Rockwell Automation Allen-Bradley PowerFlex 6000 User Manual
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Rockwell Automation Allen-Bradley PowerFlex 6000 User Manual

Medium voltage variable frequency drive
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PowerFlex 6000 Medium
Voltage Variable Frequency
Drive
Bulletin Number 6000G
User Manual
Original Instructions

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Summary of Contents for Rockwell Automation Allen-Bradley PowerFlex 6000

  • Page 1 PowerFlex 6000 Medium Voltage Variable Frequency Drive Bulletin Number 6000G User Manual 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.

  • Page 3: Table Of Contents

    Basic Configurations......... 40 Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 4 Inspect Door Position Limit Switch ......97 Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 5 Preventative Maintenance PowerFlex 6000 Maintenance Schedule ......131 Schedule Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 6 ............. . . 149 Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 7: Preface

    PowerFlex® 6000 medium voltage variable frequency drives. Rockwell Automation recognizes that some of the terms that are currently used in our industry and in this publication are not in alignment with the movement toward inclusive language in technology. We are proactively collaborating with industry peers to find alternatives to such terms and making changes to our products and content.

  • Page 8: Summary Of Changes

    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 9: Additional Resources

    Industrial Automation Wiring and Grounding Guidelines, publication 1770-4.1 Provides general guidelines for installing a Rockwell Automation industrial system. Product Certifications website, rok.auto/certifications. Provides declarations of conformity, certificates, and other certification details. You can view or download publications at rok.auto/literature.
  • Page 10 Preface Notes: Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 11: Introduction

    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

    (1) Options are available for operation up to 5000 m.a.s.l. However, these must be stated at the time of order and cannot be retrofitted in the field. (2) Options are available for ambient temperatures up to 50 °C. However, these must be stated at the time of order and cannot be retrofitted in the field. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 13: 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 Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 14 Figure 5 - 6300V / 6600V /6900V (36 Pulse - 18 Power Modules) Isolation Transformer Secondary Windings 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-UM002G-EN-P - August 2022...
  • Page 15 Analog spare 4-20 mA Emergency/Fault Trip Trip Analog spare 4-20 mA Emergency/Fault Trip Trip (Reserved) MV Close MV Close Emergency Stop status E-Stop E-Stop Emergency Stop status (Reserved) Emergency Stop Emergency Stop Three-phase Induction Motor Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 16 Chapter 1 Introduction Figure 9 - PowerFlex 6000 Principal Components All-in-One Design (A-Frame) Cooling Fan Power Modules Door Filters Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 17 Online UPS supplied as standard to support ultra long control power loss ride-through capability Available with redundant fan with automatic switchover for increased uptime Available with NEMA Type 1/IP31 or IP42 Door Filters enclosure. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 18: Standards Compliance

    IEEE Standard General Requirements for Dry-Type Distribution and Power Transformers IEEE C57.12.91-1995 IEEE Standard Test Code for Dry-Type Distribution and Power Transformers IEEE 519-1992 IEEE Practices and Requirements for Harmonic Control in Electrical Power Systems Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 19: Drive System Layout

    Isolation Transformer Cabinet Power Module Cabinet LV Control Cabinet Elevation Drawings Depending on the drive rating, the system layout may be different. Figure 10 - Drive Configurations A-Frame LV Control Power Module cabinet cabinet Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 20: Isolation Transformer Cabinet

    Power Module cabinet Isolation Transformer cabinet cabinet Isolation Transformer Cabinet Isolation Transformer Isolation Transformer Temperature Monitor Top-mounted Cooling Fans Incoming Line Power Cable Connections Outgoing Motor Cable Connections Door Position Limit Switch Voltage Sensing Board Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 21 Figure 12 - Isolation Transformer Cabinet, 140/215 A, A-Frame Limit switch HECS Incoming line power cable Surge arrestors connections (for bottom entry) Power cable connections to Power Modules Outgoing motor power cable Isolation transformer connections (for bottom entry) Cable clamp Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 22 Figure 14 - Isolation Transformer Cabinet, H-Frame (Junction cabinet not applied) Door position limit switches Voltage Sensing Board Incoming line power cable connections Outgoing motor power cable connections Power cable connections to Power Modules Isolation Transformer Cable clamp Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 23: Isolation Transformer

