0000000009 0000000000 0000000000 0000000000 0000000000 Status Indicators DB Board Interface Terminals The CPU Board accepts external inputs through the connected communication network hard wired control devices or user interactions via the HMI to determine the actions required of the drive The CPU Board also monitors motor voltage and current as well as internal inputs from the PLC analog and digital signal processor boards and Power Modules It uses these inputs in its motor control and protection algorithms to determine the necessary actions to be taken and outputs to be set In combination with the PWM Boards the CPU board sends the necessary optical PWM control signals to the Power Modules to allow the Power Modules to output the required voltage and frequency to the motor Rockwell Automation Publication 6000 UM001B EN P October 2014 HMI RS 485 Modbus Communication Board Modbus RJ45 Modbus TCP IP PWM Board A Drive System Layout Chapter 2 Figure 21 Control Unit Layout PLC F CPU Board PWM Board B Fieldbus DCS VSB HECS PWM Board C Phase A Phase B Phase C Power Modules Power Modules Power Modules Table 2 Control Unit description Board Function PWM Board A B C CPU Board Analog Signal Processor Board AT Digital Signal Processor Board DT DB Board Connector
32. 402 Acceleration Ramp Transition Time s 3 Jo Jo o 3276 P403 Acceleration Time Unit 0 1 0 1 1000 0 01 s 10000 0 15 P405 Deceleration Ramp Transition Time s 3 Jo Jo 3276 P406 Deceleration Time Unit 0 1 0 1 1000 0 01s 10000 0 1s P416 Flying Start Mode 3 0 Disable 1 Set Frequency 2 Stop Frequency Plus 5 Hz 3 Rated Frequency 21 119 m or i 200 s 00 Rockwell Automation Publication 6000 UM001B EN P October 2014 61 Chapter4 Parameters and Function Codes Parameter Number P443 P444 P445 P446 P447 P448 P449 P450 P451 P452 P453 P454 P455 P456 P457 P458 P459 P460 P461 P462 P463 P465 P466 P467 P470 P497 P498 P499 P500 62 Default Modify Value Root 16384 32767 T a S ici s Do 32767 Upper Limit 32767 Integral Coefficient Of Current Compensation m Lower Limit Of Current Compensation Output Minimum Frequency For Current Compensation 5 100 100 5 00 Proportional Coefficient Of Current Compensation 199 99 Output Upper Limit Of Frequency Compensation Output Low Speed Voltage Compensation Low Speed Voltage Compensation Frequency Threshold 20 ON OF ON V F Curve 1 g Fo 0 Linear 1 Parabolic Curve Flux Time s Modulation Index 87 99 Motor Voltage Upper Limit 87 99 Flying Start Voltage Recovery Time s Low Speed 5 KEE Ca Region Flying Start Voltage Recovery Time s High Speed 5 163 84 Region
33. 8 V Version Information 38 Screen Layout 38 Rockwell Automation Publication 6000 UM001B 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 manuals technical and application notes sample code and links to software service packs and a MySupport feature that you can customize to make the best use of these tools You can also visit our Knowledgebase at http www rockwellautomation com knowledgebase for FAQs technical information support chat and forums software updates and to sign up for product notification updates For an additional level of technical phone support for installation configuration and troubleshooting we offer TechConnect support programs For more information contact your local distributor or Rockwell Automation representative or visit http www rockwellautomation com support 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 support overview page or contact your local Rockwell Automation represe
34. B EN P October 2014 109 Chapter5 Preventative Maintenance and Component Replacement 3 Use both hands and carefully remove the board by using the handles on either side on the front of the board Only remove the board using the two handles on the front 110 Rockwell Automation Publication 6000 UM001B EN P October 2014 Preventative Maintenance and Component Replacement Chapter 5 5 Refer to the Electrical Drawings for reconnecting the fiber optic wires Connect Fiber Optic Wires here Refer to Electrical Drawings Reconnect the HMI Communication Cable OO0009090 OOO0OO0O0O0O OOO0OO0O0O0O OOOO00O OOOO000O OOOOGSOO OOO00000 O000000 OOO00000 Reconnect the bottom terminal 0009000000 Inspect the HMI 1 Verify the input and output cables and communication cables are hand tight 2 Power up the HMI 3 Verify the HMI display is operating normally Replace the HMI ATTENTION Always perform Power Lockout procedure before servicing equipment Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death The touch screen is located on the LV Control Cabinet door Rockwell Automation Publication 6000 UM001B EN P October 2014 111 Chapter5 Preventative Maintenance and Component Replacement 1 Disconnect the data cable from communication board the EtherNet IP cable from PLC the ground cable and the 24V po
35. Bracket Lock washer 4 Washer 4 i 3 Wiring Cover n e a si oN Pat M6 x 12 Bolt 8 Fan Assembly g S A Pi Washer 16 a eh a 2 Washer 16 Sk Ue Uy Tapping Screw 4 yeas apping Screw 4 ee ae e Lock washer 8 TERE Uat Q Aviation Plug Fan Housing Assembly T Rockwell Automation Publication 6000 UM001B EN P October 2014 83 Chapter5 Preventative Maintenance and Component Replacement 3 Remove and retain four M6 x 12 bolts from the top of the Fan Support Bracket and remove the bracket from the Fan Assembly 4 Remove the Wiring Cover and disconnect the wiring 5 Install the fan in the reverse order of its removal Rotate the impeller by hand to ensure that there is no contact with the Fan Housing Assembly ATTENTION The fan must be handled with extreme care Failure to do so can alter the fan balance and will negatively impact performance and life span Fan Balance Fan impellers are statically and dynamically balanced within acceptable tolerances at the factory Damage in shipping or from incorrect handling or installation may upset the balance An improperly balanced impeller can lead to excessive vibration causing undue wear on the entire unit If vibration is excessive shut down the fan and determine the cause Common causes of excessive vibration include e Drive support structure not sufficiently rigid or level e Loose mounting bolts e Loose impeller or bushing 84 Rockwell Automation Pub
36. ERREG GEHA f Henani me ff Heera HE Je EE mE miena asss TT ere i EHEHE i 4 HF HL ie eit IH BEN yaar M a or ee oe E a E img RSEN FEEN af t Space HHEH EEEH Lib pare ak Fa ie Siin HERGIN REES HAIEN HIB PALEES ie aed ae EEC EEEE i Gal TIN 5 HEHH i SIRERE H EES DEAH PEHE EELT EHE TERHI H eked oi oi a Ea a ere ee TETEE ria i FRRINH kia E Isolation Transformer Cabinet Power Module Cabinet LV Control Cabinet Rockwell Automation Publication 6000 UM001B EN P October 2014 17 Chapter2 Drive System Layout Figure 8 Drawout Power Module Drive Configuration Isolation Transformer Cabinet LV Control Cabinet Power Module Cabinet Isolation Transformer Cabinet Isolation Transformer 20 Isolation Transformer Temperature Monitor 4l Isolation Transformer Auxiliary Cooling Fans 22 Top mounted Main Cooling Fan s 22 Incoming Line Power Cable Connections 22 Outgoing Motor Cable Connections 22 Door Position Limit Switch 23 Voltage Sensing Board 24 18 Rockwell Automation Publication 6000 UM001B EN P October 2014 Drive System Layout Chapter 2 Figure 9 Isolation Transformer Cabinet Fixed mounted Power Module Drive Configuration L S566666666566608854 269966564600 05408808 SEPP TETI ET FFP CEE EEE T SSS SESE EEI SSEECEGEE DEEDS EEO E SOCCER PEER EO I Top mounted Main Cooling Fan s Lae I1 Lee emm Outgoing Motor Power Tea So Cable Con
37. IEC 61000 2 4 2002 15 IEC 61000 4 7 2002 15 IEC 61508 1 7 15 IEC 61800 3 2004 15 IEC 61800 4 2004 15 IEEE519 15 IEEE 519 1992 16 Start 35 Function 37 Stop 35 Function 37 System Settings Function 48 Rockwell Automation Publication 6000 UM001B EN P October 2014 135 Index 136 T Voltage Sensing Board 19 24 Hardware 88 T Parameters Inspect 87 List 63 Insulation Board 87 Restore 55 Location Drawout Power Module Technical Specifications 119 Configuration 19 Temperature Monitor 21 Location Fixed mounted Configuration 19 Layout 21 Maintenance Schedule 124 User Manual 21 Power Cabling Overview 24 Top Mounted Main Cooling Fan Replace 87 Hardware 83 Voltage Trends 42 Top Mounted Main Cooling Fans Fan Balance 84 Inspect 82 W Replace 83 Warning 34 Top mounted Main Cooling Fan 22 Location 19 Top mounted Main Cooling Fans 28 Maintenance Schedule 124 Topology 10 Connectivity Overview 13 Pulse Width Modulation 11 Typical Power Structure 11 Torque Requirements 129 Transformer Secondary Winding Connections Maintenance Schedule 124 Trends 41 Scroll Controls 41 Typical Power Structure 11 U UPS 32 Enclosure 106 Front Display 105 Inspect 104 LV Circuit Breaker Location 104 Maintenance Schedule 124 Mounting Bracket 107 Replace 105 Replace Batteries 106 Test Battery Output Voltage 107 UPS Batteries Maintenance Schedule 124 User Login 50 User Parameter Settings 51 Change 51 User Settings Function 4
38. Main Interface Controls 4 cnacceeseusaiy tuana ar AE EN EA 35 Ser Pregiehcy E12 siccn stin EEEN TO EET 36 Diive O peration Controls cicteeeeyevesar seer E GKE ones 37 View Version Information ccccccccccceesecccceeseees 38 PUAN se hse eta cag ace EA EI E T ee Sense we eh eee S AE EEE 39 AES ONY tas xe coeee ens anna ures tates eae NA EES 40 MTN E EE eet aos te ere eae er TE emer Ea ee 4 View Voltage Current or Frequency Trends 065 42 Operation E EE E EEE EE 43 Confirm Bypass Mode as 45 iss o08 nee ewes ew Aes eae heat 43 Choose Local Remote Operation cece eee e eee ees 45 Open Close Drive Input and Output Contactors 46 Open Close Bypass Contactors isvsicnisiseteseeseeeevusae ns 47 SOCUINGS EE Lae E E E melon eu pew ane eaenes 48 SVSCCMTOCLUIN GS co Ta EAT E EEE EES 48 User oct UNSa aa R A A 50 Change User Darameterspitaiuend nora aaeuersitmdeuthaeen 50 DEMUP Sets oes Aa A E tees esas ASE ES 53 View Chance or T Paramieterso4 ss tucsasuscenatasbotubeasee 53 Restore P or T Parameters s2si04 45 oe deans eck den ideteds oes 55 Chapter 4 PPr BCLS srs eset Gute rater Gases aie os tore A eee ars acne EERE 57 T Parane iS seraa E uenbath ies Sa0 ease aa aaa 63 P E EEEE oes TE EE ET E E EAE TOTE TA 64 Chapter 5 oae eee ee ee ELTE I EET E ee ee ee E ETE 77 LATO UCHO Reto ore teal niu lee ceeded tess A tose eede et 77 Daily INSPECHON Sue sich aE E ANTE sae 78 Regul
39. Not Compatible With PUA9 Board F3109 PWMA Board Not Compatible With PUA10 Board F3110 PWMA Board Not Compatible With PUA11 Board F3111 PWMA Board Not Compatible With PUA12 Board F3112 PWMA Board Not Compatible With PUA13 Board F3113 Primary FPGA Not Compatible With PWMA Board F3114 Primary FPGA Not Compatible With PWMB Board F3115 Primary FPGA Not Compatible With PWMC Board F3200 PWMB Board Not Compatible With PUB1 Board F3201 PWMB Board Not Compatible With PUB2 Board F3202 PWMB Board Not Compatible With PUB3 Board F3203 PWMB Board Not Compatible With PUB4 Board F3204 PWMB Board Not Compatible With PUBS Board F3205 PWMB Board Not Compatible With PUB6 Board F3206 PWMB Board Not Compatible With PUB7 Board Rockwell Automation Publication 6000 UM001B EN P October 2014 73 Chapter 4 74 Parameters and Function Codes Code F3207 F3208 F3209 F3210 F3211 F3212 F3213 F3214 F3215 F3300 F3301 F3302 F3303 F3304 F3305 F3306 F3307 F3308 F3309 F3310 F3311 F3312 F3313 F3400 F3401 F3402 FCOM1 FCOM2 FP006 FP007 FP008 W0003 w0014 W0103 W0114 W0203 W0214 W0303 W0314 W0403 Alarm PWMB Board Not Compatible With PUB8 Board PWMB Board Not Compatible With PUB9 Board PWMB Board Not Compatible With PUB10 Board PWMB Board Not Compatible With PUB11 Board PWMB Board Not Compatible With PUB12 Board PWMB Board Not Compatible With PUB13 Board Primary FPGA Not Compatible With DT Board Primary DSP Not Compatible With Primary FPGA P
40. P October 2014 Safety Introduction Chapter 5 Preventative Maintenance and Component Replacement can be hazardous Severe injury or death can result from electrical shock bump or unintended actuation of controlled equipment Recommended practice is to disconnect and lockout control equipment from power sources and release stored energy if present For countries following NEMA standards refer to National Fire Protection Association Standard No NFPA7OE Part II and as applicable OSHA rules for Control of Hazardous Energy Sources Lockout Tagout and OSHA Electrical Safety Related Work Practices safety related work practices including procedural requirements for lockout tagout and appropriate work practices personnel qualifications and training requirements where it is not feasible to de energize and lockout or tagout electric circuits and equipment before working on or near exposed circuit parts For countries following IEC standards refer to local codes and regulations A ATTENTION Servicing energized Medium Voltage Motor Control Equipment ATTENTION Use suitable personal protective equipment PPE per local codes or regulations Failure to do so may results in severe burns injury or death ATTENTION Always perform Power Lockout procedure before servicing equipment Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or d
41. Phase board cables from straining or crimping as a resulting loss in light transmission will f ATTENTION When removing the fiber optic cables be careful to prevent the impact performance 4 Disconnect the HMI communication cable from the CPU board 5 Remove four M6 x 12 bolts and remove the Control Unit 108 Rockwell Automation Publication 6000 UM001B EN P October 2014 Preventative Maintenance and Component Replacement Chapter 5 Figure 46 Remove Retaining Screws of Control Unit Washer Lock washer M6 x 12 Bolt 00000 0000 2000000 C0009 2000009 000000 So0coog a 0000g 6 Install the new Control Unit in reverse order of removal Refer to Electrical Drawings for exact placement of all wires and connections Replace a Control Board ATTENTION Some circuit boards can be destroyed by static charges Use of damaged circuit boards may also damage related components Use a grounding wrist strap when handling sensitive circuit boards 1 Turn off all the control power turn off the UPS and confirm the LV Control Cabinet is unenergized before operation If applicable remove the fiber optic wires ATTENTION When removing the fiber optic cables be careful to prevent the cables from straining or crimping as a resulting loss in light transmission will impact performance 2 Remove the fastening screws on the both sides of the board Fastening Screws Rockwell Automation Publication 6000 UM001
42. R UR E C R Module Cabinet el r Cooling Fans S a a SN oe a a i Cabinet a ee ae ea EARS SESE E ee es ee ee a BIESESRRRREVRAES es eee EVR a ERS ESRS EES Batteries ups 2 LV Control PLC Control Unit Z I LV Control Relays LV Control Circuit Breakers All Connections LV Component Terminal amp Plug in Connections Medium Voltage Cable Connections Transformer Secondary Winding Connections Power Module Input and Output Power Connections General Enhancements Firmware Hardware Operational Parameters Variables Conditions Spare Parts Inventory Needs 1 Power Modules are refurbished at factory as part of an exchange program 2 Fully discharge and recharge the UPS batteries every 6 months to extend battery life 124 Rockwell Automation Publication 6000 UM001B EN P October 2014 Preventative Maintenance Schedule Appendix C Table 9 Preventative Maintenance Schedule 11 20 yrs Interval Period in years from commissioning date Component Component Component Item Location Category Isolation Air cooling system Door Mounted Air Filters Door Door Mounted Air Filters Air Filters SR pCR CR OR OR O R aR UR C R Transformer Cabinet Top Mounted Main ae rie Fans a ee Integral Magnetics Magnetics _ Transformer LV a Isolation E Temperature Monitor ia EAEN ASENERR Power Air cooling system Door Mounted Air Filters Door Door Mounted Air Filters Air F
