Allen-Bradley PowerFlex 6000 User Manual
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Allen-Bradley PowerFlex 6000 User Manual

Medium voltage variable frequency drive
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User Manual
PowerFlex 6000 Medium Voltage Variable Frequency Drive
Publication 6000-UM002E-EN-P

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  • Page 1 User Manual PowerFlex 6000 Medium Voltage Variable Frequency Drive Publication 6000-UM002E-EN-P...

  • Page 2: Important User Information

    Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE). Allen-Bradley, Rockwell Automation, Rockwell Software, PanelView Plus, PowerFlex, and TechConnect are trademarks of Rockwell Automation, Inc. Trademarks not belonging to Rockwell Automation are property of their respective companies.

  • Page 3: Table Of Contents

    Table of Contents Important User Information ........2 Preface Introduction.
  • Page 4 Table of Contents Chapter 3 Setup and Operation Main Interface ........... 39 Drive Setup and Configuration Controls .
  • Page 5 Table of Contents Replace Voltage Sensing Board ....... . 98 Inspect Door Position Limit Switch.
  • Page 6 Appendix C Preventative Maintenance Schedule PowerFlex 6000 Maintenance Schedule ......135 Appendix D Torque Requirements Torque Requirements .

  • Page 7: Preface

    What Is Not in This Manual This manual provides information specific to maintaining the PowerFlex 6000 medium voltage variable frequency drive. It does not include topics such as: • Dimensional and electrical drawings generated for each customer’s order •...

  • Page 8: General Precautions

    Service and Support Commissioning 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: • quoting and managing product on-site start-ups •...

  • Page 9: Product Environmental Information

    Failure to complete these activities prior to the commissioning process will delay the start-up of the drive. Refer to the Pre-commissioning Checklist in the PowerFlex 6000 Medium Voltage Variable Frequency Drive Installation Manual, publication 6000-IN006.
  • Page 10 Preface Notes: Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...

  • Page 11: Introduction

    Chapter 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.

  • Page 12: Environmental Conditions

    Chapter 1 Introduction Opening time 40...60 ms Breaking time 50...75 ms Inrush current Inverter input current x 4 or Inverter input current x 5 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.
  • Page 13 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.

  • Page 14: Simplified Electrical Diagrams

    Chapter 1 Introduction Simplified Electrical Diagrams Figure 2 - 2300V / 2400V / 3300V(18 Pulse - 9 Power Modules) Isolation Transformer Secondary Windings Figure 3 - 4000V / 4160V (24 Pulse - 12 Power Modules) Isolation Transformer Secondary Windings Figure 4 - 6000V (30 Pulse - 15 Power Modules) Isolation Transformer Secondary Windings Figure 5 - 6300V / 6600V /6900V (36 Pulse - 18 Power Modules) Isolation Transformer Secondary Windings...
  • Page 15 Introduction Chapter 1 Figure 6 - 10000V (48 Pulse - 24 Power Modules) Isolation Transformer Secondary Windings Figure 7 - 11000V (54 Pulse - 27 Power Modules) Isolation Transformer Secondary Windings Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 16 Chapter 1 Introduction Figure 8 - Connectivity Overview 110/120/220/240V AC Control Power Reset MV Closed Start Stop Permit Close MV Indicator MV Pre-Closed MV Closed Indicator MV Closed Warning Indicator Warning Fault Indicator Fault Running Indicator Running Current output 4-20 mA Stop Indicator Stop Frequency output...
  • Page 17 Introduction Chapter 1 Figure 9 - PowerFlex 6000 Principal Components Generous space for terminating incoming line cables Generous space for terminating outgoing load cables Integrally mounted Multi-pulse Isolation Transformer (3 wires in & 3 wires out) ensures low line side harmonics and high input power...

  • Page 18: Standards Compliance

    Chapter 1 Introduction Standards Compliance Technical specifications and relevant standards in the manufacture, testing, and acceptance of equipment include: Standard Number Standard Description 347A Medium Voltage Power Conversion Equipment Preliminary Standard C22.2 No. 274-13 Adjustable Speed Drives ANSI Instrument Transformers C57.13 National Electric Code OSHA Occupational Safety &...

  • Page 19: Drive System Layout

    Chapter Drive System Layout All PowerFlex 6000 power modules designed as front connection. For a drive amperage rating ≤350 A (304 A for heavy duty), a fixed-mounted power module design is supplied. Fixed-mounted modules are shipped installed in the drive.

