Rockwell Automation 6012DB User Manual

Download

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.

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

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

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

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)

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

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

PC A1

PC A2

PC A3

PC B1

PC B2

PC B3

PC C1

PC C2

PC C3

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

Figure 21 - Control Unit Layout

HMI

PWM Board A

DCS

Phase A

Power Module s

Fieldbus

VSB

HECS

PLC

Communication

Board

PWM Board B PWM Board C

Phase C

Power Modules

CPU Board

Phase B

Power Modules

RJ45 Modbus TCP/IP

RS-485

Modbus

Drive System Layout Chapter 2

Table 2 - Control Unit description

Board Function

PWM Board A, B, C Output PWM and control signals to Power Modules

CPU Board Process analog input signals, switch and fault information, control DA and switch signal output,

Analog Signal Processor Board (AT)

Digital Signal Processor Board (DT)

DB Board Acts as a base board in the Control Unit and interfaces the digital and analog signal cables

Connector

HMI Communication Interface

Fiber Optic Socket Connection between Power Modules and Control Unit (two per module)

Interface Terminals Connects external inputs, outputs and the CPU Board

Status Indicators

Phase control board transceiver indicator light

CPU Board Indicator Lights

5V 5V power supply indicator

3.3V 3.3V power supply indicator

FPGA FPGA healthy indicator

DSP1 DSP1 healthy indicator

DSP2 DSP2 healthy indicator

Collect and process fault and state information from Power Modules to CPU board Each phase PWM board can control up to nine power cells

realize V/F algorithm, set and change parameters in communication with HMI

Collect and process analog input signals to CPU Board, output analog signals processed by DT board

Collect and output digital signals, digital to analog conversion function

Connection between HMI and Control Unit. Provides inputs from the HMI and PLC to the CPU Board

B: board healthy indicator T: transmit data to power module indicator R: receive data from power module indicator

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 31

Chapter 2 Drive System Layout

Power Input

Extend I/O Extend I/OPlug inPLC Plug in Plug in

EtherNet/IP Port

Digital Signal Processor Board Indicator Lights

HVEN Allow High voltage switching on indicator

RUN Drive Running indicator

Fault Drive is in fault state

Trip Drive is in trip state; any fault can result in trip

Alarm Drive in alarm state

Reserved

PLC

The PowerFlex 6000 uses a Micro850 PLC to perform many of its internal control functions. The PLC controls and monitors the cooling fans, input and bypass switching devices, door switch status, etc. The PLC is also responsible for interfacing with the user's automation control system via many optional communication protocols. Standard communication protocols are EtherNet/IP, Modbus/TCP Server and Modbus RTU. Optional communication modules are available to support other communication protocols.

Figure 22 - PLC Location

HMI

The PowerFlex 6000 HMI is a PanelView Plus 700 series, catalog number 2711PT7C4D9.

The HMI is connected to the Master Control board through a communication interface (standard RJ45 EtherNet/IP connection). The HMI configures operating parameters and input operation commands, and displays the operation status, operation parameters, and fault messages.

UPS

32 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

The UPS supplies power to the LV Control cabinet using internal batteries if the customer-supplied control power and isolation transformer control power is off. The UPS provides control power in the event of transient power loss to ensure the drive control can operate without interruption.

Setup and Operation

User

Setup

R&D

Set Several

P Parameters

Set Several

P Parameters

Set All

P Parameters

Set All

T Parameters

View K

Parameters

Settings

Default

Select

Language

Select

Bypass Mode

Operation

Bypass

Manual Bypass

Auto

Bypass

Local/

Remote

Switch Status

Open/Close

Switch

Local /

Remote

Local/

Remote

Switch Status

Tre nd s

Act. Freq.

Alarm

Alarm Status

Alarm History

Set Frequency

Start/Stop/Reset

Accel/Decel

Main Operation

Data Display

Set Frequency

Actual Frequenc y

Motor Voltage

Motor Current

Status Info.

Version Info.

Home

Main Interface

Screen Layout

1Top Menu Bar

2 Status Bar

3Set and Monitor Box

4 Actual Frequency Display Box

5 Version Information Box

6Actual Date and Time

7Operation Bar

Chapter 3

Overview

Main Interface

The structure of the touchscreen operation is shown in Figure 23.

Figure 23 - HMI Overview

The Main Interface Screen contains configuration and operation controls, monitoring parameters and actual speed.

Figure 24 - Main Interface Screen

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 33

Chapter 3 Setup and Operation

Drive Setup and Configuration Controls

There are five buttons in the Top Menu Bar. A description of the functionality is described in Ta b l e 3

Table 3 - Setup and Configuration Controls

• Return to Main Interface screen

• Check warnings

• Check faults

• Reset alarm status

• Show alarm history

• Check voltage trends

• Check current trends

• Check frequency trends

• Pause tre nding

• Confirm/change bypass configuration

• Change from local to remote control

• Close/open drive contactors (auto bypass)

• Access System Settings – Change Language – Change Bypass Mode

• Access P and T Parameters

Status Indicators

There are eight status indicators on Status Bar.

Table 4 - St atus Indi cators

Allowed The drive is in a state that will allow MV to be applied

MVClosd Indicates that the input switching device feeding MV power to the drive is closed

Ready Drive is ready to start

Connect Being connected with medium voltage

Running The drive is running

Warn ing The system has faults or warnings

Local The system is under Local Control

Remote The system is under Remote Control

34 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Setup and Operation Chapter 3

Operation Bar

Table 5 - Operation Bar Buttons

Start Starts the drive only if no fault is found during self test at startup; otherwise, this button is invalid

Accel Increases the frequency by the set step

Decel Decreases the frequency by the set step

Stop Stop output of the drive

(1)

Reset

(1) The drive must not be running to complete this operation.

Resets the drive (under fault conditions) once

Setup and Monitor Box

Main Interface Controls

The set frequency field is the only one which is user-configurable. See Set

Frequency (Hz) for instruction on how to set the frequency.

Table 6 - Monitoring Parameters

Set Frequency Frequency set for the drive (Hz)

Actual Frequenc y Actual frequency of the drive (Hz)

Motor Speed Speed of the motor (%)

Motor Voltage Voltage of the motor stator (V)

Motor Current Current of the motor stator (A)

From the Main Interface screen, you can:

Set Frequency (Hz) 36

Drive Operation Controls 37

View Version Information 38

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 35

Chapter 3 Setup and Operation

Numpad

Cancel

Backspace

Enter

Set Frequency (Hz)

1. Press the Set Frequency: input field.

2. Press the Set Freq: input field.

3. Enter desired frequency and press .

4. Press to accept or to cancel.

36 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Setup and Operation Chapter 3

Drive Operation Controls

Press the desired Drive Operation Control button, and to accept or

to cancel.

ATT EN TI ON : Drive Operation Controls will only function if using Local Control, otherwise the following dialog appears.

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 37

Chapter 3 Setup and Operation

Will always

appear blue

The number of

Power Modu les in

the drive will

appear as blue; the

rest appear as grey

Fields show the firmware version, where applicable

View Version Information

Press under Ve r s i on Inf o. to view the currently installed Firmware.

The Version Information screen shows the most current firmware installed for the applicable devices.

38 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Alarm

List of Active

Alarms

Alarm Code

Quantity

Accumulated Time

Alarm

Code Alarm code. Codes beginning with W indicates a warning, codes beginning

with F indicates a fault.

QTY How many times the alarm has occurred

Acc Time Time which has elapsed since the alarm

Message Description of the warning or fault

Reset Status

Scroll to Top or Bottom of List

Scroll Alarm

by Entry

Page Up /

Page Down

Shows Alarm History

Setup and Operation Chapter 3

If the drive encounters and alarm or warnings, will blink, indicating an active alarm.

Press the button in the Top Menu Bar to see the active alarms.

Active Alarms Controls

Reset Status

will reset just the quantity and accumulated time of the alarms. This

function does not reset the drive.

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 39

Chapter 3 Setup and Operation

TIP

Alarm History

Press to see a detailed listed of all warnings and faults on the drive.

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 gray.

40 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Setup and Operation Chapter 3

Back

Y-A xis

X-axis

Tre nd C ont rol s

Zoom Y-axis in

Zoom Y-axis out

Scroll X-axis left Scroll X-axis right Pause trending

Trends

There are three different trending options, Voltage, Current, and Trends. Press any button to view the trends.

You can view Voltage, Current, or Frequency trends. Voltage is measured in volts, Current in amps, and Frequency in Hz.

The trend controls are the same for all three screens.

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 41

Chapter 3 Setup and Operation

TIP

View Voltage, Current or Frequency Trends

1. From the Main Interface screen, press .

2. Press , , or

in the Trends Selection

screen.

3. Use the and buttons to zoom in or out.

Press the and buttons to scroll.

The time 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 Tr e nd s S el ec t io n

42 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

screen.

Setup and Operation Chapter 3

Bypass

Configuration

Select Local/ Remote Control

Open/Close Drive/Bypass Contac tors

No Bypass Cabinet

Operation

The Operation interface displays the bypass mode, control owner selection, and contactor operation.

In this screen, you can:

Confirm Bypass Mode 43

Choose Local/Remote Operation 45

Open/Close Drive Input and Output Contactors 46

Open/Close Bypass Contactors 47

Confirm Bypass Mode

1. Press from the Main Interface screen.

2. Confirm the Bypass Configuration matches one of the three Input Sup ply

graphics.

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 43

Chapter 3 Setup and Operation

Manual Bypass Cabinet

Automatic Bypass Cabinet

Note the Contactor Operation selection appears when Automatic Bypass is selected

3. To change the Bypass Mode:

a. Press .

b. Press .

c. Choose desired Bypass Mode under Select Bypass Mode

d. Press .

e. Press to confirm operation.

44 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Choose Local/Remote Operation

1. Press from the Main Interface screen.

Setup and Operation Chapter 3

2. Und er Control Owner Selection

, press either or

3. Select to confirm in the Select Local Control? or Select Remote Control? dialog box.

ATT EN TI ON : This operation can only operate while drive is not running.

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 45

Chapter 3 Setup and Operation

IMPORTANT

Open/Close Drive Input and Output Contactors

Turn the 3-position on the selector switch on the front of the LV Cabinet to the Drive position.

1. Und er Contactor Operation, press either or .

2. Select to confirm in the Close Drive Input & Output Contactors? or Open Drive Input & Output Contactors? dialog box.

ATT EN TI ON : Operations in this graphic can only operate while on local control.

ATT EN TI ON : This operation can only operate while drive is not running.

46 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Setup and Operation Chapter 3

IMPORTANT

Open/Close Bypass Contactors

Turn the 3-position on the selector switch on the front of the LV Cabinet to the Bypass position.

1. Und er Contactor Operation, press either or .

2. Select to confirm in the Close Bypass Contactors? or Open Bypass Contactors? dialog box.

ATT EN TI ON : Operations in this graphic can only operate while on local control.