    U output phase. The middle third are to feed the power modules in the V output phase. The bottom third are to feed the power modules in the W output phase (Figure 16). Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 24: Isolation Transformer Temperature Monitor

    Three temperature sensors are embedded in the isolation transformer. The monitor can be set to indicate an alarm condition or a trip condition, dependent on the temperature detected. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 25: Top-Mounted Cooling Fans

    (using top or side access). See the PowerFlex 6000 Medium Voltage Variable Frequency Drive Installation Instructions, publication 6000-IN006 for additional details. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 26: Outgoing Motor Cable Connections

    Lock out and tagout the input device before performing any work on the drive or bypass units. Figure 18 - Door Position Limit Switch Location Door position limit switch Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 27: Interlocking

    3. Open the doors of the cabinet and inspect the key assembly. Place high visibility grease on the pins of the dead-bolt counterpart. The factory recommends using yellow torque sealant, however if it is unavailable almost any grease will do (See Figure 19). Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 28 When any of the cabinet doors are open, the drive turns off the IGBT output. Simultaneously, a trip signal is sent to the circuit breaker to open the circuit. Two pairs of passive dry contacts (open and close) are provided to the user. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 29: Voltage Sensing Board

    Voltage Sensing Board PC A1 PC A2 PC A3 PC B1 Input power 3-phase AC PC B2 any voltage PC B3 PC C1 PC C2 PC C3 Isolation Transformer cabinet Power Module/LV Control cabinet Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 30: Power Module Cabinet

    IGBTs using a PWM switching pattern. Several Power Modules, after being connected in series and superposed, can output three-phase AC current with adjustable frequency and voltage to control an AC motor. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 31 Current transformers are installed into the U phase and W phase. Different models of Power Modules are used for drives of different power ratings (Figure 26). Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 32 Output terminal Fuse Optic fiber socket and Line terminals Line terminals status indicator Fuse Figure 26 - Power Module, H-Frame and B-Frame Output terminal Optic fiber socket and status indicator Fuse Line terminals Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 33 B-Frame Powercell 250 A, with Bypass Powercell 305 A, with Bypass Powercell 350 A, with Bypass Module Bypass Powercell 438 A, with Bypass Powercell 560 A, with Bypass Powercell 680 A, with Bypass Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 34: Hall Effect Current Sensors (Hecs)

    Figure 27 - LV Control Cabinet, A-Frame Control power transformer Phoenix connectors for (if necessary) power wiring Drive low voltage power supplies DTB2 terminal block strip DTB1 terminal block strip Drive controller Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • 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. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 36 In combination with the PWM Boards, the CPU board sends the necessary optical PWM control signals to the Power Modules to allow the Power Modules to output the required voltage and frequency to the motor. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 37 Receive communication signals from PLC Transmit communication signals to PLC FPGA FPGA healthy indicator DSP2 DSP2 healthy indicator DSP1 DSP1 healthy indicator 5V power supply indicator 3.3V 3.3V power supply indicator Digital Signal Processor Board Indicator Lights Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 38: Plc

    The UPS provides control power in the event of transient power loss to ensure that the drive control can operate without interruption. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 39: Synchronous Transfer

    PowerFlex 6000 drive. The board lets you acquire all the necessary executable tools, documentation, and reports required to commission, troubleshoot, and maintain the drive. IMPORTANT Any references to HIM refers to the eHIM integrated touch screen display (shipped from 2022). Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 40: Basic Configurations

    HIM are stored in the VFD. Their laptop is connected to the VFD via a hardwired Ethernet cable, when required. This is ideal for unmanned sites, where a dedicated HIM is not required. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 41: Setup And Operation

    There are five buttons in the Top Menu Bar. A description of the functionality is described in Table Table 4 - Setup and Configuration Controls • Return to Main Interface screen • Check warnings • Check faults • Reset alarm status • Show alarm history Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 42: Status Indicators

