Related Manuals for Rockwell Automation Allen-Bradley PowerFlex 6000T
Summary of Contents for Rockwell Automation Allen-Bradley PowerFlex 6000T
- Page 1 PowerFlex 6000T Drives Catalog Number 6000T Installation Instructions Original Instructions...
- Page 2 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.
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Page 3: Table Of Contents
Connect External Control Signal Wiring ......44 Connect Electrical Safety Interlock Circuit to Input Circuit Breaker . 45 Rockwell Automation Publication 6000-IN100B-EN-P - October 2020... - Page 4 ..............71 Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
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Page 5: Preface
Paper copies of the DDs and EDs are placed in the document/ hardware box in the Isolation Transformer Cabinet before shipment. Contact the local Rockwell Automation office to obtain digital copies, if required. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020... -
Page 6: General Precautions
Automation products in a secure system, harden the control system, manage user access, and dispose of equipment. Industrial Components Preventive Maintenance, Enclosures, and Contact Provides a quick reference tool for Allen-Bradley industrial automation controls and Ratings Specifications, publication IC-TD002 assemblies. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020... -
Page 7: Commissioning Support
Connecting the power cables and control wiring between cabinets that are shipped separately (a) All or part of these activities could be provided by Rockwell Automation or its representatives, based on contract INCO terms and negotiated scope of supply/services agreement. Contact the local Rockwell Automation office for further information. -
Page 8: Environmental Conditions
Rockwell Automation to perform the power cable and control wiring interconnection work immediately before the commissioning process. -
Page 9: Drive Mechanical Installation
Then remove the covers. 2. Arrange the sections as described in the Dimensional Drawings and move the sections together. 3. Align the cabinet side sheets together at the holes f r the hardware. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020... - Page 10 DV/DT Filter Cabinet Front Front Side View 4. Secure the cabinets together using two L-shaped brackets and four M12 hexagon socket bolts, D12 washers, and D12 lock washers at the front and rear side. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
- Page 11 Access for the front connections requires only opening the doors. Access for the rear connections requires removing the back plates of the cabinet. 1. Arrange the sections as directed in the Dimensional Drawings and move the sections together. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
- Page 12 3. Secure the cabinets together using M6 or M8 hardware. See Torque Requirements on page 59 for proper torque requirements. Open the doors to access front edge joining holes (four or five places). Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
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Page 13: Affix Cabinets To Floor
Power Module/LV Control Cabinet Isolation Transformer Cabinet Input cable Control signal Output cable Bottom View Secure the cabinet to the channel steel base using M12 bolt (recommended), lock washer, two flat washers, and a nut. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020... - Page 14 Handling Manual, publication 6000-PC100) for further information on the steel base and desired trench and mounting customer-specifications. ATTENTION: Failure to correctly anchor the cabinet may result in damage to the equipment or injury to personnel. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
- Page 15 Chapter 1 Drive Mechanical Installation Figure 7 - Typical Floor Drawing, A-Frame Non-seismic Seismic Secure the cabinet to the channel steel base using M12 bolt (recommended), lock washer, two flat washers, and a nut. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
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Page 16: Install Seismic Rated Enclosures
3. Remove two thermostats from the DIN rail in PC and TC at the right- hand side of the cabinet. Step 1 Step 2 Step 3 4. Remove the HECS insulation bracket. 5. Remove the grounding terminal of the right side plate at the back side. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020... - Page 17 9. Drill anchor holes at the right-hand side of the cabinet, then install the anchors. Step 7 Step 8 Step 9 10. Install all the parts in reverse order of removal. Step 10 Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
- Page 18 4. Drill anchor holes at the back of the cabinet. 5. Drill anchor holes at the front of the cabinet. Step 4 Step 5 6. Install all the removed parts in reverse order of removal. Step 6 Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
- Page 19 4. Drill anchor holes at the front of the cabinet. 5. Drill anchor holes at the back of the cabinet. Step 4 Step 5 6. Install all the removed parts in reverse order of removal. Step 6 Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
- Page 20 For condition 1, installation of power cell cabinets, follow these instructions: 1. Disassemble the grounding busbar at the front of the cabinet. 2. Disassemble the anchor cover at the front of the cabinet. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