  • Page 20: Isolation Transformer Cabinet

    Chapter 2 Drive System Layout LV Control Power Module cabinet Isolation Transformer cabinet cabinet Isolation Transformer Cabinet Isolation Transformer Isolation Transformer Temperature Monitor Top-mounted Cooling Fan(s) Incoming Line Power Cable Connections Outgoing Motor Cable Connections Door Position Limit Switch Voltage Sensing Board Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 21 Drive System Layout Chapter 2 Figure 11 - Isolation Transformer Cabinet, Type A (Junction cabinet not applied) Outgoing motor power Voltage Sensing cable connections Board Incoming line power cable connections Isolation transformer Power cable connections to Power Modules Cable clamp Figure 12 - Isolation Transformer Cabinet, Type B (Junction cabinet not applied) Door position limit switches...

  • Page 22: Isolation Transformer

    Chapter 2 Drive System Layout Figure 13 - Isolation Transformer Cabinet, Type C (Junction cabinet applied for cable connection) Junction cabinet Incoming line power cable connections Outgoing motor power cable connections Isolation Transformer Front View Side View Isolation Transformer The primary winding of the isolation transformer is rated for the voltage of the distribution system.

  • Page 23: Isolation Transformer Temperature Monitor

    Drive System Layout Chapter 2 Figure 14 - Isolation Transformer Primary and Secondary Winding Orientation PRIMARY WINDING INPUT A (L1) B (L2) C (L3) The secondary windings are brought out to corresponding vertical isolated stand- offs on the body of the transformer (orientated U, V, and W from left to right as viewed from the front).

  • Page 24: Top-Mounted Cooling Fan(S)

    Chapter 2 Drive System Layout Figure 15 - Isolation Transformer Temperature Monitors NT579 T154 A separate user manual from the manufacturer is included in the documentation package. Top-mounted Cooling Fan(s) The top mounted cooling fan(s) ensure reliable cooling of the isolation transformer.

  • Page 25: Incoming Line Power Cable Connections

    Isolation Transformer cabinet. When the Junction cabinet is applied, the incoming line cables connect to the terminals inside the Junction cabinet. See the PowerFlex 6000 Medium Voltage Variable Frequency Drive Shipping, Handling, and Installation Instructions,...

  • Page 26: Interlocking

    Chapter 2 Drive System Layout Figure 16 - Door Position Limit Switch Location Door position limit switch Interlocking Each cabinet door that allows access to medium voltage components is lockable. Access to the medium voltage areas of the drive is restricted by the use of key interlocking for safety.
  • Page 27 Drive System Layout Chapter 2 Interlocking key “KB” is used to open the left door of the isolation transformer cabinet, or the left and right doors of the power module cabinet. ATTENTION: Servicing energized industrial control equipment can be hazardous. Severe injury or death can result from electrical shock, burn, or unintended actuation of control equipment.
  • Page 28 This can be done by adding shims on the landing plate where the counterpart is mounted. Besides the mechanical interlock, PowerFlex 6000 drives also provide Guardmaster® safety limit switch on each cabinet door that interlocks with input switching devices.

  • Page 29: Voltage Sensing Board

    Drive System Layout Chapter 2 Voltage Sensing Board The Voltage Sensing Board (VSB) is connected to the medium voltage and converts medium voltage to low voltage levels which allows the drive to monitor the output/input voltage. Figure 19 - Voltage Sensing Board Figure 20 - Power Cabling Overview (3.3 kV) Motor Isolation Transformer...

  • Page 30: Power Module Cabinet

    Chapter 2 Drive System Layout Power Module Cabinet Power Modules Hall Effect Current Sensors (HECs) Top-mounted Cooling Fan(s) Figure 21 - Power Module Configuration Power Modules Power Modules are available in a wide variety of amperage ratings relating to the required motor current.
  • Page 31 Drive System Layout Chapter 2 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.
  • Page 32 Chapter 2 Drive System Layout Figure 23 - Typical Power Module Output terminal Optic fiber socket and status indicator Fuse Line terminals Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...

  • Page 33: Hall Effect Current Sensors (Hecs)

    Drive System Layout Chapter 2 Table 2 - Power Module Ratings Description Current Rating (Amps) Bypass Powercell 40 A, without Bypass Non Module bypass Powercell 75 A, without Bypass Non Module bypass Powercell 100 A, without Bypass Non Module bypass Powercell 120 A, without Bypass Non Module bypass Powercell 150 A, without Bypass...