    When the system is under DCS Control, the Remote Remote indicator will turn into a DCS indicator, as shown. When the system is under Remote Box Control, the Remote indicator will turn into a Remote Box indicator, as shown. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 43: Operation Bar

    Voltage of the motor stator (V) Motor Current Current of the motor stator (A) Main Interface Controls From the Main Interface screen, you can: Set Frequency (Hz) Drive Operation Controls View Version Information Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 44: Set Frequency (Hz)

    Set Frequency (Hz) 1. Press the Set Frequency: input field. 2. Press the Set Freq: input field. Numpad Enter Cancel Backspace 3. Enter desired frequency and press 4. Press to accept or to cancel. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 45: Drive Operation Controls

    ATTENTION: Drive Operation Controls will only function if using Local Control, otherwise the following dialog appears. ATTENTION: The Stop command will function regardless of which control method is active. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 46: View Version Information

    Will always appear black The number of Power Modules in the drive will appear as blue; the rest appears as grey Fields show the firmware revision, where applicable Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 47: Alarm

    Page Up/Page Scroll Alarm Shows Alarm History Bottom of List Down by Entry Reset Status will reset just the quantity and accumulated time of the alarms. This function does not reset the drive. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 48: Alarm History

    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; past alarms appear as grey. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 49: 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. Back Y-axis X-axis Trend controls Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 50 Chapter 3 Setup and Operation Back Y-axis X-axis Trend controls Back Y-axis X-axis Trend controls Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 51 Chapter 3 Setup and Operation 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-UM002G-EN-P - August 2022...

  • Page 52: View Voltage, Current, Or Frequency Trends

    The time that is shown in the X-axis captures 20 minutes. Scrolling left or right will scroll in 10 minute increments. 4. Press to pause the trend capture. 5. Press to return to the Trends Selection screen. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 53: 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-UM002G-EN-P - August 2022...
  • Page 54 IMPORTANT If a parameter is selected, the trend is displayed in percentage (%). If a K parameter is selected, the trend displays the actual value. 5. Press to return to the Customized (%) screen. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 55: Operation

    8. Press to return to the Trends Selection screen. 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 Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 56: Confirm Bypass Mode

    2. Confirm that the Bypass Configuration matches one of the three Input Supply graphics. No Bypass Cabinet Manual Bypass Cabinet Automatic Bypass Cabinet The Contactor Operation selection appears when Automatic Bypass is selected 3. To change the Bypass Mode, set parameter P484. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 57: Choose Local/Remote Operation

    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. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 58: Open/Close Drive Input And Output Contactors

    Contactors? or Open Drive Input & Output Contactors? dialog box. ATTENTION: Operations in this graphic can only operate while on local control. ATTENTION: This operation can only operate while drive is not running. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 59: Open/Close Bypass Contactors

    Close Bypass Contactors? or Open Bypass Contactors? dialog box. ATTENTION: Operations in this graphic can only operate while on local control. ATTENTION: This operation can only operate while drive is not running. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 60: 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. System Settings Change the HMI language and view the bypass status under System Settings. 1. Press 2.

  • Page 61: User Parameter Settings

    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. User parameter list User parameter value Parameter description Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 62: Change User Parameters

    4. If the login was successful, the Current User will show as User and the User Parameter Settings screen is displayed automatically. If the login failed, the Login dialog is shown again. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 63 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. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 64 P parameter number This range applies to all parameters 3. Press to confirm the new value. Press to return to the Parameter Access Level screen. User parameter access will logout when you exit User Settings. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 65: Parameters And Function Codes

    PowerFlex 6000 Medium Voltage Variable Frequency Drive Firmware, Parameters, and Troubleshooting Manual, publication 6000- TD004. ATTENTION: If you enter a value that is greater than the allowed range for the parameter, the input field will turn red. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 66: P Parameters

