Related Manuals for Allen-Bradley PowerFlex 6000T
Summary of Contents for Allen-Bradley PowerFlex 6000T
- Page 1 PowerFlex 6000T Drives Catalog Number 6000T Installation Instructions Original Instructions...
- Page 2 PowerFlex 6000T Drives Installation Instructions 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.
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Page 3: Table Of Contents
Table of Contents About This Publication ......... . . 5 Download Firmware, AOP, EDS, and Other Files . - Page 4 Table of Contents Appendix A Pre-Commissioning Pre-Commissioning Responsibilities......55 Pre-Commissioning Checklist........55 Appendix B Torque Requirements Torque Requirements .
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Page 5: About This Publication
NOT required for this part of the installation process, but is mandatory for subsequent processes. What Is Not in this Manual This manual provides information specific for installing a PowerFlex 6000T drive. It does not include project-specific, or drive-specific topics such as: •... -
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. -
Page 7: Commissioning Support
Preface Commissioning Support After installation, Rockwell Automation is responsible for commissioning activities for the PowerFlex 6000T 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 startups •... -
Page 8: Environmental Conditions
Preface Environmental Conditions • Elevation above sea level must be less than 1000 m (3250 ft) • Ambient air temperature must be between 0…40 °C (32…104 °F) • Relative humidity must be less than 95%, noncondensing. • Operation Vibration limited to 3M3(a) per IEC60721-3-3. •... -
Page 9: Drive Mechanical Installation
Connect DV/DT Filter Cabinet for A-Frame Drives The standard A-Frame for PowerFlex 6000T drives comes fully assembled and does not require any shipping splits. However, if a DV/DT filter is included with the drive then there is one shipping split, and the drive and filter needs to be connected as follows: 1. - Page 10 Chapter 1 Drive Mechanical Installation Figure 1 - Align the Cabinets, A-Frame Isolation Transformer Cabinet 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.
- Page 11 L-shaped bracket (x2) Connect Cabinets for B-Frame Drives The B-Frame for PowerFlex 6000T drives are shipped in two sections, the Isolation Transformer Cabinet and Power Module/LV Control Cabinet. These two cabinets must be connected after located in its final position. The cabinets are connected together in 8 or 10 places (depending on the drive rating), half along the front edge of the cabinet and half along the rear edge of the cabinet.
- Page 12 Chapter 1 Drive Mechanical Installation 2. Align the cabinet side sheets together at the holes for the hardware (see Figure Figure 3 - Align the Cabinets, B-Frame (6 kV shown) Power Module/LV Control Cabinet Isolation Transformer Cabinet Table 1 - Sidesheet Openings ❶...
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Page 13: Affix Cabinets To Floor
Chapter 1 Drive Mechanical Installation Figure 4 - Secure the Cabinets, B-Frame Secure with M6 hardware (8 places) 2-socket screw M6x16 Combination pillar Affix Cabinets to Floor Typical floor drawings show minimum clearance distance, conduit openings, and mounting holes for anchor bolts, as shown in Figure 5. - Page 14 Each weld location should be 100 mm (3.9 in.) for every 1000 mm (39.4 in.). See Mounting Requirements in the PowerFlex 6000T Drives Shipping and Handling Manual, publication 6000-PC100) for further information on the steel base and desired trench and mounting customer-specifications.
- 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-IN100A-EN-P - August 2020...
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Page 16: Install Seismic Rated Enclosures
Chapter 1 Drive Mechanical Installation Install Seismic Rated This section describes how to install the drive for seismic conditions. Enclosures Figure 8 - Guidance for Seismic Installation 1/2” Anchor bolt 1/2” Anchor bolt Effective embedded depth 5” Condition 1 Condition 2 Anchors braced at front Anchors braced at front and rear side... - Page 17 Chapter 1 Drive Mechanical Installation 6. Remove the right side plate, put the secondary cables close to Tx winding, and disassemble three horizontal baffles. Step 4 Step 5 Step 6 7. Remove the seismic cover at the front and back side of the JC, and the right side of the drive.