  • Page 34: Lv Control Cabinet

    Chapter 2 Drive System Layout LV Control Cabinet Control Unit (all modules) 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.

  • Page 35: Control Unit (All Modules)

    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 25 - PowerFlex 6000 Interface Transceiver Fiber optic sockets...
  • Page 36 Chapter 2 Drive System Layout Figure 26 - Control Unit Layout RJ45 Modbus TCP/IP Fieldbus RS-232 Modbus RTU HECS Communication Board CPU Board Fiber Optic PWM Board A PWM Board B PWM Board C Phase B Phase C Phase A Power Modules Power Modules Power Modules...

  • Page 37: Plc

    Standby – 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.

  • Page 38: Ups

    Chapter 2 Drive System Layout 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.

  • Page 39: Main Interface

    Chapter Setup and Operation Main Interface The Main Interface Screen contains configuration and operation controls, monitoring parameters and actual speed. Figure 28 - Main Interface Screen Screen Layout Top Menu Bar Status Bar Set and Monitor Box Actual Frequency Display Box Version Information Box Actual Date and Time Operation Bar...

  • Page 40: Status Indicators

    Chapter 3 Setup and Operation Table 4 - Setup and Configuration Controls • Check voltage trend • Check current trend • Check frequency trend • Check power trend • Pause trending • Confirm bypass configuration • Change from local to remote control •...

  • Page 41: Operation Bar

    Setup and Operation Chapter 3 Operation Bar Table 6 - 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...

  • Page 42: Main Interface Controls

    Chapter 3 Setup and Operation Main Interface Controls From the Main Interface screen, you can: Set Frequency (Hz) Drive Operation Controls View Version Information Set Frequency (Hz) 1. Press the Set Frequency: input field. 2. Press the Set Freq: input field. Numpad Enter Cancel...

  • Page 43: Drive Operation Controls

    Setup and Operation Chapter 3 Drive Operation Controls Press the desired Drive Operation Control button, and to accept or to cancel. ATTENTION: Drive Operation Controls will only function if using Local Control, otherwise the following dialog appears. The Stop command will function regardless of which control method is active.

  • Page 44: View Version Information

    Chapter 3 Setup and Operation View Version Information Press under Version Info. to view the currently installed Firmware. The Version Information screen shows the most current firmware installed for the applicable devices. Will always appear black The number of Power Modules in the drive will appear as blue;...

  • Page 45: Alarm

    Setup and Operation Chapter 3 Alarm If the drive encounters and alarm or warnings, will blink, indicating an active alarm. Press the button in the Top Menu Bar to see the active alarms. List of Active Alarms Quantity Accumulated Time Alarm How many times the alarm has occurred Acc Time...

  • Page 46: Alarm History

    Chapter 3 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. Sort Alarms Press once to sort once to sort by time. Press again to sort by message. Current alarms appear as red;...

  • Page 47: Trends

    Setup and Operation Chapter 3 Trends There are four different trending options, Voltage, Current, Frequency, and Customized. Press any button to view the trends. You can view Voltage, Current, and Frequency trends, or create up to five of your own customized trends. Voltage is measured in volts, Current in amps, and Frequency in Hz.
  • Page 48 Chapter 3 Setup and Operation Back Y-Axis X-axis Trend controls Back Y-Axis X-axis Trend controls Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 49 Setup and Operation Chapter 3 Back Y-Axis X-axis Trend controls The trend controls are the same for all four screens. Zoom Y-axis in Zoom Y-axis out Scroll X-axis left Scroll X-axis right Pause trending Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...

  • Page 50: View Voltage, Current Or Frequency Trends

    Chapter 3 Setup and Operation View Voltage, Current or Frequency Trends 1. From the Main Interface screen, press 2. Press , or in the Trends Selection screen. 3. Use the buttons to zoom in or out. Press the buttons to scroll. The time shown in the X-axis captures 20 minutes.

  • Page 51: Customize A Trend

    Setup and Operation Chapter 3 Customize a Trend IMPORTANT You can customize up to five trends, however these trends will not be saved. 1. From the Main Interface screen, press 2. Press in the Trends Selection screen. 3. Press in the Customized (%) screen. Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 52 Chapter 3 Setup and Operation 4. Select the parameter you want to display from the list. You can also select a K parameter to display. If a parameter is selected, the trend is displayed in percentage (%). If a K IMPORTANT parameter is selected, the trend displays the actual value.
  • Page 53 Setup and Operation Chapter 3 An example of a Customized Trend is shown below. 6. Use the buttons to zoom in or out. Press the buttons to scroll. The time shown in the X-axis captures 20 minutes. Scrolling left or right will scroll in 10 minute increments.