ATT EN TI ON : This operation can only operate while drive is not running.

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 47

Chapter 3 Setup and Operation

Current Access

Level

User Account

Settings

The Settings screen is where you can access and modify parameters, choose or change system language, or change bypass mode.

System Settings Select Language and Bypass Mode

User Set tings View or modify User-level parameter settings

Setup Settings View or modify “P” or “T” parameters

R&D Settings For use by authorized Rockwell Automation personnel only.

System Settings

Change the HMI language or bypass mode under System Settings.

1. Press .

2. Press desired language to choose that language.

48 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Setup and Operation Chapter 3

3. Select bypass mode and press to accept or to cancel.

4. Press to accept.

ATT EN TI ON : Operations in this graphic can only operate while on local control.

ATT EN TI ON : This operation can only be performed when any switch is closed.

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 49

Chapter 3 Setup and Operation

User Parameter List

User Parameter Value

Reset all Parameters

to Factory Values

Parameter Description

User Settings

You can access, view, or change the user parameters in User Settings.

Change User Parameters

1. Press .

2. The User Login dialog box appears. Press .

3. Enter the User and Password details.

Press to enter user details. Press when finished.

Press to enter password details. Press when finished.

50 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Setup and Operation Chapter 3

IMPORTANT

Numpad

Cancel

Backspace

Enter

4. Press to login.

5. If the login was successful, the Current User will show as User.

6. Press .

If the login information was incorrect, you will be prompted to login again.

In the User Parameters Settings

screen, the user parameters automatically

refresh.

Press the parameter input field to change the parameter value.

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 51

Chapter 3 Setup and Operation

TIP

Press to restore all user parameters to the factory setting.

ATT EN TI ON : Operations in this graphic can only operate while on local control.

ATT EN TI ON : This operation can only operate while drive is not running.

Press to return to the Parameter Access Level

User parameter access will logout when you exit User Settings.

screen.

52 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Setup and Operation Chapter 3

Page Up

Page Down

Parameter

Number

Parameter

Field

Select a Parameter

number to see the

description here

Reset Parameter

Val ues

IMPORTANT



Setup Settings

View or modify “P” or “T” Parameters in the Setup Settings interface.

View/Change P or T Parameters

You must have Setup login access to view or modify “P” or “T” parameters.

1. Press under Parameter Access Level.

The Setup Login dialog box appears. Press .

2. Enter the User and Password details.

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 53

Chapter 3 Setup and Operation

IMPORTANT

Press to enter user details. Press when finished.

Press to enter password details. Press when finished.

3. Press to login.

The Current User will now display Setup, indicating appropriate access has been granted.

4. Once logged in, press to proceed.

If the login information was incorrect, you will be prompted to login again.

5. Press or in the Setup

Parameter Type.

6. Press the Parameter Field and enter desired value on the keypad dialog and

press .

7. Press or to Page Up or Page Down through the parameters.

54 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Setup and Operation Chapter 3

Restore “P” or “T” Parameters

Press to restore the parameters to factory settings.

Press to accept or to cancel.

ATT EN TI ON : Operations in this graphic can only operate while on local control.

ATT EN TI ON : This operation can only operate while drive is not running.

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 55

Chapter 3 Setup and Operation

Notes:

56 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

P Parameters

Chapter 4

Parameters and Function Codes

Parameter Number

P004 Command Source

P005 Restore Factory Settings

P007 Numb er Of Po wer Cells Per Phase 9 O N 0 9

P008 Motor Rotation Direction Under Local Control

P009 Motor Rotation Direction Command Selection:

P010 Power Cell Fault Mask 32767 ON 0 32767

P017 Number Of Motor Pole Pairs 2 OFF 0 100

P018 Enable Flying Start With Encoder 0 OFF 0 1

P019 Encoder Resolution 1024 OFF 0 4096

P020 Mask Bit For System Fault 32767 ON 0 32767

P021 Mask Bit For System Warning 32767 ON 0 32767

P022 Mask Bit For Logic Fault A 32767 ON 0 32767

P023 Mask Bit For Logic Fault B 32767 ON 0 32767

P024 Stop Method

P025 Flux Reduction Enable 0 ON 0 1

P026 Power Angle Threshold For Flux Reduction 0 ON 0 180

P027 Time For Flux Reducing 5000 ON 0 32767

P028 Flux Reduction Ratio 70 ON 0 100

P029 Power Angle Threshold For Flux Restore 0 ON 0 180

P040 Safe Start Condition

P089 Skip Frequency Enable

Description Default

Value

0OFF01 0: Communication Port 1: Other Sources

0OFF050 40: User Level 30: Setup Level 50: R&D Level

1OFF01 1: Forward 0: Reverse

0OFF01 0: Local 1: DCS

0ON01 0: Ramp Down 1: Coast Stop

1OFF01 0: Zero Frequency Command Required 1: Frequency Command Allowed

0ON01 0: Disable 1: Enable

Modify Root

Lower Limit

Upper Limit

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 57

Chapter 4 Parameters and Function Codes

Parameter Number

P090 Skip Frequency 1 Lower Limit 0 ON 0 75

P091 Skip Frequency 1 Upper Limit 0 ON 0 75

P092 Skip Frequency 2 Lower Limit 0 ON 0 75

P093 Skip Frequency 2 Upper Limit 0 ON 0 75

P113 Flying Start-Initial Output Voltage Percentage (%) 5 ON 0 100

P114 Flying Start-Current Comparison Delay For Motor Speed

P115 Flying Start-Current Threshold For Successful Motor

P198 HECS Rated Current (A) 0 ON 0 5000

P199 Motor Rated Current (A) 0 ON 0 5000

P200 Ia Motor Current Memory Address 13 ON 0 500

P201 Motor Ia Scaling Correction Factor 100 ON 0 199.99

P202 Ib Motor Current Memory Address 14 ON 0 500

P203 Motor Ib Scaling Correction Factor 100 ON 0 199.99

P204 Motor Uab Voltage Address 11 ON 0 500

P205 Motor Uab Voltage Scaling Factor Correction 199.99 ON 0 199.99

P206 Motor Uac Voltage Scaling Factor Correction 199.99 ON 0 199.99

P211 Filter Time For Abnormal Output Voltage (ms) 1000 ON 0 32767

P212 Filter Time For Output Short-Circuit (ms) 10 ON 0 32767

P213 Output Short-Circuit Fault Threshold 180 ON 0 199.99

P214 Over Current Low/High Speed Region Boundary 5 ON 0 100

P215 Filter Time For Output Over Current (0.1 s) 200 ON 0 32767

P216 High-Frequency Output Over Current Threshold 120 ON 0 199.99

P217 Low-Frequency Output Over Current Threshold 70 ON 0 199.99

P218 Filter Time For Motor Over Temperature (0.1 s) 6000 ON 0 32767

P219 Motor Over Temperature Warning Threshold 110 ON 0 199.99

P220 Motor Over Temperature Fault Threshold 120 ON 0 199.99

P221 Filter Time For Output Over Voltage (ms) 100 ON 0 32767

P222 Output Over Voltage Fault Threshold 130 ON 0 199.99

P223 Output Voltage Deviation Warning Threshold 60 ON 0 199.99

P224 Output Voltage Deviation Fault Threshold 80 ON 0 199.99

P225 Motor Over Temperature Warning Cancellation

P226 Output Voltage Abnormality Warning Cancellation

P227 Ground Fault Detection Scaling Correction Factor 100 ON 0 199.99

P228 Filter Time For Ground Fault (ms) 1000 ON 0 32767

P229 Ground Fault Warning Threshold 20 ON 0 199.99

P230 Ground Fault Trip Threshold 60 ON 0 199.99

P231 Filter Time For Overspeed Fault (Upper Limit) 100 ON 0 32767

Description Default

Value

1000 ON 0 5000

Search (ms)

5ON0100

Speed Search

100 ON 0 199.99

Temperature

50 ON 0 199.99

Threshol d

Modify Root

Lower Limit

Upper Limit

58 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Parameters and Function Codes Chapter 4

