Rockwell Automation 6012DB User Manual
User Manual
PowerFlex® 6000 Medium Voltage Variable Frequency Drive
Publication 6000-UM001B-EN-P
Important User Information
IMPORTANT
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.
Activities including installation, adjustments, putting into service, use, assembly, disassembly, and maintenance are required
to be carried out by suitably trained personnel in accordance with applicable code of practice.
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.
The examples and diagrams in this manual are included solely for illustrative purposes. Because of the many variables and
requirements associated with any particular installation, Rockwell Automation, Inc. cannot assume responsibility or
liability for actual use based on the examples and diagrams.
No patent liability is assumed by Rockwell Automation, Inc. with respect to use of information, circuits, equipment, or
software described in this manual.
Reproduction of the contents of this manual, in whole or in part, without written permission of Rockwell Automation,
Inc., is prohibited.
Throughout this manual, when necessary, we use notes to make you aware of safety considerations.
WARNING: Identifies information about practices or circumstances that can cause an explosion in a hazardous environment,
which may lead to personal injury or death, property damage, or economic loss.
ATTENTION: Identifies information about practices or circumstances that can lead to personal injury or death, property
damage, or economic loss. Attentions help you identify a hazard, avoid a hazard, and recognize the consequence.
Identifies information that is critical for successful application and understanding of the product.
Labels may also be on or inside the equipment to provide specific precautions.
SHOCK HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that dangerous
voltage may be present.
BURN HAZARD: Labels may be on or inside the equipment, for example, a drive or motor, to alert people that surfaces may
reach dangerous temperatures.
ARC FLASH HAZARD: Labels may be on or inside the equipment, for example, a motor control center, to alert people to
potential Arc Flash. Arc Flash will cause severe injury or death. Wear proper Personal Protective Equipment (PPE). Follow ALL
Regulatory requirements for safe work practices and for Personal Protective Equipment (PPE).
Allen-Bradley, Rockwell Software, Rockwell Automation, and TechConnect are trademarks of Rockwell Automation, Inc.
Trademarks not belonging to Rockwell Automation are property of their respective companies.
Table of Contents
Preface
Introduction
Drive System Layout
Introduction. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Who Should Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
What Is Not in This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
Additional Resources . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Service and Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Commissioning Support . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
Chapter 1
Safety Considerations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
Environmental Conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
How it Works . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
Cascaded “H” Bridge (CHB) Topology . . . . . . . . . . . . . . . . . . . . . . . . 10
Simplified Electrical Diagrams . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
Standards Compliance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
Chapter 2
Elevation Drawings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
Isolation Transformer Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
Isolation Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
Isolation Transformer Temperature Monitor . . . . . . . . . . . . . . . . . . . 21
Isolation Transformer Auxiliary Cooling Fans . . . . . . . . . . . . . . . . . . 22
Top-mounted Main Cooling Fan(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Incoming Line Power Cable Connections . . . . . . . . . . . . . . . . . . . . . . 22
Outgoing Motor Cable Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Door Position Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Voltage Sensing Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Power Module Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
Power Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Hall Effect Current Sensors (HECs) . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Top-mounted Main Cooling Fan(s) . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
LV Control Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
Control Unit (all modules). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
PLC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
UPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Setup and Operation
Chapter 3
Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Main Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
Drive Setup and Configuration Controls . . . . . . . . . . . . . . . . . . . . . . . 34
Status Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
Operation Bar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Setup and Monitor Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 3
Table of Contents
Main Interface Controls . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
Set Frequency (Hz) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
Drive Operation Controls. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
View Version Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
Alarm . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
Alarm History. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
Trends . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
View Voltage, Current or Frequency Trends . . . . . . . . . . . . . . . . . . . . 42
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Confirm Bypass Mode . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
Choose Local/Remote Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
Open/Close Drive Input and Output Contactors . . . . . . . . . . . . . . . 46
Open/Close Bypass Contactors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
System Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
User Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Change User Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
Setup Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
View/Change P or T Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
Restore “P” or “T” Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
Parameters and Function Codes
Preventative Maintenance and
Component Replacement
Chapter 4
P Parameters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
T Parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
Alarm List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 64