43. S000 lt 000000000 000000 e OC00000000 oo0000 O0000000000 ooog O000000G000H o000 O oo000000000000 oooO 00 oo00000000000 oad 000 o000000000000 oO ZAA 0000 9000600000006 Z Three Phase oOo000 OoOog00000 00000 Input Power 00000 ao000000000000 Cam Mechanism S 00000 000000000000 rom Isolation lt 00000 60006000600 Transformer m oOo0000 ooo0o0000000 Locking Key Ga SIDE VIEW Pin TOP VIEW 96 The cam mechanism will catch the pin on the tray assembly Continue rotating the locking key until the Power Module is fully seated This ensures the finger assemblies at the back of the Power Module are fully connected to the stab assemblies at the back of the Power Module compartment Cam Mechanism Actuator Locking Key Cam Mechanism ATTENTION The Power Module finger assemblies must be fully seated on the cabinet stab assemblies Pin Rockwell Automation Publication 6000 UM001B EN P October 2014 Preventative Maintenance and Component Replacement Chapter 5 Replace Power Module Fuses Fixed mounted Power Module and tagout the input circuit breaker before performing any work on the drive or f ATTENTION Ensure the input circuit breaker feeding the drive is open Lock out bypass units 1 Remove the M8 nut lock washer and copper washer from the top and bottom of the fuse 2 Remove the cables from the top and bottom of the fuse and remove another copper washer 3 Install the new
44. Ts inverter lt 5 Near Sinusoidal Current Voltage Fiber Optic Volts per hertz 0 5 75 Hz 0 3276 seconds Yes 120 Overload for 1 min every 10 min gt 95 gt 96 5 lt 80 dB 7 in WinCE Color Touchscreen English Chinese 120V 60 Hz 240V 60 Hz 110V 50 Hz or 220V 50 Hz 3 kVA 24V DC 240V AC 2 A Four non isolated 4 20 mA or 0 10V DC two spare Two isolated 4 20 mA two isolated 0 5V DC spare RS232 422 485 Modbus Modbus Plus Profibus DP EtherNet I P IP31 standard IP42 optional Epoxy Powder Paint Exterior Sandtex Light Grey RAL 7038 Black RAL 8022 Internal Control Sub Plates High Gloss White RAL 9003 Unpainted Parts Zinc Plated Bronze Chromate 0 40 C standard 0 50 C optional with derating 25 55 C Max 95 non condensing 0 1000 m standard 1001 3000 m optional Rockwell Automation Publication 6000 UM001B EN P October 2014 Appendix Al 119 AppendixA Technical Specifications Notes 120 Rockwell Automation Publication 6000 UM001B EN P October 2014 Appendix B Catalog Number Explanation Position 1 2 3 4 5 6000 AAA 41 M R a b C d e a Bulletin Number Code Description 6000 All Drive Products b Service Duty Altitude Ambient Temperature Code Code Type Service Duty First Position Drg A Normal Duty Z Custom Contact Factory Altitude Second Position A 0 1000 m ee B 1001 2000 m C 2001 3000
45. User Manual Allen Bradley PowerFlex 6000 Medium Voltage Variable Frequency Drive Publication 6000 UM001B EN P Allen Bradley RockwellSoftwae Automation Important User Information Read this document and the documents listed in the additional resources section about installation configuration and operation of this equipment before you install configure operate or maintain this product Users are required to familiarize themselves with installation and wiring instructions in addition to requirements of all applicable codes laws and standards Activities including installation adjustments putting into service use assembly disassembly and maintenance are required to be carried out by suitably trained personnel in accordance with applicable code of practice If this equipment is used in a manner not specified by the manufacturer the protection provided by the equipment may be impaired In no event will Rockwell Automation Inc be responsible or liable for indirect or consequential damages resulting from the use or application of this equipment The examples and diagrams in this manual are included solely for illustrative purposes Because of the many variables and requirements associated with any particular installation Rockwell Automation Inc cannot assume responsibility or liability for actual use based on the examples and diagrams No patent liability is assumed by Rockwell Automation Inc with respect to use of in
46. a charge for a period of time Only after the drive equipment has been verified as isolated and de energized can subsequent work be performed Even though the input to the drive may be open it is still possible for hazardous voltage to be present Chapter1 Introduction Refer to national and local safety guidelines for detailed procedures on how to safely isolate the equipment from hazards ATTENTION The national and local electrical codes outline provisions for safely installing and working on electrical equipment Installation must comply with specifications regarding wire type conductor sizes branch circuit protection and disconnect devices Failure to do so may result in personal injury and or equipment damage Environmental Conditions e Elevation above sea level must be less than 1000 m 3250 fy e Ambient air temperature must be between 0 40 C 32 104 F 2 e Relative humidity must be less than 90 non condensing e The drive must be installed indoors there must be no dripping water or other fluids in the room e Cooling air must be clean without significant concentrations of sand corrosive or conductive dust defined by IEC 721 1 as being less than 0 2 mg m of dust or explosive gas e Free from significant vibration e The drive must be anchored on a level floor Please refer to the dimension drawing for the anchor point sizes and locations For the equipment to operate in conditions other than those specified c
47. abinet O N Power Modules co N Hall Effect Current Sensors HECs X N Top mounted Main Cooling Fan s mounted Power Module Configuration Figure 16 Fixed T H 5 D gt T i a 9 Ep m Drawout Power Module Configuration Figure 17 25 Rockwell Automation Publication 6000 UM001B EN P October 2014 Chapter2 Drive System Layout Input U Fuse 1 Input V Input W Fuse 2 26 Three phase Diode Rectifier Bridge D4 D5 Power Modules Power Modules are available in a wide variety of amperage ratings relating to the required motor current Power Modules rated up to and including 200 A are fixed mounted in the drive and ship already installed Drawout power modules are supplied for a drive current rating of gt 200 A The power modules are shipped separately and must be installed in the cabinet A Power Module lift cart is included and shipped together with the other components Basic Principle of Power Module The Power Module combines a three phase rectifier and an H bridge inverter powered from the secondary side windings of the Isolation Transformer After rectifying and filtering it outputs AC current with variable frequency and variable voltage under the control of four IGBTs using a PWM switching pattern Several Power Modules after being connected in series and superposed can output three phase AC current with adjustable frequency and voltage to control
48. ables Figure 30 Fixed mounted Power Module Component Location ee oe Output Copper Bar not shown Connection Location Fiber Optic Cables Connection Point Positioning Barriers Fuse gagag REEI 3595050 ao a8 ae giatan Igang KUELE Le KERETI KURTE UFI Center Jumper Bar Ie Three phase Input Cables Fe from Isolation Transformer gt gis a eal e a a Rockwell Automation Publication 6000 UM001B EN P October 2014 91 Chapter5 Preventative Maintenance and Component Replacement 3 Remove the Output Copper Bars that connect adjacent Power Modules Figure 31 If the Power Module is at the end of a row remove the VSB and Motor cable instead of an output copper bus 4 Disconnect the fiber optic cables ATTENTION When removing the fiber optic cables be careful to prevent the cables from straining or crimping as the resulting loss in light transmission will A impact performance ATTENTION Minimum bend radius permitted for the fiber optic cables is 50 mm 2 0 in Any bends with a shorter inside radius can permanently damage the fiber optic cable Figure 31 Close up of Fiber Optic Location and Power Cables VSB Cable Fiber Optic Cables Output Copper Bar 5 Carefully withdraw the Power Module 6 Install the new Power Module in reverse order of removal 92 Rockwell Automation Publication 6000 UM001B EN P October 2014 Preventative Maintenance and Comp
49. an 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 UM001B EN P October 2014 Copyright 2014 Rockwell Automation Inc All rights reserved Printed in Canada
50. ans Ra I rer SOC TSH 5 AET E et et 4A eon See me Power Input l a s IOOC y se OOC W WA a JA Digital Signal Processor Board Indicator Lights HVEN Allow High voltage switching on indicator RUN Drive Running indicator Fault Drive is in fault state Trip Drive is in trip state any fault can result in trip Alarm Drive in alarm state Reserved PLC The PowerFlex 6000 uses a Micro850 PLC to perform many of its internal control functions The PLC controls and monitors the cooling fans input and bypass switching devices door switch status etc The PLC is also responsible for interfacing with the user s automation control system via many optional communication protocols Standard communication protocols are EtherNet IP Modbus TCP Server and Modbus RTU Optional communication modules are available to support other communication protocols Figure 22 PLC Location IOs i TI e Troy OSS n y i nad 5500 SS SEL IS O TES c Oi ALR ERN a SS Q D SS TETTETETT wA f em eL e t a a a a D Ga a a a a a Ta a a Ca DADDIES NDAD GEG PLC Plug in Plug in Plug in Extend 1 0 Extend 1 0 HMI The PowerFlex 6000 HMI is a Panel View Plus 700 series catalog number 2711P T7C4D9 The HMI is connected to the Master Control board through a communication interface standard RJ45 EtherNet IP connection The HMI configures operating pa
51. ansformer s three phase primary coils are oriented C B and A from left to right as viewed from the front The secondary windings are also divided into three principal sections from top to bottom The upper third are to feed the power modules in the U output phase The middle third are to feed the power modules in the V output phase The bottom third are to feed the power modules in the W output phase Figure 11 Figure 11 Isolation Transformer Primary and Secondary Winding Orientation PRIMARY WINDING INPUT mej QA e A gt WJ z N The secondary windings are brought out to corresponding vertical isolated stand offs on the body of the transformer orientated C B and A from left to right as viewed from the front Rockwell Automation Publication 6000 UM001B EN P October 2014 Drive System Layout Chapter 2 For drives with fixed mounted power modules the U and W phase interconnections to the isolation transformer secondary windings are on the front of the isolation transformer and the connections to the V phase are on the rear of the isolation transformer The power cable connections to the power modules are made at the factory Therefore the field power cable connections need to be made at the isolation transformer secondary winding termination points see 6000 IN006_ EN P For drives with drawout power modules all of the interconnections between the isolation transform
52. ar Maintenance Intervals isi ctdoctede atetdaiwapicecanas 78 Physical Checks No Medium Voltage or Control Power 79 Power Connection Inspection sisarien EEEE EEEE 79 Physical ngpett ion paca eea E 79 Median Voltage Tesi NE ees aa aa 80 Maintenance after a Fault Condition 00 cee ee eee 80 Fina REPOT cas Sasuianhavase jiGegneues beau ree one EE 80 Isolation Transformer Cabinet 0 cece eee cece eee e ee ees 81 Replace Clean Door Mounted Air Filters 00005 81 Inspect Top Mounted Main Cooling Fans 05 82 Replace Top Mounted Main Cooling Fans 04 83 Fan al i CC ahs menee a adhd a heer enackd anon eta ean ee ateee ee 84 Inspect Isolation Transformer Auxiliary Cooling Fans 85 Replace Isolation Transformer Auxiliary Cooling Fans 86 Inspect Isolation Transformer 2 2c2s6s tasyigtnwtads bucsetieces 86 Inspect Voltage Sensing Board 0 cece eee eee ee ees 87 Rockwell Automation Publication 6000 UM001B EN P October 2014 Technical Specifications Catalog Number Explanation Preventative Maintenance Schedule Table of Contents Replace Voltage Sensing Board i 1dcc trauGeussersuvaassciawaes 87 Inspect Door Position Limit Switch 20s eee ee 88 Replace Door Position Limit Switch 0 20 2 eee 89 Power Module Cabinet 00 ccc cece cece cece cece cece eeenes 90 Inspect Clean or Replace Doo
53. ation Open Close Drive Bypass a ES _ In this screen you can Confirm Bypass Mode 43 Choose Local Remote Operation 45 Open Close Drive Input and Output Contactors 46 Open Close Bypass Contactors 47 Confirm Bypass Mode 1 Press from the Main Interface screen 2 Confirm the Bypass Configuration matches one of the three Input Supply graphics No Bypass Cabinet upply Control Owner Selection Rockwell Automation Publication 6000 UM001B EN P October 2014 43 Chapter3 Setup and Operation Manual Bypass Cabinet Control Owner Selection Automatic Bypass Cabinet Control Owner Selection Contactor Operation Note the Contactor Operation selection i appears when Automatic Bypass is selected 3 To change the Bypass Mode 2 Press seins System Settings b Press c Choose desired Bypass Mode under Select Bypass Mode d Press oOo wm e Press Operation to confirm operation 44 Rockwell Automation Publication 6000 UM001B EN P October 2014 Setup and Operation Chapter 3 Choose Local Remote Operation 1 Press from the Main Interface screen 2 Under Control Owner Selection press either A or 3 Select ERE o confirm in the Select Local Control or Select Remote Control dialog box Control Owner Selection ES EJ v V Select Local Control Select Remote Control ATTENTION This operation can only operate while drive is not running Drive Is Running CAN NOT Opera
54. be used for new applications and it also is ideal for retrofitting existing motors This also allows for the motor cable lengths required for most applications without the requirement for output filtering This power module concept makes maintenance quick and easy Each module has powerful built in diagnostics to identify and isolate a module needing replacement in the unlikely event of a failure This minimizes power module replacement time so process uptime is maximized Figure 1 6 6 6 kV Example Power Structure Power Modules Input Power C3 3 Phase AC e k b oe C4 Isolation Transformer Rockwell Automation Publication 6000 UM001B EN P October 2014 11 Chapter1 Introduction Simplified Electrical Figure 2 3000V 3300V 18 Pulse 9 Power Modules Diagrams Isolation Transformer page ee na si hails Figure 3 6000V 6600V 36 Pulse 18 Power Modules Isolation Transformer hepa ban i PPPE 12 Rockwell Automation Publication 6000 UM001B EN P October 2014 Introduction Chapter 1 Figure 5 Connectivity Overview AC220V Control Power S N 412 Reset Customer Input Contact MV Closed gt Start 50 OH Stop Permit Close MV VIV Pre Closec ei MV Closed Indicator LZ 2 S MV Closed p 904 Warning Indicator Warning ault Indicator Fault l l E Xn Analog Output Current Running Indicator Running B26 OL ea 4 20 mA A Hz Analog Output Frequenc top Indi