Parameter Number

P232 Filter Time For Overspeed Fault (Lower Limit) 100 ON 0 32767

P233 Threshold Of Over-Speed Fault At Lower Frequency Limit 20 ON 0 199.99

P234 Threshold Of Over-Speed Fault At Upper Frequency Limit 20 ON 0 199.99

P235 Frequency Deviation Warning Cancellation Threshold 0.99 ON 0 199.99

P236 Frequency Deviation Warning Threshold 6 ON 0 199.99

P237 Frequency Deviation Warning Delay (ms) 8 ON 0 32767

P238 Motor Stall Fault Threshold 10 ON 0 199.99

P239 Motor Stall Fault Delay (ms) 6000 ON 0 32767

P240 Transformer Over Temperature Fault Delay (ms) 5000 ON 0 32767

P241 Transformer Over Temperature Warning Delay (ms) 5000 ON 0 32767

P247 Software Interlock: 1-Disable, 0-Enable 1 ON 0 1

P250 Input Contactor/Circuit Breaker Close Delay (ms) 5000 ON 0 10000

P251 Frequency Command-Low Frequency Region Boundary 0.5 ON 0 100

P252 Motor In Stopping Condition Threshold 1 ON 0 100

P253 Motor Coast Stop Time 10 ON 0 10000

P256 Ground Fault Warning Cancellation Threshold 10 ON 0 199.99

P257 Motor Stall Warning Cancellation Threshold 2.98 ON 0 199.99

P259 Frequency Command Analog Offset 0 ON -100 199.99

P260 Frequency Command Analog Scaling Factor 100 ON 0 199.99

P261 Frequency Command Analog Minimum 0.49 ON 0 199.99

P262 Frequency Command Source Selection: 0-Digital, 1-

P270 Delayed Lockout Time Of Stop Operation (ms) 2000 ON 0 5000

P271 Flux Delay (ms ) 50 ON 0 5000

P300 Digital Output #0 Memory Address 99 ON 0 500

P301 Digital Output #0 Logic: 1-Inverting, 0-Non-Inverting 0 ON 0 1

P302 Digital Output #0 Bit Selection (0...15) 0 ON 0 15

P303 Digital Output #0 Delay (ms) 0 ON 0 32767

P304 Digital Output #1 Memory Address 99 ON 0 500

P305 Digital Output #1 Logic: 1-Inverting, 0-Non-Inverting 0 ON 0 1

P306 Digital Output #1 Bit Selection (0...15) 1 ON 0 15

P307 Digital Output #1 Delay (ms) 0 ON 0 32767

P308 Digital Output #2 Memory Address 99 ON 0 500

P309 Digital Output #2 Logic

P310 Digital Output #2 Bit Selection (0...15) 2 ON 0 15

P311 Digital Output #2 Delay (ms) 0 ON 0 32767

P312 Digital Output #3 Memory Address 99 ON 0 500

Description Default

Value

0OFF01 Analog

0ON01 1: Inverting 0: Non-Inverting

Modify Root

Lower Limit

Upper Limit

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 59

Chapter 4 Parameters and Function Codes

Parameter Number

P313 Digital Output #3 Logic

P314 Digital Output #3 Bit Selection (0...15) 3 ON 0 15

P315 Digital Output #3 Delay (ms) 0 ON 0 32767

P316 Digital Output #4 Memory Address 99 ON 0 500

P317 Digital Output #4 Logic

P318 Digital Output #4 Bit Selection (0...15) 4 ON 0 15

P319 Digital Output #4 Delay (ms) 0 ON 0 32767

P320 Digital Output #5 Memory Address 99 ON 0 500

P321 Digital Output #5 Logic

P322 Digital Output #5 Bit Selection (0...15) 5 ON 0 15

P323 Digital Output #5 Delay (ms) 0 ON 0 32767

P324 Digital Output #6 Memory Address 99 ON 0 500

P325 Digital Output #6 Logic

P326 Digital Output #6 Bit Selection (0...15) 6 ON 0 15

P327 Digital Output #6 Delay (ms) 0 ON 0 32767

P328 Digital Output #7 Memory Address 99 ON 0 500

P329 Digital Output #7 Logic

P330 Digital Output #7 Bit Selection (0...15) 7 ON 0 15

P331 Digital Output #7 Delay (ms) 0 ON 0 32767

P332 Analog Output #1 Memory Address 252 ON 0 500

P333 Analog Output #1 Filter Time (ms) 1000 ON 0 32767

P334 Analog Output #1 Offset 0 ON -100 100

P335 Analog Output #1 Scaling Factor 100 ON 0 199.99

P336 Analog Output #2 Memory Address 206 ON 0 500

P337 Analog Output #2 Filter Time (ms) 1000 ON 0 32767

P338 Analog Output #2 Offset 0 ON -100 100

P339 Analog Output #2 Scaling Factor 100 ON 0 199.99

P340 Analog Output #3 Memory Address 0 ON 0 500

P341 Analog Output #3 Filter Time (ms) 1000 ON 0 32767

P342 Analog Output #3 Offset 0 ON -100 100

P343 Analog Output #3 Scaling Factor 100 ON 0 199.99

P344 Analog Output #4 Memory Address 0 ON 0 500

P345 Analog Output #4 Filter Time (ms) 1000 ON 0 32767

Description Default

Value

0ON01 1: Inverting 0: Non-Inverting

Modify Root

Lower Limit

Upper Limit

60 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Parameters and Function Codes Chapter 4

Parameter Number

P346 Analog Output #4 Offset 0 ON -100 100

P347 Analog Output #4 Scaling Factor 100 ON 0 199.99

P351 Rated Frequency HMI Display Filter Time (ms) 100 ON 0 32767

P352 Rated Frequency HMI Display Integer Part 50 ON 0 75

P353 Rated Frequency HMI Display Decimal Par t 0 ON 0 1000

P354 Motor Voltage HMI Display Filter Time (ms) 2000 ON 0 32767

P355 Motor Voltage HMI Display Integer Part 10000 ON 0 16384

P356 Motor Voltage HMI Display Decimal Part 0 ON 0 1000

P357 Actual Frequency HMI Display Filter Time (ms) 100 ON 0 32767

P358 Actual Frequency HMI Display Integer Part 50 ON 0 75

P359 Actual Frequency HMI Display Decimal Part 0 ON 0 1000

P360 Motor Current HMI Display Filter Time (ms) 2000 ON 0 32767

P361 Motor Current HMI Display Integer Par t 0 ON 0 5000

P362 Motor Current HMI Display Decimal Par t 0 ON 0 1000

P371 Rated Frequency HMI Display Address 221 ON 0 500

P372 Motor Voltage HMI Display Address 119 ON 0 500

P373 Actual Frequency HMI Display Address 252 ON 0 500

P374 Motor Current HMI Display Address 118 ON 0 500

P399 Deceleration Time (s) 300 ON 0 3276

P400 Deceleration Time During Loss Of Input Supply (s) 200 ON 0 3276

P401 Acceleration Time (s) 200 ON 0 3276

P402 Acceleration Ramp Transition Time (s) 3 ON 0 3276

P403 Acceleration Time Unit

P405 Deceleration Ramp Transition Time (s) 3 ON 0 3276

P406 Deceleration Time Unit

P409 Amplification Coefficient Of Error Terms 100 ON 0 199.99

P413 Frequency Command Lower Limit 0 ON -16384 16384

P414 Frequency Command Deadband Upper Limit 0.49 ON 0 100

P415 Frequency Command Upper Limit 16384 ON -16384 16384

P416 Flying Start Mode

P417 Flying Start Motor Speed Search Timeout (s) 50 ON 0 1000

P438 Flying Start Current Compensation Threshold 100 ON 0 199.99

P439 Current Compensator Output Upper Limit 100 ON 0 100

P442 Current Compensation Threshold 190 ON 0 199.99

Description Default

Value

0.1 ON 0 0.1 1000 = 0.01 s 10000 = 0.1s

0ON03 0: Disable 1: Set Frequency 2: Stop Frequency Plus 5 Hz 3: Rated Frequency

Modify Root

Lower Limit

Upper Limit

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 61

Chapter 4 Parameters and Function Codes

Parameter Number

P443 Upper Limit Of Current Compensation Input Deadband 0 ON -16384 32767

P444 Lower Limit Of Current Compensation Input Deadband 0 ON -16384 32767

P445 Proportional Coefficient Of Current Compensation (%) 5 ON 0 199.99

P446 Integral Coefficient Of Current Compensation (ms) 100 ON 0 32767

P447 Lower Limit Of Current Compensation Output -100 ON -100 0

P448 Minimum Frequency For Current Compensation 5 ON 0 100

P449 Proportional Coefficient Of Current Compensation

P450 Upper Limit Of Frequency Compensation Output 100 ON 0 100

P451 Low Speed Voltage Compensation (%) 0.99 OFF 0 10

P452 Low Speed Voltage Compensation Frequency Threshold 20 ON 0 100

P453 V/F Curve

P454 Flux Time (s) 0.5 OFF 0 10

P455 Modulation Index 87.99 ON 0 199.99

P456 Motor Voltage Upper Limit 87.99 ON 0 199.99

P457 Flying Start Voltage Recovery Time (s) (Low Speed

P458 Coefficient A 40 OFF 0 100

P459 Flying Start Voltage Recovery Time (s) (High Speed

P460 Rated Output Frequency 50 OFF 0 75

P461 Restart Enable 0 ON 0 1

P462 Fault Reset Timeout (s) 120 ON 0 120

P463 Flying Start Low/High Speed Regions Boundary (%) 16 ON 0 100

P465 Power Cell Fault Auto Reset Delay (s) 4 ON 0 10

P466 Maximum Output Frequency 50 OFF 0 75

P467 Over Speed Enable 0 OFF 0 1

P470 Version Compatibility Enable 1 OFF 0 1

P497 Major Rev # Of DSP Main Firmware 0 Cannot

P498 Minor Rev # Of DSP Main Firmware 2 Cannot

P499 Display Fault Masks Button 0 ON 0 1

P500 Display DSP Variables 0 ON 0 1

Description Default

Value

0.99 ON 0 199.99

Output (%)

1OFF03 0: Linear 1: Parabolic Curve 2: Predefined Curve #1 3: Predefined Curve #2

5 ON 0 163.84 Region)

Modify Root

Modify

Lower Limit

—— ——

Upper Limit

62 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Parameters and Function Codes Chapter 4

T Parameters

Parameter Number

T01 Fault-To -Bypass

T02 Fault-To -Bypass Delay 3 ON 0 60

T03 Fault-To-Bypass Delay When Starting

T04 Fault-To-Bypass Minimum Frequency

T05 Auto Restart After Input Sup ply Power Loss

T06 Input Supply Power Loss Time for

T07 Local Frequency Command Selection

T08 Remote Frequency Command Selection

T09 Frequency Step For Accel or Decel 1 ON 1 Rated

T10 Exit Config Environment Password 555 OFF

T11 Automatic Bypass-To-Drive or

T12 PID Parameter Settings

T13 4-Step Variable Speed

Description Default

Value

0ON01

0: Disable 1: Enable

60 ON 0 60

the Motor (0...60s)

5ON0Rated

0...Rated Frequency (Hz)

0ON01

0: Disable 1: Enable

20 ON 0 20

Auto Restart (0...20s)

0ON01

0: Digital 1: Analog

1ON14

1: Analog 2: 4-Step Speed 4: Communication Port

Drive-To-Bypass Selection

P 0.01 ON 0 32767

I 0.01 ON 0 32767

D 0 ON 0 32767

D Gain 0 ON 0 32767

(available only when T8=2)

Speed 1 10 ON 0 Rated

Speed 2 20 ON 0 Rated

Speed 3 30 ON 0 Rated

Speed 4 40 ON 0 Rated

Modify Root

Lower Limit

Upper Limit

Frequenc y

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 63

Chapter 4 Parameters and Function Codes

Alarm List

Code Alarm

F0000 IGBT Set #1 Over Current In Power Cell #1

F0001 IGBT Set #2 Over Current In Power Cell #1

F0002 Input Over Voltage In Power Cell #1

F0004 Communication Error In Power Cell #1

F0005 No PWM1 Pulse For IGBT Set #1 In Power Cell #1

F0006 No PWM2 Pulse For IGBT Set #2 In Power Cell #1

F0007 IGBT Set #1 Failed To Turn On In Power Cell #1

F0008 IGBT Set #2 Failed To Turn On In Power Cell #1

F0009 Power Cell #1 Bypassed

F0010 Over Temperature In Power Cell #1

F0011 Power Cell #1 Failed To Bypass

F0012 One Phase Lost In Power Cell #1

F0013 Two Phases Lost In Power Cell #1

F0100 IGBT Set #1 Over Current In Power Cell #2

F0101 IGBT Set #2 Over Current In Power Cell #2

F0102 Input Over Voltage In Power Cell #2

F0104 Communication Error In Power Cell #2

F0105 No PWM1 Pulse For IGBT Set #1 In Power Cell #2

F0106 No PWM2 Pulse For IGBT Set #2 In Power Cell #2

F0107 IGBT Set #1 Failed To Turn On In Power Cell #2

F0108 IGBT Set #2 Failed To Turn On In Power Cell #2

F0109 Power Cell #2 Bypassed

F0110 Over Temperature In Power Cell #2

F0111 Power Cell #2 Failed To Bypass

F0112 One Phase Lost In Power Cell #2

F0113 Two Phases Lost In Power Cell #2

F0200 IGBT Set #1 Over Current In Power Cell #3

F0201 IGBT Set #2 Over Current In Power Cell #3

F0202 Input Over Voltage In Power Cell #3

F0204 Communication Error In Power Cell #3

F0205 No PWM1 Pulse For IGBT Set #1 In Power Cell #3

F0206 No PWM2 Pulse For IGBT Set #2 In Power Cell #3

F0207 IGBT Set #1 Failed To Turn On In Power Cell #3

F0208 IGBT Set #2 Failed To Turn On In Power Cell #3

F0209 Power Cell #3 Bypassed

F0210 Over Temperature In Power Cell #3

F0211 Power Cell #3 Failed To Bypass

F0212 One Phase Lost In Power Cell #3

F0213 Two Phases Lost In Power Cell #3

64 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Parameters and Function Codes Chapter 4