Chapter 5
Safety. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77
Daily Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Regular Maintenance Intervals. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
Physical Checks (No Medium Voltage or Control Power) . . . . . . . . . . . 79
Power Connection Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Physical Inspection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 79
Medium Voltage Testing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Maintenance after a Fault Condition . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Final Report . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 80
Isolation Transformer Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
Replace/Clean Door Mounted Air Filters. . . . . . . . . . . . . . . . . . . . . . . 81
Inspect Top Mounted Main Cooling Fans . . . . . . . . . . . . . . . . . . . . . . 82
Replace Top Mounted Main Cooling Fans. . . . . . . . . . . . . . . . . . . . . . 83
Fan Balance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84
Inspect Isolation Transformer Auxiliary Cooling Fans . . . . . . . . . . . 85
Replace Isolation Transformer Auxiliary Cooling Fans. . . . . . . . . . . 86
Inspect Isolation Transformer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 86
Inspect Voltage Sensing Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
4 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014
Table of Contents
Replace Voltage Sensing Board . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 87
Inspect Door Position Limit Switch. . . . . . . . . . . . . . . . . . . . . . . . . . . . 88
Replace Door Position Limit Switch . . . . . . . . . . . . . . . . . . . . . . . . . . . 89
Power Module Cabinet . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Inspect, Clean, or Replace Door Mounted Air Filters. . . . . . . . . . . . 90
Inspect or Replace Top Mounted Main Cooling Fans . . . . . . . . . . . 90
Inspect Power Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 90
Replace Power Module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Replace Power Module Fuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 97
Inspect or Replace HECS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 99
Inspect or Replace Door Position Limit Switch . . . . . . . . . . . . . . . . 100
LV Control Cabinet. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Inspect AC/DC Power Supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 101
Replace AC/DC Power Supplies. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 102
Inspect UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 104
Replace UPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105
Replace UPS Batteries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 106
Inspect PLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 108
Inspect/Replace Control Unit or Control Boards . . . . . . . . . . . . . . 108
Inspect the HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Replace the HMI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 111
Replace LV Control Relays. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 113
Replace LV Control Circuit Breakers . . . . . . . . . . . . . . . . . . . . . . . . . 114
Inspect Coils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Inspect Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Inspect Pilot Lights . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116
Inspect Locking and Interlocking Devices . . . . . . . . . . . . . . . . . . . . . 116
Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 117
Inspect LV Component Terminal and Plug-in Connections . . . . 117
Inspect Medium Voltage Cable Connections . . . . . . . . . . . . . . . . . . 117
Inspect Power Cable and Control Wire Terminals . . . . . . . . . . . . . 117
Inspect Transformer Secondary Windings. . . . . . . . . . . . . . . . . . . . . 117
Inspect Power Module Input and Output Power Connections . . 118
General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Review Firmware and Hardware . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Inspect/Review Spare Parts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 118
Technical Specifications
Catalog Number Explanation
Preventative Maintenance Schedule
Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 5
Appendix A
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 119
Appendix B
. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 121
Appendix C
PowerFlex 6000 Maintenance Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . 123
Table of Contents
Appendix D
Spare Parts
Torque Requirements
Index
Spare Parts List. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Appendix E
Torque Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 129
6 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014
Preface
Introduction
Who Should Use This Manual
What Is Not in This Manual
This document provides procedural information for managing daily or recurring
tasks involving PowerFlex 6000 medium voltage variable frequency drives.
This manual is intended for use by personnel familiar with operating medium
voltage and solid-state variable speed drive equipment. The manual contains
material that enables operation and regular maintenance of the drive system.
This manual provides information specific to maintaining the PowerFlex 6000
medium voltage variable frequency drive. It does not include topics such as:
• Dimensional and electrical drawings generated for each customer’s order
• Spare parts lists compiled for each customer’s order
Please refer to the following documents for additional product detail or
instruction relating to PowerFlex 6000 drives:
• PowerFlex 6000 Medium Voltage Variable Frequency Drive Shipping,
Handling, and Installation Instructions (6000-IN006_-EN-P
document provides procedural information for physically unloading,
moving, and installing PowerFlex 6000 medium voltage drives.
• PowerFlex 6000 Medium Voltage Variable Frequency Drive
Commissioning Manual (6000-IN007_-EN-P
information for commissioning PowerFlex 6000 medium voltage drives.
). This document provides
). This
Additional Resources
Rockwell Automation provides the site- and installation-specific electrical and
design information for each drive during the order process cycle. If they are not
available on site with the drive, contact Rockwell Automation.
These documents contain additional information concerning related products
from Rockwell Automation.
Resource Description
Industrial Automation Wiring and Grounding Guidelines,
publication 1770-4.1
Product Certifications website, http://www.ab.com Provides declarations of conformity, certificates, and
You can view or download publications at
http:/www.rockwellautomation.com/literature/
technical documentation, contact your local Allen-Bradley distributor or
Rockwell Automation sales representative.