- Page 21 3. Drill an anchor hole. Barrier bracket Grounding busbar Anchor cover Wire duct Left cabinet Step 1 Step 2 Step 3 Barrier bracket Grounding busbar Anchor cover Wire duct Right cabinet Step 1 Step 2 Step 3 Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
- Page 22 Wall bracket B Wall bracket A M12xL35 Based on bracket thickness of 11 mm (0.43 in.) Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
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Page 23: Install Main Cooling Fans
2. Secure the fan housing using M6 hardware (six places). Torque Requirements on page 3. Connect the aviation plug located on top of the cabinet with the socket on the fan housing. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020... - Page 24 3. Connect the aviation plug located on the top of the cabinet with the socket on the fan housing. Figure 11 - Main Cooling Fan Housing, A-Frame Main Cooling Fan housing Socket Noise reduction barrier Aviation plug Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
- Page 25 4. Secure the air hood with 12 M16x16 hexagon combination screws. 5. Put the fan modules onto the air hood and align with the provisions on the air hood. 6. Secure the fan modules with 16 M16x16 hexagon combination screws. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
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Page 26: Install Power Modules (If Applicable)
Store the lift cart with the tray fully lowered. The lift cart’s hydraulic cylinder can be operated by either a hand or foot crank. The lifting capacity is 400 kg (882 lb). Rockwell Automation Publication 6000-IN100B-EN-P - October 2020... - Page 27 1. You can use the lift cart to move and position the Power Module to the appropriate location in the cabinet. 2. Push the Power Module slowly along the guide rails until it cannot be pushed in further. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
- Page 28 Power Module to confirm that there is no damage and moisture. 1. Push the Power Module slowly along the guide rails until it cannot be pushed in further. 2. After installing the Power Module in place: Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
- Page 29 Power Module Guide rail Mounting brackets b. For 70 A rating – use M16x16 large flat pad galvanized nickel screws to secure two bottom corners directly. Power Module Guide rail Secure points Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
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Page 30: External Ducting
Screens must be installed in the air inlet. • The air inlet and outlet must not be at the same side of the drive room. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020... - Page 31 Chapter 1 Drive Mechanical Installation Cabinet Airflow, A-Frame Cabinet Airflow, B-Frame (a) Top ducting shown by contractor. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
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Page 32: Air Conditioning Sizing
– ------------------------------------------ - tons of AC required This is for a general estimate. See the actual heat loss data to calculate air conditioning sizing. Contact the local Rockwell Automation office for actual data. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020... -
Page 33: Drive Electrical Installation
ATTENTION: The national and local electrical codes outline provisions for safely installing electrical equipment. Installation must comply with specifications regarding wire type, conductor sizes, branch circuit protection, and disconnect devices. Failure to do so may result in personal injury and/or equipment damage. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020... -
Page 34: Electrical Drawings
The primary grounding cable must have a diameter of at least 50 mm and meet all applicable national and local electrical codes. Run the system ground cable separately from power and signal wiring so that faults: Rockwell Automation Publication 6000-IN100B-EN-P - October 2020... -
Page 35: Power Cable Insulation Requirements
Ground the drive output protective grounding connection separately, and only at the drive side. Comply with the maximum tensile stress and the minimum curvature radius that is recommended by the cable manufacturer. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020... -
Page 36: Motor Cable Sizing
Wires for digital and analog signals must be routed separately. Control cables and power cables must be routed separately; the distance between the control cable tray and the power cable tray must not be less than 300 mm (11.8 in.). Rockwell Automation Publication 6000-IN100B-EN-P - October 2020... - Page 37 Figure 15 - Vertical Ground Bus in LV Cabinet A-Frame B-Frame Ground Bus Provisions for Grounding Control Signal Wiring Shields, Ground Bus and so on. Provisions for Grounding Control Signal Wiring Shields, and so on. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
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Page 38: Electrical Installation Summary
Lock washer Flat washer M8x25 bolt IMPORTANT If an optional cabinet is supplied, the system ground cable connection is in the optional cabinet. See the PowerFlex 6000T Drives Hardware Service Manual, publication 6000-TG100. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020... -
Page 39: Insulation Resistance (Ir) Test Of Power Cables
1. Remove the three plastic M6x25 bolts that secure the removable insulation barrier. 2. Pull out the removable barrier. 3. Connect the cables. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020... - Page 40 Chapter 2 Drive Electrical Installation 4. Install the removable barrier in the reverse order of removal. Removable barrier Plastic M6x25 bolt, plastic nut, and plastic washer (3) Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