- Page 18 Chapter 1 Drive Mechanical Installation For condition 1, 140 A seismic installation, follow these instructions: 1. Open MV front door and back door. 2. Remove the JC front barrier. 3. Remove the back horizontal baffles, cable bracket, and all seismic covers. Step 1 Step 2 Step 3...
- Page 19 Chapter 1 Drive Mechanical Installation For condition 1, 215 A seismic installation, follow these instructions: 1. Open MV front door and back door. 2. Remove the JC front barrier. 3. Remove the back horizontal baffles and all seismic covers. Step 1 Step 2 Step 3 4.
- Page 20 Chapter 1 Drive Mechanical Installation For condition 2 seismic installation, if there is no rear access available, the top of the drive can be mounted to the wall rather than mounted to the floor at the back of the cabinet. If there is a fan redundancy condition for frame 1 and frame 2, then wall bracket B is not needed.
- Page 21 Chapter 1 Drive Mechanical Installation 3. Drill an anchor hole. Grounding busbar Anchor cover Left cabinet Step 1 Step 2 Step 3 Grounding busbar Anchor cover Middle cabinet Step 1 Step 2 Step 3 For condition 1, installation of transformer cabinets, follow these instructions: 1.
- Page 22 Chapter 1 Drive Mechanical Installation For condition 1, installation of standard cabinets and filter 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. 3.
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Page 23: Install Main Cooling Fans
IMPORTANT See Mounting Clearance Distance in the PowerFlex 6000T Drives Shipping and Handling Manual, publication 6000-PC100) to verify that the fans have the appropriate clearance distance on top of the cabinet. - Page 24 Chapter 1 Drive Mechanical Installation Figure 10 - Main Cooling Fan Housing, B-Frame Main Cooling Fan housing Socket Aviation plug Rear View Install the Cooling Fan and Noise Reduction Barrier for A-Frame Drives To install the cooling fan for A-Frame drives, follow these instructions. 1.
- Page 25 Chapter 1 Drive Mechanical Installation If your application uses noise reduction barriers for the fans, follow these instructions. 1. Remove the four M6 screws on the left and right sides of the front fan housing. 2. Place the noise reduction barrier in front of the fan housing. 3.
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Page 26: Install Power Modules (If Applicable)
Chapter 1 Drive Mechanical Installation Figure 13 - Install a Mixing Hood with Redundant Fan M16x16 hexagon combination screw (16) Eyebolt (4) M16x16 hexagon combination screw (12) Install Power Modules Power Modules are available in a wide variety of amperage ratings relating to the required motor current. - Page 27 Chapter 1 Drive Mechanical Installation Figure 14 - 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 28 Chapter 1 Drive Mechanical Installation 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 Install Power Modules for A-Frame Drives...
- Page 29 Chapter 1 Drive Mechanical Installation a. For 140/215 A rating – use the mounting brackets and M6x16 large flat pad galvanized nickel screws to secure the two bottom corners. 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.
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Page 30: External Ducting
• External ducting including an external filtering system must not add more than 50 Pa (0.2 in. of water) pressure drop to the PowerFlex 6000T drive airflow system. Ensure a minimum top clearance of 1500 mm (39.4 in.) above the drive top plate. - 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-IN100A-EN-P - August 2020...
