Related Manuals for Allen-Bradley PowerFlex 6000T
Summary of Contents for Allen-Bradley PowerFlex 6000T
- Page 1 PowerFlex 6000T Drives Hardware Service Manual Catalog Number 6000T Troubleshooting Guide Original Instructions...
- Page 2 PowerFlex 6000T Drives Hardware Service Manual Troubleshooting Guide 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 Preface About This Publication ......... . . 7 Download Firmware, AOP, EDS, and Other Files . - Page 4 Table of Contents Chapter 3 Component Inspection and Test Component Inspection and Maintenance ......27 Replace/Clean Door-mounted Air Filters ......28 Procedures Recommended Cleaning Method of Filters .
- Page 5 Table of Contents Chapter 7 Inspect Connections Inspect LV Component Terminal and Plug-in Connections ..65 Inspect Medium Voltage Cable Connections ..... . . 65 Inspect Power Cable and Control Wire Terminals .
- Page 6 Table of Contents Notes: Rockwell Automation Publication 6000-TG100A-EN-P - September 2020...
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Page 7: Preface
• Spare parts lists compiled for each customer’s order • Drive-specific technical specifications For additional product detail or information relating to PowerFlex 6000T drives, see the publications that are listed in Additional Resources on page Required Supplemental Review the project-specific dimensional drawings (DDs) and electrical... -
Page 8: General Precautions
These documents contain additional information concerning related products from Rockwell Automation. Resource Description PowerFlex 6000T Drives Shipping and Handling Manual, Provides instructions for shipping and handling PowerFlex 6000T drives and related publication 6000-PC100 equipment. PowerFlex 6000T Drives Installation Instructions, Provides instructions for installing PowerFlex 6000T drives and related equipment. -
Page 9: Commissioning Support
Preface 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 startups •... - Page 10 Preface Notes: Rockwell Automation Publication 6000-TG100A-EN-P - September 2020...
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Page 11: Product Advisories
Read the following precautions before you begin to test components, perform maintenance, or repair the drive. Qualified Personnel ATTENTION: Only qualified personnel familiar with PowerFlex 6000T products and associated machinery should plan or implement the installation, startup, and subsequent maintenance of the system. Failure to comply can result in personal injury and/or equipment damage. -
Page 12: Personal Safety
Chapter 1 Before You Begin Tests, Maintenance, or Repairs Personal Safety ATTENTION: To avoid an electric shock hazard, verify that the voltage on the bus capacitors has discharged before servicing. ATTENTION: Potentially fatal voltages can result from improper usage of an oscilloscope and other test equipment. -
Page 13: Safety Considerations
Chapter 1 Before You Begin Tests, Maintenance, or Repairs Safety Considerations SHOCK HAZARD: Energized industrial control equipment can be dangerous. Severe injury or death can result from electrical shock, burn, or unintended actuation of control equipment. Hazardous voltages may exist in the drive cabinet even with the input circuit breaker in the off position. -
Page 14: Commonly Used Tools
Torque seal (yellow), part number RU6048, or equivalent • Electrical joint compound, Alcoa EJC number 2, or equivalent • Shell number 7 aviation grease, part number 40025-198-01, or equivalent Documents required: • PowerFlex 6000T Drives Installation Instructions, publication 6000-IN100 • PowerFlex 6000T Drives Programming Manual, publication 6000-PM100 •... -
Page 15: Fastener Torque Sequences
Connected Components Workbench software version 12 or later, and the latest version of the PowerFlex drives device database files for Connected Components Workbench software, are required for use with PowerFlex 6000T products. For DeviceLogix™, the profile in Connected Components Workbench software can be used to set up programs. -
Page 16: Torque Requirements
Chapter 1 Before You Begin Tests, Maintenance, or Repairs Figure 3 - Six-point Mounting Initial Sequence Do not exceed 0.7 N m (6 lb in) on initial torque of all six screws. • • Final Sequence Torque Requirements Proper tightening torque must be used for installation and wiring. Table 2 - Torque Requirements Torque Thread Size... -
Page 17: Preventative Maintenance And Component Replacement
Final Report This chapter provides information on preventative maintenance for components that can affect the life and operational characteristics of PowerFlex 6000T drives. Recommended The drive can experience reduced service life if operated outside of its design parameters. Verify that the operating environment is within specifications. -
Page 18: Maintenance Schedule
RFB/R Refurbishment/Replacement The parts can be refurbished at lower cost OR the parts can be replaced with new ones. ATTENTION: Customers can replace components for the PowerFlex 6000T drives. However repairs must only be performed by qualified Rockwell Automation personnel. - Page 19 Chapter 2 Preventative Maintenance and Component Replacement Rockwell Automation Publication 6000-TG100A-EN-P - September 2020...