    Chapter 4 Parameters and Function Codes Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 67 Chapter 4 Parameters and Function Codes Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 68 Chapter 4 Parameters and Function Codes Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 69 Chapter 4 Parameters and Function Codes Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 70 Chapter 4 Parameters and Function Codes Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 71 Chapter 4 Parameters and Function Codes Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 72 Chapter 4 Parameters and Function Codes Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 73 Chapter 4 Parameters and Function Codes Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 74 Chapter 4 Parameters and Function Codes Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 75 Chapter 4 Parameters and Function Codes Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 76 Chapter 4 Parameters and Function Codes Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 77 Chapter 4 Parameters and Function Codes Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 78 Chapter 4 Parameters and Function Codes Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 79 Chapter 4 Parameters and Function Codes Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 80 Chapter 4 Parameters and Function Codes Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 81 Chapter 4 Parameters and Function Codes Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 82 Chapter 4 Parameters and Function Codes Notes: Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 83: Preventative Maintenance And Component Replacement

    ATTENTION: These tasks require persons skilled in this type of detailed work. Read and understand this manual thoroughly before commencing. Contact Rockwell Automation with any questions or for clarification. ATTENTION: Only qualified personnel with the correct PPE (Personal Protective Equipment) should service the equipment. Be sure to follow the safety procedures and local regulations to disconnect the high voltage.

  • Page 84: Introduction

    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. (1) Obstruction of the air filters is not the only cause of over temperature alarm and trip. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 85: Physical Checks (No Medium Voltage Or Control Power)

    Preventative Maintenance and Component Replacement 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. The customer may extend the maintenance interval appropriately according to the installation conditions and operating conditions of the drive.

  • Page 86: Medium Voltage Testing

    See NEMA Standards Publication No. ICS- 2, Part ICS2-302 for procedures. Use only replacement parts and devices that are recommended by Rockwell Automation to maintain the integrity of the equipment. Verify that the parts are properly matched to the model, series, and revision level of the equipment.

  • Page 87: Isolation Transformer Cabinet

    Rinse in clear clean water, let stand until completely dry and free of moisture. Use only Rockwell Automation-supplied or -approved replacement filters. Replace the filters in the reverse order of its removal. Check that there are no openings to allow foreign matter to enter the drive.
  • Page 88 Air inlet frame Cotton filter Replace Filter for H-Frame and B-Frame Drives 1. Unlatch and open the cabinet filter door more than 90°. Figure 36 - Replace the Filter, H-Frame Retaining hardware Cotton filter Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 89: Inspect Top Mounted Cooling Fans

    Users Manual. Verify that the aviation plug has a proper hand-tight connection. Verify that the ventilation passages are not blocked and the impellers can rotate freely without any obstruction. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 90: Replace Top Mounted Cooling Fans

    2. Install the new wires of the resistor in reverse order of removal. 3. After you have changed the wiring, see Replace Fan for B-Frame Fan Housing on page 93 for instructions on how to replace the fan. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 91 16 hexagon combination screws that secure the fan, and remove the fan. 9. Install the fan in the reverse order of removal. Rotate the impeller by hand to verify that there is no contact with the fan housing assembly. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 92 ATTENTION: The fan must be handled with extreme care. Failure to do so can alter the fan balance and will negatively impact performance and life span. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 93 ATTENTION: The fan must be handled with extreme care. Failure to do so can alter the fan balance and will negatively impact performance and life span. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 94: Fan Balance

    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. For A-Frame Drives 1. Open the front door of the Junction cabinet. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 95 6. Install the new VSB in the reverse order of removal. Signal wire terminals Nylon M8 x 30 bolts, nuts, and washers (6) Insulation barrier Nylon M10 x 30 bolts, nuts, and washers (6) Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 96 4. Install the new Voltage Sensing Board to the Insulation Board in reverse order of removal. 5. Reinstall the Insulation Board to the cabinet side sheet in reverse order of removal. 6. Reconnect the input and output cables according to the Electrical Drawings. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 97: Inspect Door Position Limit Switch

    Figure 40 - Replace Door Position Limit Switch, A-Frame Mounting bracket Limit Switch Aviation plug M4 x 30 bolt Figure 41 - Replace Door Position Limit Switch, H-Frame and B-Frame M4 x 35 bolt Aviation plug Washer Lock washer Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 98: Power Module Cabinet