Code Alarm

F0300 IGBT Set #1 Over Current In Power Cell #4

F0301 IGBT Set #2 Over Current In Power Cell #4

F0302 Input Over Voltage In Power Cell #4

F0304 Communication Error In Power Cell #4

F0305 No PWM1 Pulse For IGBT Set #1 In Power Cell #4

F0306 No PWM2 Pulse For IGBT Set #2 In Power Cell #4

F0307 IGBT Set #1 Failed To Turn On In Power Cell #4

F0308 IGBT Set #2 Failed To Turn On In Power Cell #4

F0309 Power Cell #4 Bypassed

F0310 Over Temperature In Power Cell #4

F0311 Power Cell #4 Failed To Bypass

F0312 One Phase Lost In Power Cell #4

F0313 Two Phases Lost In Power Cell #4

F0400 IGBT Set #1 Over Current In Power Cell #5

F0401 IGBT Set #2 Over Current In Power Cell #5

F0402 Input Over Voltage In Power Cell #5

F0404 Communication Error In Power Cell #5

F0405 No PWM1 Pulse For IGBT Set #1 In Power Cell #5

F0406 No PWM2 Pulse For IGBT Set #2 In Power Cell #5

F0407 IGBT Set #1 Failed To Turn On In Power Cell #5

F0408 IGBT Set #2 Failed To Turn On In Power Cell #5

F0409 Power Cell #5 Bypassed

F0410 Over Temperature In Power Cell #5

F0411 Power Cell #5 Failed To Bypass

F0412 One Phase Lost In Power Cell #5

F0413 Two Phases Lost In Power Cell #5

F0500 IGBT Set #1 Over Current In Power Cell #6

F0501 IGBT Set #2 Over Current In Power Cell #6

F0502 Input Over Voltage In Power Cell #6

F0504 Communication Error In Power Cell #6

F0505 No PWM1 Pulse For IGBT Set #1 In Power Cell #6

F0506 No PWM2 Pulse For IGBT Set #2 In Power Cell #6

F0507 IGBT Set #1 Failed To Turn On In Power Cell #6

F0508 IGBT Set #2 Failed To Turn On In Power Cell #6

F0509 Power Cell #6 Bypassed

F0510 Over Temperature In Power Cell #6

F0511 Power Cell #6 Failed To Bypass

F0512 One Phase Lost In Power Cell #6

F0513 Two Phases Lost In Power Cell #6

F0600 IGBT Set #1 Over Current In Power Cell #7

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 65

Chapter 4 Parameters and Function Codes

Code Alarm

F0601 IGBT Set #2 Over Current In Power Cell #7

F0602 Input Over Voltage In Power Cell #7

F0604 Communication Error In Power Cell #7

F0605 No PWM1 Pulse For IGBT Set #1 In Power Cell #7

F0606 No PWM2 Pulse For IGBT Set #2 In Power Cell #7

F0607 IGBT Set #1 Failed To Turn On In Power Cell #7

F0608 IGBT Set #2 Failed To Turn On In Power Cell #7

F0609 Power Cell #7 Bypassed

F0610 Over Temperature In Power Cell #7

F0611 Power Cell #7 Failed To Bypass

F0612 One Phase Lost In Power Cell #7

F0613 Two Phases Lost In Power Cell #7

F0700 IGBT Set #1 Over Current In Power Cell #8

F0701 IGBT Set #2 Over Current In Power Cell #8

F0702 Input Over Voltage In Power Cell #8

F0704 Communication Error In Power Cell #8

F0705 No PWM1 Pulse For IGBT Set #1 In Power Cell #8

F0706 No PWM2 Pulse For IGBT Set #2 In Power Cell #8

F0707 IGBT Set #1 Failed To Turn On In Power Cell #8

F0708 IGBT Set #2 Failed To Turn On In Power Cell #8

F0709 Power Cell #8 Bypassed

F0710 Over Temperature In Power Cell #8

F0711 Power Cell #8 Failed To Bypass

F0712 One Phase Lost In Power Cell #8

F0713 Two Phases Lost In Power Cell #8

F0800 IGBT Set #1 Over Current In Power Cell #9

F0801 IGBT Set #2 Over Current In Power Cell #9

F0802 Input Over Voltage In Power Cell #9

F0804 Communication Error In Power Cell #9

F0805 No PWM1 Pulse For IGBT Set #1 In Power Cell #9

F0806 No PWM2 Pulse For IGBT Set #2 In Power Cell #9

F0807 IGBT Set #1 Failed To Turn On In Power Cell #9

F0808 IGBT Set #2 Failed To Turn On In Power Cell #9

F0809 Power Cell #9 Bypassed

F0810 Over Temperature In Power Cell #9

F0811 Power Cell #9 Failed To Bypass

F0812 One Phase Lost In Power Cell #9

F0813 Two Phases Lost In Power Cell #9

F0900 IGBT Set #1 Over Current In Power Cell #10

F0901 IGBT Set #2 Over Current In Power Cell #10

66 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Parameters and Function Codes Chapter 4

Code Alarm

F0902 Input Over Voltage In Power Cell #10

F0904 Communication Error In Power Cell #10

F0905 No PWM1 Pulse For IGBT Set #1 In Power Cell #10

F0906 No PWM2 Pulse For IGBT Set #2 In Power Cell #10

F0907 IGBT Set #1 Failed To Turn On In Power Cell #10

F0908 IGBT Set #2 Failed To Turn On In Power Cell #10

F0909 Power Cell #10 Bypassed

F0910 Over Temperature In Power Cell #10

F0911 Power Cell #10 Failed To Bypass

F0912 One Phase Lost In Power Cell #10

F0913 Two Phases Lost In Power Cell #10

F1000 IGBT Set #1 Over Current In Power Cell #11

F1001 IGBT Set #2 Over Current In Power Cell #11

F1002 Input Over Voltage In Power Cell #11

F1004 Communication Error In Power Cell #11

F1005 No PWM1 Pulse For IGBT Set #1 In Power Cell #11

F1006 No PWM2 Pulse For IGBT Set #2 In Power Cell #11

F1007 IGBT Set #1 Failed To Turn On In Power Cell #11

F1008 IGBT Set #2 Failed To Turn On In Power Cell #11

F1009 Power Cell #11 Bypassed

F1010 Over Temperature In Power Cell #11

F1011 Power Cell #11 Failed To Bypass

F1012 One Phase Lost In Power Cell #11

F1013 Two Phases Lost In Power Cell #11

F1100 IGBT Set #1 Over Current In Power Cell #12

F1101 IGBT Set #2 Over Current In Power Cell #12

F1102 Input Over Voltage In Power Cell #12

F1104 Communication Error In Power Cell #12

F1105 No PWM1 Pulse For IGBT Set #1 In Power Cell #12

F1106 No PWM2 Pulse For IGBT Set #2 In Power Cell #12

F1107 IGBT Set #1 Failed To Turn On In Power Cell #12

F1108 IGBT Set #2 Failed To Turn On In Power Cell #12

F1109 Power Cell #12 Bypassed

F1110 Over Temperature In Power Cell #12

F1111 Power Cell #12 Failed To Bypass

F1112 One Phase Lost In Power Cell #12

F1113 Two Phases Lost In Power Cell #12

F1200 IGBT Set #1 Over Current In Power Cell #13

F1201 IGBT Set #2 Over Current In Power Cell #13

F1202 Input Over Voltage In Power Cell #13

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 67

Chapter 4 Parameters and Function Codes

Code Alarm

F1204 Communication Error In Power Cell #13

F1205 No PWM1 Pulse For IGBT Set #1 In Power Cell #13

F1206 No PWM2 Pulse For IGBT Set #2 In Power Cell #13

F1207 IGBT Set #1 Failed To Turn On In Power Cell #13

F1208 IGBT Set #2 Failed To Turn On In Power Cell #13

F1209 Power Cell #13 Bypassed

F1210 Over Temperature In Power Cell #13

F1211 Power Cell #13 Failed To Bypass

F1212 One Phase Lost In Power Cell #13

F1213 Two Phases Lost In Power Cell #13

F1300 IGBT Set #1 Over Current In Power Cell #14

F1301 IGBT Set #2 Over Current In Power Cell #14

F1302 Input Over Voltage In Power Cell #14

F1304 Communication Error In Power Cell #14

F1305 No PWM1 Pulse For IGBT Set #1 In Power Cell #14

F1306 No PWM2 Pulse For IGBT Set #2 In Power Cell #14

F1307 IGBT Set #1 Failed To Turn On In Power Cell #14

F1308 IGBT Set #2 Failed To Turn On In Power Cell #14

F1309 Power Cell #14 Bypassed

F1310 Over Temperature In Power Cell #14

F1311 Power Cell #14 Failed To Bypass

F1312 One Phase Lost In Power Cell #14

F1313 Two Phases Lost In Power Cell #14

F1400 IGBT Set #1 Over Current In Power Cell #15

F1401 IGBT Set #2 Over Current In Power Cell #15

F1402 Input Over Voltage In Power Cell #15

F1404 Communication Error In Power Cell #15

F1405 No PWM1 Pulse For IGBT Set #1 In Power Cell #15

F1406 No PWM2 Pulse For IGBT Set #2 In Power Cell #15

F1407 IGBT Set #1 Failed To Turn On In Power Cell #15

F1408 IGBT Set #2 Failed To Turn On In Power Cell #15

F1409 Power Cell #15 Bypassed

F1410 Over Temperature In Power Cell #15

F1411 Power Cell #15 Failed To Bypass

F1412 One Phase Lost In Power Cell #15

F1413 Two Phases Lost In Power Cell #15

F1500 IGBT Set #1 Over Current In Power Cell #16

F1501 IGBT Set #2 Over Current In Power Cell #16

F1502 Input Over Voltage In Power Cell #16

F1504 Communication Error In Power Cell #16

68 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Parameters and Function Codes Chapter 4