55. bus bars that exhibit dust build up Check for corrosion excessive temperature or contamination Inspect Power Module Input and Output Power Connections Verify that all Power Module input line cables and output bus connections are properly torqued Verify the output cables VSB Cables and star connection cables are properly torqued Apply torque sealer if required Check for corrosion excessive temperature or contamination Review Firmware and Hardware Verify the firmware version on the HMI Contact Rockwell Automation to determine whether there are any enhancements or changes made to the Drive Hardware and Control that would be valuable to the application Verify that the HMI is operational Check the status indicators on the Control Unit in the LV Control Cabinet register as normal ATTENTION Ensure there is no power to the drive and wear an anti static wristband Remove any dirt or foreign material Wipe components with an anti static cloth where applicable Inspect Review Spare Parts Check for signs of damage dirt or foreign material See Spare Parts on page 127 damaged circuit boards may also damage related components Use a grounding A ATTENTION Some circuit boards can be destroyed by static charges Use of wrist strap when handling sensitive circuit boards Rockwell Automation Publication 6000 UM001B EN P October 2014 Description Power Rating Range 3 kV motor voltage Power Rating Range 3 3 kV motor
56. cator Stop oE a Ready Indicator Remote Control Indicator Control Aro Z Analog set 4 20 mA T s Permit to Close Customer Permit Close CB 702 LU Analog spare 4 20 mA Emergency Fault Trip Trip EN Analog spare 4 20 mA ee ee m Emergency Stop ao A L11 Ug Three phase Induction Motor Wigs a oL13 A Rockwell Automation Publication 6000 UM001B EN P October 2014 13 Chapter1 Introduction Figure 6 PowerFlex 6000 Principal Components Outgoing Load Cables Generous space for terminating incoming line cables Generous space for terminating outgoing load cables Integrally mounted Multi pulse Isolation Transformer 3 wires in amp 3 wires out ensures low line side harmonics and high input power factor Cabinet ships in two sections to minimize shipping and handling issues All Power Modules are identical to minimize spare parts All Power Modules are designed for easy removal and replacement to minimize MTTR Power Module has a PWM pattern to reduce output harmonics All MV doors are electrically interlocked with input switching device Transformer Incoming Line Cables solation Transformer Power Modules Temperature Monitor Cooling Fans Isolation Transformer Temperature Monitor All door filters can be changed while the drive is running All cooling fans are internally powered by a dedicated winding in the Isolation Transformer no separate fan power supply is needed from customer Al
57. contains material that enables operation and regular maintenance of the drive system This manual provides information specific to maintaining the PowerFlex 6000 medium voltage variable frequency drive It does not include topics such as e Dimensional and electrical drawings generated for each customer s order e Spare parts lists compiled for each customer s order Please refer to the following documents for additional product detail or instruction relating to PowerFlex 6000 drives e PowerFlex 6000 Medium Voltage Variable Frequency Drive Shipping Handling and Installation Instructions 6000 IN006_ EN P This document provides procedural information for physically unloading moving and installing PowerFlex 6000 medium voltage drives e PowerFlex 6000 Medium Voltage Variable Frequency Drive Commissioning Manual 6000 IN007_ EN P This document provides information for commissioning PowerFlex 6000 medium voltage drives Rockwell Automation provides the site and installation specific electrical and design information for each drive during the order process cycle If they are not available on site with the drive contact Rockwell Automation 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 C
58. d Main Cooling Fans Inspect fans used for forced air cooling Replace any that have bent chipped or missing blades or if the shaft does not turn freely Apply power momentarily to check operation If unit does not operate check and replace wiring fuse or fan motor as appropriate Clean or change air filters as recommended in the Users Manual Ensure the aviation plug has a proper hand tight connection Ensure that the ventilation passages are not blocked and the impellers can rotate freely without any obstruction Rockwell Automation Publication 6000 UM001B EN P October 2014 Preventative Maintenance and Component Replacement Chapter 5 Replace Top Mounted Main Cooling Fans The top fan housing consists of a motor and impeller assembly To replace the fan it is necessary to remove the Fan Housing Lid ATTENTION Fan replacement requires working at a significant height from the floor Complete this procedure on a safe stable platform ATTENTION Always perform Power Lockout procedure before servicing equipment Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death 1 Remove and retain four tapping screws around the Fan Housing Lid and remove the Lid 2 Remove and retain eight M6 x 12 bolts from the Fan Housing Assembly which connect to the Fan Support Bracket Fan Housing Lid M6 x 12 Bolt 4 Fan Support
59. d To Bypass One Phase Lost In Power Cell 13 Two Phases Lost In Power Cell 13 IGBT Set 1 Over Current In Power Cell 14 IGBT Set 2 Over Current In Power Cell 14 Input Over Voltage In Power Cell 14 Communication Error In Power Cell 14 No PWM1 Pulse For IGBT Set 1 In Power Cell 14 No PWM2 Pulse For IGBT Set 2 In Power Cell 14 IGBT Set 1 Failed To Turn On In Power Cell 14 IGBT Set 2 Failed To Turn On In Power Cell 14 Power Cell 14 Bypassed Over Temperature In Power Cell 14 Power Cell 14 Failed To Bypass One Phase Lost In Power Cell 14 Two Phases Lost In Power Cell 14 IGBT Set 1 Over Current In Power Cell 15 IGBT Set 2 Over Current In Power Cell 15 Input Over Voltage In Power Cell 15 Communication Error In Power Cell 15 No PWM1 Pulse For IGBT Set 1 In Power Cell 15 No PWM2 Pulse For IGBT Set 2 In Power Cell 15 IGBT Set 1 Failed To Turn On In Power Cell 15 IGBT Set 2 Failed To Turn On In Power Cell 15 Power Cell 15 Bypassed Over Temperature In Power Cell 15 Power Cell 15 Failed To Bypass One Phase Lost In Power Cell 15 Two Phases Lost In Power Cell 15 IGBT Set 1 Over Current In Power Cell 16 IGBT Set 2 Over Current In Power Cell 16 Input Over Voltage In Power Cell 16 Communication Error In Power Cell 16 68 Rockwell Automation Publication 6000 UM001B EN P October 2014 Code F1505 F1506 F1507 F1508 F1509 F1510 F1511 F1512 F1513 F1600 F1601 F1602 F1604 F1605 F1606
60. d all associated drive components for loose power cable connections and ground cable connections torque them based on the required torque specifications Inspect the bus bars and check for any signs of overheating discoloration and tighten the bus connections to the required torque specifications Clean all cables and bus bars that exhibit dust build up The torques of incoming outgoing cable screws of the power unit shall be check if they are in the specified range Use torque sealer on all connections Carry out the integrity checks on the signal ground and safety grounds Physical Inspection Check for any visual physical evidence of damage or degradation of components in the low voltage compartments This includes Relays Contactors Timers Terminal connectors Circuit breakers Ribbon cables Control Wires UPS AC DC Power Supplies etc Causes could be corrosion excessive temperature or contamination Check for any visual physical evidence of damage or degradation of components in the medium voltage compartments cables contactors circuit breakers isolation disconnecting blades power units etc This includes main cooling fan power devices heat sinks circuit boards insulators cables capacitors current transformers potential transformers fuses wiring etc Causes could be corrosion excessive temperature or contamination Clean all contaminated components using a vacuum cleaner DO NOT use a b
61. e 20 Isolation Transformer Temperature Monitor 2A Isolation Transformer Auxiliary Cooling Fans 22 Top mounted Main Cooling Fan s 02 cece eee eee 22 Incoming Line Power Cable Connections 00005 22 Outgoing Motor Cable Connections 0 cece eee eee 22 Door Position Limit SwitChici iciccndcedeetecdvosivesduacccaas 23 Voltage Seming Board rerencepan tar EE AE Geese sas 24 Power Module Cabinet sive 8o hoe ce biel whe ee tae Reh eens 25 Power Modules 0 ccc ccc cece cece cece eens eeeeeneeee 26 Hall Effect Current Sensors HECs 000 c cece een ees 28 Top mounted Main Cooling Fan s 02 eens eee eee 28 LY Control Cabinet sree ed end taciin 2 kb aE E E sae wows 29 Control Unit all modules 0 ccc cece cece eee 30 P 2 ates oe eke ete oe te eae E E 32 E T i EEEE E E AE EAA EAEE EE SEE A A E A 32 UPS e A a E sass eee ae 32 Chapter 3 CONG IVC r A e E ae AET O ins Sees eee 33 Main Interface 0 ccc cece ccc ccc cece cece ese eeeeesessseusees 33 Drive Setup and Configuration Controls 005 34 SCA tis Nic aCOrS nibs oink dad ccna a e a aeeai 34 OPE AOD ates eer e E ce See ae ad ata 35 Serap aiid Monitor Box oc seiventeeeeediawaen Ea E 35 Rockwell Automation Publication 6000 UM001B EN P October 2014 3 Table of Contents Parameters and Function Codes Preventative Maintenance and Component Replacement
62. e Switch To Local Control OK ATTENTION This operation can only operate while drive is not running Drive Is Running CAN NOT Operate OK Rockwell Automation Publication 6000 UM001B EN P October 2014 47 Chapter3 Setup and Operation Settings The Settings screen is where you can access and modify parameters choose or change system language or change bypass mode Current Access Level User Account System Settings Select Language and Bypass Mode User Settings View or modify User level parameter settings Setup Settings View or modify P or T parameters R amp D Settings For use by authorized Rockwell Automation personnel only System Settings Change the HMI language or bypass mode under System Settings 1 Pre SS System Settings 2 Press desired language to choose that language Select Bypass Mode No Bypass Manual Bypass 48 Rockwell Automation Publication 6000 UM001B EN P October 2014 Setup and Operation Chapter 3 3 Select bypass mode and press i to accept or Cancel to cancel Select No Bypass Select Manual Bypass Select Bypass Mode No Bypass j Manual Bypass _ Auto Bypass ATTENTION Operations in this graphic can only operate while on local control Select Auto Bypass Control Selection ls NOT Correct Please Switch To Local Control OK f ATTENTION This operation can only be performed when any
63. e isolation transformer Separate fan control power is not required Top mounted Main Cooling Fan s The top mounted cooling fan s work with the auxiliary cooling fans to ensure reliable cooling of the isolation transformer They ensure the air is exhausted from the cabinet by creating an induced draft Incoming Line Power Cable Connections The incoming line cables connect to the line side terminals on the isolation transformer Incoming line cables can be brought in through the top or bottom of the isolation transformer cabinet Generous working space is provided if stress cones are required See publication 6000 IN006_ EN P for additional details Outgoing Motor Cable Connections The outgoing motor cables connect to a cable stand off assembly on the cabinet side sheet Fixed mounted Power Module configuration or to the cable stand offs mounted on the Isolation Transformer Drawout Power Module configuration The outgoing motor cables connect to output phase of the power module array Outgoing motor cables can be brought in through the top or bottom of the isolation transformer cabinet Generous working space is provided See publication 6000 IN006_ EN P for additional details Rockwell Automation Publication 6000 UM001B EN P October 2014 Drive System Layout Chapter 2 Door Position Limit Switch Each cabinet door that allows access to medium voltage components is lockable and also has a Guardmaster safety limit switc
64. e order of removal Rockwell Automation Publication 6000 UM001B EN P October 2014 103 Chapter5 Preventative Maintenance and Component Replacement Inspect UPS 1 Check there are no obstructions or dirt debris in the exhaust heat fan 2 Ensure there are no visible signs of damage IMPORTANT Ifthe drive has not been turned on for more than 3 months the UPS batteries must be charged for at least 10 hours Apply either MV to the drive or customer supplied control power Check UPS Output Voltage 1 Open the LV Control cabinet door 2 Turn off the back up control power circuit breaker Q5 and the customer supplied power supply circuit breaker Q1 Figure 42 Circuit Breaker Location in LV Control Cabinet Belles ihre TTL es PLC n TILL ele Bill s of ah SSSSSSSSSSSSTSOSS e T IIIT j Q a2 GB Q5 Q6_ Circuit Breakers a PCCECELEETEEY ess FF m LV Control Relays 3 Press ON on the front of the UPS 4 Using a voltmeter check the output voltage of the UPS by checking the input voltage on the line side of the Q2 circuit breaker equivalent electrical point The input voltage must be 220V AC 104 Rockwell Automation Publication 6000 UM001B EN P October 2014 Preventative Maintenance and Component Replacement Chapter 5 Replace UPS ATTENTION Always perform Power Lockout procedure before servicing equipment Verify with a hot stick or appropriat
65. e voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death 1 Turn off the Q2 Q3 and Q6 circuit breakers in the LV Control Cabinet Figure 42 2 Press and hold OFF on the front of the UPS Figure 43 Front Display of UPS Press and hold for 3 seconds to turn the UPS off 3 Turn off the Q1 and Q5 circuit breakers in the LV Control Cabinet 4 Unplug the UPS input and output power cables and disconnect the ground wire 5 Remove and retain four screws from the mounting bracket Mounting Bracket M5 x 12 Bolt x4 Rockwell Automation Publication 6000 UM001B EN P October 2014 105 Chapter5 Preventative Maintenance and Component Replacement 6 Install the replacement UPS and reconnect input and output cables 7 Turn the Q1 circuit break and press the ON button on the UPS Wait for 2 3 seconds 8 Using a voltmeter check the input voltage on the line side of the Q2 circuit breaker The input voltage must be 220V AC 9 Turn on Q2 Q3 Q5 and Q6 circuit breakers to complete the procedure ATTENTION During removal and installation of the UPS do not omit the UPS ground wire Replace UPS Batteries ATTENTION Do not handle batteries that have leaked electrolytes as they are corrosive and can cause burns The UPS must be removed from the LV Control Cabinet in order to access and replace the batteries See steps 1 5 of Replace UPS