    Failure to do so may result in injury or death. 1. Remove the mounting bolts (M6 x 20) from both sides of the Power Module. 2. Disconnect the three-phase input power cables. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 99 4. Disconnect the fiber-optic cables. ATTENTION: When removing the fiber-optic cables, be careful to prevent the cables from straining or crimping as the resulting loss in light transmission will impact performance. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 100 ATTENTION: Do not use the front-mounted positioning handles for lifting the Power Modules. They are designed to position or withdraw the Power Module when on the tray assembly. ATTENTION: The Power Module finger assemblies must be fully seated on the cabinet stab assemblies. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 101 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-UM002G-EN-P - August 2022...
  • Page 102 4. If the Power Module is at the end of a row, remove the VSB and Motor cable instead of an output copper bar. 5. Disconnect the fiber-optic cables. 6. Carefully withdraw the Power Module. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 103 Preventative Maintenance and Component Replacement 7. Install the new Power Module in reverse order of removal. 140/215 A rating Power Module Guide rail Mounting brackets 70 A rating Power Module Guide rail Secure points Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 104: Replace Power Module Fuses

    Power Module cabinet. For A-Frame and B-Frame drives they are located inside the Transformer cabinet. Verify that the current sensor wire connector is properly seated. Check for obvious signs of damage. 1. Unplug the Current Sensor Connector from the HECS. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 105 Chapter 5 Preventative Maintenance and Component Replacement Figure 48 - HECS for A-Frame Mounting insulation bracket Current Sensor connection HECS Figure 49 - HECS for H-Frame Mounting bracket Current Sensor connection HECS Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 106 Figure 51 - Exploded view of the HECS and Mounting Bracket for A-Frame Ø6 washer (4) Ø6 lock washer (4) M6 nut (4) M4 nut (4) Ø4 lock washer (4) Ø4 washer (4) M4 x 16 cross pan head combination screw (4) Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 107: Inspect Or Replace Door Position Limit Switch

    6. Install the Mounting Bracket to the cabinet using existing hardware. 7. Reroute the power cable through the HECS and reattach to the Power Module. Inspect or Replace Door Position Limit Switch Replace Door Position Limit Switch on page Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 108: Lv Control Cabinet

    Inspect AC/DC Power Supplies Verify that the input and output terminal connections are tight. Use a voltmeter to check the output voltage. A green LED indicates normal operation. Figure 54 - AC/DC Power Supplies Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 109: Replace Ac/Dc Power Supplies

    DIN rail. Figure 56 - Release the latches on the Power Supplies (PS3 Power Supply not shown for clarity) 4. Install the new power supply in reverse order of removal. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 110 Loosen screws and remove all wires 3. Remove three M3 tapping screws to remove the unit. Figure 58 - Remove AC/DC Power Supply M3 tapping screws 4. Install the new power supply in reverse order of removal. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 111: Inspect Ups

    2. Turn off the back-up control power circuit breaker (CB5) and the customer-supplied power supply circuit breaker (CB1). Figure 59 - Circuit Breaker Location in LV Control Cabinet (for A-Frame) LV control relays Circuit breakers Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 112: Replace Ups

    Failure to do so may result in severe burns, injury, or death. 1. Turn off the CB2, CB3, and CB6 circuit breakers in the LV Control cabinet (Figure 60). 2. Press and hold OFF on the front of the UPS. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 113 For H-Frame and B-Frame drives – remove and retain four screws from the mounting bracket (Figure 63). Figure 62 - Replace UPS for A-Frame Drives M6 x 16 bolt (4) Mounting bracket (2) Mounting bracket Mounting base Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 114: Inspect Plc

    • Verify that the fiber-optic cables are properly connected to the A/B/C PWM boards. Verify an appropriate bend radius (if applicable). • Check all boards for damage and properly working LEDs. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 115 Control cabinet is unenergized before operation. If applicable, remove the fiber-optic wires. ATTENTION: When removing the fiber-optic cables, be careful to prevent the cables from straining or crimping as a resulting loss in light transmission will impact performance. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 116 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 4. Install the new boards in the reverse order of removal. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 117: Inspect 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. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 118: Replace Lv Control Relays