- Page 41 Cable clamp Bottom entry Front View Side View Figure 19 - Isolation Transformer Cabinet, A-Frame (DV/DT filter cabinet applied) Input Output Shielded cable Non-shielded cable Input Output Top entry Bottom entry Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
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Page 42: Connect Control Power Wiring
Wiring Routing and Connection The opening for the control power wiring must be specified during the quotation stage. See the customer-specific Dimension Drawing for the location of the opening. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020... - Page 43 Cable entrance in top or bottom front of LV Control Cabinet The control power wiring terminates to the VFD1 terminal block strip on the left side of the LV Control cabinet (Figure 23). Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
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Page 44: Connect External Control Signal Wiring
20W for indication. Interposing relays are provided to interfacing to power switching devices and fault status information. The quantity is based on the options ordered with the drive. The rating of these contacts are Rockwell Automation Publication 6000-IN100B-EN-P - October 2020... -
Page 45: Connect Electrical Safety Interlock Circuit To Input Circuit Breaker
Always go to the input circuit breaker feeding the drive to verify if it is open. Lock out and tagout the input circuit breaker before performing any work on the drive or bypass units. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020... - Page 46 Wire Routing and Connection The electrical safety interlock control signal wiring enters the drive through the same opening as the control power wiring in the bottom of the LV Control Cabinet (Figure 22). Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
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Page 47: Electrical Interconnection Summary
The U phase is the top horizontal row, the V phase is the middle horizontal row, and the W phase is the bottom horizontal row. See the Electrical Drawing (ED) for actual wire number designations. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020... - Page 48 PC C1 PC C0 PC B2 Input power PC B1 3-phase AC any voltage PC B0 PC A2 PC A1 PC A0 Voltage Sensing Board Motor Isolation Transformer Cabinet Power Module/LV Control Cabinet Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
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Page 49: Connect Isolation Transformer Secondary Power Cables
3.0/3.3 kV configuration. The 6.0/6.6 kV and 10 kV configuration have more power modules and therefore have more corresponding isolation transformer secondary windings. The concept is the same—the top third of the winding sets feeds the power modules in the U Rockwell Automation Publication 6000-IN100B-EN-P - October 2020... -
Page 50: Connect Motor And Voltage Sensing Board Cables
For drive ratings with power modules ≥250 A, the connection points are always on the right side of the power module cabinet. For drive ratings with power modules ≤200 A, the connection points are on the left side of the power module cabinet. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020... - Page 51 (Figure Figure 30). Figure 29 - 4.16 kV Power Module Configuration – A-Frame U Phase M6x16 bolt V Phase Motor cable to Junction cabinet W Phase VSB cable Front View Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
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Page 52: Connect Lv Control And Fan Wiring Bundles
One is attached above the solid ground bus and one below (Figure 31). Ground bus connection openings are provided in the cabinet sidesheets for this connection. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020... -
Page 53: Complete The Installation
4. Check that all electrical connections have been made and torqued as specified. 5. Verify that the safety circuit is working properly (see page 45). 6. Reinstall all cabinet back plates. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020... - Page 54 Chapter 3 Drive Electrical Interconnection Notes: Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
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Page 55: Pre-Commissioning Responsibilities
Pre-Commissioning Once all points of the checklist are complete, initial each checkbox and provide the date. Photocopy the checklist and fax the copy to the Rockwell Automation Checklist Start-up Manager, along with the planned startup date. Upon receiving this checklist, the Project Manager will contact the site to finalize arrangements for a startup engineer to travel to the site at your convenience. - Page 56 All single-phase control wiring is within specified levels and has grounded neutrals. Control lines must be shielded and grounded. Control and Power lines must run in separate conduits. The electrical safety interlock wiring to input circuit breaker is correctly installed. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
- Page 57 The cable terminations, if stress cones are used, adhere to the appropriate standards. Appropriate cable insulation levels are adhered to, as per Rockwell Automation specifications. All shields for shielded cables must be grounded at the source end only.