Provides general guidelines for installing a Rockwell
Automation industrial system.
other certification details.
. To order paper copies of
Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 7
Preface
General Precautions
Service and Support
ATT EN TI ON : This drive contains ESD (Electrostatic Discharge) sensitive parts
and assemblies. Static control precautions are required when installing, testing,
servicing or repairing this assembly. Component damage may result if ESD
control procedures are not followed. If you are not familiar with static control
procedures, reference Allen-Bradley publication 8000-4.5.2, “Guarding Against
Electrostatic Damage” or any other applicable ESD protection handbook.
ATT EN TI ON : An incorrectly applied or installed drive can result in component
damage or a reduction in product life. Wiring or application errors, such as,
undersizing the motor, incorrect or inadequate AC supply, or excessive ambient
temperatures may result in malfunction of the system.
ATT EN TI ON : Only personnel familiar with the PowerFlex 6000 Adjustable
Speed Drive (ASD) and associated machinery should plan or implement the
installation, start-up and subsequent maintenance of the system. Failure to
comply may result in personal injury and/or equipment damage.
Commissioning Support
After installation, Rockwell Automation is responsible for commissioning
activities for the PowerFlex 6000 product line. Contact your local Rockwell
Automation sales representative to arrange commissioning.
Rockwell Automation support includes, but is not limited to:
• quoting and managing product on-site start-ups
• quoting and managing field modification projects
• quoting and managing customer in-house and on-site product training
The user or its representatives are responsible for pre-commissioning activities to
prepare the drive for commissioning. Failure to complete these activities prior to
the commissioning process will delay the start-up of the drive. Please refer to the
Pre-commissioning Checklist in the PowerFlex 6000 Medium Voltage Variable
Frequency Drive Shipping, Handling, and Installation Instructions
(6000-IN006_-EN-P
).
8 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014
Chapter 1
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. Better information leads to higher asset availability, reduced energ y
and maintenance costs, and asset and personnel protection - all resulting in an
increased return on your investment and real bottom-line savings. No matter
where your applications are located - and whether your requirements are simple
or complex, count on PowerFlex medium voltage drives for the optimal solution.
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. If it is necessary
to work in the vicinity of energized equipment, the safety related work
practices outlined in Electrical Safety requirements for Employee Work places
must be followed. Before attempting any work, verify the system has been
locked out and tested to have no potential.
Lockout and tagout the device feeding power to the input of the drive before
performing any drive maintenance or component replacements. After the input
device cabinet doors are opened, immediately test the outgoing power cables
feeding the drive with a live-line tool (hot stick) while wearing high voltage
gloves. Repeat the live-line tool (hot stick) testing at the drive incoming line
power cable connections to verify that medium voltage is not present. Pay special
attention to any capacitors connected to medium voltage that can retain a charge
for a period of time. Only after the drive equipment has been verified as isolated
and de-energized can subsequent work be performed. Even though the input to
the drive may be open, it is still possible for hazardous voltage to be present.
Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 9
Chapter 1 Introduction
Refer to national and local safety guidelines for detailed procedures on how to
safely isolate the equipment from hazards.
ATT EN TI ON : The national and local electrical codes outline provisions for safely
installing and working on electrical equipment. Installation must comply with
specifications regarding wire type, conductor sizes, branch circuit protection
and disconnect devices. Failure to do so may result in personal injury and/or
equipment damage.
Environmental Conditions
How it Works
• Elevation above sea level must be less than 1000 m (3250 ft)
• Ambient air temperature must be between 0...40°C (32...104°F)
(1)
.
(2)
.
• Relative humidity must be less than 90%, non-condensing.
• The drive must be installed indoors; there must be no dripping water or
other fluids in the room.
• Cooling air must be clean without significant concentrations of sand,
corrosive or conductive dust (defined by IEC 721-1 as being less than
0.2 mg/m
of dust), or explosive gas.
• Free from significant vibration.
• The drive must be anchored on a level floor. Please refer to the dimension
drawing for the anchor point sizes and locations.
For the equipment to operate in conditions other than those specified, consult
the local Rockwell Automation Sales Office.
Cascaded “H” Bridge (CHB) Topology
The proven CHB topology combines an integrally mounted phase shifting
isolation transformer and series-connected power modules for each phase. In
addition to stepping down the input voltage, the isolation transformer also
provides two other principal functions:
• Mitigate common mode voltage stress so motors with standard insulation
levels can be used.