66. e wire bundle from the top of the fan 2 Disconnect three wires at the top of the fan 3 Remove four M6 bolts and hardware and retain 4 Remove the Auxiliary Cooling Fan gure 26 Isolation Transformer Hardware Location Isolation Transformer Auxiliary Cooling Fan M6 Bolt Lock Washer 5 Install the new fan in reverse order of removal If necessary install new tie straps around the a b c and o cables through the fan vent Inspect Isolation Transformer 1 Verify the fan is rotating in the proper direction 2 Verify the incoming and outgoing power cable connections are torqued to specifications See Torque Requirements on page 129 3 Check the cabinet interior and Isolation Transformer windings and remove any foreign material Vacuum dust or debris from the Isolation Transformer cabinet 4 Check for any physical evidence of damage or degradation of components 86 Rockwell Automation Publication 6000 UM001B EN P October 2014 Preventative Maintenance and Component Replacement Chapter 5 Inspect Voltage Sensing Board The input VSB cable connections and output VSB wire connectors must be firmly fastened and show no signs of damage or accumulation of dirt dust or debris Replace Voltage Sensing Board working on the Voltage Sensing Board Verify that all circuits are voltage free using a hot stick or appropriate high voltage measuring device Failure to do so may result in injury or d
67. eady 34 Remote 34 Remote Operation 45 Reset 35 Function 37 Reset Alarm 39 Running 34 S Safety Door Switches Location 19 Secondary Windings Inspect 117 Service and Support 8 Service Duty 121 Set Frequency 35 36 Settings Overview 48 R amp D Settings 48 Setup Settings 48 System Settings 48 User Settings 48 Setup and Monitor Box 35 Actual Frequency 35 Motor Current 35 Motor Speed 35 Motor Voltage 35 Set Frequency 35 Setup Login 53 Index Setup Settings Change P Parameters 53 Change T Parameters 53 Function 48 P Parameters 53 T Parameters 53 Simplified Electrical Diagrams 12 10 000V 54 Pulse 27 Power Modules 12 3000V 3300V 18 Pulse 9 Power Modules 12 6000V 6600V 36 Pulse 18 Power Modules 12 Spare Parts 127 Inspect 118 Standards Compliance 15 16 GB 10233 2005 16 GB 12668 4 2006 16 GB 12668 701 2013 16 GB 156 2007 15 GB 2682 15 GB 3797 2005 15 GB 4208 2008 15 GB 7678 87 15 GB 13422 2013 16 GB T 12668 4 2006 16 GB T 14549 93 15 GB T 15139 94 16 GB T 16935 1 2008 15 GB T 1980 2005 15 GB T 2423 10 15 GB T 2681 15 GB T 2900 18 2008 15 GB T 3859 1 2013 15 GB T 3859 2 2013 15 GB T 3859 3 2013 15 GB T 4588 1 1996 15 GB T 4588 2 1996 15 GB1094 11 2007 16 IEC 106 1989 15 IEC 60038 1983 15 IEC 60050 151 2001 15 IEC 60050 551 1999 15 IEC 60076 15 IEC 60146 15 IEC 60721 3 1 1997 15 IEC 60721 3 2 1997 15 IEC 60721 3 3 2008 15 IEC 60757 1983 15
68. eath gt Read and understand this manual thoroughly before commencing Contact f ATTENTION These tasks require person s skilled in this type of detailed work Rockwell Automation with any questions or for clarification The drive can experience reduced service life if operated outside of its design parameters Ensure the operating environment is within specifications Daily inspection and regular maintenance will maximize the service life of the equipment Rockwell Automation Publication 6000 UM001B EN P October 2014 77 Chapter5 Preventative Maintenance and Component Replacement Daily Inspection Check the following items during normal operation of the drive e abnormal noise or vibration in the drive or motor e abnormal temperature in the drive or motor e ambient temperature in the control room above nominal e accumulation of dust or particulate on control room floor or surfaces e abnormal load current above nominal Regular Maintenance Intervals The annual maintenance requirements are summarized on page 123 asa guideline Detailed procedures referred to in the Preventative Maintenance Schedule are described beginning on page 81 Medium Voltage Motor control equipment should be inspected periodically Inspection intervals should be based on environmental and operating conditions and adjusted as indicated by experience An initial comprehensive inspection within 3 to 4 months after installation is suggested Refer to
69. eath f ATTENTION To prevent electrical shock disconnect the main power before 1 Remove the Voltage Sensing Board input and output cables 2 Remove the eight nylon nuts to remove the Insulation Board from the cabinet side sheet Figure 27 Remove the Insulation Board Nylon M10 Bolt x8 Rockwell Automation Publication 6000 UM001B EN P October 2014 87 Chapter 5 88 Preventative Maintenance and Component Replacement 3 Remove the nylon nuts which connect the Voltage Sensing Board to the Insulation Board Figure 28 Remove the Voltage Sensing Board from the Insulation Board Nylon M10 Nut x9 Insulation Board Voltage Sensing Board 4 Install the new Voltage Sensing Board to the Insulation Board in reverse order of removal 5 Reinstall the Insulation Board to the cabinet side sheet in reverse order of removal 6 Reconnect the input and output cables according to the Electrical Drawings Inspect Door Position Limit Switch Check for obvious signs of damage dust or foreign material Remove any dirt or foreign material Wipe components with an anti static cloth where applicable Check the aviation plug has a hand tight connection Rockwell Automation Publication 6000 UM001B EN P October 2014 Preventative Maintenance and Component Replacement Chapter 5 Replace Door Position Limit Switch and tagout the input circuit breaker before performing any work on the drive or f ATTENTION Ensure the
70. ection Location 19 Index Isolation Transformer 3 phase Primary Coils 20 Auxiliary Cooling Fans 22 Clean Replace Air Filters 81 Fan Balance 84 Inspect 86 Inspect Secondary Windings 117 Location 19 Maintenance Schedule 124 Power Cabling Overview 24 Primary Winding Voltage Rating 20 Replace HECS 99 Replace Isolation Transformer Auxiliary Cooling Fan 86 Replace Voltage Sensing Board 87 Secondary Winding Voltage 20 Temperature Monitor 21 Top Mounted Main Cooling Fans 82 Voltage Sensing Board 24 Isolation Transformer Auxiliary Cooling Fan 85 Circuit Breaker Location 85 Hardware 86 Inspect 85 Replace 86 Test 85 Isolation Transformer Auxiliary Cooling Fans 19 22 Maintenance Schedule 124 Isolation Transformer Cabinet Drawout Power Module Drive Configuration Components 19 Layout 19 Isolation Transformer LV Door Temperature Monitor 21 Isolation Transformer MV Door Safety Interlock 23 Isolation TransformerReplace Top Mounted Main Cooling Fans 83 L Language Change HMI Language 48 LC Control Cabinet Circuit Breaker Location 104 Replace UPS 105 UPS 104 Lift Cart 93 Operation 93 Line Frequency 122 Local 34 Local Operation 45 Lockout and tagout 9 Login 50 Setup 53 Rockwell Automation Publication 6000 UM001B EN P October 2014 133 LV Control Cabinet 29 AC DC Power Supplies 101 Component Layout 29 HMI Firmware 118 Inspect PLC 108 LV Control Circuit Breakers Hardware 115 LV Control Relay Hardware 113
71. emperature In Power Cell 4 Power Cell 4 Failed To Bypass One Phase Lost In Power Cell 4 Two Phases Lost In Power Cell 4 IGBT Set 1 Over Current In Power Cell 5 IGBT Set 2 Over Current In Power Cell 5 Input Over Voltage In Power Cell 5 Communication Error In Power Cell 5 No PWM1 Pulse For IGBT Set 1 In Power Cell 5 No PWM2 Pulse For IGBT Set 2 In Power Cell 5 IGBT Set 1 Failed To Turn On In Power Cell 5 IGBT Set 2 Failed To Turn On In Power Cell 5 Power Cell 5 Bypassed Over Temperature In Power Cell 5 Power Cell 5 Failed To Bypass One Phase Lost In Power Cell 5 Two Phases Lost In Power Cell 5 IGBT Set 1 Over Current In Power Cell 6 IGBT Set 2 Over Current In Power Cell 6 Input Over Voltage In Power Cell 6 Communication Error In Power Cell 6 No PWM1 Pulse For IGBT Set 1 In Power Cell 6 No PWM2 Pulse For IGBT Set 2 In Power Cell 6 IGBT Set 1 Failed To Turn On In Power Cell 6 IGBT Set 2 Failed To Turn On In Power Cell 6 Power Cell 6 Bypassed Over Temperature In Power Cell 6 Power Cell 6 Failed To Bypass One Phase Lost In Power Cell 6 Two Phases Lost In Power Cell 6 IGBT Set 1 Over Current In Power Cell 7 Rockwell Automation Publication 6000 UM001B EN P October 2014 65 Chapter4 Parameters and Function Codes Code F0601 F0602 F0604 F0605 F0606 F0607 F0608 F0609 F0610 F0611 F0612 F0613 FO700 FO701 F0702 F0704 F0705 F0706 F0707 F0708 F0709 F0710 F0711 F0712
72. enance and Component Replacement Replace AC DC Power Supplies equipment Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death A ATTENTION Always perform Power Lockout procedure before servicing G1 or G2 Power Supplies 1 Open the LV Control cabinet door 2 Loosen the top and bottom terminal screws and remove the wires on the G1 or G2 power supplies Unscrew the connecting wires on the top and bottom piia r AA looa NA 3 Release the spring loaded latches at the bottom of the power supply and lift the control relay off the DIN rail Figure 39 Release the latches on the Power Supplies G3 Power Supply not shown for clarity Install the new power supply in reverse order of removal 102 Rockwell Automation Publication 6000 UM001B EN P October 2014 Preventative Maintenance and Component Replacement G3 Power Supply Chapter 5 1 Loosen but do not remove the screws on the top of the G3 Power Supply 2 Remove the wires Figure 40 Remove G3 Power Supply wires G1 and G2 Power Supply not shown for clarity Loosen screws and remove all wires 3 Remove two M3 Tapping screws to remove the unit Figure 41 Remove AC DC Power Supply M3 Tapping Screw ee E D oo F Urar AEAEE i eRe Re Ee lee eee ee ee ee na 4 Install the new power supply in revers
73. ent Chapter 5 Isolation Transformer Cabinet Replace Clean Door Mounted Air Filters 81 Inspect Top Mounted Main Cooling Fans 82 Replace Top Mounted Main Cooling Fans 83 Fan Balance 84 Inspect Isolation Transformer Auxiliary Cooling Fans 85 Replace Isolation Transformer Auxiliary Cooling Fans 86 Inspect Isolation Transformer 86 Inspect Voltage Sensing Board 87 Replace Voltage Sensing Board 87 Inspect Door Position Limit Switch 88 Replace Door Position Limit Switch 89 Replace Clean Door Mounted Air Filters Periodically remove and clean or remove and replace the air filters according to the Preventative Maintenance table on page 124 The frequency with which you renew the filters depends on the cleanliness of the available cooling air The cabinet door filters are installed in six locations including four locations on the Power Module Cabinet and two locations on the Isolation Transformer Cabinet However the method to remove or clean the air filters is the same The screens may be replaced while the drive is operating but the procedure is easier to perform while the drive is shut down If the drive is running you must replace the filter as soon as possible to prevent foreign material from entering into the drive Recommended Cleaning Method of Filters e Vacuum Cleaner A vacuum cleaner on the inlet side of the filter will remove accumulated dust and dirt e Blow with Compressed Air point compressed air nozzle in oppos
74. ent for Voltage up to 35 kV Adjustable Speed Drive Electrical System Part 3 EMC Requirement and Testing Method Adjustable Speed Drive Electrical System Part 701 Communication General Technical Standard for Electrical Equipment Structure Semiconductor Converters Electrical Test Methods Practices and Requirements for Harmonic Control in Electrical Power Systems Adjustable Speed Electrical Power Drive Systems Part 4 General Requirements Rating Specifications for AC Power Power Transformer Part 11 Dry type Transformer Rockwell Automation Publication 6000 UM001B EN P October 2014 Elevation Drawings Chapter 2 Drive System Layout There are two basic power cell configurations offered in the PowerFlex 6000 product line For a drive amperage rating lt 200 A a fixed mounted power module design is supplied Fixed mounted modules are shipped installed in the drive For a drive amperage rating of gt 200 A a drawout power module design is supplied The PowerFlex 6000 drive is shipped in two sections the Isolation Transformer Cabinet and the Power Module LV Control Cabinet Refer to PowerFlex 6000 Medium Voltage Variable Frequency Drive Shipping Handling and Installation Instructions G000 IN006_ EN P Isolation Transformer Cabinet 18 Power Module Cabinet 25 LV Control Cabinet 29 Figure 7 Fixed mounted Power Module Drive Configuration in HFHH Ere CECIL ET air FI T COET Ste eit ei ee Tineramersiesneesapiar 7 H
75. er secondary windings and the power modules are made in the rear of the isolation transformer and the connection to the power modules are also in the rear The power cable connections to the isolation transformer secondary winding termination point are made at the factory Therefore the field power cable connections must be made at the power module input points see 6000 IN006_ EN P Isolation Transformer Temperature Monitor A discrete transformer temperature monitor is mounted on the LV door in the isolation transformer cabinet Three temperature sensors are embedded in the isolation transformer The monitor can be set to indicate an alarm condition or a trip condition dependent on the temperature detected Figure 12 Isolation Transformer Temperature Monitor C Sa Temperature Controller of Dry Transformer DSO Auto Hand Max Circ LD B10 10E A separate user manual from the manufacturer is included in the documentation package Rockwell Automation Publication 6000 UM001B EN P October 2014 21 Chapter 2 22 Drive System Layout Isolation Transformer Auxiliary Cooling Fans Six fans are mounted directly underneath the isolation transformer to force air directly through the windings to ensure reliable cooling A baffle structure surrounds the periphery of the transformer structure to ensure the cooling air does not bypass the interior of the transformer windings These fans are powered by a tertiary winding in th
76. erature In Power Cell 20 Power Cell 20 Failed To Bypass One Phase Lost In Power Cell 20 Two Phases Lost In Power Cell 20 IGBT Set 1 Over Current In Power Cell 21 IGBT Set 2 Over Current In Power Cell 21 Input Over Voltage In Power Cell 21 Communication Error In Power Cell 21 No PWM1 Pulse For IGBT Set 1 In Power Cell 21 No PWM2 Pulse For IGBT Set 2 In Power Cell 21 IGBT Set 1 Failed To Turn On In Power Cell 21 IGBT Set 2 Failed To Turn On In Power Cell 21 Power Cell 21 Bypassed Over Temperature In Power Cell 21 Power Cell 21 Failed To Bypass One Phase Lost In Power Cell 21 Two Phases Lost In Power Cell 21 IGBT Set 1 Over Current In Power Cell 22 IGBT Set 2 Over Current In Power Cell 22 Input Over Voltage In Power Cell 22 Communication Error In Power Cell 22 No PWM1 Pulse For IGBT Set 1 In Power Cell 22 No PWM2 Pulse For IGBT Set 2 In Power Cell 22 70 Rockwell Automation Publication 6000 UM001B EN P October 2014 Code F2107 F2108 F2109 F2110 F2111 F2112 F2113 F2200 F2201 F2202 F2204 F2205 F2206 F2207 F2208 F2209 F2210 F2211 F2212 F2213 F2300 F2301 F2302 F2304 F2305 F2306 F2307 F2308 F2309 F2310 F2311 F2312 F2313 F2400 F2401 F2402 F2404 F2405 F2406 F2407 Parameters and Function Codes Chapter 4 Alarm IGBT Set 1 Failed To Turn On In Power Cell 22 IGBT Set 2 Failed To Turn On In Power Cell 22 Power Cell 22 Bypassed Over Temperature In Power Cell 22