  • Page 54: Operation

    Chapter 3 Setup and Operation Operation The Operation interface displays the bypass mode, control owner selection, and contactor operation. Select Local/ Remote Control Bypass Configuration Open/Close Drive/Bypass Contactors In this screen, you can: Confirm Bypass Mode Choose Local/Remote Operation Open/Close Drive Input and Output Contactors Open/Close Bypass Contactors Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...

  • Page 55: Confirm Bypass Mode

    Setup and Operation Chapter 3 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 Manual Bypass Cabinet Automatic Bypass Cabinet Note the Contactor Operation selection appears when Automatic Bypass is selected...

  • Page 56: Choose Local/Remote Operation

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

  • Page 57: Open/Close Drive Input And Output Contactors

    Setup and Operation Chapter 3 Open/Close Drive Input and Output Contactors Turn the 2-position on the selector switch on the front of the LV cabinet to the IMPORTANT DCS position. 1. Under Contactor Operation, press either 2. Select to confirm in the Close Drive Input & Output Contactors? or Open Drive Input &...

  • Page 58: Open/Close Bypass Contactors

    Chapter 3 Setup and Operation Open/Close Bypass Contactors Turn the 3-position on the selector switch on the front of the LV cabinet to the IMPORTANT Bypass position. 1. Under Contactor Operation, press either 2. Select to confirm in the Close Bypass Contactors? or Open Bypass Contactors? dialog box.

  • Page 59: Settings

    Setup and Operation Chapter 3 Settings The Settings screen is where you can access and modify parameters or change the system language. Current Access Level User Account System Settings Select Language User Settings View or modify User-level parameter settings Setup Settings View or modify Setup-level parameters settings R&D Settings For use by authorized Rockwell Automation personnel only.

  • Page 60: System Settings

    Chapter 3 Setup and Operation System Settings Change the HMI language and view the bypass status under System Settings. 1. Press 2. Press to select other language from the Languages screen. 3. Select the language you want, then press to return. Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...

  • Page 61: User Parameter Settings

    Setup and Operation Chapter 3 4. The Bypass Status windows shows the current bypass mode setting. 5. To change the bypass mode setting, modify parameter P484. 6. Press to accept. User Parameter Settings You can access, view, or change the user parameters in the User Parameter Settings screen.

  • Page 62: Change User Parameters

    Chapter 3 Setup and Operation Change User Parameters To change the user parameters, you must first login to the User Access level by doing the following: 1. In the Settings screen, press The Login dialog box appears. 2. Enter the User Name and Password details. Press to enter the user name.
  • Page 63 Setup and Operation Chapter 3 In the User Parameters Settings screen, the user parameters automatically refresh. After you have logged in to the User Access level, you can change the parameter value by doing the following: 1. Press the parameter number that you want to change. A dialog box appears.
  • Page 64 Chapter 3 Setup and Operation 2. Press the parameter input field to change the parameter value. Press here to input a new P parameter number value for the parameter Use the keypad to enter a new value for the parameter. P parameter number This range applies to all parameters 3.
  • Page 65 Chapter Parameters and Function Codes For detailed descriptions on the parameters and alarms described in this chapter, see the PowerFlex 6000 Medium Voltage Variable Frequency Drive Firmware, Parameters, and Troubleshooting Manual, publication 6000-TD004. Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...

  • Page 66: P Parameters

    Parameters and Function Codes Chapter 4 Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 67 Chapter 4 Parameters and Function Codes Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 68 Parameters and Function Codes Chapter 4 Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 69 Chapter 4 Parameters and Function Codes Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 70 Parameters and Function Codes Chapter 4 Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 71 Chapter 4 Parameters and Function Codes Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 72 Parameters and Function Codes Chapter 4 Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 73 Chapter 4 Parameters and Function Codes Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 74 Parameters and Function Codes Chapter 4 Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 75 Chapter 4 Parameters and Function Codes Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 76 Parameters and Function Codes Chapter 4 Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 77 Chapter 4 Parameters and Function Codes Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 78 Parameters and Function Codes Chapter 4 Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 79 Chapter 4 Parameters and Function Codes Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 80 Parameters and Function Codes Chapter 4 Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 81 Chapter 4 Parameters and Function Codes Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 82 Parameters and Function Codes Chapter 4 Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 83 Chapter 4 Parameters and Function Codes Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 84 Parameters and Function Codes Chapter 4 Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 85 Chapter 4 Parameters and Function Codes Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 86 Chapter 4 Parameters and Function Codes Notes: Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...