Code Alarm

F1505 No PWM1 Pulse For IGBT Set #1 In Power Cell #16

F1506 No PWM2 Pulse For IGBT Set #2 In Power Cell #16

F1507 IGBT Set #1 Failed To Turn On In Power Cell #16

F1508 IGBT Set #2 Failed To Turn On In Power Cell #16

F1509 Power Cell #16 Bypassed

F1510 Over Temperature In Power Cell #16

F1511 Power Cell #16 Failed To Bypass

F1512 One Phase Lost In Power Cell #16

F1513 Two Phases Lost In Power Cell #16

F1600 IGBT Set #1 Over Current In Power Cell #17

F1601 IGBT Set #2 Over Current In Power Cell #17

F1602 Input Over Voltage In Power Cell #17

F1604 Communication Error In Power Cell #17

F1605 No PWM1 Pulse For IGBT Set #1 In Power Cell #17

F1606 No PWM2 Pulse For IGBT Set #2 In Power Cell #17

F1607 IGBT Set #1 Failed To Turn On In Power Cell #17

F1608 IGBT Set #2 Failed To Turn On In Power Cell #17

F1609 Power Cell #17 Bypassed

F1610 Over Temperature In Power Cell #17

F1611 Power Cell #17 Failed To Bypass

F1612 One Phase Lost In Power Cell #17

F1613 Two Phases Lost In Power Cell #17

F1700 IGBT Set #1 Over Current In Power Cell #18

F1701 IGBT Set #2 Over Current In Power Cell #18

F1702 Input Over Voltage In Power Cell #18

F1704 Communication Error In Power Cell #18

F1705 No PWM1 Pulse For IGBT Set #1 In Power Cell #18

F1706 No PWM2 Pulse For IGBT Set #2 In Power Cell #18

F1707 IGBT Set #1 Failed To Turn On In Power Cell #18

F1708 IGBT Set #2 Failed To Turn On In Power Cell #18

F1709 Power Cell #18 Bypassed

F1710 Over Temperature In Power Cell #18

F1711 Power Cell #18 Failed To Bypass

F1712 One Phase Lost In Power Cell #18

F1713 Two Phases Lost In Power Cell #18

F1800 IGBT Set #1 Over Current In Power Cell #19

F1801 IGBT Set #2 Over Current In Power Cell #19

F1802 Input Over Voltage In Power Cell #19

F1804 Communication Error In Power Cell #19

F1805 No PWM1 Pulse For IGBT Set #1 In Power Cell #19

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 69

Chapter 4 Parameters and Function Codes

Code Alarm

F1806 No PWM2 Pulse For IGBT Set #2 In Power Cell #19

F1807 IGBT Set #1 Failed To Turn On In Power Cell #19

F1808 IGBT Set #2 Failed To Turn On In Power Cell #19

F1809 Power Cell #19 Bypassed

F1810 Over Temperature In Power Cell #19

F1811 Power Cell #19 Failed To Bypass

F1812 One Phase Lost In Power Cell #19

F1813 Two Phases Lost In Power Cell #19

F1900 IGBT Set #1 Over Current In Power Cell #20

F1901 IGBT Set #2 Over Current In Power Cell #20

F1902 Input Over Voltage In Power Cell #20

F1904 Communication Error In Power Cell #20

F1905 No PWM1 Pulse For IGBT Set #1 In Power Cell #20

F1906 No PWM2 Pulse For IGBT Set #2 In Power Cell #20

F1907 IGBT Set #1 Failed To Turn On In Power Cell #20

F1908 IGBT Set #2 Failed To Turn On In Power Cell #20

F1909 Power Cell #20 Bypassed

F1910 Over Temperature In Power Cell #20

F1911 Power Cell #20 Failed To Bypass

F1912 One Phase Lost In Power Cell #20

F1913 Two Phases Lost In Power Cell #20

F2000 IGBT Set #1 Over Current In Power Cell #21

F2001 IGBT Set #2 Over Current In Power Cell #21

F2002 Input Over Voltage In Power Cell #21

F2004 Communication Error In Power Cell #21

F2005 No PWM1 Pulse For IGBT Set #1 In Power Cell #21

F2006 No PWM2 Pulse For IGBT Set #2 In Power Cell #21

F2007 IGBT Set #1 Failed To Turn On In Power Cell #21

F2008 IGBT Set #2 Failed To Turn On In Power Cell #21

F2009 Power Cell #21 Bypassed

F2010 Over Temperature In Power Cell #21

F2011 Power Cell #21 Failed To Bypass

F2012 One Phase Lost In Power Cell #21

F2013 Two Phases Lost In Power Cell #21

F2100 IGBT Set #1 Over Current In Power Cell #22

F2101 IGBT Set #2 Over Current In Power Cell #22

F2102 Input Over Voltage In Power Cell #22

F2104 Communication Error In Power Cell #22

F2105 No PWM1 Pulse For IGBT Set #1 In Power Cell #22

F2106 No PWM2 Pulse For IGBT Set #2 In Power Cell #22

70 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Parameters and Function Codes Chapter 4

Code Alarm

F2107 IGBT Set #1 Failed To Turn On In Power Cell #22

F2108 IGBT Set #2 Failed To Turn On In Power Cell #22

F2109 Power Cell #22 Bypassed

F2110 Over Temperature In Power Cell #22

F2111 Power Cell #22 Failed To Bypass

F2112 One Phase Lost In Power Cell #22

F2113 Two Phases Lost In Power Cell #22

F2200 IGBT Set #1 Over Current In Power Cell #23

F2201 IGBT Set #2 Over Current In Power Cell #23

F2202 Input Over Voltage In Power Cell #23

F2204 Communication Error In Power Cell #23

F2205 No PWM1 Pulse For IGBT Set #1 In Power Cell #23

F2206 No PWM2 Pulse For IGBT Set #2 In Power Cell #23

F2207 IGBT Set #1 Failed To Turn On In Power Cell #23

F2208 IGBT Set #2 Failed To Turn On In Power Cell #23

F2209 Power Cell #23 Bypassed

F2210 Over Temperature In Power Cell #23

F2211 Power Cell #23 Failed To Bypass

F2212 One Phase Lost In Power Cell #23

F2213 Two Phases Lost In Power Cell #23

F2300 IGBT Set #1 Over Current In Power Cell #24

F2301 IGBT Set #2 Over Current In Power Cell #24

F2302 Input Over Voltage In Power Cell #24

F2304 Communication Error In Power Cell #24

F2305 No PWM1 Pulse For IGBT Set #1 In Power Cell #24

F2306 No PWM2 Pulse For IGBT Set #2 In Power Cell #24

F2307 IGBT Set #1 Failed To Turn On In Power Cell #24

F2308 IGBT Set #2 Failed To Turn On In Power Cell #24

F2309 Power Cell #24 Bypassed

F2310 Over Temperature In Power Cell #24

F2311 Power Cell #24 Failed To Bypass

F2312 One Phase Lost In Power Cell #24

F2313 Two Phases Lost In Power Cell #24

F2400 IGBT Set #1 Over Current In Power Cell #25

F2401 IGBT Set #2 Over Current In Power Cell #25

F2402 Input Over Voltage In Power Cell #25

F2404 Communication Error In Power Cell #25

F2405 No PWM1 Pulse For IGBT Set #1 In Power Cell #25

F2406 No PWM2 Pulse For IGBT Set #2 In Power Cell #25

F2407 IGBT Set #1 Failed To Turn On In Power Cell #25

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 71

Chapter 4 Parameters and Function Codes

Code Alarm

F2408 IGBT Set #2 Failed To Turn On In Power Cell #25

F2409 Power Cell #25 Bypassed

F2410 Over Temperature In Power Cell #25

F2411 Power Cell #25 Failed To Bypass

F2412 One Phase Lost In Power Cell #25

F2413 Two Phases Lost In Power Cell #25

F2500 IGBT Set #1 Over Current In Power Cell #26

F2501 IGBT Set #2 Over Current In Power Cell #26

F2502 Input Over Voltage In Power Cell #26

F2504 Communication Error In Power Cell #26

F2505 No PWM1 Pulse For IGBT Set #1 In Power Cell #26

F2506 No PWM2 Pulse For IGBT Set #2 In Power Cell #26

F2507 IGBT Set #1 Failed To Turn On In Power Cell #26

F2508 IGBT Set #2 Failed To Turn On In Power Cell #26

F2509 Power Cell #26 Bypassed

F2510 Over Temperature In Power Cell #26

F2511 Power Cell #26 Failed To Bypass

F2512 One Phase Lost In Power Cell #26

F2513 Two Phases Lost In Power Cell #26

F2600 IGBT Set #1 Over Current In Power Cell #27

F2601 IGBT Set #2 Over Current In Power Cell #27

F2602 Input Over Voltage In Power Cell #27

F2604 Communication Error In Power Cell #27

F2605 No PWM1 Pulse For IGBT Set #1 In Power Cell #27

F2606 No PWM2 Pulse For IGBT Set #2 In Power Cell #27

F2607 IGBT Set #1 Failed To Turn On In Power Cell #27

F2608 IGBT Set #2 Failed To Turn On In Power Cell #27

F2609 Power Cell #27 Bypassed

F2610 Over Temperature In Power Cell #27

F2611 Power Cell #27 Failed To Bypass

F2612 One Phase Lost In Power Cell #27

F2613 Two Phases Lost In Power Cell #27

F2700 Output Short Circuit

F2701 Output Over Current

F2702 Motor Over Temperature

F2703 Output Over Voltage

F2704 Abnormal Output Voltage

F2705 Ground Fault

F2706 Over Speed Fault

F2707 Motor Stalled

72 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Parameters and Function Codes Chapter 4

Code Alarm

F2900 Cabinet Door Opened While Drive Energized

F2901 E-Stop Trip

F2902 Input Circuit Breaker Opened (Not Initiated By The Drive)