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Page 20: Maintenance Of Industrial Control Equipment
Clean the Air Filters PowerFlex 6000T drives require a continuous, smooth airflow to cool the power components, and the isolation transformer to deliver stable and reliable operation of the equipment. Obstruction of the air filters is the main cause of poor cooling airflow. -
Page 21: Regular Maintenance Intervals
IEC standards, refer to IEC 61800-5-1 Sec. 6.5 for MV Drives and IEC 60470 Sec. 10, IEC 62271-1 Sec. 10.4 for MV Controllers. The maintenance work for PowerFlex 6000T drives should normally be performed on a yearly cycle. This work is carried out by Rockwell Automation medium voltage drive customers. -
Page 22: Physical Checks
Power Connection Inspection • Inspect PowerFlex 6000T 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 23: Medium Voltage Testing
Chapter 2 Preventative Maintenance and Component Replacement transformers, fuses, wiring, and so on; Causes could be corrosion, excessive temperature, or contamination. • Clean all contaminated components using a vacuum cleaner (DO NOT use a blower), and wipe clean components where appropriate. •... -
Page 24: General Tasks
Chapter 2 Preventative Maintenance and Component Replacement General Tasks Review Firmware and Hardware Verify the firmware revision in the device definition page on the integrated touch screen display (eHIM), and in the device info page or with parameters in Connected Components Workbench software. Contact Rockwell Automation to determine whether there are any enhancements or changes that are made to the Drive Hardware and Control that would be valuable to the application. -
Page 25: Final Report
Chapter 2 Preventative Maintenance and Component Replacement • Provide information about operating conditions (environment, temperature, and so on) required for stable operation of the drive. • Obtain spare parts information from the customer to determine whether they have sufficient stock. Recommend the customer to purchase additional spare parts if necessary. -
Page 26: Prepare Final Report
Chapter 2 Preventative Maintenance and Component Replacement Prepare Final Report The Rockwell Automation service engineer will provide a maintenance report to the customer based on the outcome of the maintenance work. All steps in the preventive maintenance process will be recorded in detail in the report and will identify changes that are made. -
Page 27: Component Inspection And Maintenance
This chapter provides details on how to inspect and test the major components of the drive and includes recommendations for repairs. Review the Troubleshooting chapter in the PowerFlex 6000T Drives Programming Manual, publication 6000-PM100, for information on conditions that can cause a fault or alarm and how to troubleshoot these conditions. -
Page 28: Replace/Clean Door-Mounted Air Filters
Chapter 3 Component Inspection and Test Procedures 6. Remove the cover from the control pod and inspect all visible major components, including: circuit boards, wire harnesses, fiber-optic cables, and connectors. If any components show evidence of burn marks or breakage, replace the damaged components without further testing. 7. -
Page 29: Replace Filter For A-Frame Drives
Chapter 3 Component Inspection and Test Procedures Replace Filter for A-Frame Drives 1. Unlatch the thumbscrews and remove the air filter frame. 2. Remove and clean the cotton filter, or replace with a new cotton filter. IMPORTANT When removing the filter, prevent accumulated dirt on the inlet side of the filter from being sucked into the drive. -
Page 30: Inspect Top Mounted Cooling Fans
Chapter 3 Component Inspection and Test Procedures 3. Reinstall the cleaned or new air filter using reverse order of removal. Verify that the door is fully closed and locked. Inspect Top Mounted Inspect fans that are used for forced air cooling. Replace any that have bent, chipped, or missing blades, or if the shaft does not turn freely. -
Page 31: Replace Fan For A-Frame Fan Housing
Chapter 3 Component Inspection and Test Procedures Replace Fan for A-Frame Fan Housing To replace an EC400 fan, you need to change the wiring so that the fan runs at a different speed than what it does for the B-Frame drive. 1. -
Page 32: Replace Fan For B-Frame Fan Housing