  • Page 87: Safety

    Chapter Preventative Maintenance and Component Replacement Safety ATTENTION: Servicing energized Medium Voltage Motor Control Equipment 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.

  • Page 88: Daily Inspection

    Obstruction of the air filters is the main cause of poor cooling airflow. The PowerFlex 6000 drive uses a number of cooling fans installed at the top of the cabinet to ensure that sufficient air flow is used to cool the power components and other heating equipment.
  • Page 89 IEC 61800-5-1 Sec. 6.5 for MV Drives and IEC 60470 Sec. 10, IEC 62271-1 Sec. 10.4 for MV Controllers. The maintenance work for the PowerFlex 6000 drive should normally be performed on a yearly cycle. This work is carried out by Rockwell Automation medium voltage drive customers.

  • Page 90: Physical Checks (No Medium Voltage Or Control Power)

    Physical Checks (No Medium Power Connection Inspection Voltage or Control Power) • Inspect PowerFlex 6000 drive, input/output/bypass sections, and all associated drive components for loose power cable connections and ground cable connections: torque them based on the required torque specifications.

  • Page 91: Medium Voltage Testing

    Preventative Maintenance and Component Replacement Chapter 5 Medium Voltage Testing Medium voltage insulation resistance (IR) or dielectric withstanding voltage tests should not be used to check solid-state control equipment. When performing IR tests on electrical equipment, such as transformers or motors, solid-state devices must be bypassed before performing the test.

  • Page 92: Isolation Transformer Cabinet

    Chapter 5 Preventative Maintenance and Component Replacement Isolation Transformer Cabinet Replace/Clean Door Mounted Air Filters Inspect Top Mounted Cooling Fans Replace Top Mounted Cooling Fans Fan Balance Inspect Isolation Transformer Inspect Voltage Sensing Board Replace Voltage Sensing Board Inspect Door Position Limit Switch Replace Door Position Limit Switch ATTENTION: Wait at least 15 minutes for the stored energy to fully discharge before performing maintenance on the Isolation Transformer cabinet.
  • Page 93 Preventative Maintenance and Component Replacement Chapter 5 • 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.

  • Page 94: Inspect Top Mounted Cooling Fans

    Chapter 5 Preventative Maintenance and Component Replacement Figure 30 - Replace the Filter, Type B Screw Air inlet frame Cotton filter 2. Remove the screens by pulling up out of the door. When removing the filter, prevent accumulated dirt on the inlet side of the IMPORTANT filter from being sucked into the drive.

  • Page 95: Replace Top Mounted Cooling Fans

    Preventative Maintenance and Component Replacement Chapter 5 Replace Top Mounted Cooling Fans There are two types of top fan housings. The top fan housing consists of a motor and impeller assembly. To replace the fan, it is necessary to remove the fan housing lid.
  • Page 96 Chapter 5 Preventative Maintenance and Component Replacement 3. Remove and retain four M6 x 12 hexagon screws from the top of the fan support bracket, and remove the bracket from the fan assembly. 4. Remove the wiring cover and disconnect the wiring. 5.

  • Page 97: Fan Balance

    Preventative Maintenance and Component Replacement Chapter 5 6. Remove and retain five M6 x 16 and four M4 x 12 hexagon combination screws that secure the fan, and remove the fan. 7. Install the fan in the reverse order of its removal. Rotate the impeller by hand to ensure that there is no contact with the fan housing assembly.

  • Page 98: Replace Voltage Sensing Board

    Chapter 5 Preventative Maintenance and Component Replacement Replace Voltage Sensing Board ATTENTION: To prevent electrical shock, disconnect the main power before 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 death.

  • Page 99: Inspect Door Position Limit Switch

    Preventative Maintenance and Component Replacement Chapter 5 Figure 32 - Remove the Voltage Sensing Board from the Insulation Board Voltage Sensing Board Insulation Board Nylon M10 x 40 bolt (6) Nylon M10 nut (6) 4. Install the new Voltage Sensing Board to the Insulation Board in reverse order of removal.

  • Page 100: Replace Door Position Limit Switch

    Chapter 5 Preventative Maintenance and Component Replacement Replace Door Position Limit Switch 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.