• Reduce Total Harmonic Distortion (THD), due to the phase shifting of
its secondary windings, so input side harmonics don’t negatively impact
the plant or utility power grid.
(1) Options are available for operation up to 3000 m.a.s.l. However, these must be stated at the time of order and cannot be retrofitte d
in the field.
(2) Options are available for ambient temperatures up to 50 ºC. However, these must be stated at the time of order and cannot be
retrofitted in the field.
10 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014
Introduction Chapter 1
Input Power
3 Phase AC
Power Modules
Isolation
Transformer
A number of identical low voltage power modules are series-connected
(cascaded) together to produce the medium voltage levels required to operate the
motor.
The voltage step for each module is relatively small and a Pulse Width
Modulation (PWM) switching pattern is used so output harmonics and torque
pulsations at the motor are minimal, even at lower speeds. This technology is
very motor friendly so standard motors can be used for new applications and it
also is ideal for retrofitting existing motors. This also allows for the motor cable
lengths required for most applications, without the requirement for output
filtering.
This power module concept makes maintenance quick and easy. Each module has
powerful built in diagnostics to identify and isolate a module needing
replacement, in the unlikely event of a failure. This minimizes power module
replacement time, so process uptime is maximized.
Figure 1 - 6/6.6 kV Example Power Structure
Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 11
Chapter 1 Introduction
Isolation Transformer Secondary Windings
U
V
W
Isolation Transformer Secondary Windings
U
V
W
Isolation Transformer Secondary Windings
U
V
W
Simplified Electrical Diagrams
Figure 2 - 3000V / 3300V (18 Pulse - 9 Power Modules)
Figure 3 - 6000V /6600V (36 Pulse - 18 Power Modules)
Figure 4 - 10,000V (54 Pulse - 27 Power Modules)
12 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014
Figure 5 - Connectivity Overview
Reset
Start
Stop
Analog Output Current
4-20 mA
Analog Output Frequency
4-20 mA
Analog set 4-20 mA
Analog spare 4-20 mA
Analog spare 4-20 mA
AC220V Control Power
MV Closed
Customer Input Contact
Permit Close MV
MV Closed Indicator
Warning Indicator
Fault Indicator
Running Indicator
Stop Indicator
Ready Indicator
Remote Control Indicator
Permit to Close Customer
Emergency/Fault Trip
Emergency Stop
MV Pre-Closed
MV Closed
War nin g
Fau lt
Running
Stop
Ready
Control
Permit Close CB
Tri p
Three-p hase
Induction
Motor
Introduction Chapter 1
Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 13
Chapter 1 Introduction
Generous space for terminating incoming line
cables.
Generous space for terminating outgoing load
cables.
Integrally mounted Multi-pulse Isolation
Transformer (3 wire s in & 3 wires out) ensures
low line side harmonics and high input power
factor
Cabinet ships in two sections to minimize
shipping and handling issues.
All Power Modules are identical to minimize
spare parts.
All Power Modules are designed for easy
removal and replacement to minimize MTTR.
Power Module has a PWM pattern to reduce
output harmonics
All MV doors are electrically interlocked with
input switching device
Isolation Transformer Temperature Monitor
All door filters can be changed while the drive
is running
All cooling fans are internally powered by a
dedicated winding in the Isol ation Transfor mer
– no separate fan power supply is needed from
customer
All MV doors are lockable
Intuitive, easy-to-use, color touchscreen HMI
Many communication modules are available,
such as EtherNet I/P and Profibus DP
Automatic switchover (no trip) to internally
supplied control power if customer-supplied
single phase control power is lost
On-line UPS supplied as standard
Incoming Line Cables
Outgoing Load Cables
Isolation Transformer
Power Module s
Door
Filters
Tra ns fo rm er
Tem p er at u re
Monitor
Cooling Fans
HMI
Figure 6 - PowerFlex 6000 Principal Components
14 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014
Introduction Chapter 1
Standards Compliance
Technical specifications and relevant standards in the manufacture, testing, and
acceptance of equipment include:
Standard Number Standard Description
IEEE 519 Electrical and Electronics Engineers Institute Harmonics Control Requirements
IEC 60146 Semiconductor Converters–Specification of Basic Requirements
IEC 60038:1983 IEC Standard Voltages