77. ers 81 Clean 81 Location 81 Replace 81 Alarm Acc Time 39 Code 39 History 39 List 64 Message 39 QTY 39 Reset Alarm 39 Reset Status 39 Sort 40 Alarm History 40 Alarm Status 39 Allowed 34 Altitude 121 Ambient Air Temperature 10 Ambient Temperature Code 121 Analog Signal Processor Board AT 30 Auto Bypass 49 Batteries Disposal 107 Battery Replace UPS Batteries 106 Bulletin Number 121 Button Function Alarm 34 Home 34 Operation 34 Settings 34 Trends 34 Bypass Contactor Open Close 47 Bypass Mode Auto Bypass 49 Manual Bypass 49 No Bypass 49 Index C Catalog Number Explanation 121 Close Bypass Contactor 47 Close Drive Input Contactors 46 Close Drive Output Contactors 46 Code 39 Coils Maintenance 116 Commissioning Support 8 Confirm Bypass Mode 43 Connect 34 Connectivity Overview 13 Control Board Hardware 109 Replace 109 Control Unit 30 Analog Signal Processor Board 30 Component Layout 30 CPU Board 30 Description 30 Digital Signal Processor Board DT 30 Fiber Optic Socket Location 30 Function Summary 30 Hardware 109 HMI Communication Interface Location 30 Inspect 108 Interface Terminals 30 Maintenance Schedule 124 Part Description 31 PWM Board A 30 PWM Board B 30 PWM Board C 30 Replace 108 Replace Control Board 109 Schematic 31 Control Voltage 122 CPU Board 30 Current Trends 42 Current User User 50 D DB Board Control Unit DB Board 30 Decel 35 Function 37 Digital Sig
78. ertifications website http www ab com Provides declarations of conformity certificates and other certification details You can view or download publications at http www rockwellautomation com literature To order paper copies of technical documentation contact your local Allen Bradley distributor or Rockwell Automation sales representative Preface General Precautions Service and Support 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 8000 4 5 2 Guarding Against Electrostatic Damage or any other applicable ESD protection handbook 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 f ATTENTION An incorrectly applied or installed drive can result in component 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 f ATTENTION Only personnel familiar with the PowerFlex 6000 Adjustable Commissioning
79. erting 0 Non Inverting Digital Output 6 Bit Selection 0 15 Jo fo 15 Digital Output 6 Delay ms o Jo fo 32767 Digital Output 7 Memory Address 9 JN p 500 Digital Output 7 Logic 1 1 Inverting 0 Non Inverting Eo Rockwell Automation Publication 6000 UM001B EN P October 2014 Parameters and Function Codes Chapter 4 Parameter Description Default Modify Upper Number Value Root Limit P346 Analog Output 4 Offset o fo fao 100 P347 Analog Output 4 Scaling Factor wo Jon fo 199 99 P351 Rated Frequency HMI Display Filter Time ms w Jon fo 32767 P352 Rated Frequency HMI Display Integer Part so fo fo 75 P353 Rated Frequency HMI Display Decimal Part o Jo fo 1000 P354 Motor Voltage HMI Display Filter Time ms 2000 ON foo 32767 P355 Motor Voltage HMI Display Integer Part 10000 oN JO 16384 P356 Motor Voltage HMI Display Decimal Part o Jo fo 1000 P357 Actual Frequency HMI Display Filter Time ms aw fo fo 32767 P358 Actual Frequency HMI Display Integer Part so Jon Jo 75 P359 Actual Frequency HMI Display Decimal Part Do i 1000 P360 Motor Current HMI Display Filter Time ms 2000 so 32767 P361 Motor Current HMI Display Integer Part P362 Motor Current HMI Display Decimal Part P371 Rated Frequency HMI Display Address 2 P372 Motor Voltage HMI Display Address ns Jo Jo 500 P373 Actual Frequency HMI Display Address E 500 P400 Deceleration Time During Loss Of Input Supply s w0 P401 Acceleration Time 2w fo fo 3276 P
80. es 101 P P Parameters Restore 55 Parameter Access Level Setup Settings 53 Parameters Change 50 Physical Maintenance Checks 79 Inspect Power Connections 79 Pilot Lights Maintenance 116 PLC 32 Additional Information 108 Components 32 Inspect 108 Maintenance Schedule 124 Power Module Inspect Input Power Connections 118 Inspect Output Power Connections 118 Replace Drawout Power Module 93 Replace Fixed mounted Power Module 91 Power Module Cabinet 25 Clean Replace Air Filters 81 Drawout Power Module Configuration 25 Fan Balance 84 Fixed mounted Power Module Configuration 25 Power Cabling Overview 24 Replace HECS 99 Replace Isolation Transformer Auxiliary Cooling Fan 86 Replace Top Mounted Main Cooling Fans 83 Top Mounted Main Cooling Fans 82 Rockwell Automation Publication 6000 UM001B EN P October 2014 PowerFlex 6000 Altitude Rating 121 Ambient Temperature Code 121 Bulletin Number 121 Catalog Number Explanation 121 Drive Current Rating 121 Elevation Drawings 17 18 Enclosure Type 122 Firmware Version 38 Isolation Transformer Cabinet 18 Isolation Transformer Cabinet Layout 19 Line Frequency 122 Maintenance Schedule 123 Nominal Line Voltage 122 Nominal Load Motor Voltage 122 Power Cabling Overview 24 Service Duty 121 Technical Specifications 119 Torque Requirements 129 Principal Components 14 Pulse Width Modulation 11 Q QTY 39 R amp D Settings Function 48 R
81. for evidence of discoloration from overheating 2 Remove dust or debris from all ventilation openings on the Power Module 3 Inspect the electrolytic capacitors located in the ventilation openings of the Power Module a Inspect for signs of discoloration odor or leakage b Replace Power Modules if the capacitors have discoloration odor or leakage 90 Rockwell Automation Publication 6000 UM001B EN P October 2014 Preventative Maintenance and Component Replacement Chapter 5 Replace Power Module Table 7 Power Module Specifications Fixed mounted 420 x 180x615 mm 16 5x7 1x24 2in 20kg 44 1 Ib 420 x 260x615 mm 16 5x10 2x24 2in 25 kg 55 1 Ib Drawout 575 x 342 x 691 mm 22 6x 13 5x27 2in 40 kg 88 2 Ib 575 x 342 x 910 mm 22 6x 13 5x35 8in 50 kg 110 2 Ib A ATTENTION Two people are required to handle the Power Modules Always handle the drawout Power Modules using the two recessed lifting handles on both mounting rails Figure 33 Fixed mounted Power Module replacing a Fixed mounted Power Module Wait for 20 minutes before opening the cabinet doors Verify that all circuits are voltage free using a hot stick or appropriate high voltage measuring device Failure to do so may result in injury or death f ATTENTION The high voltage power source must be switched off before 1 Remove the positioning barriers from both sides of the Power Module 2 Disconnect the Three phase Input Power C
82. formation 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 potential Arc Flash Arc Flash will cause severe injury or death Wear proper Personal Protective Equipment PPE Fo
83. ge In Power Cell 6 Warning W0514 Input Over Voltage In Power Cell 6 Warning W0603 DC Bus Under Voltage In Power Cell 7 Warning W0614 Input Over Voltage In Power Cell 7 Warning W0703 DC Bus Under Voltage In Power Cell 8 Warning W0714 Input Over Voltage In Power Cell 8 Warning W0803 DC Bus Under Voltage In Power Cell 9 Warning W0814 Input Over Voltage In Power Cell 9 Warning W0903 DC Bus Under Voltage In Power Cell 10 Warning W0914 Input Over Voltage In Power Cell 10 Warning W1003 DC Bus Under Voltage In Power Cell 11 Warning W1014 Input Over Voltage In Power Cell 11 Warning W1103 DC Bus Under Voltage In Power Cell 12 Warning W1114 Input Over Voltage In Power Cell 12 Warning W1203 DC Bus Under Voltage In Power Cell 13 Warning W1214 Input Over Voltage In Power Cell 13 Warning W1303 DC Bus Under Voltage In Power Cell 14 Warning W1314 Input Over Voltage In Power Cell 14 Warning W1403 DC Bus Under Voltage In Power Cell 15 Warning W1414 Input Over Voltage In Power Cell 15 Warning W1503 DC Bus Under Voltage In Power Cell 16 Warning W1514 Input Over Voltage In Power Cell 16 Warning W1603 DC Bus Under Voltage In Power Cell 17 Warning W1614 Input Over Voltage In Power Cell 17 Warning W1703 DC Bus Under Voltage In Power Cell 18 Warning W1714 Input Over Voltage In Power Cell 18 Warning W1803 DC Bus Under Voltage In Power Cell 19 Warning W1814 Input Over Voltage In Power Cell 19 Warning W1903 DC Bus Under Voltage In Power Cell 20 War
84. h If the cabinet door is opened when the input switching device feeding power to the drive is closed the input device will be tripped off solely as a part of the plant operation process to ensure the drive has been disconnected from input medium voltage Keep the medium voltage doors locked as standard practice If access to the medium voltage rated cabinets is required always go to the input device feeding the drive to verify if it is open Lock out and tagout the input device before performing any work on the drive or bypass units f ATTENTION The door position interlock is a safety feature It must not be used Figure 13 Door Position Limit Switch Location Door Position Limit Switch M eee QQ SS OS lt lt eto a a is Sh Rockwell Automation Publication 6000 UM001B EN P October 2014 23 Chapter2 Drive System Layout Voltage Sensing Board The Voltage Sensing Board VSB is connected to the drive output terminals that connect to the motor The VSB converts motor voltage to low voltage levels which allows the drive to monitor the output voltage to the motor Figure 14 Voltage Sensing Board Voltage Sensing Board Hs Input power 3 phase AC D PE BD any voltage e D A B PA A I S 09 PCC Isolation Transformer Cabinet Power Module LV Control Cabinet 24 Rockwell Automation Publication 6000 UM001B EN P October 2014 Chapter 2 Drive System Layout Power Module C
85. h conditions can cause damage to medium voltage motor control equipment Before restoring power the fault condition must be corrected and any necessary repairs or replacements must be made to restore the medium voltage motor control equipment to good working order Refer to NEMA Standards Publication No ICS 2 Part ICS2 302 for procedures Use only replacement parts and devices recommended by Rockwell Automation to maintain the integrity of the equipment Ensure the parts are properly matched to the model series and revision level of the equipment After maintenance or repair of the equipment always test the control system for proper functioning under controlled conditions that avoid hazards in the event of a control malfunction For additional information refer to NEMA ICS 1 3 PREVENTIVE MAINTENANCE OF INDUSTRIAL CONTROL AND SYSTEMS EQUIPMENT published by the National Electrical Manufacturers Association and NFPA70B ELECTRICAL EQUIPMENT MAINTENANCE published by the National Fire Protection Association A complete detailed report on all steps in the Preventive Maintenance procedures should be recorded to identify changes A detailed description of all adjustments and measurements that were taken during the process must be recorded Interlock Adjustments Loose Connections Voltage Readings Megger Results Parameters etc Rockwell Automation Publication 6000 UM001B EN P October 2014 Preventative Maintenance and Component Replacem
86. higher asset availability reduced energy and maintenance costs and asset and personnel protection all resulting in an increased return on your investment and real bottom line savings No matter where your applications are located and whether your requirements are simple or complex count on PowerFlex medium voltage drives for the optimal solution Severe injury or death can result from electrical shock burn or unintended actuation of control equipment Hazardous voltages may exist in the drive cabinet even with the input circuit breaker in the off position 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 Energized industrial control equipment can be dangerous Lockout and tagout the device feeding power to the input of the drive before performing any drive maintenance or component replacements After the input device cabinet doors are opened immediately test the outgoing power cables feeding the drive with a live line tool hot stick while wearing high voltage gloves Repeat the live line tool hot stick testing at the drive incoming line power cable connections to verify that medium voltage is not present Pay special attention to any capacitors connected to medium voltage that can retain
87. ilters boa eR CARI CIR CIR SR zs IR C R Module Cabinet ia O Al Cooling Fans ee er eo T Ca a Ae AL WW Cabinet EA RS RS EERE EEE oS ee ae ef a eee oe ae ee a ei ee E oe a pe a Batteries UPS LV Control PLC Control Unit HMI LV Control Relays LV Control Circuit Breakers All Connections LV Component Terminal amp Plug in Connections Medium Voltage Cable Connections Transformer Secondary Winding Connections Power Module Input and Output Power Connections JJ lt General Enhancements Firmware Hardware Operational Parameters Variables Conditions Spare Parts Inventory Needs JIJ JIJ JIJ lt lt lt 1 Power Modules are refurbished at factory as part of an exchange program 2 Fully discharge and recharge the UPS batteries every 6 months to extend battery life Rockwell Automation Publication 6000 UM001B EN P October 2014 125 AppendixC Preventative Maintenance Schedule Notes 126 Rockwell Automation Publication 6000 UM001B EN P October 2014 Spare Parts List Appendix D Spare Parts Part Number Part Description Replace H5JZ 065 276 R Power Module Control Board 315 4 H5JZ 065 269 R DB Board Ver 1 0 0 O H5JZ 065 271 01 R Control Unit Digital Signal Processor Board H5JZ 065 271 01 Lo H5JZ 065 270 R Control Unit Analog Signal Processor Board Version 1 0 0 Co H5JZ 065 272 01 R CPU Board H5JZ 065 272 01 a H5JZ 065 277 01 R PWM B
88. in Connections 117 Inspect Medium Voltage Cable Connections 117 Inspect Power Cable and Control Wire Terminals 117 Inspect Transformer Secondary Windings 006 117 Inspect Power Module Input and Output Power Connections 118 HCE AL Sisk E eee eam Gand od bobs EA E A EENET 118 Review Firmware and Hardware cceeeee cece eeeeee 118 INSpect Review Spare Parts c imi es ae bees e res giudy sed ees Reet 118 Appendix A state E EEE AIEA EEE UU Cee ise eee ea iain eee A 119 Appendix B EES is Den ee A EEA Ae Gots a ieee ee ease eee et 121 Appendix C PowerFlex 6000 Maintenance Schedule cee eee 123 Rockwell Automation Publication 6000 UM001B EN P October 2014 5 Table of Contents Spare Parts Torque Requirements Index Appendix D Spare Parts List t4ccptresatendpiw EN T Appendix E Torge Kegle meN eenaa a bees Aan teas emiran RaT Rockwell Automation Publication 6000 UM001B EN P October 2014 Introduction Who Should Use This Manual What Is Not in This Manual Additional Resources Rockwell Automation Publication 6000 UM001B EN P October 2014 Preface This document provides procedural information for managing daily or recurring tasks involving PowerFlex 6000 medium voltage variable frequency drives This manual is intended for use by personnel familiar with operating medium voltage and solid state variable speed drive equipment The manual