F2903 Non-Zero Frequency Command Exists Upon Start

F2904 Flying Start Failed

F2905 Input Circuit Breaker Tripped

F2909 System Locked

F2910 CPU Board In Wrong Position

F2911 AT Board In Wrong Position

F2912 5V Power Supply Fault

F2913 15V Power Supply Fault

F2914 24V DCS Power Supply Fault

F2915 24V PLC Power Supply Fault

F3000 PWMA Board In Wrong Position

F3001 PWMB Board In Wrong Position

F3002 PWMC Board In Wrong Position

F3003 DT Board In Wrong Position

F3100 PWMA Board Not Compatible With PUA1 Board

F3101 PWMA Board Not Compatible With PUA2 Board

F3102 PWMA Board Not Compatible With PUA3 Board

F3103 PWMA Board Not Compatible With PUA4 Board

F3104 PWMA Board Not Compatible With PUA5 Board

F3105 PWMA Board Not Compatible With PUA6 Board

F3106 PWMA Board Not Compatible With PUA7 Board

F3107 PWMA Board Not Compatible With PUA8 Board

F3108 PWMA Board Not Compatible With PUA9 Board

F3109 PWMA Board Not Compatible With PUA10 Board

F3110 PWMA Board Not Compatible With PUA11 Board

F3111 PWMA Board Not Compatible With PUA12 Board

F3112 PWMA Board Not Compatible With PUA13 Board

F3113 Primary FPGA Not Compatible With PWMA Board

F3114 Primary FPGA Not Compatible With PWMB Board

F3115 Primary FPGA Not Compatible With PWMC Board

F3200 PWMB Board Not Compatible With PUB1 Board

F3201 PWMB Board Not Compatible With PUB2 Board

F3202 PWMB Board Not Compatible With PUB3 Board

F3203 PWMB Board Not Compatible With PUB4 Board

F3204 PWMB Board Not Compatible With PUB5 Board

F3205 PWMB Board Not Compatible With PUB6 Board

F3206 PWMB Board Not Compatible With PUB7 Board

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 73

Chapter 4 Parameters and Function Codes

Code Alarm

F3207 PWMB Board Not Compatible With PUB8 Board

F3208 PWMB Board Not Compatible With PUB9 Board

F3209 PWMB Board Not Compatible With PUB10 Board

F3210 PWMB Board Not Compatible With PUB11 Board

F3211 PWMB Board Not Compatible With PUB12 Board

F3212 PWMB Board Not Compatible With PUB13 Board

F3213 Primary FPGA Not Compatible With DT Board

F3214 Primary DSP Not Compatible With Primary FPGA

F3215 Primary DSP Not Compatible With Secondary DSP

F3300 PWMC Board Not Compatible With PUC1 Board

F3301 PWMC Board Not Compatible With PUC2 Board

F3302 PWMC Board Not Compatible With PUC3 Board

F3303 PWMC Board Not Compatible With PUC4 Board

F3304 PWMC Board Not Compatible With PUC5 Board

F3305 PWMC Board Not Compatible With PUC6 Board

F3306 PWMC Board Not Compatible With PUC7 Board

F3307 PWMC Board Not Compatible With PUC8 Board

F3308 PWMC Board Not Compatible With PUC9 Board

F3309 PWMC Board Not Compatible With PUC10 Board

F3310 PWMC Board Not Compatible With PUC11 Board

F3311 PWMC Board Not Compatible With PUC12 Board

F3312 PWMC Board Not Compatible With PUC13 Board

F3313 Versions Of System Not Compatible

F3400 Primary DSP Not Compatible With PLC

F3401 HMI Not Compatible With PLC

F3402 Primary DSP Not Compatible With HMI

FCOM1 DSP Communication Fault

FCOM2 PLC Communication Fault

FP006 Transformer Over Temperature Trip

FP007 Auxiliary Power Off

FP008 Cabinet Door Open

W0003 DC Bus Under Voltage In Power Cell #1 Warning

W0014 Input Over Voltage In Power Cell #1 Warning

W0103 DC Bus Under Voltage In Power Cell #2 Warning

W0114 Input Over Voltage In Power Cell #2 Warning

W0203 DC Bus Under Voltage In Power Cell #3 Warning

W0214 Input Over Voltage In Power Cell #3 Warning

W0303 DC Bus Under Voltage In Power Cell #4 Warning

W0314 Input Over Voltage In Power Cell #4 Warning

W0403 DC Bus Under Voltage In Power Cell #5 Warning

74 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Parameters and Function Codes Chapter 4

Code Alarm

W0414 Input Over Voltage In Power Cell #5 Warning

W0503 DC Bus Under Voltage In Power Cell #6 Warning

W0514 Input Over Voltage In Power Cell #6 Warning

W0603 DC Bus Under Voltage In Power Cell #7 Warning

W0614 Input Over Voltage In Power Cell #7 Warning

W0703 DC Bus Under Voltage In Power Cell #8 Warning

W0714 Input Over Voltage In Power Cell #8 Warning

W0803 DC Bus Under Voltage In Power Cell #9 Warning

W0814 Input Over Voltage In Power Cell #9 Warning

W0903 DC Bus Under Voltage In Power Cell #10 Warning

W0914 Input Over Voltage In Power Cell #10 Warning

W1003 DC Bus Under Voltage In Power Cell #11 Warning

W1014 Input Over Voltage In Power Cell #11 Warning

W1103 DC Bus Under Voltage In Power Cell #12 Warning

W1114 Input Over Voltage In Power Cell #12 Warning

W1203 DC Bus Under Voltage In Power Cell #13 Warning

W1214 Input Over Voltage In Power Cell #13 Warning

W1303 DC Bus Under Voltage In Power Cell #14 Warning

W1314 Input Over Voltage In Power Cell #14 Warning

W1403 DC Bus Under Voltage In Power Cell #15 Warning

W1414 Input Over Voltage In Power Cell #15 Warning

W1503 DC Bus Under Voltage In Power Cell #16 Warning

W1514 Input Over Voltage In Power Cell #16 Warning

W1603 DC Bus Under Voltage In Power Cell #17 Warning

W1614 Input Over Voltage In Power Cell #17 Warning

W1703 DC Bus Under Voltage In Power Cell #18 Warning

W1714 Input Over Voltage In Power Cell #18 Warning

W1803 DC Bus Under Voltage In Power Cell #19 Warning

W1814 Input Over Voltage In Power Cell #19 Warning

W1903 DC Bus Under Voltage In Power Cell #20 Warning

W1914 Input Over Voltage In Power Cell #20 Warning

W2003 DC Bus Under Voltage In Power Cell #21 Warning

W2014 Input Over Voltage In Power Cell #21 Warning

W2103 DC Bus Under Voltage In Power Cell #22 Warning

W2114 Input Over Voltage In Power Cell #22 Warning

W2203 DC Bus Under Voltage In Power Cell #23 Warning

W2214 Input Over Voltage In Power Cell #23 Warning

W2303 DC Bus Under Voltage In Power Cell #24 Warning

W2314 Input Over Voltage In Power Cell #24 Warning

W2403 DC Bus Under Voltage In Power Cell #25 Warning

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 75

Chapter 4 Parameters and Function Codes

Code Alarm

W2414 Input Over Voltage In Power Cell #25 Warning

W2503 DC Bus Under Voltage In Power Cell #26 Warning

W2514 Input Over Voltage In Power Cell #26 Warning

W2603 DC Bus Under Voltage In Power Cell #27 Warning

W2614 Input Over Voltage In Power Cell #27 Warning

W2800 Motor Over Temperature Warning

W2801 Abnormal Output Voltage Warning

W2802 Ground Fault Warning

W2803 Output Frequency Deviation Warning

W3314 Version Fault Identification Code Error

WP001 Control Power Switch Warning

WP002 Transformer Cabinet Fan Fault

WP003 Power Module Cabinet Fan Fault

WP004 Transformer Over Temperature Warning

WP005 Analog Loss Warning

WP009 Power Module Cabinet Fan Circuit Breaker Open

WP010 Transformer Cabinet Fan Circuit Breaker Open

76 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Safety

Chapter 5

Preventative Maintenance and Component Replacement

ATT EN TI ON : Servicing energized Medium Voltage Motor Control Equipment

can be hazardous. Severe injury or death can result from electrical shock, bump, or unintended actuation of controlled equipment. Recommended practice is to disconnect and lockout control equipment from power sources, and release stored energy, if present.For countries following NEMA standards, refer to National Fire Protection Association Standard No. NFPA70E, Part II and (as applicable) OSHA rules for Control of Hazardous Energy Sources (Lockout/ Tagout) and OSHA Electrical Safety Related Work Practices safety related work practices, including procedural requirements for lockout/tagout, and appropriate work practices, personnel qualifications and training requirements, where it is not feasible to de-energize and lockout or tagout electric circuits and equipment before working on or near exposed circuit parts.For countries following IEC standards, refer to local codes and regulations.

Introduction

ATT EN TI ON : Use suitable personal protective equipment (PPE) per local codes

or regulations. Failure to do so may results in severe burns, injury, or death.

ATT EN TI ON : 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.

ATT EN TI ON : These tasks require person(s) skilled in this type of detailed work. Read and understand this manual thoroughly before commencing. Contact Rockwell Automation with any questions or for clarification.

The drive can experience reduced service life if operated outside of its design parameters. Ensure the operating environment is within specifications. Daily inspection and regular maintenance will maximize the service life of the equipment.

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 77

Chapter 5 Preventative Maintenance and Component Replacement

IMPORTANT

Daily Inspection

Check the following items during normal operation of the drive:

• abnormal noise or vibration in the drive or motor

• abnormal temperature in the drive or motor

• ambient temperature in the control room above nominal

• accumulation of dust or particulate on control room floor or surfaces

• abnormal load current above nominal

Regular Maintenance Intervals

The annual maintenance requirements are summarized on page 123 as a guideline. Detailed procedures referred to in the Preventative Maintenance

Schedule are described beginning on page 81.

Medium Voltage Motor control equipment should be inspected periodically. Inspection intervals should be based on environmental and operating conditions and adjusted as indicated by experience. An initial comprehensive inspection, within 3 to 4 months after installation, is suggested. Refer to the following standards for general guidelines for setting-up a periodic maintenance program.For countries following NEMA standards, refer to National Electrical Manufacturers Association (NEMA) Standard No. ICS 1.1 (Safety Guidelines for the Application, Installation, and Maintenance of Solid-Sate Control) for MV Drives and ICS 1.3 (Preventive Maintenance of Industrial Control and Systems Equipment) for MV Controllers. For countries following 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.

If inspection reveals that dust, dirt, moisture or other contamination has reached the control equipment, the cause must be eliminated. This could indicate unsealed enclosure openings (conduit or other) or incorrect operating procedures. Replace any damaged or embrittled seals, and repair or replace any other damaged or malfunctioning parts. Replace dirty, wet, or contaminated control devices unless they can be cleaned effectively by vacuuming or wiping.

Compressed air is not recommended for cleaning because it may displace dirt, dust, or debris into other parts or equipment, or damage delicate parts.

78 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Preventative Maintenance and Component Replacement Chapter 5

Physical Checks (No Medium Voltage or Control Power)

Power Connection Inspection

• Inspect PowerFlex 6000 drive, input/output/bypass sections, and all associated drive components for loose power cable connections and ground cable connections: torque them based on the required torque specifications.

• Inspect the bus bars and 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.

• The torques of incoming / outgoing cable screws of the power unit shall be

check if they are in the specified range.

• Use torque sealer on all connections. Carry out the integrity checks on the signal ground and safety grounds.

Physical Inspection

• Check for any visual/physical evidence of damage or degradation of components in the low voltage compartments.

– This includes Relays, Contactors, Timers, Terminal connectors, Circuit

breakers, Ribbon cables, Control Wires, UPS, AC/DC Power Supplies etc.; Causes could be corrosion, excessive temperature, or contamination.

• Check for any visual/physical evidence of damage or degradation of components in the medium voltage compartments (cables, contactors, circuit breakers, isolation disconnecting blades, power units, etc.).