IEC 60050-151:2001 International Electrotechnical Vocabulary, Chapter 151: Electrical and Magnetic Devices
IEC 60050-551:1999 International Electrotechnical Vocabulary, Chapter 551: Power Electronics
IEC 60076 Electric Power Transformer
IEC 60721-3-1:1997 Classification of Environmental Conditions, Part 3: Classification of Groups of Environmental
Parameters and their Severities. Section 1: Storage
IEC 60721-3-2:1997 Classification of Environmental Conditions, Part 3: Classification of Groups of Environmental
Parameters and their Severities
IEC 60721-3-3:2008 Classification of Environmental Conditions, Part 3: Classification of Groups of Environmental
Parameters and their Severities. Stationary Use at Weather-protected Locations
IEC 61000-2-4:2002 Electromagnetic Compatibility (EMC), Part 2, Environment, Chapter 4: Compatibility Levels in
Industrial Plants for Low Frequency Conducted Disturbances
IEC 61000-4-7:2002 Electromagnetic Compatibility (EMC) Part 4: Testing and Measurement Techniques, Chapter 7:
General Guide on Harmonics and Inter-harmonics Measurements and Instrumentation, for
Power Supply Systems and Equipment Connected Thereto
IEC 61800-3:2004 Adjustable Speed Electrical Power Drive Systems, Part 3: EMC Requirements and Specific Test
Methods
IEC 61800-4:2004 Adjustable Speed Electrical Power Drive Systems, Part 4: General Requirement—Rating
Specifications for AC Power Drive Systems above 1000V AC and not Exceeding 35 kV
IEC 60757-1983 Code for Designation of Colors
IEC 106:1989 Environment Condition Guides for Specifying Performance Rating of Equipment
IEC 61508.1-7 Functional Safety of Electrical/Electronic/Programmable Electronic Safety-related Systems
GB/T 2900.18-2008 Electrotechnical terminology—Low Voltage Apparatus (IEC60050-441:1984)
GB/T 3859.1-2013 Semiconductor Converters. Specification of Basic Requirements (IEC60146-1-1:1991)
GB/T 3859.2-2013 Semiconductor Converters. Application Guide (IEC60146-1-2:1991)
GB/T 3859.3-2013 Semiconductor Converters. Transformers and Reactors (IEC 60146-1-3,1991)
GB 7678-87 Semiconductor Self-commutated Converters
GB 3797-2005 Electric-driving Control Gear, Part 2: Electric- driving Control Gear Incorporating Electronic
Devices
GB/T 14549-93 Quality of Electric Energy Supply Harmonics in Public Supply Network
GB 4208-2008 Degrees of Protection Provided by Enclosures (IP Code) (IEC 60529:1989)
GB/T 16935.1-2008 Insulation Coordination for Equipment within Low Voltage Systems, Part 1: Principles,
Requirements, and Tests (IEC 60664-1:1992)
GB 156-2007 Standard Voltages
GB/T 1980-2005 Standard Frequencies
GB/T 2423.10 Electric and Electronic Products—Basic Environmental Test Regulations for Electricians—
Guidelines for Vibration (sine)
GB/T 2681 Colors of Insulated Conductors Used in Electrical Assembly Devices
GB 2682 Colors of Indicator Lights and Push Buttons Used in Electrical Assembly Devices
GB/T 4588.1-1996 Specification for Single and Double-sided Printed Boards with Plain Holes
GB/T 4588.2-1996 Sectional Specification: Single and Double-sided Printed Boards with Plated-through Holes
Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 15
Chapter 1 Introduction
Standard Number Standard Description
GB 10233.2005 Basic Test Method for Low Voltage Switchgear and Controlgear
GB 12668.4-2006 Adjustable Speed Drive Electrical System, Part 4: General Requirement for Voltage up to 35 kV
GB 12668.3-2006 Adjustable Speed Drive Electrical System, Part 3: EMC Requirement and Testing Method
GB 12668.701-2013 Adjustable Speed Drive Electrical System, Part 701: Communication
GB/T 15139-94 General Technical Standard for Electrical Equipment Structure
GB/ 13422-2013 Semiconductor Converters—Electrical Test Methods
IEEE 519-1992 Practices and Requirements for Harmonic Control in Electrical Power Systems
GB/T 12668.4-2006 Adjustable Speed Electrical Power Drive Systems, Part 4: General Requirements. Rating
Specifications for AC Power
GB1094.11-2007 Power Transformer, Part 11: Dry-type Transformer
16 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014
Chapter 2
Isolation Transformer Cabinet Power Module Cabinet LV Control
Cabinet
Drive System Layout
There are two basic power cell configurations offered in the PowerFlex 6000
product line. For a drive amperage rating
design is supplied. Fixed-mounted modules are shipped installed in the drive. For
a drive amperage rating of >200 A, a drawout power module design is supplied.