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Page 32: Air Conditioning Sizing
Chapter 1 Drive Mechanical Installation Air Conditioning Sizing If the drive is located in an enclosed space, install air conditioners for each drive. A general formula to calculate air conditioner power required: DriveRating kW 1 DriveEfficiency –... -
Page 33: Drive Electrical Installation
Chapter Drive Electrical Installation The installation of all external power cables and control signal wiring is covered in this chapter. General electrical safety and installation guideline topics are also included. The basic activities include connecting the system ground cable, line and motor cables, control power, and all control signal wiring from the sources to the drive. -
Page 34: Electrical Drawings
Terminal block designations for all connections to external customer control signal wiring and control power supply cables. The practice that is used within the PowerFlex 6000T electrical drawing is based on the IEC or NEMA standard depending on the requirements. The symbols used to identify components on the drawings are international. -
Page 35: Power Cable Insulation Requirements
Chapter 2 Drive Electrical Installation • do not damage the grounding circuit • will not interfere with or damage the protection or metering systems, or cause undue disturbance on power lines. Power Cable Insulation Incoming line power cable ratings are shown on the Electrical Drawings and reflect what would typically be supplied, based on line voltage rating. -
Page 36: Motor Cable Sizing
Use shielded cables for all analog and digital control cables. Design Considerations Steel conduit or a cable tray can be used for all PowerFlex 6000T drive power or control wiring; however, use only steel conduit for all signal wiring. ATTENTION: Steel conduit is required for all control and signal circuits when the drive is installed in European Union countries. - Page 37 General Wire Categories on page 61 identifies general wire categories for installing the PowerFlex 6000T drive. Each category has an associated wire group number that is used to identify the required wire. Application and signal examples, along with the recommended type of cable for each group, are provided.
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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-IN100A-EN-P - August 2020... -
Page 39: Insulation Resistance (Ir) Test Of Power Cables
(see Figure 19). See the PowerFlex 6000T Drives Hardware Service Manual, publication 6000-TG100. 1. Connect the three-phase medium voltage inputs L1, L2, and L3 for top or bottom entry to the user-provided input three-phase AC power. - 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-IN100A-EN-P - August 2020...
- Page 41 Chapter 2 Drive Electrical Installation Figure 18 - Isolation Transformer Cabinet, A-Frame (DV/DT cabinet not applied) Top entry Top entry Incoming line power cable connections Outgoing motor power cable connections Bottom entry Incoming line power cable connections Outgoing motor power cable connections Cable clamp Bottom entry...
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Page 42: Connect Control Power Wiring
IMPORTANT If an optional cabinet is supplied, the incoming line and outgoing motor cable connections are in the Bypass cabinet. See the PowerFlex 6000T Drives Hardware Service Manual, publication 6000-TG100. 1. Connect the three-phase medium voltage inputs L1, L2, and L3 to the user-provided input three-phase AC power. - Page 43 Chapter 2 Drive Electrical Installation Figure 21 - Control Power Wiring Opening, A-Frame Cable entrance in top of LV Control Cabinet Wire duct for bundling cable Bracket for bundling cable Cable entrance in bottom of LV Control Cabinet Figure 22 - Control Power Wiring Opening, B-Frame Cable entrance in top or bottom front of LV Control Cabinet...
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Page 44: Connect External Control Signal Wiring
Chapter 2 Drive Electrical Installation Figure 23 - Terminal Block Strip locations VFD1 Terminal Block strip Connect External Control This section summarizes the control signal wiring from the remote DCS/PLC or discrete control to the drive. General connections are detailed in Power Signal Wiring Cabling and Control Signal Wiring Details on page... -
Page 45: Connect Electrical Safety Interlock Circuit To Input Circuit Breaker
MV Door Safety Interlock If the MV cabinet door is opened, the Allen-Bradley Guardmaster® Limit Switch (440P-CRPS11D4B) on the cabinet door will actuate. The drive will send a trip signal to the input circuit breaker to disconnect the medium voltage power supply to the drive. - Page 46 Chapter 2 Drive Electrical Installation Figure 24 - Interlock for Cabinet Doors Door Position Limit Switch When the doors of the Power Module/LV Control Cabinet or Isolation Transformer Cabinet are not closed, when the drive is being maintained or when the control power switch is not closed, the drive will not send a signal allowing the input circuit breaker to close;...
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Page 47: Drive Electrical Interconnection
Chapter Drive Electrical Interconnection The drive is shipped in two sections, the Isolation Transformer cabinet and the Power Module/LV Control cabinet. An optional cabinet may also be supplied. Drive Mechanical Installation on page 9 describes mechanically joining these cabinets together. This chapter describes the activities that are required to electrically connect these drive cabinets’... - Page 48 Chapter 3 Drive Electrical Interconnection Figure 25 - Power Cabling Overview (3.3 kV shown), A-Frame Motor Isolation Transformer Voltage Sensing Board PC A0 PC A1 PC A2 PC B0 Input power 3-phase AC PC B1 any voltage PC B2 PC C0 PC C1 PC C2 Isolation Transformer Cabinet...