89. input circuit breaker feeding the drive is open Lock out bypass units 1 Open the drive cabinet door 2 Disconnect the aviation plug from the back of the Limit Switch 3 Remove two M4 x 35 bolts and hardware from the mounting bracket 4 Install the new Limit Switch in reverse order of removal Figure 29 Replace Door Position Limit Switch M4 x 35 Bolt Aviation oe j Nie a Washer Nut Lock washer Rockwell Automation Publication 6000 UM001B EN P October 2014 89 Chapter5 Preventative Maintenance and Component Replacement Power Module Cabinet Inspect Clean or Replace Door Mounted Air Filters 90 Inspect or Replace Top Mounted Main Cooling Fans 90 Inspect Power Modules 90 Replace Power Module 91 Install Drawout Power Modules 95 Replace Power Module Fuses 97 Inspect or Replace HECS 99 Inspect or Replace Door Position Limit Switch 100 Inspect Clean or Replace Door Mounted Air Filters See Replace Clean Door Mounted Air Filters on page 81 Inspect or Replace Top Mounted Main Cooling Fans See Inspect Top Mounted Main Cooling Fans on page 82 Inspect Power Modules 1 Check for damage or degradation of the Power Modules a Inspect the power connections for loose connections or any evidence of discoloration of connections from heating b For Drawout Power Module configurations remove the back plates from the Power Module Cabinet and inspect the plug in connectors on the back of each Power Module Look
90. intenance and Component Replacement Inspect Coils If a coil exhibits evidence of overheating cracked melted or burned insulation it must be replaced In that event check for and correct overvoltage or undervoltage conditions which can cause coil failure Be sure to clean any residue of melted coil insulation from other parts of the device or replace such parts Inspect Contacts Check contacts for excessive wear and dirt accumulations Vacuum or wipe contacts with a soft cloth if necessary to remove dirt Contacts are not harmed by discoloration and slight pitting Do not file contacts Do not use contact spray cleaners as residues on magnet pole faces or in operating mechanisms can cause sticking and can interfere with electrical continuity Replace contacts only after the contact face material is badly worn Replace contacts in complete sets to avoid misalignment and uneven contact pressure Inspect Pilot Lights Replace any burned out lamps or damaged lenses Do not use solvents or cleaning agents on the lenses Do not use test equipment for solid state controls which is not factory recommended Doing so can result in damage to the control or test equipment or unintended actuation of the controlled equipment Solid state devices require little more than a periodic visual inspection Replace discolored charred or burned components Necessary replacements should be made only at the PC board or plug in component level Verify the p
91. ite direction of operating air flow Blow from exhaust side toward intake side e Cold Water Rinse Under normal conditions the foam media used in the filters require no oily adhesives Collected dirt is washed away quickly and easily using just a standard hose nozzle with plain water A N ATTENTION The filter must be completely dry before reinstalling e Immersion in Warm Soapy Water Where stubborn air borne dirt is present the filter may be dipped in a solution of warm water and mild detergent Rinse in clear clean water let stand until completely dry and free of moisture Rockwell Automation Publication 6000 UM001B EN P October 2014 81 Chapter 5 82 Preventative Maintenance and Component Replacement Use only Rockwell Automation supplied or approved replacement filters see Spare Parts List on page 127 Replace the filters in the reverse order of its removal Check that there are no openings to allow foreign matter to enter the drive 1 Unlatch and open the cabinet filter door more than 90 2 Remove the screens by pulling up out of the door IMPORTANT When removing the filter prevent accumulated dirt on the inlet side of the filter from being sucked into the drive It may be difficult to remove the filter material without tearing due to the suction at the air inlet 3 Re install the cleaned or new air filter using reverse order of removal Ensure the door is fully closed and locked Inspect Top Mounte
92. l MV doors are lockable Intuitive easy to use color touchscreen HMI Many communication modules are available such as EtherNet I P and Profibus DP Automatic switchover no trip to internally supplied control power if customer supplied single phase control power is lost On line UPS supplied as standard Door Filters ae 14 Rockwell Automation Publication 6000 UM001B EN P October 2014 Standards Compliance Introduction Chapter 1 Technical specifications and relevant standards in the manufacture testing and acceptance of equipment include Standard Number IEEE 519 IEC 60146 IEC 60038 1983 IEC 60050 151 2001 IEC 60050 551 1999 IEC 60076 IEC 60721 3 1 1997 IEC 60721 3 2 1997 IEC 60721 3 3 2008 IEC 61000 2 4 2002 IEC 61000 4 7 2002 IEC 61800 3 2004 IEC 61800 4 2004 IEC 60757 1983 IEC 106 1989 IEC 61508 1 7 GB T 2900 18 2008 GB T 3859 1 2013 GB T 3859 2 2013 GB T 3859 3 2013 GB 7678 87 GB 3797 2005 GB T 14549 93 GB 4208 2008 GB T 16935 1 2008 GB 156 2007 GB T 1980 2005 GB T 2423 10 GB T 2681 GB 2682 GB T 4588 1 1996 GB T 4588 2 1996 Standard Description Electrical and Electronics Engineers Institute Harmonics Control Requirements Semiconductor Converters Specification of Basic Requirements IEC Standard Voltages International Electrotechnical Vocabulary Chapter 151 Electrical and Magnetic Devices International Electrotechnical Vocabulary Chapter 551 Power Electronics
93. lace UPS on page 105 to reinstall the UPS Rockwell Automation Publication 6000 UM001B EN P October 2014 107 Chapter5 Preventative Maintenance and Component Replacement Inspect PLC 1 Verify all input and output terminal connections are secure 2 Verify all LEDs are working and indicate normal status See publication 2080 UM002_ EN P for further information for the PLC or publication 2080 WD002_ EN P for further information regarding the Isolated Serial Port Plug in Modules Inspect Replace Control Unit or Control Boards equipment Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death f ATTENTION Always perform Power Lockout procedure before servicing e Verify that the terminal connections on the bottom of the Control Unit are secure and are free of dirt dust or foreign material Clean with an anti static cloth e Verify the fiber optic cables are properly connected to the A B C PWM boards Verify an appropriate bend radius if applicable e Check all boards for damage and properly working LEDs Replace a Control Unit IMPORTANT The Control Unit does not have to be removed to replace Control Boards 1 Turn off all the control power turn off the UPS and confirm the LV Control Cabinet is unenergized before operation 2 Disconnect all of the bottom terminals 3 Disconnect the fiber optic wires from A B C
94. lication 6000 UM001B EN P October 2014 Preventative Maintenance and Component Replacement Chapter 5 Inspect Isolation Transformer Auxiliary Cooling Fans When the drive is running verify that each of the coil temperatures are the same on the Isolation Transformer Temperature Monitor display If there is more than a 5 C difference between the highest and lowest temperature check the Isolation Transformer Auxiliary Cooling Fans Test the Isolation Transformer Auxiliary Cooling Fans appropriate high voltage measuring device Failure to do so may result in injury or death A ATTENTION Verify that all circuits are voltage free using a hot stick or 1 Open the LV Control Door on the Isolation Transformer Cabinet Locate the correct circuit breaker s 2 Disconnect the wires from the load side of the Isolation Transformer Auxiliary Cooling Fan circuit breaker Refer to Electrical Drawings Figure 25 Circuit Breaker Location on LV Control Door 3 Connect 380V power to the wires to verify operation of the fans If a fan is not operational see Replace Isolation Transformer Auxiliary Cooling Fans on page 86 4 Remove the power source and reconnect the wires to the circuit breaker Rockwell Automation Publication 6000 UM001B EN P October 2014 85 Chapter5 Preventative Maintenance and Component Replacement Replace Isolation Transformer Auxiliary Cooling Fans 1 Ifthe fan is in the front cut the tie straps to loosen th
95. llow 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 Drive System Layout Setup and Operation Table of Contents IAEROCUCHIONS lt 2545 ss th de Seo dawceedice aa a eres ee 7 Who Should Use This Manual 0 ccc cece eee eee eee e cence 7 What Is Netin This Mantal oc 2scc25 sees t irunia eiee a Se 7 Additional RESOUTCES 4 3 00 tn ie dinanedut diadeantiwneiatesmeeentieeees 7 General Precautions ccc ccc c ccc cence cee esececeseesseunees 8 Sevice ANd SUDPOrt dese ca es docue stds cisedewy does cuteness 8 COMMISSIONING SUPPO ekerin eie EnA REATUS 8 Chapter 1 Salety Considerations e ie o ET e E OE DE 9 Environmental Conditions ccc cece eee ee eee eee eeenees 10 TAGW EM Ol KG asnan ee atk ee te enter AD ee aaa 10 Cascaded H Bridge CHB Topology 2e2 osiain Satusigsexanien 10 Simplified Electrical Dis eras cinkctenioceesseceenesscicnadaders 12 Standards Compliance 2ssictedisevenesporesoreeaniesansh sewers 15 Chapter 2 Elevation Drawn S rb eeter eai aa oe Era ea aa aes 17 Isolation Transformer Cabinet ccc cece eee cece cece eens 18 Isolation Transformer 0 cece cece ec cece ence eee eeeee
96. loaded latches at the bottom of the control relay and lift the control relay off the DIN rail Figure 49 Release the spring loaded latch on the LV Control Relay Install the new control relay in reverse order of removal Replace LV Control Circuit Breakers equipment Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death ATTENTION Always perform Power Lockout procedure before servicing 1 Open the LV Control cabinet door 2 Switch the circuit breaker to the off position Figure 50 Circuit Breaker Location in LV Control Cabinet 114 Rockwell Automation Publication 6000 UM001B EN P October 2014 Preventative Maintenance and Component Replacement Chapter 5 3 Loosen the top and bottom screws and remove the wires on the circuit breaker Figure 51 Screw location on Circuit Breaker remove wires Loosen screws and SSS SS Ss E Circuit Breaker Switch must be in the Off position Loosen screws and remove wires s 4 Release the spring loaded latches at the bottom of the circuit breaker and lift the circuit breaker off the DIN rail Figure 52 Release spring loaded latch on LV Circuit Breakers ONR Soa aas S Install the new circuit breaker in reverse order of removal Rockwell Automation Publication 6000 UM001B EN P October 2014 115 Chapter 5 116 Preventative Ma
97. lower and wipe clean components where appropriate Carry out the physical inspection and verification for the proper operation of the contactor isolator interlocks and door interlocks Carry out the physical inspection and verification for the proper operation of the key interlocks Carry out the cleaning of the fans and ensure that the ventilation passages are not blocked and the impellers are freely rotating without any obstruction Carry out the insulation megger test on the transformer motor and associated cabling Check all bolts for fastening and adjust them as necessary Rockwell Automation Publication 6000 UM001B EN P October 2014 79 Chapter5 Preventative Maintenance and Component Replacement Final Report 80 Medium Voltage Testing Medium voltage insulation resistance IR or dielectric withstanding voltage megger tests should not be used to check solid state control equipment When meggering electrical equipment such as transformers or motors solid state devices must be bypassed before performing the test Even though no damage may be readily apparent after a megger test the solid state devices are degraded and repeated application of high voltage can lead to failure Maintenance after a Fault Condition Opening of the short circuit protective device such as fuses or circuit breakers in a properly coordinated motor branch circuit is an indication of a fault condition in excess of operating overload Suc
98. m2 Z Custom Contact Factory Ambient Temperature Third Position A A 0 40 C B 0 50 0c 8 Z Custom Contact Factory 1 0 1000 m e A B is the only valid altitude for 50 C as a standard supported option 2 Derating for altitude is 10 of the stated A A A Drive Current Rating for 1001 2000 m and 20 of the stated A A A Drive Current Rating for 2001 3000 m 3 Derating for ambient temperature is 2 5 of the stated A A A Drive Current Rating per degree over 40 C C A A A Drive Current Rating Code IW Code 33 36 40 41 45 48 50 54 56 60 63 66 71 15 80 84 90 96 100 108 7 AL g c continued A A A Drive Current Rating omw 315 90 Amp 350 96 Amp 380 100 Amp 420 108 Amp 9 1 etc i 112 Amp 120 Amp 125 Amp 138 Amp 140 Amp 150 Amp 160 Amp 168 Amp 180 Amp 192 Amp 200 Amp 225 Amp 250 Amp 280 Amp 300 Amp 315 Amp 350 Amp 380 Amp 420 Amp A A A Drive Current Ratings shown are only for Normal Duty 0 1000 m altitude and 0 40 C ambient temperature Not all drive current ratings are available in all voltages Refer to the PowerFlex 6000 Selection Guide Rockwell Automation Publication 6000 UM001B EN P October 2014 121 AppendixB Catalog Number Explanation 1 2 3 6000 AAA 41 a b c d Enclosure Type Code M W e Nominal Line Voltage Code B C F J R S f Line Frequency Code 5 6 122 Position 4 5 7 8 9 M
99. n In Power Cell 2 Power Cell 2 Bypassed Over Temperature In Power Cell 2 Power Cell 2 Failed To Bypass One Phase Lost In Power Cell 2 Two Phases Lost In Power Cell 2 IGBT Set 1 Over Current In Power Cell 3 IGBT Set 2 Over Current In Power Cell 3 Input Over Voltage In Power Cell 3 Communication Error In Power Cell 3 No PWM1 Pulse For IGBT Set 1 In Power Cell 3 No PWM2 Pulse For IGBT Set 2 In Power Cell 3 IGBT Set 1 Failed To Turn On In Power Cell 3 IGBT Set 2 Failed To Turn On In Power Cell 3 Power Cell 3 Bypassed Over Temperature In Power Cell 3 Power Cell 3 Failed To Bypass One Phase Lost In Power Cell 3 Two Phases Lost In Power Cell 3 64 Rockwell Automation Publication 6000 UM001B EN P October 2014 Code F0300 F0301 F0302 F0304 F0305 F0306 F0307 F0308 F0309 F0310 F0311 F0312 F0313 F0400 F0401 F0402 F0404 F0405 F0406 F0407 F0408 F0409 F0410 F0411 F0412 F0413 F0500 F0501 F0502 F0504 F0505 F0506 F0507 F0508 F0509 F0510 F0511 F0512 F0513 F0600 Parameters and Function Codes Chapter 4 Alarm IGBT Set 1 Over Current In Power Cell 4 IGBT Set 2 Over Current In Power Cell 4 Input Over Voltage In Power Cell 4 Communication Error In Power Cell 4 No PWM1 Pulse For IGBT Set 1 In Power Cell 4 No PWM2 Pulse For IGBT Set 2 In Power Cell 4 IGBT Set 1 Failed To Turn On In Power Cell 4 IGBT Set 2 Failed To Turn On In Power Cell 4 Power Cell 4 Bypassed Over T
100. n or withdraw the Power Module when on the tray assembly 94 Rockwell Automation Publication 6000 UM001B EN P October 2014 Preventative Maintenance and Component Replacement Chapter 5 Install Drawout Power Modules 1 Place the Power Module module on the lift cart Ensure the Power Module is properly oriented the finger assemblies must face towards the drive 2 Position the lift cart in front of the cabinet and raise the Power Module to the proper height 3 Align the wheels on the Power Module with the tray assembly guides on each side of the Power Module tray assembly Power Module Positioning Handles 00g 00 8000 gt S00 900g as O00 9006 9009 8006 8880 OOo Gabana Oon p TISSI Q Sd09g0200 98 a Ooo Pa 90069892080 7 Qi OO Dogg Oo0eR8 900 ALATT TEE Cam Mechanism Actuator Tray Assembly Guides Wheels 4 Push the Power Module slowly backwards into the cabinet until the cam mechanism contacts the pin mounted on the tray assembly Rockwell Automation Publication 6000 UM001B EN P October 2014 95 Chapter 5 5 Cabinet Stab Finger Assemblies Assemblies Preventative Maintenance and Component Replacement Insert the locking key into the cam mechanism actuator and rotate clockwise while gently pushing on the face of the Power Module E 0 O8000 NU TT 00 00000 g 000 o0000 Connection to z J ooo0 ooo0oo0 Motor Phase Bus oo0008 Oo