Chapter 3 Component Inspection and Test Procedures 2. Remove and retain the fourteen M6 x 16 hexagon combination screws around the wire screen frame, and remove the frame. 3. Remove and retain the eight M4 x 12 hexagon combination screws, M4 nut washer, and lock washer that secure the L-shape fan housing bracket and fan housing lid, and remove the bracket. -
Page 33: Fan Balance
Chapter 3 Component Inspection and Test Procedures 4. Disconnect the fan from the terminal block. 5. Remove and retain eight M8 x 20 hexagon combination screws that secure the fan support bracket, and remove the bracket. 6. Remove and retain five M6 x 16 and four M4 x 12 hexagon combination screws that secure the fan, and remove the fan. -
Page 34: Component Fuse Tests
Chapter 3 Component Inspection and Test Procedures Figure 6 - Replace Door Position Limit Switch, A-Frame Mounting bracket Limit Switch Aviation plug M4 x 30 bolt Figure 7 - Replace Door Position Limit Switch, B-Frame Mounting bracket M4 x 35 bolt Limit Switch Aviation plug Component Fuse Tests... -
Page 35: Control Pod Cover Removal
Chapter LV Control Cabinet Topic Page Control Pod Cover Removal Fiber Transceiver Circuit Board Replacement Main Control Circuit Board Replacement Backplane Circuit Board Replacement Power I/O Board Replacement Smart Fiber Interface Circuit Board Replacement Control Pod Fan Assembly Replacement Control Pod Replacement Inspect the Integrated Touch Screen Display Replace the Integrated Touch Screen Display Control Pod Cover Removal... - Page 36 Chapter 4 LV Control Cabinet 5. Remove the top two M4 x 8 mm slotted-torx screws that secure the cover to the assembly and remove the cover. M4 x 8 mm 4, 5 T20 or F - 6.4 mm (0.25 in.) 2.6 N m (23 lb •...
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Page 37: Fiber Transceiver Circuit Board Replacement
Chapter 4 LV Control Cabinet Fiber Transceiver Circuit Replace a fiber transceiver circuit board with kit part number PN-579788. Board Replacement Follow these steps to replace the fiber transceiver circuit board. 1. Review the Product Advisories on page 11. 2. Remove power from the system. See Remove Power from the System on page 13. -
Page 38: Main Control Circuit Board Replacement
Chapter 4 LV Control Cabinet 6. Loosen the two captive thumbscrews that secure the board and fiber- optic cables to the chassis and remove the board and cables. – T15 or F - 5 mm (0.19 in.) 0.45 N m (4 lb •... - Page 39 Chapter 4 LV Control Cabinet 5. Remove the DPI™ cable from the port on the main control board if present. 6. Disconnect any Ethernet cables from the ports on the bottom of the main control board. 7. Disconnect the plug-in terminal block (TB 1) on the bottom of the main control board.
- Page 40 Chapter 4 LV Control Cabinet 10. Loosen the three captive thumbscrews that secure the main control board to the pod chassis and remove the board. HIM bezel not shown for clarity only. – T15 or F - 5 mm (0.19 in.) 0.45 N m (4 lb •...
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Page 41: Backplane Circuit Board Replacement
Chapter 4 LV Control Cabinet Backplane Circuit Board Replace a control pod backplane circuit board with kit catalog number SK-RM-PODBP1. Replacement Follow these steps to replace the backplane circuit board. 1. Review the Product Advisories on page 11. 2. Remove power from the system. See Remove Power from the System on page 13. -
Page 42: Power I/O Board Replacement
Chapter 4 LV Control Cabinet Power I/O Board Replace a Power I/O board with kit part number PN-579786. Replacement Follow these steps to replace the power I/O board. 1. Review the Product Advisories on page 11. 2. Remove power from the system. See Remove Power from the System on page 13. -
Page 43: Smart Fiber Interface Circuit Board Replacement
Chapter 4 LV Control Cabinet 6. Loosen the three captive thumbscrews and remove the two loose screws that secure the power I/O board to the smart fiber interface circuit board. M4 x 8 mm T20 or F - 5 mm (0.19 in.) 2.6 N m (23 lb •... - Page 44 Chapter 4 LV Control Cabinet 6. Disconnect the two fan power supply connectors from connectors J18 and J25 on the Smart Fiber interface circuit board. IMPORTANT Minimum inside bend radius for fiber-optic cable is 50 mm (2 in.). Any bends with a shorter inside radius can permanently damage the fiber-optic cable.