  • Page 101: Power Module Cabinet

    Preventative Maintenance and Component Replacement Chapter 5 Power Module Cabinet Inspect, Clean, or Replace Door Mounted Air Filters Inspect or Replace Top Mounted Cooling Fans Inspect Power Modules Replace Power Module Replace Power Module Fuses Inspect or Replace HECS Inspect or Replace Door Position Limit Switch Inspect, Clean, or Replace Door Mounted Air Filters Replace/Clean Door Mounted Air Filters on page Inspect or Replace Top Mounted Cooling Fans...
  • Page 102 Chapter 5 Preventative Maintenance and Component Replacement ATTENTION: The high-voltage power source must be switched off before replacing a 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.
  • Page 103 Preventative Maintenance and Component Replacement Chapter 5 Figure 35 - Close up of Fiber Optic Location and Power Cables VSB cable Motor cable Fiber optic cables Output copper bar 5. Carefully withdraw the Power Module. 6. Install the new Power Module in reverse order of removal. ATTENTION: Do not use the front mounted positioning handles for lifting the Power Modules.
  • Page 104 Chapter 5 Preventative Maintenance and Component Replacement Figure 36 - Lift Cart Procedure 1. Check the lift tray before use to ensure the tray can be raised and lowered smoothly. 2. Rotate the Pressure Release Knob counterclockwise to ensure that the tray is in the lowest position.

  • Page 105: Replace Power Module Fuses

    Preventative Maintenance and Component Replacement Chapter 5 3. After installing the Power Module in place, use the mounting brackets and the M6 × 16 large flat pad galvanized nickel screws to fix the four corners, as shown below. Mounting brackets Power Module Guide rail Mounting brackets...

  • Page 106: Inspect Or Replace Hecs

    Failure to do so may result in injury or death. PowerFlex 6000 drives have two current sensors. For Power Module rating of <200 A, they are located inside the Power Module cabinet. For Power Module rating of 200...680 A, they are located inside the Transformer cabinet. Verify that the current sensor wire connector is properly seated.
  • Page 107 Preventative Maintenance and Component Replacement Chapter 5 Figure 38 - HECS for Power Module rating <200 A Mounting bracket Current Sensor connection HECS Figure 39 - HECS for Power Module rating 200...680 A Mounting bracket HECS Current Sensor connection 2. Disconnect one end of the power cable that goes through the HECS from the Power Module.
  • Page 108 Chapter 5 Preventative Maintenance and Component Replacement Figure 40 - Exploded view of the HECS and Mounting Bracket (Power Module rating <200 A) M5 nut Ø5 washer Ø5 lock washer M5 x 16 cross pan head screw Ø6 washer Ø6 lock washer M6 nut Figure 41 - Exploded view of the HECS and Mounting Bracket (Power Module rating 200...680 A) M5 x 16 cross pan head screw...

  • Page 109: Inspect Or Replace Door Position Limit Switch

    Preventative Maintenance and Component Replacement Chapter 5 7. Reroute the power cable through the HECS and reattach to the Power Module. Inspect or Replace Door Position Limit Switch Replace Door Position Limit Switch on page 100. LV Control Cabinet Inspect AC/DC Power Supplies Replace AC/DC Power Supplies Inspect UPS Replace UPS...

  • Page 110: Inspect Ac/Dc Power Supplies

    Chapter 5 Preventative Maintenance and Component Replacement 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 42 - AC/DC Power Supplies Replace AC/DC Power Supplies ATTENTION: Always perform Power Lockout procedure before servicing equipment.
  • Page 111 Preventative Maintenance and Component Replacement Chapter 5 Figure 43 - Remove AC/DC Power Supply wires (PS3 Power Supply not shown for clarity) Unscrew the connecting wires on the top and bottom 3. Release the spring-loaded latches at the bottom of the power supply and lift the control relay off the DIN rail.
  • Page 112 Chapter 5 Preventative Maintenance and Component Replacement PS3 Power Supply 1. Loosen, but do not remove, the screws on the top of the PS3 Power Supply. 2. Remove the wires. Figure 45 - Remove PS3 Power Supply wires (PS1 and PS2 Power Supply not shown for clarity) Loosen screws and remove all wires 3.

  • Page 113: Inspect Ups

    Preventative Maintenance and Component Replacement Chapter 5 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. If the drive has not been turned on for more than 3 months, the UPS batteries IMPORTANT must be charged for at least 10 hours.