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Page 49: Connect Isolation Transformer Secondary Power Cables
Chapter 3 Drive Electrical Interconnection Connect Isolation The isolation transformer’s three-phase primary coils are oriented A, B, and C from left to right, as viewed from the front. The secondary windings are also Transformer Secondary divided into three principal sections from top to bottom. The upper third are to Power Cables feed the power modules in the U output phase. -
Page 50: Connect Motor And Voltage Sensing Board Cables
Chapter 3 Drive Electrical Interconnection phase, the middle third feeds the power modules in the V phase, and the bottom third feeds the power modules in the W phase. Each three-phase secondary winding set of the isolation transformer has three individual single-phase power cables connecting its output to the three-phase power input of its corresponding power module. - Page 51 Chapter 3 Drive Electrical Interconnection A typical connection with connection points on the left side of the power module cabinet are shown in the following diagrams (Figure Figure 30). Figure 29 - 4.16 kV Power Module Configuration – A-Frame U Phase M6x16 bolt V Phase Motor cable...
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Page 52: Connect Lv Control And Fan Wiring Bundles
Chapter 3 Drive Electrical Interconnection Figure 30 - 6.6/6.9 kV Power Module Configuration – B-Frame Hex bolt VSB cable Motor cable Hex nut Lock washer U Phase Flat washer V Phase W Phase Front View Connect LV Control and Fan There are control wiring bundles that must be reconnected after the drive cabinets are connected together. -
Page 53: Complete The Installation
Chapter 3 Drive Electrical Interconnection Figure 31 - Interconnection Ground M8 Hex Nut Lock Washer Grounding Bus Connector Flat Washer Grounding M8x30 Hex Bolt Complete the Installation 1. Inspect the interior of all cabinets carefully for hardware or tools that may have been misplaced. - Page 54 Chapter 3 Drive Electrical Interconnection Notes: Rockwell Automation Publication 6000-IN100A-EN-P - August 2020...
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Page 55: Pre-Commissioning Responsibilities
Appendix Pre-Commissioning Pre-Commissioning Rockwell Automation manages the startup service for each installed drive at the customer’s site, but there are a number of tasks the customer or its Responsibilities representatives must complete before scheduling Rockwell Automation personnel for drive commissioning. Review this information before commissioning the drive as a reference for drive line-up commissioning. - Page 56 Appendix A Pre-Commissioning Print the following information: Name: Date: Company: Phone: Pages: Fax: Drive Serial Number: Rockwell Automation Service Engineer Requested (YES/ NO): Scheduled Commissioning Date: Table 6 - Receiving and Unpacking Initials Date Check The drives have been checked for shipping damage upon receiving. After unpacking, the items received are verified against the bill of materials.
- Page 57 Appendix A Pre-Commissioning Table 10 - Power Wiring Initials Date Check The power cable connections to the drive, motor, and isolation transformer adhere to national and local electrical codes. The cable terminations, if stress cones are used, adhere to the appropriate standards.
- Page 58 Appendix A Pre-Commissioning Notes: Rockwell Automation Publication 6000-IN100A-EN-P - August 2020...
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Page 59: Torque Requirements
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-IN100A-EN-P - August 2020... - Page 60 Appendix B Torque Requirements Notes: Rockwell Automation Publication 6000-IN100A-EN-P - August 2020...
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Page 61: General Wire Categories
Appendix General Wire Categories General Wire Categories Conductors Category Voltage Class Signal Examples Recommended Cable Conductors Group Notes Per IEC / NEC, Local Should only be run with 120 or 240 digital Customers Control Power <240V AC 120 or 220V, 1Ø codes and application Tray or Conduit control... - Page 62 Appendix C General Wire Categories Notes: Rockwell Automation Publication 6000-IN100A-EN-P - August 2020...
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Page 63: Schematic Diagrams
Appendix Power Cabling and Control Signal Wiring Details 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-IN100A-EN-P - August 2020... - Page 64 Appendix D Power Cabling and Control Signal Wiring Details 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.