- Page 45 Chapter 4 LV Control Cabinet 14. Rotate the left side of Smart Fiber interface circuit board away from the control pod so that the board clears the mounting tab on right sidewall of the control pod. Remove the board from the control pod. M4 x 8 mm T20 or F - 6.4 mm (0.25 in.) 2.6 N...
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Page 46: Control Pod Fan Assembly Replacement
Chapter 4 LV Control Cabinet Control Pod Fan Assembly Replace the control pod fan assembly with kit catalog number SK-RM-PODFAN1-F8. Replacement Follow these steps to replace the control pod fan assembly. 1. Review the Product Advisories on page 11. 2. Remove power from the system. See Remove Power from the System on page 13. -
Page 47: Control Pod Replacement
Chapter 4 LV Control Cabinet – T20 or F - 6.4 mm (0.25 in.) 2.6 N m (23 lb • • 8. To install the control pod fan assembly, perform the operation in the reverse order of removal. Control Pod Replacement Replace the control pod assembly with kit part number PN-579789. - Page 48 Chapter 4 LV Control Cabinet 8. Loosen the six M4 x 8 mm torx screws that secure the pod chassis to the back panel. M4 x 8 mm T20 or F - 5 mm (0.19 in.) 2.6 N m (23 lb •...
- Page 49 Chapter 4 LV Control Cabinet 9. Slide the pod up, so that the keyholes on the pod clear the mounting screws, and remove the control pod. M4 x 8 mm T20 or F - 5 mm (0.19 in.) 2.6 N m (23 lb •...
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Page 50: Inspect The Integrated Touch Screen Display
Chapter 4 LV Control Cabinet Inspect the Integrated 1. Verify the input and output cables and communication cables are hand- tight. Touch Screen Display 2. Power up the integrated touch screen display. 3. Verify that the integrated touch screen display is operating normally. Replace the Integrated Touch Screen Display ATTENTION: Always perform Power Lockout procedure before servicing... - Page 51 Chapter 4 LV Control Cabinet This gasket forms a compression type seal. Do not use sealing compounds. Sealing gasket 2. Place the integrated touch screen display in the panel opening. 3. Install all mounting levers in the mounting slots on the integrated touch screen display.
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Page 52: Remove The Power Terminal Block
Chapter 4 LV Control Cabinet 6. Reconnect all cables in reverse order of removal. Remove the Power Terminal Block The integrated touch screen display ships with a power terminal block installed. You can remove the power terminal block for ease of installation, wiring, and maintenance. -
Page 53: Inspect Isolation Transformer
Chapter Isolation Transformer Cabinet Topic Page Inspect Isolation Transformer Inspect/Replace Voltage Sensing Board Inspect/Replace HECS ATTENTION: Wait at least 15 minutes for the stored energy to discharge fully before performing maintenance on the Isolation Transformer cabinet. Failure to do so may result in severe burns, injury, or death. Inspect Isolation 1. - Page 54 Chapter 5 Isolation Transformer Cabinet 2. Remove and retain the nine M6 nuts, D6 washers, and D6 lock washers that secure the VSB PC cover, and remove the cover. Junction cabinet front door VSB signal wires M6 nuts, washers, and lock washers (9) VSB PC cover VSB cables...
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Page 55: Inspect/Replace Hecs
Chapter 5 Isolation Transformer Cabinet 5. Install the new VSB in the reverse order of removal. Junction cabinet front door M8 x 30 bolts and washers (4) VSB PC cover Inspect/Replace HECS There are three current sensors that are located inside the Isolation Transformer cabinet. - Page 56 Chapter 5 Isolation Transformer Cabinet Figure 9 - HECS for B-Frame Mounting bracket HECS Current Sensor connection 2. Disconnect one end of the power cable that goes through the HECS from the Power Cell. 3. Remove the Mounting Bracket with the HECS still attached. 4.