  • Page 114: Replace Ups

    Chapter 5 Preventative Maintenance and Component Replacement Replace UPS 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.

  • Page 115: Inspect Plc

    Preventative Maintenance and Component Replacement Chapter 5 8. Using a voltmeter, check the input voltage on the line side of the CB2 circuit breaker. The input voltage must be 220V AC. 9. Turn on CB2, CB3, CB5, and CB6 circuit breakers to complete the procedure.
  • Page 116 Chapter 5 Preventative Maintenance and Component Replacement 3. Disconnect the fiber optic wires from A/B/C Phase board. 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.
  • Page 117 Preventative Maintenance and Component Replacement Chapter 5 2. Remove the fastening screws on the both sides of the board. Fastening screws 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 Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...

  • Page 118: Inspect The Hmi

    Chapter 5 Preventative Maintenance and Component Replacement 4. Install the new boards in the reverse order of removal. 5. Refer to the Electrical Drawings for reconnecting the fiber optic wires. Connect fiber optic wires here (Refer to electrical drawings) Reconnect the PLC cable Reconnect the bottom terminal Inspect the HMI 1.

  • Page 119: Replace The Hmi

    Preventative Maintenance and Component Replacement Chapter 5 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.

  • Page 120: Replace Lv Control Relays

    Chapter 5 Preventative Maintenance and Component Replacement The following HMI components can be replaced: • Logic Module • Display Module • Bezel • Backlight • Battery See publication 2711P-UM006_-EN-P for further information. Replace LV Control Relays ATTENTION: Always perform Power Lockout procedure before servicing equipment.
  • Page 121 Preventative Maintenance and Component Replacement Chapter 5 Figure 51 - Loosen screws on the LV Control Relay Loosen screws and remove wires Loosen screws and remove wires 3. Release the spring-loaded latches at the bottom of the control relay and lift the control relay off the DIN rail.

  • Page 122: Replace Lv Control Circuit Breakers

    Chapter 5 Preventative Maintenance and Component Replacement Replace LV Control Circuit Breakers 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.
  • Page 123 Preventative Maintenance and Component Replacement Chapter 5 Figure 54 - Screw location on Circuit Breaker Loosen screws and remove wires Circuit breaker switch must be in the Off position Loosen screws and remove wires 4. Release the spring-loaded latches at the bottom of the circuit breaker and lift the circuit breaker off the DIN rail.

  • Page 124: Inspect Coils

    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.

  • Page 125: Connections

    Preventative Maintenance and Component Replacement Chapter 5 Connections 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 Inspect LV Component Terminal and Plug-in Connections All LV control connections must be secure.

  • Page 126: Inspect Power Module Input And Output Power Connections

    Chapter 5 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 bus bars that exhibit dust build-up. Check for corrosion, excessive temperature, or contamination.

  • Page 127: Professional Maintenance Service

    Preventative Maintenance and Component Replacement Chapter 5 Professional Maintenance Service Rockwell Automation also offers professional maintenance service provided by the Rockwell Automation field support engineer, contact your local Rockwell Automation sales person for more information. Miscellaneous Preventive Maintenance Work • Communicate with the customer regarding problems found during the preventive maintenance process.

  • Page 128: Tools/Materials/Documentation Requirements

    Tools/Materials/Documentation Requirements The tools listed below for maintaining the PowerFlex 6000 drives are listed below. Only a subset of the tools are required for specific drive preventive maintenance work, but if all of the above work is to be done, all of the following tools are required.