101. nal Processor Board DT 30 Door Mounted Air Filters Maintenance Schedule 124 Door Position Limit Switch Inspect 88 Drawount Power Module Basic Principles 26 Rockwell Automation Publication 6000 UM001B EN P October 2014 131 Index 132 Drawout Power Module Catalog Number 28 Configuration 25 Dimensions 91 Lift Cart 93 Locking Key 96 Low Voltage Power Module 26 Output Rating 91 Replace 93 95 Replace Fuse 98 Spare Part NumberDrawout Power Module Current Rating 28 Weight 91 Drive Current Rating 121 Drive Input Contactors Close 46 Open 46 Drive Output Contactors Close 46 Open 46 Drive Setup and Configuration Controls 34 Elevation 10 Elevation Drawings 17 Drawout Power Module Configuration 18 Fixed mounted Power Module Configuration 17 Enclosure Type 122 Environmental Conditions 10 Ambient Air Temperature 10 Elevation 10 IEC721 1 10 F Firmware Maintenance Schedule 124 Firmware Version 38 Fixed mounted Power Module Basic Principles 26 Catalog Number 28 Components 27 91 Configuration 25 Current Rating 28 Dimensions 91 Fuse Location 27 Hardware 91 Line Terminal Location 27 Low Voltage Power Module 26 Output Rating 91 Output Terminal Location 27 Replace 91 Replace Fuse 97 Spare Part Number 28 Specifications 91 Weight 91 Frequency Trends 42 Fuse Drawout Power Module Fuse Hardware 98 Fixed Mounted Power Module Fuse Hardware 97 Replace Drawout Power Module 98 Replace Fixed m
102. nder Local Control Remote The system is under Remote Control 34 Rockwell Automation Publication 6000 UM001B EN P October 2014 Setup and Operation Chapter 3 Operation Bar Table 5 Operation Bar Buttons Start Starts the drive only if no fault is found during self test at startup otherwise this button is invalid Accel Increases the frequency by the set step Decel Decreases the frequency by the set step Stop Stop output of the drive Reset Resets the drive under fault conditions once 1 The drive must not be running to complete this operation Setup and Monitor Box Monitoring Parameters Actual Frequency 0 00 Hz Motor Speed 0 Motor Voltage 0 0 V Motor Current 0 00 A The set frequency field is the only one which is user configurable See Set Frequency Hz for instruction on how to set the frequency Table 6 Monitoring Parameters Set Frequency Frequency set for the drive Hz Actual Frequency Actual frequency of the drive Hz Motor Speed Speed of the motor Motor Voltage Voltage of the motor stator V Motor Current Current of the motor stator A Main Interface Controls From the Main Interface screen you can Set Frequency Hz 36 Drive Operation Controls 37 View Version Information 38 Rockwell Automation Publication 6000 UM001B EN P October 2014 35 Chapter3 Setup and Operation Set Frequency Hz 1 Press the Set Frequency input field 2 Press the Set Freq input field
103. nections L Se Ss a Incoming Line Power l Door Position Cable Connections gl Limit Switches aes F aA elim d ch I E taj Isolation Transformer i Voltage Sensing lpn j Board am at Power Cable Connections E to Power Modules Cable Clam a eS Isolation Transformer Auxiliary Cooling Fans Figure 10 Isolation Transformer Cabinet Drawout Power Module Drive Configuration a a i cake hibited dl ieee dada Peed ee te be Top mounted Main Cooling Fans Incoming Line Power Cable Connections Door Position Limit Switches Outgoing Motor Power Cable Connections Voltage Sensing Board Isolation Transformer Cable Clamp Isolation Transformer Auxiliary Cooling Fans Rockwell Automation Publication 6000 UM001B EN P October 2014 19 Chapter 2 20 Drive System Layout Isolation Transformer The primary winding of the isolation transformer is rated for the voltage of the distribution system It is connected to the distribution system by the incoming line power cables The secondary windings of the isolation transformer are connected to the inputs of the power modules The secondary winding voltage is typically 690V to feed the low voltage power modules There are between 9 and 27 three phase secondary side windings dependent on the motor voltage requirements The phase relationship between the secondary windings are optimized to provide the highest reduction of line side harmonics The isolation tr
104. ning W1914 Input Over Voltage In Power Cell 20 Warning W2003 DC Bus Under Voltage In Power Cell 21 Warning W2014 Input Over Voltage In Power Cell 21 Warning W2103 DC Bus Under Voltage In Power Cell 22 Warning W2114 Input Over Voltage In Power Cell 22 Warning W2203 DC Bus Under Voltage In Power Cell 23 Warning W2214 Input Over Voltage In Power Cell 23 Warning W2303 DC Bus Under Voltage In Power Cell 24 Warning W2314 Input Over Voltage In Power Cell 24 Warning W2403 DC Bus Under Voltage In Power Cell 25 Warning Rockwell Automation Publication 6000 UM001B EN P October 2014 75 Chapter 4 76 Parameters and Function Codes Code W2414 W2503 W2514 W2603 W2614 W2800 W2801 W2802 W2803 W3314 WP001 WP002 WP003 WP004 WP005 WP009 WP010 Alarm Input Over Voltage In Power Cell 25 Warning DC Bus Under Voltage In Power Cell 26 Warning Input Over Voltage In Power Cell 26 Warning DC Bus Under Voltage In Power Cell 27 Warning Input Over Voltage In Power Cell 27 Warning Motor Over Temperature Warning Abnormal Output Voltage Warning Ground Fault Warning Output Frequency Deviation Warning Version Fault Identification Code Error Control Power Switch Warning Transformer Cabinet Fan Fault Power Module Cabinet Fan Fault Transformer Over Temperature Warning Analog Loss Warning Power Module Cabinet Fan Circuit Breaker Open Transformer Cabinet Fan Circuit Breaker Open Rockwell Automation Publication 6000 UM001B EN
105. nit all modules 30 PLC 32 IS a S z wie Ko Ko The LV Control Cabinet consists of the Control Unit the human machine Interface HMI PLC AC DC power supplies contactors and relays The HMI is located on the front door of the LV Control Cabinet where an operator can setup monitor and control the drive Control Unit PLC PAI ABs Achy ches Achy Ads Ad BRRERRERRRR RRR LV Circuit Breakers ks eke aks ahh OE LEE LL E CELLED sores LV Control Relays UPS Rockwell Automation Publication 6000 UM001B EN P October 2014 29 Chapter2 Drive System Layout Fiber Optic Sockets Board Handle Board Mounting Screw HMI Communication Interface Power Indication Status 30 0000000000 Control Unit all modules The control unit provides the core functionality of the variable frequency drive This includes controlling the power modules to produce the required output voltage and frequency monitoring the power modules motor voltage and motor current to provide alarm and trip signals based on the information Figure 20 PowerFlex 6000 Interface Transceiver Indicators PWM Board A PWM Board B PWM Board C Lar S CPU Board Analog Signal Processor Board AT Digital Signal Processor Board DT NN ee Nc QOOOOQ000 Al Y M 0000000000 0000000000 0000000000 0000000000 0000000000 0000000000 0000000000 0009000090 00000000
106. ntative 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 Middle East Africa Rockwell Automation NV Pegasus Park De Kleetla
107. oard H5JZ 065 277 01 Co H02040199 01 R Control Unit H02040199 01 including all boards H01020062 R Door Filter 005 BK 25P P2 1700 1000 10 La HFL 000090 R Standby Fiber Plug T R 5 Meters fe Rockwell Automation Publication 6000 UM001B EN P October 2014 127 AppendixD Spare Parts H01220097 R UPS KR1000 1000VAH AC220V 1 0 aa r H01200077 R Hall Effect Current Sensor CHF 100G 100A 15V 5V D35 m H01200078 R Hall Effect Current Sensor CHF 200G 200A 15V 5V D35 a H01200079 R Hall Effect Current Sensor CHF 300G 300A 15V 5V D35 M HDQ 000015 R Hall Effect Current Sensor CHF 400G 400A 15V 5V D35 D H01200112 R Hall Effect Current Sensor CHF 500G 500A 15V 5V D35 Lo 128 Rockwell Automation Publication 6000 UM001B EN P October 2014 Torque Requirements Appendix E Torque Requirements Proper tightening torque must be used for installation and wiring Table 10 Torque Requirements Torque Thread Size a y E K K e M20 184 Rockwell Automation Publication 6000 UM001B EN P October 2014 lb ft 1 0 2 1 3 4 8 1 16 2 28 8 45 7 70 1 135 7 129 AppendixE Torque Requirements Notes 130 Rockwell Automation Publication 6000 UM001B EN P October 2014 A AC DC Power Supplies 101 Check Output Voltage 101 Inspect 101 Maintenance Schedule 124 Replace 102 Replace G1 102 Replace G2 102 Replace G3 103 Acc Time 39 Accel 35 Function 37 Actual Frequency 35 Additional Resources 7 Air Filt
108. ober 2014 39 Chapter 3 40 Setup and Operation Alarm History Press to see a detailed listed of all warnings and faults on the drive The controls to scroll through the alarms are the same Alarm time 1 21 2014 10 44 12 AM 1 21 2014 10 44 12 AM 1 21 2014 10 44 12 AM 1 21 2014 10 44 12 AM 1 21 2014 10 44 12 AM 1 21 2014 10 44 12 AM 1 20 2014 4 04 36 PM 1 20 2014 3 36 33 PM 1 20 2014 3 36 11 PM 1 20 2014 3 36 11 PM 1 16 2014 1 43 25 PM 1 16 2014 1 43 25 PM 1 16 2014 1 43 25 PM 1 16 2014 1 43 25 PM 1 16 2014 1 43 25 PM 1 16 2014 1 34 11 PM 1 16 2014 1 34 11 PM 1 16 2014 1 34 11 PM Sort Alarms Sort Message Transformer Cabinet Fan Circuit Breaker Open Power Module Cabinet Fan Circuit Breaker Open Cabinet Door Open Auxiliary Power Off E Stop Trip System Locked DSP Communication Fault Analog Loss Warning Transformer Cabinet Fan Circuit Breaker Open Power Module Cabinet Fan Circuit Breaker Open Versions Of System Not Compatible Power Module Cabinet Fan Fault System Locked Transformer Cabinet Fan Fault Communication Error In Power Cell 1 Communication Error In Power Cell 2 Communication Error In Power Cell 3 Versions Of System Not Compatible Power Module Cabinet Fan Fault Transformer Cabinet Fan Fault Press Alarms once to sort once to sort by time Press again to sort by Message TIP Current alarms appear as red past alarms appear as gray Rockwell Automation Publicati
109. on 6000 UM001B EN P October 2014 Setup and Operation Chapter 3 Trends There are three different trending options Voltage Current and Trends Press any button to view the trends Voltage Trend Current Trend Frequency Trend You can view Voltage Current or Frequency trends Voltage is measured in volts Current in amps and Frequency in Hz Back Y Axis X axis 09 43 M7 O TAO T 25 00P Trend Controls Zoom Y axis in Zoom Y axis out Scroll X axis left Scroll X axis right Pause trending Rockwell Automation Publication 6000 UM001B EN P October 2014 41 Chapter 3 42 Setup and Operation View Voltage Current or Frequency Trends 1 Fromthe Main Interface screen press omenaa Voltage Trend Current Trend 2 Press or Frequency Trend in the Trends Selection screen 3 Use the A and Y buttons to zoom in or out Press the a and gt buttons to scroll TIP The time shown in the X axis captures 20 minutes Scrolling left or right will scroll in 10 minute increments 4 Press Pause to pause the trend capture 5 Press ck to return to the Trends Selection screen Rockwell Automation Publication 6000 UM001B EN P October 2014 Setup and Operation Chapter 3 Operation The Operation interface displays the bypass mode control owner selection and contactor operation Input Supply Control Owner Selection Select Local Remote Contactor Operation Bypass Configur
110. onent Replacement Chapter 5 Replace Drawout Power Module and feet away from the lifting mechanism Do not stand under the lift tray f ATTENTION Only authorized personnel should operate the lift cart Keep hands when in use Store the lift cart with the tray fully lowered Lift Carts are supplied and shipped separately with drawout power module configurations The unit s hydraulic cylinder can be operated by either a hand or foot crank The lifting capacity is 1000 kg 2206 Ib Figure 32 Lift Cart Procedure 1 Visually inspect the lift cart to ensure it is fully operational 2 Turn the Pressure Release Knob clockwise until tight Hand Crank 3 Raise the lift tray using the Hand Crank or the Foot Crank TIP The Foot Crank raises the lift tray faster than the Hand Crank Use this to raise the Power Module to just below the tray assembly in the drive Use the Hand Crank for final precise positioning 4 Lower the lift tray by turning the Pressure Pressure in Release Knob counter clockwise Cylinder Pressure in Cylinder Lift Tray Foot Crank Rockwell Automation Publication 6000 UM001B EN P October 2014 93 Chapter5 Preventative Maintenance and Component Replacement Figure 33 Drawout Power Module Lifting Handles Finger Assemblies Mounting Rail Recessed Lifting Handles ATTENTION Do not use the front mounted positioning handles for lifting the Power Modules They are designed to positio
111. onsult the local Rockwell Automation Sales Office How it Works Cascaded H Bridge CHB Topology The proven CHB topology combines an integrally mounted phase shifting isolation transformer and series connected power modules for each phase In addition to stepping down the input voltage the isolation transformer also provides two other principal functions e Mitigate common mode voltage stress so motors with standard insulation levels can be used e Reduce Total Harmonic Distortion THD due to the phase shifting of its secondary windings so input side harmonics don t negatively impact the plant or utility power grid 1 Options are available for operation up to 3000 m a s However these must be stated at the time of order and cannot be retrofitted in the field 2 Options are available for ambient temperatures up to 50 C However these must be stated at the time of order and cannot be retrofitted in the field 10 Rockwell Automation Publication 6000 UM001B EN P October 2014 Introduction Chapter 1 A number of identical low voltage power modules are series connected cascaded together to produce the medium voltage levels required to operate the motor The voltage step for each module is relatively small and a Pulse Width Modulation PWM switching pattern is used so output harmonics and torque pulsations at the motor are minimal even at lower speeds This technology is very motor friendly so standard motors can
112. ounted Power Module 97 G G1 Power Supply Location 101 Replace 102 G2 Power Supply Location 101 Replace 102 G3 Power Supply Location 101 Replace 103 General Precautions 8 Guardmaster Safety Limit Switch 23 HECS Hardware 99 Inspect 99 Maintenance Schedule 124 Mounting Bracket 100 Replace 99 History Alarm 39 Rockwell Automation Publication 6000 UM001B EN P October 2014 HMI 24V Power Supply 112 Acc Time 39 Additional Information 112 Alarm 34 Alarm History 40 Alarm Status 39 Change Interface Language 48 Change P Parameters 53 Change Parameters 50 Change T Parameters 53 Choose Local Remote Operation 45 Code 39 Configuration Controls 34 Confirm Bypass Mode 43 Connect 34 Current Trends 42 Data Cable 112 Drive Setup Controls 34 EtherNet IP 112 Firmware 118 Frequency Trends 42 Ground Cable 112 Home 34 Local 34 Maintenance Schedule 124 Message 39 MVClsd 34 Open Close Bypass Contactor 47 Open Close Drive Input Contactors 46 Open Close Drive Output Contactors 46 Operation 34 Operation Bar 35 Operation Layout 43 Overview 33 QTY 39 Ready 34 Remote 34 Restore P Parameters 55 Restore T Parameters 55 Running 34 Select Bypass Mode 49 Set Frequency 36 Settings 34 48 Setup and Monitor Box 35 Sort Alarms 40 Status Indicators 34 Trend Selection 41 Trends 34 41 User Login 50 Version Information 38 Voltage Trends 42 Warning 34 IEC721 1 10 Incoming Line Power Cable Conn