- Page 57 Chapter 5 Isolation Transformer Cabinet Figure 11 - Exploded view of the HECS and Mounting Bracket for B-Frame M5 x 16 cross pan head screw Ø5 washer M5 nut M6 nut Ø6 washer 5. Install the HECS on the Mounting Bracket using the existing hardware. ATTENTION: Verify that the current sampling direction is correct.
- Page 58 Chapter 5 Isolation Transformer Cabinet Notes: Rockwell Automation Publication 6000-TG100A-EN-P - September 2020...
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Page 59: Inspect Power Cells
Chapter Power Cell Cabinet Topic Page Inspect Power Cells Replace Power Cell Replace Power Cell Fuses Inspect Power Cells 1. Inspect the power connections for loose connections or any evidence of discoloration of connections from heating. 2. Remove dust or debris from all ventilation openings on the Power Cell. 3. - Page 60 Chapter 6 Power Cell Cabinet Figure 12 - Power Cell Component Location 30/50 A rating power cells with three fuses shown Fiber-optic cables connection point Output copper bar connection location Fuse M6 x 16 hexagon combination screws (2) Three-phase input cables from isolation transformer 3.
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Page 61: Install The Power Cell
Chapter 6 Power Cell Cabinet Install the Power Cell ATTENTION: Do not use the front-mounted positioning handles for lifting the Power Cells. They are designed to position or withdraw the Power Cell when on the tray assembly. ATTENTION: The Power Cell finger assemblies must be fully seated on the cabinet stab assemblies. -
Page 62: Using The Lift Cart
Chapter 6 Power Cell Cabinet 3. After installing the Power Cell in place, use the mounting brackets and the M6 × 16 large flat pad galvanized nickel screws to fix the four corners, as shown in the following illustration. 438/560/680 A rating power cell with two fuses shown Mounting points Mounting points... -
Page 63: Replace Power Cell Fuses
Chapter 6 Power Cell Cabinet Figure 14 - Lift Cart Procedure 1. Check the lift tray before use to verify that the tray can be raised and lowered smoothly. 2. Rotate the Pressure Release Knob counterclockwise to verify that the tray is in the lowest position. - Page 64 Chapter 6 Power Cell Cabinet Figure 15 - Replace Power Cell Fuse Example Washer Lock washer Fuse Rockwell Automation Publication 6000-TG100A-EN-P - September 2020...
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Page 65: Inspect Connections
Chapter Inspect Connections Topic Page 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 Cell Input and Output Power Connections Inspect LV Component All LV control connections must be secure. Check for dirt, debris, or foreign material, and clean with anti-static cloth if necessary. -
Page 66: Inspect Power Cell Input And Output Power Connections
Chapter 7 Inspect Connections Inspect Power Cell Input Verify that all Power Cell input line cables and output bus connections are properly torqued. Verify that the output cables, VSB Cables, and star and Output Power connection cables are properly torqued. Apply torque sealer if necessary. Check Connections for corrosion, excessive temperature, or contamination. - Page 67 Index filter inspect 27 AC/DC Power Supplies Firmware Inspect 22 Maintenance Schedule 19 Maintenance Schedule 19 Fuse Air Filters Replace 63 Clean 20 Replace 28 apply power 13 General Precautions 8 backplane circuit board install 41 HECS remove 41 Hardware 55 Inspect 55 Maintenance Schedule 19 Mounting Bracket 56...
- Page 68 Index PowerFlex 6000 Torque Requirements 16 main control circuit board (frame 8...15) precautions 11 install 40 remove 38 Maintenance Estimated Time Required 25 remove power 13 Final Report 25 Inspect Components 65 Inspect Connections 65 Inspect Power Connection 22 Inspect Terminals 65 Safety Considerations Inspect/Review Spare Parts 24 Lockout and tagout 13...
- Page 69 PowerFlex 6000T Drives Hardware Service Manual Troubleshooting Guide Rockwell Automation Publication 6000-TG100A-EN-P - September 2020...
- Page 70 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, Connected Components Workbench, DeviceLogix, DPI, expanding human possibility, FactoryTalk, PowerFlex, Rockwell Automation, Studio 5000 Logix Designer, and TechConnect are trademarks of Rockwell Automation, Inc.