    Verify with a hot stick or appropriate voltage measuring device that all circuits are voltage free. Failure to do so may result in severe burns, injury, or death. 1. Open the LV Control cabinet door. Figure 65 - LV Control Relay Location Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 119 3. Release the spring-loaded latches at the bottom of the control relay and lift the control relay off the DIN rail. Figure 67 - Release the spring-loaded latch on the LV Control Relay 4. Install the new control relay in reverse order of removal. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 120: Replace Lv Control Circuit Breakers

    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. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 121: Inspect Coils

    Board locking tabs should also be in place. Protect solid-state devices from contamination, and maintain appropriate cooling provisions. Do not use solvents on printed circuit boards. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 122: Inspect Locking And Interlocking Devices

    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. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 123: Inspect Power Module Input And Output Power Connections

    General Review Firmware and Hardware Verify the firmware revision on the HMI. 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 124: Tools/Materials/Documentation Requirements

    • Safety gloves that can withstand at least 17 kV • Vacuum cleaner with anti-static hose (provided by customers) • Anti-static cleaning cloth • Power Module lift cart (required for pull-out Power Modules) Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 125: Final Report

    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 126 Chapter 5 Preventative Maintenance and Component Replacement Notes: Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 127: Technical Specifications

    Diodes (rectifier), IGBTs (inverter) Medium Voltage Isolation Fiber-optic Control Method Sensorless Vector Control and Volts per Hertz Output Frequency Range 1…75 Hz Acceleration/Deceleration Time 0…3276 seconds configurable Ride Through, minimum 5 cycles Flying Start Capability Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 128 Motor Cable Distance, maximum 600 m (1968 ft) Available up to 2000 m (6561 ft) with filter Seismic Enclosure Rating IBC 2018 for worst case excluding class F, ASCE-7-16 (1) Depends on Transformer. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 129: Catalog Number Explanation

    Code Description 15 Amp 680 Amp Control Voltage Code Description Code Description 110V 220V Enclosure Type – – 230V Code Description 120V 240V Type 1/IP31 (with door gaskets) Type 1/IP42 (with door gaskets) Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 130 - 4160V: 4000V/4160V - 6000V: 6000V - 6600V: 6300V or 6600V Options - 7200V: 6900V Other Nominal Line/Motor Voltage Configurations can be supplied (contact factory). See PowerFlex 6000 Medium Voltage Drives Options List. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 131: Preventative Maintenance Schedule

    This indicates the cleaning of a part that can be reused, and refers specifically to the door-mounted air filters. Rv – Review This refers to a discussion with Rockwell Automation to determine whether any of the enhancements/changes made to the Drive Hardware and Control would be valuable to the application.
  • Page 132 (1) Based on full load/full speed operation at 8700 hours per year at 30 °C (86 °F) ambient temperature. For higher ambient temperatures the replacement should be done sooner, contact factory for details. (2) Fully discharge and recharge the UPS batteries every 6 months, to extend battery life. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 133 Hardware — — — — — — — General Operational Parameters / Variables Conditions Spare Parts Inventory Needs (1) Fully discharge and recharge the UPS batteries every 6 months, to extend battery life. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 134 Appendix C Preventative Maintenance Schedule Notes: Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 135 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-UM002G-EN-P - August 2022...
  • Page 136 Appendix D Torque Requirements Notes: Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 137: Spare Parts Storage

    Power Components Connection Guidelines on page 142 or the Knowledgebase article “Procedure of Electrolytic Capacitors Rejuvenation for Storage”, available at: rok.auto/knowledgebase. Signal Conditioners These components have a lifetime storage period of three years. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 138: Control Equipment And Boards

    (2) It is recommended to energize the item for 1…2 hours every year of storage. If the item was stored for a longer time without energizing (longer than one year) or the yearly procedure was skipped, then the reforming procedure must be performed instead. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 139: Spare Parts Connection Matrix