The PowerFlex 6000 drive is shipped in two sections, the Isolation Transformer
Cabinet and the Power Module/LV Control Cabinet. Refer to PowerFlex 6000
Medium Voltage Variable Frequency Drive Shipping, Handling, and Installation
Instructions (6000-IN006_-EN-P
Isolation Transformer Cabinet 18
Power Module Cabinet 25
LV C ont ro l Ca bin et 29
≤200 A, a fixed-mounted power module
).
Elevation Drawings
Figure 7 - Fixed-mounted Power Module Drive Configuration
Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 17
Chapter 2 Drive System Layout
Isolation Transformer Cabinet Power Module CabinetLV C ont ro l Ca bin et
Figure 8 - Drawout Power Module Drive Configuration
Isolation Transformer Cabinet
Isolation Transformer 20
Isolation Transformer Temperature Monitor 21
Isolation Transformer Auxiliary Cooling Fans 22
Top-mounted Main Cooling Fan(s) 22
Incoming Line Power Cable Connections 22
Outgoing Motor Cable Connections 22
Door Position Limit Switch 23
Voltage Sensing Board 24
18 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014
Drive System Layout Chapter 2
Isolation Transformer
Cable Clamp
Volt age S ensing
Board
Door Position
Limit Switches
L11
L12
L13
U
V
W
Isolation Transformer
Auxiliary Cool ing Fans
Power Cable Connections
to Power Modules
Incoming Line Power
Cable Connections
Outgoing Motor Power
Cable Connections
Top-mounted Main
Cooling Fan(s)
Cable Clamp
Voltage Sensing
Board
Isolation Transformer
Door Position
Limit Switches
L13 L12
L11
WV U
Incoming Line Power
Cable Connections
Outgoing Moto r Power
Cable Connections
Isolation Transformer
Auxiliary Cool ing Fans
Top-mounted Main
Cooling Fans
Figure 9 - Isolation Transformer Cabinet (Fixed-mounted Power Module Drive Configuration)
Figure 10 - Isolation Transformer Cabinet (Drawout Power Module Drive Configuration)
Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 19
Chapter 2 Drive System Layout
PRIMARY WINDING INPUT
SECONDARY WINDING OUTPUT
C (L3) B (L2) A (L1)
U
V
W
Isolation Transformer
The primary winding of the isolation transformer is rated for the voltage of the
distribution system. It is connected to the distribution system by the incoming
line power cables. The secondary windings of the isolation transformer are
connected to the inputs of the power modules. The secondary winding voltage is
typically 690V, to feed the low voltage power modules.
There are between 9 and 27 three-phase secondary side windings, dependent on
the motor voltage requirements. The phase relationship between the secondary
windings are optimized to provide the highest reduction of line side harmonics.
The isolation transformer’s three-phase primary coils are oriented C, B, and A
from left to right, as viewed from the front. The secondary windings are also
divided into three principal sections from top to bottom. The upper third are to
feed the power modules in the 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 11
Figure 11 - Isolation Transformer Primary and Secondary Winding Orientation
).
The secondary windings are brought out to corresponding vertical isolated standoffs on the body of the transformer (orientated C, B, and A from left to right as
viewed from the front).
20 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014
Drive System Layout Chapter 2
For drives with fixed-mounted power modules, the U and W phase
interconnections to the isolation transformer secondary windings are on the
front of the isolation transformer and the connections to the V phase are on the
rear of the isolation transformer. The power cable connections to the power
modules are made at the factory. Therefore, the field power cable connections
need to be made at the isolation transformer secondary winding termination
points (see 6000-IN006_-EN-P
).
For drives with drawout power modules, all of the interconnections between the
isolation transformer secondary windings and the power modules are made in the
rear of the isolation transformer and the connection to the power modules are
also in the rear. The power cable connections to the isolation transformer
secondary winding termination point are made at the factory. Therefore, the field
power cable connections must be made at the power module input points (see
6000-IN006_-EN-P
).
Isolation Transformer Temperature Monitor
A discrete transformer temperature monitor is mounted on the LV door in the
isolation transformer cabinet. 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.
Figure 12 - Isolation Transformer Temperature Monitor
A separate user manual from the manufacturer is included in the documentation
package.
Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 21
Chapter 2 Drive System Layout
Isolation Transformer Auxiliary Cooling Fans
Six fans are mounted directly underneath the isolation transformer to force air
directly through the windings - to ensure reliable cooling. A baffle structure
surrounds the periphery of the transformer structure to ensure the cooling air
does not bypass the interior of the transformer windings. These fans are powered
by a tertiary winding in the isolation transformer. Separate fan control power is
not required.
Top-mounted Main Cooling Fan(s)
The top mounted cooling fan(s) work with the auxiliary cooling fans to ensure
reliable cooling of the isolation transformer. They ensure the air is exhausted
from the cabinet by creating an induced draft.
Incoming Line Power Cable Connections
The incoming line cables connect to the line side terminals on the isolation
transformer. Incoming line cables can be brought in through the top or bottom of
the isolation transformer cabinet. Generous working space is provided, if stress
cones are required. See publication 6000-IN006_-EN-P
for additional details.
Outgoing Motor Cable Connections
The outgoing motor cables connect to a cable stand-off assembly on the cabinet
side sheet (Fixed-mounted Power Module configuration) or to the cable standoffs mounted on the Isolation Transformer (Drawout Power Module
configuration).
The outgoing motor cables connect to output phase of the power module array.
Outgoing motor cables can be brought in through the top or bottom of the
isolation transformer cabinet. Generous working space is provided. See
publication 6000-IN006_-EN-P
for additional details.
22 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014
Drive System Layout Chapter 2
Door Position Limit Switch
Door Position Limit Switch
Each cabinet door that allows access to medium voltage components is lockable
and also has a Guardmaster® safety limit switch. If the cabinet door is opened
when the input switching device feeding power to the drive is closed, the input
device will be tripped off.
ATT EN TI ON : The door position interlock is a safety feature. It must not be used
solely as a part of the plant operation process to ensure the drive has been
disconnected from input medium voltage. Keep the medium voltage doors
locked as standard practice. If access to the medium voltage rated cabinets is
required, always go to the input device feeding the drive to verify if it is open.
Lock out and tagout the input device before performing any work on the drive
or bypass units.
Figure 13 - Door Position Limit Switch Location
Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 23
Chapter 2 Drive System Layout
L11
L12
L13
A1
B1
C1
A2
B2
C2
A3
B3
C3
A4
B4
C4
A5
B5
C5
A6
B6
C6
A7
B7
C7
A8
B8
C8
A9
B9
C9
U
V
W
PC A1
PC A2
PC A3
PC B1
PC B2
PC B3
PC C1
PC C2
PC C3
U
V
W
Input power
3-phase AC
any voltage
Isolation Transformer
Motor
Volt age Sens ing
Board
Isolation Transformer Cabinet Power Module/LV Control Cabinet
Voltage Sensing Board
The Voltage Sensing Board (VSB) is connected to the drive output terminals that
connect to the motor. The VSB converts motor voltage to low voltage levels
which allows the drive to monitor the output voltage to the motor.
Figure 14 - Voltage Sensing Board
Figure 15 - Power Cabling Overview (3.3 kV Fixed-mounted Power Module Configuration)
24 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014
Power Module Cabinet
Drive System Layout Chapter 2
Power Modules 26
Hall Effect Current Sensors (HECs) 28
Top-mounted Main Cooling Fan(s) 28
Figure 16 - Fixed-mounted Power Module Configuration
Figure 17 - Drawout Power Module Configuration
Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 25
Chapter 2 Drive System Layout
Input U
Input V
Input W
Fuse 1
Fuse 2
Three-phase Diode
Rectifier Bridge
DC Bus
Capacitor Network
Single Phase IGBT
Inverter Network
IGBT 1 IGBT 2
Output A Output B
D1 D2 D3
D4 D5 D6
C1 R1
C2 R2
C3 R3
Power Modules
Power Modules are available in a wide variety of amperage ratings relating to the
required motor current. Power Modules rated up to and including 200 A are
fixed-mounted in the drive and ship already installed.
Drawout power modules are supplied for a drive current rating of >200 A. The
power modules are shipped separately and must be installed in the cabinet. A
Power Module lift cart is included and shipped together with the other
components.
Basic Principle of Power Module
The Power Module combines a three phase rectifier and an “H” bridge inverter,
powered from the secondary side windings of the Isolation Transformer. After
rectifying and filtering, it outputs AC current with variable frequency and
variable voltage under the control of four IGBTs using a PWM switching pattern.
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.