– This includes main cooling fan, power devices, heat sinks, circuit

boards, insulators, cables, capacitors, current transformers, potential transformers, fuses, wiring, etc.; Causes could be corrosion, excessive temperature, or contamination.

• Clean all contaminated components using a vacuum cleaner (DO NOT use a blower), and wipe clean components where appropriate.

• Carry out the physical inspection and verification for the proper operation of the contactor/isolator interlocks, and door interlocks.

• Carry out the physical inspection and verification for the proper operation of the key interlocks.

• Carry out the cleaning of the fans and ensure that the ventilation passages are not blocked and the impellers are freely rotating without any obstruction.

• Carry out the insulation megger test on the transformer, motor, and associated cabling.

• Check all bolts for fastening and adjust them as necessary.

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 79

Chapter 5 Preventative Maintenance and Component Replacement

Medium Voltage Testing

Medium voltage insulation resistance (IR) or dielectric withstanding voltage (megger) tests should not be used to check solid-state control equipment. When meggering electrical equipment, such as transformers or motors, solid-state devices must be bypassed before performing the test. Even though no damage may be readily apparent after a megger test, the solid-state devices are degraded and repeated application of high voltage can lead to failure.

Maintenance after a Fault Condition

Opening of the short circuit protective device (such as fuses or circuit breakers) in a properly coordinated motor branch circuit is an indication of a fault condition in excess of operating overload. Such conditions can cause damage to medium voltage motor control equipment. Before restoring power, the fault condition must be corrected and any necessary repairs or replacements must be made to restore the medium voltage motor control equipment to good working order. Refer to NEMA Standards Publication No. ICS-2, Part ICS2-302 for procedures. Use only replacement parts and devices recommended by Rockwell Automation to maintain the integrity of the equipment. Ensure the parts are properly matched to the model, series and revision level of the equipment. After maintenance or repair of the equipment, always test the control system for proper functioning under controlled conditions (that avoid hazards in the event of a control malfunction). For additional information, refer to NEMA ICS 1.3, PREVENTIVE MAINTENANCE OF INDUSTRIAL CONTROL AND SYSTEMS EQUIPMENT, published by the National Electrical Manufacturers Association, and NFPA70B, ELECTRICAL EQUIPMENT MAINTENANCE, published by the National Fire Protection Association.

Final Report

80 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

A complete, detailed report on all steps in the Preventive Maintenance procedures should be recorded to identify changes.

A detailed description of all adjustments and measurements that were taken during the process must be recorded (Interlock Adjustments, Loose Connections, Voltage Readings, Megger Results, Parameters, etc.).

Isolation Transformer Cabinet

Preventative Maintenance and Component Replacement Chapter 5

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

Replace Voltage Sensing Board 87

Inspect Door Position Limit Switch 88

Replace Door Position Limit Switch 89

Replace/Clean Door Mounted Air Filters

Periodically remove and clean, or remove and replace, the air filters according to the Preventative Maintenance table on page 124

. The frequency with which you

renew the filters depends on the cleanliness of the available cooling air.

The cabinet door filters are installed in six locations, including four locations on the Power Module Cabinet, and two locations on the Isolation Transformer Cabinet. However, the method to remove or clean the air filters is the same. The screens may be replaced while the drive is operating, but the procedure is easier to perform while the drive is shut down.

If the drive is running, you must replace the filter as soon as possible to prevent foreign material from entering into the drive.

Recommended Cleaning Method of Filters:

• Vacuum Cleaner – A vacuum cleaner on the inlet side of the filter will remove accumulated dust and dirt.

• Blow with Compressed Air – point compressed air nozzle in opposite direction of operating air flow (Blow from exhaust side toward intake side)

• Cold Water Rinse – Under normal conditions the foam media used in the filters, require no oily adhesives. Collected dirt is washed away quickly and easily using just a standard hose nozzle with plain water.

ATT EN TI ON : The filter must be completely dry before reinstalling.

• Immersion in Warm Soapy Water – Where stubborn air-borne dirt is present, the filter may be dipped in a solution of warm water and mild detergent. Rinse in clear clean water, let stand until completely dry and free of moisture.

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 81

Chapter 5 Preventative Maintenance and Component Replacement

IMPORTANT

Use only Rockwell Automation-supplied or -approved replacement filters (see

Spare Parts List

removal. Check that there are no openings to allow foreign matter to enter the drive.

1. Unlatch and open the cabinet filter door more than 90°.

on page 127). Replace the filters in the reverse order of its

2. Remove the screens by pulling up out of the door.

When removing the filter, prevent accumulated dirt on the inlet side of the filter from being sucked into the drive. It may be difficult to remove the filter material without tearing due to the suction at the air inlet.

3. Re-install the cleaned or new air filter using reverse order of removal. Ensure the door is fully closed and locked.

Inspect Top Mounted Main Cooling Fans

Inspect fans used for forced air cooling. Replace any that have bent, chipped, or missing blades, or if the shaft does not turn freely. Apply power momentarily to check operation. If unit does not operate, check and replace wiring, fuse, or fan motor as appropriate. Clean or change air filters as recommended in the Users Manual. Ensure the aviation plug has a proper hand-tight connection. Ensure that the ventilation passages are not blocked and the impellers can rotate freely without any obstruction.

82 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Preventative Maintenance and Component Replacement Chapter 5

M6 x 12 Bolt (4)

Lock wash er (4)

Washer (4)

Tap pin g S crew ( 4)

M6 x 12 Bolt (8)

Washer (16)

Lock wash er (8)

Fan H ousi ng Li d

Fan Support Bracket

Fan Housing Assembly

Fan Assembly

Wiring Cover

Aviation Plug

Replace Top Mounted Main Cooling Fans

The top fan housing consists of a motor and impeller assembly. To replace the fan, it is necessary to remove the Fan Housing Lid.

ATT EN TI ON : Fan replacement requires working at a significant height from the floor. Complete this procedure on a safe, stable platform.

1. Remove and retain four tapping screws around the Fan Housing Lid, and remove the Lid.

2. Remove and retain eight M6 x 12 bolts from the Fan Housing Assembly which connect to the Fan Support Bracket.

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 83

Chapter 5 Preventative Maintenance and Component Replacement

3. Remove and retain four M6 x 12 bolts from the top of the Fan Support

4. Remove the Wiring Cover and disconnect the wiring.

5. Install the fan in the reverse order of its removal. Rotate the impeller by

Fan Balance

Fan impellers are statically and dynamically balanced within acceptable tolerances at the factory. Damage in shipping or from incorrect handling or installation may upset the balance. An improperly balanced impeller can lead to excessive vibration causing undue wear on the entire unit.

Bracket, and remove the bracket from the Fan Assembly.

hand to ensure that there is no contact with the Fan Housing Assembly.

ATT EN TI ON : 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.

If vibration is excessive, shut down the fan and determine the cause. Common causes of excessive vibration include:

• Drive support structure not sufficiently rigid or level

• Loose mounting bolts

• Loose impeller or bushing

84 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Preventative Maintenance and Component Replacement Chapter 5

Inspect Isolation Transformer Auxiliary Cooling Fans

When the drive is running, verify that each of the coil temperatures are the same on the Isolation Transformer Temperature Monitor display. If there is more than a 5 °C difference between the highest and lowest temperature, check the Isolation Transformer Auxiliary Cooling Fans.

Test the Isolation Transformer Auxiliary Cooling Fans:

ATT EN TI ON : 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.

1. Open the LV Control Door on the Isolation Transformer Cabinet.

Locate the correct circuit breaker(s).

2. Disconnect the wires from the load side of the Isolation Transformer Auxiliary Cooling Fan circuit breaker. Refer to Electrical Drawings.

Figure 25 - Circuit Breaker Location on LV Control Door

3. Connect 380V power to the wires to verify operation of the fans.

If a fan is not operational, see Replace Isolation Transformer Auxiliary

Cooling Fans on page 86.

4. Remove the power source and reconnect the wires to the circuit breaker.

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 85

Chapter 5 Preventative Maintenance and Component Replacement

M6 Bolt

Lock Wash er

Was her

M6 Nut

Isolation Transformer

Auxiliary Cooling Fan

Replace Isolation Transformer Auxiliary Cooling Fans

1. If the fan is in the front, cut the tie straps to loosen the wire bundle from

2. Disconnect three wires at the top of the fan.

3. Remove four M6 bolts and hardware and retain.

4. Remove the Auxiliary Cooling Fan.

Figure 26 - Isolation Transformer Hardware Location

the top of the fan.

5. Install the new fan in reverse order of removal.

If necessary, install new tie straps around the a, b, c, and o cables through the fan vent.

Inspect Isolation Transformer

1. Verify the fan is rotating in the proper direction.

2. Verify the incoming and outgoing power cable connections are torqued to

specifications.

SeeTorque Requirements

3. Check the cabinet interior and Isolation Transformer windings and remove any foreign material. Vacuum dust or debris from the Isolation Tra ns fo rm er c ab in et .

4. Check for any physical evidence of damage or degradation of components.

on page 129.

86 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Preventative Maintenance and Component Replacement Chapter 5

Nylon M10 Nut (x8)

Nylon M10 Bolt (x8)

Inspect Voltage Sensing Board

The input VSB cable connections and output VSB wire connectors must be firmly fastened and show no signs of damage or accumulation of dirt, dust, or debris.

Replace Voltage Sensing Board

ATT EN TI ON : To prevent electrical shock, disconnect the main power before

working on the 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.

1. Remove the Voltage Sensing Board input and output cables.

2. Remove the eight nylon nuts to remove the Insulation Board from the

cabinet side sheet.

Figure 27 - Remove the Insulation Board

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 87

Chapter 5 Preventative Maintenance and Component Replacement

Nylon M10 Nut (x9)

Insulation Board

Voltage Sensing Board

3. Remove the nylon nuts which connect the Voltage Sensing Board to the

Figure 28 - Remove the Voltage Sensing Board from the Insulation Board

Insulation Board.

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.

Inspect Door Position Limit Switch

Check for obvious signs of damage, dust, or foreign material. Remove any dirt or foreign material. Wipe components with an anti-static cloth, where applicable. Check the aviation plug has a hand-tight connection.

88 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Preventative Maintenance and Component Replacement Chapter 5

Nut

Lock washer

Was her

M4 x 35 Bolt

Aviati on Plug

Replace Door Position Limit Switch

ATT EN TI ON : Ensure the input circuit breaker feeding the drive is open. Lock out

and tagout the input circuit breaker before performing any work on the drive or bypass units.

1. Open the drive cabinet door.

2. Disconnect the aviation plug from the back of the Limit Switch.

3. Remove two M4 x 35 bolts and hardware from the mounting bracket.

4. Install the new Limit Switch in reverse order of removal.

Figure 29 - Replace Door Position Limit Switch

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 89

Chapter 5 Preventative Maintenance and Component Replacement

Power Module Cabinet

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

Install Drawout Power Modules 95

Replace Power Module Fuses 97

Inspect or Replace HECS 99

Inspect or Replace Door Position Limit Switch 100

Inspect, Clean, or Replace Door Mounted Air Filters

See Replace/Clean Door Mounted Air Filters on page 81.