    1. Connect the variable AC source to the AC input terminals of the 1606 power supply through a 4 A circuit breaker. 2. Use 2.1 mm (14 AWG) wire to connect the devices. Figure 71 - 1606 Power Supply AC input terminals Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 140: Control Equipment And Boards Connection Guidelines

    DC input terminals P1 and P2 of the DB Board, according Table 3. Use 1.3 mm (16 AWG) wire to connect the devices. WARNING: Do not apply any voltage until all boards are plugged into the DB Board. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 141 WARNING: Do not apply any voltage until the DT and PWM boards are plugged into the DB Board. The CPU Board is not required to perform the engergizing procedure. You can leave the CPU Board slot empty. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 142: Power Components Connection Guidelines

    WARNING: If abnormalities occur, verify the connections as described in Step 1. Verify that the power cell fuse is in good condition and record any abnormality. Contact a Rockwell Automation field support engineer for assistance. 3. Once this procedure is complete, decrease the voltage source to 0V and open the MCB.
  • Page 143 WARNING: If abnormalities occur, verify the connections as described in Step 1. Verify that the power cell fuse is in good condition and record any abnormality. Contact a Rockwell Automation field support engineer for assistance. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 144: Cooling System Connection Guidelines

    1. Connect the variable AC source (380/480V AC) to the AC input terminals of the EC cooling fan. 2. Use 1.3 mm (16 AWG) wire to connect the devices. Figure 75 - EC Cooling Fans Power input terminals Power input terminals Delta fan Ziehl-Abegg fan Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 145: Connection Wire Sizes

    0.0720 1.83 2630 0.0641 1.63 2080 0.0571 1.45 1650 0.0508 1.29 1310 0.0453 1.15 1040 0.0403 1.02 0.0359 0.91 0.0320 0.81 0.0285 0.72 0.0254 0.65 0.0226 0.57 0.0201 0.51 0.0179 0.45 0.0159 0.40 Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 146: Guidelines For Extended Shutdown Or Storage

    Storage Environment on page 146 also apply to the power cells. Perform the reforming procedure on the power cells annually, as detailed in the Knowledgebase article “Procedure of Electrolytic Capacitors Rejuvenation for Storage”, available at: rok.auto/knowledgebase. Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...

  • Page 147: Guidelines For Inspection After Extended Shutdown Or Storage

    Firmware Upon drive startup, check for any new firmware revisions. Verify compatibility before you upgrade the drive to a new firmware revision. You can download firmware revisions from the Rockwell Automation Product Compatibility and Download Center (PCDC) at rok.auto/pcdc. Interlocks Inspect the contactor/isolator interlocks and door interlocks for physical damage and verify that they operate correctly.
  • Page 148 Appendix E Spare Parts Storage Notes: Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 149 Open/Close Drive Input 58 IEC721-1 12 Open/Close Drive Output 58 Relative Humidity 12 Control Board Vibration 12 Hardware 116 Inspect/Replace 114 Control Owner Selection Local/Remote 57 Firmware Maintenance Schedule 132 Version Information 46 Fuse Replace 104 Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 150 LV Control Circuit Breakers Hardware 120 LV Control Relay Hardware 119 Maintenance Schedule 132 Replace AC/DC Power Supplies 109 Replace HMI 117 Replace LV Control Circuit Breakers 120 Replace LV Control Relay 118 Replace UPS 112 UPS 38 Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 151 Line-toGround 11 List 65 Lockout and tagout 11 Physical Maintenance Checks Safety Door Switches Inspect Power Connections 85 Location 22 Physical Inspection 85 Service and Support 8 Pilot Lights Service Duty 129 Maintenance 121 Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 152 Typical Power Structure 13 Front Display 113 Inspect 85 LV Circuit Breaker Location 111 Maintenance Schedule 132 Overview 38 Replace 112 User Access Level 62 User Parameter Settings Change 62 Screen Layout 61 Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 153 PowerFlex 6000 Medium Voltage Variable Frequency Drive User Manual Rockwell Automation Publication 6000-UM002G-EN-P - August 2022...
  • Page 154 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, Micro850, PowerFlex, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc. EtherNet/IP is a trademark of ODVA, Inc.

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