Figure 18 - Low Voltage Power Module
Control signals to the Power Module and the feedback signals from the Power
Module are transmitted by fiber optic cables which provide electrical isolation
between the medium voltage and low voltage sections of the drive, and protects
against electromagnetic interference.
Although the voltage produced by each power unit is typically less than 690V, the
voltage-to-ground can reach the VFD rated output voltage, if operating at rated
frequency.
The control signals from the main control unit, through the optical-electrical
converter, are sent to the Power Module control board for further processing and
to the corresponding gate drive circuits to turn the IGBTs on or off.
26 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014
Drive System Layout Chapter 2
Line Terminals
Fuse
Optic Fiber Socket
and Status Indicator
Output Terminal
The status information of the Power Module is transmitted through the
electrical-optical converter and sent to the main control unit. When there is a
fault, the main control unit sends control signals to lockout or bypass the affected
Power Module.
The Power Module cabinet consists of Power Modules, current transformers and
high-voltage cable.
The Power Modules are divided evenly into three phases (U, V, and W). The
units in each phase are connected end-to-end at the output terminals. Then
individual phases are formed, using a star connection. Current transformers are
installed into the U phase and W phase.
Different models of Power Modules are used for VFDs of different power ratings
(Figure 19
Figure 19 - Typical Fixed-mounted Power Module
).
Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 27
Chapter 2 Drive System Layout
Table 1 - Power Module Ratings
Catalog Number Spare Part Number Current Rating (Amps)
TPUxx/030-AC3 HTPUXX/030-AC3-R 30
TPUxx/040-AC3
TPUxx/050-AC3 HTPUXX/050-AC3-R 50
TPUxx/060-AC3 HTPUXX/060-AC3-R 60
TPUxx/075-AC3 HTPUXX/075-AC3-R 75
TPUxx/080-AC3
TPUxx/100-AC3 HTPUXX/100-AC3-R 100
TPUxx/120-AC3 HTPUXX/120-AC3-R 120
TPUxx/150-AC3
TPUxx/180-AC3 HTPUXX/180-AC3-R 180
TPUxx/200-AC3 HTPUXX/200-AC3-R 200
TPUxx/300-AC3
TPUxx/380-AC3 HTPUXX/380-AC3-R 380
TPUxx/420-AC3 HTPUXX/420-AC3-R 420
HTPUXX/040-AC3-R 40
HTPUXX/080-AC3-R 80
HTPUXX/150-AC3-R 150
HTPUXX/300-AC3-R 300
Hall Effect Current Sensors (HECs)
The Hall Effect Current Sensors are current transformers capable of measuring
current throughout the output frequency range of the drive. They monitor the
current waveform in each of the phases going to the motor and provide feedback
to the control system.
Top-mounted Main Cooling Fan(s)
The Top-mounted Cooling Fans ensure reliable cooling of the Power Modules.
They draw cool air in through the vents in the Power Module Cabinet doors,
through the Power Modules, and exhaust the heated air out through the top of
the cabinet.
28 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014
Drive System Layout Chapter 2
Control Unit
PLC
LV C irc uit B rea ker s
LV Control Relays
UPS
LV Control Cabinet
Control Unit (all modules) 30
PLC 32
HMI 32
UPS 32
The LV Control Cabinet consists of the Control Unit, the human-machine
Interface (HMI), PLC, AC/DC power supplies, contactors and relays.
The HMI is located on the front door of the LV Control Cabinet, where an
operator can setup, monitor, and control the drive.
Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 29
Chapter 2 Drive System Layout
Tra ns ce iv er
Indicators
PWM Board A
PWM Board B
PWM Board C
CPU Board
Analog Signal
Processor Board
(AT)
Digital Signal
Processor Board
(DT)
Status Indicators
Interface Terminals
Fiber Optic Sockets
Board
Handle
Board
Mounting
Screw
HMI
Commu nication
Interface
Power Indication
Status
DB Board
Control Unit (all modules)
The control unit provides the core functionality of the variable frequency drive.
This includes controlling the power modules to produce the required output
voltage and frequency, monitoring the power modules, motor voltage, and motor
current to provide alarm and trip signals based on the information.
Figure 20 - PowerFlex 6000 Interface
The CPU Board accepts external inputs through the connected communication
network, hard-wired control devices or user interactions via the HMI to
determine the actions required of the drive. The CPU Board also monitors
motor voltage and current as well as internal inputs from the PLC, analog and
digital signal processor boards and Power Modules. It uses these inputs in its
motor control and protection algorithms to determine the necessary actions to
be taken and outputs to be set. 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
30 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014
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