- Page 58 Appendix A Pre-Commissioning Notes: Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
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Page 59: 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-IN100B-EN-P - October 2020... - Page 60 Appendix B Torque Requirements Notes: Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
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Page 61: General Wire Categories
(3) 18 AWG, twisted-pair, shielded (4) Internal Drive Link Communication — The recommended cable to use is AB 1485C-P1Cxxx, where xxx is the length of the cable on the spool (Belden type YR 39660). Rockwell Automation Publication 6000-IN100B-EN-P - October 2020... - Page 62 Appendix C General Wire Categories Notes: Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
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Page 63: Schematic Diagrams
Figure 32 - Schematic Diagram of the Drive System without a Bypass Cabinet, A-Frame (a) Wiring locations are for design reference only; actual wiring must comply with the drawings that are provided with the drive. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020... - Page 64 Figure 33 - Schematic Diagram of the Drive System without a Bypass Cabinet, B-Frame with one Transformer (a) Wiring locations are for design reference only; actual wiring must comply with the drawings that are provided with the drive. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
- Page 65 Figure 34 - Schematic Diagram of the Drive System without a Bypass Cabinet, B-Frame with two Transformers (a) Wiring locations are for design reference only; actual wiring must comply with the drawings that are provided with the drive. Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
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Page 66: Standard Input/Output Connection Points
Hardwired to POD Option Card Port 7 Remote Preset Speed 6/7 1538/1442A -3LL/-3LB Customers use based on - DI3 selections available in POD I/O Hardwired to POD Option Card Port 8 Fault Reset 1444/1052A -3LL/-3LB Fault Reset - DI3 Rockwell Automation Publication 6000-IN100B-EN-P - October 2020... - Page 67 Local/Remote/DCS when closed Selector switch DCS is selected for control NC Relay contacts from interposing DCS Selected (NC) D-765/D765A -3LB source (NC) - DCS selected relay driven by Local/Remote/DCS when open Selector switch Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
- Page 68 Appendix D Power Cabling and Control Signal Wiring Details Notes: Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
- Page 69 Maximum sizing stated accounts for minimum rated cable insulation requirements and the next higher-rated cable (that is, 8 kV is not commercially available in many areas of the world, therefore Rockwell Automation provides an 8 kV (minimum rating) and a 15 kV rating, when applicable. Enclosure openings accommodate the thicker insulation on the higher-rated cable.
- Page 70 Maximum sizing stated accounts for minimum rated cable insulation requirements and the next higher-rated cable (that is, 8 kV is not commercially available in many areas of the world, therefore Rockwell Automation provides an 8 kV (minimum rating) and a 15 kV rating, when applicable. Enclosure openings accommodate the thicker insulation on the higher-rated cable.
- Page 71 EU EN779 Class F6 30 External Control Signal Wiring 44 Analog I/O 44 Design Considerations 36 Digital I/O 44 Documentation box Torque Requirements 59 Wiring Routing 45 Electrical Drawings 34 External Ducting Specifications 30 Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
- Page 72 Line Cable Sizes 69 Line-to-Ground Rated Power Frequency Load Cable Sizes 69 Voltage 35 Mechanical Installation 9 Line-to-Line Power Frequency Maximum Power Module Lift Cart 26 Voltage 35 Pre-Commissioning 55 Schematic (No Bypass) 63 Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
- Page 73 Align the Cabinets 12 Connection 9 Weld locations 14 Hardware 12 Wiring Specifications External Control Signal Wiring 44 Cable Insulation Rating 35 LV Control Bundles 52 External Ducting 30 Standard Input/Output Connection Points 66 Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
- Page 74 Index Notes: Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
- Page 75 PowerFlex 6000T Drives Installation Instructions Rockwell Automation Publication 6000-IN100B-EN-P - October 2020...
- Page 76 At the end of life, this equipment should be collected separately from any unsorted municipal waste. Rockwell Automation maintains current product environmental compliance information on its website at rok.auto/pec. Allen-Bradley, expanding human possibility, FactoryTalk, Guardmaster, PowerFlex, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc. EtherNet/IP is a trademark of ODVA, Inc.