- Page 65 Appendix D Power Cabling and Control Signal Wiring Details 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.
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Page 66: Standard Input/Output Connection Points
Appendix D Power Cabling and Control Signal Wiring Details Standard Input/Output Connection Points Table 14 - Standard I/O Connections Points Signal Name Wire Numbers Signal Usage Signal Logic MV Close Permissive (NO) 2535, 2538 Allows MV device to close when closed PIOB - DO1 (NO) + Estop (NO) + MV Doors Closed (NO) PIOB - DO1 (NC) parallel with Estop (NC) parallel with MV Doors MV Close Permissive (NC) - Page 67 Appendix D Power Cabling and Control Signal Wiring Details Table 15 - I/O Connections related to Remote Distributed Control System (Continued) Standard Option Signal Name Wire Numbers Signal Usage Signal Logic Drive Code 2436/2437 Hardwired in series with Emergency Emergency Stop Emergency Stop Interlock 2439/2440 Stop PB on Door...
- Page 68 Appendix D Power Cabling and Control Signal Wiring Details Notes: Rockwell Automation Publication 6000-IN100A-EN-P - August 2020...
- Page 69 Appendix Line and Load Cable Sizes Cable Sizes The data in the following tables are informative only; do not base final design criteria solely on this data. Follow national and local installation codes, industry best practices, and cable manufacturer recommendations. As cabling methods can vary widely, maximum cables sizes do not account for the size of the conduit hub.
- Page 70 Appendix E Line and Load Cable Sizes (1) Cable sizes are based on overall dimensions of compact-stranded three-conductor shielded cable (common for industrial cable tray installations). Maximum sizing stated accounts for minimum rated cable insulation requirements and the next higher-rated cable (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.
- Page 71 Index Air Conditioning Calculation 32 Sizing 32 Ambient Air Temperature 8 Anchor bolts 13 ASHRAE Standard 52.2 MERV 11 30 Aviation Plug 23 Cables Control Power Wiring Location 42 Electrical Safety Interlock Wire routing 46 Fan Wiring Bundles 52 General Wire Categories 61 Ground Bus 52 Incoming Line Cables 39 Insulation Resistance (IR) Test of Power Cables 39...
- Page 72 Index Drive Electrical Installation 33 Cable Connections 50 Cable Insulation Rating 35 Cable Routing 50 Control Power Wiring 42 Control Power Wiring Installation 42 Control Signal Wiring Design 36 Control Signal Wiring Shield Grounding 37 Electrical Drawings 34 External Control Signal Wiring 44 Grounding System Requirements 34 Incoming Line Cables 39 Isolation Transformer Secondary Power Cables 49...
- Page 73 Index Ground Bus LV Cabinet 37 System Ground Cable Installation 38 Grounding System Requirements 34 Hardware Fan Housing 23 Ground Bus 52 Power Module Power Cables 50 Secondary Winding Connections 50 Shipping Splits 12 System Ground Cable 38 Torque Requirements 59 IEC721-1 8 Incoming Line Power Cable Connections Location 41...
- Page 74 Lift Cart 27 Lift cart 26 Motor Cable connection 51 Voltage Sensing Board connection 51 Power Terminals 39 PowerFlex 6000T Electrical Installation 33 External Ducting Specifications 30 Isolation Transformer Cabinet Layout 41 Line Cable Sizes 69 Load Cable Sizes 69...
- Page 75 Index Safety and Codes 33 ASHRAE Standard 52.2 MERV 11 30 EU EN779 Class F6 30 IEC721-1 30 Lockout and tagout 33 Shielded Cables 35 Shipping Splits 9 Align the Cabinets 12 Connection 9 Hardware 12 Specifications Cable Insulation Rating 35 External Ducting 30 Standard Input/Output Connection Points 66 System Ground Cable...
- Page 76 Index Rockwell Automation Publication 6000-IN100A-EN-P - August 2020...
- Page 77 Publication Title User Manual Rockwell Automation Publication 6000-IN100A-EN-P - August 2020...
- Page 78 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.