113. pect or Replace HECS ATTENTION To prevent electrical shock disconnect the main power before working on the drive Verify that all circuits are voltage free using a hot stick or appropriate high voltage measuring device Failure to do so may result in injury or death Two current sensors are located at the top inside the Power Module Cabinet Verify that the current sensor wire connector is properly seated Check for obvious signs of damage 1 Unplug the Current Sensor Connector from the HECS eer 5 4 AN ks a r hy i 4 1 w i 7 Mounting Bracket Current Sensor Connection HECS i hs i f F F Fi a wh i F 7 i e N l aF F _ 4 k i pi lt j F k 7 i aS P 2 Gi i f AL k a r a a h k i Fa mer w aj j 4 a 7 sh ho a j kan Be a T N Fi k a a 3 a th a ee e L1 a r 7 7 LA p _ Mn 5 i en i r 3 i i i A k i w 2 Disconnect one end of the power cable that goes through the HECS from the Power Module 3 Remove the Mounting Bracket with the HECS still attached Rockwell Automation Publication 6000 UM001B EN P October 2014 99 Chapter5 Preventative Maintenance and Component Replacement 4 Remove and retain M5 x 12 hardware connecting the HECS to the Mounting Bracket IMPORTANT _ Note the orientation of the HECS on the bracket The new HECS must be installed facing the same direction Figure 36 Exploded view of the HECS and Mounting Bracket
114. r Mounted Air Filters 90 Inspect or Replace Top Mounted Main Cooling Fans 90 Inspect Power MOG US iimsas cued repay ranae E a 90 Replace Power Module 50 gscrceeeetc ace eueeeniaeatans 91 Replace Power Module Puses 0 x icdureedecweeinendaiydsade 97 Inspector Replace HEC Swicvacactverves vee eor E OORREED 99 Inspect or Replace Door Position Limit Switch 100 LY ContiolCabinetsc lt s soa cencc dct che bows eae mnie lt cedaeace hase 101 Inspect AC DC Power Supplies cccics ios ctivieetsiaesaeees 101 Replace AC DC Power Supplcs cngesoncn ee eeciweees tees 102 Inspect OPS reran gerne nies cabelas ass EET aED 104 Replace UP Sita bias Get ha tebe bets ie laa a ete a ia 105 Replace UPS Battetesier oni n ecds ee ayn es nn Made each awaits 106 Mis pect a E OE E E EE EE E E 108 Inspect Replace Control Unit or Control Boards 108 Inspechtne IMT pstccccncinwwdicte teen a E Leceneen es 111 Replacechie Miena kein e TE ERE 111 Replace LV Control Relaysicc ncubedueeechecekenadeasededweesa 113 Replace LV Control Circuit Breakers 20 ee ee 114 Inspect C Olsen nat tonite wins cratiaee a a st sees 116 Iispecr Ontacts E E E E E ene tates 116 lis pect PIOT IGN snircntmiuenccctendauaanenciumansalasatumets 116 Inspect Locking and Interlocking Devices 04 116 COMME CUIONS ttre cht atteuanactiante eacetGaakisectacsuacaceweans 117 Inspect LV Component Terminal and Plug
115. rameters and input operation commands and displays the operation status operation parameters and fault messages UPS The UPS supplies power to the LV Control cabinet using internal batteries if the customer supplied control power and isolation transformer control power is off The UPS provides control power in the event of transient power loss to ensure the drive control can operate without interruption Rockwell Automation Publication 6000 UM001B EN P October 2014 Chapter 3 Setup and Operation Overview The structure of the touchscreen operation is shown in Figure 23 Figure 23 HMI Overview Main Interface Alarm j V 7 LS oe tee ei gt lt a gt Data Display Alarm Status Set Frequency H Set Frequency R amp D i jik Alarm History Local Local Select Set Several Set Several Set All Actual Frequency Start Stop Reset Act Freq Remote P Parameters P Parameters Switch Switch Switch Motor Voltage Accel Decel Select Set All View K Bypass Mode T Parameters Parameters Motor Current ppemeog Switch Status Info _ Version Info Main Interface The Main Interface Screen contains configuration and operation controls monitoring parameters and actual speed Figure 24 Main Interface Screen Screen Layout 1 1 Top Menu Bar a 2 Status Bar 2 e 3 Set and Monitor Box Allowed MVClosd Ready Connect Running
116. rimary DSP Not Compatible With Secondary DSP PWMC Board Not Compatible With PUC1 Board PWMC Board Not Compatible With PUC2 Board PWMC Board Not Compatible With PUC3 Board PWMC Board Not Compatible With PUC4 Board PWMC Board Not Compatible With PUCS Board PWMC Board Not Compatible With PUC6 Board PWMC Board Not Compatible With PUC7 Board PWMC Board Not Compatible With PUC8 Board PWMC Board Not Compatible With PUC9 Board PWMC Board Not Compatible With PUC10 Board PWMC Board Not Compatible With PUC11 Board PWMC Board Not Compatible With PUC12 Board PWMC Board Not Compatible With PUC13 Board Versions Of System Not Compatible Primary DSP Not Compatible With PLC HMI Not Compatible With PLC Primary DSP Not Compatible With HMI DSP Communication Fault PLC Communication Fault Transformer Over Temperature Trip Auxiliary Power Off Cabinet Door Open DC Bus Under Voltage In Power Cell 1 Warning Input Over Voltage In Power Cell 1 Warning DC Bus Under Voltage In Power Cell 2 Warning Input Over Voltage In Power Cell 2 Warning DC Bus Under Voltage In Power Cell 3 Warning Input Over Voltage In Power Cell 3 Warning DC Bus Under Voltage In Power Cell 4 Warning Input Over Voltage In Power Cell 4 Warning DC Bus Under Voltage In Power Cell 5 Warning Rockwell Automation Publication 6000 UM001B EN P October 2014 Parameters and Function Codes Chapter 4 Code Alarm W0414 Input Over Voltage In Power Cell 5 Warning W0503 DC Bus Under Volta
117. rinted circuit boards are seated in the edge board connectors Board locking tabs should also be in place Protect solid state devices from contamination and maintain appropriate cooling provisions Do not use solvents on printed circuit boards Inspect Locking and Interlocking Devices Check these devices to verify proper working condition Make any necessary replacements only with Allen Bradley renewal parts or kits Adjust or repair only in accordance with Allen Bradley instructions found in the product User Manuals Rockwell Automation Publication 6000 UM001B EN P October 2014 Connections Preventative Maintenance and Component Replacement Chapter 5 N4 Inspect LV Component Terminal and Plug in Connections Inspect Medium Voltage Cable Connections Inspect Power Cable and Control Wire Terminals Inspect Transformer Secondary Windings Inspect Power Module Input and Output Power Connections Nyl Nl i co Inspect LV Component Terminal and Plug in Connections All LV control connections must be secure Check for dirt debris or foreign material and clean with anti static cloth if necessary Check relays contactors timers terminal connectors circuit breakers ribbon cables control wires etc Check for corrosion excessive temperature or contamination Clean all components using a vacuum cleaner Inspect Medium Voltage Cable Connections Verify that all MV
118. te OK Rockwell Automation Publication 6000 UM001B EN P October 2014 45 Chapter3 Setup and Operation Open Close Drive Input and Output Contactors IMPORTANT Turn the 3 position on the selector switch on the front of the LV Cabinet to the Drive position 1 Under Contactor Operation press either o or Eg 2 Select 5 to confirm in the Close Drive Input amp Output Contactors or Open Drive Input amp Output Contactors dialog box Contactor Operation Close Drive Input amp Open Drive Input amp Output Contactors Output Contactors Yes Cancel Yes Cancel A ATTENTION Operations in this graphic can only operate while on local control Control Selection Ils NOT Correct Please Switch To Local Control OK f ATTENTION This operation can only operate while drive is not running Drive Is Running CAN NOT Operate OK 46 Rockwell Automation Publication 6000 UM001B EN P October 2014 Setup and Operation Chapter 3 Open Close Bypass Contactors IMPORTANT Turn the 3 position on the selector switch on the front of the LV Cabinet to the Bypass position 1 Under Contactor Operation press either Faces or Pener 2 Select a to confirm in the Close Bypass Contactors or Open Bypass Contactors dialog box Contactor Operation Close Bypass Contactor Open Bypass Contactor Cancel A ATTENTION Operations in this graphic can only operate while on local control Control Selection Ils NOT Correct Pleas
119. te while drive is not running Drive Is Running CAN NOT Operate Rockwell Automation Publication 6000 UM001B EN P October 2014 55 Chapter3 Setup and Operation Notes 56 Rockwell Automation Publication 6000 UM001B EN P October 2014 P Parameters Chapter 4 Parameters and Function Codes Parameter Number P004 P005 P007 P008 P009 P010 P017 P018 P019 P020 P021 P022 P023 P024 P025 P026 P027 P028 P029 P040 P089 Description Default Modify Upper Value Root Limit Command Source 0 Communication Port 1 Other Sources Restore Factory Settings OFF 50 40 User Level 30 Setup Level 50 R amp D Level Number Of Power Cells Per Phase ZR Motor Rotation Direction Under Local Control 1 Forward 0 Reverse Motor Rotation Direction Command Selection 0 Local 1 DCS memso o e e Stop Method 1 0 Ramp Down 1 Coast Stop Fares e a a Ye 0 Safe Start Condition 0 Zero Frequency Command Required 1 Frequency Command Allowed Skip Frequency Enable 0 Disable 1 Enable Rockwell Automation Publication 6000 UM001B EN P October 2014 57 Chapter4 Parameters and Function Codes Parameter Number P090 P091 P092 P093 P113 P114 P115 P198 P199 P200 P201 P202 P203 P204 P205 P206 P211 P212 P213 P214 P215 P216 P217 P218 P219 P220 P221 P222 P223 P224 P225 P226 P227 P228 P229 P230 P231 Description Default Modify Value
120. tomation Publication 6000 UM001B EN P October 2014 71 Chapter4 Parameters and Function Codes Code F2408 F2409 F2410 F2411 F2412 F2413 F2500 F2501 F2502 F2504 F2505 F2506 F2507 F2508 F2509 F2510 F2511 F2512 F2513 F2600 F2601 F2602 F2604 F2605 F2606 F2607 F2608 F2609 F2610 F2611 F2612 F2613 F2700 F2701 F2702 F2703 F2704 F2705 F2706 F2707 Alarm IGBT Set 2 Failed To Turn On In Power Cell 25 Power Cell 25 Bypassed Over Temperature In Power Cell 25 Power Cell 25 Failed To Bypass One Phase Lost In Power Cell 25 Two Phases Lost In Power Cell 25 IGBT Set 1 Over Current In Power Cell 26 IGBT Set 2 Over Current In Power Cell 26 Input Over Voltage In Power Cell 26 Communication Error In Power Cell 26 No PWM1 Pulse For IGBT Set 1 In Power Cell 26 No PWM2 Pulse For IGBT Set 2 In Power Cell 26 IGBT Set 1 Failed To Turn On In Power Cell 26 IGBT Set 2 Failed To Turn On In Power Cell 26 Power Cell 26 Bypassed Over Temperature In Power Cell 26 Power Cell 26 Failed To Bypass One Phase Lost In Power Cell 26 Two Phases Lost In Power Cell 26 IGBT Set 1 Over Current In Power Cell 27 IGBT Set 2 Over Current In Power Cell 27 Input Over Voltage In Power Cell 27 Communication Error In Power Cell 27 No PWM1 Pulse For IGBT Set 1 In Power Cell 27 No PWM2 Pulse For IGBT Set 2 In Power Cell 27 IGBT Set 1 Failed To Turn On In Power Cell 27 IGBT Set 2 Failed To Turn On In Power Cell
121. ve To Bypass Selection Pf fe Poraanewsatns a Gain Dean ON 32767 4 Step Variable Speed available only when T8 2 Speed 1 Rated Frequency Speed 2 Rated Frequency Speed 3 Rated Frequency Speed 4 Rated Frequency Rockwell Automation Publication 6000 UM001B EN P October 2014 63 Chapter4 Parameters and Function Codes Alarm List Code F0000 F0001 F0002 F0004 F0005 F0006 F0007 F0008 F0009 F0010 F0011 F0012 F0013 F0100 F0101 F0102 F0104 F0105 F0106 F0107 F0108 F0109 F0110 F0111 F0112 F0113 F0200 F0201 F0202 F0204 F0205 F0206 F0207 F0208 F0209 F0210 F0211 F0212 F0213 Alarm IGBT Set 1 Over Current In Power Cell 1 IGBT Set 2 Over Current In Power Cell 1 Input Over Voltage In Power Cell 1 Communication Error In Power Cell 1 No PWM1 Pulse For IGBT Set 1 In Power Cell 1 No PWM2 Pulse For IGBT Set 2 In Power Cell 1 IGBT Set 1 Failed To Turn On In Power Cell 1 IGBT Set 2 Failed To Turn On In Power Cell 1 Power Cell 1 Bypassed Over Temperature In Power Cell 1 Power Cell 1 Failed To Bypass One Phase Lost In Power Cell 1 Two Phases Lost In Power Cell 1 IGBT Set 1 Over Current In Power Cell 2 IGBT Set 2 Over Current In Power Cell 2 Input Over Voltage In Power Cell 2 Communication Error In Power Cell 2 No PWM1 Pulse For IGBT Set 1 In Power Cell 2 No PWM2 Pulse For IGBT Set 2 In Power Cell 2 IGBT Set 1 Failed To Turn On In Power Cell 2 IGBT Set 2 Failed To Turn O
122. ver Temperature In Power Cell 9 Power Cell 9 Failed To Bypass One Phase Lost In Power Cell 9 Two Phases Lost In Power Cell 9 IGBT Set 1 Over Current In Power Cell 10 IGBT Set 2 Over Current In Power Cell 10 66 Rockwell Automation Publication 6000 UM001B EN P October 2014 Code F0902 F0904 F0905 F0906 F0907 F0908 F0909 F0910 F0911 F0912 F0913 F1000 F1001 F1002 F1004 F1005 F1006 F1007 F1008 F1009 F1010 F1011 F1012 F1013 F1100 F1101 F1102 F1104 F1105 F1106 F1107 F1108 F1109 F1110 F1111 F1112 F1113 F1200 F1201 F1202 Parameters and Function Codes Chapter 4 Alarm Input Over Voltage In Power Cell 10 Communication Error In Power Cell 10 No PWM1 Pulse For IGBT Set 1 In Power Cell 10 No PWM2 Pulse For IGBT Set 2 In Power Cell 10 IGBT Set 1 Failed To Turn On In Power Cell 10 IGBT Set 2 Failed To Turn On In Power Cell 10 Power Cell 10 Bypassed Over Temperature In Power Cell 10 Power Cell 10 Failed To Bypass One Phase Lost In Power Cell 10 Two Phases Lost In Power Cell 10 IGBT Set 1 Over Current In Power Cell 11 IGBT Set 2 Over Current In Power Cell 11 Input Over Voltage In Power Cell 11 Communication Error In Power Cell 11 No PWM1 Pulse For IGBT Set 1 In Power Cell 11 No PWM2 Pulse For IGBT Set 2 In Power Cell 11 IGBT Set 1 Failed To Turn On In Power Cell 11 IGBT Set 2 Failed To Turn On In Power Cell 11 Power Cell 11 Bypassed Over Temperature In Power Cell
123. wer supply cable a HMI papata a Pa aa a Fn Pa Data Cable from 24V Power Supply Communication Board EtherNet IP Cable from PLC Ground Cable 2 Remove and retain four screws from HMI IMPORTANT Support the HMI from the outside of the door to prevent it from falling through the front of the door HMI Hardware 4 Reconnect all cables in reverse order of removal TIP The following HMI components can be replaced e Logic Module e Display Module e Bezel e Backlight e Battery See publication 2711P UM006_ EN P for further information 112 Rockwell Automation Publication 6000 UM001B EN P October 2014 Preventative Maintenance and Component Replacement Chapter 5 Replace LV Control Relays equipment Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free Failure to do so may result in severe burns injury or death f ATTENTION Always perform Power Lockout procedure before servicing 1 Open the LV Control cabinet door Figure 47 LV Control Relay Location 2 Loosen the top and bottom screws and remove the wires on the control relay Figure 48 Loosen screws on the LV Control Relay a E ma Co a a _ Loosen screws and remove wires Loosen screws and remove wires Rockwell Automation Publication 6000 UM001B EN P October 2014 113 Chapter5 Preventative Maintenance and Component Replacement 3 Release the spring

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