  • Page 129: Final Report

    • Adjustments and measurements during maintenance (including mechanical adjustment, connection status, voltage reading, vibration test results, parameters, and so on). This information will be sent to the PowerFlex 6000 Technical Support and Product Support for the latest on-site information for future maintenance and technical support.
  • Page 130 Chapter 5 Preventative Maintenance and Component Replacement Notes: Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 131 Appendix Technical Specifications Table 10 - Specifications Description Power Rating Range @ 2.3/2.4 kV motor voltage 137...2390 kW (183...3205 HP) Power Rating Range @ 3.0 kV motor voltage 160...2990 kW (214...4010 HP) Power Rating Range @ 3.3 kV motor voltage 176...3280 kW (235...4398 HP) Power Rating Range @ 4.0/4.16 kV motor voltage 220...4140 kW (294...5552 HP)
  • Page 132 Appendix A Technical Specifications Description Control Power 120V 60 Hz, 240V 60 Hz, 110V 60 Hz, or 220V 50 Hz (3 kVA) External Input Contact Ratings 24V DC External Output Contact Ratings 240V AC/5 A Analog Inputs Four non-isolated, 4…20 mA Analog Outputs Four isolated: 4…20 mA or 0…5V DC (optional) Communications Protocols (Optional)
  • Page 133 Appendix Catalog Number Explanation PowerFlex 6000 Medium Voltage Variable Frequency Drives Position 6000G ...etc. Bulletin Number Nominal System Voltage Code Description Code Description Code Description 6000G PowerFlex 6000 2,400V 7,200V 3,000V 8,320V 3,300V 10,000V Drive Frame Size 4,160V 11,000V Code...
  • Page 134 (2) Standard Nominal Line/Motor Voltage Configurations supported for UL rated version are: - 2400V: 2300V/2400V - 3000V: 3000V Options - 3300V: 3300V - 4160V: 4000V/4160V Refer to PowerFlex 6000 Medium Voltage Drives Options List. - 6000V: 6000V - 6600V: 6300V or 6600V - 7200V: 6900V - 10000V: 10000V - 11000V: 11000V Other Nominal Line/Motor Voltage Configurations can be supplied (Contact Factory).
  • Page 135 Appendix Preventative Maintenance Schedule PowerFlex 6000 This Annual Preventative Maintenance Program includes a visual inspection of all drive components visible from the front of the unit, power supply voltage level Maintenance Schedule checks, general cleaning and maintenance, checking of all accessible power connections for tightness, and other tasks.
  • Page 136 Appendix C Preventative Maintenance Schedule ATTENTION: Customers can replace components for the PowerFlex 6000 drives. However repairs must only be performed by qualified Rockwell Automation personnel. Table 11 - Preventative Maintenance Schedule (0...10 yrs.) Interval Period (in years from commissioning date)
  • Page 137 Preventative Maintenance Schedule Appendix C ATTENTION: Customers can replace components for the PowerFlex 6000 drives. However repairs must only be performed by qualified Rockwell Automation personnel. Table 12 - Preventative Maintenance Schedule (11...20 yrs.) Interval Period (in years from commissioning date)
  • Page 138 Appendix C Preventative Maintenance Schedule Notes: Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 139 Appendix Torque Requirements Torque Requirements Proper tightening torque must be used for installation and wiring. Table 13 - Torque Requirements Torque Thread Size Class 8.8 N•m lb•ft 10.5 26.0 19.2 51.0 37.6 89.0 65.7 141.0 104.1 215.0 158.7 420.0 310.0 Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 140 Appendix D Torque Requirements Notes: Rockwell Automation Publication 6000-UM002E-EN-P - April 2018...
  • Page 141 Index Control Unit Analog Signal Processor Board (AT) 35 AC/DC Power Supplies Component Description 36 Check Output Voltage 110 Component Layout 35 Inspect 90 CPU Board 35 Location 34 DB Board 35 Maintenance Schedule 136 Digital Signal Processor Board (DT) 35 Replace 110 Fiber Optic Socket 35 Additional Resources 7...
  • Page 142 Index Firmware IEC721-1 12 Maintenance Schedule 136 Incoming Line Power Cable Connections Version Information 44 Location 21 Fuse Overview 25 Replace 105 Install Power Module 104 Isolation Transformer 3-phase Primary Coils 22 Clean/Replace Air Filters 92 General Precautions 8 Drive Configuration 19 Fan Balance 97 Guardmaster Safety Limit Switch 25 Incoming Line Power Cable Connections 25...
  • Page 143 Index LV Control Cabinet AC/DC Power Supplies 110 Open Bypass Contactor 58 Circuit Breaker Location 113 Open Drive Input Contactors 57 Control Unit 35 Operation Drive Configuration 19 HMI Firmware 126 Confirm Bypass Mode 55 Inspec/Replace Control Unit 115 Contactor Operation 57 Inspect PLC 115 Local/Remote 56 Inspect/Replace Control Boards 115...
  • Page 144 Index PowerFlex 6000 Top-mounted Cooling Fans 24 Catalog Number Explanation 133 Fan Balance 97 Components 17 Hardware 95 Firmware Version 44 Inspect 94 Isolation Transformer Cabinet Layout 21 Maintenance Schedule 136 LV Control Cabinet Layout 34 Replace 95 Maintenance Schedule 135...
  • Page 146 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.

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