Inspect or Replace Top Mounted Main Cooling Fans

See Inspect Top Mounted Main Cooling Fans on page 82.

Inspect Power Modules

1. Check for damage or degradation of the Power Modules a. Inspect the power connections for loose connections or any evidence of

discoloration of connections from heating

b. For Drawout Power Module configurations, remove the back plates

from the Power Module Cabinet and inspect the plug-in connectors on the back of each Power Module. Look for evidence of discoloration from overheating.

2. Remove dust or debris from all ventilation openings on the Power Module

3. Inspect the electrolytic capacitors, located in the ventilation openings of

the Power Module. a. Inspect for signs of discoloration, odor, or leakage. b. Replace Power Modules if the capacitors have discoloration, odor, or

leakage.

90 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Preventative Maintenance and Component Replacement Chapter 5

Fuse

Position ing Barrie rs

Output Copper Bar (not shown)

Connection Location

Fiber Optic Cables Connection Point

Three-phase Input Cables

from Isolation Transformer

Center Jumper Bar

Replace Power Module

Table 7 - Power Module Specifications

Type Output Rating (Amps) Dimensions (HxWxD), approx. Weight, approx.

Fixed-mounted ≤150 A 420 x 180 x 615 mm (16.5 x 7.1 x 24.2 in.) 20 kg (44.1 lb)

151...200 A 420 x 260 x 615 mm (16.5 x 10.2 x 24.2 in.) 25 kg (55.1 lb)

Drawout 201...380 A 575 x 342 x 691 mm (22.6 x 13.5 x 27.2 in.) 40 kg (88.2 lb)

381...420 A 575 x 342 x 910 mm (22.6 x 13.5 x 35.8 in.) 50 kg (110.2 lb)

ATT EN TI ON : Two people are required to handle the Power Modules. Always handle the drawout Power Modules using the two recessed lifting handles on both mounting rails (Figure 33

Fixed-mounted Power Module

ATT EN TI ON : The high-voltage power source must be switched off before replacing a Fixed-mounted Power Module. Wait for 20 minutes before opening the cabinet doors. 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.

1. Remove the positioning barriers from both sides of the Power Module.

2. Disconnect the Three-phase Input Power Cables.

Figure 30 - Fixed-mounted Power Module Component Location

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 91

Chapter 5 Preventative Maintenance and Component Replacement

Motor Cable

VSB Cable

Output Copper Bar

Fiber Optic Cables

3. Remove the Output Copper Bars that connect adjacent Power Modules

4. Disconnect the fiber optic cables.

Figure 31 - Close up of Fiber Optic Location and Power Cables

(Figure 31

If the Power Module is at the end of a row, remove the VSB and Motor cable instead of an output copper bus.

ATT EN TI ON : 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.

ATT EN TI ON : Minimum bend radius permitted for the fiber optic cables is 50 mm (2.0 in.). Any bends with a shorter inside radius can permanently damage the fiber-optic cable.

5. Carefully withdraw the Power Module.

92 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

6. Install the new Power Module in reverse order of removal.

Preventative Maintenance and Component Replacement Chapter 5

Hand Crank

Foot C rank

Pressure Release Knob

1. Visually inspect the lift cart to ensure it is fully operational.

2. Turn the Pressure Release Knob clockwise until tight.

3. Raise the lift tray using the Hand Crank or the Foot Crank.

4. Lower the lift tray by turning the Pressure Release Knob counter-clockwise.

TIP

The Foot Crank raises the lift tray faster than the Hand Crank. Use this to raise the Power Module to just below the tray assembly in the drive. Use the Hand Crank for final precise positioning.

Lift Tray

Release Pressure in Cyl ind er

Seal Pressure in Cyl ind er

Replace Drawout Power Module

ATT EN TI ON : Only authorized personnel should operate the lift cart. Keep hands and feet away from the lifting mechanism. Do not stand under the lift tray when in use. Store the lift cart with the tray fully lowered.

Lift Carts are supplied and shipped separately with drawout power module configurations. The unit’s hydraulic cylinder can be operated by either a hand or foot crank. The lifting capacity is 1000 kg (2206 lb).

Figure 32 - Lift Cart Procedure

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 93

Chapter 5 Preventative Maintenance and Component Replacement

Recessed Lifting Handles

Mounting Rail

Finger Assemblies

Figure 33 - Drawout Power Module Lifting Handles

ATT EN TI ON : 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.

94 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Preventative Maintenance and Component Replacement Chapter 5

Wheels

Tray Assembly Guides

Cam Mechanism Actuator

Power Module

Posit ionin g

Handles

Install Drawout Power Modules

1. Place the Power Module module on the lift cart.

Ensure the Power Module is properly oriented; the finger assemblies must face towards the drive.

2. Position the lift cart in front of the cabinet and raise the Power Module to the proper height.

3. Align the wheels on the Power Module with the tray assembly guides on each side of the Power Module tray assembly.

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 95

4. Push the Power Module slowly backwards into the cabinet until the cam mechanism contacts the pin mounted on the tray assembly.

Chapter 5 Preventative Maintenance and Component Replacement

Locking Key

Cam Mechanism

Cabinet

Stab

Assemblies

Finger

Assemblies

SIDE VIEW

Connection to

Motor Phase Bus

Three Phase Input Power

from Isolation

Transformer

Cam Mechanism

TOP VIEW

Locking Key

Cam Mechanism Actuator

5. Insert the locking key into the cam mechanism actuator and rotate clockwise while gently pushing on the face of the Power Module.

The cam mechanism will catch the pin on the tray assembly.

6. Continue rotating the locking key until the Power Module is fully seated.

This ensures the finger assemblies at the back of the Power Module are fully connected to the stab assemblies at the back of the Power Module compartment.

96 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

ATT EN TI ON : The Power Module finger assemblies must be fully seated on the

cabinet stab assemblies.

Preventative Maintenance and Component Replacement Chapter 5

Copper Washer

Lock washer

M8 Nut

Fuse

Replace Power Module Fuses

Fixed-mounted Power Module

ATT EN TI ON : Ensure the input circuit breaker feeding the drive is open. Lock out and tagout the input circuit breaker before performing any work on the drive or bypass units.

1. Remove the M8 nut, lock washer, and copper washer from the top and bottom of the fuse.

2. Remove the cables from the top and bottom of the fuse, and remove another copper washer.

3. Install the new fuse, and replace cables and hardware in reverse order of removal.

4. Torque all hardware to specifications (see Torque Requirements

page 129).

Figure 34 - Exploded View of Fixed-mounted Power Module Fuse

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 97

Chapter 5 Preventative Maintenance and Component Replacement

Was her

Lock washer

M12 x 30 Bolt

Fuse

Was her

Nut

Power Cabl e

Bus bar

Drawout Power Module

1. Remove and retain the M12 bolt, washer, lock washer, and nut from the

2. Remove the fuse from between the fixed bracket and the power cable and

3. Install the new fuse, and the hardware in reverse order of removal.

ATT EN TI ON : Ensure the input circuit breaker feeding the drive is open. Lock out and tagout the input circuit breaker before performing any work on the drive or bypass units.

top and bottom of the fuse.

bus bar.

4. Torque all hardware to specifications (see Torque Requirements

page 129).

ATT EN TI ON : The hardware connecting the Drawout Power Modules MUST be reinstalled facing up, as shown in Figure 35

. Failure to install the hardware in

this manner will affect clearance distance between bolts and can cause an arc.

Figure 35 - Exploded View of Fixed-mounted Power Module Fuse

98 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Preventative Maintenance and Component Replacement Chapter 5

Current Sen sor Connec tion

HECS

Mounting Bracket

Inspect or Replace HECS

ATT EN TI ON : To prevent electrical shock, disconnect the main power before

working on the drive. 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.

Two current sensors are located at the top inside the Power Module 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.

2. Disconnect one end of the power cable that goes through the HECS from

the Power Module.

3. Remove the Mounting Bracket with the HECS still attached.

Rockwell Automation Publication 6000-UM001B-EN-P - October 2014 99

Chapter 5 Preventative Maintenance and Component Replacement

IMPORTANT

M5 x 12 Nut

Was her

4. Remove and retain M5 x 12 hardware connecting the HECS to the

Figure 36 - Exploded view of the HECS and Mounting Bracket

Mounting Bracket.

Note the orientation of the HECS on the bracket. The new HECS must be installed facing the same direction.

5. Install the HECS on the Mounting Bracket using the existing hardware.

ATT EN TI ON : Verify that the current sampling direction is correct. This is indicated by an arrow symbol on the top of the HECS.

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

See Replace Door Position Limit Switch on page 89.

100 Rockwell Automation Publication 6000-UM001B-EN-P - October 2014

Rockwell Automation 6012DB User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

Important User Information

Table of Contents

Preface

Introduction

Who Should Use This Manual

What Is Not in This Manual

Additional Resources

General Precautions

Service and Support

Commissioning Support

Safety Considerations

Environmental Conditions

How it Works

Cascaded “H” Bridge (CHB) Topology

Simplified Electrical Diagrams

Standards Compliance

Elevation Drawings

Isolation Transformer Cabinet

Isolation Transformer

Isolation Transformer Temperature Monitor

Isolation Transformer Auxiliary Cooling Fans

Top-mounted Main Cooling Fan(s)

Incoming Line Power Cable Connections

Outgoing Motor Cable Connections

Door Position Limit Switch

Voltage Sensing Board

Power Module Cabinet

Power Modules

Hall Effect Current Sensors (HECs)

Top-mounted Main Cooling Fan(s)

LV Control Cabinet

Control Unit (all modules)

Main Interface

Overview

Drive Setup and Configuration Controls

Status Indicators

Operation Bar

Setup and Monitor Box

Main Interface Controls

Set Frequency (Hz)

Drive Operation Controls

View Version Information

Alarm

Alarm History

Trends

View Voltage, Current or Frequency Trends

Operation

Confirm Bypass Mode

Choose Local/Remote Operation

Open/Close Drive Input and Output Contactors

Open/Close Bypass Contactors

Settings

System Settings

User Settings

Change User Parameters

Setup Settings

View/Change P or T Parameters

Restore “P” or “T” Parameters

P Parameters

T Parameters

Alarm List

Safety

Introduction

Daily Inspection

Regular Maintenance Intervals

Physical Checks (No Medium Voltage or Control Power)

Power Connection Inspection

Physical Inspection

Medium Voltage Testing

Maintenance after a Fault Condition

Final Report

Isolation Transformer Cabinet

Replace/Clean Door Mounted Air Filters

Inspect Top Mounted Main Cooling Fans

Replace Top Mounted Main Cooling Fans

Fan Balance